SINUMERIK 802D

Technical Manual 04.2000 Edition

Description of Functions

Manufacturer Documentation
 Document Structure SINUMERIK 802D

General Documentation: Catalog

SINUMERIK 802D

Turning,
Milling

User’s Guide: Operation and Programming

SINUMERIK 802D SINUMERIK 802D

Turning Milling

User’s Guide: Diagnostics Guide

SINUMERIK 802D

Turning,
Milling

Technical Manual: Start–up

SINUMERIK 802D
Documentation

Turning, SIMODRIVE
Milling 611U

Technical Manual: Description of Functions

SINUMERIK 802D

Turning,
Milling
 Preface, Table of Contents
1
EMERGENCY STOP (N2)
2
Axis Monitoring (A3)
Velocities, Setpoint/Actual–Value
Systems, Closed–Loop Control 3
(G2)
4
Acceleration (B2)
5
Spindle (S1)
SINUMERIK 802D
Description of Functions 6
Rotary Axes (R2)
7
Transverse Axes (P1)
Technical Manual
8
Reference Point Approach (R1)

Manufacturer / Service Documentation

Manual Traversing and Hand– 9
wheel Traversing (H1)
Operating Modes, Program Mode 10
(K1)
11
Feed (V1)
Continous Path Mode, Exact Stop 12
and LookAhead
Output of Auxiliary Functions to 13
the PLC (H2)
14
Tool Compensation (W1)
15
Measuring (M5)
16
Compensation (K3)
17
Various Interface Signals (A2)
18
List of Interface Signals
19
Various Machine Data

Glossary, Index

04.00 Edition
 SINUMERIK Documentation
3ls

Printing history

Brief details of this edition and previous edition are listed below.

The status of each edition is shown by the code in the “Remarks” column.

Status code in the “Remarks” column:

A . . . . . New documentation.
B . . . . . Unrevised reprint with new Order No.
C . . . . . Revised edition with new status.
If actual changes have been made on the page since the last edition, this is indicated by
a new edition coding in the header on that page.

Edition Order No. Remarks

04.00 6FC5 697–2AA10–0BP0 A

This Manual is included on the documentation on CD ROM (DOCONCD)

Edition Order No. Remarks

Trademarks
SIMATIC
, SIMATIC HMI
, SIMATIC NET
, SIROTEC
, SINUMERIK
and SIMODRIVE
are registered
trademarks of Siemens. Third parties using for their own purpose any other names in this document which
refer to trademarks might infringe upon the rights of trademark owners.

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.

This publication was produced with Interleaf V 7. We have checked that the contents of this document correspond to
the hardware and software described. Nonetheless, differences might
The reproduction, transmission or use of this document or its exist and therefore we cannot guarantee that they are completely
contents is not permitted without express written authority.Offenders identical. The information contained in this document is, however,
will be made liable for damages. All rights, including rights created by reviewed regularly and any necessary changes will be included in the
patent grant or registration of utility model or design, are reserved. next edition. We welcome suggestions for improvement.
 Siemens AG 2000. All rights reserved. Subject to change without prior notice.

Order No.: 6FC5 697–2AA10–0BP0 Siemens–Aktiengesellschaft

Printed in the Federal Republic of Germany
Preface

Notes for the reader

The descriptions of functions are only valid for or up to the specified software release. When new
software releases are issued, the relevant descriptions of functions must be requested. Old descrip-
tions of functions can only partially be used for new software releases.

Note
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.

Technical notes
Notations
The following notations and abbreviations are used in this Documentation:

 PLC interface signals –> IS ”Signal name” (signal data)

Example: IS ”Feed override“ (VB380x 0000)
The variable byte is in the range “at axis“, “x” stands for the axis: 0 axis 1
1 aixs 2
n axis n+1.
 Machine data –> MD MD_NR: MD_NAME
 Setting data –> SD SD_NR: SD_NAME
 The Chapter headlines are added by a short designation in brackets (e.g. Chapter 1: EMER-
GENCY STOP (N1)). This short designation is used in references to individual Chapters/Sec-
tions.

Explanation of the short designations

In the Chapters/Sections of each Description of Functions, the data and/or signals are explained
which are important for the function discussed. Within these explanations provided in the form of
tables, some terms and abbreviations are used, which are explained here.
Default value:
This is the default value of the machine/setting data when loading the standard machine data.

Range of values (minimum/maximum value):

specifies the input limits. If no range of values is specified, the data type defines the input limits, and
the field is marked with ”***”.
Activation of changes:
Changes in machine data, setting data or the like come not immediately into effect in the control
system. The conditions for activation are therefore always specified. The possibilities used are listed
below by their priority:
 POWER ON (po) Turning off/turning on the power supply
or softkey “StartUp/Normal” on HMI
 NEW_CONF (cf) ”RESET” key on the control unit
 RESET (re) ”RESET” key on the control unit

SINUMERIK 802DDescription of Funktions

6FC5 697–2AA10–0BP0 (04.00) v
Preface

 immediately (im) after input of a value

Protection level:
There are the protection levels 0 to 7 whereby the interlock for protection levels 1 to 3 can be cance-
led by setting a password and the interlock for protection levels 4 to 7 via the IS “Protection level”
(e.g.: keyswitch position). Protection level 0 cannot be accessed (see Chapter “Various Interface
Signals”).
The operator has only access to information that corresponds to this particular protection level and
the lower protection levels. The machine data are assigned different protection levels by default and
are marked by a Write/Read value (e.g. 4/7).
Note: In this document, the machine and setting data of protection levels 2 to 7 are documented.
Notes on machine data of protection level 1 are only provided in special cases (expert mode).

Unit:
The unit refers to the default setting (see Section “Velocities, Setpoint/Actual Value System, Closed–
Loop Control“).
If the MD has no physical unit as the basis, the field is marked with ”–”.

Data type:
The following data types are used in the control system:

 DOUBLE
Floating point value (64–bit value )
Input limits from +/–4.19*10–307 to +/–1.67*10308
 DWORD
Integer values (32–bit value)
Input limits from –2 147 483 648 to +2 147 483 648 (decimal),
as a hexadecimal value: 0000 to FFFF
 BYTE
Integer values (8–bit value)
Input limits from –128 to +127 (decimal), as a hexadecimal value: 00 to FF
 BOOLEAN
Boolean value: TRUE (1) or FALSE (0)
 STRING
consisting of a maximum of 16 ASCII characters (uppercase letters, digits and underscore)

Example machine data

36210 CTRLOUT_LIMIT[0]
MD number Maximum speed setpoint
Default: 110.0 Min. input limit: 0.0 Max. input limit: 200.0
Change valid after NEW_CONF Protection level: 2/7 Unit: %
Data type: DOUBLE Valid from SW release:
Meaning:

Alarms
For detailed explanations on occurring alarms, please refer to:
References: ”Diagnostics Guide“.

SINUMERIK 802DDescription of Funktions

vi 6FC5 697–2AA10–0BP0 (04.00)
 Table of Contents

Table of Contents
1 EMERGENCY STOP (N2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.1 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.2 EMERGENCY STOP sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.3 EMERGENCY STOP acknowlededgement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.4 Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.5 Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.6 Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.6.1 Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.6.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
2 Axis Monitoring (A3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.1 Overview of monitoring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.2 Motion monitoring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.2.1 Contour monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.2.2 Positioning monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2.2.3 Zero speed monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2.2.4 Clamping monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2.2.5 Speed setpoint monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2.2.6 Actual velocity monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2.3 Encoder monitoring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
2.3.1 Encoder limit frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
2.3.2 Zero mark monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
2.4 Monitoring of static limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2.4.1 Limit switch monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2.4.2 Working area limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
2.5 Boundary conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
2.6 Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
2.6.1 Channel–specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
2.6.2 Axis/spindle–specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
2.6.3 Axis/spindle–specific setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
2.7 Signal description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
2.7.1 Axis/spindle–specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
2.8 Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
2.8.1 Axis/spindle–specific interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
2.8.2 Axis/spindle–specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
2.8.3 Channel–specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
2.8.4 Axis/spindle–specific setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
3 Velocities, Setpoint/Actual–Value Systems, Closed–Loop Control (G2) . . . . . . . . . . 3-47
3.1 Velocities, traversing ranges, accuracies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
3.1.1 Velocities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
3.1.2 Traversing ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.1.3 Input/display resolution, computational resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3.1.4 Standardization of physical quantities of machine and setting data . . . . . . . . . . . . . . . . . . . 3-50
3.2 Metric/inch scaling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
3.2.1 Conversion of the scaling system using the part program . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
3.2.2 Switching over the scaling system manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
3.3 Setpoint/actual–value system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
3.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
3.3.2 Drives connected to Profibus DP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

SINUMERIK 802DDescription of Funktions

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Table of Contents

3.3.3 Speed setpoint and actual–value assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

3.3.4 Speed setpoint output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
3.3.5 Actual–value processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
3.4 Closed–loop control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
3.5 Data description (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
3.5.1 General machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
3.5.2 Channel–specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
3.5.3 Axis–specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
3.6 Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
3.7 Data fields, data lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
3.7.1 Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
3.7.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
4 Acceleration (B2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
4.1 Acceleration profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
4.2 Jerk limitation on interpolator level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
4.3 Jerk limitation in JOG mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76
4.4 Percentage acceleration correction, ACC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76
4.5 Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
4.6 Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78
5 Spindle (S1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
5.1 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
5.2 Spindle modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80
5.2.1 Spindle mode: Control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81
5.2.2 Spindle mode: Oscillation mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81
5.2.3 Spindle mode: Positioning mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84
5.3 Synchronizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87
5.4 Gear stage change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88
5.5 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91
5.6 Spindle monitoring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5.6.1 Axis/spindle stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93
5.6.2 Spindle in set range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93
5.6.3 Max. spindle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94
5.6.4 Min./max. speed of the gear stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94
5.6.5 Max. encoder limit frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
5.6.6 Target position monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96
5.7 Analog spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
5.8 Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
5.8.1 Axis/spindle–specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
5.8.2 Spindle–specific setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105
5.9 Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-106
5.9.1 Axis/spindle–specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-106
5.10 Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
5.10.1 Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
5.10.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115
5.10.3 Setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-116
6 Rotary Axes (R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-117
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-117

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6.2 Modulo 360 degrees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119

6.3 Programming rotary axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119
6.3.1 Rotary axis with active modulo conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-120
6.3.2 Rotary axis without modulo conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-121
6.4 Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-122
6.4.1 Axis/spindle–specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-122
6.5 Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-124
6.5.1 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-124
6.5.2 Setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-124
7 Transverse Axes (P1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-125
7.1 Defining a transverse axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-125
7.2 Diameter programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-125
7.3 Constant cutting rate: G96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-126
8 Reference Point Approach (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-127
8.1 Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-127
8.2 Referencing using incremental measuring systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-129
8.3 Referencing using absolute encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-132
8.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-132
8.3.2 Operator–sssisted adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-132
8.4 Boundary conditions for absolute encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-133
8.4.1 Adjusting the absolute encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-133
8.5 Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-134
8.5.1 Channel–specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-134
8.5.2 Axis/spindle–specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-134
8.6 Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-142
8.6.1 Channel–specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-142
8.6.2 Axis/spindle–specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-143
8.7 Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-143
8.7.1 Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-143
8.7.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-144
9 Manual Traversing and Handwheel Traversing (H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-145
9.1 General features when traversing in JOG mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-145
9.2 Continuous traversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-149
9.3 Incremental traversing (INC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-150
9.4 Handwheel traversing in JOG mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-151
9.5 Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-153
9.5.1 General machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-153
9.5.2 Axis/spindle–specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-154
9.5.3 General setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-155
9.6 Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-156
9.6.1 Signals from HMI to PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-156
9.6.2 NCK signals and signals in the operating mode area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-157
9.6.3 Channel–specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-158
9.6.4 Axis/spindle–specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-163
9.7 Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-166
9.7.1 Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-166
9.7.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-167
9.7.3 Setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-167

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10 Operating Modes, Program Mode (K1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169

10.1 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169
10.2 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169
10.2.1 Mode change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170
10.2.2 Possible functions in the individual operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-171
10.2.3 Monitoring functions in the individual operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-173
10.2.4 Interlocks in the individual operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-174
10.3 Execution of a part program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-174
10.3.1 Program mode and part program selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-174
10.3.2 Starting the part program or part program block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-175
10.3.3 Part program interruption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-176
10.3.4 RESET command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-176
10.3.5 Program control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-177
10.3.6 Program status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-177
10.3.7 Channel status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-178
10.3.8 Reactions to operator or program actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-179
10.3.9 Example of time diagram for a program sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-181
10.4 Program test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-181
10.4.1 General remarks on program test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-181
10.4.2 Program execution without axis movements (PRT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-182
10.4.3 Program execution in single block mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-182
10.4.4 Program execution with Dry Run Feed (DRY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-183
10.4.5 Block search: Execution of certain program sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-184
10.4.6 Skipping part program blocks (SKP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186
10.4.7 Graphical simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-187
10.5 Timer for program runtime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-188
10.6 Workpiece counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-189
10.7 Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-191
10.7.1 Display machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-191
10.7.2 Channel–specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194
10.7.3 Channel–specific setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-196
10.7.4 Axis–specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-197
10.8 Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-198
10.8.1 Mode signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-198
10.8.2 Channel–specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200
10.9 Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-211
10.9.1 Channel machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-211
10.9.2 Channel–specific setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-212
10.9.3 Axis/spindle–specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-212
10.9.4 Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-212
11 Feed (V1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-215
11.1 Feedrate F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-215
11.1.1 Feed with G33 (thread cutting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-216
11.1.2 Feed with G63 (tapping with compensating chuck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-217
11.1.3 Feed with G331, G332 (rigid tapping = tapping without compensating chuck) . . . . . . . . . . 11-217
11.2 Rapid traverse G0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-218
11.3 Feed override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-219
11.3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-219
11.3.2 Feed disable and feed/spindle stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-219
11.3.3 Feed Override from the machine control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-220
11.4 Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-222
11.5 Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-222
11.5.1 Channel–specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-222

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11.5.2 Axis/spindle–specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-227

11.6 Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-230
11.6.1 Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-230
11.6.2 Machine data/setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-230
12 Continuous–Path Mode, Exact Stop and LookAhead (B1) . . . . . . . . . . . . . . . . . . . . . . 12-231
12.1 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-231
12.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-231
12.3 Exact Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-232
12.4 Continuous path mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-233
12.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-233
12.4.2 Velocity reduction according to the overload factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-235
12.4.3 Velocity reduction for jerk limitation on the path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-235
12.4.4 Machine axis–specific jerk limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-236
12.5 LookAhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-237
12.6 Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-238
12.6.1 Channel–specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-238
12.6.2 Axis–specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-239
12.7 Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-239
12.7.1 Channel–specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-239
12.7.2 Axis–specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-239
12.8 Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-240
12.8.1 Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-240
12.8.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-240
13 Output of Auxiliary Functions to the PLC (H2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-241
13.1 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-241
13.2 Programming of auxiliary functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-241
13.3 Transfer of values and signals to the PLC interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-243
13.4 Division of auxiliary functions into groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-243
13.5 Behavior on block search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-245
13.6 Description of the auxiliary functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-245
13.6.1 M function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-245
13.6.2 T function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-245
13.6.3 D function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-246
13.6.4 H function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-246
13.6.5 S function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-246
13.7 Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-246
13.7.1 General machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-246
13.7.2 Channel–specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-247
13.8 Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-248
13.9 Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-250
13.9.1 Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-250
13.9.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-250
14 Tool Compensation (W1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-251
14.1 Overview: Tool and tool compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-251
14.2 Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-251
14.3 Tool compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-252
14.4 Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-253

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14.5 Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-253

14.5.1 Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-253
14.5.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-253
15 Measuring (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-255
15.1 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-255
15.2 Hardware requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-255
15.2.1 Probes that can be used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-255
15.2.2 Connecting the probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-257
15.3 Channel–specific measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-259
15.3.1 Measuring mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-259
15.3.2 Measurement results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-259
15.4 Measuring accuracy and testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-260
15.4.1 Measuring accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-260
15.4.2 Sensing probe function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-260
15.5 Boundary conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-261
15.6 Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-261
15.7 Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-262
15.8 Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-262
15.8.1 Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-262
15.8.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-262
16 Compensation (K3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-263
16.1 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-263
16.2 Backlash compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-263
16.3 Interpolatory compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-264
16.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-264
16.3.2 Leadscrew error compensation (LEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-266
16.3.3 Special features of interpolatory compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-268
16.4 Following error compensation (feedforward control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-269
16.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-269
16.4.2 Speed feedforward control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-270
16.5 Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-270
16.6 Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-272
16.6.1 Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-272
16.6.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-272
17 Various Interface Signals (A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-273
17.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-273
17.2 Signals from PLC to NCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-274
17.3 Signals from NCK to PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-278
17.4 Signals from PLC to HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-280
18 PLC User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-281
18.1 Address ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-281
18.2 User data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-282
18.2.1 User data 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-282
18.2.2 User Data 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-282
18.2.3 Battery–backed data range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-282
18.3 User alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-283
18.3.1 User alarm: Enabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-283

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18.3.2 Variable for alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-283

18.3.3 Active alarm reaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-283
18.4 Signals from/to HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-284
18.4.1 Program control signals from HMI (battery–backed range) . . . . . . . . . . . . . . . . . . . . . . . . . . 18-284
18.4.2 General selection/status signals from MMC (battery–backed range) . . . . . . . . . . . . . . . . . . 18-284
18.4.3 General selection/status signals to MMC (battery–backed range) . . . . . . . . . . . . . . . . . . . . 18-285
18.5 Auxiliary function transfer from NC channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-285
18.5.1 Decoded M signals (M0 – M99) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-286
18.5.2 T functions transferred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-286
18.5.3 M functions transferred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-287
18.5.4 S functions transferred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-287
18.5.5 D functions transferred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-287
18.5.6 H functions transferred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-288
18.6 NCK signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-288
18.7 Channel signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-290
18.7.1 Signals to NC channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-290
18.7.2 Signals from NC channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-291
18.8 Axis/spindle signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-293
18.8.1 Transferred M/S functions, axis–specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-293
18.8.2 Signals to axis/spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-293
18.8.3 Signals from axis/spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-295
18.9 PLC machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-297
18.9.1 INT values (MD 14510 USER_DATA_INT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-297
18.9.2 HEX values (MD 14512 USER_DATA_HEX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-297
18.9.3 FLOAT values (MD 14514 USER_DATA_FLOAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-297
18.9.4 User alarm: Configuration (MD 14516 USER_DATA_PLC_ALARM) . . . . . . . . . . . . . . . . . . 18-298
19 Various Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-299
19.1 Display machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-299
19.2 General machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-300
19.3 Channel–specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-302
19.4 Axis–specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-303

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EMERGENCY STOP (N2) 1
1.1 Brief description

! Important
We would like to draw the machine manufacturer’s attention to his duty to observe the
relevant international and national standards (see notes on standards further below in the
text). The
SINUMERIK 802D supports the machine manufacturer in implementing the EMER-
GENCY STOP function according to the specifications in this Description of Functions.
The EMERGENCY STOP function (release, sequence and acknowledgement) is the sole
and only responsibility of the machine manufacturer.

Note
The following standards are relevant for the EMERGENCY STOP function:
 EN 292 Part 1
 EN 292 Part 2
 EN 418
 EN 60204 Part 1:1992 Section 10.7
The VDE 0113 Part 1 is only valid for a transition period and is replaced by EN 60204.

EMERGENCY STOP in the control system

The following arrangements are provided in the control system to support the machine manufactu-
rer in implementing the EMERGENCY STOP function:

 Initiation of the EMERGENCY STOP sequence in the NC via the PLC input.
 The EMERGENCY STOP sequence in the NC will decelerate all axes and spindles in the NC as
fast as possible.
 The EMERGENCY STOP status cannot be canceled by unlocking the EMERGENCY STOP
button. Resetting the control device will not result in a restart.
 After the EMERGENCY STOP status has been canceled, it is not necessary to reference axes
or synchronize spindles (the positions are corrected).

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EMERGENCY STOP (N2)

EMERGENCY STOP button

A mushroom button (with one normally closed and normally open contact each), further referred to
as EMERGENCY STOP button, is installed in the Siemens machine control panel (MCP) for the
802D.

1.2 EMERGENCY STOP sequence

Prerequisite
The actuation of the EMERGENCY STOP button or a signal directly derived from it must be carried
to the control (PLC) as a PLC input. In the PLC user program, this PLC input must be passed on to
the NC to the IS ”EMERGENCY STOP“ (V2600 0000.1).

Resetting of the EMERGENCY STOP button or a signal directly derived from it must be carried to
the control (PLC) as a PLC input. In the PLC user program, this PLC input must be passed on the
NC to the IS “Acknowledge EMERGENCY STOP” (V2600 0000.2).

Sequence in the NC
In the control system, the predetermined sequence (as per EN 418) of internal functions for the
EMERGENCY STOP status is as follows:
1. The part program execution is interrupted. All axes and spindles are stopped along defined brak-
ing ramps according to MD 36610: AX_EMERGENCY_STOP_TIME.
2. The IS ”802–READY” (V3100 0000.3) is reset.
3. The IS ”EMERGENCY STOP active” (V2700 0000.1) is set.
4. Alarm 3000 is set.
5. The servo enable is disabled after an axis/spindle–specific time that can be set in MD 36620:
SERVO_DISABLE_DELAY_TIME (servo enable cutout delay) has been elapsed. In this context,
make sure that 36620: SERVO_DISABLE_DELAY_TIME must be specified at least as large as
MD 36610: AX_EMERGENCY_STOP_TIME.

Sequence on the machine

The EMERGENCY STOP sequence on the machine is exclusively defined by the machine
manufacturer. The following must be observed in conjunction with the sequence in the NC:
 The sequence in the NC is started using the IS ”EMERGENCY STOP“ (V2600 0000.1). After the
axes and spindles have been stopped, the power supply must be interrupted acc. to EN418.
 The sequence in the NC has no influence on the PLC I/Os (digital outputs). If you wish individual
outputs to have a certain status in case of EMERGENCY STOP, the machine manufacturer must
implement the appropriate functions in the PLC program.

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! Important
To interrupt the power supply, is the sole and only responsibility of the machine manufac-
turer.
If you wish the sequence in the NC in case of EMERGENCY STOP not to be carried out
as defined, the IS “EMERGENCY STOP” (V2600 0000.1) may not be set until an EMER-
GENCY STOP status defined by the machine manufacturer in the PLC user program is
reached. Until the IS “EMERGENCY STOP” is not yet set and no other alarm is pending,
all IS are active in the NC. Thus, any manufacturer–specific EMERGENCY STOP status
is possible.

1.3 EMERGENCY STOP acknowlededgement

Acknowledging EMERGENCY STOP

The EMERGENCY STOP status will only be reset if first the IS “Acknowledge EMERGENCY STOP”
(V2600 0000.2) and then the IS “Reset” (V3000 0000.7) is set. When doing so, make sure that the
IS ”Acknowledge EMERGENCY STOP” and the IS ”Reset” must be set together at least as long as
the IS “EMERGENCY STOP active” (V2700 0000.1) has been reset (see Fig. 1-1).

IS ”EMERGENCY STOP”
V2600 0000.1
1
IS ”Acknoweledge EMER-
GENCY STOP“
V2600 0000.2

IS ”EMERGENCY STOP
active“
V2700 0000.1 2
IS ”RESET”
V3000 0000.7 3
1 The IS ”Acknowledge EMERGENCY STOP” has no effect.
2 The IS ”RESET” has no effect.
3 The IS ”Acknowledge EMERGENCY STOP” and ”RESET” will reset ”EMERGENCY STOP active.

Fig. 1-1 Resetting EMERGENCY STOP

Resetting the EMERGENCY STOP status:

 resets the IS ”EMERGENCY STOP active”;
 connect servo enable;
 set the IS ”Position control active“;
 set the IS ”802–READY”;
 clear alarm 3000;
 cancel the part program execution.

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EMERGENCY STOP (N2)

PLC I/Os
The PLC I/Os must be brought again by the PLC user program to the appropriate status required to
operate the machine.

Reset
It is not possible to reset the EMERGENCY STOP status with the IS ”Reset” (V3000 0000.7) alone
(see diagram above).

Power ON
Power ON (turning off/turning off the power supply) will clear the EMERGENCY STOP status, ex-
cept the IS ”EMERGENCY STOP” (V2600 0000.1), which remains set.

1.4 Data descriptions (MD, SD)

Axis–specific machine data

36620 SERVO_DISABLE_DELAY_TIME
MD number Servo enable cutout delay
Default: 0.1 Min. input limit: 0.02 Max. input limit: ***
Change valid after NEW_CONF Protection level: 2/2 Unit: s
Data type: DOUBLE Valid from SW release:
Meaning: Maximum time delay for cancellation of “Servo enable” after faults.
The speed enable (servo enable) of the drive is canceled internally in the control system at the
latest after a set delay time if the axis / spindle is moving.
The entered delay time acts due to the following events:
 in case of errors resulting in immediate axis stop
 if the IS “Servo enable” is canceled from the PLC.
Once the actual speed reaches the zero speed range (MD 36060: STANDSTILL_VELO_ TOL),
“Servo enable” is disabled for the drive.
The time should be set as large as the axis / spindle needs to come to a standstill from maximum
traversing velocity or speed.
If the axis / spindle is already at a standstill, “Servo enable” is disabled for the drive immediately.
Application example(s) The speed control of the drive should be maintained for this time to make sure that the axis/spindle
can come to a standstill from maximum traversing velocity or speed. For this time, the cancellation
of “Servo enable” should be delayed for an axis/spindle moving.
Special cases, errors, ...... CAUTION: If the servo enable cutout delay is set too small, the “Servo enable” is already canceled
even if the axis/spindle is still traversing. In this case, it is suddenly stopped with setpoint 0.
The time set in this MD should therefore be greater than the time of the braking ramp in case of
error statuses (MD 36610: AX_EMERGENCY_STOP_TIME).
Related to .... IS ”Servo enable” (V380x 0002.1)
MD 36610: AX_EMERGENCY_STOP_TIME (time of braking ramp in case of error statuses)

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1.5 Signal descriptions

General signals

V2600 0000.1 EMERGENCY STOP

Interface signal Signal(s) to NC (PLC –––> NC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The NC is set to the EMERGENCY STOP status and the EMERGENCY STOP sequence in the
change 0 ––>1 NC is started.
Signal state 0 or edge  The NC is not in the EMERGENCY STOP status.
change 1 ––>0  The EMERGENCY STOP status is (still) active, but can be reset using the IS ”Acknowledge
EMERGENCY STOP” and IS ”Reset”.
Related to .... IS ”Acknowledge EMERGENCY STOP” (V2600 0000.2)
IS ”EMERGENCY STOP active” (V2700 0000.1)

V2600 0000.2 Acknowledge EMERGENCY STOP

Interface signal Signal(s) to NC (PLC –––> NC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The EMERGENCY STOP status will only be reset if first the IS ”Acknowledge EMERGENCY
change 0 ––>1 STOP“ and then the IS ”Reset” (V3000 0000.7) are set. When doing so, make sure that the IS
“Acknowledge EMERGENCY STOP” and the IS ”Reset” must be set together at least as long
as the IS ”EMERGENCY STOP active” (V2600 0000.1) has been reset.
Resetting the EMERGENCY STOP status:
 resets the IS ”EMERGENCY STOP active”;
 connects “Servo enable”;
 sets the IS ”Position control”;
 sets the IS ”802–Ready”;
 lcears alarm 3000;
 aborts the part program execution.
Related to .... IS ”EMERGENCY STOP” (V2600 0000.1)
IS ”EMERGENCY STOP active” (V2700 0000.1)
IS ”Reset” (V3000 0000.7)

V2700 0000.1 EMERGENCY STOP active

Interface signal Signal(s) to NC (PLC –––> NC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The NC is in the EMERGENCY STOP status.
change 0 ––>1
Related to .... IS ”EMERGENCY STOP” (V2600 0000.1)
IS ”Acknowledge EMERGENCY STOP” (V2600 0000.2)

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EMERGENCY STOP (N2)

1.6 Data fields, lists

1.6.1 Interface signals

Number .Bit Name Ref.

General
V2600 0000 .1 EMERGENCY STOP
V2600 0000 .2 Acknowledge EMERGENCY STOP
V2700 0000 .1 EMERGENCY STOP active
Mode signal range
V3000 0000 .7 Reset K1

1.6.2 Machine data

Number Identifier Name Ref.

Axis–specific
36610 AX_EMERGENCY_STOP_TIME Duration of braking ramp in case of error statuses A3
36620 SERVO_DISABLE_DELAY_TIME Servo enable cutout delay

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2.1 Overview of monitoring functions

 Motion monitoring functions

– Contour monitoring
– Positioning monitoring
– Zero speed monitoring
– Clamping position monitoring
– Speed setpoint monitoring
– Actual velocity monitoring
– Encoder monitoring functions
 Monitoring of static limitations
– limit switch monitoring
– Work area monitoring

2.2 Motion monitoring functions

2.2.1 Contour monitoring

Function
The principle of functioning of the contour monitoring is based on the permanent comparison of
measured actual position value and the actual position value calculated from the NC position set-
point. To calculate the following error in advance, a model is used which simulates the dynamic
properties of the position control including feedforward control.
To make sure that the monitoring system does not respond already in the case of slight speed vari-
ations (caused by load changes), a tolerance band is permitted for the maximum contour deviation.

If the permissible actual value deviation entered in MD 36400: CONTOUR_TOL (contour monitoring
tolerance band) is exceeded, an alarm is output, and the axes are stopped.

Activation
The contour monitoring is active for axes and a position–controlled spindle.

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Axis Monitoring (A3)

Effect
If the contour error is too large, the following will occur:

 Alarm 25050 ”Contour monitoring” is output.

 The axis/spindle concerned is stopped with rapid stop (with open position feedback loop) via a
speed setpoint ramp.
The duration of the braking ramp is defined in the MD 36610: AX_EMERGENCY_STOP_TIME
(duration of braking ramp in case of error statuses).
 If the axis/spindle interpolates with other axes/spindles, these are stopped by rapid stop with
reduction of the following error (position setpoint = constant).

Remedy
 Increase tolerance band of monitoring function in MD 36400.
 The real servo gain factor must correspond to the desired servo gain factor set in
MD 32200: POSCTRL_GAIN (servo gain factor).
With an analog spindle, check
MD 32260: RATED_VELO (rated motor speed) and
MD 32250: RATED_OUTVAL (rated output voltage).
 Check optimization of speed controller.
 Check smooth running of axes.
 Check machine data for traversing movements (feedoverride, acceleration, max. velocities, ... )

2.2.2 Positioning monitoring

Function
To make sure that an axis is positioned within a specified time, the time configured in MD 36020:
POSITIONING_TIME (exact stop fine time delay) is started after a motion block has been ended
(set point has reached the target), and after this time has elapsed, it is checked whether the axis
has reached its set position within the tolerance of MD 36010: STOP_LIMIT_FINE (exact stop fine).

”Exact stop coarse and fine“ see:

References: Chapter ”Continuous–Path Mode, Exact Stop and LookAhead”

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 Axis Monitoring (A3)

V or s
active tolerance in case of zero

speed or clamping monitoring

Actual value
Interface signal
”Clamping process
running“ (V380x
0002.3)
MD: CLAMP_POS_TOL
Setpoint

MD:
STANDSTILL_POS_TOL

MD: STOP_LIMIT_COARSE

MD: STOP_LIMIT_FINE

t
MD: “Exact stop fine” – interface signal
STANDSTILL_ “Exact stop coarse“ – interface signal
DELAY_TIME
MD: POSITIONING_TIME

Fig. 2-1 Interrelation between positioning, zero speed and clamping monitoring

Enabling
The positioning monitoring is always enabled after a “setpoint–dependent” completion of motion
blocks (setpoint has reached the target).

The positioning monitoring is active for axes and a position–controlled spindle.

Disabling
The positioning monitoring is disabled after the specified ”Exact stop limit fine” has been reached or
after output of a new setpoint position (e.g. when positioning to ”Exact stop coarse“ followed by a
block change).

Effect
If the limit value for “Exact stop fine” has not yet been reached after the positioning monitoring time
has elapsed, the following action is carried out:

 Alarm 25080 ”Positioning monitoring” is output.

 The axis/spindle concverned is stopped with rapid stop (with open position control loop) via a
speed setpoint ramp.
The duration of the braking ramp is defined in MD 36610: AX_EMERGENCY_STOP_TIME
(duration of braking ramp in case of error statuses).
 If the axis/spindle interpolates with other axes/spindles, these will be stopped by rapid stop with
reduction of the following error (specification of partial position setpoint = 0).

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Axis Monitoring (A3)

Error cause/error elimination

 Too small position controller gain ––> change machine data for position control gain
MD 32200: POSCTRL_GAIN(servo gain factor)
 Positioning window (exact stop fine), positioning monitoring time and position control gain are
not matched another to one ––> change machine data:
MD 36010: STOP_LIMIT_FINE (exact stop fine),
MD 36020: POSITIONIG_TIME (exact stop fine delay time),
MD 32200: POSCTRL_GAIN (servo gain factor)

General rule
 Large positioning window ––> a relative short max. positioning monitoring time can be selected
 Small positioning window ––> a relatively long positioning monitoring time must be selected
 Small position control gain ––> a relatively long max. positioning monitoring time must be
selected
 High position control gain ––> a relatively short max. positioning monitoring time can be
selected

Note
The size of the positioning window will influence the block change time. The smaller the-
se tolerances are chosen, the longer will last the positioning process and the longer it will
last until the next command can be executed.

2.2.3 Zero speed monitoring

Function
After a motion block has been completed (position setpoint has reached target), it is monitored
whether the axis is no more away from its setpoint position than specified in MD 36060:
STANDSTILL_POS_TOL (standstill tolerance) after the delay time that can be parameterized in MD
36040: STANDSTILL_DELAY_TIME (standstill monitoring delay time) has elapsed. Otherwise, an
alarm is generated.
See Fig. 2-1

Activation
The zero speed monitoring is always active after the “Standstill monitoring delay time” has elapsed,
provided that no new traversing command is active.
The standstill monitoring is active for axes and a position–controlled spindle.

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Effect
The response of the monitoring function has the following effect:

 Alarm 25040 ”Standstill monitoring” is output.

 The axis/spindle concerned is stopped with rapid stop (with open position control loop) via a
speed setpoint ramp. The duration of the braking ramp is defined in MD
36610: AX_EMERGENCY_STOP_TIME (duration of braking ramp in case of error statuses).
 If the axis interpolates with other axes/spindles, these will be stopped by rapid stop with reduc-
tion of the following error (specification of partial position setpoint = 0).

Error cause/error elimination

 Position control gain too large (vibrations of servo loop) ––>change machine data for controller
gain MD 32200: POSCTRL_GAIN (servo gain factor)
 Standstill window too small ––> change machine data
MD 36030: STANDSTILL_POS_TOL (standstill tolerance)
 Axis is mechanically pushed off position ––> eliminate cause

2.2.4 Clamping monitoring

Function
If you wish the axis to be clamped at the end of the positioning process, the clamping monitoring
can be activated using the IS “Clamping monitoring running” (V380x 0002.3).

This can be necessary because it is possible that during the clamping process the axis has been
pushed off its setpoint position farther than permitted by the standstill tolerance. The amount by
which the setpoint position can be left is specified in MD 36050: CLAMP_POS_TOL (clamping posi-
tion tolerance at interface signal “Clamping running“).
See Fig. 2-1

Activation
The clamping position monitoring is activated by the interface signal ”Clamping process running”. It
replaces the standstill monitoring during the clamping process.
The clamping position monitoring is active for axes and a position–controlled spindle.

Effect
If during the clamping process the axis is pushed off its position farther than permitted by the clamp-
ing position tolerance, the following will occur:

 Alarm 26000 ”Clamping position monitoring” is output.

 The axis/spindle concerned is stopped with rapid stop (with open position control loop) via a
speed setpoint ramp. The duration of the braking ramp is defined in
MD 36610: AX_EMERGENCY_STOP_TIME (duration of braking ramp in case of error sta-
tuses).
 If the axis/spindle interpolates with other axes/spindles, these will also be stopped by rapid stop
with reduction of the following error (specification of partial position setpoint = 0).

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Axis Monitoring (A3)

2.2.5 Speed setpoint monitoring

Function
The speed setpoint monitoring checks whether the setpoint specification does not exceed the maxi-
mum permissible speed for the drives specified in MD 36210: CTRLOUT_LIMIT (maximum speed
setpoint). If necessary, it is limited to this value, and the axis/spindle is stopped and an alarm is out-
put.
For the axes, the maximum speed setpoint (as a percentage) is above the speed at which the ve-
locity defined in MD 3200: MAX_AX_VELO is reached (100%). This also defines the control margin.
With an analog spindle, the maximum output speed cannot be greater than the speed reached at a
maximum setpoint output voltage of 10V (100%).

The speed setpoint consists of the speed setpoint of the position controller and the feedforward
control value (if feedforward control is active).

Feedforward control value

+ to speed
KV
Following controller
error
Speed setpoint
monitoring
Position controller

Fig. 2-2 Speed setpoint monitoring

Activation
The speed setpoint monitoring is always active for axes and for a spindle.

Effect
The following will occur if the maximum speed setpoint is exceeded:

 Alarm 25060 ”Speed setpoint limitation” is output.

 The axis/spindle concerned is stopped with rapid stop (with open position control loop) via a
speed setpoint ramp.
The duration of the braking ramp is defined in MD 36610: AX_EMERGENCY_STOP_TIME
(duration of braking ramp in case of error statuses).
 If the axis interpolates with other axes/spindles, these will be stopped by rapid stop with reduc-
tion of the following error (specification of partial position setpoint = 0).
Note: At the access level “Expert mode” (protection level 1), a delay time can be set in
MD 36220: CTRLOUT_LIMIT_TIME, after which the alarm is generated, stopping the axes. This
time is zero by default.
The beginning limitation of the speed setpoint makes this servo loop non–linear. Generally, this re-
sults in path deviations when an axis dwells in a speed setpoint limitation. Therefore, a control mar-
gin must be set (see Section 3.3.4 “Speed setpoint output”).

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Error causes
 A measuring error circuit or a drive error exists in the measuring circuit.
 Too high setpoints specified (accelerations, velocities, reduction factors)
 Obstacle in working area (e.g. coming into contact with the work table)
 Tachogenerator adjustment with analog spindle has not been carried out correctly or a measur-
ing circuit or drive error exists.

2.2.6 Actual velocity monitoring

Function
The actual velocity is monitored for exceeding of a permissible limit value entered in MD 36200:
AX_VELO_LIMIT (threshold value for velocity monitoring).

Activation
The actual velocity monitoring is always active if the active measuring circuit that has been acti-
vated via the iS “Position measuring system 1” (V380x 0001.5) provides actual values, i.e. is still
below the imit frequency.

The actual velocity momnitoring is active for axes and for a spindle.

Effect
The following will occur if the “Threshold value for velocity monitoring” is exceeded:
 Alarm 25030 ”Actual velocity alarm limit”
 The axis/spindle concerned is stopped with rapid stop (with open position control loop) via a
speed setpoint ramp.
The duration of the brake ramp is defined in MD 36610: AX_EMERGENCY_STOP_TIME (dura-
tion of braking ramp in case of error statuses).
 If the axis/spindle interpolates with other axes/spindles, these will also be stopped by rapid stop
with reduction of the following error (specification of partial setpoint = 0).

Notes for fault finding

 Check actual values.
 Check position control direction.
 Check MD 36200: AX_VELO_LIMIT (threshold value for velocity monitoring).
 In the case of an analog spindle, check speed setpoint cable.

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2.3 Encoder monitoring functions

2.3.1 Encoder limit frequency

Function
If the limit frequency of a measuring system, which is entered in MD 36300: ENC_FREQ_LIMIT(en-
coder limit frequency), is exceeded, the position synchronization (reference point) between machine
and control system will be lost. A correct position control is no longer possible in this cases. This
status is signaled to the PLC.

Activation
The encoder limit frequency monitoring is always active if the encoder is turned on and is active for
axes and for a spindle.

Effect
The following will occur if the limit frequency of an encoder is exceeded:

 The IS “Encoder limit frequency exceeded 1” (V390x 0000.2) is set.

 Spindle continues running withspeed control
If the spindle speed is reduced such that the encoder frequency falls below the value specified
in MD 36302: ENC_FREQ_LIMIT_LOW (% value of MD 36300: ENC_FREQ_LIMIT), the
spindle will automatically resynchronize with the reference system of the encoder.
 If with an active measuring system of a position–controlled axis/spindle, the limit frequency is
exceeded, alarm 21610 ”Frequency exceeded” is output.
 The axis/spindle concerned is stopped with rapid stop (with open position control loop) via a
speed setpoint ramp.
The duration of the brake ramp is defined in MD 36610: AX_EMERGENCY_STOP_TIME (dura-
tion of braking ramp in case of error statuses).
 If the axis/spindle interpolates with other axes/spindles, these will also be stopped by rapid stop
with reduction of the following error (specification of partial setpoint = 0).

Error elimination
 After the axes have come to a standstill, the position control will resume automatically.

Note
The axis concerned must be rereferenced.

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2.3.2 Zero mark monitoring

Function
The zero mark monitoring checks whether pulses have been lost between two zero mark passages
of the position actual–value encoder. The number of detected zero mark errors at which the moni-
toring function is to respond is entered in MD 36310: ENC_ZERO_MONITORING (zero mark moni-
toring).

Activation
The monitoring is activated using MD 36310: ENC_ZERO_MONITORING.
The counting of the zero mark errors starts from zero after the encoder has been turned on.

Effect
If the number of the zero mark errors entered in MD 36310: ENC_ZERO_MONITORING is reached
for a measuring system, alarm 25020 ”Zero mark monitoring” is output.

The axis/spindle concerned is stopped with rapid stop (with open position control loop) via a speed
setpoint ramp.
The duration of the brake ramp is defined in MD 36610: AX_EMERGENCY_STOP_TIME (duration
of braking ramp in case of error statuses).
If the axis/spindle interpolates with other axes/spindles, these will also be stopped by rapid stop
with reduction of the following error (specification of partial setpoint = 0).

Error causes
 MD 36300: ENC_FREQ_LIMIT (encoder limit frequency) set too high.
 Encoder cable damaged.
 Encoder or encoder electronics defective.

Note
In case of an error, the IS “Referenced/synchronized 2” (V390x 0000.4) is canceled, i.e.
the axis must be rereferenced.

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2.4 Monitoring of static limitations

2.4.1 Limit switch monitoring

2nd SW limit switch HW limit switch Mechanical

(activated via PLC) traversing stop

1st SW limit switch EMERGENCY STOP

Fig. 2-3 Overview of limit stops of a linear axis

Hardware limit switches

Function
For each axis, one hardware limit switch each is provided for each traversing direction to prevent
the slide moving off the slide bed.
If the hardware limit switch is overtraveled, the PLC will signal it to the NC via the IS ”Hardware limit
switch plus/minus” (V380x 1000.1 or .0), and the movement of all axes is stopped.
The kind of braking can be defined via the MD 36600: BRAKE_MODE_CHOICE (braking behavior
with hardware limit switch).

Activation
The hardware limit switch monitoring is active in all operating modes after the control system has
powered up.

Effect
 When a hardware limit switch is overtraveled, depending on the direction, alarm 21614
”Hardware limit switch + or –” is output.
 Depending on MD 36600: BRAKE_MODE_CHOICE (braking behavior with hardware limit
switch), the axis is stopped.
 If the axis/spindle interpolates with other axes/spindles, these will also be stopped, depending
on MD 36600: BRAKE_MODE_CHOICE (braking behavior with hardware limit switch).
 The direction keys in the direction of approach are disabled.

Remedy
 initiate Reset.
 Move away in the opposite direction (in JOG mode).
 Correct the program.

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Software limit switches

Function
The software limit switches serve as limitations of the maximum traversing range of each individual
axis.
2 software limit switch pairs are provided per axis, which are defined via the following machine data
in the machine axis system:
MD 36110: POS_LIMIT_PLUS (1st software limit switch plus)
MD 36100: POS_LIMIT_MINUS (1st software limit switch minus)
MD 36130: POS_LIMIT_PLUS2 (2nd software limit switch plus)
MD 36120: POS_LIMIT_MINUS2 (2nd software limit switch minus)

Activation
 The software limit switch monitoring is active in all operating modes after reference point ap-
proach.
 The position of the software limit switches can be approached.
 The 2nd software limit switch can be activated from the PLC via the interface signal ”2nd soft-
ware limit switch plus/minus” (V380x 1000.3 or .2). The change will come into effect immediate-
ly. The 1st software limit switch plus/minus is thus inactive.
 The SW limit switch monitoring is not active with endlessly rotating rotary axes, i.e. if
MD 30310: ROT_IS_MODULO = 1. (modulo conversion for rotary axis and spindle)

Effect/reactions
Depending on the operating mode, there are different reactions if it was tried to overtravel a soft-
ware limit switch:
AUTO, MDA:

– The block that would violate the software limit switches will not start. The previous block is
completed correctly.
– The program execution is canceled.
– Alarm 10720 ”Software limit switch + or –” is output.
JOG:
– The axis is stopped at the software limit switch position.
– Alarm 10621 ”Axis has stopped on software limit switch + or –”.
– The direction keys in the direction of approach are disabled.

Special features:

– Switching over the software limit switch:

If the current position after switching over lies after the new software limit switch, the axis is
decelerated at the maximum permissible acceleration. If the axis interpolates with other
axes, these will also be decelerated. A contour violation may result.

Remedy
 Initiate Reset.
 Move away in the opposite direction (in JOG mode).
 Correct the program.

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2.4.2 Working area limitation

Function
Working area limitations describe the range in which a machining can be carried out. In addition to
the limit switches, the working area limitation is another means for the user to limit the traversing
range of the axes.

References: ”Operation and Programming“.

It is monitored whether the tool tip P is within the protected working area. The value entered in the
working area limitation is the last permissible position for the axis.
Using MD 21020: WORKAREA_WITH_TOOL_RADIUS (taking into account the tool radius in the
case of working area limitation), it can be determined whether the tool radius is taken into account
in the monitoring.

One pair of values (minus/plus) can be specified per axis to describe the protected working area.

Specifying the working area limitation

The working area limitation can be specified and modified in two different ways:
 via the operator panel in the “Parameters” operating area using the following setting data:
SD 43430: WORKAREA_LIMIT_MINUS (working area limitation minus)
SD 43420: WORKAREA_LIMIT_PLUS (working area limitation plus)
Any changes in Automatic mode are only possible in the Reset status and will then come into
effect immediately.
In Jog mode, changes are always possible, but come only into effect when a new movement
starts.
 in the program with G25/G26. Any changes come into effect immediately.
A programmed limitation has first priority; it will overwrite the value entered in the setting data
and is kept after RESET and program end.

XMachine
G26
Xmax

Tool tip

Working area

W ZMachine
G25
Xmin
G25 G26
Zmin Zmax

Fig. 2-4 Working area limitation shown using the example of a turning machine

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Activation
 Using SD 43410: WORKAREA_MINUS_ENABLE, SD 43400: WORKAREA_PLUS_ENABLE
(working area limitation in the negative or positive direction active), it is possible to activate the
working area limitation; it comes into effect after reference point approach.
 During the program execution, the working area limitation can be activated using the modal G
codes ”WALIMON” and deactivated using ”WALIMOF”.
 The working area limitation is not active with endlessly rotating rotary axes, i.e. if MD 30310:
ROT_IS_MODULO = 1 (modulo conversion for rotary axis and spindle).

Effect/reaction
Depending on the operating mode, there are different reactions if it has been tried to overtreavel the
work area limitation:
AUTO, MDA:

– The block that violates the working area limitation is not started. The previous block is still
completed correctly.
– The program execution is aborted.
– Alarm 10730 ”Working area limitation + or –” is set.
JOG:
– The axis stops at the position of the working area limitation.
– Alarm 10631 ”Axis stopped at working area limitation + or –” is set.
– The direction keys in the direction of approach are disabled.

Remedy
 Initiate Reset.
 Check the working area limitation in the part program (G25/G26) or in the setting data.
 Move away in the opposite direction (in JOG mode).

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2.5 Boundary conditions

To make sure that the monitoring functions respond correctly, make especially sure that the ma-
chine data are correct:
 MD 31030: LEADSCREW_PITCH (leadscrew pitch)
 Gear transmission ratio (load gear):
MD 31050: DRIVE_AX_RATIO_DENOM(load gear denominator)
MD 31060: DRIVE_AX_RATIO_NUMERA(load gear numerator)
Gear transmission ratio (encoder), also for spindle if any:
MD 31070: DRIVE_ENC_RATIO_DENOM (resolver gearbox denominator)
MD 31080: DRIVE_ENC_RATIO_NUMERA (resolver gearbox denominator)
 MD 32810: EQUIV_SPEEDCTRL_TIME
(speed control loop equivalent time constant for feedforward control)
 Ratio output voltage / output speed
(only applicable to analog spindle):
MD 32260: RATED_VELO (rated motor speed)
MD 32250: RATED_OUTVAL (rated output voltage)
 Encoder resolution
The corresponding machine data are described in

References: Chapter ”Velocities, Setpoint/Actual–Value Systems, Closed–Loop Control”

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2.6 Data descriptions (MD, SD)

2.6.1 Channel–specific machine data

21020 WORKAREA_WITH_TOOL_RADIUS
MD number Taking into account the tool radius with working area limitation
Default: 0 Min. input limit: 0 Max. input limit: 1
Change valid after RESET Protection level: 2/2 Unit: –
Data type: BOOLEAN Valid from SW release:
Meaning: 0: The tool radius is not taken into account.
1: The tool radius is taken into account in the working area limitation.

2.6.2 Axis/spindle–specific machine data

36000 STOP_LIMIT_COARSE
MD number Exact stop coarse
Default: 0.04 Min. input limit: 0.0 Max. input limit: ***
Change valid after NEW_CONF Protection level: 2/2 Unit: mm, degrees
Data type: DOUBLE Valid from SW release:
Meaning: An NC block is considered completed if the actual position of the path axes is away from the
setpoint position by the value of the entered exact stop limit. If the actual position of a path axis
is not within this limit, the NC block is not considered completed and the part program cannot be
continued. The time when the next block is processed depends on the size of the value entered.
The larger the value is, the earlier is the block change initiated. If the specified exact stop limit is
not reached,
– the block is not considered completed;
– the axis cannot be traversed further;
– the alarm 25080 “Positioning monitoring” is output after the time defined in
MD 36020: POSITIONING_TIME (exact stop fine monitoring time) has elapsed;
– the direction of movement +/– is displayed for the axis on the position display. The eaxt stop
window is also evaluated for spindles in the position–controlled mode.
Special cases, errors, ...... This MD may not be less than MD 36010: STOP_LIMIT_FINE (exact stop fine). To achieve the
same block change behavior as with the exact stop fine criterion, the exact stop coarse window
may be identical to the exact stop fine window.
This MD may not be equal to or greater than MD 36030: STANDSTILL_POS_TOL (standstill
position tolerance).
Related to .... MD 36020: POSITIONING_TIME (exact stop fine delay time)

36010 STOP_LIMIT_FINE
MD number Exact stop fine
Default : 0.01 Min. input limit: 0.0 Max. input limit: ***
Change valid after NEW_CONF Protection level: 2/2 Unit: mm, degrees
Data type: DOUBLE Valid from SW release:
Meaning: See MD 3600: STOP_LIMIT_COARSE (exact stop coarse)
Special cases, errors, ...... This MD may not be greater than MD 36000: STOP_LIMIT_COARSE (exact stop coarse).
This MD may not be equal to or greater than MD 36030: STANDSTILL_POS_TOL (standstill
position tolerance).
Related to .... MD 36020: POSITIONING_TIME (exact stop fine delay time)

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36020 POSITIONING_TIME
MD number Time delay for exact stop fine
Default: 1.0 Min. input limit: 0.0 Max. input limit: ***
Change valid after NEW_CONF Protection level: 2/2 Unit: s
Data type: DOUBLE Valid from SW release:
Meaning: This MD is used to specify the time after which the following error must have reached the limit
value for exact stop fine after the time for approaching the position has elapsed (partial position
set value=0 at the end of the movement). If this is not the case, the alarm 25080 ”Positioning
monitoring” is set and the axis concerned is decelerated.
The MD should be selected so generously that the monitoring does not respond in normal mode,
since the entire traversing process (acceleration, constant traversing, braking) is monitored by
other functions continuously.
Related to .... MD 36010: STOP_LIMIT_FINE (exact stop fine)

36030 STANDSTILL_POS_TOL
MD number Standstill position tolerance
Default: 0.2 Min. input limit: 0.0 Max. input limit: ***
Change valid after NEW_CONF Protection level: 2/2 Unit: mm, degrees
Data type: DOUBLE Valid from SW release:
Meaning: On completion of a traversing block (position setpoint has reached target), it is monitored whe-
ther the axis is no farther away from its set position than specified in
MD 36060: STANDSTILL_POS_TOL (standstill tolerance) after the parameterizable delay time
defined in MD 36040 STANDSTILL_DELAY_TIME (standstill monitoring delay time) has elapsed.
If the standstill position tolerance exceeds or falls below the set position, alarm 25040 ”Standstill
monitoring” is output and the axis is stopped.
Special cases, errors, ...... The standstill tolerance must be greater than the “Exact stop limit coarse”.
Related to .... MD 36040: STANDSTILL_DELAY_TIME (standstill monitoring delay time)

36040 STANDSTILL_DELAY_TIME
MD number Standstill monitoring delay time
Default: 0.4 Min. input limit: 0.0 Max. input limit: ***
Change valid after NEW_CONF Protection level: 2/2 Unit: s
Data type: DOUBLE Valid from SW release:
Meaning: see MD 36030: STANDSTILL_POS_TOL (standstill position tolerance)
Related to .... MD 36030: STANDSTILL_POS_TOL (standstill position tolerance)

36050 CLAMP_POS_TOL
MD number Clamping tolerance at interface signal ”Clamping active“
Default: 0.5 Min. input limit: 0.0 Max. input limit: ***
Change valid after NEW_CONF Protection level: 2/2 Unit: mm; degrees
Data type: DOUBLE Valid from SW release:
Meaning: The interface signal ”Clamping process running” (V380x0002.3) activates clamping monitoring. If
the monitored axis is pushed off the set position (exact stop limit) more than specified in the
clamping tolerance, alarm 26000 ”Clamping monitoring” is generated and the axis stopped.
Special cases, errors, ...... The clamping tolerance must be greater than the “Exact stop limit coarse”.
Related to .... IS ”Clamping process running“

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36060 STANDSTILL_VELO_TOL
MD number Max. velocity/speed ”Axis/spindle at a standstill“
Default: 5.0 mm/min, Min. input limit: 0.0 Max. input limit: ***
0.0138 rpm
Change valid after NEW_CONF Protection level: 2/2 Unit:
Linear axis: mm/min
Rotary axis: rpm
Data type: DOUBLE Valid from SW release:
Meaning: This machine date defines the standstill area for the axis velocity and/or for spindle speed.
If the current actual velocity of the axis and/or the actual speed of the spindle is less than the
value entered and if the NC does no longer deliver setpoints to the axis/spindle, the
IS ”Axis/spindle at a standstill” (V390x0001.4) is set.
Vact

MD:STANDSTILL_VELO_TOL
Vstill
t
1
IS
Spindle at a standstill

0
Application example(s) In order to allow a controlled stop of the axis/spindle, the pulse enable should only be canceled if
the axis/spindle has stopped. Otherwise, the axis would coast down.
Related to .... IS ”Axis/spindle at a standstill” (V390x0001.4)

36100 POS_LIMIT_MINUS
MD number 1st software limit switch minus
Default: – 100 000 000 Min. input limit: *** Max. input limit: ***
Change valid after Power On Protection level: 2/7 Unit: mm; degrees
Data type: DOUBLE Valid from SW release:
Meaning: The same meaning as the 1st software limit switch plus, but for the traversing area limit in the
negative direction.
The MD is active after reference point approach if the PLC interface signal
”2nd software limit switch minus” is not set.
MD inapplicable if ...... the axis is not referenced.
Related to .... IS ”2nd software limit switch minus”

36110 POS_LIMIT_PLUS
MD number 1st software limit switch plus
Default: 100 000 000 Min. input limit: *** Max. input limit: ***
Change valid after Power On Protection level: 2/7 Unit: mm; degrees
Data type: DOUBLE Valid from SW release:
Meaning: In addition to the hardware switch, it is also possible to use a software switch. The absolute posi-
tion in the machine coordinate system of the positive traversing limit is entered in this MD for
each axis.
The MD is active after reference point approach if the IS ”2nd software limit switch plus” is not
set.
MD inapplicable if ...... the axis is not referenced.
Related to .... IS ”2nd software limit switch plus”

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36120 POS_LIMIT_MINUS2
MD number 2nd software limit switch minus
Default: – 100 000 000 Min. input limit: *** Max. input limit: ***
Change valid after Power On Protection level: 2/7 Unit: mm; degrees
Data type: DOUBLE Valid from SW release:
Meaning: The same meaning as the 2nd software limit switch plus, but for the traversing area limit in the
negative direction.
Which of the two SW limit switches 1 or 2 is to be active can be selected from the PLC using the
interfrace signal.
e. g. V380x1000 bit 2 = 0 ”1st software limit switch minus” active for 1st axis
Bit 2 = 1 ”2nd software limit switch minus” active for 1st axis
MD inapplicable if ...... the axis is not referenced.
Related to .... IS ”2nd software limit switch minus”

36130 POS_LIMIT_PLUS2
MD number 2nd software limit switch plus
Default: 100 000 000 Min. input limit: *** Max. input limit: ***
Change valid after Power On Protection level: 2/7 Unit: mm; degrees
Data type: DOUBLE Valid from SW release:
Meaning: This machine data can be used to specify a 2nd software limit switch position in the machine
axis system in the positive direction.
Which of the two software limit switches 1 or 2 is to be active can be selected from the PLC
using the interface signal.
e. g.: V380x1000 Bit 3 = 0 ”1st software limit switch plus” active for the 1st axis
Bit 3 = 1 ”2nd software limit switch plus” active for 1st axis
MD inapplicable if ...... the axis is not referenced.
Related to .... IS ”2nd software limit switch plus”

36200 AX_VELO_LIMIT[0]....[5]
MD number Threshold value for velocity monitoring
Default: 11500 mm/min, Min. input limit: 0.0 Max. input limit: ***
31.944 rpm
Change valid after NEW_CONF Protection level: 2/7 Unit: mm/min
rpm
Data type: DOUBLE Valid from SW release:
Meaning: This MD is used to specify the threshold value of the actual–value velocity monitoring.
If the axis has at least one active encoder and this is below its limit frequency, alarm 25030 “Ac-
tual velocity alarm limit” is output if the threshold value is exceeded, and the axes are stopped.
Settings:
 For axes, select a value that is 10–15 % higher than
MD 32000: MAX_AX_VELO (max. axis velocity).
 For spindles, select a value per gear stage, which is 10–15 % higher than
MD 35110: GEAR_STEP_MAX_VELO_LIMIT[n] (max. gear stage speed).
The machine data index is coded as follows:
[control parameter block No.]: 0–5
For the activation of the control parameter records, please refer to:
References: Section ”Velocities, Setpoint/Actual–Value Systems, Closed–Loop Control“

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36300 ENC_FREQ_LIMIT[0]
MD number Encoder limit frequency
Default: 300000 Min. input limit: 0.0 Max. input limit: ***
Change valid after Power On Protection level: 2/2 Unit: Hz
Data type: DOUBLE Valid from SW release:
Meaning: This MD is used to specify the encoder limit frequency.

The active encoder is defined via the IS ”Position measuring system 1” (V380x0001.5).
Related to .... MD 36302: ENC_FREQ_LIMIT_LOW

36310 ENC_ZERO_MONITORING[0]
MD number Zero mark monitoring
Default: 0 Min. input limit: 0 Max. input limit: ***
Change valid after NEW_CONF Protection level: 2/2 Unit: –
Data type: DWORD Valid from SW release:
Meaning: This machine data is used to activate the zero reference mark monitoring and to define the num-
ber of illegal zero reference mark errors.
0: Zero mark monitoring OFF, encoder HW monitoring ON
1–99, > 100: Number of detected zero mark errors at which the monitoring is to respond
100: Zero mark monitoring OFF, encoder HW monitoring OFF
Examples: MD value = 1: The monitoring will respond at the 1st error.
MD value = 2: The 1st error is tolerated. The monitoring will respond at the 2nd error.
MD value = 3: The 1st and 2nd errors are tolerated. At the 3rd error, the monitoring will re-
spond.
After turning on the encoder, the error count will always start from zero.
Special cases, errors, ...... For absolute encoders, the zero mark monitoring must be disabled with the value = 0!

36400 CONTOUR_TOL
MD number Contour monitoring tolerance band
Default: 1.0 Min. input limit: 0.0 Max. input limit: ***
Change valid after NEW_CONF Protection level: 2/2 Unit: mm; degrees
Data type: DOUBLE Valid from SW release:
Meaning: The tolerance band for maximum contour deviation.
The admissible deviation between the real and the expected actual value is entered in this MD.
The input of a tolerance band is intended to avoid false trippings of the contour monitoring due to
slight speed variations resulting from process–related control operations (e.g. on first cut).
This MD has to be adapted to the position controller gain and, in case of feedforward control, to
the accuracy of the line motion model MD 32810: EQUIV_SPEEDCTRL_TIME (equivalent time
constant for feedforward control of speed control loop) and to the permissible accelerations and
velocities.
Further references see Section 2.2.1

36600 BRAKE_MODE_CHOICE
MD number Braking behavior with hardware limit switch
Default: 1 Min. input limit: 0 Max. input limit: 1
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BYTE Valid from SW release:
Meaning: If with a traversing axis a rising edge of the axis–specific hardware switch is detected, the axis is
decelerated immediately.
The deceleration mode is set in the machine data:

0: Controlled braking according to the acceleration ramp defined by

MD 32300: MAX_AX_ACCEL (axis acceleration).
1: Rapid deceleration (specification of setpoint = 0) with reduction of the following error
Related to .... IS ”Hardware limit switch plus or minus” (V380x1000.1 or V380x1000.0)

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36610 AX_EMERGENCY_STOP_TIME
MD number Duration of brake ramp in case of errors
Default: 0.05 Min. input limit: 0.02 Max. input limit: 1000

Change valid after NEW_CONF Protection level: 2/2 Unit: s

Data type: DOUBLE Valid from SW release:
Meaning: For axis: The axis concerned is stopped with rapid stop (with open position control loop) via a
brake ramp of the speed setpoint if the monitoring functions listed below respond:
 EMERGENCY STOP
 Following error monitoring
 Positioning monitoring
 Zero–speed control
 Clamping monitoring
 Set speed monitoring
 Actual velocity monitoring
 Encoder limit frequency monitoring (except for speed–controlled spindles)
 Zero mark monitoring
 Contur tunnel monitoring
If the encoder limit frequency is exceeded, the speed setpoint is displayed in the NC basic
screen as an actual value.
Enter the time needed to reduce the speed setpoint from the maximum speed setpoint to setpo-
int = 0 in MD 36610. The time until standstill depends on the current speed setpoint if a monito-
ring function responds.

Speed setpoint
MD 36210:
CTRLOUT_LIMIT

e.g. current
speed setpoint

Current time until axis t [s]

standstill

Check MD 36610:
AX_EMERGENCY_STOP_TIME
Fig. 4–1 Braking ramp in case of errors
For spindle: With spindles without active position control, the speed–controlled spindle may go
on rotating if the encoder frequency monitoring responds (i.e. without valid actual value informa-
tion); rapid stop is not carried out. If the encoder is turned on, the speed setpoint monitoring is
active, but the actual–velocity monitoring (MD 36200) is active. The limiting of the spindle speed
has only a limiting effect (no alarm), the setpoint is limited to the max. chuck speed (MD 35100)
and displayed in the IS ”Programmed speed too high”.
The current speed is no longer displayed, since no valid actual value exists at this moment.
Meaning: With interpolating axes, it is not guaranteed that the contour is not violated during the brake
phase.
CAUTION: If you have set the time of the brake ramp in errored states too much, servo enable
will be canceled even if the axis/spindle is still traversing/rotating. It will then sud-
denly be stopped with speed setpoint 0. That’s why the time in MD 36610:
AX_EMERGENCY_STOP_TIME should be less than the time in MD 36620:
SERVO_DISABLE_DELAY_TIME (servo disable delay time).
Related to .... MD 36620: SERVO_DISABLE_DELAY_TIME Servo disable delay time
MD 36210: CTRLOUT_LIMIT Max. speed setpoint

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2.6.3 Axis/spindle–specific setting data

43400 WORKAREA_PLUS_ENABLE
SD number Working area limitation in the positive direction active
Default: 0 Min. input limit: 0 Max. input limit: 1
Change valid: immediately Protection level: 7/7 Unit: –
Data type: BOOLEAN Valid from SW release:
Meaning: 0: The working area limitation of the axis in the positive direction is disabled.
1: The working area limitation of the axis in the positive direction is active.
The parameterization of the setting data is carried out from the operator panel in the “Parame-
ters” operating area by enabling/disabling the working area limitation.
SD inapplicable to ...... G code: WALIMOF

43410 WORKAREA_MINUS_ENABLE
SD number Working area limitation in the negative direction active
Default: 0 Min. input limit: 0 Max. input limit: 1
Change valid: immediately Protection level: 7/7 Unit: –
Data type: BOOLEAN Valid from SW release:
Meaning: 0: The working area limitation of the axis in the negative direction is disabled.
1: The working area limitation of the axis in the negative direction is active.
The parameterization of the setting data is carried out from the operator panel in the “Parame-
ters” operating area by enabling/disabling the working area limitation.
SD inapplicable to ...... G code: WALIMOF

43420 WORKAREA_LIMIT_PLUS
SD number Working area limitation plus
Default: 100 000 000 Min. input limit: *** Max. input limit: ***
Change valid: immediately Protection level: 7/7 Unit: mm, degrees
Data type: DOUBLE Valid from SW release:
Meaning: The working area limitation can be used to limit the working area of the MCS (machine coordina-
te system) in the positive direction of the corresponding axis.
The setting data can be modified from the operator panel in the ”Parameters” operating area.
The positive working area limitation can be modified in the program using G26.
SD inapplicable to ...... G code: WALIMOF
Related to .... SD 43400: WORKAREA_PLUS_ENABLE

43430 WORKAREA_LIMIT_MINUS
SD number Working area limiting minus
Default: – 100 000 000 Min. input limit: *** Max. input limit: ***
Change valid: immediately Protection level: 7/7 Unit: mm, degrees
Data type: DOUBLE Valid from SW release:
Meaning: The working area limitation can be used to limit the working area in the MCS (machine coordi-
nate system) in the negative direction of the corresponding axis.
The setting data can be modified from the operator panel in the ”Parameters” operating area.
The negative working area limitation can be modified in the program using G25.
SD inapplicable to ...... G code: WALIMOF
Related to .... SD 43410: WORKAREA_MINUS_ENABLE

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2.7 Signal description

2.7.1 Axis/spindle–specific signals

.
Signals to axis (V380x....) . Signals from axis (V390x....)
.
x=0 –> axis 1, Axis 3 x=0 –> axis 1,
x=1 –>axis 2, ... Axis 2 x=1 –>axis 2, ...
Axis 1

Clamping process running (V380x0002.3)

Hardware limit switch plus (V380x1000.1) Axis

monitoring
Hardware limit switch minus (V380x1000.0) functions Encoder limit frequency exceeded 1
(V390x0000.2)
2nd software limit switch plus (V380x1000.3)

2nd software limit switch minus (V380x1000.2)

Fig. 2-5 PLC interface signals for axis monitoring functions

Signals to axis/spindle

V380x0002.3 Clamping process running

Data block Signal(s) to axis/spindle (PLC –––> NCK)

Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge Clamping process running.
change 0 –––> 1. The clamping monitoring is activated.
Signal state 0 or edge Camping process completed.
change 1 –––> 0 The clamping monitoring is replaced by zero–speed control.
Related to .... MD 36050: CLAMP_POS_TOL (clamping position tolerance)
Further references Section 2.2.4

V380x0003.6 Velocity/spindle speed limitation

Data block Signal(s)

Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The NCK limits the velocity/spindle speed to the limit value specified in MD 35160:
change 0 –––> 1 SPIND_EXTERN_VELO_LIMIT.
Signal state 0 or edge No limitation active.
change 1 –––> 0
Related to .... MD 35100: SPIND_VELO_LIMIT (max. spindle speed)
SD 43220: SPIND_MAX_VELO_G26 (progr. spindle speed limiting G26)
SD 43230: SPIND_MAX_VELO_LIMIT (progr. spindle speed limiting G96)

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V380x1000.1 and .0 Hardware limit switch plus or minus

Data block Signal(s) to axis/spindle (PLC –––> NCK)

Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge One switch each can be installed at the end of both sides of the traversing range of a machine
change 0 –––> 1 axis, which provides a signal “Hardware limit switch plus or minus” to the NC via the PLC when
approaching the position.
If the signal is detected set, alarm 021614 ”Hardware limit switch + or –” is output and the axis is
decelerated immediately. How the axis is decelerated is defined by
MD 36600: BRAKE_MODE_CHOICE (braking behavior with hardware limit switch).
Signal state 0 or edge Normal state, no HW limit switch responded.
change 1 –––> 0
Related to .... MD 36600: BRAKE_MODE_CHOICE (braking behavior with hardware limit switch)

V380x1000.3 or .2 2nd software limit switch plus or minus

Data block Signal(s) to axis/spindle (PLC –––> NCK)

Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge 2nd software limit switch is active for the plus and/or minus direction.
change 0 –––> 1 1st software limit switch is inactive for the plus or minus direction.
In addition to the 1st software limit switches (plus and/or minus), 2nd software limit switches
(plus and/or minus) can be activated via the interface signals.
The position is defined by MD 36130: POS_LIMIT_PLUS, MD 36120:
POS_LIMIT_MINUS2 (2nd software limit switch plus, 2nd software limit switch minus).
Signal state 0 or edge 1st software limit switch is active for the plus and/or minus direction
change 1 –––> 0 2nd software limit switch is inactive for the plus and/or minus direction.
Related to .... MD 36110: POS_LIMIT_PLUS, MD 36130: POS_LIMIT_PLUS,
MD 36100: POS_LIMIT_MINUS, MD 36120: POS_LIMIT_MINUS2, (software limit switch plus,
software limit switch minus)

Signals from axis/spindle

V390x0000.2 Encoder frequency exceeded 1

Data block Signal(s) from axis/spindle (NCK –––> PLC)

Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The limit frequency set in MD 36300: ENC_FREQ_LIMIT (encoder limit frequency) has been
change 0 –––> 1 exceeded. The reference point for the position encoder has got lost (IS:
Referenced/synchronized has signal state 0). No position control is possible any more. The
spindles go on running with speed control.
The axes are stopped with rapid stop (with open position control loop) via a speed setpoint ramp.
Signal state 0 or edge The limit frequency set in MD 36300: ENC_FREQ_LIMIT is no longer exceeded (encoder
change 1 –––> 0 frequency).
For the edge change 1 ––> 0, the encoder frequency must have undershot the value
defined in MD 36302: ENC_FREQ_LIMIT_LOW (percentage value of MD 36300:
ENC_FREQU_LIMIT).

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2.8 Data fields, lists

2.8.1 Axis/spindle–specific interface signals

Number .Bit Name Ref.

Axis/spindle–specific
V380x0001 .5 Position encoder 1 A2
V380x0002 .3 Clamping process running
V380x0003 .6 Velocity/spindle speed limitation
V380x1000 .0 / .1 Hardware limit switch minus / hardware limit switch plus
V380x1000 .2 / .3 2nd software limit switch minus / 2nd software limit switch plus
V390x0000 .2 Encoder limit frequency exceeded 1
V390x0000 .4 Referenced/synchronized 1 R1

2.8.2 Axis/spindle–specific machine data

Number Identifier Name Ref.

Axis/spindle specific ($MA_ ... )
30310 ROT_IS_MODULO Modulo conversion for rotary axis and spindle R2
32000 MAX_AX_VELO Maximum axis velocity G2
32200 POSTCTRL_GAIN[n] Servo gain factor (”kv factor”) G2
32250 RATED_OUTVAL Rated output voltage G2
32260 RATED_VELO Rated motor speed G2
32300 MAX_AX_ACCEL Axis acceleration B2
32810 EQUIV_SPEEDCTRL_TIME[n] Speed control loop equivalent time constant for K3
feedforward control
35160 SPIND_EXTERN_VELO_LIMIT Spindle speed limiting from PLC S1
36000 STOP_LIMIT_COARSE Exact stop coarse
36010 STOP_LIMIT_FINE Exact stop fine
36020 POSITIONING_TIME Exact stop fine delay time
36030 STANDSTILL_POS_TOL Standstill position tolerance
36040 STANDSTILL_DELAY_TIME Standstill monitoring delay time
36050 CLAMP_POS_TOL Clamping position tolerance at IS ”Clamping
running”
36060 STANDSTILL_VELO_TOL Max. velocity/speed ”Axis/spindle at a standstill“
36100 POS_LIMIT_MINUS 1st software limit switch minus
36110 POS_LIMIT_PLUS 1st software limit switch plus
36120 POS_LIMIT_MINUS 2nd software limit switch minus
36130 POS_LIMIT_PLUS 2nd software limit switch plus

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Number Identifier Name Ref.

36200 AX_VELO_LIMIT[n] Threshold value for velocity monitoring
36210 CTRLOUT_LIMIT[n] Max. speed setpoint G2
36300 ENC_FREQ_LIMIT[n] Encoder limit frequency
36302 ENC_FREQ_LIMIT_LOW Encoder limit frequency resynchronization R1
36310 ENC_ZERO_MONITORING[n] Zero mark monitoring
36400 CONTOUR_TOL Tolerance band for contour monitoring
36500 ENC_CHANGE_TOL Large backlash values/ K3
maximum tolerance at actual position value
switchover
36600 BRAKE_MODE_CHOICE Braking behavior with hardware limit switch
36610 AX_EMERGENCY_STOP_TIME Duration of brake ramp in case of errors
36620 SERVO_DISABLE_DELAY_TIME Servo disable delay time N2

2.8.3 Channel–specific machine data

Number Identifier Name Ref.

Channel–specific ($MC_ ... )
21020 WORKAREA_WITH_TOOL_RADIUS Taking into account the tool radius with working
area limitation

2.8.4 Axis/spindle–specific setting data

Number Identifier Name Ref.

Axis/spindle–specific ($SA_ ... )
43400 WORKAREA_PLUS_ENABLE Working area limitation in the positive direction is
active
43410 WORKAREA_MINUS_ENABLE Working area limitation in the negative direction
is active
43420 WORKAREA_LIMIT_PLUS Working area limitation plus
43430 WORKAREA_LIMIT_MINUS Working area limitation minus

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Closed–Loop Control (G2) 3
3.1 Velocities, traversing ranges, accuracies

3.1.1 Velocities

The maximum path, axis velocity and spindle speed depend on the machine design, the dimensio-
ning of the drive dynamics and the limit frequency of the actual–value acquisition (encoder limit fre-
quency).
The maximum axis velocity is defined in MD 32000: MAX_AX_VELO (maximum axis velocity).
The maximum permissible spindle speed is preset using MD 35100: SPIND_VELO_LIMIT (maxi-
mum spindle speed).
References: Chapter ”Spindle”

In addition to the limitation by MD 32000: MAX_AX_VELO, the control system limits the maximum
path velocity acc. to the formula below, depending on the particular situation:

progr. path length in a part programblock [mm or degrees]

Vmax  * 0.9
IPOcycle [s]

In case the feed is higher (resulting from a feed programmed higher or due to feed override), it is
limited to Vmax.
With programs generated using CAD programs that contain extremely short blocks, this may result
in speed/velocity reduction over several blocks.
Example:
IPO cycle = 12 ms
N10 G0 X0 Y0; [mm]
N20 G0 X100 Y100; [mm]
⇒ programmed path length in the block = 141.42 mm

% Vmax = (141.42 mm / 12 ms) * 0.9 = 10606.6 mm/s = 636.39 m/min

The minimum path or axis velocitiy is subject to the following limitation:

Vmin  10 3

Computational resolution[mm orIncr.

degrees
] * IPOcycle [s]

The computational resolution is defined in MD 10200: INT_INCR_PER_MM (computational resolu-

tion for linear positions) or MD 10210: INT_INCR_PER_DEG (computational resolution for angle
positions). It is described on the following pages in detail.

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If Vmin is undershot, no traversing movement is carried out.

Example: MD 10200: INT_INCR_PER_MM = 1000 [Incr. / mm] ;

IPO clock = 12 ms;
⇒Vmin = 10 –3 / (1000 Incr/mm x 12 ms) = 0.005 mm / min;
The range of feed values is dependent on the computational resolution selected. If the default set-
ting has been chosen for MD 10200: INT_INCR_PER_MM (computational resolution for linear posi-
tions) (1,000 incr./mm) or MD 10210: INT_INCR_PER_DEG (computational resolution for angle
positions) (1,000 incr./degree), the range of values can be programmed with the resolution speci-
fied:
Range of values for feedrate F:
Metric system:
0.001 ≤ F ≤999,999.999 [mm/min, mm/rev., degrees/min, degrees/rev.]

Range of values for spindle speed S:

0.001 ≤ S ≤999,999.999 [rpm]

If the computational resolution is increased/reduced by factor 10, the ranges of values will change
accordingly.

3.1.2 Traversing ranges

The ranges of values of the traversing ranges is dependent on the computational resolution selec-
ted.

If the default setting has been selected for MD 10200: INT_INCR_PER_MM (computational resolu-
tion for linear positions) (1,000 incr./mm) and/or MD 10210: INT_INCR_PER_DEG (computational
resolution for angle positions) (1,000 incr./degree), the range of values can be programmed with the
resolution specified:

Table 3-1 Traversing ranges of the axes

G71 [mm, degrees] G70 [inch, degrees]

Range Range

Linear axes X, Y, Z, ... ± 999,999.999 ± 399,999.999

Rotary axes A, B, C, ... ± 999,999.999 ± 999,999.999

Interpolation parameters I, J, K ± 999,999.999 ± 399,999.999

Rotary axes are always specified in degrees.

If the computational resolution is increased/reduced by factor 10, the ranges of values will change
accordingly.

The traversing range can be limited using SW limit switches and work areas.
References: Section ”Axis Monitoring Functions“

The traversing range for rotary axes can be limited using machine data.

References: Section ”Rotary Axes“

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3.1.3 Input/display resolution, computational resolution

The resolutions of linear and angle positions, velocities, accelerations and jerk differ by:

 the input resolution, i.e. the input of data from the operator panel or via the part programs.
 the display resolution, i.e. the display of data on the operator panel.
 the computational resolution, i.e. the internal of the data input via the operator panel or the part
program.
The input and display resolution is determined by the operator panel used (display of machine
data), whereas the display resolution for position values/spindle speed can be modified using
MD 203: DISPLAY_RESOLUTION (display resolution, metric linear position, angle position general)
and/or MD 205: DISPLAY_RESOLUTION_SPINDLE (display resolution for spindle speed).
MD 204: DISPLAY_RESOLUTION_INCH can be used to configure the display resolution for linear
position values with inch setting.

For programming in part programs, the input resolutions indicated in the Programming Instructions
will apply.
The desired computational resolution is defined using the MD 10200: INT_INCR_PER_MM (compu-
tational resolution for linear positions) and MD 10210: INT_INCR_PER_ DEG (computational resolu-
tion for angle positions). It is independent of the input/display resolution, but should have at least the
same resolution.
The computational resolution defines the maximum number of the active places after the decimal
point for position values, speed values etc. in the part program, as well as the number of places af-
ter the decimal point for tool compensations, zero offsets etc. (and with it the maximum accuracy
that can be obtained).
The input accuracy of angle and linear positions is limited to the computational resolution by roun-
ding the product of the programmed value with the computational resolution to an integer number.
In order to ensure that the executed rounding can easily be traced, it is recommended to use num-
bers raised to the power of 10 for the computational resolution.

Example of rounding:

Computational resolution : 1,000 increments / mm

Programmed path : 97.3786 mm
active value = 97.379 mm

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3.1.4 Standardization of physical quantities of machine and setting data

Machine and setting data that have a physical quantity are interpreted by default with the following
input/output units, depending on the basic scaling system used (metric/inch):

Physical unit: Input/output

units for standard
scaling system:
Metric Inch

Linear position 1 mm 1 inch

Angular position 1 degree 1 degree
Linear velocity 1 mm/min 1 inch/min
Angular velocity 1 rpm 1 rpm
Linear acceleration 1 m/s2 1 inch/s2
Angular acceleration 1 rev./s2 1 rev./s2
Linear jerk 1 m/s3 1 inch/s3
Angular jerk 1 rev./s3 1 rev./s3
Time 1s 1s
Position controller servo gain 1/s 1/s
Revolutional feed 1 mm/rev. 1 inch/rev.
Compensation value of linear position 1 mm 1 inch
Compensation value of angle position 1 degree 1 degree

3.2 Metric/inch scaling system

The control system can use either the inch or the metric scaling system. The default setting is deter-
mined using MD 10240: SCALING_SYSTEM_IS_METRIC (default scaling system: metric). Depen-
ding on this setting, all geometric values are interpreted either as metric or inch dimensions. All ma-
nual settings, zero offset settings, tool compensation values, etc. with the related displays also refer
to this initial setting (e.g. handwheel, INC, conventional feed).
The setting MD 10260: CONVERT_SCALING_SYSTEM=1 makes the switching of the scaling sy-
stem considerably easier:

 Availability of an MMC softkey for scaling system switchover.

 Automatic conversion of NC active data in the case of scaling system switchover;
 Data back–up with identification of the scaling system currently used;
 MD 10240: SCALING_SYSTEM_IS_METRIC is activated by Reset.

3.2.1 Conversion of the scaling system using the part program

For certain workpiece–related data, it is possible to switchover between the scaling systems using
G70/G71 and G700/G710. The data that can be influenced by G70/G71/G700/G710 are described
in the Programming Instructions.

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When the scaling system is switched over using the appropriate MMC softkey, these reset positions
are defaulted with G700 or G710, depending on the new scaling system.

Application:
This function can be used, e.g. with a metric scaling system to machine an inch thread in a metric
part program. Tool offsets, zero offsets and feeds remain metric.

Machine data are output on the screen in the scaling system selected using the MD 10240:
SCALING_SYSTEM_IS_METRIC (metric scaling system).

Any displays in the machine coordinate system, as well as displays of the tool data and zero offsets
are carried out in the default setting, displays in the workpiece coordinate system with the current
setting.

Note:
If programs, incl. data records (ZO, tool offset) are read in from an external source, which have been
programmed in a scaling system other from the inital system, first the inital setting must be changed
using MD 10240: SCALING_SYSTEM_IS_METRIC.

For interface signals that contain dimension–dependent information, such as feed for path and posi-
tioning axes, the data exchange with the PLC is always carried out using the selected default sy-
stem.

G700/G710 is to be considered an extension of G70/G71 by the following functionality:

1. The feed is interpreted in the programmed scaling system:
 G700: Length information [inch]; feeds [inch/min]
 G710: Length information [mm]; feeds [mm/min]
The programmed feedrate acts modally, i.e. remains active beyond any following
G70/G71/G700/G710. If you wish the feedrate to become active in the new
G70/G71/G700/G710 context, it must be reprogrammed.
2. Reading and writing of length–related system variables and machine data in the part program is
carried out in the scaling system programmed.
These properties can be used to realize part programs that are independent of the current basic
setting of the scaling system.

Comparison of the effects of G70 and G700 on machine data and system variables in the part pro-
gram:

 G70: is used for reading and writing in the scaling system.

 G70: is used for reading and writing in programmed scaling system

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Comparison of G70/G71–G700/G710
Meaning:
P: Reading/writing of data are carried out in the programmed scaling system
G: Reading/writing of data are carried out in the initial scaling system
(MD 10240: SCALING_SYSTEM_IS_METRIC) R/W:
Read/Write

Table 3-2 Comparison

Range G70/G71 G700/G710

Part program Part program
Displays, digits after the comma (WCS) P/P P/P
Displays, digits after the comma (MCS) G/G G/G
Feedrates G/G P/P
Positional data X, Y, Z P/P P/P
Interpolation parameters I, J, K P/P P/P
Circle radius (CR) P/P P/P
Polar radius (RP) P/P P/P
Thread lead/pitch P/P P/P
Programmable offset rotation P/P P/P
Settable offset G54, G55, etc. G/G P/P
Working area limitations (G25/G26) G/G P/P
Tool offsets G/G P/P
Length–related machine data G/G P/P
Length–related setting data G/G P/P
Length–related system variables G/G P/P
R parameters G/G G/G
Siemens cycles P/P P/P
Increment weighting JOG/handwheel G/G G/G

3.2.2 Switching over the scaling system manually

General
The scaling system switchover for the whole machine is carried out using an MMC softkey “Switch
to mm > inch” and “Switch to inch > mm“ in the “POSITION” area.
Access to this softkey is only granted in JOG or MDA mode. The switchover will only be accepted if:

 The channel is in the Reset status.

 The axes are not traversed.
For the duration of the switchover operation, actions, such as part program start or mode change,
are disabled.

If no switchover can be carried out, an appropriate message will appear on the user interface. This
definition ensures that the program currently executed always finds a consistent data record with
reference to the scaling system.

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The actual process of switching over to the scaling system is internally carried out by writing of all
required machine data and then activating them by RESET.

MD 10240: SCALING_SYSTEM_IS_METRIC and the corresponding settings G70/G71/G700/G710

in MD 20150: GCODE_RESET_VALUES are switched over for all channels configured automati-
cally. Note: MD 20150 can only be read/written in expert mode (protection level 1).

During this process, the value specified in MD 20150: GCODE_RESET_VALUES[12] changes

between G700 and G710, i.e. the default position of the G commands changes between G700 and
G710.
This process is carried out independently of the protection level currently set.

System data
When switching over the scaling system, from the view of the operator, all length–related data are
automatically converted to the new scaling system. These data include:

 Positions
 Feedrates
 Accelerations
 Jerk
 Tool offsets
 Compensation values
 Machine data
 Jog and handwheel weightings
After switchover, all a/m data will be available in the physical quantities according to Section 3.1.4.

Data for which no unambiguous physical quantities are defined, such as:
 R parameters
will not be included in the automatic conversion. This is the user’s task to take into account the sca-
ling system currently active (MD 10240: SCALING_SYSTEM_IS_METRIC).

The scaling system setting currently active can be read from the PLC interface using the signal
”Inch scaling system“ V27000001.7.

Reference point
The reference point remains stored. Re–referencing is not necessary.

Input and computational resolution

The input/computational resolution is set in the control system using
MD 10200: INT_INCR_PER_MM. The default setting for a metric system is 1,000 (0.001 mm). For
an inch system, the setting must be 0.0001.

Example:

1 inch = 25.4 mm % 0.0001 inch = 0.00254 mm = 2.54 mm

To be able to program and display the last 40 nm, a value of 100,000 must be entered in MD 10200.
Only this setting, which must be the same for both scaling systems, scaling system switchover ac-
tions can be carried out without substantial losses in accuracy. If you have done this setting once,
the MD 10200 need not to be changed with each scaling system switchover.

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Jog and incremental weighting

The MD 31090: JOG_INCR_WEIGHT consists of two values containing the axis–specific increment
weightings for each of the two unit systems. The control system automatically selects the matching
value, depending on the current setting in MD 10240: SCALING_SYSTEM_IS_METRIC.

Note: The MD 31090: JOG_INCR_WEIGHT can only be read/writtten in the “Expert mode” access
level (protection level 1).
 Metric: MD 31090: JOG_INCR_WEIGHT[0;AX1]=0.001 mm
 Inch: MD 31090: JOG_INCR_WEIGHT[1;AX1]=0.00254 mm ⇒ 0.0001 inch

Data back–up
Data records that can be read from the control system separately and that have scaling system rele-
vant data, are assigned an inch and/or metric ID on reading, which corresponds to
MD 10240: SCALING_SYSTEM_IS_METRIC. This will save from which scaling system the data
have origininally been read.
This information is used to avoid that data records with a scaling system setting other than currently
set are re–read into the control system. In such a case, an appropriate alarm is provided (15030)
and the writing process is aborted.

Since the language statement is also evaluated in part programs, these can also be “protected”
against maloperation in the above mentioned manner. Thus it can be prevented that part programs
that, e.g. contain only metric data, can be run in an inch scaling system.

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3.3 Setpoint/actual–value system

3.3.1 General

Block diagram
A servo loop with the following structure can be configured for each controlled axis/spindle:

Speed setpoint Motor

Closed– Speed setpoint
output M
loop
control assignment

IS Position measuring system 1 MD 30130:

CTRLOUT_TYPE=0 (SIMULATION)
MD 30240:
ENC_TYPE=0 (SIMULATION)

Actual– Encoder
Actual–value value
processing G
assignment

Fig. 3-1 Block diagram of a closed–loop control circuit

Setpoint output
One setpoint each per axis/spindle can be output. The setpoint output to the actuator is provided
either digitally or, with an analog spindle 10 V unidirectionally/bidirectionally.

Simulation axes
For testing purposes, it is possible to simulate the speed control loop of an axis. In this case, the
axis will “traverse” with a following error, similar to a real axis.
A simulation axis is defined by setting the two MD 30130: CTRLOUT_TYPE[n] (setpoint output type)
and MD 30240: ENC_TYPE[n] (actual–value output type) to ”0”.

After loading the standard machine data, the axes are set to simulation.

With reference point approach, setpoint and actual value can be set to the reference point value.
MD 30350: SIMU_AX_VDI_OUTPUT (output of axis signals with simulation axes) can be used to
define whether the axis–specific IS are output to the PLC during the simulation.

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3.3.2 Drives connected to Profibus DP

General
The I/O devices connected to Profibus DP (e.g. SIMODRIVE 611-UE drives, I/O modules) are ac-
cessible through DP slave. A DP slave is a profibus node that has a PROFIBUS address (PB ad-
dress) and is loaded with values which is supplied by a master (in this case the SINUMERIK 802D).

SINUMERIK 802D
DP master
Profibus–DP

DP slave: PB address12 DP slave: PB address 3

Basic Drive Drive 72E 48A

device A B
unit

SIMODRIVE 611 universal E I/O module (digital)

Fig. 3-2 Principle of a Profibus configuration with drive 611UE (double–axis power section: drives A and B) and
I/O module

Drive configuration for SINUMERIK 802D with Profibus DP

A ready–to–use system data block is provided for the SINUMERIK 802D. This data block allows to
select a certain configuration of the SIMODRIVE 611UE drives and I/O modules using
MD 11240: PROFIBUS_SDB_NUMBER.
For the entire range of options, please refer to the detailed machine data description in the Section
“Data Description”.

The following numbers are assigned to the drives in accordance with the PB addresses and the axis
power section type (single– or double axis type) :
PB addr.10 –>drive number 5
PB addr.12 (drive A) –>drive number 1
PB addr.12 (drive B) –>drive number 2
PB addr.13 (drive A) –>drive number 3
PB addr.13 (drive B) –>drive number 4
This drive number allows the assignment of the machine axis to the corresponding drive (refer to the
next Section “Speed Setpoint and Actual–Value Assignment”

Note
With double–axis power sections, both drives (A and B) must always be assigned to one
axis. Otherwise, during power–up, an error message will occur, and the entire power sec-
tion will not be ready. If you wish to connect only one axis, the drive must be reparamete-
rized.

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MD 13060: DRIVE_TELEGRAM_TYPE[n] is used to set the default message type for the communi-
cation with any drive. When using the SIMODRIVE 611UE drive as a digital axis drive, the required
value = 102 is already set (default value).
For a drive operating as a spindle control, other settings may be required:
MD value = 0: for an additional analog spindle control on the drive
MD value = 104: for a digital spindle with direct position encoder
For a digital sindle with motor measuring system, MD value = 102 will apply.

Example of a digital drive (axis or spindle):

Drive number 1 –> MD 13060: DRIVE_TELEGRAM_TYPE[0] = 102
Drive number 2 –> MD 13060: DRIVE_TELEGRAM_TYPE[1] = 102
Drive number 3 –> MD 13060: DRIVE_TELEGRAM_TYPE[2] = 102
etc.

The drive parameterization is carried out as follows:

– on the display and control unit at the SIMODRIVE 611-UE
– using the parameterization and start–up tool “SimoCom U”
To do so, you will need the following documentation:
Description of Functions “SIMODRIVE 611 UE“

3.3.3 Speed setpoint and actual–value assignment

Prerequisites for the assignment

All NC machine data must be defined unambiguously in
MD 10000: AXCONF_MACHAX_NAME_TAB[n] (machine axis name). This name must be defined
unambiguously for the entire system.

Note
If you wish to use an analog spindle (instead of a digital one) in conjunction with the SIMODRIVE
611UE drive, some additional notes must be observed. Please refer to the Chapter “Spindle”.

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Speed setpoint assignment

The speed setpoint assignment is shown in the illustration below; the parameterization of the corres-
ponding machine data is described in the following:

Example: X1 axis = machine axis1: CTRLOUT_MODULE_NR = 1 –>drive number 1

Y1 axis = machine axis2: CTRLOUT_MODULE_NR = 2 –>drive number 2
Z1 axis = machine axis3: CTRLOUT_MODULE_NR = 3 –>drive number 3
SP spindle = machine axis5: CTRLOUT_MODULE_NR = 5 –>drive number 5
A1 axis = machine axis4: CTRLOUT_MODULE_NR = 4 –>drive number 4
Profibus DP
SINUMERIK
802D

(PB address 13)

(PB address 12)
(PB address 10)

Drive No. 1

Drive No.2

Drive No. 3

Drive No. 4
Drive No. 5

A A B A B

Example:
Single– and 2x double–axis power sec-
tion SIMODRIVE 611UE
(MD 11240:
PROFIBUS_SDB_NUMBER = 4)

Setpoint output
Single–axis Double–axis Double–axis
power section power section power section

Fig. 3-3 Speed setpoint assignment, example

Parameterize the following machine data of each machine axis:

 MD 30110: CTRLOUT_MODULE_NR[0]: Assignment of drive number
 MD 30130: CTRLOUT_TYPE[0] (setpoint output type): Enter here the type of the speed setpoint
output.

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Actual–value assignment
Due to the fixed assignment of the encoder (measuring system) to the drive, the actual value as-
signment must be carried out identically to the speed setpoint assignment (same drive number).
The actual–value assignment is shown in the illustration below. The parameters are described in the
corresponding machine data:

Example: X1 axis = machine axis1: CTRLOUT_MODULE_NR = 1 –>drive number 1

Y1 axis = machine axis2: CTRLOUT_MODULE_NR = 2 –>drive number 2
Z1 axis = machine axis3: CTRLOUT_MODULE_NR = 3 –>drive number 3
SP spindle = machine axis5: CTRLOUT_MODULE_NR = 5 –>drive number 5
A1 axis = machine axis4: CTRLOUT_MODULE_NR = 4 –>drive number 4
Profibus DP
SINUMERIK
802D

(PB address 13)

(PB address 12)
(PB address 10)

Drive No. 1

Drive No.2

Drive No. 3

Drive No. 4
Drive No. 5

A A B A B

Example:
Single– and 2x double–axis power sec-
tion SIMODRIVE 611UE
(MD 11240:
PROFIBUS_SDB_NUMBER = 4)

Setpoint output
Single–axis Double–axis Double–axis
power section power section power section

Fig. 3-4 Actual value assignment, example

Parameterize the following machine data of each machine axis:

 MD 30220: ENC_MODULE_NR[0] : Assignment of drive number

 MD 30240: ENC_TYPE[0] (actual–value acquisition mode): Enter here the encoder type used

Special features
 MD 30110: CTRLOUT_MODULE_NR[0] and
MD 30220: ENC_MODULE_NR[0] of a machine axis must have the same drive number.
 To operate a digital spindle with a direct position encoder, set
MD 30230: ENC_INPUT_NR[0] = 2 for the corresponding machine axis, and, if necessary, cor-
rect the direction using
MD 32110: ENC_FEEDBACK_POL[0] = –1.
Set the message type for the appropriate drive n to:
MD 13060: DRIVE_TELEGRAM_TYPE[n–1] = 104
In addition, parameterize the drive (via SimoComU).

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3.3.4 Speed setpoint output

MD 32100: AX_MOTION_DIR

nMotor nSpindle

ÍÍÍÍÍ
MD 31030: LEADSCREW_PITCH
Controller M
Load Ball screw
gear only for linear axes

MD 31060: DRIVE_AX_RATIO_NUMERA[n] Number of motor rev’s

=
MD 31050: DRIVE_AX_RATIO_DENOM[n] Number of load revolutions (spindle)

Fig. 3-5 Speed setpoint output

Traversing direction
MD 32100: AX_MOTION_DIR (traversing direction) can be used to revert the traversing direction of
the axis (without effect on the control direction of the position control).

Maximum speed setpoint

The maximum speed setpoint is defined using MD 36210: CTRLOUT_LIMIT. The value as a per-
centage refers to the speed (100 %) at which the axis velocity of MD 32000: MAX_AX_VELO is re-
ached. A value greater than 100 % contains the required control margin for the position control of
axes.

n set = speed setpoint

Max. speed setpoint
MD 36210: CTRLOUT_LIMIT
5–25% Speed at:
Max. axis velocity
MD 32000: MAX_AX_VELO

t [sec]

Fig. 3-6 Speed setpoint output

If values above the limit are specified, the value is limited to the value defined in MD 36210, the
axes are stopped, and an alarm is output. For detailed information, see Section “Axis monitoring
functions”.

In the case of an analog spindle, the maximum output speed is limited by the maximum setpoint
output voltage of 10 V. The value of MD 36210: CTRLOUT_LIMIT should not be above the speed
setpoint reached at this voltage (100 %).

Note
For special features regarding the control of a spindle, please refer to the Chapter
“Spindle”.

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3.3.5 Actual–value processing

Actual–value resolution
To create a position control loop that is connected correctly, it is necessary to convey the actual–va-
lue resolution to the control system.
Parameterize the following machine data for the main applications depending on the axis type (li-
near axis, rotary axis/spindle, analog spindle) and depending on the type of actual value acquisition
(direct, indirect) to calculate the actual value resolution:

Machine Data Linear Axis Rotary Axis Spindle

Encoder on Encoder on Encoder on Encoder on without

motor motor motor machine measuring
system

MD 30200: NUM_ENCS 1 1 1 1 0
(number of encoders)

MD 30300: IS_ROT_AX 0 1 1 1 1
(rotary axis)

MD 31040: ENC_IS_DIRECT[0] 0 0 0 1 1
(encoder is installed directly on the machine)

MD 31020: ENC_RESOL[0] incr./rev. incr./rev. incr./rev. incr./rev. –

(encoder increments per revolution)

MD 31030: LEADSCREW_PITCH mm/rev. – – – –

(leadscrew pitch)

MD 31080: – – – load rev’s –

DRIVE_ENC_RATIO_NUMERA[n]
(measuring gear numerator)

MD 31070: – – – encoder –
DRIVE_ENC_RATIO_DENOM[n] rev’s
(resolver gearbox denominator)

MD 31060: motor rev’s Motor rev’s Motor rev’s see –

DRIVE_AX_RATIO_NUMERA[n] note *)
(load gear numerator)

MD 31050: ball screw load rev’s load rev’s see –

DRIVE_AX_RATIO_DENOM[n] spindle note *)
(load gear denominator) rev’s

– = not applicable to this combination

The index [n] of the machine data is coded as follows:
MD: DRIVE_AX_...[servo parameter record no.] : 0–5

Note
*) These MD are not required for the encoder adaptation (path evaluation). For setpoint
calculation, however, they must be entered correctly! Otherwise, the desired loop gain
factor will not be set.

Variants of actual–value sensing

The appropriate machine data for the individual variants of actual value sensing are decribed in the
following.

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Linear axis with rotatory encoder installed on the motor

MD: IS_ROT_AX = 0
nEncoder
MD: ENC_IS_DIRECT=0

ÍÍÍÍÍ
Table
G M Ball screw

Load
gear nSpindle LEADSCREW_PITCH
nMotor
MD: MD: DRIVE_AX_RATIO_NUMERA No. of motor rev’s
ENC_RESOL =
MD: DRIVE_AX_RATIO_DENOM No. of spindle rev’s

Fig. 3-7 Linear axis with rotary encoder installed on the motor

Rotary axis with rotary encoder installed on the motor

MD: MD:
n ENC_IS_DIRECT=0 n IS_ROT_AX=1
Encoder Load

G M L Rotary table
Load
gear
n MD: DRIVE_AX_RATIO_NUMERA No. of motor rev’s
MD: Motor =
ENC_RESOL MD: DRIVE_AX_RATIO_DENOM No. of load rev’s

Fig. 3-8 Rotary axis with rotary encoder installed on the motor

Spindle with rotary encoder installed on the machine

n Load

Spindle chuck
MD:
ENC_IS_DIRECT=1
n Encoder
MD:
M L G ENC_RESOL

MD: MD: DRIVE_ENC_RATIO_NUMERA No. of load rev’s

IS_ROT_AX=1 =
MD: DRIVE_ENC_RATIO_DENOM No. of load rev’s
Load Resolver
gear gear

Fig. 3-9 Spindle with rotarory encoder installed on the the machine

Note:
MD 32110: ENC_FEEDBACK_POL (sign of actual value) can be used to change the sign of the
actual–value sensing and thus also the control direction of the position control.

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3.4 Closed–loop control

General
The closed–loop control of an axis consists of the current and of the speed control loop of the drive
and of a higher–livel position–control loop in the NC.
The speed and current control are explained in:
References: Description of Functions “SIMODRIVE 611 UE”

MD 32400: AX_JERK_ENABLE
MD 32410: AX_JERK_TIME MD 32200: POSCTRL_GAIN

Interpolator/ Feedforward Closed–loop Speed

jerk limitation control control setpoint
processing

MD 32100: AX_MOTION_DIR

IS: Position encoder 1

Actual–value
value
MD 32620: FFW_MODE processing
MD 32630: FFW_ACTIVATION_MODE
MD 32610: VELO_FFW_WEIGHT MD 32110: ENC_FEEDBACK_POL
MD 32810: EQUIV_SPEEDCTRL_TIME MD 32700: ENC_COMP_ENABLE
MD 32450: BACKLASH

Fig. 3-10 Principle of the position control of an axis/spindle

For the description of the jerk limitation, see:

References: Section ”Acceleration”

For the description of feedforward control, backlash and backlash error compensation, see:
References: Section ”Compensations”

Servo gain factor

To ensure that there are only small contour deviations in continuous–path mode, a high servo gain
factor MD 32200: POSCTRL_GAIN[n] (position controller–loop gain) is required.

The index[n] of the machine data is coded as follows:

[control parameter record No.]: 0 – 5

If the loop gain factor is too high, however, overshot and (in some cases) inadmissible high loads on
the machine may be the consequence.

The maximum permissible servo gain depends on:

 dimensioning and dynamic properties of the drive

(rise time, acceleration and brake properties)
 quality of machine (elasticity, vibration dampening)
 position–control clock

Speed [mmin]
KV  ; Unit of servo gain factor acc. to the VDI standard
Followingerror [mm]

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Parameter records of the position controller

The position control can use up to 6 different parameter records. These serve for
 quick accomodation of the position controller to modified properties of the machine during opera-
tion, e.g. when switching over the spindle gearbox.
 accomodation of the dynamic properties of an axis to another axis, e.g. on tapping.
The following machine data can jointly be changed by parameter record switchover during opera-
tion.

MD 31050: DRIVE_AX_RATIO_DENOM[n] (load gear denominator)

MD 31060: DRIVE_AX_RATIO_NUMERA[n] (load gear numerator)
MD 32200: POSCTRL_GAIN[n] (servo gain factor)
MD 32810: EQUIV_SPEEDCTRL_TIME[n] (equivalent time constant of speed control loop for
feedforward control)
MD 36200: AX_VELO_LIMIT[n] (threshold value for velocity monitoring)
The index [n] of the machine data is coded as follows:
[control parameter record No.]: 0–5

Parameter records for spindle:

With the spindle, each gear stage isassigned its own parameter record. Depending on the IS “Actual
gear stage” (V380x2000.0 to .2), the appropriate parameter record is activated.
Note: For the machine data required to switchover the gear stage of the spindle, please refer to the
Chapter “Spindle”.

IS ”Actual Gear Stage“ Active Parameter Record

000 2 (Index=1)
001 2 (Index=1)
010 3 (Index=2)
011 4 (Index=3)
100 5 (Index=4)
101 6 (Index=5)

Parameter records for axes

– For axes not involved in tapping or thread cutting, parameter record 1 (index=0) is activated
in any case.
– For axes involved in tapping or thread cutting, the same parameter record number is activa-
ted as for the current gear stage of a spindle.
The current parameter record is displayed in the operating area “Diagnosis” in the display ”Service
of axis”.

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3.5 Data description (MD, SD)

3.5.1 General machine data

10200 INT_INCR_PER_MM
MD number Computational resolution for linear positions
Default: 1000 Min. input limit: 1.0 Max. input limit: ***
Change valid after Power On Protection level: 2/2 Unit: –
Data type: DOUBLE Valid from SW release:
Meaning: This MD is used to define the number of internal increments per millimiter.
The input accuracy of linear positions is limited to the computational resolution by rounding the
product of the programmed value with the computational resolution to an integer number.
To be able to trace the rounding easily, numbers raised to the power of 10 should be used for the
computational resolution.
Application example(s) In the case of high demands on the accuracy of linear axes, the computational resolution can be
increased to values greater than 1,000 incr./mm.

10210 INT_INCR_PER_DEG
MD number Computational resolution for angular positions
Default: 1000 Min. input limit: 1.0 Max. input limit: ***
Change valid after Power On Protection level: 2/2 Unit: –
Data type: DOUBLE Valid from SW release:
Meaning: This MD is used to define the number of internal increments per degree.
The input accuracy of angular positions is limited to the computational resolution by rounding the
product of the programmed value with the computational resolution to an integer number.
To be able to trace the rounding easily, numbers raised to the power of 10 should be used for the
computational resolution.
Application example(s) For a high–resolution rotary axis, the computational resolution can be changed to < 1,000 incr./de-
grees.

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10240 SCALING_SYSTEM_IS_METRIC
MD number Metric scaling system
Default: 1 Min. input limit: 0 Max. input limit: 1
Change valid after Power On Protection level: 2/7 Unit: –
Data type: BOOLEAN Valid from SW release:
Meaning: The MD defines the scaling system used by the control system for the scaling of length–dependent
physical quantities for data I/O.
Internally, all data are stored in the basic units 1 mm, 1 degree and 1 sec.
When accessing from the part program, the operator panel or via external communication, the
following units are used for scaling:
SCALING_SYSTEM_IS_METRIC = 1: scaled in:
mm, mm/min, m/s2, m/s3, mm/rev.
SCALING_SYSTEM_IS_METRIC = 0: scaled in:
inch, inch/min, inch/s2, inch/s3, inch/rev.
The selection of the scaling system also defines the interpretation of the F value programmed for
linear axes:
metric inch
G94 mm/min inch/min
G95 mm/rev. inch/rev.
After the machine data have been modified, the control system must be rebooted; otherwise, the
machine data with physical units will not be scaled correctly.
Observe the following procedure:
 MD change by manual input
Reboot the control system and then enter the appropriate machine data with their
physical units
 MD change is carried out using a machine data file
Reboot the control system and then reload the machine data file so that the physical
units come into effect.
If the machine data are modified, the alarm 4070 ”Scaled machine data changed” is output.
Application example(s) Start–up in the metric system and then conversion to the inch system

11240 PROFIBUS_SDB_NUMBER
MD number SDB1000 number
Default: 0 Min. input limit: 0 Max. input limit: 5
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BYTE Valid from SW release:
Meaning: Number of system data block used (SDB1000) for configuring the Profibus I/Os.
With SINUMERIK 802D, the following options are offered to choose from:
0, 1, 5: reserved
0: I/O module: 1st PP (DP addr. 9), 2nd PP (DP addr. 8) = digital inputs/outputs
Drives: none (simulated axes)

3: I/O module: 1st PP (DP addr. 9 ), 2nd PP (DP addr. 8) = digit. inputs
in uts and out uts
outputs
Drives:
Double–axis power section (DP addr. 12: drive A = drive no. 1, drive B = drive no. 2)
+ single–axis power section (DP addr. 10 = drive no. 5)
+ single–axis power section (DP addr. 11 = drive no. 6)

4: I/O module: 1st PP (DP addr. 9 ), 2nd PP (DP addr. 8) = digit. inputs and outputs
Drives:
Double–axis power section (DP addr.12: drive A = drive no. 1, drive B = drive no. 2)
+ double–axis power section (DP addr.13: drive A = drive no. 3, drive B = drive no. 4)
+ single–axis power section (DP addr.10 = drive no. 5)

Note:
The assignment of a drive to the related machine axis is carried out using the axis–specific ma-
chine data CTRLOUT_MODULE_NR = ENC_MODULE_NR = drive number.

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13060 DRIVE_TELEGRAM_TYPE[n]
MD number Default message type for drives at Profibus DP
Default: Min. input limit: 0 Max. input limit: ***
(102, 102, 102, 102, 102)
Change valid after Power On Protection level: 2/2 Unit: –
Data type: DWORD Valid from SW release:
Meaning: Specify the message type for each drive at Profibus DP:
0: for additional analog spindle control on the drive
102: SIMODRIVE 611UE – digital axis/spindle
104: SIMODRIVE 611UE – spindle with direct measuring system
Index [n] of the machine data is coded as follows: [drive index]:
n=0: drive 1
n=1: drive 2, etc.

3.5.2 Channel–specific machine data

20150 GCODE_RESET_VALUES[n]
MD number Erase position of the G groups [G group no.]: 0...59
Default: see below Min. input limit: 0 Max. input limit: 14
Change valid after RESET Protection level: 1/1 Unit: –
Data type: BYTE Valid from SW release:
Meaning: Definition of the G codes that become active during start–up and reset or at the end of the part
program and when starting the part program.
As a default value, the index of the G codes must be specified in the appropriate groups.
Designation Group Standard Value
GCODE_RESET_VALUES[0] 1 2 (G01)
GCODE_RESET_VALUES[1] 2 0 (inactive)
GCODE_RESET_VALUES[2] 3 0 (inactive)
GCODE_RESET_VALUES[3] 4 1 (START FIFO)
GCODE_RESET_VALUES[4] 5 0 (inactive)
GCODE_RESET_VALUES[5] 6 1 (G17) for milling
GCODE_RESET_VALUES[6] 7 1 (G40)
GCODE_RESET_VALUES[7] 8 1 (G500)
GCODE_RESET_VALUES[8] 9 0 (inactive)
GCODE_RESET_VALUES[9] 10 1 (G60)
GCODE_RESET_VALUES[10] 11 0 (inactive)
GCODE_RESET_VALUES[11] 12 1 (G601)
GCODE_RESET_VALUES[12] 13 2 (G71)
GCODE_RESET_VALUES[13] 14 1 (G90)
GCODE_RESET_VALUES[14] 15 2 (G94)
GCODE_RESET_VALUES[15] 16 1 (CFC)
...
Further references
For a list of the G groups and the functions assigned to them, please refere to:
References: “Operation and Programming”

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3.5.3 Axis–specific machine data

30110 CTRLOUT_MODULE_NR[n]
MD number Setpoint: Drive number/module number
Default: 1 Min. input limit: 1 Max. input limit: 9
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BYTE Valid from SW release:
Meaning: Enter the drive number for a standard axis.

For an analog spindle:

Enter the transferring drive number used to address the output for the analog spindle.
Index [n] of the machine data is coded as follows: [Setpoint branch]: 0

30120 CTRLOUT_NR[n]
MD number Setpoint: Output on the module
Default: 1 Min. input limit: 1 Max. input limit: 2
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BYTE Valid from SW release:
Meaning: Number of output on a module used to address the setpoint output.

Index [n] of the machine data is coded as follows: [setpoint branch]: 0

30130 CTRLOUT_TYPE[n]
MD number Setpoint output type
Default: 0 Min. input limit: 0 Max. input limit: 1
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BYTE Valid from SW release:
Meaning: In this MD, the type of the speed setpoint output is entered:
0: Simulation (no hardware required)
1: Setpoint output active
Index [n] of the machine data is coded as follows: [setpoint branch]: 0
Application example(s) Simulation: Machine functions can also be simulated without a drive connected.

30200 NUM_ENCS
MD number Number of encoders
Default: 1 Min. input limit: 0 Max. input limit: 1
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BYTE Valid from SW release:
Meaning: 1: Spindle/axis with direct measuring system (integrated in the motor or direct)
0: without measuring system (possible with spindle)

30220 ENC_MODULE_NR[n]
MD number Actual value: Drive number/measuring circuit number
Default: 1 Min. input limit: 1 Max. input limit: 9
Change valid after Power On Protection level: 2/7 Unit: –
Data type: BYTE Valid from SW release:
Meaning: Enter the drive number for a standard axis/spindle.

For an analog spindle:

Enter the transferring drive number used to address the output for the analog spindle.
Index [n] of the machine data is coded as follows: [encoder no.]: 0

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30230 ENC_INPUT_NR[n]
MD number Actual value: Input number on module/measuring circuit card
Default: 0 Min. input limit: 0 Max. input limit: 5
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BYTE Valid from SW release:
Meaning: Number of the input on a module, which is used to address the encoder.

The index[n] of the machine data is coded as follows: [encoder no.]: 0

Application example(s) Simulation:
Machine functions can be simulated even without a measuring system connected.

30240 ENC_TYPE[n]
MD number Actual value: Encoder type
Default: 0 Min. input limit: 0 Max. input limit: 4
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BYTE Valid from SW release:
Meaning: In this MD, the type of the encoder used is entered:
0: Simulation
1: Signal generator (1VSS, sin, cos)
4: Absolute encoder with EnDat interface
2, 3, 5: reserved
Index [n] of the machine data is coded as follows: [encoder No.]: 0
Application example(s) Simulation:
Machine functions can also be simulated without measuring system connected.

30350 SIMU_AX_VDI_OUTPUT
MD number Output of axis signals with simulation axes
Default: 0 Min. input limit: 0 Max. input limit: 1
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BOOLEAN Valid from SW release:
Meaning: This machine data is used to define whether during the simulation of an axis axis–specific interface
signals are output to the PLC.
1: The axis–specific IS (interface signals) of a simulated axis are output to the PLC.
It is thus possible to test the PLC user program without the need to connect drives.
0: The axis–specific interface signals of a simulated axis are not output to the PLC.
All axis–specific interface signals are set to “0”.
MD inapplicable ...... MD 30130: CTRLOUT_TYPE (setpoint output type) = 1
Application example(s) MD: SIMU_AX_VDI_OUTPUT = 0
This prevents, e.g. that during the simulation of an axis the brake is released.

31020 ENC_RESOL[n]
MD number Increments per revolution
Default: 2048 Min. input limit: 0 Max. input limit: ***
Change valid after Power On Protection level: 2/2 Unit: –
Data type: DWORD Valid from SW release:
Meaning: In this MD, the increments per encoder revolution are entered.
The index [n] of the machine data is coded as follows: [encoder No.]: 0

31030 LEADSCREW_PITCH
MD number Leadscrew pitch
Default: 10.0 Min. input limit: 0.0 Max. input limit: ***
Change valid after Power On Protection level: 2/2 Unit: mm/rev.
Data type: DOUBLE Valid from SW release:
Meaning: In this MD, the leadscrew pitch is entered.

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31040 ENC_IS_DIRECT[n]
MD number The encoder is directly mounted on the machine.
Default: 0 Min. input limit: 0 Max. input limit: 1
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BOOLEAN Valid from SW release:
Meaning: 1: Encoder for actual position sensing is mounted directly on the machine.
0: Encoder for actual position sensing is mounted on the motor.
Index [n] of the machine data is coded as follows: [encoder No.]: 0
Special cases, errors, ...... A wrong entry may result in wrong encoder resolution, since, e.g. the wrong gear transmission
ratios are calculated.

31050 DRIVE_AX_RATIO_DENOM[n]
MD number Load gear denominator
Default: 1 Min. input limit: 1 Max. input limit: 2 147 000 000
Change valid after Power On Protection level: 2/2 Unit: –
Data type: DWORD Valid from SW release:
Meaning: In this MD, the denominator of the load gear must be entered.
Index [n] of the machine data is coded as follows: [control parameter record No.]: 0–5
Further references

31060 DRIVE_AX_RATIO_NUMERA[n]
MD number Load gear numerator
Default: 1 Min. input limit: –2 147 000 000 Max. input limit: 2 147 000 000
Change valid after Power On Protection level: 2/2 Unit: –
Data type: DWORD Valid from SW release:
Meaning: In this MD, the numerator of the load gear is entered.
Index [n] of the machine data is coded as follows: [control parameter record No.]: 0–5

31070 DRIVE_ENC_RATIO_DENOM[n]
MD number Resolver gearbox denominator
Default: 1 Min. input limit: 1 Max. input limit: 21 47 000 000
Change valid after Power On Protection level: 2/2 Unit: –
Data type: DWORD Valid from SW release:
Meaning: In this MD, the name of the resolver gearbox is entered.
Index [n] of the machine data is coded as follows: [encoder No.]: 0

31080 DRIVE_ENC_RATIO_NUMERA[n]
MD number Resolver gearbox numerator
Default: 1 Min. input limit: 1 Max. input limit: 2 147 000 000
Change valid after Power On Protection level: 2/2 Unit: –
Data type: DWORD Valid from SW release:
Meaning: In this MD, the numerator of the resolver gearbox is entered.
The index [n] of the machine data is coded as follows: [encoder No.]: 0

32000 MAX_AX_VELO
MD number Maximum axis velocity
Default: 10 000 mm/min, Min. input limit: 0.0 Max. input limit: ***
27.77 rpm
Change valid after NEW_CONF Protection level: 2/7 Unit: mm/min,
rpm
Data type: DOUBLE Valid from SW release:
Meaning: In this MD, enter the limit velocity up to which the axis can accelerate (rapid traverse limitation).
If rapid traverse G0 is programmed, this speed is used for traversing. Depending on
MD: IS_ROT_AX, enter the maximum linear ond/or rotary axis speed in the MD.
The max. permissible axis velocity depends on the machine and axis dynamics and the limit fre-
quency of actual–value sensing.

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32100 AX_MOTION_DIR
MD number Traversing direction
Default: 1 Min. input limit: –1 Max. input limit: 1
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BYTE Valid from SW release:
Meaning: This MD can be used to revert the direction of rotation of the machine axis. The control direction,
however, is not reverted, i.e. the closed–loop control remains stable.
0 or 1: no direction reversal
–1: direction reversal

32110 ENC_FEEDBACK_POL[n]
MD number Sign of actual value (control direction)
Default: 1 Min. input limit: – 1 Max. input limit: 1
Change valid after Power On Protection level: 2/2 Unit: –
Data type:BYTE Valid from SW release:
Meaning: In this MD, the direction of evaluation of the encoder signals is entered.
0 or 1: no direction reversal
–1: direction reversal
In the case of direction reversal, the control direction is also reverted if the encoder is used for the
position control.
Index [n] of the machine data is coded as follows: [encoder No.]: 0
Special cases, errors, ...... If a wrong control direction is entered, the axis may run away.
Depending on the setting of the corresponding limit values, one of the following alarms may occur:
Alarm 25040 ”Zero–speed control“
Alarm 25050 ”Contour monitoring“
Alarm 25060 ”Speed setpoint limitation”
The corresponding limit values are described in:
References: Section ”Axis Monitoring Functions”
If there is an uncontrolled, sudden setpoint change when connecting a drive, a wrong control direc-
tion may have been set.

32200 POSCTRL_GAIN[n]
MD number Servo gain factor
Default: 1.0 Min. input limit: 0.0 Max. input limit: 2000
Change valid after NEW_CONF Protection level: 2/7 Unit: (m/min)/mm
Data type: DOUBLE Valid from SW release:
Meaning: Position controller gain, so–called servo gain factor.
The input/output unit for the user is [ (m/min)/mm].
i.e. POSCTRL_GAIN[n] = 1 corresponds to 1 mm following error at V = 1 m/min.

If ”0” is entered, the position controller is disconnected.

When entering the servo gain factor, take into account that the gain factor of the entire position
control loop is also dependent on other parameters of the controlled system. A distinction must
therefore be made between a ”desired servo gain factor” (MD: POSCTRL_GAIN) and a ”real servo
gain factor“ (resulting on the machine). Only if all parameters of the control loop are matched an-
other to one correctly, these servo gain factors are identical.
Note:
The axes which interpolate another to one and have to carry out a machining process, must have
the same gain (i.e. the same following error at the same velocity).
The real servo gain factor can be checked by means of the following error in the service displays.
Index [n] of the machine data is coded as follows: [control parameter record No.]: 0–5

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36210 CTRLOUT_LIMIT[n]
MD number Max. speed setpoint
Default: 110.0 Min. input limit: 0.0 Max. input limit: 200
Change valid after NEW_CONF Protection level: 2/7 Unit: %
Data type: DOUBLE Valid from SW release:
Meaning: This MD is used to define the maximum speed setpoint value in per cent.
This specification refers to the speed (100 %) at which the velocity defined in MD 32000:
MAX_AX_VELO is reached. A value greater than 100 % contains the required control margin with
digital drives.
If values above the limit are specified, the value is limited to the MD value, the axes are stopped
and an alarm is generated.

With an analog spindle, the maximum output speed is limited by the maximum setpoint output
voltage of 10 V. The value in this MD should not be above the speed setpoint reached at this volta-
ge (100 %).
Index[n] of the machine data is coded as follows: [setpoint branch]: 0
Further references see Section “Axis monitoring functions”

3.6 Signal descriptions

V2700 0001.7 System inch unit

Interface signal Signal(s) to NC (PLC –––> NC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 The NC uses the inch scaling system.
Signal state 0 The NC uses the metric scaling system.

3.7 Data fields, data lists

3.7.1 Interface signals

Number .Bit Name Ref.

General
V27000001 .7 System inch unit
Axis–specific
V380x 2000 .0 to .2 Actual gear stage of spindle S1

3.7.2 Machine data

Number Identifier Name Ref.

Operator–panel specific
203 DISPLAY_RESOLUTION Display resolution Chapter 19
204 DISPLAY_RESOLUTION_INCH Display resolution for INCH scaling system Chapter 19
205 DISPLAY_RESOLUTION_SPINDLE Display resolution for spindle Chapter 19

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Number Identifier Name Ref.

General
10000 AXCONF_MACHAX_NAME_TAB[n] Machine axis name Chapter 19
10200 INT_INCR_PER_MM Computational resolution for linear positions
10210 INT_INCR_PER_DEG Computational resolution for angle positions
10240 SCALING_SYSTEM_IS_METRIC Metric scaling system
11240 PROFIBUS_SDB_NUMBER SDB1000 number (Profibus DP)
13060 DRIVE_TELEGRAM_TYPE[n] Default message type for drives at Profibus DP
Channel–specific
20150 GCODE_RESET_VALUES[n] Reset position of G groups
Axis–specific
30110 CTRLOUT_MODULE_NR[n] Setpoint assignment: Drive number/module number
(analog spindle)
30120 CTRLOUT_NR[0] Setpoint: Output on module
30130 CTRLOUT_TYPE[n] Setpoint output type
30134 IS_UNIPOLAR_OUTPUT Setpoint output is unipolar (analog spindle) S1
30200 NUM_ENCS Number of encoders =1 (spindle without encoder
value =0)
30220 ENC_MODULE_NR[n] Actual–value: Drive module no./measuring circuit no.
30230 ENC_INPUT_NR[0] Actual value: Input number on module/measuring cir-
cuit card
30240 ENC_TYPE[n] Actual–value sensing mode (actual position)
30300 IS_ROT_AX Rotary axis R2
30350 SIMU_AX_VDI_OUTPUT Output of axis signals with simulation axes
31020 ENC_RESOL[n] Increments per revolution
31030 LEADSCREW_PITCH Leadscrew pitch
31040 ENC_IS_DIRECT[n] Encoder is mounted directly on the machine
31050 * DRIVE_AX_RATIO_DENOM[n] Load gear denominator
31060 * DRIVE_AX_RATIO_NUMERA[n] Load gear numerator
31070 DRIVE_ENC_RATIO_DENOM[n] Resolver gearbox denominator
31080 DRIVE_ENC_RATIO_NUMERA[n] Resolver gearbox numerator
32000 MAX_AX_VELO Maximum axis velocity
32100 AX_MOTION_DIR Traversing direction
32110 ENC_FEEDBACK_POL[n] Sign of actual value (control direction)
32200 * POSCTRL_GAIN[n] Servo gain factor
32450 BACKLASH[n] Backlash K3
32700 ENC_COMP_ENABLE[n] Interpolatory compensation K3
32810 * EQUIV_SPEEDCTRL_TIME[n] Equivalent time constant of speed control loop for K3
feedforward control
33630 FFW_ACTIVATION_MODE Activate feedforward control from program K3
35100 SPIND_VELO_LIMIT Maximum spindle speed S1
36200 * AX_VELO_LIMIT[n] Threshold value for velocity monitoring A3
36210 CTRLOUT_LIMIT[n] Max. speed setpoint
The machine date marked with an * (asterisk) are contained
in a parameter record of the position controller.

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Acceleration (B2) 4
4.1 Acceleration profiles

Sudden acceleration
In case of the v/t linear velocity control of an axis, which is usually used, the motion is controlled
such that the acceleration changes suddenly over the time. With this discontinuous, sudden accel-
eration, jerk–free starting and deceleration of the axes is not possible, but a time–optimized velocity/
time profile can be realized.

Jerk–limited acceleration
The jerk is the change of the acceleration over the time. With jerk–limited acceleration, the
maximum acceleration is specified not suddenly, but along a ramp. Due to the smoother accelera-
tion characteristic, the traversing time increases towards a sudden acceleration whereas the path,
velocity and acceleration remain the same. In some cases, this loss in time can be compensated by
setting a higher settable axis acceleration.

This, however, has the following advantages:

 Saving of the machine mechanics

 Reduction of the excitation of high–frequency vibrations of the machine, which can badly be
controlled.

4.2 Jerk limitation on interpolator level

Selection and deselection of jerk–limited acceleration

MD 32431: MAX_AX_JERK (maximum axial jerk on path traversing) can be used to limit the
acceleration change for each machine axis separately. It is active for the axes that are interpolated
by the path provided that SOFT is active. The jerk–limited acceleration is exclusively carried out on
the interpolator level.
The jerk–limited acceleration is enabled by:

programming SOFT in the part program. SOFT is modally active and deselects the sudden
acceleration profile (BRISK). If SOFT is programmed with path axes in one and the same block,
the previous block is completed with exact stop.
The jerk–limited acceleration (SOFT) is disabled by:

programming BRISK in the part program. BRISK is modally active. If path axes are programmed
with BRISK in one and the same block, the previous block is completed with exact stop. The
sudden acceleration profile of the v/t linear velocity control is enabled using BRISK.

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Acceleration (B2)

Active range
The path–related jerk limitation is available for the interpolating path axes in the operating modes
AUTO and MDA. The acceleration profiles SOFT and BRISK can be used together with the travers-
ing mode “Exact stop” G09, G60, continuous–path mode G64 and LookAhead. The profiles are also
active with the function “Dry Run Feed”. Alarms that trigger off a rapid stop will disable both
acceleration profiles.
For more detailed information on the behavior of velocity, acceleration, jerk when traversing in the
continuous–path mode and, in particular, at block transitions, please refer to:

References: Section ”Continuous Path Mode, Exact Stop and Look Ahead”

Note: It is recommended to set the MD 32431: MAX_AX_JERK and

MD 32432: PATH_TRANS_JERK_LIM (maximum axis–specific jerk with path movement at the
block transition) to the same values for the appropriate axis.

4.3 Jerk limitation in JOG mode

The jerk limitation is active for axes in JOG mode on

 manual traversing
 handwheel traversing
 repositioning.
The jerk limitation is not active
 during reference point approach.
 for alarms that cause rapid stop.
The jerk limitation can be specified axis–specifically. The acceleration behavior corresponds to the
acceleration profile SOFT of the path–related jerk limitation. This limitation cannot be deselected for
the axes in the individual operating modes.

Which of the desired axes will be provided with a jerk limitation, can be set in MD 32420:
JOG_AND_POS_JERK_ENABLE. The permissible axis–specific maximum jerk is stored in MD
32430: JOG_AND_POS_MAX_JERK.

4.4 Percentage acceleration correction, ACC

Function
Some program sections may require to programmably modify the axis or spindle acceleration
defined in machine data. This programmable acceleration is a percentage acceleration correction.

The program command: ACC[channel axis name] = percentage value

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 Acceleration (B2)

can be used to program a percentage value > 0% and  200% for each axis (e.g.: X) or spindle
(S1). In this case, the axis interpolation is carried out on the basis of this proportional acceleration.
The acceleration stored in the axis–specific MD 32300: MAX_AX_ACCEL constitutes the reference
for an axis (100%). For the spindle, this reference (100%) depends on the active spindle mode and
the gear stage (n = 1 ... 5)
MD 35200: GEAR_STEP_SPEEDCTRL_ACCEL[n] in control mode or
MD 35210: GEAR_STEP_POSCTRL_ACCEL[n] in positioning mode.

References: Chapter ”Spindle”

Example: N10 ACC[X]=80 ; 80% of the acceleration for the X axis

References: ”Operation and Programming”

Activation
The limitation is active in all interpolation modes of AUTOMATIC and MDA modes. The limitation is
not active in JOG mode and during reference point approach.

The value assignment ACC[...] = 100 disables the correction (100% of the MD values); the same
applies to RESET and end of program.
The programmed value is also active during dry run feed.

Error states
The limitation of the acceleration is inactive in error states that lead to a rapid stop with open
position control loop (since the axis is stopped along a braking ramp of the speed setpoint value).
Note: A value programmed greater than 100% can only be executed if the drives have the
appropriate reserves – otherwise, alarm messages are output.

4.5 Data descriptions (MD, SD)

32300 MAX_AX_ACCEL
MD number Axis acceleration
Default: 1.0 m/s2 Min. input limit: 0.0 Max. input limit: ***
2.77 rev/s2
Change valid after NEW_CONF Protection level: 2/7 Unit: m/s2, rev/s2
Data type: DOUBLE Valid from SW release:
Meaning: The acceleration specifies a velocity change of the axis over a certain time. Different axes need
not absolutely necessary have the same acceleration. The lowest acceleration value will be used
for interpolating axes.
For rotary axes, the entered value corresponds to the angular acceleration.
The machine manufacturer must find out for which permanent brake mode and which permanent
acceleration is suited for the machine. This value must then be entered in this machine data.
The acceleration value is active for each acceleration/deceleration process.
MD inapplicable to ...... error states resulting in rapid stop

32420 JOG_AND_POS_JERK_ENABLE
MD number Enable axis–specific jerk limitation
Default: 0 Min. input limit: 0 Max. input limit: 1
Change valid after RESET Protection level: 2/2 Unit: –
Data type: BOOLEAN Valid from SW release:
Meaning: Enables the function of axis–specific jerk limitation for the modes JOG, REF and the positioning
axis mode.
Related to .... MD 32430: JOG_AND_POS_MAX_JERK (axis–specific jerk)

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Acceleration (B2)

32430 JOG_AND_POS_MAX_JERK
MD number Axis–specific jerk
Default: 1000.00 m/s3, Min. input limit: 0.0 Max. input limit: ***
2777.77 rev./s3
Change valid after RESET Protection level: 2/2 Unit: m/s3, rev./s3
Data type: DOUBLE Valid from SW release:
Meaning: The jerk limit value limits the change in axis acceleration in JOG mode.
MD inapplicable to ...... path interpolation and error states resulting in rapid stop
Related to ...... MD 32420: JOG_AND_POS_JERK_ENABLE (enable axis–specific jerk limitation)

32431 MAX_AX_JERK
MD number Maximum axis–specific jerk when traversing along the contour
Default: 1000.00 m/s3, Min. input limit: 0.0 Max. input limit: ***
2777.77 rev./s3
Change valid after NEW_CONF Protection level: 3/3 Unit: m/s3, rev./s3
Data type: DOUBLE Valid from SW release:
Meaning: This maximum axis–specific jerk is active with path movements.
Path movements are possible in AUTO and MDA modes..
Related to ... MD 32432: PATH_TRANS_JERK_LIM is active at block transition.
It is recommended to set both MD to the same value.

4.6 Data fields, lists

Number Identifier Name Ref.

Axis–specific machine data
32300 MAX_AX_ACCEL Axis acceleration
32420 JOG_AND_POS_JERK_ENABLE Enable axis–specific jerk limitation
32430 JOG_AND_POS_MAX_JERK Axial jerk
32431 MAX_AX_JERK Maximum axis–specific jerk for path movement
32432 PATH_TRANS_JERK_LIM Maximum axis–specific jerk for path movement at block B1
transition

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Spindle (S1) 5
5.1 Brief description

Spindle application
Depending on the machine type, the following functions are possible for an NC–controlled spindle:
 Definition of a direction of rotation of the spindle (M3, M4)
 Definition of a spindle speed (S)
 Spindle stop, without orientation (M5)
 Spindle positioning (SPOS=)
(position–controlled spindle required)
 Gear step switchover (M40 to M45)
 Thread cutting/tapping (G33, G331, G332, G63)
 Revolutional feed (G95)
 Constant cutting speed (G96)
 Programmable spindle speed limitations (G25, G26, LIMS=)
 Position encoder mounted on the spindle or on the spindle motor
 Spindle monitoring for min. and max. speed
 Dwell time in spindle revolutions (G4 S)
Instead of the controlled spindle, a “switched” spindle can be used. In this case, the spindle speed
(S) is not specified from the program, but, e.g. by manual operation (gearbox) on the machine. It is
thus also not possible to program any speed limitations. The following is possible via the program:
 Definition of a direction of rotation of the spindle (M3, M4)
 Spindle stop, without orientation (M5)
 Tapping (G63)
If the spindle is equipped with a position encoder, in addition to the above mentioned functions, the
functions listed below are possible:
 Thread cutting/tapping (G33)
 Revolutional feed (G95)
For a switched spindle, the setpoint output for the spindle via
MD 30130: CTRLOUT_TYPE =0 must be suppressed.

Defining the spindle

A machine axis is declared a spindle by setting the following machine data:
MD 30300: IS_ROT_AX, MD 30310: ROT_IS_MODULO, MD 30320: DISPLAY_IS_MODULO and
MD 35000: SPIND_ASSIGN_TO_MACHAX. The spindle mode is signaled by the IS “Spindle/no
axis“ (V390x 0000.0).

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Spindle (S1)

5.2 Spindle modes

Spindle modes
The spindle can be operated in the following modes:
 Control mode see Section 5.2.1
 Oscillation mode see Section 5.2.2.
 Positioning mode see Section 5.2.3
 Tapping without compensating chuck also refer to Section“Feed” (Thread Interpolation)
and
References: ”Operation and Programming“

Changing the spindle mode

Oscillation m.

Change Gear stage

gear stage changed
SPOS
Control mode Positioning mode

M3, M4, M5,

M41–45
SPOS
G331
G332

Rigid tapping
(without compen-
sating chuck)

Fig. 5-1 Changing between the spindle modes

 Control mode –––> oscillation mode

The spindle changes to oscillation mode if a new gear stage has been specified using the auto-
matic gear stage selection (M40) in conjunction with a new S value or by M41 to M45. The
spindle will only change to oscillation mode if the new gear stage is other than the current actual
gear stage.
 Oscillation mode –––> control mode
If the new gear stage has been selected, the IS “Oscillation mode” (V390x2002.6) is reset, and
the IS “Gear switched over” (V380x2000.3) will cause the spindle to change to control mode.
The spindle speed last programmed (S value) is active again.
 Control mode –––> positioning mode
If the spindle is to be stopped from rotation (M3 or M4) with orientation or if the spindle is to be
re–oriented from the standstill (M5), switchover to positioning mode is carried out using SPOS.
 Positioning mode –––> control mode
To end the orientation of the spindle, M3, M4 or M5 are used to switch over to control mode. The
spindle speed last programmed (S value) is active again.
 Positioning mode –––> oscillation mode
To end the orientation of the spindle, M41 to M45 can be used to switch over to oscillation mode.
If the gear stage change is completed, the spindle speed last programmed (S value) and M5
(control mode) are active again.

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 Spindle (S1)

 Positioning mode –––> tapping without compensating chuck (rigid tapping)

Tapping without compensating chuck (helix interpolation) is activated using G331/G332. First the
spindle must be switched to position–controlled mode using SPOS.

5.2.1 Spindle mode: Control mode

When control mode?

The spindle is in control mode if the following functions are active:
 Constant spindle speed S, M3/M4/M5 and G94, G95, G97, G33, G63
 Constant cutting rate G96 S, M3/M4/M5

Prerequisites
A spindle actual position encoder is absolutely necessary for M3/M4/M5 in conjunction with revolu-
tional feed (G95, F in mm/rev. or inch/rev.), constant cutting rate (G96, G97) and thread cutting
(G33).

Separate spindle reset

MD 35040: SPIND_ACTIVE_AFTER_RESET is used to set the reaction of the spindle after reset or
program end (M2, M30):

 In the case of MD value=0, the spindle is immediately braked down to a standstill at the valid
acceleration. The spindle speed last programmed and the direction of rotation of the spindle will
be deleted.
 In the case of MD value=1 (separate spindle reset), the last programmed spindle speed (S func-
tion) and the last programmed sense of rotation of the spindle (M3, M4, M5) will be maintained.
If prior to reset or end of program the constant cutting rate (G96) is active, the current spindle
speed (referred to 100% spindle override) is internally accepted as the spindle speed last pro-
grammed.

Note
The spindle can always be decelerated using the IS ”Delete distance to go/spindle reset”.
CAUTION: If G94 is provided, the program will go on running. With G95, the axes will come to a
standstill due to the missing feed and thus also the program run if G1, G2, ... is active.

5.2.2 Spindle mode: Oscillation mode

Starting the oscillation mode

This oscillating movement facilitates meshing of a new gear stage. Generally, the new gear stage
may also be switched on without oscillation.
The spindle is in oscillation mode if a new gear stage has been set by the automatic gear stage se-
lection (M40) or by M41 to M45 (IS ”Switch over gear” (V390x2000.3) has been set). The IS ”Switch
over gear” is only set if the new gear stage specified is other than the current actual gear stage.
Oscillation of the spindle is started using the IS ”Oscillation speed” (V380x202.5).

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Spindle (S1)

If only the IS “Oscillation speed” is set without specifying a new gear stage, the spindle will not
change to oscillation mode.

The oscillation is started using the IS “Oscillation speed”. For the functional sequence, a distinction
is made between the following cases, depending on the IS ”Oscillation by the PLC” (V380x2002.4):
 Oscillation by the NCK
 Oscillation by the PLC

Oscillation time
For each direction of rotation, the oscillation time can be defined in a machine data:

 Oscillation time in M3 direction (in the following referred to as t1) in

MD 35440: SPIND_OSCILL_TIME_CW
 Oscillation time in M4 direction (in the following referred to as t2) in
MD 35450: SPIND_OSCILL_TIME_CCW

Oscillation by the NCK

Phase 1: The IS ”Oscillation speed” (V380x2002.5) enables the spindle motor to accelerate to the
speed set in MD 35400: SPIND_OSCILL_DES_VELO (oscillation speed) (with oscillation accelera-
tion). The start direction is determined by MD 35430: SPIND_OSCILL_START_DIR (start direction
on oscillation).

Phase 2: If time t1 (t2) has elapsed, the spindle motor accelerates in the opposite direction to the
speed set in the MD 35400: SPIND_OSCILL_DES_VELO (oscillation speed) in the opposite direc-
tion. Time t2 (t1) is started.

Phase 3: If time t2 (t1) has elapsed, the spindle motor accelerates in the opposite direction (the
same direction as in phase 1), etc.

Oscillation by the PLC

The IS ”Oscillation speed” (V380x2002.5) accelerates the spindle motor to the speed set in
MD 35400: SPIND_OSCILL_DES_VELO (oscillation speed) (with oscillation acceleration). The di-
rection of rotation is set by the IS ”Set direction CCW” or IS ”Set direction CW” (V380x2002.7 or .6).
The oscillation (oscillation movement) and the two times t1 and t2 (time for direction of rotation CW
and CCW) must be simulated in the PLC.

End of oscillation mode

The IS ”Gear has been switched over” (V380x2000.3) tells the NCK that the new gear stage (IS ”Ac-
tual gear stage” (V380x2000.0 to .2)) is valid, and that the oscillation mode is ended. The actual
gear stage should correspond to the set gear stage. The oscillation mode is also ended if the IS
”Oscillation speed” (V380x2002.5) is still set. The spindle speed last programmed (S function) and
the direction of rotation of the spindle (M3, M4 or M5) are active again.
After the oscillation mode has been ended, the spindle is in control mode again.

All gear–specific limit values (min./max. speed of the gear stage, etc.) corresponding to the specified
values of the actual gear stage are switched off at spindle standstill.

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 Spindle (S1)

Block change
If the spindle has been switched over to oscillation mode (IS ”Switchover gear” (V390x2000.3) is
set), the part program execution is stopped. No new block will be started. If the oscillation mode is
ended by the IS ”Gear has been switched over” (V380x2000.3), the part program execution is resu-
med. A new block will be executed.

Speed
(1/min)

IS: Gear switched

Block change is carried out here

Time (s)

Fig. 5-2 Block change after oscillation mode

Special features
 The acceleration is defined in MD 35410: SPIND_OSCILL_ACCEL (acceleration on oscillation).
 If the IS ”Oscillation speed” (V380x2002.5) is reset, the oscillation stops. The spindle mode
“Oscillation”, however, is not quitted.
 The gear stage change should always be ended by the IS “Gear is switched over”.
 The IS ”Reset” (V30000000.7) will not cancel the oscillation mode.
 If an indirect measuring system is used, the synchronization gets lost. Upon next zero mark
overtravel, a synchronization is carried out again.

Reset during gear stage change

A spindle stop is not possible through the IS ”Reset” (V30000000.7) or the IS ”NC stop”
(V32000007.3), if the spindle is in oscillation mode for gear stage change and if the IS ”Gear is swit-
ched over” (V380x2000.3) is not yet present.

In these cases if reset is selected the alarm 10640 ”Stop not possible during gear stage change” is
displayed.
After the gear steps have been changed, the reset request is carried out and the alarm cleared if
this is still provided at the interface.

Note
Possibility to abort: Set IS ”Delete distance–to–go/spindle reset” (V380x0002.2)

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Spindle (S1)

5.2.3 Spindle mode: Positioning mode

When positioning mode?

In positioning mode, the spindle is stopped at the specified position. The position control is enabled
and remains active until it is deselected. During the program function SPOS =....., the spindle is in
positioning mode (also refer to Chapter 5.5 “Programming”).

Block change
Programming with SPOS:
The block change is carried out as soon as all functions programmed in the block have reached
their block end criterion (e.g. axes terminated, all auxiliary functions acknowledged from the PLC)
and as soon as the spindle has reached its position (IS ”Exact stop fine” for the spindle
(V390x0000.7)).

Prerequisites
Spindle actual position encoder is absolutely necessary.

Positioning from rotation

Phases 1 to 5:

Speed
(1/min) 1 MD 36300: ENC_FREQ_LIMIT
( limit frequency of the encoder)
MD 36302: ENC_FREQ_LIMIT_LOW
(encoder limit frequency resynchronization)
2

3 MD 35300: SPIND_POSCTRL_VELO
(position controller threshold speed)
1a 4
4a

5 Time (s)
SPOS=...

Fig. 5-3 Positioning from the rotation at different speeds

Sequence
Phase 1: The spindle rotates at a speed less than the encoder limit frequency. The spindle is syn-
chronized. It is in control mode. Continued with phase 2.
Phase 1a: The spindle rotates at a speed less than the position controller threshold speed. The
spindle is synchronized. It is in control mode. Continuation is possible with 4a.
Phase 1b (not shown): The spindle rotates at a speed higher greater than the encoder limit fre-
quency. First, the spindle is not synchronized, but will be synchronized when the speed defined in
MD 3602: ENC_FREQ_LIMIT_LOW (percentage value of MD 36300) is undershot. Continued with
phase2.

Phase 2: When the SPOS instruction comes into effect, the spindle starts to decelerate to the posi-
tion controller threshold speed at the acceleration stored in MD 35200:
GEAR_STEP_SPEEDCTRL_ACCEL.

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 Spindle (S1)

Phase 3: When the position controller threshold speed stored in

MD 35300: SPIND_POSCTRL_VELO + is reached:

 the position control is connected,

 the distance to go (to the target position) is calculated , (it is more likely to be possible from
phase 1a)
 the acceleration to MD 35210: GEAR_STEP_POSCTRL_ACCEL (acceleration in position con-
trol mode) is switched over (is always active below the position controller threshold speed)
Phase 4: The spindle brakes from the calculated ”braking point” at
MD 35210: GEAR_STEP_POSCTRL_ACCEL until the target position is reached.

Phase 5: The position control remains active and keeps the spindle in the programmed position.
The IS ”Position reached at exact stop fine” (V390x0000.7) and ”... coarse” (V390x0000.6) are set,
if the distance between the actual spindle position and the programmed position (spindle setpoint
position) is less than the exact stop fine and coarse (determined in MD 36010: STOP_LIMIT_FINE
and MD 36000 :STOP_LIMIT_COARSE).

Positioning from the standstill, spindle not synchronized

After the control system has been turned on, spindle is not synchronized. The first movement of the
spindle will be positioning (SPOS=...).

Speed
(1/min) Phases 1 to 4:
MD 35300:
SPIND_POSCTRL_VELO 2
(Position controller threshold speed)
3
1

Position reached Time (s)

Start at: SPOS=...
Brake threshold point
sychronized at zero mark

Fig. 5-4 Positioning with the spindle stopped and not synchronized

Sequence
Phase 1: If SPOS is programmed, the spindle will accelerate at the acceleration defined in
MD 35210: GEAR_STEP_ POSCTRL_ACCEL (acceleration in position control mode) until the
speed entered in MD 35300: SPIND_POSCTRL_VELO (position controller switch–on speed) is re-
ached.
The direction of rotation is determined by MD 35350: SPIND_POSITIONING_ DIR (direction of rota-
tion when positioning from the standstill), unless there is no preset value from the SPOS program-
ming ( ACN, ACP, IC). The spindle is synchronized with the next zero mark of the position actual–
value encoder.

Phase 2: After the spindle has been synchronized, the position control is enabled. The spindle will
rotate not faster than specified in MD 35300: SPIND_POSCTRL_VELO until the brake starting point
calculation recognizes when the spindle may exactly approach the programmed spindle position
with the acceleration defined.

Phase 3: The spindle brakes at the brake threshold point at the acceleration defined in
MD 35210: GEAR_STEP_ POSCTRL_ACCEL (acceleration in position control mode).

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Spindle (S1)

Phase 4: The spindle has reached the position and is at a standstill. The position control is active
and keeps the spindle in the programmed position. The IS ”Position reached with exact stop fine”
(V390x0000.7) and ”... coarse” (V390x0000.6) are set if the distance between the spindle actual
position and the programmed position (spindle setpoint position) is less than the value of exact stop
fine and coarse ( MD 36010: STOP_LIMIT_FINE and MD 36000: STOP_LIMIT_COARSE).

Positioning from the standstill, spindle is synchronized

The spindle has already been rotated by at least one spindle revolution using M3 or M4 and has
then be stopped with M5.

Speed
(1/min) Phases 1 to 4:
MD 35300:
SPIND_POSCTRL_VELO 2
(Position controller switch–on speed)
3a 3
1

4a 4

Position reached Time (s)

Start at: SPOS=...
Brake threshold point

Fig. 5-5 Positioning with the spindle stopped and synchronized

Sequence
The spindle is traversed time–optimized until the programmed time is reached. Depending on the
related boundary conditions, the spindle will pass the phases 1 - 2 - 3 - 4 or 1 - 3a - 4a.

Phase 1: SPOS will switch the spindle to position control mode. The acceleration from the
MD 35210: GEAR_STEP_POSCTRL_ACCEL (acceleration in position control mode) becomes ac-
tive. The direction of rotation is determined by the present distance to go (type of path specification
with SPOS). The limit frequency set in MD 35300: SPIND_POSCTRL_VELO (position control
threshold speed) will not be exceeded.
The calculation of the distance to be traversed to the target position will be carried out. If the target
point can be reached from this phase immediately, it is continued with phases 3a and 4a, instead of
phase 2.

Phase 2: The system has been accelerated up to the speed entered in

MD 35300: SPIND_POSCTRL_VELO (position controller threshold speed). The brake threshold
point calculation will recognize at which time the programmed spindle position (SPOS=...) can be
approached at the acceleration stored in MD 35210: GEAR_STEP_POSCTRL_ACCEL .

Phase 3 and phase 4: “Braking” and “Position reached” have the same sequence as with a non–
synchronized spindle.

Spindle reset
The positioning process can be canceld using the IS ”Delete distance to go/spindle reset”
(V380x0002.2). However, the spindle will remain in positioning mode.

Notes
 The spindle override switch continues to apply in Positioning mode.
 The positioning (SPOS) can be canceled either with “Reset” or “NC STOP”.

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 Spindle (S1)

5.3 Synchronizing

Why synchronizing?
To ensure that the control system exactly finds the 0 degree position after the control system has
been turned on, the control system must be synchronized with the position encoder of the spindle.
Only a synchronized spindle can perform thread cutting or positioning.
As far as axes are concerned, this process is called “referencing” (see Chapter “Reference Point
Approach”).

Mounting locations of the position measuring systems

 directly on the motor plus BERO switch on the spindle (zero marker encoder)
 directly on the spindle
 on the spindle above the resolver gearbox plus BERO switch on the spindle

Synchronization options
After the control system has been turned on, the spindle can be synchronized as follows:
 The spindle is started at a spindle speed (S function) and with a spindle rotation direction (M3 or
M4) and synchronizes itself with the next zero mark of the position measuring system or BERO
signal. The 0–degree position is offset by MD 34080: REFP_MOVE_DIST + MD 34090:
REFP_MOVE_DIST – MD 34100: REFP_SET_POS.
Note: To offset the 0–degree position, only use MD 34080: REF_MOVE_DIST. The monitoring
using MD 34060: REFP_MAX_MARKER_DIST should be set to two spindle revolutions (720
degrees).
 by programming SPOS=... from different states (see Section 5.2.3 “Spindle mode: Positioning
mode”)
 In JOG mode, the spindle is started in speed control mode using the direction keys and synchro-
nizes itself with the next zero mark of the position measuring system or the BERO SIGNAL.

Value acceptance
When synchronizing the spindle, the corresponding reference point value and a resulting offset of
the reference point (if any) is accepted from MD 34100: REFP_SET_POS[0] (default value =0). The-
se offsets (machine data) act independently of the connected measuring system and are described
in the Section “Reference point approach”.

Max. encoder frequency exceeded

If in spindle mode “Control mode” the spindle reaches a speed (large S value programmed) that is
greater than the max. encoder frequency (the max. speed of the encoder may not be exceeded),
the synchronization gets lost. The spindle goes on rotating, but with reduced functionality.

If thereafter a speed is reached which is below the maximum encoder limit frequency (smaller S
value programmed, spindle override switch changed, etc.), the spindle synchronizes itself automati-
cally from the next zero mark signal.

Resynchronizing
In the following case, however, the position measuring system of the spindle must be resynchro-
nized:
The position measuring system is mounted on the motor, a BERO (clearance sensor for synchroni-
zation signal) is mounted on the spindle, and the gear stage is changed. The synchronization is
internally initiated when the spindle rotates at the new gear stage.

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Spindle (S1)

5.4 Gear stage change

Number of gear stages

5 gear steps can be configured for the spindle. If the spindle motor is mounted directly on the
spindle (1:1) or via a transmission ratio that cannot be changed,
MD 35010: GEAR_STEP_CHANGE_ENABLE (gear stage change possible) must be set to zero.

Motor
speed With automatic gear stage change,
(1/min) this speed range will not be utilized
in gear stage 1.
Max. motor speed

Gear
stage 1
Gear
stage 2

0
Spindle speed (1/min)
n n2max
1max
g1min g1max
g2min g2max
Can be defined by MD:
n1max ...max. spindle speed of the 1st gear stage
g1min ... min. spindle speed of the 1st gear stage
for autom. gear stage selection
g1max ...max. spindle speed of the 1st gear stage
for autom. gear stage selection
n2max ...max. spindle speed of the 2nd gear stage
g2min ... min. spindle speed of the 2nd gear stage
for autom. gear stage selection
g2max ...max. spindle speed of the 2nd gear stage
for autom. gear stage selection

Fig. 5-6 Gear stage change with gear stage selection

Preselecting a gear stage

A gear stage can be defined:
 as a fixed gear stage by the part program (M41 to M45)
 automatically by the programmed spindle speed (M40)
If M40 is active and automatic gear stage selection is to be carried out using an S word, the spindle
must be in control mode. Otherwise, the gear stage change is denied, and alarm 22000 “No gear
stage change possible” is set.

M41 to M45
The gear stage can be firmly defined in the part program using M41 to M45. If a gear stage is speci-
fied using M41 to M45, which is not equal to the current (actual) gear stage, the IS ”Switch over
gear” (V390x2000.3) and the IS ”Set gear stage A to C” (V390x2000.0 bis .2) are set. The program-
med spindle speed (S function) refers to the gear stage defined as a fixed gear stage. If a spindle
speed is programmed which is above the max. speed of the firmly determined gear stage, a limita-
tion of the max. speed of the gear stage is carried out, and the IS ”Setpoint speed limited”
(V390x2001.1) is set.

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 Spindle (S1)

M40
M40 in the part program serves to define the gear stage by the control system automatically. A
check is carried out to see whether the programmed spindle speed (S function) is possible. If a gear
stage is found which is not equal to the current (actual) gear stage, the IS ”Switch over gear”
(V390x2000.3) and the IS ”Set gear stage A to C” (V390x2000.0 bis .2) are set.

The automatic gear stage selection is carried out such that first the programmed spindle speed is
compared with the min. and max. speed of the current gear stage. If the comparison is positive, no
new gear stage is set. If the comparison is negative, the comparison is carried out for all 5 gear
steps (starting with gear stage 1) until it is positive. If the comparison is not positive even for the 5th
gear stage, no gear stage change is carried out. The speed is limited, if necessary, to the maximum
speed of the current gear stage, and/or is raised to the minimum speed of the current gear stage,
and the IS ”Setpoint speed limited” (V390x2001.1) and/or ”Setpoint speed increased”
(V390x2001.2) is set).

Speed
(1/min)

stage 1

stage 2
Gear

Gear
ÉÉÉ
MD35100:SPIND_VELO_LIMIT: Max. spindle speed
MD35130:GEAR_STEP_MAX_VELO_LIMIT[2]: Max. speed of gear stage 2
MD35110:GEAR_STEP_MAX_VELO[2]: Max. speed for gear stage change 2
ÉÉÉ
ÉÉÉ
ÉÉÉ
Max. speed of gear stage 1
ÉÉÉ
ÉÉÉ
ÉÉÉ
MD35130:GEAR_STEP_MAX_VELO_LIMIT[1]:
MD35110:GEAR_STEP_MAX_VELO[1]: Max. speed for gear stage change 1

ÉÉÉ
ÉÉÉ
MD35120:GEAR_STEP_MIN_VELO[2]: Min. speed of gear stage change 2 ÉÉÉ
ÉÉÉ
ÉÉÉ
MD35120:GEAR_STEP_MIN_VELO_LIMIT[2]:

MD35120:GEAR_STEP_MIN_VELO[1]:

MD35120:GEAR_STEP_MIN_VELO_LIMIT[1]:
Min. speed for gear stage change 1
Min. speed for gear stage 1
ÉÉÉ
Min. speed for gear stage 2

Fig. 5-7 Example of speed ranges with automatic gear stage selection (M40)

Changing the gear stage when the spindle is at a standstill

It is possible to switch over to a new gear stage while the spindle is at a standstill.
After the new gear stage has been preselected by M40 and the spindle speed by M41 to M45, the
IS ”Set gear steps A to C” (V390x2000.0 bis .2) and IS ”Switch over gear” (V390x2000.4) are set.
Depending on to which time the IS ”Oscillation speed” (V380x2002.5) is set, the spindle brakes
down to a standstill at the acceleration defined for oscillation or at the acceleration defined for speed
control mode/position control mode.

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Spindle (S1)

The next block in the part program after a gear stage switchover using M40 and S value or M41 to
M45 will not be executed (same effect as if the IS ”Read disable“ (V32000006.1) would be set.).

When the spindle is at a standstill (IS ”Axis/spindle stop” (V390x0001.4) ), the oscillation can be
switched on by the IS ”Oscillation speed” (V380x2002.5) (see Section LEERER MERKER). After the
new gear stage has been switched on, the PLC user sets the IS ”Actual gear stage” (V380x2000.0
bis .2) and IS ”Gear is switched over” (V380x2000.3). The gear stage change is considered comple-
ted (spindle mode “Oscillation mode“ is deselected) and the spindle is switched to the parameter
block of the new actual gear stage. The spindle accelerates to the last programmed spindle speed
in the new gear stage (provided that M3 or M4 is active). The IS ”Switch over gear” (V390x2000.3)
is reset by the NCK, whereupon the PLC user has to reset the IS ”Gear is switched over”
(V380x2000.3). The next block in the part program can be executed.
Typical sequence of a gear stage change:

IS ”Control mode”

IS ”Oscillation mode”

Programmed S value 1000 1300

IS ”Gear is switched over”

IS ”Switch over gear”

IS ”Set gear stage” 1 2

IS ”Spindle in set range”

IS ”Spindle stopped”

IS ”Actual gear stage” 1 2

1
IS ”Oscillation speed”

1st gear stage engaged

2nd gear stage engaged

Internal feed disable

T1 T2

Spindle speed

IS ”Spindle STOP” 0
t1 t2 t3 t4
t1 The NCK recognizes a new gear stage by programming S1300 (2nd gear stage),
sets the IS ”Switch over gear” and disables the execution of the next part program block.

t2 The spindle is at a standstill and oscillation is started (oscillation by the NCK).

The IS ”Oscillation speed” must be set at the time t2 at the latest.
t3 The new gear stage is engaged. The PLC user transfers the new (actual)
gear stage to the NCK and sets the IS ”Gear is switched over”.
t4 The NCK accepts the IS ”Switch over gear”, completes oscillation,
enables the next part program block for execution and accelerates the spindle
to the new S value (S1300).

Fig. 5-8 Gear stage change with the spindle stopped

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 Spindle (S1)

Parameter record
One parameter record each is provided for each of the 5 gear stages. The appropriate parameter
record is enabled by the IS “Actual gear stage A” to “... C” (V380x2000.0 to .2). The parameter re-
cord assignment is as follows:

Parameter PLC interface, coding for the Data of data record Contents,
block, IS “Actual gear stage A”, machine data
Index to “...C” for
n CBA
0 - Data for axis mode
servo gain factor,
factor
1 000 Data for 1st gear stage monitoring functions,
001 min/max speed,,
2 010 Data for 2nd gear stage accelerations
l ti

3 011 Data for 3rd gear stage

4 100 Data for 4th gear stage
5 101 Data for 5th gear stage

The machine data that are contained in a parameter block are especially marked in Section 3.7.2
“Machine data”. For each gear stage, the following machine data are added to parameter block in-
dex n (n=1 –> 1st gear stage of the spindle, etc.):
MD 35110: GEAR_STEP_MAX_VELO[n]
MD 35120: GEAR_STEP_MIN_VELO[n]
MD 35130: GEAR_STEP_MAX_VELO_LIMIT[n]
MD 35140: GEAR_STEP_MIN_VELO_LIMIT[n]
MD 35200: GEAR_STEP_SPEEDCTRL_ACCEL[n]
MD 35210: GEAR_STEP_POSCTRL_ACCEL[n]

5.5 Programming

Functions
The spindle can be programmed for the following functions:

 G95 Revolutional feed

 G96 S... LIMS=... Constant cutting rate in m/min,
Upper limit speed
 G97 Cancel G96 and freeze last spindle speed
 G33, G331, G332 Thread cutting, tapping
 G4 S... Dwell time in spindle revolutions
M3 Spindle rotation CW
M4 Spindle rotation CCW
M5 Spindle stop, without orientation
S... Spindle speed in 1/min, e.g.: S300

SPOS=... Spindle positioning, e.g.: SPOS=270 –> to position 270 degrees.

The block change is only carried out if the spindle is positioned.
SPOS=DC(Pos) The direction of movement is maintained when positioning from the move
ment, and the position is approached. When positioning from the standstill,
the positon is approached using the shortest path.
SPOS=ACN(Pos) The position is always approached in the negative direction of movement.

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Spindle (S1)

If necessary the direction of movement is inverted prior to positioning.

SPOS=ACP(Pos) The position is always approached in the positive direction of movement.
If necessary the direction of movement is inverted prior to positioning.
SPOS=IC(Pos) The distance to be traversed is given. The traversing direction results from
the sign of the distance to be traversed. If the spindle already rotates, the
direction of traversing may possible be inverted in order to be able to tra
verse in the programmed direction.

M40 Automatic gear stage selection for the spindle

M41 to M45 Selection of gear stage 1 to 5 for the spindle

G25 S... Programmable lower spindle speed limitation, e.g.: G25 S8

G26 S... Programmable upper spindle speed limitation, e.g.: G26 S1200
LIMS=... Programmable maximum spindle speed at G96

References: “Operation and Programming“

5.6 Spindle monitoring functions

Speed ranges
The spindle monitoring functions and the currently active functions (G94, G95, G96, G33, G331,
G332, etc.) define the admissible speed ranges of the spindle.

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 Spindle (S1)

Speed

Max. encoder limit frequency

Max. spindle speed

Max. spindle speed of current gear stage

Programmable speed limitation G26

Programmable speed limitation LIMS

Programmable spindle speed limitation G25

Min. spindle speed of current gear stage

Spindle stopped
0

Speed range of current gear stage

Speed range of current gear stage

Speed range of current gear stage

IS ”Referenced/synchronized”
at constant cutting speed
IS ”Axis/spindle stopped”

limited by G25 and G26

Speed range of spindle
or spindle chuck

Fig. 5-9 Ranges of spindle monitoring functions / speeds

5.6.1 Axis/spindle stopped

Only if the spindle has stopped, e.g. if the spindle actual speed falls below a value defined in
MD 36060: STANDSTILL_VELO_TOL, the IS “Axis/spindle stopped” (V390x 0001.4) is set. It is thus
possible to enable such function as tool change, open machine door or feedrate.
The monitoring is active in all three spindle modes.

5.6.2 Spindle in set range

The spindle monitoring “Spindle in set range” checks whether the programmed spindle speed has
been reached, whether the spindle has stopped (IS ”Axis/spindle stopped”) or is still in the accelera-
tion phase.

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Spindle (S1)

A comparison between the setpoint speed (programmed speed with spindle correction taking into
account the active limitations) and the actual speed is made in the spindle mode “Control mode”.

If the actual speed deviates from the setpoint speed more than the spindle speed tolerance value
(MD 35150: SPIND_DES_VELO_TOL (spindle speed tolerance):
 the IS ”Spindle in set range” (V390x2001.5) is set to zero.
 the next processing block is not enabled, if MD 35500: SPIND_ON_SPEED_AT_IPO_START is
set.

5.6.3 Max. spindle speed

Max. spindle speed

For the spindle monitoring ”Max. spindle speed“, a max. speed is defined which may not be excee-
ded by the spindle. The max. spindle speed is entered in MD 35100: SPIND_VELO_LIMIT. The con-
trol system will limit a spindle speed that is too large to this value. If the actual spindle speed
nevertheless exceeds the max. spindle speed taking into account the spindle speed tolerance
(MD 35150: SPIND_DES_VELO_TOL (spindle speed tolerance)), there is a drive error, and the
IS ”Speed limit exceeded” (V390x2002.0) is set. In addition, the alarm 22100 is output and the
spindle is decelerated.

Speed limitation from the PLC

The spindle speed can be limited to a defined value by the PLC: This value is contained in
MD 35160: SPIND_EXTERN_VELO_UNIT and is activated via the IS ”Velocity/spindle speed limita-
tion” (V380x0003.6).

5.6.4 Min./max. speed of the gear stage

Max. speed
The maximum speed of the gear stage is entered in MD 35130: GEAR_STEP_MAX_VELO_LIMIT.
In the gear stage engaged, this (set) speed can never be exceeded. In the case of a limitation of the
programmed spindle speed, the IS ”Setpoint speed limited” (V390x2001.1) is set.

Min. speed
In MD 35140: GEAR_STEP_MIN_VELO_LIMIT, the minimum speed of the gear stage is entered. It
is not possible that the speed falls below this (set) speed if an S value is programmed, which is too
small; the interface signal ”Setpoint speed increased” (V390x2001.2) is set in this case.

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 Spindle (S1)

The min. speed of the gear stage is only active in control mode of the spindle and can only be un-
dershot of by:

 Spindle override 0%
 M5
 S0
 IS ”Spindle stop“
 Disable IS ”Servo enable“
 IS ”Reset”
 IS ”Spindle Reset”
 IS ”Oscillation speed”
 NST ”NC-STOP Axis and spindle”
 IS ”Axis/spindle lock”

5.6.5 Max. encoder limit frequency

Warning
! The max. encoder limit frequency of the spindle actual position encoder is monitored by
the control system (exceeding possible). The machine tool manufacturer must ensure by
appropriate dimensioning of the components spindle motor, gearbox, resolver gearbox
and encoder in conjunction with the corresponding machine data that the max. speed
(mechanical limit speed) of the spindle actual position encoder cannot be exceeded.

Max. encoder limit frequency exceeded

If in spindle mode “Control mode” the spindle reaches a speed (large S value programmed) that is
above the max. encoder limit frequency (the max. mechanical limit speed of the encoder must not
be exceeded), the synchronization gets lost. However, the spindle will go on rotating.
If one of the functions thread cutting (G33), revolutional feedrate (G95) or constant cutting rate (G96,
G97) is programmed, the spindle speed is automatically lowered until the active measuring system
operates safely again.

The max. encoder limit frequency is exceeded in spindle mode “Positioning mode” and for position–
controlled threads (G331, G332).

If the encoder limit frequency is exceeded, the IS ”Referenced / synchronized 1” (V390x0000.4) for
the measuring system is reset, and the IS ”Encoder limit frequency 1 exceeded” (V390x0000.2) is
set.

If the max. encoder limit frequency is exceeded and then a speed is reached again which is below
the limit frequency defined in MD 36302: ENC_FREQ_LIMIT_LOW (percentage value of MD36300:
ENC_FREQ_LIMIT), the spindle automatically synchronizes itself with the next zero mark or the
next Bero signal.

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Spindle (S1)

5.6.6 Target position monitoring

Function
On positioning (spindle is in spindle mode “Positioning mode”), the distance how far the actual posi-
tion of the spindle is away from the programmed spindle set position (target point) is monitored.
To this aim, two limit values can be set in MD 36000: STOP_LIMIT_COARSE (exact stop coarse)
and MD 36010: STOP_LIMIT_FINE (exact stop fine) as an incremental path (starting from the set-
point position). Irrespective of the two limit values, the accuracy of the spindle positioning is always
as good as specified by the connected spindle transducer, the backlash, the gear transmission ratio,
etc.

Set position
Speed

Position
Exact stop limit fine

Exact stop limit coarse

Fig. 5-10 Exact stop zones of a spindle when positioning

IS “Position reached with exact stop ...”

When the limit values MD 36000: STOP_LIMIT_COARSE and MD 36010: STOP_LIMIT_FINE (ex-
act stop limit coarse and fine) are reached, the corresponding IS ”Position reached with exact stop
coarse” (V390x0000.6) and IS ”Position reached with exact stop fine” (V390x0000.7) are output to
the PLC.

Block change at SPOS

When positioning the spindle using SPOS, the block change is carried out in accordance with the
target point monitoring using the IS ”Position reached with exact stop fine”. During this process, all
the other functions programmed in the block must also have reached their block end criterion (e.g.
axes ready, all auxiliary functions acknowledged by the PLC).

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 Spindle (S1)

5.7 Analog spindle

Function
For the function “Analog spindle”, the analog output of the SIMODRIVE 611UE closed–loop control
unit is used as the setpoint output and the encoder interface as the actual value input.
For special machine data settings and the parameterization of the SIMODRIVE 611UE drive, please
refer to:
References: “Start–Up Guide 802D”
References: “Description of Functions, SIMODRIVE 611UE“

5.8 Data descriptions (MD, SD)

5.8.1 Axis/spindle–specific machine data

30134 IS_UNIPOLAR_OUTPUT
MD number Setpoint output is unipolar
Default: 0 Min. input limit: 0 Max. input limit: 2
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BYTE Valid from SW release:
Meaning:
Application example(s) Unipolar output driver (for unipolar analog drive actuators) –>analog spindle:
In the case of unipolar setting, only positive speed setpoint values are delivered to the drive; the
sign of the speed setpoint is output separately in a separate digital control sign.

0: bipolar output ( 10V) with pos./neg. speed setpoint, servo enable (normal case)
1: unipolar output 0...+10V with enable and direction signals
(servo enable, neg. traversing direction)
2: unipolar output 0...+10V with linking of the enable and direction signals
(servo enable for pos. traversing direction, servo enable for neg. traversing direction)
Further references For the assignment of the signal terminals on the SIMODRIVE 611UE drive, please refer to:
“Start–Up Guide 802D”

35000 SPIND_ASSIGN_TO_MACHAX
MD number Assignment of spindle to machine axis
Default: 0 Min. input limit: 0 Max. input limit: 1
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BYTE Valid from SW release:
Meaning: This MD is used to enter which machine axis is used as the spindle.
Application example(s) Example of a milling machine with 3 machine axes (X1, Y1, Z1) and a spindle:
SPIND_ASSIGN_TO_MACHAX [AX1] = 0 –––> X1
SPIND_ASSIGN_TO_MACHAX [AX2] = 0 –––> Y1
SPIND_ASSIGN_TO_MACHAX [AX3] = 0 –––> Z1
SPIND_ASSIGN_TO_MACHAX [AX4] = 1 –––> Spindle 1 is the 4th machine axis
Related to .... MD 30300: IS_ROT_AX (rotary axis/spindle)
MD 30310: ROT_IS_MODULO (modulo conversion for rotary axis/spindle)
These machine data must be set; otherwise, the alarms 4210 ”Rotary axis declaration missing”
and 4215 ”Modulo axis declaration missing” (modula display 360 degrees) are output.
IS “Spindle/no axis” (V390x 0000.0)

SINUMERIK 802DDescription of Funktions

6FC5 697–2AA10–0BP0 (04.00) 5-97
Spindle (S1)

35010 GEAR_STEP_CHANGE_ENABLE
MD number Gear stage change is possible
Default: 0 Min. input limit: 0 Max. input limit: 1
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BOOLEAN Valid from SW release:
Meaning: If the spindle motor is directly mounted on the spindle (1:1) or with a transmission ratio that cannot
be changed, GEAR_STEP_CHANGE_ENABLE (gear stage change is possible) must be set to
zero. A gear stage change with M40 to M45 is not possible.
If the spindle motor is mounted on the spindle via a gear with variable gear steps,
GEAR_STEP_CHANGE_ENABLE must be set to one. The gear may have up to 5 gear stages
that can be selected using M40, M41 to M45.
Related to .... MD 35110: GEAR_STEP_MAX_VELO (max. speed for gear stage change)
MD 35120: GEAR_STEP_MIN_VELO (min. speed for gear stage change)
GEAR_STEP_MAX_VELO and GEAR_STEP_MIN_VELO must cover the entire speed range.

35040 SPIND_ACTIVE_AFTER_RESET
MD number Spindle activate after RESET
Default: 0 Min. input limit: 0 Max. input limit: 1
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BOOLEAN Valid from SW release:
Meaning: This MD is used to set how the spindle behaves after reset (V32000000.7) and program end (M2,
M30). It is only active in the spindle mode “Control mode”.
0:
Control mode: – Spindle stops, is valid for M2/M30 and reset
– Program is aborted; applies to M2/M30

Oscillation mode: – Alarm 10640 ”No stop during gear stage change“
– Oscillation is not aborted
– Axes are stopped
– Program is aborted after gear stage change or spindle reset;
the alarm is deleted.
Positioning mode: – is stopped.
Axis mode: – is stopped.
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
1:
Control mode: – Spindle does not stop
– Program is aborted.

Oscillation mode: – Alarm 10640 ”No stop during gear stage change“
– Oscillation is not aborted
– Axes are stopped
– Program is aborted after gear stage change, the
alarm is deleted and the spindle continues to rotate
at the programmed M and S values.
Positioning mode: – is stopped.
Axis mode: – is stopped

The IS ”Spindle reset” (V380x0002.2) is always active, irrespective of

SPIND_ACTIVE_AFTER_RESET.

MD inapplicable to ...... spindle modes other than control mode

Related to .... IS ”Reset” (V32000000.7)
IS ”Spindle Reset” (V380x0002.2)

SINUMERIK 802DDescription of Funktions

5-98 6FC5 697–2AA10–0BP0 (04.00)
 Spindle (S1)

35100 SPIND_VELO_LIMIT
MD number Maximum spindle speed
Default: 10 000.0 Min. input limit: 0.0 Max. input limit: ***
Change valid after Power On Protection level: 2/7 Unit: rpm
Data type: DOUBLE Valid from SW release:
Meaning: In this MD, the max. spindle speed is entered which may not be exceeded by the spindle (the
spindle chuck with the workpiece or the tool). The NCK limits the set spindle speed to this value if
the set speed is too large. If the max. actual spindle speed with consideration of the spindle tole-
rance (MD 35150: SPIND_DES_VELO_TOL) is nevertheless exceeded, a drive error exists and
the IS ”Speed limit exceeded“ (V390x2001.0) is set. In addition, the alarm 22050 ”Maximum speed
reached“ is output, and all axes and spindle of the channel are decelerated (prerequisite: encoder
is not defective).
Related to .... MD 35150: SPIND_DES_VELO_TOL (spindle speed tolerance)
IS ”Speed limit exceeded“ (V390x2001.0)
Alarm 22050 ”Maximum speed reached“

35110 GEAR_STEP_MAX_VELO[n]
MD number Max. speed for gear stage change [gear stage number]: 0...5
(Index 0 has no meaning for spindles)
Default: Min. input limit: 0.0 Max. input limit: ***
(500, 500, 1000, 2000, 4000, 8000 )
Change valid after NEW_CONF Protection level: 2/7 Unit: rpm
Data type: DOUBLE Valid from SW release:
Meaning: The max. of the gear stage for the automatic gear stage change (M40 ) is preset. The gear stages
must be defined by this MD and the MD 35120: GEAR_STEP_MIN_VELO such that no gaps re-
sult between the gear stages in the programmed spindle speed range.
Wrong
GEAR_STEP_MAX_VELO [gear stage 1] =1000
GEAR_STEP_MIN_VELO [gear stage 2] =1200
Right
GEAR_STEP_MAX_VELO [gear stage 1] =1000
GEAR_STEP_MIN_VELO [gear stage 2] =950
Related to .... MD 35010: GEAR_STEP_CHANGE_ENABLE (gear stage change is possible)
MD 35120: GEAR_STEP_MIN_VELO (min. speed for gear stage change)
MD 35140: GEAR_STEP_MIN_VELO_LIMIT (min. speed of gear stage)
MD 35130: GEAR_STEP_MAX_VELO_LIMIT (max. speed of gear stage)

35120 GEAR_STEP_MIN_VELO[n]
MD number Min. speed for gear stage change [gear stage number]: 0...5
Default: Min. input limit: 0.0 Max. input limit: ***
(50, 50, 400, 800, 1500, 3000)
Change valid after NEW_CONF Protection level: 2/7 Unit: rpm
Data type: DOUBLE Valid from SW release:
Meaning: The min. speed of the gear stage is preset for the automatic gear stage change (M40).
For further details, see MD 35120: GEAR_STEP_MAX_VELO.
Related to .... MD 35110: GEAR_STEP_MAX_VELO (max. speed for gear stage change)
MD 35010: GEAR_STEP_CHANGE_ENABLE (gear stage change possible)
MD 35140: GEAR_STEP_MIN_VELO_LIMIT (min. speed of gear stage)
MD 35130: GEAR_STEP_MAX_VELO_LIMIT (max. speed of gear stage)

SINUMERIK 802DDescription of Funktions

6FC5 697–2AA10–0BP0 (04.00) 5-99
Spindle (S1)

35130 GEAR_STEP_MAX_VELO_LIMIT[n]
MD number Max. speed of gear stage [gear stage number]; 0...5
Default: Min. input limit: 0.0 Max. input limit: ***
(500, 500, 1000, 2000, 4000, 8000 )
Change valid after NEW_CONF Protection level: 2/2 Unit: rpm
Data type: DOUBLE Valid from SW release:
Meaning: The maximum speed of the gear stage is entered. This speed can never be exceeded in the gear
stage currently engaged.
Special cases, errors, ......  If the position control is enabled, the speed is limited to 90% of this value (control margin)
 If an S value is programmed, which is greater than the max. speed of the gear stage
engaged, the speed setpoint is limited to the max. speed of the gear stage (with gear stage
selection – M41 to M45); furthermore, the IS: ”Programmed speed too high” is set.
 If the programmed S value is greater than the max. speed required for the gear stage change, a
new gear stage will be specified (with automatic gear stage selection – M40).
 If the programmed S value is greater than the max. speed of the highest gear stage, the
speed is limited to the max. speed of the gear stage (with automatic gear stage
selection – M40).
 If an S value is programmed for which no matching gear stage exists, no gear stage
change is carried out.
Related to .... MD 35010: GEAR_STEP_CHANGE_ENABLE (gear stage change is possible)
MD 35110: GEAR_STEP_MAX_VELO (max. speed for gear stage change)
MD 35120: GEAR_STEP_MIN_VELO (min. speed for gear stage change)
MD 35140: GEAR_STEP_MIN_VELO_LIMIT (min. speed of gear stage)
IS ”Set speed limited” (V390x 2001.1)

35140 GEAR_STEP_MIN_VELO_LIMIT[n]
MD number Min. speed of gear stage [gear stage number]: 0...5
Default: Min. input limit: 0.0 Max. input limit: ***
(5, 5, 10, 20, 40, 80)
Change valid after NEW_CONF Protection level: 2/7 Unit: rpm
Data type: DOUBLE Valid from SW release:
Meaning: The minimum speed of the gear stage is entered. This speed cannot be undershot by program-
ming an S value that is too small.
The minimum speed can only be undershot by the signals/commands/states that occur in conjunc-
tion with ”Min./max. speed of gear stage”.
MD inapplicable to ......  Spindle modes “Oscillation mode”, “Positioning mode”
Application example(s) Smooth run of the motor is no longer guaranteed below the minimum speed.
Related to .... MD 35010: GEAR_STEP_CHANGE_ENABLE (gear stage change is possible)
MD 35110: GEAR_STEP_MAX_VELO (max. speed for gear stage change)
MD 35120: GEAR_STEP_MIN_VELO (min. speed for gear stage change)
MD 35130: GEAR_STEP_MAX_VELO_LIMIT (max. speed of gear stage)
IS ”Set speed increased” (V390x 2001.2)

SINUMERIK 802DDescription of Funktions

5-100 6FC5 697–2AA10–0BP0 (04.00)
 Spindle (S1)

35150 SPIND_DES_VELO_TOL
MD number Spindle speed tolerance
Default: 0.1 Min. input limit: 0.0 Max. input limit: 1.0
0.1 = 10%
Change valid after RESET Protection level: 2/2 Unit:
Data type: DOUBLE Valid from SW release:
Meaning: factor for the spindle speed for determining the tolerance in the spindle mode “Control mode”.
The setpoint speed (programmed speed x spindle override with taking into account the limitations)
is compared with the actual speed.
 If the actual speed differs from the set speed more than SPIND_DES_VELO_TOL,
the IS ”Spindle in set range“ (V390x2001.5) is set to zero.
 If the actual speed exceeds the maximum spindle speed (MD 35100: SPIND_VELO_LIMIT)
more than SPIND_DES_VELO_TOL, the IS ”Speed limit exceeded” (V390x2001.0) is set and
the alarm 22050 ”Maximum speed reached” is output. All axes and spindles of the channel are
decelerated.
MD inapplicable ...... Spindle mode “Oscillation mode”
Spindle mode “Positioning mode”
Fig. 5-11
Speed
(1/min) SPIND_DES_VELO_TOL

Upper
spindle speed tolerance
Set speed
Lower
spindle speed tolerance

Actual speed

Time (t)
Related to .... MD 35500: SPIND_ON_SPEED_AT_IPO_START
MD 35100: SPIND_VELO_LIMIT (max. spindle speed)
IS ”Spindle in set range“ (V390x2001.5)
IS ”Speed limit not reached“ (V390x2001.0)
Alarm 22050 ”Max. speed reached“

35160 SPIND_EXTERN_VELO_LIMIT
MD number Spindle speed limiting from PLC
Default: 1000.0 Min. input limit: 0.0 Max. input limit: ***
Change valid after NEW_CONF Protection level: 2/7 Unit: rpm
Data type: DOUBLE Valid from SW release:
Meaning: A limit value for the spindle speed is entered, which is taken into account if the IS ”Velocity/speed
limitation” (V380x0003.6) is set. The control system will limit the speed to this value.

SINUMERIK 802DDescription of Funktions

6FC5 697–2AA10–0BP0 (04.00) 5-101
Spindle (S1)

35200 GEAR_STEP_SPEEDCTRL_ACCEL[n]
MD number Acceleration in speed control mode [gear stage number]: 0...5
Default: Min. input limit: 0.001 Max. input limit: ***
(30, 30, 25, 20, 15, 10)
Change valid after NEW_CONF Protection level: 2/7 Unit: rev./s2
Data type: DOUBLE Valid from SW release:
Meaning: If the spindle is in control mode, the acceleration is entered in
GEAR_STEP_SPEEDCTRL_ACCEL.
Special cases, errors, ...... The acceleration in speed control mode can be set in such a way that the current limit is reached.
Related to .... MD 35210: GEAR_STEP_POSCTRL_ACCEL (acceleration in position control mode)

35210 GEAR_STEP_POSCTRL_ACCEL[n]
MD number Acceleration in position control mode [gear stage number]: 0...5
Default: Min. input limit: 0.001 Max. input limit: ***
(30, 30, 25, 20, 15, 10)
Change valid after NEW_CONF Protection level: 2/7 Unit: rev./s2
Data type: DOUBLE Valid from SW release:
Meaning: The acceleration in position control mode must be adjusted such that the current limit is not
reached.
Related to .... MD 35200: GEAR_STEP_SPEEDCTRL_ACCEL

35300 SPIND_POSCTRL_VELO
MD number Position control threshold speed
Default: 500.0 Min. input limit: 0.0 Max. input limit: ***
Change valid after NEW_CONF Protection level: 2/2 Unit: rpm
Data type: DOUBLE Valid from SW release:
Meaning: When positioning a spindle not operated in position control mode, the position control is only con-
nected if the spindle has reached the speed defined in SPIND_POSCTRL_VELO. The speed can
be varied using FA[Sn] from the part program.
For the behavior of the spindle under different boundary conditions (positioning from the move-
ment, positioning from the standstill), see Section “Spindle mode: ”Positioning mode”
Related to .... MD 35350: SPIND_POSITIONING_DIR (direction of rotation when positioning from the standstill)
if no snychronization is provided.

35350 SPIND_POSITIONING_DIR
MD number Direction of rotation when positioning with the spindle not synchronized
Default: 3 Min. input limit: 3 Max. input limit: 4
Change valid after RESET Protection level: 2/2 Unit: –
Data type: BYTE Valid from SW release:
Meaning: The programming of SPOS switches the spindle to position control mode and accelerates it at the
acceleration defined in MD 35210: GEAR_STEP_POSCTRL_ACCEL (acceleration in position
control mode) if no synchronization is provided. The direction of rotation is determined by
MD 35350: SPIND_POSITIONING_ DIR (direction of rotation when positioning from the standstill).
SPIND_POSITIONING_DIR = 3 –––> direction of rotation in CW direction
SPIND_POSITIONING_DIR = 4 –––> direction of rotation in CCW direction
Related to .... MD 35300: SPIND_POSCTRL_VELO (position control threshold speed)

SINUMERIK 802DDescription of Funktions

5-102 6FC5 697–2AA10–0BP0 (04.00)
 Spindle (S1)

35400 SPIND_OSCILL_DES_VELO
MD number Oscillation speed
Default: 500.0 Min. input limit: 0.0 Max. input limit: ***
Change valid after NEW_CONF Protection level: 2/2 Unit: rpm
Data type: DOUBLE Valid from SW release:
Meaning: On oscillation, a certain motor speed is specified for the spindle motor using the IS ”Oscillation
speed“ (V380x2002.5). This motor speed is defined here. This motor speed does not depend on
the current motor speed. In the AUTOMATIC and MDA screen forms, the oscillation speed is dis-
played in the Set Spindle window until the gear stage change has been carried out.
MD inapplicable ...... spindle modes other than oscillation mode
Application example(s) The engaging of a new gear stage can be facilitated by oscillation of the spindle motor, since the
gear wheels may thus be better meshed.
Special cases, errors, ...... For the oscillation speed defined in this MD, the acceleration on oscillation applies
(MD 35410: SPIND_OSCILL_ACCEL).
Related to .... MD 35410: SPIND_OSCILL_ACCEL (acceleration on oscillation)
MD 35130: GEAR_STEP_MAX_VELO_LIMIT[n] (maximum speed ofthe gear stage)
IS ”Oscillation by the PLC“ (V380x2002.4)
IS ”Oscillation speed” (V380x2002.5)

35410 SPIND_OSCILL_ACCEL
MD number Acceleration on oscillation
Default: 16.0 Min. input limit: 0.001 Max. input limit: ***
Change valid after NEW_CONF Protection level: 2/2 Unit: rev./s2
Data type: DOUBLE Valid from SW release:
Meaning: The acceleration defined here only applies to the output of the oscillation speed
(MD 35400: SPIND_OSCILL_DES_VELO) to the spindle motor. The oscillation speed is selected
using the IS ”Oscillation speed”.
MD inapplicable ...... spindle modes other than oscillation mode
Related to .... MD 35400: SPIND_OSCILL_DES_VELO (oscillation speed)
IS ”Oscillation speed“ (V380x2002.5)
IS ”Oscillation from PLC” (V380x2002.4)

35430 SPIND_OSCILL_START_DIR
MD number Start direction on oscillation
Default: 0 Min. input limit: 0 Max. input limit: 4
Change valid after RESET Protection level: 2/2 Unit: –
Data type: BYTE Valid from SW release:
Meaning: With the IS ”Oscillation speed”, the spindle motor accelerates to the speed defined in MD 35400:
SPIND_OSCILL_DES_VELO. The starting direction is defined by this
MD: SPIND_OSCILL_START_DIR if the IS ”Oscillation from PLC” is not set.
0: Starting direction according to the last direction of rotation
1: Start direction opposite to the last direction of rotation
2: Start direction opposite to the last direction of rotation
3: Start direction is M3
4: Start direction is M4
MD inapplicable ...... spindle modes other than oscillation mode
Related to .... MD 35400: SPIND_OSCILL_DES_VELO (oscillation speed)
IS ”Oscillation speed“ (V380x2002.5)
IS ”Oscillation by the PLC” (V380x2002.4)

SINUMERIK 802DDescription of Funktions

6FC5 697–2AA10–0BP0 (04.00) 5-103
Spindle (S1)

35440 SPIND_OSCILL_TIME_CW
MD number Oscillation time for M3 direction
Default: 1.0 Min. input limit: 0.0 Max. input limit: ***
(”0” means a time from one interpolation
clock)
Change valid after NEW_CONF Protection level: 2/2 Unit: s
Data type: DOUBLE Valid from SW release:
Meaning: The oscillation time set here is active in the M3 direction.
MD inapplicable ......  spindle modes other than oscillation mode
 if oscillation by the PLC (IS ”Oscillation by PLC“ (V380x2002.4) is set)
Related to .... MD 35450: SPIND_OSCILL_TIME_CCW (oscillation time for M4 direction)
NST ”Oscillation speed” (V380x2002.5)
NST ”Oscillation by PLC” (V380x2002.4)

35450 SPIND_OSCILL_TIME_CCW
MD number Oscillation time for M4 direction
Default: 0.5 Min. input limit: 0.0 Max. input limit: ***
(”0” means a time from one interpolation
clock)
Change valid after NEW_CONF Protection level: 2/2 Unit: s
Data type: DOUBLE Valid from SW release:
Meaning: The oscillation time defined here acts in the M4 direction.
MD inapplicable ......  spindle modes other than oscillation mode
 if oscillation by the PLC (IS ”Oscillation from PLC“ (V380x2002.4) is set)
Fig. 5-12
Speed
(1/min)

Oscillation time

Time (t)

Related to .... MD 35440: SPIND_OSCILL_TIME_CW (oscillation time for M3 direction)

IS ”Oscillation speed“ (V380x2002.5)
IS ”Oscillation by the PLC” (V380x2002.4)

35500 SPIND_ON_SPEED_AT_IPO_START
MD number Feed enable for spindle in set range
Default: 1 Min. input limit: 0 Max. input limit: 2
Change valid after RESET Protection level: 2/2 Unit: –
Data type: BYTE Valid from SW release:
Meaning: 0: The path interpolation is not influenced
1: The path interpolation is only enabled if the spindle has reached the preset speed (tolerance
band is set via MD 35150).
2: Function as with value=1,
value=1 and,and in addition:
Traversing path axes are also stopped before the machining starts, e.g.:, continuous path mode
(G64) and change from rapid traverse (G0) to a machining block (G1, G2,..). The path is stopped
at the last G0 block and starts only when the spindle is in the speed setpoint range.
Application example(s) see MD 35510
Related to .... MD 35150: SPIND_DES_VELO_TOL (spindle speed tolerance)
IS ”Spindle in set range” (V390x2001.5)

SINUMERIK 802DDescription of Funktions

5-104 6FC5 697–2AA10–0BP0 (04.00)
 Spindle (S1)

35510 SPIND_STOPPED_AT_IPO_START
MD number Feed enable with the spindle stopped
Default: 0 Min. input limit: 0 Max. input limit: 1
Change valid after RESET Protection level: 2/2 Unit: –
Data type: BOOLEAN Valid from SW release:
Meaning: If a spindle is stopped (M5), the path feed is disabled if SPIND_STOPPED_AT_IPO_START is set
and the spindle is in control mode.
If the spindle has come to a standstill (IS ”Axis/spindle stopped” (V390x0001.4) is set), the fee-
drate will be enabled.
Application example(s) MD 35500 and this MD 35510 can be used to handle the feedrate as follows, depending on the
spindle actual speed (control mode):
 If the spindle is in the acceleration phase (programmed set speed not yet reached), the feedrate
will be disabled.
 If the actual speed deviates from the set speed less than the spindle speed tolerance
(MD 35150: SPIND_DES_VELO_TOL), the feedrate is enabled.
 If the spindle is in the brake phase, the feedrate will be disabled.
 If the spindle is signaled stopped (IS: ”Axis/spindle stopped” V390x0001.4),
the feedrate is enabled.
 Blocks that contain G0 cannot be manipulated in this way.
Related to .... MD 35500: SPIND_ON_SPEED_AT_IPO_START (feed enable for spindle in set range)

5.8.2 Spindle–specific setting data

43210 SPIND_MIN_VELO_G25
SD number Programmable lower spindle speed limitation with G25
Default: 0.0 Min. input limit: 0.0 Max. input limit: ***
Change valid: immediately Protection level: 7/7 Unit: rpm
Data type: DOUBLE Valid from SW release:
Meaning: In this SDS, a min. spindle speed limitation is entered, which may not be exceeded by the spindle.
If the spindle speed is too low, the NCK will limit it to this value.
The minimum spindle speed may ony be undershot by:
 Spindle override 0%
 M5
 S0
 IS ”Spindle stop“ (V380x0004.3)
 IS ”Servo enable“ (V380x0002.1)
 IS ”Reset” (V30000000.7)
 IS ”Spindle reset” (V380x0002.2)
 IS ”Oscillation speed” (V380x2002.5)
SD inapplicable ...... any other spindle modes than control mode
Special cases, errors, ...... The value in SPIND_MIN_VELO_G25 can be modified by:
 G25 S.... in the part program
 Operation from HMI
The value in SD: SPIND_MIN_VELO_G25 remains stored even after RESET or mains power off.
Related to .... SD 43220: SPIND_MAX_VELO_G26
SD 43230: SPIND_MAX_VELO_LIMS (progr. spindle speed limitation with G96)

SINUMERIK 802DDescription of Funktions

6FC5 697–2AA10–0BP0 (04.00) 5-105
Spindle (S1)

43220 SPIND_MAX_VELO_G26
SD number Progr. spindle speed limitation with G26
Default: 1000.0 Min. input limit: 0.0 Max. input limit: ***
Change valid: immediately Protection level: 7/7 Unit: rpm
Data type: DOUBLE Valid from SW release:
Meaning: In this SD, a max. spindle speed limitation is entered which may not be exceeded by the spindle. If
the spindle speed is too high, the NCK will limit the spindle speed to this value.
SD inapplicable to ...... spindle modes other than control mode
Special cases, errors, ...... The value in SD: SPIND_MIN_VELO_G26 can be modified by:
 G26 S.... in the part program
 Operation from HMI
The value in SD: SPIND_MIN_VELO_G26 remains stored even after RESET or mains power off.
Related to .... SD 43210: SPIND_MIN_VELO_G25 (progr. spindle speed limiting G25)
SD 43230: SPIND_MAX_VELO_LIMS (progr. spindle speed limiting with G96)

43230 SPIND_MAX_VELO_LIMS
SD number Progr. spindle speed limitation G96
Default: 100.0 Min. input limit: 0.0 Max. input limit: ***
Change valid: immediately Protection level: 7/7 Unit: rpm
Data type: DOUBLE Valid from SW release:
Meaning: With constant cutting rate (G96 and G97), in addition to the limitations permanently active, an addi-
tional limitation acts, which is entered in SPIND_MAX_VELO_LIMS. Furthermore, it is possible to
describe SPIND_MAX_VELO_LIMS in the part program using LIMS=.... .
SD inapplicable to ...... all spindle modes except for G96 and G97 (constant cutting rate)
Application example(s) On parting and in the case of very small machining diameters, the spindle with the workpiece (tur-
ning machine) accelerates higher and higher at constant cutting rate (G96), theoretically reaching
an infinitely high set speed in the position of the traverse axis X=0. In these cases, the spindle
accelerates to its max. spindle speed of the current gear stage (if applicable, limited by G26). If
you wish to limit the spindle to a lower speed (especially, with G96), this can be dopne using
LIMS=.... SPIND_MAX_VELO_LIMS.
Special cases, errors, ...... The value in SD 43210: SPIND_MIN_VELO_LIMS can be modified by:
 LIMS S.... in the part program
 Operation from HMI
The value in SD: SPIND_MIN_VELO_LIMS remains stored even after RESET and mains off.
Related to .... SD 43220: SPIND_MAX_VELO_G26 (max. spindle speed)
SD 43210: SPIND_MIN_VELO_G25 (min. spindle speed)

5.9 Signal descriptions

5.9.1 Axis/spindle–specific signals

Transferred M/S functions, axis–specific

VD370x 0000 M function for spindle

Interface signal Signal(s) from axis/spindle (NCK –> PLC), axis–specific
Edge evaluation: Signal(s) updated: cyclically Signal(s) valid from SW release:
Generally, the M functions are output channel–specifically in V2500.... In the range V25001...., they
are present only for one PLC cycle, and in V25003..., they are only present until a new output is
provided.
This IS ”M function for spindle” provides selected M functions for the spindle as integer current
values of the PLC.
 M3 –> value: 3
 M4 –> value: 4
 M5 –> value: 5
Related to .... IS ”S function for spindle“ (VD370x 0004), axis–specific
IS Transfer of auxiliary function from NC channel (V2500...)

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 Spindle (S1)

VD370x 0004 S function for spindle

Interface signal Signal(s) from axis/spindle (NCK –> PLC), axis–specific
Edge evaluation: Signal(s) updated: cyclically Signal(s) valid from SW release:
Generally, the S function is transferred to the PLC channel–specifically in VD2500 4000 as a floa-
ting point value.
In this IS “S function for spindle”, the output is provided as a floating point value to the PLC axis–
specifically:
 S.... as a spindle speed in 1/min (programmed value)
 S.... as a constant cutting rate in m/min or ft/min with G96

The following S functions are not output here:

 S.... as a progr. spindle speed limitation G25
 S.... as a progr. spindle speed limitation G26
 S.... as a dwell time in spindle revolutions
Related to .... IS ”M function for spindle” (VD370x 0000), axis–specific
IS ”Transferred S function“ (VD2500 4000 ), channel–specific

Signals to axis/spindle

V380x 0002.2 Spindle reset/delete distance to go

Interface signal Signal(s) to axis/spindle (PLC –> NCK)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Edge change 0 –––> 1 Irrespective of MD 35040: SPIND_ACTIVE_AFTER_RESET, Spindle reset selects the following
spindle modes in the following way:
Control mode: – Spindle stops.
– Program is continued.
– Spindle goes on rotating with the next following M and S commands

Oscillation mode: – Oscillation is aborted

– Axes go on moving
– Program is continued with current gear stage
– If necessary the IS “Set speed limited” (V390x2001.1) is set with the
next following M value and a larger S value.
Positioning mode: – is stopped
Signal state 0 or edge No effect
change 1 –––> 0
Related to .... MD 35040: SPIND_ACTIVE_AFTER_RESET (separate spindle reset)
IS ”Reset” (V30000000.7)
IS ”Delete distance to go“ (V380x0002.2) is another name for the same signal, but applicable to
the axis

V380x 2000.3 Gear is switched over

Interface signal Signal(s) to axis/spindle (PLC –> NCK)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge If the new gear stage is engaged, the IS ”Actual gear stages A to C” and the IS ”Gear is switched
change 0 –––> 1 over“ are set by the PLC user. This will tell the NCK that the right gear stage has been sucessfully
engaged. The gear stage change is considered completed (spindle mode “Oscillation mode” dese-
lected), the spindle rotates in the new gear stage to the spindle speed last programmed and the
next block in the part program can be executed. The IS ”Switch over gear” is reset by the NCK,
and the PLC user will reset the IS ”Gear is switched over” as a reaction.
Signal state 0 or edge No effect
change 1 –––> 0
Signal inapplicable ...... spindle modes other than oscillation mode

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6FC5 697–2AA10–0BP0 (04.00) 5-107
Spindle (S1)

V380x 2000.3 Gear is switched over

Interface signal Signal(s) to axis/spindle (PLC –> NCK)
Special cases, errors, ...... If an actual gear stage other than that fed back from the NCK to the PLC as the set gear stage is
fed back from the PLC user to the NCK, then the gear stage is nevertheless considered success-
fully completed and the actual gear stage A to C is activated.
Related to .... IS ”Actual gear stage A to C ”(V380x2000.0 to .2)
IS ”Set gear stage A to “...C” (V390x2000.0 to .2)
IS ”Switch over gear“ (V390x2000.3)
IS ”Oscillation speed” (V380x2002.5)

V380x 2000.0 to .2 Actual gear stages A to C

Interface signal Signal(s) to axis/spindle (PLC –> NCK)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 (status–con- If the new gear stage is engaged, the IS ”Actual gear stages A to C” and the IS ”Gear is switched
trolled) over“ are set by the PLC user. This will tell the NCK that the right gear stage has been success-
fully engaged. The gear stage change is considered completed (spindle mode “Oscillation mode”
is deselected), the spindle accelerates in the new gear stage to the spindle speed last program-
med and the next block in the part program can be executed.
The actual gear stage is specified in coded form.
For each of the 5 gear steps, one parameter record each is provided, which is assigned as follows:

Parameter Data of data record Contents

Record No. Code
CBA
0 – Data for axis mode Servo gain factor
Monitoring functions
1 000 Data for 1st gear stage M40 speed
001 Min./max. speed
.Accelerations
2 010 Data for 2nd gear stage etc.
3 011 Data for 3rd gear stage
4 100 Data for 4th gear stage
5 101 Data for 5th gear stage
110
111
Special cases, errors, ...... If an actual gear stage other than that fed back from the NCK to the PLC as the set gear stage is
fed back from the PLC user to the NCK, then the gear stage is nevertheless considered success-
fully completed and the actual gear stage A to C is activated.
Related to .... IS ”Set gear stage A to C” (V390x2000.0 to .2)
IS ”Switch over gear” (V390x2000.3)
IS ”Gear switched over” (V380x2000.3)
IS ”Oscillation speed” (V380x2002.5)
Parameter records (MDs) for gear stages

V380x 2001.4 Resynchronize spindle when positioning 1

Interface signal Signal(s) to axis/spindle (PLC –> NCK)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 The spindle is to be resynchronized when positioning.
Signal state 0 or edge No effect
change 1 –––> 0
Signal inapplicable ...... spindle modes other than positioning mode
Application example(s) The spindle has an indirect measuring system, and a slip may occur between motor and workhol-
der. When the positioning process is started if the signal=1, the old reference is deleted and the
zero marker is searched again before the final position is approached.
Related to .... IS ”Referenced/synchronized 1” (V390x0000.4)

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 Spindle (S1)

V380x 20016 Invert M3/M4

Interface signal Signal(s) to axis/spindle (PLC –> NCK)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The direction of rotation of the spindle motor changes with the following functions:
change 0 –––> 1  M3
 M4
 M5
 SPOS from the movement; not active for SPOS from the standstill.
Application example(s) The machine can be switched over between vertical and horizontal spindle. It is mechanically desi-
gned such that with the horizontal spindle one gear wheel more is meshed than with the vertical
spindle. As a result, the direction of rotation of the vertical spindle must be changed if the spindle is
always to rotate clockwise with M3.

V380x 2002.7 / .6 Set direction of rotation CCW / set direction of rotation CW

Interface signal Signal(s) to axis/spindle (PLC –> NCK)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release: 1.1
Signal state 1 or edge If the IS ”Oscillation from PLC” is set, the two IS ”Set direction of rotation CCW and CW” can be
change 0 –––> 1 used to define the direction of rotation for the oscillation speed. The times for the oscillation move-
ment of the spindle motor are defined such that the IS ”Set direction of rotation CCW and CW” are
set correspondingly long.
Signal inapplicable ...... spindle modes other than oscillation
Application example(s) see IS ”Oscillation by the PLC”
Special cases, errors, ......  If both IS are set at the same time, no oscillation speed is output.
 If no IS is set, no oscillation speed is output.
Related to .... IS ”Oscillation by the PLC” (V380x2002.4)
IS ”Oscillation speed” (V380x2002.5)

V380x 2002.5 Oscillation speed

Interface signal Signal(s) to axis/spindle (PLC –> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release: 1.1
Signal state 1 or edge To carry out a gear stage change (IS ”Switch over gear” (V390x2000.3) is set), the spindle mode
change 0 –––> 1 changes to oscillation mode.
Depending on at which moment the IS ”Oscillation speed” (V380x2002.5) is set, the spindle will
brake to a standstill at different accelerations:
1. The IS ”Oscillation speed” is set before the IS ”Switch over gear” is set by the NCK. The
spindle is decelerated to a standstill at the acceleration of oscillation
(MD: SPIND_OSCILL_ACCEL). If the spindle has stopped, the oscillation is started
immediately.
2. The IS ”Oscillation speed” is set after the IS ”Switch over gear” has been set by the NCK and
after the spindle has come to a standstill. The position control is switched off. The spindle will
be decelerated at the acceleration of the speed control mode. After the IS ”Oscillation speed”
has been set, the spindle starts to oscillate at the oscillation acceleration
(MD: SPIND_OSCILL_ACCEL).
If the IS ”Oscillation from PLC” (V380x2002.4) is not set, the IS ”Oscillation speed” is used to
carry out automatic oscillation in the NCK. The two times for the directions of rotation are entered
in SPIND_OSCILL_TIME_CW (oscillation time for M3 direction) and SPIND_OSCILL_TIME_CCW
(oscillation time for M4 direction).
If the IS ”Oscillation by the PLC” is set, a speed is output with the IS ”Oscillation speed” only in
conjunction with the IS ”Set direction of rotation CW and CCW”. The oscillation, i.e. the continuous
change of the direction of rotation, is carried out by the PLC user using the IS ”Set direction of
rotation CW and CCW” (oscillation from PLC).
Signal state 0 or edge The spindle will not oscillate.
change 1 –––> 0
Signal inapplicable ...... all spindle modes except for oscillation mode
Application example(s) The oscillation speed is used to facilitate meshing of a new gear stage.
Related to .... IS “Oscillation by the PLC” (V380x2002.4)
IS “Set direction of rotation CCW” (V380x2002.7)
IS “Set direction of rotation CW” (V380x2002.6)

SINUMERIK 802DDescription of Funktions

6FC5 697–2AA10–0BP0 (04.00) 5-109
Spindle (S1)

V380x 2002.4 Oscillation by the PLC

Interface signal Signal(s) to axis/spindle (PLC –> NCK)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge If the IS ”Oscillation by the PLC” is set, a speed is output with the IS ”Oscillation speed” only in
change 0 –––> 1 conjunction with the IS ”Set direction of rotation CW and CCW”. The oscillation, i.e. the continuous
change of the direction of rotation, is carried out by the PLC user using the IS ”Set direction of
rotation CW and CCW” (oscillation from PLC).
Signal state 0 or edge If the IS ”Oscillation by the PLC” is not set, the IS ”Oscillation speed” is used to carry out automa-
change 1 –––> 0 tic oscillation in the NCK. The two time values for the directions of rotation are entered in the
MD 35440: SPIND_OSCILL_TIME_CW (oscillation time for the M3 direction) and MD 35450:
SPIND_OSCILL_TIME_CCW (oscillation time for the M4 direction).
Application example(s) If the new gear stage cannot be engaged despite several attempts during oscillation by the NCK, it
is possible to switch over to oscillation by the PLC. In this case, the two time values for the direc-
tions of rotation can be modified by the PLC user as he wants. This will guarantee that a safe
switch–over of the gear stage is possible even if the gears are in unfavorable position.
Related to .... MD 35440: SPIND_OSCILL_TIME_CW (oscillation time for M3 direction)
MD 35450: SPIND_OSCILL_TIME_CCW (oscillation time for M4 direction)
IS ”Oscillation speed” (V380x2002.5)
IS ”Set direction of rotation CCW“ (V380x2002.7)
IS ”Set direction of rotation CW” (V380x2002.6)

Signals from axis/spindle

V390x 0000.0 Spindle/no axis

Interface signal Signal(s) from axis/spindle (NCK –> PLC)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The machine axis is operated as a spindle in the following spindle operating modes:
change 0 –––> 1  Control mode
 Oscillation mode
 Positioning mode
 Tapping without compensating chuck
The IS provided to the axis (V380x1000 to V380x1003) and from the axis (V390x1000 to
V390x1003) are invalid.
The IS provided to the spindle (V380x2000 tois V380x2003) and from the spindle (V380x2000 to
V380x2003) are invalid.
Signal state 0 or edge The machine axis is operated as an axis.
change 1 –––> 0 The IS provided to the axis (V380x1000 to V380x1003)) and from the axis (V390x1000 to
V390x1003) are valid.
The IS provided to the spindle (V380x2000 to V380x2003) and from the spindle (V380x2000 to
V380x2003) are invalid.
Application examples If a spindle on a machine tool is sometimes also operated as a rotary axis (turning machine with
spindle/C axis or milling machine with spindle/rotary axis for rigid tapping), it is possible to reco-
gnize from the IS ”Spindle/no axis” whether the machine axis is in axis or in spindle mode.

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 Spindle (S1)

V390x 2000.3 Switch gear

Interface signal Signal(s) from axis/spindle (NCK –> PLC)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge A gear stage can be defined:
change 0 –––> 1  fixed by the part program (M41 to M45)
 automatically by the programmed spindle speed (M40)
M41 to M45:
 The gear stage can be specified in the part program as a fixed gear stage using M41 to M45.
If a gear stage other than the current (actual) gear stage is specified using M41 to M45, the
IS ”Switch over gear” and the IS ”Set gear stage A to C” is set.
M40:
D With M40 in the part program, the gear stage is automatically set by the control system. In
this case a check is carried out to see in which gear stage the programmed spindle
speed (S function) is possible. If a gear stage is found which is different than the current
(actual) gear stage, the IS ”Switch gear” and the IS ”Set gear stage A to C” is set.
 When the signal = 1, the text “Waiting for gear stage change ...” is displayed in the channel
process message.
Special cases, errors, ...... The IS ”Switch over gear” is only set if the new gear stage specified is other than the current ac-
tual gear stage.
Related to .... IS ”Set gear stage A to C” (V390x2000.0 to .2)
IS ”Actual gear stage A to C” (V380x2000.0 to .2)
IS ”Gear is switched over” (V380x2000.3)

V390x 2000.0 to .2 Set gear stages A to C

Interface signal Signal(s) from axis/spindle (NCK –> PLC)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge A gear stage can be defined:
change 0 –––> 1  fixed by the part program (M41 to M45)
 automatically by the programmed spindle speed (M40)
M41 to M45:
 The gear stage can be specified in the part program as a fixed gear stage using M41
to M45. If a gear stage other than the current (actual) gear stage is specified using M41 to
M45, IS ”Switch gear” and the IS ”Set gear stage A to C” is set.
M40:
 With M40 in the part program, the gear stage is automatically set by the control system. In this
case a check is carried out to see in which gear stage the programmed spindle speed (S
function) is possible. If a gear stage other than the current (actual) gear stage is found, the
IS ”Switch over gear” and the IS ”Set gear stage A to C” is set.
The set gear stage is output coded:
1st gear stage 0 0 0 (C B A)
1st gear stage 001
2nd gear stage 010
3rd gear stage 011
4th gear stage 100
5th gear stage 101
Invalid value 110
Invalid value 111
Signal inapplicable to ...... all spindle modes except for oscillation mode
Related to .... IS ”Switch over gear” (V390x2000.3)
IS ”Actual gear stage A to C” (V380x2000.0 to .2)
IS ”Gear is switched over” (V380x2000.3)

V390x 2001.7 Actual direction of rotation CW

Interface signal Signal(s) from axis/spindle (NCK –> PLC)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge When the spindle rotates, the IS ”Actual direction of rotation CW” = 1 signals CW direction of rota-
change 0 –––> 1 tion. The actual direction of rotation is derived from the spindle position encoder.

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6FC5 697–2AA10–0BP0 (04.00) 5-111
Spindle (S1)

V390x 2001.7 Actual direction of rotation CW

Interface signal Signal(s) from axis/spindle (NCK –> PLC)
Signal state 0 or edge When the spindle rotates, the IS ”Actual direction of rotation CCW” = U signals CCW direction of
change 1 –––> 0 rotation.
Signal inapplicable to ......  Spindle at a standstill, IS ”Axis/spindle stopped“ = 1 (at a standstill, no evaluation of a
direction of rotation possible)
 Spindles without position encoder
Related to .... IS ”Spindle stopped“ (V390x0001.4)

V390x2001.5 Spindle in set range

Interface signal Signal(s) from axis/spindle (NCK –> PLC)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The IS ”Spindle in set range” signals whether the programmed and (sometimes) limited spindle
change 0 –––> 1 speed is reached.
In the spindle mode “Control mode”, the set speed (programmed speed * spindle override with
taking into account the limitations) is compared with the actual speed. If the actual speed deviates
from the set speed less than allowed by the spindle speed tolerance MD 35150:
SPIND_DES_VELO_TOL, the IS ”Spindle in set range” is set.
Signal state 0 or edge The IS ”Spindle in set range” signals whether the spindle is still in the acceleration/brake phase.
change 1 –––> 0 In the spindle mode “Control mode”, the set speed (programmed speed * spindle override with
consideration of the limitings) is compared with the actual speed. If the actual speed deviates from
the set speed more than allowed by the spindle tolerance SPIND_DES_VELO_TOL, the
IS ”Spindle in set range” is reset.
Signal inapplicable to ...... all spindle modes except for speed control mode (control mode).
Application example(s) When the spindle is in the acceleration phase (programmed set speed not yet reached), normally,
the feedrate must be disabled.
This can be done in the following manner:
 The IS ”Spindle in set range” is evaluated and the IS ”Feed disable“ (V32000006.0) set.
 The MD 35500: SPIND_ON_SPEED_AT_IPO_START (feed enable for spindle in set
range) is set and the NCK internally evaluates whether the spindle is in the set range. The
feedrate will only be enabled if the spindle is in set range again. Positioning axes will never be
stopped by this function.
Related to .... MD 35500: SPIND_DES_VELO_TOL (spindle speed tolerance)

V390x 2001.2 Set speed increased (programmed speed too low)

Interface signal Signal(s) from axis/spindle (NCK –> PLC)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge If a spindle speed (1/min) or a constant cutting rate (m/min and/or ft/min) is programmed, one of
change 0 –––> 1 the following limit values has been undershot:
 min. speed of the specified gear stage
 min. spindle speed
 speed limitation by the PLC
 programmed spindle speed limitation G25
 programmed spindle speed limitation with G96
The spindle speed is limited to the min. limit value.
Signal state 0 or edge If a spindle speed (1/min) or constant cutting speed (m/min or ft/min) has been programmed, no
change 1 –––> 0 limit values have been undershot.
Application example(s) It can be recognised from the IS ”Set speed increased“ that the programmed speed cannot be
reached. The PLC user can recognise this state as inadmissible and disable the feedrate, or he
can disable the feedrate or the entire channel. If the IS “Spindle in set range” is set, the machining
is carried out.

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 Spindle (S1)

V390x 2001.1 Set speed limited (programmed speed too high)

Interface signal Signal(s) from axis/spindle (NCK –> PLC)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge If a spindle speed (1/min) or a constant cutting rate (m/min and/or ft/min) is programmed, one of
change 0 –––> 1 the following limit values has been exceeded:
 max. speed of the specified gear stage
 max. spindle speed
 speed limitation by interface signal from PLC
 progr. spindle speed limitation G26
 progr. spindle speed limitation with G96
The spindle speed will be limited to the max. limit value.
Signal state 0 or edge If a spindle speed (1/min) or a constant cutting rate (m/min or ft/min) has been programmed, no
change 1 –––> 0 limit values have been exceeded.
Application example(s) It can be recognized from the IS ”Set speed limited“ that the programmed speed cannot be re-
ached. The PLC user can recognise this state as inadmissible and disable the feedrate, or he can
disable the feedrate or the entire channel. If the IS “Spindle in set range” is set, the machining is
carried out.

V390x2001.0 Speed limit exceeded

Interface signal Signal(s) from axis/spindle (NCK –> PLC)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge If the actual speed exceeds the max. spindle speed MD 35100: SPIND_VELO_ LIMIT more than
change 0 –––> 1 allowed by the spindle speed tolerance MD 35150: SPIND_DES_VELO_TOL, the IS ”Speed limit
exceeded“ is set and alarm 22050 ”Max. speed reached” is output. All axes and spindles of the
channel are decelerated.
Related to .... MD 35150: SPIND_DES_VELO_TOL (spindle speed tolerance)
MD 35100: SPIND_VELO_LIMIT (max. spindle speed)
Alarm 22050 ”Max. speed reached“

V390x 2002.7 Active spindle mode “Control mode”

Interface signal Signal(s) from axis/spindle (NCK –> PLC)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge With the following function, the spindle is in control mode:
change 0 –––> 1 Specification of direction of rotation of the spindle M3/M4 or spindle stop M5
Related to .... IS ”Active spindle mode ’Oscillation mode’” (V390x2002.6)
IS ”Active spindle mode ’Positioning mode’” (V390x2002.5)

V390x 2002.6 Active spindle mode “Oscillation mode”

Interface signal Signal(s) from axis/spindle (NCK –> PLC)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The spindle is in oscillation mode if a new gear stage has been specified (IS “Switch over gear” is
change 0 –––> 1 set)) either by automatic gear stage selection (M40) or by M41 to M45 (IS “Switch over gear” is
set). The IS ”Switch over gear” is only set if the new gear stage specified is other than the current
actual gear stage.
Related to .... IS ”Active spindle mode ’Control mode’” (V390x2002.7)
IS ”Active spindle mode ’Positioning mode’” (V390x2002.5)
IS ”Switch over gear” (V390x2000.3)

V390x 2002.5 Active spindle mode “Positioning mode”

Interface signal Signal(s) from axis/spindle (NCK –> PLC)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge If SPOS=..... is programmed, the spindle is in positioning mode.
change 0 –––> 1
Related to .... IS ”Active spindle mode ’Control mode’” (V390x2002.7)
IS ”Active spindle mode “Oscillation mode’” (V390x2002.6)

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6FC5 697–2AA10–0BP0 (04.00) 5-113
Spindle (S1)

V390x 2002.3 Rigid tapping active

Interface signal Signal(s) from axis/spindle (NCK –> PLC)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release :
Signal state 1 or edge The spindle is operated with the function “Rigid tapping” (thread interpolation G331/G332).
change 0 –––> 1 On rigid tapping (tapping without compensating chuck), the spindle speed programming is also
carried out with S.... in 1/min, but the direction of rotation is defined by a sign and stored with the
pitch.
No reaction or updating of all spindle–specific interface signals is carried out, such as:
IS ”Spindle reset“
IS ”Synchronize spindle“
IS ”Invert M3/M4”
IS ”Spindle in set range”
IS ”Programmable speed too high”
Application example(s) During rigid tapping, certain functions should not be used, e.g.:
 Reset IS ”Servo enable“ (V380x0002.1)
 IS ”Set feed stop” (V380x0004.3)
 Reset
 If EMERGENCY STOP is pushed during rigid tapping, it should be taken into account that a
workpiece is clamped in the tool.
Related to ....

V390x 2002.0 Constant cutting rate active

Interface signal Signal(s) from axis/spindle (NCK –> PLC)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge If G96 S... is programmed, the function “Constant cutting rate” is executed.
change 0 –––> 1 The S word is now applicable as the cutting value.
Related to ....

5.10 Data fields, lists

5.10.1 Interface signals

Number .Bit Name Ref.

Axis–specific
VD30x 000 – M function for the spindle (DINT), axis–specific
VD30x 004 – S function for the spindle (REAL), axis–specific
VB380x 0000 – Feed override
V380x 0001 .7 Override active
V380x 0001 .5 Position measuring system 1
V380x 0001 .3 Axis/spindle lock
V380x 0002 .2 Spindle reset/delete distance to go
V380x 0002 .1 Servo enable
V380x 0003 .6 Velocity/spindle speed limitation
V380x 2000 .3 Gear is switched over
V380x 2000 .0 to .2 Actual gear stages A to C
V380x 2001 .4 Resynchronize when positioning 1 (spindle)
V380x 2001 .6 Invert M3/M4
V380x 2002 .7 Set direction of rotation CCW

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 Spindle (S1)

Number .Bit Name Ref.

V380x 2002 .6 Set direction of rotation CW
V380x 2002 .5 Oscillation speed
V380x 2002 .4 Oscillation by the PLC
VB380x 2003 – Spindle override
V390x 0000 .7 Position reached with exact stop fine
V390x 0000 .6 Position reached with exact stop coarse
V390x 0000 .4 Referenced/synchronized 1
V390x 0000 .2 Encoder limit frequency exceeded 1
V390x 0000 .0 Spindle/no axis
V390x 0001 .7 Current controller acitve
V390x 0001 .6 Speed controller active
V390x 0001 .5 Position controller active
V390x 0001 .4 Axis/spindle stopped (n < nmin )
V390x 2000 .3 Switch over gear
V390x 2000 .0 to .2 Set gear stage A to ...C
V390x 2001 .7 Actual direction of rotation CW
V390x 2001 .5 Spindle in set range
V390x 2001 .2 Set speed increased
V390x 2001 .1 Set speed limited
V390x 2001 .0 Speed limit exceeded
V390x 2002 .7 Active spindle mode “Control mode”
V390x 2002 .6 Active spindle mode “Oscillation mode”
V390x 2002 .5 Active spindle mode “Positioning mode”
V390x 2002 .3 Rigid tapping active
V390x 2002 .0 Constant cutting rate active (G96)

5.10.2 Machine data

Number Identifier Name Ref.

Axis–specific
30134 IS_UNIPOLAR_OUTPUT Setpoint output is unipolar
30300 IS_ROT_AX Rotary axis R2
30310 ROT_IS_MODULO Modulo conversion R2
30320 DISPLAY_IS_MODULO Position display R2
31050 * DRIVE_AX_RATIO_DENOM[n] Load gear denominator G2
31060 * DRIVE_AX_RATIO_NUMERA[n] Load gear numerator G2
32200 * POSCTRL_GAIN[n] Servo gain factor G2
32810 * EQUIV_SPEEDCTRL_TIME[n] Equivalent time constant for feedforward control of K3
speed control loop
34040 REFP_VELO_SEARCH_MARKER Reference shutdown speed R1
34060 REFP_MAX_MARKER_DIST Monitoring of zero reference mark distance R1
34080 REFP_MOVE_DIST Reference point distance/target position with R1
distance–coded system
34090 REFP_MOVE_DIST_CORR Reference–point offset/absolute offset distance R1
coded

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Spindle (S1)

Number Identifier Name Ref.

Axis–specific
34100 REFP_SET_POS Reference–point value R1
34200 ENC_REFP_MODE Referencing mode R1
35000 SPIND_ASSIGN_TO_MACHAX Assignment of spindle to machine axis
35010 GEAR_STEP_CHANGE_ENABLE Gear step change possible
35040 SPIND_ACTIVE_AFTER_RESET Spindle activated by reset
35100 SPIND_VELO_LIMIT Max. spindle speed
35110 * GEAR_STEP_MAX_VELO[n] Max. speed for gear stage change
35120 * GEAR_STEP_MIN_VELO[n] Min. speed for gear stage change
35130 * GEAR_STEP_MAX_VELO_LIMIT[n] Max. speed of gear stage
35140 * GEAR_STEP_MIN_VELO_LIMIT[n] Min. speed of gear stage
35150 SPIND_DES_VELO_TOL Spindle speed tolerance
35160 SPIND_EXTERN_VELO_LIMIT Spindle speed limitation from PLC
35200 * GEAR_STEP_SPEEDCTRL_ACCEL[n] Acceleration in speed control mode
35210 * GEAR_STEP_POSCTRL_ACCEL[n] Acceleration in position control mode
35300 SPIND_POSCTRL_VELO Position control threshold speed
35350 SPIND_POSITIONING_DIR Direction of rotation when positioning with the
spindle not synchronized
35400 SPIND_OSCILL_DES_VELO Oscillation speed
35410 SPIND_OSCILL_ACCEL Acceleration on oscillation
35430 SPIND_OSCILL_START_DIR Start direction on oscillation
35440 SPIND_OSCILL_TIME_CW Oscillation time for M3 direction
35450 SPIND_OSCILL_TIME_CCW Oscillation time for M4 direction
35500 SPIND_ON_SPEED_AT_IPO_START Feed enable with spindle in set range
35510 SPIND_STOPPED_AT_IPO_START Feed enable with the spindle stopped
36060 STANDSTILL_VELO_TOL Threshold speed ”Axis/spindle stopped“ A3
36200 * AX_VELO_LIMIT[n] Threshold for speed monitoring A3
36300 ENC_FREQ_LIMIT Encoder limit frequency A3
36302 ENC_FREQ_LIMIT_LOW Encoder limit frequency – resynchronization R1

The machine data marked with a * (asterisk) are contained in

the parameter block for one gear stage.

5.10.3 Setting data

Number Identifier Name Ref.

General
41200 JOG_SPIND_SET_VELO JOG speed for spindle H1
Spindle–specific
43210 SPIND_MIN_VELO_G25 Progr. spindle speed limitation G25
43220 SPIND_MAX_VELO_G26 Progr. spindle speed limitation G26
43230 SPIND_MAX_VELO_LIMS Progr. spindle speed limitation with G96

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Rotary Axes (R2) 6
6.1 General

Features of a rotary axis

Rotary axes are generally programmed in degrees. In general, they are characterized by the fact
that they are back to the same position exactly after one rotation (modulo 360 degrees). Depending
on the application type, the traversing range of the rotary axis can be limited to values less than 360
degrees (e.g., with swivel axes for tool holders) or endlessly (e. g., with rotary movements of the tool
or workpiece).

Definition of the rotary axis

An axis is declared a rotary axis using MD 30300: IS_ROT_AX = 1.

Note
The geometry axes (generally X, Y, Z) cannot be used as rotary axes or as a spindle.
These geometry axes are defined by MD 20050: AXCONF_GEOAX_ASSIGN_TAB (as-
signment of geometry axes to channel axis).

Axis adresses, axis identifier, direction

Cartesian coordinate system +Y

+B
–X –Z

+C +A
+Z +X

–Y

Fig. 6-1 Axis designations and positive direction of movement of rotary axes

For axes/rotary axes, an extended addressing (e.g.: C2=) or a free axis address (name) can be defi-
ned by configuration using MD 1000: AXCO=NF_MACHAX_NAME_TAB or
MD 20080: AXCONF_CHANAX_NAME_TAB.

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Rotary Axes (R2)

Units
By default, the following units are used for the input and output of rotary axes:

Table 6-1 Units for rotary axes

Physical Quantity Unit

Angular position Degrees
Programmed angular speed Degrees/minute
MD for angular speed Rev./minute 1)

MD for angular acceleration Rev./second2 1)

MD for angular jerk limitation Rev./second3 1)

1) These units will be interpreted by the control system with axis–specific machine data if the axis concerned is
declared a rotary axis.
References: Section ”Velocities, Setpoint/Actual–Value Systems, Closed–Loop Control“

Feed
With rotary axes alone in a block, the programmed feedrate F corresponds to a certain angular
speed [degrees/min].

If rotary axes and linear axes traverse along a certain path with G94 or G95, the feed must be inter-
preted in the unit of the linear axes [e.g. mm/min, inch/min].
The tangential velocity of the rotary axes refers to the diameter DE (unit diameter DE = 360/p whe-
reby p = circular constant). If the diameter is equal to the unit diameter (D=DE), the numerical values
of the programmed angular speed in degrees/min. and of the tangential speed in mm/min (or inch/
min) are the same.
The following general rule applies to the tangential speed:

F = FW * D / DE F = tangential speed [mm/min]

FW = angular speed [degrees/min]
D = diameter at which F is active [mm]

with DE = 360 / p DE = unit diameter [mm]

p = circular constant Pi = 3.14...

JOG speed for rotary axes

SD 41130: JOG_ROT_AX_SET_VELO (JOG speed for rotary axes) can be used to define a JOG
speed that will apply to all rotary axes.

If value = 0 is entered in the setting data, the axis–specific MD 32020: JOG_VELO (conventional
axis velocity) will be active for the JOG velocity of the rotary axis.

References: Section ”Manual Traversing and Handwheel Traversing“

Software limit switches

The software limit switches and work area limitings are active and are required for swiveling axes
with a limited work area. However, for endlessly turning rotary axes, (with MD 30310:
ROT_IS_MODULO=1) the software limit switches and work area limitings are switched
axis–specifically to the inactive condition.

References: Section ”Axis monitoring”

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6.2 Modulo 360 degrees

The term “modulo 360 degrees“

The term ”modulo” in conjuncion with a rotary axis means a control–internal imaging of the rotary
axis position in the range from 0 to 359,999 degrees. For path specifications > 360 degrees (e.g. for
incremental programming G91), the position is imaged to the range of values from 0 to <360 de-
grees using a control system–internal conversion. The imaging is carried out both in JOG mode and
in AUTOMATIC mode. Exception: Service display.

Machine data settings

The programming and positioning (MD 30310: ROT_IS_MODULO), as well as the position display
(MD 30320: DISPLAY_IS_MODULO) in modulo 360° can be defined for each rotary axis separately
in modulo 360° by means of machine data according to the machine requirements.

Axis is modulo
MD 30310 : ROT_IS_MODULO = 1:
With activation of the machine data, the specific rotary axes features become obvious. These featu-
res also determine the positioning behavior of the rotary axis on programming (G90, AC, ACP, ACN
or DC). After taking into account the current zero offsets internally by the control system, a modulo
360° imaging is carried out. The target position determined in this way is then approached within
one revolution.
The software limit switches and the work area limitings are not active and the work area is thus
endless.
For a modulo axis, the position display Modulo 360° should always be selected
(MD 30320: DISPLAY_IS_MODULO = 1).

Modulo position display

MD 30320: DISPLAY_IS_MODULO = 1:
The position display for rotary axes is often needed in ”modulo 360°” (1 revolution), i.e. in the positi-
ve direction of rotation, the control system internally resets the display to 0.000° periodically after
359.9995; in the negative direction of rotation, the positions are also displayed in the range
0°...359,999°.
MD 30320 : DISPLAY_IS_MODULO = 0:
In contrast to the display Modulo 360°, +360° is displayed after one revolution, and +720° after two
revolutions etc. in absolute position display mode, e.g. for a positive direction of rotation. In this
case, the display range is limited by the controller according to the linear axes.

6.3 Programming rotary axes

Note
For general information on programming, refer to:
References: “Operation and Programming“

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Rotary Axes (R2)

6.3.1 Rotary axis with active modulo conversion

Absolute programming (AC, ACP, ACN, G90)

Example with ACP: C=ACP(5.33), generally: axis name=ACP(value)
 The value describes the target position of the rotary axis in a range from 0 ... 359.999°. In case
of values with a negative sign or ≥360°, alarm 16830 Wrong modulo position programmed is
output.
 ACP (positive) and ACN (negative) define the traversing direction of the rotary axis (irrespective
of the actual position) unambiguously.
 If AC or G90 is programmed, the traversing direction is dependent on the actual position of the
rotary axis. If the target position is greater than the actual position, the axis will traverse in the
positive direction of rotation, otherwise, in the negative direction of rotation.
 Use of ACP and ACN: For unsymmetrical workpieces, it must be possible to define the
traversing direction to rule out collisions during the rotary movement.

Absolute programming on the shortest path (DC)

Example with DC: C=DC(25.3), generally: axis name=DC(value)

 The value defines the target position of the rotary axis in a range of 0 ... 359.999°. In case of
values with a negative sign or ≥360°, the alarm 16830 “Wrong modulo position programmed” is
output.
 With DC (Direct Control), the rotary axis approaches the programmed position on the shortest
path within one revolution (traversing movement max. +180°).
 Depending on the current actual position, the control system determines the direction of rotation
and the distance to be traversed. If the distance to be traversed is the same (180°) in both
directions, the positive direction of rotation is given preference.
 Application example of DC: The rotary table is to approach the change position within the
shortest possible time (and thus on the shortest path).
Note: If DC is programmed for a linear axis, the alarm message 16800 “Unable to execute
traversing instruction DC“ is displayed.

Incremental programming (IC, G91)

 The value defines the distance to be traversed by the rotary axis. The value can be either
negative or ≥ 360°.
 The sign of the value specifies the traversing direction of the rotary axis definitely..
Example:
C=IC(720) ;C axis incrementally traverses in the positive direction by 720° (2 revolutions)
C=IC(–180) ;C axis incrementally traverses in negative direction by 180°

Endless traversing range

Once the modulo function is active, the traversing range will not be limited (software limit switches
not active). Through appropriate programming, the rotary axis can be traversed in an endless range.
Example:
N10 LOOP: C=IC(7200)
N20 GOTOB LOOP

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6.3.2 Rotary axis without modulo conversion

Absolute programming (AC, G90)

Example of AC: C=AC(–410), generally: axis name=AC (+/–value)
 The value and its sign define the target position of the rotary axis unambiguously. The value can
be greater than +/–360 degrees. The position value is limited by the software limit switches.
 The traversing direction is determined by the control system, depending on the signed actual
position of the rotary axis.
 If ACP or ACN are programmed, the alarms 16810 “Unable to execute traversing instruction
ACP” or 16820 “Unable to execute traversing instruction ACN” are output.

Absolute programming on the shortest path (DC)

Example of DC: C=DC(60.3), generally: axis name=DC(value)
Even if the rotary axis is not defined as a modulo axis, the axis can be positioned using DC (Direct
Control). In this case, the behavior is as a modulo axis.

Incremental programming (IC, G91)

Example of IC: C=IC(–532.4), generally: axis name=IC(+/–value)

With incremental programming, the rotary axis traverses the same path as with the modulo axis.
The traversing range, however, is limited here by SW limit switches.

Traversing range limited

The traversing range is limited as with the linear axes. The range limits are defined by the software
limit switches plus and minus.

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Rotary Axes (R2)

6.4 Data descriptions (MD, SD)

6.4.1 Axis/spindle–specific machine data

30300 IS_ROT_AX
MD number Rotary axis
Default: 0 Min. input limit: 0 Max. input limit: 1
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BOOLEAN Valid from SW release:
Meaning: 1: Axis: The axis is defined as a “rotary axis”.
By default, the units of the axis–specific machine and setting data are interpreted
by the control system as follows:
Positions in degrees
Velocities in rev./minute
Accelerations in rev./s2
Jerk limiting in rev./s3
Spindle:
For a spindle, the machine data must generally be set to “1”; otherwise,
alarm 4210 ”Rotary axis declaration missing” is signaled.
0: The axis is defined as a “lineary axis”.
Special cases, errors, ...... For axis: Alarm 4200 if the axis is already defined as a geometry axis.
For spindle: Alarm 4210
Related to .... The following machine data are active only after activation of
MD 30300:IS_ROT_AX = 1 :
MD 30310:ROT_IS_MODULO (Modulo conversion for rotary axis)
MD 30320:DISPLAY_IS_MODULO (Position display is modulo)
MD 10210:INT_INCR_PER_DEG (Calculation resolution for angular positions)
Further references Tab. 2.2 Possible combinations of machine data

30310 ROT_IS_MODULO
MD number Modulo conversion for a rotary axis
Default: 0 Min. input limit: 0 Max. input limit: 1
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BOOLEAN Valid from SW release:
Meaning: 1: With the setpoint positions for the rotary axis, a modulo conversion is carried out.
The software limit switches and the work area limitations are inactive; the
traversing range is therefore endless in both directions.
The MD 30300: IS_ROT_AX must be set to ”1”

0: no modulo conversion
MD inapplicable ...... MD 30300: IS_ROT_AX = 0 (Linear axis)
Tab. 2.2 possible combinations of machine data
Application example(s) Endless rotating rotary axes (e. g. for out–of–center turning, grinding, winding)
Related to .... MD 30320: DISPLAY_IS_MODULO (position display is modulo 360°)
MD 30300: IS_ROT_AX = 1 (rotary axis)
MD 36100: POS_LIMIT_MINUS (software limit switch minus)
MD 36110: POS_LIMIT_PLUS (software limit switch plus)
SD 43430: WORKAREA_LIMIT_MINUS (working area limitation minus)
SD 43420: WORKAREA_LIMIT_PLUS (working area limitation plus)

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30320 DISPLAY_IS_MODULO
MD number Position display is modulo 360°
Default: 1 Min. input limit: 0 Max. input limit: 1
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BOOLEAN Valid from SW release:
Meaning: 1: Position display ”Modulo 360°” is active:
The position display of rotary axis or spindle (with base or machine coordinate system) is
defined to ”Modulo 360°”. With the positive direction of rotation, the position display is
thus internally reset by the control system to 0.000 degrees periodically after 359.999°. The
display range is always positive and always between 0° and 359,999°.
0: Absolute position display is active:
In contrast to the position display Modulo 360°, with the absolute position display, e.g. with the
positive direction of rotation +360° is displayed after 1 revolution, +720° after 2 revolutions, etc.
The display range is limited according to the linear axes.
MD inapplicable to ...... Linear axes MD 30300: IS_ROT_AX = 0
Application example(s)  For endlessly turning rotary axes (MD 30310:ROT_IS_MODULO = 1), it is
recommended to activate also the position display by modulo 360°.
 For spindles, the position display must always be activated with modulo 360°.
Related to .... MD 30300: IS_ROT_AX = 1 (axis is rotary axis)

34220 ENC_ABS_TURNS_MODULO[n]
MD number Range of rotatory absolute encoders
Default: 4096 Min. input limit: 1 Max. input limit: 4096
Change valid after Power On Protection level: 2 / 2 Unit: –
Data type: DWORD Valid from SW release:
Meaning: Number of encoder revolutions that a rotatory absolute encoder can resolve.
0 degrees <= position <= n*360 degrees, (where n = ENC_ABS_TURNS_MODULO)
Note: If the control system is turned off, the encoder may be turned by max. the half of this value.
Special cases, errors, ...... Only numbers raised to the power of 2 are permitted as values ( 1, 2, 4, 8, 16, ..., 4096).
If any other values are entered, these will be “rounded off”. If such a rounding has been carried
out, it is visible in the machine data and signaled by alarm 26025.
The MD only applies to rotary encoders (at linear and rotary axes).
Important recommendation:
When using an encoder with smaller Multiturn information or when using single–turn encoders, this
value must be reduced accordingly. In any case the value for multiturn–absolute encoders should
be matched with the value max. supported in order to be able to use the max. defined traversing
range (Note: This value also influences the permissible position offset with the encoder inactive/
Power Off).
Related to ....

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Rotary Axes (R2)

6.5 Data fields, lists

6.5.1 Machine data

Number Identifier Name Ref.

General
10000 AXCONF_MACHAX_NAME_TAB Machine axis name Chpt. 19

10210 INT_INCR_PER_DEG Computational resolution for angular positions G2

Channel–specific
20050 AXCONF_GEOAX_ASSIGN_TAB Assignment ’geometry axis – channel axis’ Chpt. 19

20080 AXCONF_CHANAX_NAME_TAB Channle axis name Chpt. 19

Axis/spindle–specific
30300 IS_ROT_AX Axis is a rotary axis
30310 ROT_IS_MODULO Modulo conversion for rotary axis
30320 DISPLAY_IS_MODULO Actual–value display modulo
34220 ENC_ABS_TURNS_MODULO Range of rotary absolute encoders
36100 POS_LIMIT_MINUS Software limit switch minus A3
36110 POS_LIMIT_PLUS Software limit switch plus A3

6.5.2 Setting data

Number Identifier Name Ref.

General
41130 JOG_ROT_AX_SET_VELO JOG speed for rotary axes H1
Axis–specific
43430 WORKAREA_LIMIT_MINUS Working area limitation minus A3
43420 WORKAREA_LIMIT_PLUS Working area limitation plus A3

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Transverse Axes (P1) 7
7.1 Defining a transverse axis

Geometry axis as a transverse axis

The geometry axis X is defined as a transverse axis. A transverse axis is important for turning ma-
chine functions..

7.2 Diameter programming

Enabling and disabling

Transverse axes can be programmed either in radius or diameter dimensions.
The program commands “DIAMON” or “DIAMOF” can be used to enable/disable the diameter pro-
gramming of a transverse axis.
DIAMON and DIAMOF are G commands of group 29 and are modally active.

JOG mode
If DIAMON is active, the increments of the related transverse axis, which have been entered for the
machine functions INC (incremental dimension) and hand–wheel traversing in JOG mode, will be
interpreted in and traversed by diameter values (traversing in the WCS with this axis).

Setpoint/actual value display

If the function “DIAMON” is active for a transverse axis, position, distance to go and REPOS offset
are displayed in diameter dimensions provided the workpiece coordinate system is selected.
In the machine coordinate system (MCS), the display is always carried out in radius dimensions.

Offsets
All offsets (e. g. tool offsets, programmable and settable zero offsets) are always entered, program-
med and displayed as radius dimensions (even if they are active for the transverse axis and if DIA-
MON is active).

Working area limitations, software limit switches, feed values

These data are always entered, programmed and displayed as radius values.

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Transverse Axes (P1)

Conversion of diameter values to internal radius values

In case of active diameter programming, a conversion to internal radius values is carried out for the
transverse axis (i.e. halving of the programmed values):

 programmed end positions

 absolute interpolation parameters (e. g. I, J, K) for G2/G3 programming
Absolute interpolation parameters will be referred to the coordinate zero of WCS.
Any interpolation parameters programmed in relative dimensions will not be converted.
References: “Operation and Programming“

Conversion of internal radius values to diameter values

In case of active diameter programming, when measuring in the WCS using the functions “MEAS”
and “MEASW”, the results of measurement are converted to diameter values for the transverse axis
(i.e. doubling of the internal radius values) and stored.

When measuring or reading in the MCS, the values determined are stored as radius values.

7.3 Constant cutting rate: G96

Functionality
Prerequisite: A controlled spindle must be provided.
With the G96 function enabled, the spindle speed is matched with the diameter of the workpiece
currently machined (position of the transverse axis=geometry axis X) such that a programmed cut-
ting rate S at the tool edge remains constant (spindle speed by diameter = constant).
From the block that contains G96, the S word is interpreted as the cutting rate. G96 is modally ac-
tive until it is canceled by another G function of the group (G94, G95, G97).

Programming
G96 S... LIMS=... F... ;Constant cutting rate ON
G97 ;Constant cutting rate OFF
S Cutting rate, unit m/min
LIMS= Upper limit speed of spindle, only active with G96
F Feed in the measuring unit mm/rev. –as with G95
References: “Operation and Programming“

X (Transverse axis)

M D2 W SD=Spindle speed
D1

D1, D2 =Diameter

D1 x SD1=D2 x SD2=Dn x SDn=constant

Fig. 7-1 Constant cutting rate G96

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Reference Point Approach (R1) 8
8.1 Fundamentals

Why referencing?
To ensure that the control system detects the machine zero point exactly after the control system
has been turned on, it must be synchronized with the position measuring system of each machine
axis. This process is called referencing.
The procedure for the spindle (synchronization) is to a large degree described in the Chapter
“Spindle”.

Positions measuring systems

The following position measuring systems can be installed on the motor/machine for an axis:

 incremental rotatory measuring system

 absolute rotatory measuring system
The referencing can be set for the installed position measuring systems using
MD 34200: ENC_REFP_MODE (referencing mode).

Cams
A cam for the reference point approach may be required for linear axes and performs the following
tasks using its signal :

 Selection of the traversing direction when approaching the zero mark (synchronous pulse)
 Selection of the zero mark as necessary

BERO
A BERO (inductive proximity switch) can be used as an encoder for the synchronous pulse (instead
of the position encoder zero mark) (preferrably for rotary axes, spindle).
In this case, the connection is made on the drive SIMODRIVE 611U. This drive must be parameteri-
zed accordingly (using SimoComU).

References: “Start–Up Guide“

IS “Active machine function REF” (V3100 0001.2)

The reference point approach is carried out with the machine function REF (IS ”Active machine
function REF”) enabled. The machine function REF can be selected in the operating mode JOG
(IS ”Machine function REF” (V3000 0001.2)).

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Reference Point Approach (R1)

Axis–specific referencing
The axis–specific referencing is started for each machine axis separately using the IS ”Traversing
keys plus/minus” (V380x0004.7 /.6). All axes can be referenced simultaneously. To reference the
machine axes in a certain order, the following is necessary:
 The operator must observe the starting order.
 The PLC user program must either check the starting order or define it automatically.
 The order is defined in MD 34110: REFP_CYCLE_NR (see channel–specific referencing).

Channel–specific referencing
The channel–specific referencing is started using the IS ”Enable referencing“ (V3200 0001.0). The
control system acknowledges the successful start with the IS ”Referencing active” (V3300 0001.0).
Using the channel–specific referencing, it is possible to reference each machine axis assigned to
the channel. (To this aim, the control system internally simulates the traversing keys plus/minus.)
The axis–specific MD 34110: REFP_CYCLE_NR (axis order on channel–specific referencing) can
be used to define in which order the machine axes are referenced. If all axes specified in
REFP_CYCLE_NR have reached their reference points, the IS ”All axes to be referenced are refe-
renced” (V33000004.2) is set.

Special features
 The IS ”Reset” (V3000 0000.7) is used to cancel referencing. All axes that have not yet reached
their reference points until this moment are considered not referenced.
The IS ”Referencing active” is reset, and alarm 20005 is output.
 Working area limitations and software limit switches are not active for machine axes not referen-
ced.
 When referencing, the specified axis–specific accelerations are observed at all times (except in
case of alarms).
 To start reference–point approach, only the direction key defined for the corresponding direction
in MD 34010: REFP_CAM_DIR_IS_MINUS will be active.

Referencing in the part program

One or several axes can be referenced at the same time, which have lost their reference during
operation. The sequence of the individual phases completely corresponds to the axis–specific refe-
rencing, while the start is not carried out using the traversing keys plus/minus, but using the G74
command and the machine axis identifiers.
References: “Operation and Programming“

Note: MD 20700: REFP_NC_START_LOCK = 1 will disable the start of a part program (alarm out-
put), unless all the specified axes are referenced.

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8.2 Referencing using incremental measuring systems

Time sequence
The time sequence when referencing using incremental measuring systems can be divided into 3
phases:

1st phase: Traversing to the reference cam

2nd phase: Synchronization with the zero mark

3rd phase: Traversing to the reference point

IS ”Delayed reference point approach”

(V380x1000.7)

IS ”Traversing command plus”

(V390x0004.7)

IS ”Traversing command minus”

(V390x0004.6)

NST ”Traversing key plus/minus”

(V380x0004.7 und .6)

IS ”Referenced/synchronized
(V390x0000.4)
Position encoder zero mark
|Velocity|
MD 34020: REFP_VELO_SEARCH_CAM
Reference point approach velocity
MD 34070: REFP_VELO_POS
Reference point approach velocity
MD 34040: REFP_VELO_SEARCH_MARKER
Reference point shutdown velocity
t

Phase 1 Phase 2 Phase 3

Fig. 8-1 Referencing sequence when using incremental measuring systems (example)

Features when traversing to the reference point cam (phase 1)

 Feed override and feed stop are active.
 The machine axis can be stopped/started.
 The cam must be areched within the traversing range defined by
MD 34030: REFP_MAX_CAM_DIST. Otherwise, an appropriate alarm is output.
 The machine axis must come to a standstill on the cam. Otherwise, an alarm is output.

Features when synchronizing with the zero pulse (phase 2)

 The feed override is not active. The feed override of 100 % is active. The operation is aborted at
a feed override of 0 %.
 Feed Stop is active, the axis stops and an appropriate alarm is displayed.
 The machine axis cannot be stopped/started using NC Stop/NC Start.
 The monitoring of the zero mark using MD 34060: REFP_MAX_MARKER_DIST is active.

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Features when traversing to the reference point (phase 3)

 Feed override and feed stop are active.
 The machine axis can be stopped/started using NC Stop/NC Start.
 If the reference point offset is less than the braking distance of the machine axis from the
reference point approch velocity to the standstill, the reference point is approached from the
other direction.

Different sequences of motion when referencing:

Synchronuous
Type of referencing pulse Sequence of motions
(zero mark, BERO)
Synchronuous pulse
before cam, RV
VC
reference coordinate be-
fore synchronuous pulse VP
with reference point cams
VM
(MD 34000: = without reversal:
REFP_CAM_IS_ACTIVE = 1) (MD 34050: Start RK
REFP_SEARCH_MAR-
KER_REVERSE = 0) Cam
Synchronuous
pulse

Synchronuous pulse RV
on the cam, VC

reference coordinate af- VP

ter synchronuous pulse VM
on the cam

= with reversal: Start RK

(MD 34050:
REFP_SEARCH_MAR- Cam
KER_REVERSE = 1)
Synchronous pulse

RV

Without reference cams VP

VM
Reference coordi-
nate after synchro-
(MD 34000: nouspulse Start
REFP_CAM_IS_ACTIVE = 0)
RK
Synchronuous pulse

VC - reference point approach velocity (MD 34020: REFP_VELO_SEARCH_CAM)

VM - ref. point shutdown velocity (MD 34040: REFP_VELO_SEARCH_MARKER)
VP - reference point approach velocity (MD 34070: REFP_VELO_POS)
RV - reference point offset (MD 34080: REFP_MOVE_DIST + MD 34090:
REFP_MOVE_DIST_CORR)
RK - reference point coordinate (MD 34100: REFP_SET_POS

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What is the required minimum length of the reference cam?

Example for the case: Synchronuous pulse before the cam, reference coordinate before
synchronuous pulse = synchronuous pulse search with falling cam edge).
The reference cam must have such a length that the braking procedure is terminated on the cam
when approaching the cam at reference point approach velocity (standstill on the cam), and that the
cam is left again when starting in the opposite direction at reference point shutdown velocity
(leaving at a constant velocity).
To calculate the minimum length of the cam, insert the larger of the following speeds in the formula
below:

( reference point approach velocity or shutdown speed)2

Minimum length =
2 x axis acceleration (MD 32300: MAX_AX_ACCEL)

If the machine axis does not come to a standstill at the reference cam (IS ”Reference point appro-
ach delay” (V380x1000.7) has been reset), alarm 20001 is output. Alarm 20001 may occur if the
reference–cam is too short and the machine axis overruns the reference cam when decelerating in
phase 1.
If the reference cam extends up to the traversing end of the axis, an inadmissible starting point for
the referencing (after the cam) is excluded.

Reference cam adjustment

The reference cam must be adjusted exactly. The following factors influence the time response for
recognition of the reference cam (IS “Reference point approach delay”):

 Switching accuracy of the reference cam switch

 Time delay of reference cam switch (normally closed contact)
 Time delay at the PLC input
 PLC cycle time
 Internal processing time
Practice has shown that it is best to adjust the edge of the reference cam required for the synchro-
nization in the middle between two synchronuous pulses (zero marks). This can be achieved as
follows:
 Set MD 34080: REFP_MOVE_DIST = MD 34090: REFP_MOVE_DIST_CORR = MD 34100:
REFP_SET_POS = 0.
 Reference axis.
 In JOG mode, traverse the axis by half the length of the distance to be traversed between two
zero marks. This distance is dependent on the leadscrew pitch S and the gear ratio n (e.g.:
S=10 mm/rev. , n=1:1 results in a distance to be traversed of 5 mm).
 Adjust the cam switches such that the switching action is carried out exactly at this position (IS
“Reference point approach delay (V380x 1000.7).
 Alternative, instead of shifting the cam switch, the value of MD 34092: REFP_CAM_SHIFT can
be changed.

Warning
! If the reference cam is not adjusted exactly, it may happen that a false sychronuous pulse (zero mark) is evalua-
ted. As a result, the control system is assigned an incorrect machine zero point and it will traverse the axes to
wrong positions. The software limit switches will be active at false positions and will therefore not be able to
protect the machine.

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8.3 Referencing using absolute encoders

8.3.1 General

Prerequisites
Referencing of an axis using absolute encoders is carried out automatically when turning on the
control system and if the appropriate axis is recognized adjusted. This acceptance of the absolute
value is carried out without axis movement, e.g. at POWER ON. Two conditions must be met for
automatic referencing:
 The axis has an absolute encoder for the position control.
 The absolute encoder is adjusted (MD 34210: ENC_REFP_STATE=2)

Adjustment
In case of axes provided with absolute encoders, the measuring system is not synchronized by ap-
proaching a reference cam. Instead of this, an adjustment is carried out. The actual value of the
absolute encoder is set during the start–up once and accepted by the control system.

8.3.2 Operator–sssisted adjustment

General procedure
Move the axis to be adjusted to a defined position and then set the appropriate actual value.

Chronological sequence

1. Set MD 34200: ENC_REFP_MODE and MD 34210: ENC_REFP_STATE to 0 and enable it by

POWER ON.
(MD: ENC_REFP_MODE = 0 means that the actual value of the axis is set once.)
2. In JOG mode, traverse the axis manually to a known position. The direction in which the position
is approached must correspond to the direction defined in
MD 34010: REFP_CAM_DIR_IS_MINUS (0 = positive direction, 1 = negative direction).

Note
This known position must be approached at a slow velocity and always from a defined
direction to make sure that this position is not invalidated by the backlash in the drive sy-
stem.

3. Enter the actual value that corresponds to the position approached in

MD 34100: REFP_SET_POS. This value may be a specific design–related value (e. g. fixed
stop), or it can now be determined using a measuring system.

4. Set MD 34210: ENC_REFP_STATE to “1”. This will enable the “Adjustment” function.
5. Press RESET to enable the changed machine data.

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6. Change to JOG–REF mode.

7. Pressing the traversing key already used in step 2 will enter the current offset into
MD 34090:REF_MOVE_DIST_CORR, and MD 34210: ENC_REFP_STATE will change to “2”,
i.e. the axis is considered adjusted.
(Pressing the traversing keys will also update the display.)

Note
The axis will not move if the appropriate traversing key is pressed. The value entered in
MD 34100: REFP_SET_POS will be displayed in the actual–value display of the axis po-
sition.

8. Quit JOG–REF mode; the axis is thus adjusted.

8.4 Boundary conditions for absolute encoders

8.4.1 Adjusting the absolute encoder

Adjusting time
The adjustment determines the offset between the machine zero point and the encoder zero point
and stores it in a non–volatile memory. Normally, this adjustment must be made only once during
the commissioning. The control system will then know this value and can calculate the absolute
machine position from the encoder absolute value at any time. This status is characterized by
MD 34210: ENC_REFP_STATE=2.
The offset is stored in MD 34090: REFP_MOVE_DIST_CORR (SRAM).
This adjustment must be repeated:

 after removing/installing or replacing the encoder or the motor with motor–integrated encoder;
 after switching over a gearbox (if any) between motor (with absolute encoder) and load;
 generally, whenever the mechanical connection between encoder and load has been disconnec-
ted and has not been mounted exactly in the way it was.
CAUTION: The control system cannot detect all cases that require a re–adjustment! If the control
system detects it, it will note this by setting machine data MD 34210: ENC_REFP_STATE to the
value 0 or 1.
The following is detected: Switching over to a gear stage with a different transmission ratio between
encoder and load.

In any other cases the user himself must overwrite the machine data
MD 34210: ENC_REFP_STATE.

Data back–up
Saving the machine data will also save the state of MD 34210: ENC_REFP_STATE.
By loading such a data record, the axis is therefore automatically declared adjusted.

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Warning
! If the data record arises from another machine (e. g. in case of series machine start–up),
an adjustment must be carried out after loading and enabling the data.

8.5 Data descriptions (MD, SD)

8.5.1 Channel–specific machine data

20700 REFP_NC_START_LOCK
MD number NC START inhibit without reference point
Default: 1 Min. input limit: 0 Max. input limit: 1
Change valid after RESET Protection level: 2/7 Unit: –
Data type: BOOLEAN Valid from SW release:
Meaning: 0: The IS ”NC START“ (V32000007.1) for starting part programs or part program blocks (MDA)
is possible even if none or not all axes of the channel are referenced. To ensure that the
axes nevertheless reach the correct position after NC START, the workpiece coordinate
system (WCS) must be set to a correct value using other methods (scratching method).
1: NC START only if all axes are referenced.

8.5.2 Axis/spindle–specific machine data

31122 BERO_DELAY_TIME_PLUS[0]
MD number BERO delay time plus
Default: 0.000110 Min. input limit: 0.0 Max. input limit: ***
Change valid after NEW_CONF Protection level: 2/2 Unit: s
Data type: DOUBLE Valid from SW release:
Meaning: In conjunction with the setting MD 34200: ENC_REFP_MODE = 7, this MD results in a signal
runtime compensation in the positive direction of movement when determining the position using
a BERO (zero mark).
Related to .... MD 34200: ENC_REFP_MODE

31123 BERO_DELAY_TIME_MINUS[0]
MD number BERO delay time minus
Default: 0.000078 Min. input limit: 0.0 Max. input limit: ***
Change valid after NEW_CONF Protection level: 2/2 Unit: s
Data type: DOUBLE Valid from SW release:
Meaning: In conjunction with the setting MD 34200: ENC_REFP_MODE = 7, this MD results in a signal
runtime compensation in the negative direction of movement when determining the position
using a BERO (zero mark).
Related to .... MD 34200: ENC_REFP_MODE

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34000 REFP_CAM_IS_ACTIVE
MD number Axis with reference point cam
Default: 1 Min. input limit: 0 Max. input limit: 1
Change valid after RESET Protection level: 2/2 Unit: –
Data type: BOOLEAN Valid from SW release:
Meaning: Machine axes that have only one zero mark over their entire traversing range or rotary axes that
have only one zero mark per revolution will not be marked as a machine axis with reference cam
by REF_CAM_IS_ACTIVE. The machine axis marked in this way will accelerate to the velocity
specified in MD 34040: REFP_VELO_SEARCH_MARKER (reference point shutdown velocity)
after the traversing key plus/minus has been pressed, and will synchronize itself with the next
zero mark.
MD inapplicable ......

34010 REFP_CAM_DIR_IS_MINUS
MD number Reference–point approach in minus direction
Default: 0 Min. input limit: 0 Max. input limit: 1
Change valid after RESET Protection level: 2/2 Unit: –
Data type: BOOLEAN Valid from SW release:
Meaning: 0: Reference point approach in plus direction
1: Reference point approach in minus direction
Approach with incremental measuring systems:
Starting using the traversing key is only possible in the specified direction. If the wrong traversing
key is pressed, no reference point approach start is carried out.

If the machine axis is upstream the reference cam, it accelerates to the velocity specified in
MD 34020: REFP_VELO_SEARCH_CAM (reference point approach velocity).
If the machine axis is on the reference cam, it accelerates to the velocity specified in MD 34020:
REFP_VELO_SEARCH_CAM and first moves in the opposite direction of the cam.

Note regarding absolute encoders:

The direction of the traversing key is also important for the adjustment of absolute encoders:
Approach in the direction of a fixed position; update of values in MD 34090 and MD 34210.

34020 REFP_VELO_SEARCH_CAM
MD number Reference point approach velocity
Default: 5000.0 mm/min Min. input limit: 0.0 Max. input limit: ***
13.88 rpm
Change valid after RESET Protection level: 2/2 Unit: mm/min,
rpm
Data type: DOUBLE Valid from SW release:
Meaning: The reference point approach velocity is the velocity at which the machine axis traverses in the
direction of the reference cam after pressing the traversing key (phase 1). This value should be
set to such a large value that the axis can be decelerated to 0 before it reaches a hardware limit
switch.
MD inapplicable ......

34030 REFP_MAX_CAM_DIST
MD number Max. distance to be traversed to the reference cam
Default: 10000.0 Min. input limit: 0.0 Max. input limit: ***
Change valid after RESET Protection level: 2/2 Unit: mm, degrees
Data type: DOUBLE Valid from SW release:
Meaning: If the machine axis traverses a path defined by REFP_MAX_CAM_DIST from its home position
in the direction of the reference cam without reaching the reference cam (IS ”Delayed
reference–point approach” is reset), the axis stops, and alarm 20000 ”Reference cam not
reached” is output.
MD inapplicable ......

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34040 REFP_VELO_SEARCH_MARKER[n]
MD number Reference point shutdown velocity [encoder No.]: 0
Default: 300.0 mm/min Min. input limit: 0.0 Max. input limit: ***
0.833 rpm
Change valid after RESET Protection level: 2/2 Unit: mm/min,
rpm
Data type: DOUBLE Valid from SW release:
Meaning: 1) With incremental measuring systems:
The axis traverses at this velocity within the time from detecting the first reference
cam and until the synchronization with the first zero mark (phase 2).
Traversing direction: opposite to the direction set for the cam search
(MD 34010: REFP_CAM_DIR_IS_MINUS)
If MD 34050: REFP_SEARCH_MARKER_REVERSE (direction reversal to reference
cam) is set, in case of synchronization with the rising reference cam will traverse to
the cam at the velocity specified in MD 34020: REFP_VELO_SEARCH_CAM.

2) Indirect measuring system with load–end BERO (preferably for the spindle)
The zero mark belonging to the BERO is searched at this speed/velocity.
The zero mark is accepted if the actual speed is within the tolerance range
determined by MD 35150: SPIND_DES_VELO_TOL of the speed/velocity specified by
MD 34040: REFP_VELO_SEARCH_MARKER[n].

34050 REFP_SEARCH_MARKER_REVERSE[n]
MD number Direction reversal to the reference cam [encoder No.]: 0
Default: 0 Min. input limit: 0 Max. input limit: 1
Change valid after RESET Protection level: 2/2 Unit: –
Data type: BOOLEAN Valid from SW release:
Meaning: This machine data can be used to set the direction in which the zero mark is searched.
0: Synchronization with falling reference cam edge
The machine axis accelerates to the velocity defined in MD 34040:
REFP_VELO_SEARCH_MARKER (reference–point shutdown velocity).
When leaving the reference point (IS ”Delayed reference point approach” is reset), the control
system will synchronize itself with the first zero mark.
1: Synchronization with rising reference cam edge
The machine axis accelerates to the velocitiy specified in MD 34020:
REFP_CAM_DIR_IS_MINUS, irrespective of the pressed traversing key plus/minus. When
leaving the reference point (IS ”Delayed reference point approach” is reset), the machine axis
will decelerate to a standstill and will then traverse at the velocity specified in MD:
REFP_VELO_SEARCH_MARKER in the opposite direction to the reference cam. If the
reference cam is reached (IS ”Delayed reference–point approach” is set), the control system
synchronizes itself with the first zero mark.
MD inapplicable ......

34060 REFP_MAX_MARKER_DIST[n]
MD number Max. distance to the reference mark [encoder No.]: 0
Default: 20.0 Min. input limit: 0.0 Max. input limit: ***
Change valid after RESET Protection level: 2/2 Unit: mm, degrees
Data type: DOUBLE Valid from SW release:
Meaning: With incremental measuring systems:
If the machine axis traverses a distance defined in MD: REFP_MAX_MARKER_DIST (IS
”Delayed reference point approach” is reset) without detecting the reference mark, the axis stops
and alarm 20002 ”Zero mark missing” is output.
Application example(s) If it is intended that with incremental measuring systems the control system reliably detects that
the same zero mark is always used for synchronization (otherwise, a wrong machine zero point
is recognized), the max. value in this MD may not exceed the distance between two reference
marks.

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34070 REFP_VELO_POS
MD number Reference point approach velocity
Default: 1000.0 mm/min Min. input limit: 0.0 Max. input limit: ***
2.77 rpm
Change valid after RESET Protection level: 2/2 Unit: mm/min,
rpm
Data type: DOUBLE Valid from SW release:
Meaning: With incremental measuring systems:
The axis traverses at this velocity from the synchronization with the zero mark until the reference
point is reached.

34080 REFP_MOVE_DIST[n]
MD number Reference point distance/target position with distance–coded system [encoder No.]: 0
Default: –2.0 Min. input limit: *** Max. input limit: ***
Change valid after RESET Protection level: 2/2 Unit: mm, degrees
Data type: DOUBLE Valid from SW release:
Meaning: With incremental measuring systems:
After synchronization with the first zero mark, the machine axis accelerates to the velocity
specified in MD 34070: REFP_VELO_POS (reference point approach velocity), and
traverses a distance resulting from adding up the distances efined in
MD:REFP_MOVE_DIST and MD 34090: REFP_MOVE_DIST_CORR (reference point
offset). The distance determined by addition is exactly the distance between the zero mark
(in phase 2) and the reference point.

MD 34100: REFP_SET_POS[0]

Velocity MD: REFP_MOV_DIST + MD: REFP_SET_POS_CORR

MD 34020:
REFP_VELO_SEARCH_CAM
(ref. point approach velocity)
MD 34040: REFP_VELO_SEARCH_
MARKER
(ref. point shutdown velocity)

Delayed
Zero mark ref. pt. approach Ref. point cam

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34090 REFP_MOVE_DIST_CORR[n]
MD number Reference point offset/absolute offset distance–coded, n: [encoder No.]: 0
Default: 0.0 Min. input limit: *** Max. input limit: ***
Change valid after RESET Protection level: 2/2 Unit: mm, degrees
Data type: DOUBLE Valid from SW release:
Meaning:  Incremental encoder with zero mark(s):
After detecting the zero reference mark, the axis is positioned away from the zero mark by the
distance MD 34080: REFP_MOVE_DIST + REFP_MOVE_DIST_CORR. If this axis has been
traversed, the axis has reached its reference point. MD 34100: REFP_SET_POS is accepted as
the actual value.
During the traversing movement as defined in REFP_MOVE_DIST+REFP_MOVE_DIST_CORR,
override switches are active
 Absolute value encoder:
REFP_MOVE_DIST_CORR acts as an absolute offset. It describes the offset between machine
zero point and the zero point of the absolute measuring system.
Note: The control system will change this machine data in conjunction with absolute encoders if
adjusting processes and modulo corrections are required.

34092 REFP_CAM_SHIFT
MD number Electronic reference cam offset for incremental measuring systems with equidistant zero marks
Default: 0.0 Min. input limit: 0.0 Max. input limit: ***
Change valid after RESET Protection level: 2/2 Unit: mm
Data type: DOUBLE Valid from SW release:
Meaning: When the reference cam signal occurs, the search for the zero mark is started not imme-
diately, but with a delay after the distance defined in REFP_CAM_SHIFT has been traver-
sed. This ensures the repeatability of the zero mark search even in case of a tempera-
ture–dependent extension of the reference cam by defined selection of a zero mark.
Since the reference cam offset is calculated by the control system in the interpolation
clock, the real cam offset is at least REFP_CAM_SHIFT and max.
REFP_CAM_SHIFT+(MD 34040: REFP_VELO_SEARCH_MARKER*interpolation clock)

The reference cam offset acts in the search direction of the zero mark.
Only if the cam exists (MD 34000: REFP_CAM_IS_ACTIVE=1), the reference cam offset
is active.

ÉÉÉÉ
Thermal extension

ÉÉÉÉ
ÉÉÉÉÉÉÉ
Cam signal

ÉÉÉÉÉÉÉ Zero mark search

Zero marker

ÉÉÉ
ÇÇÇÇ 1 2

ÉÉÉ
ÇÇÇÇ
Cam signal with
REMEDY offset
REFP_CAM_SHIFT 1+2

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34100 REFP_SET_POS[0]
MD number Reference point with incremental systems
Default: 0.0 Min. input limit: *** Max. input limit: ***
Change valid after RESET Protection level: 2/2 Unit: mm, degrees
Data type: DOUBLE Valid from SW release:
Meaning:  Incremental encoder with zero mark(s):
Position value set after detecting the zero mark and traversing the distance defined in
REFP_MOVE_DIST + REFP_MOVE_DIST_CORR (relative to the zero mark) as the current axis
position.
 Absolute value encoder:
REFP_SET_POS corresponds to the correct actual value at the adjusting position. The reaction
of the machine depends on the state of MD34210: ENC_REFP_STATE:
If MD 34210: ENC_REFP_STATE = 1, the value of REFP_SET_POS is accepted as an absolute
value.
If MD 34210: ENC_REFP_STATE = 2 and MD 34330: REFP_STOP_AT_ABS_MARKER = 0, the
axis approaches the target position stored in REFP_SET_POS. The value defined in
REFP_SET_POS is used.

Note: MD: REFP_SET_POS[1]...[3] is reserved – do not use.

Related to ....

34110 REFP_CYCLE_NR
MD number Axis order on channel–specific referencing
Default: 0 Min. input limit: –1 Max. input limit: 4
Change valid after RESET Protection level: 2/2 Unit: –
Data type: BYTE Valid from SW release:
Meaning: 0: Axis–specific referencing
The axis–specific referencing is started by the IS ”Traversing keys plus/minus” for each machine
axis separately. All axes can be referenced at the same time. If the machine axes are to be
referenced in a defined order, the following is required:
 The operator must observe the starting sequence.
 The PLC must either check the starting sequence or define it automatically.
The machine axis will not be started by channel–specific referencing. NC Start is not possible
without referencing this axis.
–1 : The machine axis will not be started by channel–specific referencing.
NC Start is not possible without referencing this axis.
Note:
The effect of setting all axes of a channel to “–1” can be achieved by setting the channel–specific
MD 20700: REF_NC_START_LOCK (NC Start inhibited without reference point) to zero.).

> 0 : Channel–specific referencing

The channel–specific referencing is started using the IS “Enable referencing” (V3200 0001.0).
The control system acknowledges the successful start with the IS “Referencing active”.
Channel–specific referencing can be used to reference any machine axis assigned to the
channel (to this aim, the plus/minus traversing keys are simulated).
The MD: REFP_CYCLE_NR can be used to define in which order the machine axes are
referenced:
1: The machine axis is started by channel–specific referencing.
2: The machine axis is started by channel–specific referencing if all machine axes marked
in MD: REFP_CYCLE_NR with 1 have been referenced.
3: The machine axis is started by channel–specific referencing if all machine axes marked
in MD: REFP_CYCLE_NR with 2 have been referenced.
4: The machine axis is started by channel–specific referencing if all machine axes marked in
MD: REFP_CYCLE_NR with 3 have been referenced.
MD inapplicable to ...... axis–specific referencing
Related to .... IS ”Enable referencing”
IS ”Referencing active“

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34200 ENC_REFP_MODE[n]
MD number Referencing mode [encoder No.]: 0
Default: 1 Min. input limit: 0 Max. input limit: 7
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BYTE Valid from SW release:
Meaning: The installed position measuring systems can thus be divided for referencing as follows:
0: If an absolute encoder is provided: Acceptance of MD 34100: REFP_SET_POS
Other encoders: no reference point approach possible
1: Referencing using incremental measuring systems:
incremental rotary measuring system
incremental linear measuring system (length measuring system)
zero pulse on the encoder track
(not for absolute encoders)
2, 3, 4, 5, 6: not available
7: Synchronize spindle with BERO, configured approach velocity (MD 34040)
Related to ....

34210 ENC_REFP_STATE[n]
MD number Status of absolute encoder [encoder No.]: 0
Default: 0 Min. input limit: 0 Max. input limit: 2
Change valid: immediately Protection level: 2/2 Unit: –
Data type: BYTE Valid from SW release:
Meaning:  Absolute value encoder:
0: Default on comissioning: Encoder not adjusted
1: Encoder adjustment enabled, encoder not yet adjusted
2: Encoder adjusted
 Incremental encoder:
0: Default: No automatic referencing
1: Automatic referencing enabled, but encoder not yet referenced and/or not at exact stop
2: Encoder is referenced and at exact stop, automatic referencing will be active with the
next encoder activation
Application example(s) MD ENC_REFP_STATE can be modified by the start–up engineer and from the operating sy-
stem:
 Absolute–value encoder:
– Modification by the start–up engineer:
The data must be set to “1” if an adjustment of the encoder is necessary or desired.
– Modification from the operating system:
in case of successful adjustment from 1 ==> 2
in case of invalid adjustment from 2 ==> 0 or 1
Any losses in the SRAM information or gear switchover operations with changes in the
transmission ratio will be detected by the operating system.
Any modifications to the construction of the machine mechanics
(e.g. change of encoder, motor incl. encoder etc.) will not be detected.
 Incremental encoder:
– Modification by the start–up engineer:
The data must be set to “1” if automatic referencing is required or desired.
– Modification from the operating system:
in case of referenced axis and ”Axis at exact position stop“ from 1 ==> 2
in case of invalid referencing position reference or if the axis on exact position stop does
not change from 2 ==> 1
In contrast to the absolute encoder, any changes of the position with inactive encoder or
during Power–Off will not be detected.
MD inapplicable ......

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36302 ENC_FREQ_LIMIT_LOW
MD number Encoder limit frequency for re–synchronization
Default: 99.9 Min. input limit: 0.0 Max. input limit: 100
Change valid after NEW_CONF Protection level: 2/2 Unit: %
Data type: DOUBLE Valid from SW release:
Meaning: The encoder limit frequency uses a hysteresis.
MD 36300: ENC_FREQ_LIMIT defines the encoder limit frequency at which the encoder is swit-
ched off, and ENC_FREQ_LIMIT_LOW the frequency at which the encoder is switched on again.
ENC_FREQ_LIMIT_LOW is a fraction of ENC_FREQ_LIMIT as a percentage.
Normally, the preselection of ENC_FREQ_LIMIT_LOW is sufficient. When using absolute enco-
ders with an En–Dat interface, however, the limit frequency of the absolute track is considerably
lower than the limit frequency of the incremental track. With a smaller value in
MD: ENC_FREQ_LIMIT_LOW, it can be achieved that the encoder is only switched on below the
limit frequency of the absolute track and therefore only referenced if this is permitted by the ab-
solute track. For spindles, this referencing is carried out automatically.
Example EQN 1325:
Encoder limit frequency of the incremental track: 430 kHz
===>MD 36300: ENC_FREQ_LIMIT = 430,000 Hz
Limit frequency of absolute track approx. 2,000 encoder rpm at 2,048 increments, i.e. at a limit
frequency of (2000/60) * 2048 Hz = 68 kHz
===>MD 36302: ENC_FREQ_LIMIT_LOW = 68/430 = 15 %
Related to ....

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8.6 Signal descriptions

8.6.1 Channel–specific signals

Signals to channel

V32000001.0 Enable referencing

Interface signal Signal(s) to channel (PLC –> NCK)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge Channel–specific referencing is started using the IS ”Enable referencing”. The control system
change 0 –––> 1 acknowledges the successful start with the IS ”Referencing active”. Channel–specific referencing
can be used to reference each machine axis assigned to the corresponding channel (to this aim,
the traversing keys plus/minus are simulated internally in the control system). The axis–specific
MD 34110: REFP_CYCLE_NR (axis order on channel–specific referencing) can be used to
define in which order the machine axes are referenced. If all axes entered in REFP_CYCLE_NR
have reached their reference points, the IS ”All axes referenced“ (V33000004.2) is set.
Application example(s) To reference the machine axes in a certain order, the following is necessary:
 The operator must observe the starting order.
 The PLC must either check the starting sequence or define it.
 The function “Channel–specific referencing” is used.
Related to .... IS ”Referencing active” (V33000001.0)
IS ”All axes to be referenced are referenced” (V33000004.2)

Signals from channel

V33000001.0 Referencing active

Interface signal Signal(s) to channel (PLC –> NCK)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The channel–specific referencing has been started by the IS ”Enable referencing” and the
change 0 –––> 1 successful start has been acknowledged by the IS ”Referencing active”. The channel–specific
referencing is on.
Signal state 0 or edge  Channel–specific referencing is completed.
change 1 –––> 0  Axis–specific referencing is running.
 No referencing active.
Signal inapplicable to ...... spindles
Related to .... IS ”Activate referencing“ (V32000001.0)

V33000001.2 All axes to be referenced are referenced

Interface signal Signal(s) from channel (PLC –> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release: 1.1
Signal state 1 or edge All axes to be referenced are referenced.
change 0 –––> 1 (note for axes to be referenced:
MD 34110: REFP_CYCLE_NR, MD 20700: REFP_NC_START_LOCK )
Signal state 0 or edge One or several axes of the channel, which are to be referenced are not referenced.
change 1 –––> 0
Special cases, errors, ...... The spindles of the channel do not affect this IS.
Related to .... IS ”Referenced/synchronized 1” (V390x0000.4)

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8.6.2 Axis/spindle–specific signals

Signals to axis/spindle

V380x1000.7 Delayed reference point approach

Interface signal Signal(s) to axis/spindle (PLC –> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The machine axis is on the reference cam.
change 0 –––> 1
Signal state 0 or edge The machine axis is before the reference cam. An appropriately long reference cam (up to the
change 1 –––> 0 end of the traversing range) should be used to rule out that the machine axis is after the
reference cam.
Related to ....

Signals from axis/spindle

V390x0000.4 Referenced/synchronized 1
Interface signal Signal(s) from axis/spindle (NCK –> PLC)
Edge evaluation: Signal(s) updated: Signal(s) valid from SW release:
Signal state 1 or edge Axes:
change 0 –––> 1 If the machine axis has arived at the reference point (incremental measuring systems) or at
the target point (length measuring systems with clearance–coded reference marks) during
the reference point approach; the machine axis is referenced and the
IS ”Referenced/synchronized 1” is set (depending on which position encoder is active on
referencing).
Spindles:
After mains ON, a spindle is synchronized after one spindle revolution at the latest (zero
mark) or when the BERO is overrun.
Signal state 0 or edge The machine axis/spindle is not referenced/synchronized with position measuring system 1.
change 1 –––> 0
Related to .... IS ”Position measuring system 1” (V380x0000.5)
Further references Chapter “Spindles”

8.7 Data fields, lists

8.7.1 Interface signals

Number .Bit Name Ref.

Mode–specific
V30000001 .2 Machine function REF
V31000001 .2 Active machine function REF
Channel–specific
V32000001 .0 Enable referencing
V33000001 .0 Referencing active
V33000004 .2 All axes to be referenced are referenced.
Axis–specific
V380x0000 .5 Position measuring system 1
V380x1000 .7 Delayed reference–point approach
V390x0000 .4 Referenced, synchronized 1

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8.7.2 Machine data

Number Identifier Name Ref.

Channel–specific
20700 REFP_NC_START_LOCK NC START inhibited without reference point
Axis–specific
30200 NUM_ENCS Number of encoders G1
30240 ENC_TYP Actual–value encoder type G1
31122 BERO_DELAY_TIME_PLUS BERO delay time in the plus direction
31123 BERO_DELAY_TIME_MINUS BERO delay time in the minus direction
34000 REFP_CAM_IS_ACTIVE Axis with reference cam
34010 REFP_CAM_DIR_IS_MINUS Reference point approach in the minus direction
34020 REFP_VELO_SEARCH_CAM Reference point approach velocity
34030 REFP_MAX_CAM_DIST Max. distance to be traversed to the reference cam
34040 REFP_VELO_SEARCH_MARKER[0] Reference point shutdown speed
34050 REFP_SEARCH_MARKER_REVERSE[0] Direction reversal on reference cam
34060 REFP_MAX_MARKER_DIST[0] Max. distance to be traversed to the reference cam;
max. distance to 2 reference marks with
clearance–coded scales
34070 REFP_VELO_POS Reference point approach velocity
34080 REFP_MOVE_DIST[0] Reference point distance/target point with clearance–
coded system
34090 REFP_MOVE_DIST_CORR[0] Reference point/absolute offset, clearance–coded
34092 REFP_CAM_SHIFT Electronic reference cam offset for incremental mea-
suring systems with equidistant zero marks
34100 Reference point value
34110 REFP_CYCLE_NR Axis order on channel–specific referencing
34200 ENC_REFP_MODE[0] Referencing mode
34210 ENC_REFP_STATE[0] State of absolute encoder
34220 ENC_ABS_TURNS_MODULO Range of absolute encoder with rotary encoders R2
36300 ENC_FREQ_LIMIT Encoder limit frequency A3
36302 ENC_FREQ_LIMIT_LOW Encoder limit frequency for re–synchronization
36310 ENC_ZERO_MONITORING Zero mark monitoring A3

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(H1) 9
9.1 General features when traversing in JOG mode

JOG mode
In JOG mode, the axes/spindle can be traversed by manual operation. The active operating mode
is signaled to the PLC via the IS “Active mode: JOG” (V3100 000.2) and is displayed on the screen.

References: Chapter “Operating Modes, Program Mode“

Traversing options
The axes can be traversed either using the traversing keys of a connected machine control panel
(manual traversing) or via connected handwheels (handwheel traversing).

It is possible either to use the keys to traverse all machine axes simultaneously (provided an appro-
priate design of a user–specific machine control panel) or to traverse the axes using the handwheel
according to the number of handwheels connected.
In the case of this simultaneous movement of several machine axes, no interpolation is carried out
between the axes.

Coordinate systems
The operator can traverse the axes in the following coordinate systems:

 Machine coordinate system (MCS); each axis can be traversed manually.

 Workpiece coordinate system (WCS); the geometry axes can be traversed manually.

Machine functions
There are the following variants of manual traversing (the so–called machine functions):

 Continuous traversing
 Incremental traversing (INC, specification of a certain number of traversing increments)
With metric scaling setting of the system, an increment is evaluated with 0.001 mm.
A machine function present at the machine control panel interface of the user must be converted by
the PLC user program to the appropriate PLC/NCK interface. To this aim, the axis–specific NCK/
PLC interface must be used in the case of a machine axis/spindle, in the case of a geometry axis,
the channel–specific NCK/PLC interface, and for all axes/spindle and the geometry axes the signals
in the mode area (see also next Section).

Handwheel traversing
Traversing of the axes using the handwheel is also possible in the MCS or WCS. To evaluate the
handwheel pulses, set an incremental traversing method (INC...) (see Section 9.4).

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Traversing the geometry axes

If workpieces are machined the workpiece coordinate system of which is not parallel to the machine
coordinate system (clamping at an angle, programmed rotation in the contour active), it is possible
to traverse along the axes of the workpiece coordinate system using the traversing keys or the
handwheel. In this case, you will change from AUTO to JOG when the axes are stopped and will
traverse a geometry axis instead of a machine axis. In this case, 1 ... 3 machine axes will move,
depending on the active rotation of the workpiece coordinate system.
While a machine axis traverses, it cannot additionally be traversed using the traversing keys of a
geometry axis; first, the traversing movement of the machine axis must be completed. Otherwise,
alarm 20062 ”Axis already active“ is output.
The handwheels 1 to 3 can be used to traverse 3 geometry axes simultaneously.
Note: Geometry axes are loaded with values via a separate, channel–specific PLC interface.

Transverse axis in conjunction with turning

A geometry axis is defined as a transverse axis. If radius programming (DIAMOF) is selected here
instead of diameter programming (DIAMON), the following must be observed when traversing in
JOG mode:
 Continuous traversing:
There are no differences when a transverse axis is transversed continuously.
 Incremental traversing:
Only the half of the distance of the selected increment size is traversed.
 Traversing using the handwheel:
As with incremental traversing, in this case, too, only the half of the distance is traversed per
handwheel pulse when using the handwheel.
References: Section ”Transerve axis”

Manual traversing of the spindle

In JOG mode, it is also possible to traverse the spindle manually. This is subject mainly to the same
conditions as manual traversing of the axes. The spindles can be traversed continuously in JOG
mode using the traversing keys/the IS “continuous” and/or “INC...”. The selection and enabling is
carried out via the axis/spindle–specific PLC interface analogously to the axes.
manual traversing of the spindle is possible noth in the positioning mode (spindle in position control)
and in control mode.
The parameter record (machine data) of the current gear stage will apply.

References: Chapter ”Spindle”

Velocity
The velocity/speed of the axes/spindle on manual traversing in JOG mode is defined by the follo-
wing value specifications:
 in the case of linear axes using the general SD 41110: JOG_SET_VELO (JOG velocity with
G94) and in the case of rotary axes using SD 41130: JOG_ROT_AX_SET_VELO (JOG velocity
with rotary axes) er SD 41200: JOG_SPIND_SET_VELO (JOG speed for the spindle).
 If the appropriate SD is zero, the appropriate axis–specific MD 32020: JOG_VELO (conventio-
nal axis velocity) will apply.
With geometry axes, the value of the assigned machine axis is used in this case: X–>X1,
Y–>Y1, Z–>Z1 (with default setting).

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Rapid traverse override

If with machine axes the rapid traverse override key is pressed in addition to the traversing keys,
the movement is carried out at the rapid traverse rate defined in the axis–specific MD 32010:
JOG_VELO_RAPID (axis velocity in JOG mode with rapid traverse override).
In the case of geometry axes, the value of the assigned machine axis is used: X–>X1, Y–>Y1,
Z–>Z1 (with default setting). To the control, the separate PLC interface range of the geometry axes
must be used.

Speed override
The speed in JOG mode can additionally be controlled using the axis–specific feed override switch
provided the axial IS ”Override active“ (V380X0001.7) is set.
In switch position 0%, the axis will not be traversed even if the IS “Override active” is not set.
In the case of geometry axes, the channel–specific feed override switch or, in the case of rapid tra-
verse override, the rapid traverse override switch will be active.
If a spindle is used, the enabled spindle override switch willö be active.

References: Section ”Feed”

Acceleration
The maximum axis acceleration is defined using the axis–specific MD 32300: MAX_AX_ACCEL.
When traversing in JOG mode, it is also possible to set the acceleration according to a specified
characteristic. For possible settings, please refer to:

References: Section ”Acceleration“

PLC interface
For geometry axes (axes in the WCS), a separate PLC interface is provided (VB 3200 1000, ff or
VB 3300 1000, ff), which contains the same signals as the axis–specific PLC interface.
When traversing the spindle manually, the PLC interface signals between NCK and PLC act analo-
gously as with the machine axes. The IS ”Position reached with exact stop fine or coarse“ will only
be set if the spindle is in position control mode.
For the purely spindle–specific interface signals, the following must be observed when traversing
the spindle in JOG mode:

 The following PLC interface signals provided to the spindle will not be active:
– IS ”Invert M3/M4” (V380x2001.6)
– IS ”Set direction of rotation CCW“ or ”Set direction of rotation CW” (V380x2002.7 or .6)
– IS ”Oscillation speed“ (V380x2001.5)
 The following PLC interface signals provided from the spindle will not be set:
– IS ”Actual rotation CW“ (V390x2001.7)
– IS ”Spindle in set range“ (V390x2001.5)

Note
Pressing Reset will cancel the manual traversing movement (axis/spindle) and generate a braking
ramp.

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Limitations
On manual traversing, the following limitations are active:

 Working area limitation (axis must be referenced)

 Software limit switches 1 or 2 (axis must be referenced)
 Hardware limit switches
The control system internally ensures that the traversing movement is aborted once the first valid
limitation is reached. The velocity control ensures that the braking process is initiated in due time so
that the axis comes to a stop exactly at the limit position (e.g. software limit switch). The axis will
only be decelerated with “Rapid stop” if the hardware limit switch responds.

If the corresponding limitation is reached, an alarm message is output. A continuation of the move-
ment in this direction is internally prevented by the control system. The traversing keys and the
handwheel remain inactive for this direction.

! Important
To ensure that the software limit switches and working area limitations are enabled, first
the axis must be referenced.

Machine manufacturer
The retraction of an axis that has approached the limit position depends on the machine manufac-
turer. Please refer to the Documentation of the machine manufacturer.

For further information on working area limitations, as well as hardware and software limit switches,
refer to:
References: Section ”Axis monitoring functions“

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9.2 Continuous traversing

Selection
Selecting JOG mode will automatically set the active machine function IS “continuous”:
with geometry axes: V3300 1001.6, V3300 1005.6, V3300 1009.6)
with machine axes/spindle: V390x0005.6.
In JOG mode, it is also possible to activate continuous traversing via the PLC interface (IS ”Ma-
chine function: continuous“).
The PLC determines in which signal area the INC/continuous signals are provided to the NCK via
the IS “INC inputs in mode group area active” (V26000001.0):
V26000001.0 = 1 –> in mode group area: VB30000002,
applicable to all axes
V26000001.0 = 0 –> in geometry/axis area:
VB32001001, VB32001005,
VB32001009, VB380x0005

Traversing keys +/–

The traversing keys plus and minus will traverse the corresponding axis in the desired direction.
PLC traversing key signals to NCK IS:
with geometry axes (traversing in the WCS): V3200 1000.7 /.6, V3200 1004.7 /.6,
V3200 1008.7 /.6
with machine axes/spindle (traversing in MCS): V380x 004.7 /.6V32001000.7/.6.
Pressing both traversing keys of an axis at the same time will not result in a traversing movement or
will stop an axis being traversed.

Traversing commands +/–

Once a traversing request is provided for an axis (e.g. when the traversing key is pressed), the IS
”Traversing command +” or ”Traversing command –” is output to the PLC, depending on the direc-
tion of movement.
with geometry axes: V3300 1000.7 /.6, V3300 1004.7 /.6, V3300 1008.7 /.6
with machine axes/spindle: V390x 004.7 /.6

Continuous traversing in non–maintained command mode

The axis will traverse as long as the traversing key is pressed unless no axis limitation is reached
beforehand. When the traversing key is released, the axis is decelerated to the standstill, and the
movement is considered completed.

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9.3 Incremental traversing (INC)

Setting increments
The distance to be traversed by the axis is defined by so–called increments (also called incremental
dimension). Before the machine operator traverses the axis, he must set the desired increment.
The setting is carried out, e.g. on the machine control panel. The IS “Machine function: INC1 to
INCvar” corresponding to the desired increment must be set in the PLC user program after an ap-
propriate logic operation.
The PLC defines in which signal area the INC signals are provided to the NCK via the IS “INC in-
puts in mode group area active” (V26000001.0):
V26000001.0 = 1 –> in mode group area: VB30000002,
applicable to all axes
V26000001.0 = 0 –> in geometry/axis area:
VB32001001, VB32001005,
VB32001009, VB380x0005
The active machine function: IS “INC... “ is signaled from the NCK to the PLC:
with geometry axes: V3300 1001.0 , V3300 1005.0, V3300 1009.0 to .5
with machine axes/spindle: V390x 0005.0 to .5

Settable increments
The operator can set different increment sizes. These divide into:

 fixed increments whose increment sizes are common for all axes: INC1, INC10, INC100,
INC1000 (only via IC: INC10000 ).
 and a variable increment (INCvar). Specifying an increment for a variable increment is also
possible together for all axes using the general SD: JOG_VAR_INCR_SIZE (size of the variable
increment with INC/handwheel).

Incremental traversing in non–maintained command mode

Pressing the traversing key for the desired direction (e.g. +), the axis starts to traverse the set incre-
ment. If the traversing key is released before the increment has been traversed completely, the mo-
vement is interrupted and the axis stops. If the same traversing key is pressed again, the axis will
traverse the remaining distance to go. The movement can also be interrupted by releasing the tra-
versing key.
Pressing the traversing key in the opposite direction will have no effect unless the increment has
not been traversed completely or the movement has been canceled.

Traversing keys and traversing command

as with continuous traversing (see Section 9.2)

Aborting the traversing movement

If you wish not to traverse the increment completely, use RESET or the axis–specific IS ”Delete axis
distance to go” (V380x0002.2) to abort the movement.

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9.4 Handwheel traversing in JOG mode

Selection
JOG mode must be active. In addition, the operator must set the increment INC1, INC10, ... active
when traversing using the handwheel.

A maximum of 3 handwheels can be connected. It is thus possible to move simultaneously and in-
dependently up to 3 axes using handwheels.
The geometry or machine axes (WCS or MCS) is assigned a handwheel via interface signals.
Which axis is traversed by turning the handwheel 1 ... 3, can be set:

 via the PLC user interface with the IS ”Enable handwheel 1 to 3”

with a machine axis (traversing in the MCS): V380x 0004.0 to .2
with a geometry axis (traversing in the WCS): V3200 0000.0 to .2, V3200 0004.0 to .2,
V3200 0008.0 to .2
The linking to the PLC interface is carried out by the PLC user program. It is possible to assign
a handwheel several machine axes at a time
 or via menu–assisted operation (HMI)
When the softkey Handwheel is pressed in the main menu of JOG mode, the window “Hand–
wheel” will be displayed. In this window, each handwheel can be assigned an axis (WCS or
MCS).
To activate the handwheel from the operator panel (HMI), a separate user interface is provided bet-
ween HMI and PLC. This interface provided by the PLC basic program for handwheels 1 to 3 con-
tains the following information:

 the axis numbers assigned to the corresponding handwheel

IS ”Axis number of handwheel n” (VB19001003, ff)
 the additional information ’machine or geometry axis’
IS ”Machine axis“ (VB19001003.7, ff)
The PLC user program must set the appropriate IS ”Enable handwheel” either to ”0” (Disable) or to
”1” (Enable) for the given axis.

Specification as a path or as a velocity

Turning the electronic handwheel will traverse the assigned axis either in the positive direction or in
the negative direction, depending on the direction of rotation.
The specification type of the handwheel can be set and thus adapted to the particular application
using the general MD 11346: HANDWH_TRUE_DISTANCE (handwheel path or velocity specifica-
tion).
MD value=0 (default):
The handwheel specifications are velocity specifications. The braking process when the handwheel
stops is carried out on the shortest path.
MD value=1 :
The handwheel specifications are path specifications. No pulse are lost. Due to a limitation to the
maximum admissible velocity, the axes may follow up. This should be taken into account in particu-
lar in the case of a high handwheel pulse weighting.
Further variants of path or velocity specification are possible using value =2 or 3.

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Weighting
The resulting distance to be traversed (=path)/velocity when turning the handwheel depends on the
following factors:
 Number of handwheel pulses received at the interface
 Active increment (machine function INC1, INC10, INC100, ... )
With metric system scaling setting, one increment is weighted with 0.001 mm.
 Pulse weighting of handwheel using the general MD: HANDWH_IMP_PER_LATCH (handwheel
pulses per lathc position)

Traversing commands +/–

During the axis movement, the IS ”Traversing command +” or ”Traversing command –” is provided
to the PLC, depending on the direction of movement.
with geometry axes: V3300 1000.7/.6, V3300 1004.7/6, V3300 1008.7/.6
with machine axes/spindle: V390x 004.7/.6.
If the axis is already traversed using the traversing keys, additional handwheel traversing is not
possible. The alarm 20051 ”Handwheel traversing not possible” is output.

Velocity
The velocity results from the pulses generated using the handwheel and the pulse weighting:
Distance to be traversed per time unit.
This velocity is limited by the value in the axis–specific
MD 32000: MAX_AX_VELO.

Aborting/interrupting the traversing movement

RESET or the axis–specific IS ”Delete distance to go” (V380x0002.2) will abort the traversing mo-
vement. The current set/actual difference are deleted.

The NC STOP command will only interrupt the traversing movement. Pressing NC START will re–
enable the handwheel movement.

Traversing in the opposite direction

Depending on MD 11310: HANDWH_REVERSE, the behavior when reversing the traversing direc-
tion is as follows:
 MD value =0:
If the handwheel is rotated in the opposite direction, the resulting distance to be traversed is
calculated and the end point calculated in this way is approached as fast as possible: If this end
point is before the point to which the traversing axis can brake with the traversing direction cur-
rently selected, the axis will decelerate, and the end point will be approached by traversing in
the opposite direction. Otherwise, the newly calculated end point will be approached immedia-
tely.
 MD value >0:
If the handwheel is rotated by at least the number of pulses specified in the machine data, the
axis will be decelerated as fast as possible, and all pulses ariving until the end of the interpola-
tion will be ignored, ie. the axis will be traversed again only after the standstill (as far as the set-
point is concerned).

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Behavior at software limit switch/working area limitation

When traversing in JOG mode, the axes are traversed only to the first active limitation and the ap-
propriate alarm is output. Depending on the machine data MD 11310: HANDWH_REVERSE, the
behavior is as follows (provided the axis has not yet reached its setpoint end position):
 MD value =0:
The distance to go resulting from the handwheel pulses constitutes a fictive end point which will
be used for the calculations to follow. If this fictive end point is, e.g. 10 mm behind the limitation,
these 10 mm must only be traversed in the opposite direction before the axis will be able to tra-
verse. If you wish to traverse from the limitation immediately in the opposite direction again, the
fictive distance to go can be deleted either by deleting the distance to go or deselecting the
handwheel assignment.
 MD value >0:
All handwheel pulses resulting in any end point behind the limitation will be ignored. Moving the
handwheel in the opposite direction will immediately result in traversing in the opposite direction,
i.e. from the limitation away.

9.5 Data descriptions (MD, SD)

9.5.1 General machine data

11310 MN_HANDWH_REVERSE
MD number Threshold for handwheel direction reversal
Default: 2 Min. input limit: 0 Max. input limit: ***
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BYTE Valid from SW release:
Meaning: 0: No immediate traversing in the opposite direction
>0: Immediate traversing in the oppositie direction if the handwheel is rotated in the
opposite direction at least by the specified number of pulses

11320 HANDWH_IMP_PER_LATCH[n]
MD number Handwheel pulses per latch position [handwheel index]:
Default: (1, 1, 1) Min. input limit: *** Max. input limit: ***
Change valid after Power On Protection level: 2/2 Unit: –
Data type: DOUBLE Valid from SW release
Meaning: This MD is used to match the connected handwheels with the control system.
In this MD, the number of pulses generated by the handwheel per latch position is entered. The
handwheel pulse weighting must be defined for each connected handwheel (1 ... 3) separately.
With this matching, each handwheel latch position has the same effect as a traversing key would
have been pressed on incremental traversing.
A negative value will result in a direction reversal of the handwheel rotation.
Related to .... MD: JOG_INCR_WEIGHT (weighting of an increment of a machine axis with INC/handwheel)

11346 HANDWH_TRUE_DISTANCE
MD number Handwheel path or velocity specification
Default: 0 Min. input limit: 0 Max. input limit: 3
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BYTE Valid from SW release:
Meaning: 0: The specifications from the handwheel are velocity specifications. The braking
to the handwheel standstill is carried out on the shortest possible path.
1: The specifications from the handwheel are path specifications. No pulses are lost.
Due to a limitation to the maximum admissible velocity, overtraveling of the axes may occur.
2: The same ffect as with value=0, but longer deceleration dist. when the handwheel stops.
3: The same effect as with value=1, but longer deceleration dist. when the handwheel stops.
Related to ....

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9.5.2 Axis/spindle–specific machine data

32010 JOG_VELO_RAPID
MD number Conventional rapid traverse
Default: 10000 mm/min, Min. input limit: 0.0 Max. input limit: ***
27.77 rpm
Change valid after RESET Protection level: 2/7 Unit:
Linear axis: mm/min
Rotary axis: rpm
Data type: DOUBLE Valid from SW release:
Meaning: The entered axis velocity applies to traversing in JOG mode with the rapid traverse override key
pressed and an axial feed override of 100%.
The entered value may not exceed the max. permissible axis velocity (MD MAX_AX_VELO).
MD 32010 is not used for the programmed rapid traverse G0.
MD inapplicable to ...... AUTOMATIC and MDA modes
Related to .... MD 32000: MAX_AX_VELO (max. axis velocity)
IS ”Rapid traverse override“ (V32001000.5, V32001004.5, V32001008.5, V380x0004.5,)
IS ”Feed override” (VB380x 0000), axis–specific
IS “Rapid traverse override” (VB3200 0005), with geometry axes

32020 JOG_VELO
MD number Conventional axis velocity
Default: 2000 mm/min Min. input limit: 0.0 Max. input limit: ***
5.55 rpm
Change valid after RESET Protection level: 2/7 Unit:
Linear axis: mm/min
Rotary axis: rpm
Data type: DOUBLE Valid from SW release:
Meaning: The entered velocity applies to traversing axes in JOG mode with the feed override switch posi-
tion 100%.
The velocity of MD 32020: JOG_VELO is only used if the general SD 41110: JOG_SET_VELO =
0 for linear axes or if the SD 41130: JOG_ROT_AX_SET_VELO = 0 is set for rotary axes.
If this is the case, the axis velocity is active:
– for continuous traversing
– for incremental traversing (INC1, ... INCvar)
The value entered must not exceed the maximum admissible velocity
(MD 32000: (MAX_AX_VELO).

Spindles in JOG mode:

It is thus also possible to specify the velocity spindle–specifically when traversing the spindles in
JOG mode if
SD 41200: JOG_SPIND_SET_VELO = 0.
In this case, the velocity is influenced by the spindle override switch.
MD inapplicable to ...... AUTOMATIC and MDA modes
Application example(s) If different velocities are required for the individual axes/spindles in JOG mode, the velocity can
be determined axis–specifically. The SD: JOG_SET_VELO must be set to 0!
Related to .... MD 32000: MAX_AX_VELO (max. axis velocity)
SD 41110: JOG_SET_VELO (JOG velocity for G94)
SD 41130: JOG_ROT_AX_SET_VELO (JOG velocity for rotary axes)
SD 41200: JOG_SPIND_SET_VELO (JOG speed for the spindle)
Axis–specific IS “Feed override” (VB380x 0000)
Axis–specific IS “Spindle override” (VB380x 2003)
Channel–specific IS “Feed override” (VB3200 0004) with geometry axes

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9.5.3 General setting data

41010 JOG_VAR_INCR_SIZE
SD number Size of the variable increment with INC/handwheel
Default: 0.0 Min. input limit: *** Max. input limit: ***
Change valid: immediately Protection level: 7/7 Unit: mm or degrees
Data type: DOUBLE Valid from SW release: 1.1
Meaning: This setting data defines the number of increments when selecting the variable increment
(INCvar). This increment size is traversed by the axis per latch position when pressing the tra-
versing key or turning the handwheel if the variable increment is selected (IS “Active machine
function: INC variable” if the machine or geometry axis has a 1–signal).
Note: Please take into account that the increment size applies both to incremental traversing
and handwheel traversing.
SD inapplicable ...... if INCvar is not active
Related to .... IS ”Active machine function: INCvariabel”(V32001001.5, V32001005.5, V32001009.5,
V380x0005.5)

41110 JOG_SET_VELO
SD number JOG velocity for linear axes (for G94)
Default: 0.0 Min. input limit: 0.0 Max. input limit: ***
Change valid: immediately Protection level: 7/7 Unit: mm/min
rpm
Data type: DOUBLE Valid from SW release:
Meaning: Value > 0:
The entered velocity applies to all linear axes traversed in JOG mode if these are traversed ma-
nually using the traversing keys plus or minus..
The axis velocity is active:
– for continuous traversing
– for incremental traversing (INC1, ... INCvar)
The value entered may not exceed the maximum admissible axis velocity
(MD 32000: (MAX_AX_VELO).

Value = 0:
The appropriate axis–specific MD 32020: JOG_VELO “Conventional axis velocity” acts as the
feedrate in JOG mode. It is thus possible to define for each axis its own JOG velocity (axial MD).
SD inapplicable ...... – for rotary axes (SD 41130: JOG_ROT_AX_SET_VELO is active here)
Related to .... Axis–specific MD 32020: JOG_VELO (conventional axis velocity)
Axis–specific MD 32000: MAX_AX_VELO (maximum axis velocity)
SD 41130: JOG_ROT_AX_SET_VELO (JOG velocity for rotary axes)

41130 JOG_ROT_AX_SET_VELO
SD number JOG velocity for rotary axes
Default: 0.0 Min. input limit: 0.0 Max. input limit: ***
Change valid: immediately Protection level: 7/7 Unit: rpm
Data type: DOUBLE Valid from SW release: 1.1
Meaning: as SD 41110: JOG_AX_SET_VELO – but for all rotary axes instead of linear axes

Application example(s) The operator can thus specify a JOG velocity application–specifically.
Related to .... MD 32020: JOG_VELO (conventional velocity)
MD 32000: MAX_AX_VELO (maximum axis velocity)

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41200 JOG_SPIND_SET_VELO
SD number JOG speed for the spindle
Default: 0.0 Min. input limit: 0.0 Max. input limit: ***
Change valid: immediately Protection level: 7/7 Unit: rpm
Data type: DOUBLE Valid from SW release:
Meaning: Value > 0:
The entered velocity applies to spindles in JOG mode if these are traversed manually using the
traversing keys plus or minus.
The velocity is active:
– for continuous traversing
– for incremental traversing (INC1, ... INCvar)
The value entered may not exceed the max. admissible velocity (MD 32000: (MAX_AX_VELO).

Value = 0:
If 0 has been entered in the setting data, MD 32020: JOG_VELO will act as the JOG velocity
(conventional axis velocity). It is thus possible to define a separate JOG velocity for each axis
(axis–specific MD).
When the spindle is traversed in JOG mode, the maximum speeds of the active gear stage are
taken into account (MD 35130 : GEAR_STEP_MAX_VELO_LIMIT).
SD inapplicable ...... axes
Related to .... MD 32020: JOG_VELO (conventional axis velocity)
MD 35130: GEAR_STEP_MAX_VELO_LIMIT (maximum speed of gear stages)
Further references Section ”Spindle”

9.6 Signal descriptions

9.6.1 Signals from HMI to PLC

V1900 0003.7 Machine axis for handwheel 1

V1900 0004.7 for handwheel 2
V1900 0005.7 for handwheel 3
Interface signal Signal(s) from NC (HMI –> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The operator has assigned the handwheel (1, 2, 3) an axis directly from the operator panel. This
change 0 –––> 1 axis is a machine axis – no geometry axis (axis in WCS).
For more information, see IS ”Axis number”.
Signal state 0 or edge The operator has assigned the handwheel (1, 2, 3) an axis directly from the operator panel. This
change 1 –––> 0 axis is a geometry axis – no geometry axis (axis in WCS).
For more information, see IS ”Axis number”.
Related to .... IS ”Axis number” (V19000003.0 to .4, ff)

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V19001003.0 to .2 Axis number for handwheel 1

V19001004.0 to .2 for handwheel 2
V19001005.0 to .2 for handwheel 3
Interface signal Signal(s) from NC (HMI –> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal meaning The operator can assign each handwheel an axis directly from the operator panel. To this aim,
he specifies the desired axis (e.g. X).
The axis number assigned to the axis plus the information ’machine or geometry axis’ (IS “Ma-
chine axis”) is provided by the PLC user interface in the form of HMI interface signals.
The interface signal ”Enable handwheel” must be set by the PLC user program for the specified
axis. Depending on the HMI interface signal ”Machine axis”, the interface to the geometry axis or
the machine axis is used.
For the assignment of the axis name to the axis number, the following applies:
 IS ”Machine axis” = 1; i.e. machine axis – not geometry axis:
The assignment is carried out via MD 10000: AXCONF_MACHAX_NAME_TAB[n]
(machine axis name).
 IS ”Machine axis” = 0; i.e. geometry axis (axis in WCS):
The assignment is carried out via MD 20060: AXCONF_GEOAX_NAME_TAB[n]
(name of geometry axis in the channel). With the IS ”Channel number Geometry axis
Handwheel n”, the channel number assigned to the handwheel is specified.
The following coding applies to the axis number:
Bit 2 Bit 1 Bit 0 Axis number
0 0 0 –
0 0 1 1
0 1 0 2
0 1 1 3
1 0 0 4
1 0 1 5
Note: Bit 3 and bit 4 must always remain 0.

Related to ....
IS ”Machine axis” (V19001003.7 ff)
IS ”Enable handwheel” 1 to 3 /geometry axes 1, 2, 3
(V32001000.0 to .2, V32001004.0 to .2, V32001008.0 to .2)
IS ”Enable handwheel 1 to 3 /machine axes (V380x0004.0 to .2)
MD 10000: AXCONF_MACHAX_NAME_TAB [n] (machine axis name)
MD 20060: AXCONF_GEOAX_NAME_TAB [n] (name of geometry axis in the channel)

9.6.2 NCK signals and signals in the operating mode area

Description of the signals provided to the NCK

V2600 0001.0 INC inputs in the mode group area active

Interface signal Signal(s) to NCK (PLC–> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge
change 0 –––> 1 The IS “INC1”, “INC10”, ..., “Continuous“ in the operating mode area are used as input signals
(V3000 0002.0 to .6).
Signal state 0 or edge
change 1 –––> 0 The IS “INC1”, “INC10”, ..., “Continuous” in the axis and geometry axis areas are used as input
signalsi.
Related to .... IS “Machine function INC1 to Continuous“ in the operating mode area (V3000 0002.0 to .6)
IS ”Machine function INC1,...,Continuous”
for geometry axis 1 (V3200 1001.0 to .6)
for geometry axis 2 (V3200 1005.0 to .6)
for geometry axis 3 (V3200 1009.0 to .6)
IS ”Machine function INC1,...,Continuous” in the axis area (V380x 0005.0 to .6)

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Description of the signals provided to the operating modes

V3000 0000.0 to .6 Machine function INC1, INC10, INC100, INC1000, INC10000, INCvar, continuous
Interface signal Signal(s) to operating modes (PLC–> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge This input area is only used if the IS “INC inputs in mode group area active” (V2600 0001.0) is
change 0 –––> 1 set. In this case, the signals will apply to all axes and geometry axes.

The IS “INC...” defines how many increments the axis traverses per latch position when the tra-
versing key is pressed or the handwheel is turned. When doing so, JOG mode must be active.
With “INCvar”, the value in the general SD 41010: JOG_VAR_INCR_SIZE will apply.
With “Continuous”, the appropriate axis can be traversed using the plus or minus traversing key
with holding down the traversing key as required.
Once the selected machine function is active, this is signaled to the PLC interface (IS ”Active
machine function INC1; ...” ). If several machine function signals (INC1, INC... or ”Continuous
traversing”) are selected at the interface at the same time, no machine function is enabled inter-
nally in the control system.
Note:
The input IS “INC...” or “Continuous” to modify an active machine function must be present at
least one PLC cycle. It need not be present statically.
Signal state 0 or edge The appropriate machine function is not selected. No modification to the active machine function
change 1 –––> 0 is requested.
If an axis is just traversing an increment, the movement is aborted with deselection or switchover
of the machine function.
Related to .... IS “INC inputs in mode group area active“ (V2600 0001.0)
IS ”Machine function INC1, ..., continuous”
for geometry axis 1 (V3200 1001.0 to .6)
for geometry axis 2 (V3200 1005.0 to .6)
for geometry axis 3 (V3200 1009.0 to .6)
IS ”Machine function INC1, ..., continuous” in the axis area (V380x 0005.0 to .6)
IS ”Active machine function INC1, ..., continuous”
for geometry axis 1 (V3300 1001.0 to .6)
for geometry axis 2 (V3300 1005.0 to .6)
for geometry axis 3 (V3300 1005.0 to .6)
IS ”Active machine function INC1, ..., continuous” in the axis area (V390x 0005.0 to .6)

9.6.3 Channel–specific signals

Description of the signals provided to the channel

V3200 1000.0 to .2 Enable handwheel (1 to 3) for geometry axis 1

V3200 1004.0 to .2 for geometry axis 2
V3200 1008.0 to .2 for geometry axis 3
Interface signal Signal(s) to channel (PLC –> NCK)s
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge These PLC interface signals define whether the geometry axis is assigned to handwheel 1, 2, 3
change 0 –––> 1 or no handwheel.
One axis can be assigned only one handwheel at a time.
If several interface signals ”Enable handwheel“ are set, the priority is ’Handwheel 1’ before
’Handwheel 2’ before ’Handwheel 3’.

Note: Using handwheels 1 to 3, 3 geometry axes can be traversed simultaneously.

Signal state 0 or edge This axis is not assigned handwheel 1, 2 or 3.
change 1 –––> 0
Application example(s) The manipulation of the geometry axis by turning the handwheel can be locked via the interface
signal from the PLC user program.
Related to .... IS ”Handwheel active” 1 to 3 for geometry axis 1: V33001000.0 to .2
for geometry axis 2: V33001004.0 to .2
for geometry axis 3: V33001008.0 to .2

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V3200 1000.4 Traversing key lock for geometry axis 1

V3200 1004.4 for geometry axis 2
V3200 1008.4 for geometry axis 3
Interface signal Signal(s) to channel (PLC –> NCK)s
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The traversing keys plus and minus have no effect on the geometry axes. For example, traver-
change 0 –––> 1 sing of the geometry axis using the traversing keys on the MCP is not possible in JOG mode.
If the traversing key lock is enabled during a traversing movement, the geometry axis is stopped.
Signal state 0 The traversing keys plus and minus are enabled.
Application example(s) Depending on the operating status, traversing of the geometry axis in JOG mode can be locked
from the PLC user program.
Related to .... IS ”Traversing key plus” and ” ... minus” for geometry axis 1 (V32001000.7 and .6 )
for geometry axis 2 (V32001004.7 and .6 )
for geometry axis 3 (V32001008.7 and .6 )

V3200 1000.5 Rapid traverse override for geometry axis 1

V3200 1004.5 for geometry axis 2
V3200 1008.5 for geometry axis 3
Interface signal Signal(s) to channel (PLC –> NCK)s
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release: 1.1
Signal state 1 or edge If the PLC interface signal “Rapid traverse override” is provided together with the traversing keys
change 0 –––> 1 plus or minus, the selected geometry axis will traverse at rapid traverse.
The rapid traverse velocity is defined in the machine data JOG_VELO_RAPID.
The rapid traverse override is active in JOG mode for the following variants:
– continuous traversing
– incremental traversing
With rapid traverse override active, the velocity/speed can be manipulated using the rapid tra-
verse override switch.
Signal state 0 or edge The geometry axis traverses at the specified JOG velocity (SD: JOG_SET_VELO or MD:
change 1 –––> 0 JOG_VELO).
Signal inapplicable ...... – AUTOMATIC and MDA modes
– Reference point approach (JOG mode)
Related to .... IS ”Traversing key plus” and ” ... minus” for geometry axis 1 (V32001000.7 and .6 )
for geometry axis 2 (V32001004.7 and .6 )
for geometry axis 3 (V32001008.7 and .6 )
Further references Section ”Feeds”

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V3200 1000.7 and .6 Traversing keys plus and minus for geometry axis 1
V3200 1004.7 and .6 for geometry axis 2
V3200 1008.7 and .6 for geometry axis 3
Interface signal Signal(s) to channel (PLC –> NCK)s
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge In JOG mode, the traversing keys plus and minus can be used to traverse the selected axis in
change 0 –––> 1 both directions.
Incremental traversing
With signal state 1, the axis starts to traverse the set increment. If the signal changes
to 0 status before the increment has been traversed, the traversing movement will be
aborted. If the signal state is 1 again, the traversing movement will be continued.
Until the increment is traversed completely, the traversing movement of the axis can
be stopped and continued several times as described.
Continuous traversing
If no INC dimension is selected, the axis will traverse as long as the traversing axis
remains pressed.
If both traversing signals (plus and minus) are set at the same time, no traversing movement is
carried out or the traversing movement is aborted.
The effect of the traversing keys can be disabled for each axis separately using the PLC inter-
face signal ”Traversing key lock”.
CAUTION: In contrast to machine axes, with geometry axes it is possible to traverse only
one geometry each simultaneously. If you try to traverse more than one
geometry axis using the traversing keys, alarm 20062 will be output.
Signal state 0 or edge no traversing
change 1 –––> 0
Signal inapplicable ...... AUTOMATIC and MDA modes
Special cases, errors, ...... The geometry axes cannot be traversed in JOG mode.
– if it is already traversed (as a machine axis) via the axial PLC interface;
– if another geometry axis is already traversed via the traversing keys.
Alarm 20062 ”Axis is already active” is output.
Related to .... IS ”Traversing keys plus and minus” for machine axes (V380x0004.7 and .6)
IS ”Traversing key lock” for geometry axis 1 (V32001000.4)
for geometry axis 2 (V32001004.4)
for geometry axis 3 (V32001008.4)

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Machine function INC1, INC10, INC100, INC1000, INC10000, INCvar, continuous

V3200 1001.0 to .6 for geometry axis 1
V3200 1005.0 to .6 for geometry axis 2
V3200 1009.0 to .6 for geometry axis 3
Interface signal Signal(s) to channel (PLC –> NCK)s
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge This input area is only used if the IS “INC inputs in mode group area active” (V2600 0001.0) is
change 0 –––> 1 not set.
The IS “INC...” defines how many increments the axis traverses per latch position when the tra-
versing key is pressed or the handwheel is turned. When doing so, JOG mode must be active.

With “INCvar”, the value in the general SD 41010: JOG_VAR_INCR_SIZE will apply.
With “Continuous”, the appropriate axis can be traversed using the plus or minus traversing key
with holding down the traversing key as required.
Once the selected machine function is active, this is signaled to the PLC interface (IS ”Active
machine function INC1; ...” ).
If several machine function signals (INC1, INC... or ”Continuous traversing”) are selected at the
interface at the same time, no machine function is enabled internally in the control system.
Note:
The input IS “INC...” or “Continuous” to modify an active machine function must be present at
least one PLC cycle. It need not be present statically.
Signal state 0 or edge The appropriate machine function is not selected. No modification to the active machine function
change 1 –––> 0 is requested.
If an axis is just traversing an increment, the movement is aborted with deselection or switchover
of the machine function.
Related to .... IS ”Active machine function INC1, ...” for geometry axis 1 (V33001001.0 ... .6)
for geometry axis 2 (V33001005.0 ... .6)
for geometry axis 3 (V33001005.0 ... .6)
IS “INC inputs in mode group area active” (V2600 0001.0)

Description of the signals provided from the channel

V3300 1000.0 to .2 Handwheel active (1 to 3) for geometry axis 1

V3300 1004.0 to .2 for geometry axis 2
V3300 1008.0 to .2 for geometry axis 3
Interface signal Signal(s) from channel (NCK –> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge These PLC interface signals specify if this geometry axis is assigned to handwheel 1, 2, 3 or to
change 0 –––> 1 no handwheel.
One axis can be assigned only one handwheel at a time.
If several interface signals ”Enable handwheel“ are set, the priority is ’Handwheel 1’ before
’Handwheel 2’ before ’Handwheel 3’.
If the assignment is active, the geometry axis can be traversed in JOG mode using the
handwheel.
Signal state 0 or edge This geometry axis is not assigned handwheel 1, 2 or 3.
change 1 –––> 0
Related to .... IS ”Enable handwheel” (V32000000.0 to .2, V32000004.0 to .2, V32000008.0 to .2

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V33001000.7 and .6 Traversing commands plus and minus for geometry axis 1
V33001004.7 and .6 for geometry axis 2
V33001008.7 and .6 for geometry axis 3
Interface signal Signal(s) from channel (NCK –> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge A traversing movement is to be carried out in the axis direction concerned. The traversing com-
change 0 –––> 1 mand is initiated in different ways, depending on the operating mode.
– JOG mode: using the traversing key plus or minus
– REF submode: using the traversing key leading to the reference point
– AUTO/MDA modes: A program block that contains a coordinate value for the axis
concerned is carried out.
Signal state 0 or edge No traversing request is currently pending for the axis direction concerned or a traversing move-
change 1 –––> 0 ment carried out has been completed.
 JOG mode:
– The traversing key is cancaled.
– When quitting traversing using the handwheel
 REF submode:
when the reference point is reached
 AUT/MDA modes:
– The program block has been executed (and the next following program block does not
contain a coordinate value for the axis concerned)
– Abortion by ”RESET”, etc.
– IS ”Axis lock“ is provided
Application example(s) Release of clamping (in case of axes with clamping)
Note: If the clamping is only released with the traversing command, no continuous–
path mode is possible for these axes.
Related to .... IS ”Traversing key plus” and ” ... minus” for geometry axis 1 (V32001000.7 and .6 )
for geometry axis 2 (V32001004.7 and .6 )
for geometry axis 3 (V32001008.7 and .6 )

Active machine function INC1, ..., continuous

V33001001.0, ..., .6 for geometry axis 1
V33001005.0, ..., .6 for geometry axis 2
V33001009.0, ..., .6 for geometry axis 3
Interface signal Signal(s) from channel (NCK –> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge A signal is fed back to the PLC interface to define which machine function is active for the geo-
change 0 –––> 1 metry axes in JOG mode.
Signal state 0 or edge The appropriate machine function is not active.
change 1 –––> 0
Related to .... IS ”Machine function INC1,...,continuous for geometry axis 1 (V32000001.0 ... .6)
for geometry axis 2 (V32000005.0 ... .6)
for geometry axis 3 (V32000009.0 ... .6)

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9.6.4 Axis/spindle–specific signals

Description of the signals provided to the axis/spindle

V380x0004.0 ... .2 Enable handwheel (1 ... 3)

Interface signal Signal(s) to axis/spindle (PLC –> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge These PLC interface signals are used whether the machine axis is assigned handwheel 1, 2, 3
change 0 –––> 1 or no handwheel.
One axis can be assigned only one handwheel at a time.
If several interface signals ”Activate handwheel“ are set, the priority is ’Handwheel 1’ before
’Handwheel 2’ before ’Handwheel 3’.
If the assignment is active, the machine axis can be traversed in JOG mode using the hand–
wheel.
Signal state 0 or edge This machine axis is not assigned handwheel 1, 2 or 3.
change 1 –––> 0
Application example(s) This interface signal can be used to lock the manipulation of the axis by turning the handwheel
from the PLC user program.
Related to .... IS ”Handwheel active” 1 to 3 (V390x0004.0 to .2)

V380x0004.4 Traversing key lock

Interface signal Signal(s) to axis/spindle (PLC –> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The traversing keys plus and minus have no effect on the appropriate machine axis. For exam-
change 0 –––> 1 ple, traversing the axis in JOG mode using the traversing keys on the MCP is not possible.
If the traversing key lock is enabled during a traversing movement, the machine axis is stopped.
Signal state 0 or edge The traversing keys plus and minus are enabled.
change 1 –––> 0
Application example(s) Depending on the operating status, traversing of the machine axis in JOG mode using the traver-
sing keys can thus be locked from the PLC program.
Related to .... IS ”Traversing key plus” and ”Traversing key minus” (V380x0004.7 and .6)

V380x0004.5 Rapid traverse override

Interface signal Signal(s) to axis/spindle (PLC –> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge If the PLC interface signal “Rapid traverse override” is provided together with the “Traversing key
change 0 –––> 1 plus” or the “Traversing key minus”, the selected machine axis will traverse at rapid traverse rate.
The rapid traverse velocity is defined in the machine data JOG_VELO_RAPID.
The rapid traverse override is active in JOG mode for the following variants:
– continuous traversing
– incremental traversing
With rapid traverse override active, the velocity can be manipulated using the axial feed override
switch.
Signal state 0 or edge The machine axis will traverse at the specified JOG velocity (SD: JOG_SET_VELO or MD:
change 1 –––> 0 JOG_VELO).
Signal inapplicable ...... – AUTOMATIC and MDA modes
– Reference point approach (JOG mode)
Related to .... IS ”Traversing key plus” and ”Traversing key minus” (V380x0004.7 and .6)
IS “Axis–specific feed override“ (VB380x0000)

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V380x0004.7 and .6 Traversing keys plus and minus

Interface signal Signal(s) to axis/spindle (PLC –> NCK)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge In JOG mode, the traversing keys plus and minus can be used to traverse the selected axis in
change 0 –––> 1 both directions.
Incremental traversing
With signal state 1, the axis starts to traverse the set increment. If the signal
changes to 0 state before the increment has been traversed, the traversing
movement will be aborted. If the signal state is 1 again, the traversing movement will
be continued. Until the increment is traversed completely, the traversing movement
of the axis can be stopped and continued several times as described above.
Continuous traversing
If no INC dimension is selected, the axis will traverse as long as the traversing axis
is hold down.

If both traversing signals (plus and minus) are set at the same time, no traversing movement is
carried out or the traversing movement is aborted.
The effect of the traversing keys can be disabled for each axis separately using the PLC inter-
face signal ”Traversing key lock”.

Signal state 0 or edge No traversing

change 1 –––> 0
Signal inapplicable ...... AUTOMATIC and MDA modes
Application example(s) The machine axis cannot be traversed in JOG mode if it is already traversed via the channel–
specific PLC interface (as a geometry axis). Alarm 20062 is output.
Special cases, ...... Indexing axes
Related to .... IS ”Traversing key plus” and ” ... minus” for geometry axis 1 (V32001000.7 and .6 )
for geometry axis 2 (V32001004.7 and .6 )
for geometry axis 3 (V32001008.7 and .6 )
IS ”Traversing key lock”(V380x0004.4 )

V380x0005.0 ... .6 Machine function INC1, INC10, INC100, INC1000, INC10000, INCvar, continuous
Interface signal Signal(s) to axis/spindle (PLC –> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge This input area is only used if the IS “INC inputs in mode group area active” (V2600 0001.0) is
change 0 –––> 1 not set.
The IS “INC...” defines how many increments the axis traverses per latch position when the tra-
versing key is pressed or the handwheel is turned. When doing so, JOG mode must be active.
With “INCvar”, the value in the general SD 41010: JOG_VAR_INCR_SIZE will apply.
With “Continuous”, the appropriate axis can be traversed using the plus or minus traversing key
with holding down the traversing key as required.

Once the selected machine function is active, this is signaled to the PLC interface (IS ”Active
machine function INC1; ...” ).
If several machine function signals (INC1, INC... or ”Continuous traversing”) are selected at the
interface at the same time, no machine function is enabled internally in the control system.
Note:
The input IS “INC...” or “Continuous” to modify an active machine function must be present at
least one PLC cycle. It need not be present statically.
Signal state 0 or edge The corresponding machine function is not selected.
change 1 –––> 0 While an axis traverses an incremental dimension, abortion or switching of the machine function
will also abort the movement.
Related to .... IS ”Active machine function INC1, ...” (V390x0005.0 ... .6)
IS “INC inputs in mode group area active” (V2600 0001.0)

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Description of the signals provided from the axis/spindle

V390x0004.0 to .2 Handwheel active (1 to 3)

Interface signal Signal(s) from axis/spindle (NCK –> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release: 1.1
Signal state 1 or edge These PLC interface signals are used whether the machine axis is assigned handwheel 1, 2, 3
change 0 –––> 1 or no handwheel.
One axis can be assigned only one handwheel at a time.
If several interface signals ”Activate handwheel“ are set, the priority is ’Handwheel 1’ before
’Handwheel 2’ before ’Handwheel 3’.
If the assignment is active, the machine axis can be traversed in JOG mode using the handw-
heel.
Signal state 0 or edge This machine axis is not assigned handwheel 1, 2 or 3.
change 1 –––> 0
Related to .... IS ”Enable handwheel” (V380x0004.0 to .2)
IS ”Handwheel selected” from HMI (V19000003, ff)

V390x0004.7 and .6 Traversing commands plus and minus

Interface signal Signal(s) from axis/spindle (NCK –> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge A traversing movement is to be carried out in the axis direction concerned. The traversing com-
change 0 –––> 1 mand is initiated in different ways, depending on the operating mode.
– JOG mode: using the traversing key plus or minus
– REF submode: using the traversing key leading to the reference point
– AUTO/MDA modes: A program block that contains a coordinate value for the axis
concerned is carried out.
Signal state 0 or edge No traversing request is currently pending for the axis direction concerned or a traversing move-
change 1 –––> 0 ment carried out has been completed.
 JOG mode:
– The traversing key is cancaled.
– When quitting traversing using the handwheel
– REF submode: when the reference point is reached
 AUT/MDA modes:
– The program block has been executed (and the next following program block does not
contain a coordinate value for the axis concerned)
– Abortion by ”RESET”, etc.
– IS ”Axis lock“ is provided
Application example(s) Release of the clamping of the axes (in case of axes with clamping) (e.g. with rotary tables).
Note: If the clamping is released only with the traversing command, no continuous–path
mode is possible for these axes.
Related to .... IS ”Traversing key plus” and ”Traversing key minus” (V380x0004.7 and .6)

V390x0005.0, ..., .6 Active machine function INC1, ..., continuous

Interface signal Signal(s) from axis/spindle (NCK –> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release: 1.1
Signal state 1 or edge A signal is fed back to the PLC interface which machine function is active for the geometry axes
change 0 –––> 1 in JOG mode.
Signal state 0 or edge The appropriate machine function is not active.
change 1 –––> 0
Related to .... IS ”Machine function INC1,...,continuous“ (V380x0005.0, ..., .6)

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9.7 Data fields, lists

9.7.1 Interface signals

Number .Bit Name Ref.

Signals from HMI to PLC
VB19001003 – Axis number, machine/geometry axis for handwheel 1
VB19001004 for handwheel 2
VB19001005 for handwheel 3
NCK–specific
V2600 0001 .0 INC inputs in operating mode area active
Mode–specific
V3000 0000 .2 JOG mode
V3000 0002 .0 to .6 Machine function INC1 to continuous in operating mode area
V3100 0000 .2 Active mode JOG
Channel–specific
V32001000 .2, .1, .0 Activate handwheel (3, 2, 1) for geometry axis 1
V32001004 .2, .1, .0 for geometry axis 2
V32001008 .2, .1, .0 for geometry axis 3
V32001000 .4 Traversing key lock for geometry axis 1
V32001004 .4 for geometry axis 2
V32001008 .4 for geometry axis 3
V32001000 .5 Rapid traverse override for geometry axis 1
V32001004 for geometry axis 2
V32001008 for geometry axis 3
V32001000 .7 or .6 Traversing keys plus or minus for geometry axis 1
V32001004 .7 or .6 for geometry axis 2
V32001008 .7 or .6 for geometry axis 3
V32001000 .0, ..., .6 Machine function INC1, ..., continuous for geometry axis 1
V32001004 .0, ..., .6 for geometry axis 2
V32001008 .0, ..., .6 for geometry axis 3
V33001000 .2, .1, .0 Handwheel active (3, 2, 1) for geometry axis 1
V33001004 .2, .1, .0 for geometry axis 2
V33001008 .2, .1, .0 for geometry axis 3
V33001000 .7 or .6 Traversing command plus or minus for geometry axis 1
V33001004 .7 or .6 for geometry axis 2
V33001008 .7 or .6 for geometry axis 3
Active machine function INC1, ..., continuous
V33001001 .0, ..., .6 for geometry axis 1
V33001005 .0, ..., .6 for geometry axis 2
V33001009 .0, ..., .6 for geometry axis 3
Axis/spindle–specific
VB380x0000 – Feed override
V380x0000 .7 Override active
V380x0002 .2 Delete distance to go
V380x0004 .2, .1, .0 Enable handwheel (3, 2, 1)
V380x0004 .4 Traversing key lock
V380x0004 .5 Rapid traverse override

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Axis/spindle–specific
V380x0004 .7 or .6 Traversing keys plus or minus
V380x0005 .0 to .6, Machine function continuous,
V390x0000 .7 / .6 Position reached with exact stop coarse / fine
V390x0004 2, .1, .0 Handwheel active (3, 2, 1)
V390x0004 .7 or .6 Traversing command plus or minus
V390x0005 .0, ..., .6 Active machine function INC1, ..., continuous

9.7.2 Machine data

Number Identifier Name Ref.

General
10000 AXCONF_MACHAX_NAME_TAB [n] Machine axis name [n = axis index] Chpt. 19
11310 HANDWH_REVERSE Defines traversing in the opposite direction
11320 HANDWH_IMP_PER_LATCH[n] Handwheel pulses per latch position [handwheel index]
11346 HANDWH_TRUE_DISTANCE Handwheel path or velocity specification
Channel–specific
20060 AXCONF_GEOAX_NAME_TAB [n] Geometry axis in channel [n = geo. axis index] Chpt. 19
20100 DIAMETER_AX_DEF Geometry axes with transverse axis function P1
Axis/spindle–specific
32000 MAX_AX_VELO Maximum axis velocity G2
32010 JOG_VELO_RAPID Conventional rapid traverse
32020 JOG_VELO Conventional axis velocity
32300 MAX_AX_ACCEL Axis acceleration B2
32420 JOG_AND_POS_JERK_ENABLE Enable axis–specific jerk limitation B2
32430 JOG_AND_POS_MAX_JERK Axis–specific jerk B2
35130 GEAR_STEP_MAX_VELO_LIMIT[n] Maximum speed for gear stage/spindle S1

9.7.3 Setting data

Number Identifier Name Ref.

General
41010 JOG_VAR_INCR_SIZE Size of variable increment with INC/handwheel
41110 JOG_SET_VELO JOG velocity for linear axes
41130 JOG_ROT_AX_SET_VELO JOG velocity for rotary axes
41200 JOG_SPIND_SET_VELO JOG velocity for the spindle

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Operating Modes, Program Mode (K1) 10
10.1 Brief description

Program mode
Program mode is provided if part programs or part program blocks are processed in either of the
modes AUTOMATIC or MDA. During the program execution, the program sequence can be mani-
pulated by PLC interface signals and commands.

Channel
A channel is a unit in which a part program can be processed.
The system assigns the channel an interpolator with related program execution. A certain operating
mode will apply.
The SINUMERIK 802D control system has one channel.

10.2 Operating modes

Enabling
The desired operating mode is enabled via the interface signals in VB3000 0000. There is no prio-
rity if several operating modes are selected at the same time:
 JOG (high priority): Traversing of the axes by manual operation of the hand wheel or traversing
keys. Channel–specific signals and interlocks are not taken into account.
 MDA: Program blocks can be executed.
 AUTOMATIC (low priority): Automatic execution of part programs

Check–back signal
The active mode is indicated via the interface signals in VB 3100 0000.

Possible machine functions

The following machine functions can be selected in JOG mode:

 REF (reference point approach)

The desired machine function is activated by the IS “REF” (V300 00001.2). The display can be
seen in the IS “Active machine function REF” (V3100 0001.2).

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Stop
The IS ”NC Stop” (V3200 0007.3), IS ”NC Stop for axes and spindles” (V3200 0007.4) or ”NC Stop
at block border” (V3200 0007.2) can be used to provide a stop signal. Depending on the stop signal
selected either only the axes or, in addition, also the spindle or the axes are stopped at block end.

RESET
The IS ”Reset” (V3000 0000.7) will abort the active part program.
The following actions are carried out after the IS ”Reset”:

 The part program preparation is stopped immediately.

 Axes and spindles are stopped.
 Any auxiliary functions of the current block not yet output at this moment are no longer output.
 The block pointer is reset to the beginning of the corresponding part program.
 All reset alarms are deleted from the display.
 The reset is completed if the IS ”Channel status: Reset” (V3300 0003.7) is set.

Ready to operate
Readiness for operation is displayed by the IS ”802–Ready” (V 3100 0000.3).

10.2.1 Mode change

General
A mode change is requested and activated via the interface.

Note
The mode will only be changed internally in the control system if ”Channel status active”
(IS V3300 0003.5) is no longer provided.

In the channel status Reset (IS V3300 0003.7), e.g. after pressing the RESET key, it is possible to
switch over from one mode to another.
In the channel status “Interrupted“ (IS V3300 0003.6), switching over is bound to certain conditions
(see Table 10–1).
If you quit AUTO to switch over to JOG, you must return to AUTO or press RESET. A change
AUTO–JOG–MDA is thus impossible. The same applies to MDA from which you can neither directly
nor indirectly change to AUTO unless the RESET status is not provided.

For the operating mode changes possible according to the current operating mode and the channel
status (”Channel in reset” or “Channel interrupted”), please refer to the following Table.

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Table 10-1 Mode change depending on the channel status

AUTOMATIC JOG MDA

From AUTO MDA

previously pre-
viously

To Reset Interr. Reset Interr. Interr. Reset Interr.

AUTOMATIC X X X

JOG X X X X

MDA X X X

The positions marked with an ”X” are possible mode changes.

Errors on mode change

If a mode change request has been denied by the system, an appropriate error message is output.
This error message can be cleared without changing the channel.

Mode change lock

The IS ”Mode change lock” (V3000 0000.4) can be used to disable the mode change. The signal
acts such that the mode change request is already suppressed.

10.2.2 Possible functions in the individual operating modes

Overview of functions
Which function can be selected in which operating mode and in which operating status, is to be
seen in the following Table.

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Table 10-2 Possible functions in the individual operating modes

Channel interrupted JOG during AUTO interrupted

Channel active JOG interrupted MDA mode

Channel interrupted JOG during MDA mode
Channel in reset state AUTOMATIC

Channel in RESET state MDA

Channel active JOG in MDA

Channel in Reset state JOG
Channel interrupted

Channel interrupted
Channel active

Channel active

Channel active

Channel active

Channel active
Functionalities
Loading a program from ex- sb sb sb sb sb sb sb sb

ternal using ”Services”

Execution of a part program/ s s b s s b
block
Block search s s b
Reference point approach per sb sb

part program command (G74)

s: Function cannot be started in this status
b: Function can be executed in this status

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 Operating Modes, Program Mode (K1)

10.2.3 Monitoring functions in the individual operating modes

Overview of monitoring functions

In the individual operating modes, various monitoring functions are active.

Table 10-3 Monitorings and interlockings

Channel interrupted JOG during AUTO interrupted

Channel active JOG interrupted MDA mode

Channel interrupted JOG during MDA mode
Channel in reset state AUTOMATIC

Channel in RESET state MDA

Channel active JOG in MDA

Channel in Reset state JOG
Channel interrupted

Channel interrupted
Channel active

Channel active

Channel active

Channel active

Channel active
Axis–specific monitoring functions or when positioning the spindle
SW limit switch + x x x x x x x
SW limit switch - x x x x x x x
HW limit switch + x x x x x x x x x x x x x x
HW limit switch - x x x x x x x x x x x x x x
Exact stop coarse/fine x x x x x x x x x x x x x x
Clamping tolerance x x x x x x x x x x x x x x
DAC limitation x x x x x x x x x x x x x x
(analog spindle)
Contour monitoring x x x x x x x
Spindle–specific monitoring functions
Speed limit exceeded x x x x x x
Spindle stopped x x x x x x x x x x x x x x
Spindle synchronized x x x x x x
Speed within set range x

Max. permissible speed x x x x x x

Encoder limit frequency x x x x x x

x: Monitoring is active in this status.

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10.2.4 Interlocks in the individual operating modes

Overview of interlocks
In the individual operating modes, various interlocks can be active.
Which interlock can be enabled in which operating mode and in which operating status is to be
seen in the Table below:

Channel interrupted JOG during AUTO interrupted

Channel active JOG interrupted MDA mode

Channel interrupted JOG during MDA mode
Channel in reset state AUTOMATIC

Channel in RESET state MDA

Channel active JOG in MDA

Channel in Reset state JOG
Channel interrupted

Channel interrupted
Channel active

Channel active

Channel active

Channel active

Channel active
General interlocks
802–Ready x x x x x x x x x x x x x x
Mode change lock x x x x x x x x x x x x x x
Channel–specific interlocks
Feed stop x x x x x x x
NC Start inhibited x x x x x x x x x x x x x x
Read–in disable x x x x x x x x x x x x x x
Axis/specific interlocks
Spindle disable x x x x x x x x x x x x x x
Servo disable x x x x x x x x x x x x x x
Axis disable x x x x x x x x x x x x x x
Spindle–specific interlocks
Servo disable x x x x x x x x x x x x x x
Spindle lock x x x x x x x x x x x x x x
x: Interlock can only be enabled in this status

10.3 Execution of a part program

10.3.1 Program mode and part program selection

Definition
Program mode means that a part program is carried out in AUTOMATIC mode and/or program
blocks are carried out in MDA mode.

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Program manipulation
During program mode, it is possible to manipulate the program mode from the PLC via interface
signals. The manipulation is carried out using mode–specific or channel–specific interface signals.
The channel advises the PLC of its current program mode status.

Selection
The selection of a part program can only be carried out if the channel concerned is in the RESET
status.

10.3.2 Starting the part program or part program block

START command, channel status

The channel–specific IS ”NC Start” (V3200 0007.1), which is normally controled by an MCP key
“NC Start”, will start the program execution.

The START command will only be executed in the modes AUTOMATIC and MDA. To this aim, the
channel must be in the status ”Channel status: RESET” (V3300 0003.7) or ”Channel status: Inter-
rupted” (V3300 0003.6).

Required signal statuss

The selected part program can only be enabled for execution with the START command.
The following enable signals will apply:
 IS ”802–Ready” must be set (V3100 0000.3)
 IS ”Activate program test” may not be set (V3200 0001.7)
 IS ”NC START inhibited” may not be reset (V3200 0007.0)
 IS ”NC STOP at block border” may not be set (V3200 0007.2)
 IS ”NC Stop” may not be set (V32000007.3)
 IS ”NC Stop axes and spindle” may not be set (V3200 0007.4)
 IS ”EMERGENCY STOP” may not be set (V2700 0000.1)
 Axis or NCK alarm may not be present

Execution of the command

The part program or the part program block is executed automatically and the IS ”Channel status
active” (V3300 0003.5) and the IS ”Program status: running” (V3300 0003.0) are set.
The program is processed as long as the program end is reached and/or the channel is interrupted
and/or aborted by a STOP or RESET command.

Alarms
The START command will not come into effect if this prerequisite is not fulfilled. In this case one of
the following alarms will occur: 10200, 10202, 10203

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10.3.3 Part program interruption

Channel status
The STOP command can only be executed if the channel concerned is in the status ”Channel ac-
tive” (V3300 0003.5).

STOP commands
There are various commands to stop the program execution and to set the channel status to ”Inter-
rupted”. These are:

 IS ”NC STOP at block border” (V3200 0007.2)

 IS ”NC STOP” (V3200 0007.3)
 IS ”NC STOP axes and spindle” (V3200 0007.4)
 IS ”Single block” (V3200 0000.4)
 Programming command ”M0” and/or ”M1” and the appropriate enabling

Execution of the command

If the STOP command has been executed, the IS “Program status: Stopped” (V3300 0003.2) and
the IS ”Program status: Interrupted” (V3300 0003.3) are set. If another START command is provi-
ded, the interrupted part program can be continued from the interruption position.

Generally, the following actions can be executed after the STOP command has been provided:
 Stopping the part program execution at the next block border (with NC Stop at the block border,
M0/M1 or single block); any other STOP commands will stop it immediately.
 Any auxiliary functions of the current block which are not yet output at this moment will no lon-
ger be output.
 The axes are stopped and the part program execution is also stopped.
 The block pointer remains stopped at the interruption position.

10.3.4 RESET command

Function
The RESET command (IS ”Reset” (V3000 0000.7)) can be executed in each channel status. This
command cannot be interrupted by any other command.
A RESET command allows to abort an active part program and/or part program blocks. After execu-
tion of the RESET command, the IS ”Channel status: Reset” (V3300 0003.7) and the IS “Program
status: Aborted” (V3300 0003.4) are set.
It is now no longer possible to continue the part program from the interruption position. All axes in
the channel are at exact stop.

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After the RESET command, the following actions are carried out:
 The part program preparation is stopped immediately.
 Axes and (if any) the spindle are decelerated.
 Any auxiliary functions of the current block, which are not yet output at this moment, will not be
output any more.
 The block pointer is reset to the beginning of the corresponding part program.
 All alarms will be deleted from the display if they are not POWER ON alarms.

10.3.5 Program control

Selection/activation
The user can control the execution of the part program from the operator interface. In the “Program
control” menu (AUTOMATIC mode, operating area “Position”), certain functions can be selected,
whereas some functions have an influcence on PLC interface signals. These interface signals are
merely to be understood as selection signals from the user interface. They will not yet activate the
selected function.
In order to render the selected functions active, these signal states must be transferred to a diffe-
rent area. For a manipulation on the part of the PLC, these signals must be set directly.

Table 10-4 Program control

Function Selection signal Enable signal Check–back signal

SKP Skip Block V1700 0001.0 V3200 0002.0
DRY Dry Run Feed V1700 0000.6 V3200 0000.6
ROV Feed Override V1700 0001.3 V3200 0006.6
Preselection:
SBL1 –Single block coarse – –
SBL2 –Single block fine – –
Single block user–specific V3200 0000.4
M1 Programmed stop V1700 0000.5 V3200 0000.5 V3300 0000.5
PRT Program test V1700 0000.7 V3200 0001.7 V3300 0001.7

10.3.6 Program status

Program statuses
The status of the selected program for the particular channel is displayed in AUTOMATIC and MDA
modes at the interface. If you change to JOG moide with the program stopped, the program status
“Interrupted” or, in case of Reset, “Aborted” is displayed.

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The following program statuses are possible:

 IS ”Program status: Aborted” (V3300 0003.4)
 IS ”Program status: Interrupted” (V3300 0003.3)
 IS ”Program status: Stopped” (V3300 0003.2)
 IS ”Program status: Running” (V3300 0003.0)

Effects of commands/signals
The program status can be manipulated by activating various commands or interface signals. The
Table below illustrates the resulting program status (supposed status prior to the signal -> Program
status: Running).

Table 10-5 Effects on the program status

States of program execution

Commands
Aborted Interrupted Stopped Waiting Running
IS ”Reset” X
IS ”NC Stop” X
IS ”NC Stop at block border” X
IS ”NC Stop for axes and spindles” X
IS ”Read–in disable” X
IS ”Feed stop, channel lock” X
IS ”Feed stop, axis lock” X
Feed override = 0% X
IS ”Spindle stop” X
M2 in the block X
M0/M1 in the block X
IS ”Single block” X
Auxiliary function output to PLC, X
but not yet acknowledged

10.3.7 Channel status

Channel statuses
The current status of the channel is imaged to the interface. Based on this status, the PLC can in-
itiate certain reactions or interlocks, which can be configured by the manufacturer. The channel
status is displayed in all operating modes.
The following channel states are possible:
 IS ”Channel status: Reset” (V3300 0003.7)
 IS ”Channel status: Interrupted” (V3300 0003.6)
 IS ”Channel status: Active” (V3300 0003.5)

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Effects of commands/signals
The channel status can be manipulated by enabling various commands or interface signals. The
Table below shows the resulting channel status (supposed status prior to the signal -> channel sta-
tus: Active).
The ”Channel status: Active” is achieved if a part program or part program block is executed or the
axes are traversed in JOG mode.

Table 10-6 Effects on the channel status

Channel status after the command

Commands
Reset Interrupted Active
IS ”Reset” X
IS ”NC Stop” X
IS ”NC Stop at block border” X
IS ”NC Stop for axes and spindles” X
IS ”Read–in disable” X
IS ”Feed stop, channel lock” X
IS ”Feed stop, axis lock” X
Feed override = 0%
IS ”Spindle stop” X
M2 in the block X
M0/M1 in the block X
IS ”Single block” X
Auxiliary function output to PLC, X
but not yet acknowledged

10.3.8 Reactions to operator or program actions

Reactions
The Table below contains a list of channel and program statuses that may occur after certain opera-
tor or program actions.

The left part of the Table contains the channel and program statuses, as well as the operating mo-
des under which the initial situation must be searched. The right part of the Table contains certain
operating/program actions; the number of the situation is specified for each action in brackets after
the corresponding action has been carried out.

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Table 10-7 Reactions to operator or program actions

Situation Channel Program status Active mode Operator or program action

status (situation after the action)

R U A N U S W A A M J
1 x x x RESET (4)
2 x x x RESET (5)
3 x x x RESET (6)
4 x x x NC Start (13); mode change (5 or 6)
5 x x x NC Start (14); mode change (4 or 6)
6 x x x Direction key (15); mode change (4 or 5)
7 x x x NC Start (14)
8 x x x NC Start (15)
9 x x x NC Start (13); mode change (10 or 11)
10 x x x NC Start (16); mode change (9 or 11)
11 x x x Direction key (17); mode change (9 or 10)
12 x x x NC Start (13); mode change (10 or 11)
13 x x x NC Stop (12)
14 x x x NC Stop (7); at block end (5)
15 x x x NC Stop (8); at JOG end (6)
16 x x x NC Stop (10); at block end (10)
17 x x x NC Stop (11); at JOG end (11)

Channel status: Program status: Operating modes:

R→Aborted N→Aborted A→AUTOMATIC
U→Interrupted U→Interrupted M→MDA
A→Running S→Stopped J→JOG
W→Waiting
A→Running

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10.3.9 Example of time diagram for a program sequence

NC START (from PLC) ......

NC–STOP , (from PLC).........
IS .”NC Start inhibited” (V3200 0007.0)... ........
IS “Read–in disable” ” (V3200 0006.1).............................

IS ”Servo enable“, axis (V380 x 0002.1)......................

IS ”Feed STOP”, axis (V380x 0004.3)...........................

IS ”Servo enable”, spindle (V380x 0002.1)...................

IS ”Spindle STOP” (V380x 0004.3)................................

IS ”Program status: Running” (V3300 0003.0)..............

IS ”Program status: Interrupted” (V3300 0003.4)..........

IS ”Program status: Stopped” (V3300 0003.2)................

M0

IS ”Traversing command plus” (V390x 0004.7).............

IS ”Exact stop fine” (V390x 0000.7)..............................

IS ”Spindle stopped ” (V390x 0001.4)...........................

IS ”Spindle within set range” (V390x 2001.5).................

Explanation: t4 t5
Linking by PLC user program
t4: Block relaying to N20 with “Read–in disable” stopped, Spindle run–up Axis running
t5: Program interrupted with RESET Program:
N10 G01 G90 X100 M3 S1000 F1000 M88
N20 M0

Fig. 10-1 Example of signals during program execution

10.4 Program test

10.4.1 General remarks on program test

Objective
For testing a new part program, various control functions are provided. These functions considera-
bly reduce any hazards to the machine during the test phase and also reduce the required time. It is
possible to enable several program test functions at the same time.

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The following test possibilities will be described in the following:

 Program execution without axis movements
 Program execution in single block mode
 Program execution with dry run feed
 Execution of certain program sections
 Skipping certain program parts
 Graphic simulation

10.4.2 Program execution without axis movements (PRT)

Functionality
With the Program Test function active, the part program can be started and executed using the IS
”NC Start” (V32000007.1), i.e. including auxiliary function output, dwell times, etc. Merely the axes/
spindle are simulated. The safety function of the software limit switches remains active.

The position control is not interrupted so that the axes need not be referenced after switching–off of
the function.
The user can thus check the programmed axis positions and the auxiliary function outputs of a part
program.
NOTE: The program execution without axis movements can also be enabled together with the func-
tion ”Dry run feed”.

Selection/enabling
This function is selected using the user interface in the menu “Program control”. With the selection,
the IS ”Program test selected” (V1700 0001.7) is set.
The function must be enabled by the PLC user program using the IS ”Enable program test”
(V3200 0001.7).

Display
As a check–back message that the program test function is active, ”PRT” is displayed in the status
line of the operator interface and the IS” Program test active” (V3300 0001.7) is set in the PLC.

10.4.3 Program execution in single block mode

Functionality
The user can use this function to execute a part program step by step and check the individual ma-
chining steps. If he has found the executed part program block to be correct, he can request the
next block. Progression to the next part program block is carried out via the IS “NC Start”
(V3200 0007.1).
With the single block function activated, however, the execution of the part program will stop after
each program block. The program status will change to ”Program status: Stopped”. The channel
status remains set active.

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Single block type

The following single block types are distinguished:

 Single block coarse

With this single block type, all blocks that initiate actions (traversing movements, auxiliary func-
tion outputs, etc.) are executed separately. If the tool radius compensation is enabled
(G41,G42), the program execution will stop after each intermediate block inserted by the control
system. In case of computational blocks, however, the program execution will not be stopped,
since they do not initiate any actions.
 Single block fine
With this single block type, all blocks of the part program (also the pure computational blocks
without traversing movements) are executed one after the other by ”NC Start”.
”Single block coarse” is the default setting when the control system is turned on.

Caution
! For a series of G33 blocks, single block is only active if DRY RUN FEED is selected.

Selection/enabling
As a rule, the selection signal comes from a user machine control panel.
This function must be enabled from the PLC user program via the IS ”Enable single block”
(V3200 0000.4).

The selection “Single block coarse” or “Single block fine” is made on the user interface in the “Pro-
gram control” menu.

Display
As a check–back message of active single block mode, ”SBL” is displayed in the appropriate field of
the user interface.
Once the part program execution has completed a part program block in single block mode, the IS
”Channel status: Interrupted” (V3300 0003.6) and the IS “Program status: Stopped“ (V3300 0003.2)
are set and the IS “Channel status: Active” (V3300 0003.5) and the IS “Program status: Running”
(V3300 0003.0) are reset.

10.4.4 Program execution with Dry Run Feed (DRY)

Functionality
The part program can be started via the IS ”NC Start” (V3200 0007.1). With the function enabled,
the traversing rates that have been programmed in conjunction with G1, G2, G3, CIP, CT, are repla-
ced by the feed value stored in SD 42100: DRY_RUN_FEED. The dry run feed will also be used
instead of the programmed revolutional feed in program blocks with G95. If, however, the program-
med feed is greater than the dry run feed, the larger value will be used.

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Caution
! If the function “Dry run feed” is enabled, no workpiece machining must be carried out,
since the cutting rates of the tools may be exceeded and/or the workpiece or the machine
tool may be destroyed due to the changed feed values.

Selection/enabling
The operation with dry run feed is selected in the operating area “Position”–> softkey “Program con-
trol” (AUTOMATIC mode). This selection will set the IS ”Dry run feed selected” (V17000000.7). In
addition, the desired value of the dry run feed must be entered in the setting data menu. This will,
however, not yet enable the function.

The function is enabled using the IS ”Enable dry run feed” (V3200 0000.4) and is evaluated with NC
Start.
The dry run feed must have been entered in SD 42100: DRY_RUN_FEED before program start.

Display
As a check–back message of active dry run feed, ”DRY” is displayed in the status line of the user
interface.

10.4.5 Block search: Execution of certain program sections

Functionality
To position the control system on a certain block (target block) of a part program, the Block search
function can be used.. When doing so, it can be selected whether or not during the block search to
the target block the same calculations are to be carried out as in normal program mode.
After the target block has been reached, the program can be started via the IS ”NC Start” (to be
provided 2x) (V3200 0007.1). If necessary an automatic compensation movement of the axes to the
starting or end position of the target block is carried out. Then the program is continued.

Note: Make absolutely sure that a collision–free starting position and the appropriate technological
values are provided and that the appropriate tools are enabled. If necessary first a collision–free
starting position must be approached using JOG mode. Select the target block with due considera-
tion of the selected block search type.

Selection/enabling
The block search function is selected from the operator interface in AUTOMATIC mode.
The block search function can be enabled for the following functions using the appropriate softkey:

 Block search with calculation at the contour

Is used to be able to approach the contour in any situation. ”NC Start” is used to approach the
starting position of the target block or the end position of the block prior to the target block.
This will be traversed up to the end position. The execution of this block is carried out true to the
contour.

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 Block search with calculation at the block end point

is used to be able to approach the target position (e. g. tool change position) in any situation.
The end point of the target block or the next programmed position is approached using the
interpolation type valid in the target block. This will not be carried out true to the contour. Only
the axes programmed in the target block will be approached.
 Block search without calculation
is used for quick search in the main program.
No calculation is carried out. The control–internal values are in the states as prior to the block
search. Whether or not a processing can be carried out, depends on the program and must be
decided by the operator.
This block search type is especially suited to carry out fast syntax checks for new programs.

Interface signal
The IS

 ”Block search active” (V3300 0001.4)

 ”Action block active” (V3300 0000.3)
 ”Approach block active” (V3300 0000.4)
 ”Last action block active” (V3300 0000.6)
are set according to the time sequence shown in Fig. 10–2.

Note
The IS “Approach block active” will only be set in case of “Block search with calculation
at the contour”, since in case of “Block search with calculation at the block end point” no
separate approach block is generated (approach block is identical to target block).

Start Sear- NC Start Last ac- NC Start Target

block ched Output action tion block Output ap- block in
search block blocks proach block main pro-
found gram part

Block search active

(V3300 0001.4)

Action block active

(V3300 0000.3)

Approach block
active
(V3300 0000.4)

Last action block active

(V3300 0000.6)

Fig. 10-2 Time sequence of interface signals

After the IS “Block search with calculation at the block end point” and from the moment “Last action
block active” until the part program execution is continued by NC Start, no automatic repositioning
is executed. The start point of the current axis position is NC Start, and the end point results from
the execution of the part program.

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Action blocks
Action blocks contain the actions accumulated during ”Block search with calculation”, such as auxi-
liary function outputs, tool (T, D), spindle (S), feed programming.
During ”Block search with calculation” (contour or block end point), actions, such as the output of M
functions, are accumulated in so–called action blocks. These blocks are output with ”NC Start” after
”Searched block found”.

Note
With the action blocks, the accumulated spindle programming (S value, M3/M4/M5,
SPOS) will also become active. It must be guaranteed by the PLC user program that the
tool can be operated and the spindle programming is reset via the IS “Spindle re-
set“(V380x0002.2).

PLC actions after block search

To enable PLC actions to be activated after block search, the IS “Last action block active” is provi-
ded. It is intended to make sure that all action blocks are executed and actions on side of the PLC
or the operator (e.g. mode change) are now possible. For example, the PLC can carry out tool
change before the movement is started.
By default, at this moment the alarm 10208 is output. This will tell the operator that NC Start is re-
quired to continue the program.

Boundary condition
The approach movement ”Block search with calculation at the block end point” is carried out using
the interpolation type valid for the target block. Reasonably, it should be G0 or G1. With other inter-
polation types, the approach movement can be aborted with alarm (e. g. circle end point error with
G2/G3).

Note
For further information on the function ”Block search”, please refer to:
References: “Operation and Programming“

10.4.6 Skipping part program blocks (SKP)

Functionality
To test new programs, it is useful to lock or skip certain part program blocks for program execution.

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PROGRAM1 Main program or subroutine

N10 ...

N20 ...
Block being N30 ...
processed Blocks
/N40 ... N40 and N50 are skip-
ped during the
/N50 ...
program execution
N60 ...

N70 ...
N80 ...

N90 M2

Fig. 10-3 Skipping part program blocks

Selection/enabling
The skip function is selected on the user interface from the menu “Program control”. The selection
will set the IS ”Skip block” (V1700 0002.0). In addition, a slash ”/ ” must be put in front of the block
to be skipped (see Fig. 10–3). This will, however, not yet enable the function.

The activation of the function is carried out via the IS ”Enable block skip” (V3200 0002.0).

Display
As a check–back message of the activated function ”Skip block”, ”SKP” is displayed in the status
line of the user interface.

10.4.7 Graphical simulation

Function
A selected and opened program can be simulated graphically on the screen of the control system in
AUTOMATIC mode. The motions of the programmed axes are recorded as broken–line graphics
after actuating “NC Start”.

Selection/deselection
The graphical simulation is accessible for the program selected via the operating area “Program”,
“Load program” and using the “Simulation” softkey. At the same time, the IS “Simulation active”
(V1900 0000.6) is set and is reset again when quitting the operating area “Program” or changing
over to “Edit”.

Display
Various operating options are provided to show an entire workpiece or simply a magnified section of
the workpiece on the screen.
References: “Operation and Programming“

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PLC user program

The PLC user program must manipulate the desired behavior of the control system during simula-
tion by itself, for example:
 Stopping the axes/spindle by changing to program test: Set IS “Enable program test”
(V3200 0001.7)
 Abortion of the running program if “Simulation” is quitted by setting the IS “Reset”
(V300 00000.7), etc.

Display machine data

Various display machine data are provided for user–specific design of graphic simulation
(MD 283 to MD 292).
References: Section 10.7.1 “Display machine data”

Note
In addition to the graphical simulation, the “Record” function is provided. This function can be used
to record the axes movements of a running program in the operating area “Position” –> Softkey
“Record” as a broken–line graphics on the screen. This function is available in AUTOMATIC mode.
The display is carried out in the same way as with the graphical simulation.
References: “Operation and Programming“

10.5 Timer for program runtime

Function
The function “Program runtime” provides timers that can be used for the monitoring of technological
processes in the program or simply on the display.
These timers are read–only timers. There are timers that are always active; other timers are activa-
ted via machine data.

Timers – always active

 Time since the last “booting of the CNC with default values” ( in minutes ):
$AN_SETUP_TIME
With “Power–up of control system with default values), the timer is automatically set to zero.
 Time since the last power–up of the control system ( in minutes ):
$AN_POWERON_TIME
In this case, the control system is automatically set to zero with each power up of the control.

Timers that can be disabled

These timers can be enabled using machine data (default setting).
The start is timer–specific. Each active runtime measurement is automatically interrupted whe the
program is stopped or if feed override=zero.
The behavior of the enabled time measurements when dry run feed and program test are active
can be defined by means of machine data.

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 Overall runtime of NC programs in automatic mode ( in seconds ):

$AC_OPERATING_TIME
The runtimes of all programs between NC start and program end / reset are summed up in Au-
tomatic mode. The timer is set to zero with each power–up of the control system.
 Runtime of the selected NC program ( in seconds ):
$AC_CYCLE_TIME
The runtime between NC start and program end/reset is measured in the selected NC program.
The timer is deleted when a new NC program is started.
 Tool cutting time ( in seconds ):
$AC_CUTTING_TIME
The runtime of the path axes without active rapid traverse is measured in all NC programs bet-
ween NC start and program end / reset when the tool is active.
The measurement is additionally interrupted when the dwell time is active.
The timer is automatically set to zero with each power–up of the control system.

Display
The contents of the timers is displayed on the screen in the operating area
“OFFSET/PARAM” –> Softkey “Setting data”–>PageDown (2nd page):
Run time = $AC_OPERATING_TIME
Cycle time = $AC_CYCLE_TIME
Cutting time = $AC_CUTTING_TIME
Setup time = $AN_SETUP_TIME
Power on time = $AN_POWERON_TIME

“Cycle time” is additionally displayed in AUTOMATIC mode in the operating area “Position” in the
Tips line.

References: “Operation and Programming“

10.6 Workpiece counter

Function
The function “Workpiece counter” provides counters which can be used to count workpieces.
These counters exist as channel–specific system variables with read/write access from the program
or operator panel (observe the protection level for writing).
The range of values is: 0 to 999 999 999.
Channel–specific machine data MD 27880: PART_COUNTER and
MD 27882: PART_COUNTER_MCODE can be used to control the counter activation, the time of
resetting to zero and the counting algorithm.

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Counters
 Number of the required workpieces ( workpiece setpoint number ):
$AC_REQUIRED_PARTS
This counter can be used to define the number of workpieces at which the number of current
workpieces $AC_ACTUAL_PARTS is set to zero.
MD 27880: PART_COUNTER (bit 1) can be used to activate the generation of the display alarm
21800 “ Workpiece setpoint number reached” and the output of the IS “Workpiece setpoint num-
ber reached” (V330040002.1).
 Total number of workpieces manufactured ( total actual number ):
$AC_TOTAL_PARTS
The counter indicates the number of all workpieces manufactured from the start time.
 Number of current workpieces ( current actual number ):
$AC_ACTUAL_PARTS
This counter registers the number of all workpieces manufactured from the start time. When the
workpiece setpoint number is reached ( $AC_REQUIRED_PARTS ), the timer is automatically
set to zero ( provided that $AC_REQUIRED_PARTS is unequal to 0.).
 Number of workpieces specified by the user:
$AC_SPECIAL_PARTS
This counter allows the user to carry out workpiece counting according to his own definition. An
alarm output can be defined in case of identity with
$AC_REQUIRED_PARTS ( workpiece setpoint number ). The user must reset the counter to
zero by himself.
As the starting time, the first output of the M command for counting after setting the counter to zero
is used. This M command is set for the appropriate counter in MD 27880: PART_COUNTER or
MD 27882: PART_COUNTER_MCODE.

Display
The contents of the counters is displayed on the screen in the operating area “OFFSET/PARAM” –>
softkey “Setting data”–>PageDown (2nd page):
Part total = $AC_TOTAL_PARTS
Part required = $AC_REQUIRED_PARTS
Part count = $AC_ACTUAL_PARTS
$AC_SPECIAL_PARTS not available on the display
“Part count” is additionally displayed in AUTOMATIC mode in the operating area “Position” in the
Tips line.

References: “Operation and Programming“

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10.7 Data descriptions (MD, SD)

10.7.1 Display machine data

283 MM_CTM_SIMULATION_DEF_X
MD number Simulation of default value X
Default: 0 Min. input limit: –10000 Max. input limit: 10000
Change valid: immediately Protection level: Unit: mm and/or inch
Data type: INTEGER Valid from SW release:
Meaning: This MD is used to define the size of the X coordinate of the display range. In ”Simula-
tion”, you will get to the default value set here after pressing the softkey TO ORIGIN.
Related to ... MD 284: MM_CTM_SIMULATION_DEF_Y
MD 285: MM_CTM_SIMULATION_DEF_VIS_AREA

284 MM_CTM_SIMULATION_DEF_Y
MD number Simulation of default value Z
Default: 0 Min. input limit: –10000 Max. input limit: 10000
Change valid: immediately Protection level: Unit: mm and/or inch
Data type: INTEGER Valid from SW release:
Meaning: This MD defines the size of the 2nd coordinate (Y or Z) of the display range. In ”Simula-
tion”, you will get to the default value set here after pressing the softkey TO ORIGIN.
Related to ... MD 283: MM_CTM_SIMULATION_DEF_X
MD 285: MM_CTM_SIMULATION_DEF_VIS_AREA

285 MM_CTM_SIMULATION_DEF_VIS_AREA
MD number Simulation of default value for display range
Default: 100 Min. input limit: –10000 Max. input limit: 10000
Change valid: immediately Protection level: Unit: mm and/or inch
Data type: INTEGER Valid from SW release:
Meaning: These machine data are used to define the size of the display range for the X coordinate.
The Z coordinate will be calculated from this value automatically.
Related to ... MD 283: MM_CTM_SIMULATION_DEF_X
MD 284: MM_CTM_SIMULATION_DEF_Z

286 MM_CTM_SIMULATION_MAX_X
MD number Simulation of max. display X
Default: 0 Min. input limit: –10000 Max. input limit: 10000
Change valid: immediately Protection level: Unit: mm and/or inch
Data type: INTEGER Valid from SW release:
Meaning: This MD is used to define the size of the X coordinate of a second display range (e.g. in
case of larger workpieces).
In ”Simulation”, you will get to the default value set here after pressing the MAX softkey.

Related to ... MD 287: MM_CTM_SIMULATION_MAX_Z

MD 288: MM_CTM_SIMULATION_MAX_VIS_AREA

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287 MM_CTM_SIMULATION_MAX_Y
MD number Simulation for max. display Z
Default: 0 Min. input limit: –10000 Max. input limit: 10000

Change valid: immediately Protection level: Unit: mm and/or inch

Data type: INTEGER Valid from SW release:
Meaning: This MD defines the size of the 2nd coordinate (Y or Z) of a second display range.
In ”Simulation”, you will get to the default value set here after pressing the MAX softkey.
Related to ... MD 286: MM_CTM_SIMULATION_MAX_X
MD 288: MM_CTM_SIMULATION_MAX_VIS_AREA

288 MM_CTM_SIMULATION_MAX_VIS_AREA
MD number Simulation for max. display range
Default: 1000 Min. input limit: –10000 Max. input limit: 10000
Change valid: immediately Protection level: Unit: mm and/or inch
Data type: INTEGER Valid from SW release:
Meaning: This MD is used to define the second display range for the X coordinate. The Z coordi-
nate will be calculated from this value automatically.
Related to ... MD 286: MM_CTM_SIMULATION_MAX_X
MD 287: MM_CTM_SIMULATION_MAX_Y

289 MM_CTM_SIMULATION_TIME_NEW_POS
MD number Simulation for actual–value updating rate
Default: 100 Min. input limit: 0 Max. input limit: 4000
Change valid: immediately Protection level: Unit: ms
Data type: WORD Valid from SW release:
Meaning: This MD is used to define in which intervals the simulation graphics is visualized for the
current processing on the machine tool.
Value = 0 means ’no updating’.

290 MM_CTM_POS_COORDINATE_SYSTEM
MD number Position of the coordinate system
Default: 2 Min. input limit: 0 Max. input limit: 7
Change valid: immediately Protection level: Unit: –
Data type: BYTE Valid from SW release:
Meaning: The position of the coordinate system can be changed as follows:
+X +X

0 1

+Z +Z
+Z +Z

2 3

+X +X
+Z +Z

4 5

+X +X
+X +
X
6 7

+Z +Z

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291 MM_CTM_CROSS_AX_DIAMETER_ON
MD number Diameter display for transverse axes active
Default: 1 Min. input limit: 0 Max. input limit: 1
Change valid: immediately Protection level: Unit: –
Data type: BYTE Valid from SW release:
Meaning: 0: Inputs for absolute values as a radius value.
Zero point offsets always in radius,
tool lengths always in radius,
tool wear always in radius

1: Position display in diameter,

distance to go in diameter,
absolute paths in diameter

292 MM_CTM_G91_DIAMETER_ON
MD number Incremental infeed
Default: 0 Min. input limit: 0 Max. input limit: 1
Change valid: immediately Protection level: Unit: –
Data type: BYTE Valid from SW release:
Meaning: 0: Input in radius
1: Input in diameter

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10.7.2 Channel–specific machine data

21000 CIRCLE_ERROR_CONST
MD number Circle end point monitoring constant
Default: 0.01 Min. input limit: 0.0 Max. input limit: ***
Change valid after Power On Protection level: 2/7 Unit: mm
Data type: DOUBLE Valid from SW release:
Meaning: This machine data describes the admissible absolute circle difference.
With circle programming, the radius from the programmed center point to the start point or to
the end point are usually not equal (the circle is ”overdetermined”). The max. permissible
difference of these two radii accepted without an alarm is determined by the greater value in
the following data:
- MD: CIRCLE_ERROR_CONST
- Start radius multiplied with 0.001
This means that the tolerance for small circles is a fixed value (MD: CIRCLE_ER-
ROR_CONST) and for large circles, it is proportional to the start radius.
Application example MD 21000: CIRCLE_ERROR_CONST = 0.01 mm
With this MD value and a radius of 10 mm, the constant will apply, and with > 10 mm, the
proportional factor will apply.

27860 PROCESSTIMER_MODE
MD number Enable program runtime measurement
Default: 0x7 Min. input limit: 0 Max. input limit: 0x3F (HEX)
Change valid after RESET Protection level: 2/7 Unit: –
Data type: BYTE Valid from SW release:
Meaning: This machine data can be used to enable/disable the channel–specific timers.

Meaning:
Bit 0 = 0 No measurement of the overall runtime for all part programs
Bit 0 = 1 The measurement of the overall runtime for all part programs
is active ( $AC_OPERATING_TIME )
Bit 1 = 0 No measurement of the current program runtime
Bit 1 = 1 The measurement of the current program runtime is active
( $AC_CYCLE_TIME )
Bit 2 = 0 No measurement of the tool cutting time
Bit 2 = 1 The measurement of the tool cutting time is active
( $AC_CUTTING_TIME )
Bit 3 Reserved

Further bits only if bit 0, 1, 2 = 1:

Bit 4 = 0 No measurement with active dry run feed
Bit 4 = 1 Measurement also with active dry run feed
Bit 5 = 0 No measurement with program test
Bit 5 = 1 Measurement also with program test
Bit 6, 7 Reserved
Application example
Special cases, errors, ....... It is recommended to disable timers not needed permanently. This will have a positive influence
on the calculation time for other applications.

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27880 PART_COUNTER
MD number Enable workpiece counters
Default: 0x0 Min. input limit: 0x0 Max. input limit: 0x0FFFF
Change valid after RESET Protection level: 2/7 Unit: –
Data type: DWORD Valid from SW release:
Meaning: This machine date can be used to set the workpiece counters.
Meaning of the individual bits:
Bit 0 – 3: Enable $AC_REQUIRED_PARTS
––––––––––––––––––––––––––––––––––––––––––––––
Bit 0 = 1: Counter $AC_REQUIRED_PARTS is active
Further meaning: Bits 1–3 only if bit 0 =1:
Bit 0=1: Alarm/IS output if $AC_ACTUAL_PARTS corresponds
to $AC_REQUIRED_PARTS
Bit 1 = 1: Alarm/IS output if $AC_SPECIAL_PARTS corresponds
to $AC_REQUIRED_PARTS
Bits 2, 3 Reserved

Bits 4 – 7: Enable $AC_TOTAL_PARTS

–––––––––––––––––––––––––––––––––––––––––––
Bit 4 = 1: Counter $AC_TOTAL_PARTS is active
Further meaning: Bits 5–7 only if bit 4 =1:
Bit 5=1: Counter $AC_TOTAL_PARTS is incremented by amount 1,
if M02/M30 is output by IS
Bit 5 = 1: Counter $AC_TOTAL_PARTS is incremented by amount 1, when the
M command is output from MD 27882: PART_COUNTER_MCODE[0]
Bit 6, 7 Reserved

Bit 8 – 11: Enable $AC_ACTUAL_PARTS

––––––––––––––––––––––––––––––––––––––––––––
Bit 8 = 1: Counter $AC_ACTUAL_PARTS is active
Further meaning: Bits 9–11 only if bit 8 =1:
Bit 9=1: Counter $AC_ACTUAL_PARTS is incremented by amount 1,
if M02/M30 is output by IS
Bit 9 = 1: Counter $AC_ACTUAL_PARTS is incremented by amount 1, when the
M command is output from MD 27882: PART_COUNTER_MCODE[1]
Bits 10, 11 Reserved

Bit 12 – 15:Enable $AC_SPECIAL_PARTS

–––––––––––––––––––––––––––––––––––––––––––––
Bit 12 = 1: Counter $AC_SPECIAL_PARTS is active
Further meaning: Bits 13–15 only if bit 12 =1:
Bit 13=1: Counter $AC_SPECIAL_PARTS is incremented by amount 1,
if M02/M30 is output by IS
Bit 13 = 1: Counter $AC_SPECIAL_PARTS is incremented by amount 1, when the
M command is output from MD 27882: PART_COUNTER_MCODE[2]
Bits 14, 15 Reserved
Application example
Related to ... MD 27882: PART_COUNTER_MCODE
IS “Required parts reached” (V3300 40001.1)

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Operating Modes, Program Mode (K1)

27882 PART_COUNTER_MCODE[n] n = 0 ... 2 , index for counter assignment

MD number Workpiece counting using an M command
Default: (2, 2, 2) Min. input limit: 0 Max. input limit: 99
Change valid after Power On Protection level: 2/7 Unit:
Data type: BYTE Valid from SW release:
Meaning: If the workpiece counting is enabled via MD 27880: PART_COUNTER,
the counting pulse can be triggered using a special M command.
The defined values are taken into account only in this case.
Meaning:
The workpiece counters are incremented by 1 when the described M command is output with
the appropriate IS signal. In this case, the following applies:
$PART_COUNTER_MCODE[0] for $AC_TOTAL_PARTS
$PART_COUNTER_MCODE[1] for $AC_ACTUAL_PARTS
$PART_COUNTER_MCODE[2] for $AC_SPECIAL_PARTS
Application example
Related to ... MD 27880: PART_COUNTER

10.7.3 Channel–specific setting data

42000 THREAD_START_ANGLE
SD number Start angle for thread G33
Default: 0.0 Min. input limit: 0.0 Max. input limit: ***
Change valid: immediately Protection level: 7/7 Unit: degrees
Data type: DOUBLE Valid from SW release:
Meaning: This setting data can be used to set the offset of the individual turns for multiple threads.
This SD can be modified from the part program using the command SF=... . If SF=... is pro-
grammed in the G33 block of the part program, the setting data will be active.
Further references ”Operation and Programming”

42010 THREAD_RAMP_DISP[n] (index n = 0: Acceleration distance, n = 1: Braking distance)

SD number Acceleration and braking behavior of feed axis on thread cutting G33
Default: (–1, –1) Min. input limit: –1 Max. input limit: 999 999.
Change valid: immediately Protection level: 7/7 Unit: mm/inch
Data type: DOUBLE Valid from SW release:
Meaning: Acceleration distance and braking distance of the feed axis on thread cutting:
–1: Starting/braking of the feed axis is carried out with the configured acceleration.
The jerk will act according to the currently programmed BRISK/SOFT.
0: Start/braking of the feed axis on thread cutting is carried out following a step–like curve.
>0: The max. acceleration/brake distance is specified. Under certain circumstances, the
specified path may lead to an acceleration overload of the axis.
Reset/part program end is used to activate the default setting.
Example:
THREAD_RAMP_DISP[0] = 2 acceleration distance 2 mm
Further references Description of Functions, Section “Feed”

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42100 DRY_RUN_FEED
SD number Dry run feed
Default: 5000 Min. input limit: 0 Max. input limit: ***
Change valid: immediately Protection level: 7/7 Unit: mm/min
Data type: DOUBLE Valid from SW release:
Meaning: To test a part program with reference to the distance to be traversed (without a workpiece to
be machined), the operator can enable the function ”Dry run feed” from the operator interface
(softkey ”Program control”). The value of this setting data will then be accepeted instead of the
programmed feed value. Feed override values will not be modified.
The dry run feed value can be entered in the Setting Data menu.
The function is only active in the modes AUTOMATIC and MDA.
SD inapplicable to ...... dry run feed function not enabled
Application example(s) Check of distances to be traversed with new part programs
Special cases, errors, ... The function may not be enabled if a workpiece is to be machined. Due to the fact that dry run
feed is enabled, the max. cutting speed of the tool could be exceeded. This may destroy the
workpiece and the tool.

10.7.4 Axis–specific machine data

30600 FIX_POINT_POS
MD number Fixed–value positions of the axes with G75
Default: 0.0 Min. input limit: *** Max. input limit: ***
Change valid after Power On Protection level: 2/7 Unit: mm, degrees
Data type: DOUBLE Valid from SW release:
Meaning: In these machine data, the fixed–point position is specified for each axis, which is approached
if G75 is programmed.
Application example(s) Travel to fixed point: G75 X1=0
The machine axis identifier is programmed here. A dummy value, in this case 0, must be spe-
cified for the axis.
Further references ”Operation and Programming”

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10.8 Signal descriptions

10.8.1 Mode signals

V3000 0000.0 AUTOMATIC mode

Interface signal Signal(s) to NCK (PLC ---> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge AUTOMATIC mode is selected from PLC program.
change 0 ––> 1
Signal state 0 or edge AUTOMATIC mode is not selected from PLC program.
change 1 ––> 0
Signal inapplicable ...... to the signal ”Mode change lock” is active.
Related to .... IS ”Active mode: AUTOMATIC”

V3000 0000.1 MDA mode

Interface signal Signal(s) to NCK (PLC ---> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge MDA mode is selected from the PLC program.
change 0 ––> 1
Signal state 0 or edge MDA mode is not selected from the PLC program.
change 1 ––> 0
Signal inapplicable ...... to the signal ”Mode change lock” is active.
Related to .... IS ”Active mode: MDA”

V3000 0000.2 JOG mode

Interface signal Signal(s) to NCK (PLC ---> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge JOG mode is selected from the PLC program.
change 0 ––> 1
Signal state 0 or edge JOG mode is not selected from the PLC program.
change 1 ––> 0
Signal inapplicable ...... to the signal ”Mode change lock” is active.
Related to .... IS ”Active mode: JOG”

V3000 0000.4 Mode change lock

Interface signal Signal(s) to NCK (PLC ---> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The mode currently active (JOG, MDA or Automatic) cannot be changed.
change 0 ––> 1
Signal state 0 The mode can be changed.

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 Operating Modes, Program Mode (K1)

V3000 0000.7 Reset

Interface signal Signal(s) to NCK (PLC ---> NCK)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The channel should change to the RESET status. The current program is then in the program
change 0 ––> 1 status “Aborted”. All spindles and axes running will be decelerated along their acceleration
characteristics to a standstill without contour violation.The basic settings will be recovered
(e. g. G functions). The alarms will be cleared if they are not POWER ON alarms.
Signal state 0 or edge Channel status and program sequence are not influenced by this signal.
change 1 ––> 0
Related to .... IS ”Channel RESET”
IS ”All channels in RESET status”
Special cases, errors, .... An alarm that cancels the IS ”Ready” will ensure that the channel is no longer in the reset
status. In order to be able to switch the mode, RESET must be provided.

V3000 0001.2 Machine function REF

Interface signal Signal(s) to NCK (PLC ---> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The machine function REF will be enabled in JOG mode.
change 0 ––> 1
Signal state 0 or edge The machine function REF will not be enabled.
change 1 ––> 0
Signal inapplicable ...... if JOG mode is not active.

V31000 000.0 Active mode: AUTOMATIC

Interface signal Signal(s) from NCK (NCK ---> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge AUTOMATIC mode is active.
change 0 ––> 1
Signal state 0 or edge AUTOMATIC mode is not active.
change 1 ––> 0

V3100 0000.1 Active mode:MDA

Interface signal Signal(s) from NCK (NCK ---> PLC)
Edge evaluation: Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge MDA mode is active.
change 0 ––> 1
Signal state 0 or edge MDA mode is active.
change 1 ––> 0

V3100 0000.2 Active mode: JOG

Interface signal Signal(s) from NCK (NCK ---> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge JOG mode is active
change 0 ––> 1
Signal state 0 or edge JOG mode is not active
change 1 ––> 0

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Operating Modes, Program Mode (K1)

V3100 0000.3 802–READY

Interface signal Signal(s) from NCK (NCK ---> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge This signal is set after Mains Power On and all voltages have been established. The operating
change 0 –––> 1 mode group is now ready for operation, and part programs can be executed in the channel
and/or axes can be traversed.
Signal state 0 or edge The operating mode group / channel is not ready for service. Possible causes are:
change 1 –––> 0 – a serious axis or spindle alarm is present
– hardware fault
– mode group configured not correctly (machine date)

If “Mode group ready” changes to signal status ”0”,

– the axis and spindle drives are decelerated to a standstill at the maximum braking current;
– the signals from the PLC to the NCK are set to the active status (clear position).
Special cases, errors, ...... An alarm that cancels the IS ”802–READY” ensures that the channel is no longer in the RESET
status. To be able to switch over the operating mode, RESET (V30000000.7) must be provided.

V3100 0001.2 Active machine function: REF

Interface signal Signal(s) from NCK (NCK ---> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The machine function REF is active in JOG mode.
change 0 ––> 1
Signal state 0 or edge The machine function REF is not active.
change 1 ––> 0

10.8.2 Channel–specific signals

V3200 0000.4 Enable ”Single block”

Interface signal Signal(s) to channel (PLC ---> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge In AUTOMATIC mode, the program is run in single block mode; in MDA, any way only one
change 0 ––> 1 block can be entered.
Signal state 0 or edge No effect
change 1 ––> 0
Application example(s) To test a new program, it can first be run in single block mode to be able to check the indivi-
dual program steps more exactly.
Special cases, errors, .... - If tool radius compensation is selected (G41,G42), intermediate blocks will be inserted if
necessary.
- With a series of G33 blocks, ”Single block” is only active if ”Dry run feed” is selected.
- With “Single block coarse”, pure computational blocks will not be executed in single block
mode; this is only possible in “Single block fine”. The preselection is carried out using the
“Program control” softkey.
Related to .... IS ”Single block selected”
IS ”Program status: Interrupted”
Further references Section 10.4

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 Operating Modes, Program Mode (K1)

V3200 000.5 Enable M1

Interface signal Signal(s) to channel (PLC ---> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge In AUTOMATIC or MDA, M1 contained in the part program will result in a programmed stop.
change 0 ––> 1
Signal state 0 or edge M1 programmed in a part program will not result in a programmed stop.
change 1 ––> 0
Related to .... IS ”M01 selected” (V1700 0000.5)
IS ”M0/M1 active” (V3300 0000.5)

V3200 0001.7 Enable program test

Interface signal Signal(s) to channel (PLC ---> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge Axis lock will be provided internally for all axes (not for the spindle). The machine axes will
change 0 ––> 1 therefore not move when a part program block or a part program is executed. However, the
axis movements are simulated on the user interface by changing axis position values. The
axis position values for the display are generated from the calculated setpoints.
In all remaining points, the part program execution is executed as usual.
Signal state 0 or edge The “Program test” function has no influence on the execution of the part program.
change 1 ––> 0
Related to .... IS ”Program test selected”
IS ”Program test active”

V3200 0002.0 Skip block

Interface signal Signal(s) to channel (PLC ---> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The blocks of the part program, which are marked with a slash (/), will be skipped. For a
change 0 ––> 1 series of blocks to be skipped, this signal will only be active if it is provided prior to decoding
the first block of this series, best before “NC Start”.
Signal state 0 or edge The marked program blocks will not be skipped.
change 1 ––> 0
Related to .... IS ”Skip block” selected

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Operating Modes, Program Mode (K1)

V3200 0006.1 Read–in disable

Interface signal Signal(s) to channel (PLC ---> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The data transfer to the interpolator will be disabled for the next block. This signal is only
change 0 ––> 1 active in AUTOMATIC and MDA modes.
Signal state 0 or edge The data transfer to the interpolator will be enabled for the next block. This signal is only ac-
change 1 ––> 0 tive in AUTOMATIC and MDA modes.
Application example(s) If the execution of the auxiliary function must be completed for the execution of the
next NC block (e. g. for tool change), the automatic block change must be preven-
ted by ”Read–in disable”.

 N20 T... N21 G...

X ...M...

N20 T... N21

T M

Reading to clipboard
Block executed
 Signal ”Read–in disable“
 Data transfer
Contents of interpolator
Output of auxiliary function
Data transfer to interpolator
Read–in disable for tool change
Polling point of read–in disable
Cancel ”Read–in disable”
Related to .... IS ”Program status: Running”

V3200 0006.4 Program level abortion

Interface signal Signal(s) to channel (PLC ---> NCK)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge With each edge change 0 -> 1, the currently processed program level (subroutine level) will
change 0 ––> 1 be aborted immediately. The part program will be continued on the next–higher program
level from the interruption position.
Signal state 0 or edge no effect
change 1 ––> 0
Special cases, errors, ...... The main program level cannot be aborted using this IS, but only using the IS ”Reset”.

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 Operating Modes, Program Mode (K1)

V3200 0007.0 NC Start inhibited

Interface signal Signal(s) to channel (PLC ---> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release: 1.1
Signal state 1 or edge IS ”NC Start” is inactive.
change 0 ––> 1
Signal state 0 or edge IS ”NC Start” is active.
change 1 ––> 0
Application example(s) This signal is used, e.g. to suppress that the program is executed once more due to a lack of
lubricant.
Related to .... IS ”NC Start”

V3200 0007.1 NC Start

Interface signal Signal(s) to channel (PLC ---> NCK)
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release
Signal state 1 or edge AUTOMATIC mode: The selected NC program is started or continued.
change 0 ––> 1 If data are transferred from the PLC to the NC in the program status ”Program interrupted”,
these will be taken into account with NC start immediately.

MDA mode: The entered part program block are enabled for execution or continued.
Signal state 0 or edge No effect
change 1 ––> 0
Related to .... IS ”NC Start inhibited”

V3200 0007.2 NC STOP at block border

Interface signal Signal(s) to channel (PLC ---> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(e) valid from SW release:
Signal state 1 or edge The current NC program is stopped after the current part program block has been executed
change 0 ––> 1 completely. As far as any other respects are concerned, the same as with ”NC Stop”.
Signal state 0 or edge no effect
change 1 ––> 0
Related to .... IS ”NC Stop”
IS ”NC Stop axes and spindles”
IS ”Program status: Stopped”
IS ”Channel status: Interrupted”

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Operating Modes, Program Mode (K1)

V3200 0007.3 NC Stop

Interface signal Signal(s) to channel (PLC ---> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The current NC program is stopped immediately, and the current block will not be completed.
change 0 ––> 1 Only the axes are stopped without contour violation.
Any distances to go will only be traversed after restart.
The program status will change to “Stopped”, and the channel status will change to
“Interrupted”.
Signal state 0 or edge no effect
change 1 ––> 0
Application example(s)
With NC Start, the program will be continued from the interruption position.

IS ”NC Stop”

IS ”NC Start”
Program running
 Axis running
Block executed

Special cases, errors, .... The signal ”NC Stop” must be provided at least one PLC cycle time.

Related to .... IS ”NC Stop at block border”

IS ”NC Stop for axes and spindles”
IS ”Program status: Stopped”
IS ”Channel status: Interrupted”

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 Operating Modes, Program Mode (K1)

V3200 0007.4 NC Stop for axes and spindles

Interface signal Signal(s) to channel (PLC ---> NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The current NC program is stopped immediately, and the current block will not be completed.
change 0 ––> 1 Any distances to go will only be traversed after restart. Axes and spindle will be stopped.
These, however, will be stopped controlled.
The program status will change to “Stopped”, and the channel status will change to
“Interrupted”.
Signal state 0 or edge no effect
change 1 ––> 0
Signal inapplicable to ..... Channel status: Reset
Program status: Aborted
Special cases, errors...... All axes and spindles that have not been triggered by a program or a program block (e.g. axes
are running because the traversing keys on the MCP have been pressed), will not decelerate to
a standstill with “NC Stop axes plus spindles”.

Press “NC Start” to continue the program from the interruption position.

The signal ”NC Stop Axes plus spindles” must be provided at least one PLC cycle time.

Signal “NC Stop: Axes”

Signal “NC Start”

Program running

Axis running

Spindle running

Block executed
Related to .... IS ”NC STOP at block border”
IS ”NC STOP”
IS ”Program status: Stopped”
IS ”Channel status: Interrupted”

V3300 0000.3 Action block active

Interface signal Signal(s) from channel (NCK ---> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge Block search: Output with accumulated auxiliary function outputs is running (see Section
change 0 ––> 1 10.4.5)
Application example(s)

V3300 0000.4 Approach block active

Interface signal Signal(s) from channel (NCK ---> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge Block search with calculation / at contour: Approach block is running (see Section 10.4.5)
change 0 ––> 1
Application example(s)

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Operating Modes, Program Mode (K1)

V3300 0000.5 M0/M1 active

Interface signal Signal(s) from channel (NCK ---> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The part program block is executed, the auxiliary functions are output and
change 0 ––> 1 - M0 is stored in the user memory or
- M1 is stored in the user memory and IS ”Activate M01” is active
The program status changes to “Stopped”.
Signal state 0 or edge - With the IS ”NC Start”
change 1 ––> 0 - In case of program abortion by Reset

Data transfer to the

user memory

Block executed

NC block with M0 M0

M change signal
(1 PLC cycle time)

IS ”M0/M1 active”

IS ”NC Start”
Related to .... IS ”Enable M01” )
IS ”M01 selected”

V3300 0000.6 Last action block active

Interface signal Signal(s) from channel (NCK ---> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge Block search: Last block of the output with accumulated auxiliary function outputs (see Sec-
change 0 ––> 1 tion 10.4.5)
Application example(s)

V3300 0001.4 Block search active

Interface signal Signal(s) from channel (NCK ---> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The function ”Block search” is active. It has been selected and started from the user interface.
change 0 ––> 1
Signal state 0 or edge The function ”Block search” is not active.
change 1 ––> 0
Application example(s) The Block Search function can be used to jump to a certain block in the part program and to
start the program execution only from this block.

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 Operating Modes, Program Mode (K1)

V3300 0001.5 M2/M30 active

Interface signal Signal(s) from channel (NCK ---> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The NC block that contains M2 is executed completely. If the block also contains traversing
change 0 ––> 1 movements, the signal will be output only when the target position is reached.

Signal state 0 or edge - No end of program or abortion of program

change 1 ––> 0 - State after starting the CNC
- Start of an NC program

Data transfer to
the user memory

Block executed

NC block with M2
M2
M change signal
(1 PLC cycle time)

IS ”M2/M30 active“

Application example(s) The PLC can use this signal to detect the end of program execution and react accordingly.
Special cases, errors, .... – The functions M2 and M30 have the same effect. It is recommended to use only M2.
– The IS ”M2/M30 active” is present at the end of the program statically.
– Not intended for automatic follow–up functions, such as workpiece counting, bar feed, etc.
For these functions, M2 must be programmed in a separate block, and either the word M2
or the decoded M signal must be used.
– The last block of a program may not contain any auxiliary functions that will result in Read–
In disable.

V3300 0001.7 Program test active

Interface signal Signal(s) from channel (NCK ---> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The program control “Program test” is active. Axis lock is internally provided for all axes (not
change 0 ––> 1 for a spindle). The machine axes will therefore not move when a part program block or a part
program is executed. However, the axis movements are simulated on the user interface by
changing axis position values. The axis position values for the display are generated from the
calculated setpoints.
In all remaining points, the part program execution is executed as normal.
Signal state 0 or edge The program control “Program test” is not active.
change 1 ––> 0
Related to .... IS ”Enable program test”
IS ”Program test selected”

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V3300 0003.0 Program status running

Interface signal Signal(s) from channel (NCK ---> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The part program has been started with the IS ”NC Start” and is running.
change 0 ––> 1
Signal state 0 or edge - Program stopped by M00/M01 or NC Stop or mode change.
change 1 ––> 0 - The block has been executed in single block mode.
- End of program reached (M2)
- Abortion of program by Reset
- Current block cannot be executed
Special cases, errors, .... The IS ”Program status: Running” will not change to 0 if the machining of the workpiece is
stopped by either of the following events:
- Output of feed disable or spindle lock
- IS ”Read–in disable”
- Feed override to 0%
- Response of spindle and axis monitoring functions

V3300 0003.2 Program status stopped

Interface signal Signal(s) from channel (NCK ---> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The NC part program has been stopped either by ”NC Stop”, ”NC Stop: Axes plus spindles”,
change 0 ––> 1 ”NC Stop at block border”, programmed M0 or M1 or single block mode.
Signal state 0 or edge Program status “Stopped” is not present.
change 1 ––> 0
Related to .... IS ”NC Stop”
IS ”NC Stop: Axes plus spindles”
IS ”NC Stop at block border”

V3300 0003.3 Program status interrupted

Interface signal Signal(s) from channel (NCK ---> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge When changing the mode from AUTOMATIC or MDA (in program status ”Stopped”) to JOG,
change 0 ––> 1 the program status will change to “Interrupted”. The program can then be continued from the
interruption position in AUTOMATIC or MDA by pressing “NC Start”.
Signal state 0 or edge Program status ”Aborted” is not present.
change 1 ––> 0
Special cases, errors, .... The IS ”Program status: Interrupted” indicates that the part program can be continued by
restart.

V3300 0003.4 Program status aborted

Interface signal Signal(s) from channel (NCK ---> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The program is selected but not started, or the current program has been aborted with Reset.
change 0 ––> 1
Signal state 0 or edge Program status ”Aborted” is not provided.
change 1 ––> 0
Related to .... IS ”Reset”

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V3300 0003.5 Channel status active

Interface signal Signal(s) from channel (NCK ---> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge In this channel
change 0 ––> 1 - a part program or a block is currently executed in either of the modes Automatic or MDA
- at least one axis is traversed in JOG mode
Signal state 0 or edge ”Channel status ”Interrupted” or channel status ”Reset” is not present.
change 1 ––> 0

V3300 0003.6 Channel status interrupted

Interface signal Signal(s) from channel (NCK ---> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The NC part program in AUTOMATIC mode or the block in MDA mode has been interrupted
change 0 ––> 1 by ”NC Stop”, ”NC Stop for axes and spindles”, ”NC Stop at block border”, programmed M0
or M1 or single block mode.
The part program or the interrupted traversing movement can be continued with NC START.
Signal state 0 or edge ”Channel status ”Active” or channel status ”Reset” is present.
change 1 ––> 0

V3300 0003.7 Channel status Reset

Interface signal Signal(s) from channel (NCK ---> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The signal will be set to ”1” once the channel is in the RESET status, i.e. if no machining is
change 0 ––> 1 active.
Signal state 0 or edge The signal will be set to ”0” once the channel is processed.
change 1 ––> 0 Execution of a part program or block search

V3300 4001.1 Required part number reached

Interface signal Signal(s) from channel (NCK ---> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The preset number of parts to be produced is reached.
change 0 ---> 1
Depending on the setting of MD 27880: PART_COUNTER:
Bit 1 = 0: with $AC_REQUIRED_PARTS = $AC_ACTUAL_PARTS
Bit 1 = 1: with $AC_REQUIRED_PARTS = $AC_SPECIAL_PARTS
Signal state 0 or edge The preset number of parts to be produced is reached.
change 1 ---> 0

V1700 0000.5 M01 selected

Interface signal Signal(s) von MMC ---> PLC
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The program control ”Enable M1” has been selected from the user interface. The function will
change 0 ––> 1 thus not yet come into effect.
Signal state 0 or edge The program control ”Enable M1” has not been selected from the user interface.
change 1 ––> 0
Related to .... IS ”Enable M01” )
IS ”M0/M01 active”

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Operating Modes, Program Mode (K1)

V1700 0000.6 Dry run feed selected

Interface signal Signal(s) von HMI ---> PLC
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The program control ”Dry run feed” has not been selected from the user interface. The func-
change 0 ––> 1 tion will thus not yet come into effect.
Signal state 0 or edge The program control ”Dry run feed” has not been selected from the user interface.
change 1 ––> 0
Related to .... IS ”Enable dry run feed”

V1700 0001.7 Program test selected

Interface signal Signal(s) von HMI ---> PLC
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The program control ”Program test” has not been selected from the user interface. The func-
change 0 ––> 1 tion will thus not yet come into effect.
Signal state 0 or edge The program control ”Program test” has not been selected from the user interface.
change 1 ––> 0
Related to .... IS ”Enable program test”
IS ”Program test active”

V1700 0001.3 ”Feed override for rapid traverse” selected

Interface signal Signal(s) von HMI ---> PLC
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The program control ”Feed override for rapid traverse” has been selected from the user inter-
change 0 ––> 1 face. The function will thus not yet come into effect.
Signal state 0 or edge The program control ”Feed override for rapid traverse” has not been selected from the user
change 1 ––> 0 interface.
Related to .... IS ”Rapid traverse override active”

V1700 0002.0 ”Skip block” selected

Interface signal Signal(s) von HMI ---> PLC
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The program control ”Skip block” has been selected from the user interface. The function will
change 0 ––> 1 thus not yet come into effect.
Signal state 0 or edge The program control ”Skip block” has not been selected from the user interface.
change 1 ––> 0
Related to .... IS ”Enable ’Skip block’”

V1900 0000.6 Simulation active

Interface signal Signal(s) von HMI ---> PLC
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The Simulation function has been selected from the user interface.
change 0 ––> 1
Signal state 0 or edge The Simulation function has not been selected from the user interface.
change 1 ––> 0
Related to ....

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10.9 Data fields, lists

10.9.1 Channel machine data

Basic machine data of the channel

Number Identifier Name Ref.

Channel–specific
20050 AXCONF_GEOAX_ASSIGN_TAB[n] Assignment ’geometry axis – channel axis’ Chpt. 19
[GEO axis No.]: 0...2
20060 AXCONF_GEOAX_NAME_TAB[n] Geometry axis in channel Chpt. 19
[GEO axis No.]: 0...2
20070 AXCONF_MACHAX_USED[n] Machine axis number valid in channel Chpt. 19
[Channel axis No.]: 0...4
20080 AXCONF_CHANAX_NAME_TAB[n] Channel axis name in the channel Chpt. 19
[Channel axis No.]: 0...4
20100 DIAMETER_AX_DEF Geometry axis with transversal axis function P1
20700 REFP_NC_START_LOCK NC start inhibited without reference point R1
21000 CIRCLE_ERROR_CONST Circle end point monitoring constant

Auxiliary function settings of the channel

Number Identifier Name Ref.

Channel–specific)
22000 AUXFU_ASSIGN_GROUP[n] Auxiliary function group H2
[AuxFuncNo in channel]: 0...63
22010 AUXFU_ASSIGN_TYPE[n] Type of auxiliary function H2
[AuxFuncNo. in channel]: 0...63
22020 AUXFU_ASSIGN_EXTENSION[n] Auxiliary function extension H2
[AuxFuncNo. in channel]: 0...63
22030 AUXFU_ASSIGN_VALUE[n] Auxiliary function group H2
[AuxFuncNo in channel]: 0...63
22550 TOOL_CHANGE_MODE New tool offset with M function W1

Timers and counters of the channel

Number Identifier Name Ref.

Channel–specific )
27860 PROCESSTIMER_MODE Enable the program runtime measurement
27880 PART_COUNTER Enable workpiece counters
27882 PART_COUNTER_MCODE[n] Workpiece counting using M command , n = 0 ... 2

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Operating Modes, Program Mode (K1)

Display machine data

Number Identifier Name Ref.

Display MD
283 ... Display settings for the graphical simulation
293

10.9.2 Channel–specific setting data

Number Identifier Name Ref.

Channel–specific
42000 THREAD_START_ANGLE Start angle for thread
42010 THREAD_RAMP_DISP Acceleration and braking distance of feed axis on
thread cutting G33
42100 DRY_RUN_FEED Dry run feed

10.9.3 Axis/spindle–specific machine data

Number Identifier Name Ref.

Axis/spindle–specific
30600 FIX_POINT_POS Fixed–value positions of the axes with G75

10.9.4 Interface signals

Mode group signals

Number .Bit Name Ref.

PLC to NCK
V30000000 .0 AUTOMATIC mode
V30000000 .1 MDA mode
V30000000 .2 JOG mode
V30000000 .4 Mode change lock
V30000000 .7 Reset
V30000001 .2 Machine function REF

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 Operating Modes, Program Mode (K1)

Number .Bit Name Ref.

NCK to PLC
V31000000 .0 Active mode: AUTOMATIC
V31000000 .1 Active mode: MDA
V31000000 .2 Active mode: JOG
V31000000 .3 802–READY
V31000001 .2 Active machine function REF

Channel signals
Number .Bit Name Ref.
PLC to NCK
V32000000 .3 Enable DRF
V32000000 .4 Enable ”Single block”
V32000000 .5 Enable M01
V32000000 .6 IS ”Enable dry run feed”
V32000001 .0 Enable ”Referencing”
V32000001 .7 Enable ”Program test”
V32000002 .0 Skip block
V32000006 .0 Feed lock
V32000006 .1 Read–in disable
V32000006 .2 Delete distance to go
V32000006 .3 Delete number of subroutine cycles
V32000006 .4 Program level abortion
V32000006 .6 Rapid traverse override active
V32000006 .7 Feed override active
V32000007 .0 NC START inhibited
V32000007 .1 NC Start
V32000007 .2 NC Stop at block border
V32000007 .3 NC Stop
V32000007 .4 NC Stop: Axes plus spindles
V32000007 .7 Reset

Number .Bit Name Ref.

NCK to PLC
V33000000 .3 Action block active
V33000000 .4 Approach block active
V33000000 .5 M00/M01 active
V33000000 .6 Last action block active
V33000001 .0 Referencing active R1
V33000001 .4 Block search active
V33000001 .5 M2/M30 active

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Operating Modes, Program Mode (K1)

Number .Bit Name Ref.

NCK to PLC
V33000001 .7 Program test active
V33000003 .0 Program status: Running
V33000003 .2 Program status: Stopped
V33000003 .3 Program status: Interrupted
V33000003 .4 Program status: Aborted
V33000003 .5 Channel status: Active
V33000003 .6 Channel status: Interrupted
V33000003 .7 Channel status: Reset
V33004002 .1 Required parts number reached

Number .Bit Name Ref.

MMC to PLC
V17000000 .5 M01 selected
V17000000 .6 Dry run feed selected
V17000001 .3 Feed override for rapid traverse selected
V17000001 .7 Program test selected
V17000002 .0 ”Skip block” selected
V19000000 .6 Simulation active

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Feed (V1) 11
11.1 Feedrate F

Functionality
The feedrate F is the tool path velocity of the tool along the programmed workpiece contour. The
individual axis velocities result from the portion of the axis path in the total distance to be traversed
along the contour.
The feed F is active for the interpolation types G1, G2, G3, CIP,CT and remains stored in a program
until a new F word is programmed.
References: “Operation and Programming”

Measuring unit for F: G94, G95

The unit of the F word is determined by G functions:
 G94 F as the feed in mm/min or inch/min
 |G95 F as the feed in mm/spindle rotation
or inch/rev. (is only useful if the spindle is running)
The inch unit system applies to G700 or to the system setting “inch” with
MD 10240: SCALING_SYSTEM_IS_METRIC =0.

Unit for F with G96, G97

For turning machines, the group that contains G94, G95, is extended by the functions G96, G97
for the constant cutting rate (ON/OFF). These functions have an additional influence on the S
word.
With the function G96 enabled, the spindle speed is matched with the diameter of the workpiece
(transverse axis) currently machined such that a programmed cutting rate S remains constant at the
tool edge (spindle speed by diameter = constant).
From block G96, the S word will be evaluated as the cutting rate. G96 is modally active until it is
canceled by another G function of the group (G94, G95, G97).
The feed F is always rated in the measuring unit mm/revolution or
inch/revolution (as with G95).

Maximum tool path velocity

The maximum tool path velocity results from the maximum velocities of the axes involved (MD
32000: MAX_AX_VELO) and their portion in the total distance to be traversed. The maximum axis
velocity defined in the MD may not be exceeded.

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Feed (V1)

Feed override with circles CFC

When machining circle contours using milling tools and with the tool radius compensation
(G41/G42) enabled, the feedrate must be corrected at the cutter tool center to ensure that the pro-
grammed F value acts at the circle contour. With the feed override CFC enabled, internal and exter-
nal machining are detected automatically.
CFTCP can be used to switch off the feed override.
References: “Operation and Programming”

Interface signals
With revolutional feed active, the IS “Revolutional feed active” (V33000001.2) is set.
If the G96 function is enabled, the IS “Constant cutting rate active” (V390x 2002.0) is set for the
spindle.

Alarms
 If no F word is programmed with G1, G2, G3, ... , alarm 10860 is output. No axis movement
can be carried out. However, note SD 42110: DEFAULT_FEED.
 If F0 is programmed, alarm 14800 is output.
 If the spindle has stopped with G95 active, no axis movement can be carried out. No alarm is
output.

Notes
 With the “Dry run feed” function enabled and the program started, the feedrates programmed in
conjunction with G1, G2, G3, CIP and CT are replaced by the feedrate value defined in
SD 42100: DRY_RUN_FEED.
References: Section 10.4.4 “Program execution with dry run feed”
 The velocity of the traversing movement of an axis in JOG mode is defined by machine data/
setting data. For a detailed description of the velocities including possible rapid traverse overri-
de, please refer to:
References: Chapter 9 “Manual Traversing and Handwheel Traversing”

11.1.1 Feed with G33 (thread cutting)

Velocity of the axes

For G33 threads, the velocity of the axes for the thread length results from the set spindle speed
and the programmed thread pitch. The limit frequency defined in MD 32000: MAX_AX_VELO ,
however, cannot be exceeded.
The feed F will not apply in this case. It remains, however, stored.

The axis velocity, e.g. for a cylinder thread, results from the preset spindle speed (S ) and the pro-
grammed thread pitch (e.g. K):

Fz [mm/min] = speed S [rpm] * thread lead K[mm/rev.]

References: “Operation and Programming“

NC STOP, Single Block

NC STOP and Single Block are active only at the end of a velocity chain.

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 Feed (V1)

Information
 The spindle override switch should remain unchanged when machining a thread.
 The feed override switch has no meaning in a block that contains G33.

11.1.2 Feed with G63 (tapping with compensating chuck)

Feed F
With G63, a feedrate F must be programmed. It must match with the selected spindle speed S (pro-
grammed or set) and with the thread lead of the tap:
Feed F[mm/min] = speed S [rpm] x thread lead [mm/rev.]

The compensating chuck compensates any path differences of the tap axis to a certain degree.
References: “Operation and Programming”

11.1.3 Feed with G331, G332 (rigid tapping = tapping without compensating
chuck)

References: “Operation and Programming”

Axis velocity
For G331/G332 – tapping –, the axis velocity for the thread length results from the active spindle
speed S and the programmed thread lead. The limit frequency defined in
MD 32000: MAX_AX_VELO, however, cannot be exceeded.
The feed F will not apply here. It remains, however, stored.
References: “Operation and Programming”

Interface signal
With the G331/G332 function active, the IS “Rigid tapping active” (V390x 2002.3) is set for the
spindle.

Note
It is only possible to work without a compensating chuck if spindle and axis involved have been
matched another to one exactly. With G331/G332, parameter record n (0...5) of the axis will auto-
matically come into effect which is also active for the current gear stage of the spindle (M40, M41 to
M45 – see also Chapter 5 “Spindle”). As a rule, the axis of the more inert spindle will also be mat-
ched accordingly.

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Feed (V1)

11.2 Rapid traverse G0

Application
The rapid traverse movement G0 is used for quick positioning of the tool, not for direct workpiece
machining.
All axes can be traversed simultaneously. This results in a straight contour.

The maximum velocity (rapid traverse) is defined in the machine data

(MD 32000:MAX_AX_VELO ). If only one axis traverses, it will traverse at its rapid traverse. If, for
example, two path axes are traversed at the same time, the tool path velocity (resulting velocity) is
selected such that the largest tool path velocity results taking into account both axes.
For example, if two axes have maximum velocity and have also to be traversed the same distance,
the
tool path velocity will be 1.41 * max. axis velocity
(geometrical total of the two axis components).
The feedrate F will not apply with G0. It remains, however, stored.

Rapid traverse override

The operating range “Position” -> softkey ”Program control” can be enabled in AUTOMATIC mode
so that the override switch for the feed is also active for rapid traverse. If the function is active,
”ROV” is displayed in the status line. The IS “Feed override selected for rapid traverse“
(V1700 0001.3) is provided from the HMI to the PLC. This signal must be provided by the PLC user
program to the IS “Rapid traverse override active” (V3200 0006.6).

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 Feed (V1)

11.3 Feed override

11.3.1 Overview

Progr. F value Progr. S value

X axis (radius)
IS ”Enable dry run feed”
Stored
SD: DRY_RUN_FEED G96 S value
G95
(dry run
feed)
F value G97
(G94) SG96
G95/G96/G97 2*Π*X

G94
Maximum
*

Spindle override
* from machine PLC
control panel

IS ”Enable dry run feed”

Spindle set speed

G94 G95

*
100%
Feed override
from machine control
* PLC
panel 0 - xxx %
IS: Feed override active
IS: Feed override active
IS: Override active
Tool path velocity

Fig. 11-1 Possibilites of feed programming and feed control

11.3.2 Feed disable and feed/spindle stop

General
”Feed disable“ and “Feed/spindle stop” will stop the axes. The path contour will be observed
(exception: G33 block).

Feed disable
The channel–specific interface signal ”Feed disable” (V3200 0006.0) will stop all axes (geometry
and additional axes) in all operating modes.
This feed disable is not active with active G33, but it will be active for G63, G331, G332.

Feed Stop for axes in the WCS

The interface signals “Feed Stop” (V3200 1000.3, V3200 1004.3 and V3200 1008.3) will stop the
geometry axes (axes in WCS) when traversing in the workpiece coordinate system in JOG mode.

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Feed (V1)

Axis–specific FEED STOP

The axis–specific interface signal ”Feed Stop” (V380x0004.3) will stop the corresponding machine
axis. For AUTOMATIC mode, the following applies:
If ”Feed Stop” is provided for a path axis, all axes moved in the current block and involved in the
path group will be stopped.

In JOG mode, only the corresponding axis is stopped.

The axis–specific Feed Stop is active if G33 is enabled (but: In this case, contour deviations result =
thread errors!).

Spindle Stop
The interface signal ”Spindle Stop” (V380x0004.3) is used to stop the spindle.
“Spindle Stop“ is active with G33, G63 (but: In this case, contour deviations result = thread errors!).

11.3.3 Feed Override from the machine control panel

General
The operator can use the feed override switch to reduce or increase the traversed feedrate
relatively to the programmed feedrate as a percentage directly on site. The feedrates will be
multiplied with the override values.

The override possible for the feedrate is between 0 and 120%.

The rapid traverse override switch is used to run traversing programs more slowly when testing part
programs.
The rapid traverse possible for the feedrate is between 0 and 100%.

The spindle override can be used to modify the spindle speed and the cutting rate (with G96). The
override possible is between 50 and 120%.

A modification is carried out with compliance of the machine–specific acceleration and velocity
limits and without contour error.

The overrides will apply to the programmed values before the limitations (e. g. G26) come into
effect.

Channel–specific override and rapid traverse override

For feed and override, one enable signal and a bit each are provided for the override switch in per
cent.

IS ”Feed override” (VB3200 0004)

IS ”Feed override switch active” (V3200 0006.7)
IS ”Rapid traverse override” (VB3200 0005)
IS ”Rapid traverse override active (V3200 0006.6)
The interface for the override (value) is provided from a machine control panel via the PLC to the
NC in the Gray code.
An active feed override will applies to all path axes. An active rapid traverse override will apply to all
axes tha traverse at rapid traverse.

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 Feed (V1)

If no separate rapid traverse switch is provided, the feed override switch can be used whereby feed
overrides exceeding 100% will be limited to 100% rapid traverse override.
Which override will be active, can be selected either via PLC or from the operator panel.
When selection is made through the control panel (display:ROV), the IS “Feed override for rapid
traverse selected” (V1700 0001.3) is set, transferred to the IS “Rapid traverse override active”
(V3200 0006.6), and the value is to be transferred from a machine control panel to the IS “Rapid
traverse override“ (VB3200 0005) from the PLC user program.

The channel–specific feed and rapid traverse override is disabled if G33, G63 G331 and G332 are
active.

Axis–specific feed override

For each axis, one enable signal and a byte each are provided for the feed override factor in per
cent.

IS ”Feed override” (VB380x 0000)

IS ”Override active” (V380x 0000.7)
The axis–specific feed override is inactive if G33, G331, G331, G63 are enabled (internally fixed to
100%).

Spindle override
For each spindle, one enable signal and one byte each are provided for the PLC interface spindle
override factor in per cent.

IS ”Spndle override” (VB380x 0000)

IS ”Feed override active” (V380x 0000.7)
Another IS “Feed override valid for spindle” (V380x 2001.0) is provided for the PLC user program to
specify that the value of the IS “Feed override” (VB380x 0000) will apply.

The spindle override is active with G33, but should not be actuated for reasons of accuracy; is also
active with G331, G332. With G63, the spindle override is fixed to 100 %.

Override enabled
The set override values are active in all modes and for all machine functions, provided that the IS
”Rapid traverse override active”, ”Feed override active” or ”Override active” are set.

An override value of 0% will have the same effect as feed disable.

Override disabled
If the override is disabled (above interface signals are set to ”0”), override factor ”1” will be used
internally in the NC, i.e. the override will be 100%.
Note:
A special characteristic for this value is the 1st switch position of the Gray–coded interfaces. Even if
the IS “Rapid traverse override active”, “Feed override active” and “Override active”, the override
factor of the 1st switch position will be used and 0 % will thus be output as the override value for the
axes (has the same effect as “Feed disable”). Override value 50 % will apply to the spindle if the IS
“Override active” is not set.

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Feed (V1)

11.4 Data descriptions (MD, SD)

Setting data, channel–specific

42110 DEFAULT_FEED
SD number Default value for feedrate
Default: 0.0 Min. input limit: 0.= Max. input limit: ***
Change valid: immediately Protection level: 7/7 Unit:
mm/min, mm/rev.
Data type: DOUBLE Valid from SW release:
Meaning: The setting data is evaluated at part program start, taking into account the feedrate type of the
default setting after turning on.
Default settings when turning on:
Turning: G95 – feedrate in mm/rev. of spindle
Milling: G94 – feedrate in mm/min
If no F word is programmed for the appropriate feedrate type with G1, G2, G2, ... and the SD
value is not zero, the feedrate from this SD will be used. Otherwise, an alarm is output with a
notice that the feedrate is missing.
SD inapplicable to ...... Turning: G94 programmed
Milling: G95 programmed
Related to ....

11.5 Signal descriptions

11.5.1 Channel–specific signals

V3200 0000.6 Enable dry run feed

Interface signal Signal(s) to channel (PLC → NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge SD 42100: DRY_RUN_FEED will be used instead of the programmed feed (with G1, G2, G3,
change 0 --->1 CIP, CT).
The interface signal is evaluated on NC Start if the channel was in the RESET state.
When using the selection via PLC, the interface signal ”Enable dry run feed” must be set from
the PLC user program.
Signal state 0 or edge The programmed feed will be used for traversing.
change 1 --->0 active after RESET state
Application example(s) Testing a workpiece at increased feedrate.
Related to .... IS “Dry run feed selected” (V1700 0000.6)
SD 42100: DRY_RUN_FEED (dry run feed)

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 Feed (V1)

VB3200 0004 Feed override

Interface signal Signal(s) to channel (PLC → NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge Table 11-1 Gray coding for the feed override
change 0 --->1
Switch Feed override factor
position Code Max. input limit:
1 00001 0.0
2 00011 0.01
3 00010 0.02
4 00110 0.04
5 00111 0.06
6 00101 0.08
7 00100 0.10
8 01100 0.20
9 01101 0.30
10 01111 0.40
11 01110 0.50
12 01010 0.60
13 01011 0.70
14 01001 0.75
15 01000 0.80
16 11000 0.85
17 11001 0.90
18 11011 0.95
19 11010 1.00
20 11110 1.05
21 11111 1.10
22 11101 1.15
23 11100 1.20
24 10100 1.20
25 10101 1.20
26 10111 1.20
27 10110 1.20
28 10010 1.20
29 10011 1.20
30 10001 1.20
31 10000 1.20
Related to .... IS ”Feed override active” (V3200 0006.7)

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Feed (V1)

VB3200 0005 Rapid traverse override

Interface signal Signal(s) to channel (PLC → NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge
change 0 --->1 Table 11-2 Gray coding for the rapid traverse override

Switch Code Rapid traverse override

position Max. input limit:

1 00001 0.0
2 00011 0.01
3 00010 0.02
4 00110 0.04
5 00111 0.06
6 00101 0.08
7 00100 0.10
8 01100 0.20
9 01101 0.30
10 01111 0.40
11 01110 0.50
12 01010 0.60
13 01011 0.70
14 01001 0.75
15 01000 0.80
16 11000 0.85
17 11001 0.90
18 11011 0.95
19 11010 1.00
20 11110 1.00
21 11111 1.00
22 11101 1.00
23 11100 1.00
24 10100 1.00
25 10101 1.00
26 10111 1.00
27 10110 1.00
28 10010 1.00
29 10011 1.00
30 10001 1.00
31 10000 1.00
Related to .... IS ”Rapid traverse override active”

V3200 0006.0 Feed disable

Interface signal Signal(s) to channel (PLC → NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The signal of a channel is active in all operating modes.
change 0 --->1  The signal results in feed disable for all axes involved in interpolation provided G33
(thread) is not active.
All axes will be stopped with compliance of the path contour. If the feed disable (0 signal)
has been canceled, the interrupted part program will be continued.
 The position control remains stored, i.e. the following error will be reduced.
 If for an axis for which Feed Disable is provided, a traversing request is provided, this will
remain stored. The traversing request provided will be carried out directly at the moment
when ”Feed disable” is canceled.
If the axis in question interpolates with other axes, this will also apply to these axes.
Signal state 0 or edge  The feed is enabled for all axes of this channel.
change 1 --->0  If a traversing request (”Traversing command”) is provided for an axis or an axis group if
”Feed disable” is canceled, this will be carried out directly.
Special cases, errors, .... “Feed disable” is disabled if G33 is enabled.

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 Feed (V1)

V3200 0006.6 Rapid traverse override active

Interface signal Signal(s) to channel (PLC → NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The rapid traverse override 0 to max. 100 % entered in the PLC interface acts
change 0 --->1 channel–specifically.
Signal state 0 or edge The rapid traverse override entered in the PLC interface will not be taken into account.
change 1 --->0 If the rapid traverse override is disabled, 100 % will be used internally in the NC as the
override factor.
Note:
An exception for this value is the 1st switch position of the Gray coded interface. In this case,
this override factor is used even if “Rapid traverse override” is inactive, and 0 % is output as
the override value for the axes.
Special cases, errors,..... The rapid traverse override is disabled if G33 is active.
Related to .... IS ”Rapid traverse override”

V3200 0006.7 Feed override active

Interface signal Signal(s) to channel (PLC → NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The feed override 0 to max. 120 % entered in the PLC interface is active for the tool feed and
change 0 --->1 thus automatically for the corresponding axes.
In JOG mode, the feed override is directly active for the axes.
Signal state 0 or edge The feed override entered in the PLC interface will not be taken into account.
change 1 --->0 If feed override is active, 100 % will be used internally in the NC as the override factor.
Note:
An exception for this value is the 1st switch position of the Gray coded interface. In this case,
this override factor is used even if “Rapid traverse override” is inactive, and 0 % is output as
the override value for the axes.
Special cases, errors, .... The feed override is disabled if G33 is active.
Related to .... IS ”Feed override”

V3200 1000.3
and Feed Stop Geo axes (axes in WCS)
V3200 1008.3
Interface signal Signal(s) to channel (PLC → NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The signal is only active in JOG mode (traversing the axes in the WCS).
change 0 --->1  Signal results in Feed Stop of the corresponding axis. For a traversing axis, this signal
results in a controlled deceleration up to standstill (ramp stop). No alarm message is
provided in this case.
 The position control remains stored, i.e. the following error will be reduced.
 If for an axis for which ”Feed Stop” is provided, a traversing request is provided, this will
remain. This traversing request will be carried out directly at the moment when ”Feed
Stop” is canceled.
Signal state 0 or edge  The feed for the axis is enabled.
change 1 --->0  If a traversing request (”traversing command”) is provided for the axis when ”Feed Stop”
is canceled, this will be carried out directly.

V1700 0000.6 Dry run feed selected

Interface signal Signal(s) to channel (HMI → PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge Dry run feed selected.
change 0 –––> 1 Instead of the programmed feed, the dry run feed entered in SD 42100: DRY_RUN_FEED
will be active.
If dry run feed is enabled from the operator panel, the signal will automatically be entered in the
PLC interface and transferred by the PLC basic program to the PLC interface signal ”Enable dry
run feed”.
Signal state 0 or edge Dry run feed is not selected.
change 1 –––> 0 The programmed feed is active.
Related to .... IS ”Enable dry run feed” (V3200 0000.6)
SD: DRY_RUN_FEED (dry run feed)

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Feed (V1)

V1700 0001.3 Feed override for rapid traverse selected

Interface signal Signal(s) to channel (HMI → PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The feed override switch will also be used as the rapid traverse override switch.
change 0 –––> 1 Any overrides exceeding 100% will be limited to the maximum value of 100% rapid traverse
override.
The IS ”Feed override for rapid traverse selected” will automatically be entered from the operator
panel in the PLC interface and transferred by the PLC basic program to the PLC interface signal
”Rapid traverse override active”.
Furthermore, the IS ”Feed override” (VB3200 0004) will be copied from the PLC basic program
to the IS ”Rapid traverse override” (VB3200 0005).
Signal state 0 or edge The feed override will not also be used as the rapid traverse override switch.
change 1 –––> 0
Application example(s) This signal is used if no separate rapid traverse override switch is provided.

Signals from channel

V3300 0001.2 Revolutional feed active

Interface signal Signal(s) from channel (NCK → PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge When programming G95 (rotation speed) in automatic mode.
change 0 –––> 1
Application example(s)
Related to ....

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 Feed (V1)

11.5.2 Axis/spindle–specific signals

Signals to axis/spindle

VB380x 0000 Feed override (axis–specific)

Interface signal Signal(s) to axis (PLC → NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The axis–specific feed override is specified from the PLC using the Gray code.
change 0 ---> 1

Switch Code Axial feed override

position factor

1 00001 0.0
2 00011 0.01
3 00010 0.02
4 00110 0.04
5 00111 0.06
6 00101 0.08
7 00100 0.10
8 01100 0.20
9 01101 0.30
10 01111 0.40
11 01110 0.50
12 01010 0.60
13 01011 0.70
14 01001 0.75
15 01000 0.80
16 11000 0.85
17 11001 0.90
18 11011 0.95
19 11010 1.00
20 11110 1.05
21 11111 1.10
22 11101 1.15
23 11100 1.20
24 10100 1.20
25 10101 1.20
26 10111 1.20
27 10110 1.20
28 10010 1.20
29 10011 1.20
30 10001 1.20
31 10000 1.20

Table 11-3 Gray coding for the axis–specific feed override

Related to .... IS ”Override active”

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Feed (V1)

VB380x 2003 Spindle override

Interface signal Signal(s) to spindle (PLC → NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The spindle override is specified from the PLC using the Gray code.
change 0 ---> 1 The override value determines the percentage of the programmed speed setpoint provided
to the spindle.

Switch Code Spindle override factor

position

1 00001 0.5
2 00011 0.55
3 00010 0.60
4 00110 0.65
5 00111 0.70
6 00101 0.75
7 00100 0.80
8 01100 0.85
9 01101 0.90
10 01111 0.95
11 01110 1.00
12 01010 1.05
13 01011 1.10
14 01001 1.15
15 01000 1.20
16 11000 1.20
17 11001 1.20
18 11011 1.20
19 11010 1.20
20 11110 1.20
21 11111 1.20
22 11101 1.20
23 11100 1.20
24 10100 1.20
25 10101 1.20
26 10111 1.20
27 10110 1.20
28 10010 1.20
29 10011 1.20
30 10001 1.20
31 10000 1.20

Table 11-4 Gray coding for spindle override

Related to .... IS ”Override active” (V380x 0001.7)
IS ”Feed override active for spindle“ (V380x 2001.0)

V380x 2001.0 Feed override active for spindle (instead of spindle override)
Interface signal Signal(s) from axis/spindle ( PLC ->NCK )
Edge evaluation: yes Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge Instead of the spindle override value, the feed override value (VB38030000) will be used for
change 0 ---> 1 the spindle.
Signal state 0 or edge The spindle override value will be used.
change 1 ---> 0
Related to .... IS ”Spindle override” (VB380x 2003)
IS ”Feed override” (VB380x 0000)
IS ”Override active” (V380x 0001.7)

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 Feed (V1)

V380x 0001.7 Override active

Interface signal Signal(s) to axis/spindle (PLC → NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge Feed override active:
change 0 ---> 1  The axis–specific feed override 0 to max. 120 % entered in the PLC interface will be
taken into account.
Spindle override active:
 The spindle override 0 to max. 120 % entered in the PLC interface will be taken into
account.
Signal state 0 or edge The present axis–specific feed override or spindle override is inactive.
change 1 ---> 0 If the override is not active, 100 % will be used internally in the NC as the override factor.
Note:
An exception for this value is the 1st switch position of the Gray coded interface. In this case,
this override factor is used even if “Override” is inactive, and 0 % is output as the override
value for the axes (has the same effect as “Feed disable”); for the spindle correspondingly
50 %.
Special cases, errors, ....  In spindle mode ”Oscillation”, the spindle override is always supposed to be 100 %.
 The spindle override effects the programmed values before the limitations
(e. g. G26) come into effect.
 The feed override is disabled if G33 is active.
Related to .... IS ”Feed override” and IS “Spindle override”

V380x 0004.3 Feed Stop/Spindle Stop (axis–specific)

Interface signal Signal(s) to axis/spindle (PLC → NCK)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The signal is active in all operating modes.
change 0 ---> 1 Feed Stop:
 Signal results in Feed Stop of the corresponding axis. For a traversing axis, this signal
results in a controlled deceleration up to standstill (ramp stop). No alarm message is
provided in this case.
 This signal results in Feed Stop for all axes interpolating if ”Feed Stop” is provided for one
of the path axes. In this case, all axes will be stopped, observing the path contour. After
canceling the Feed Stop signal, the interrupted part program will be continued.
 The position control remains stored, i.e. the following error will be reduced.
 If a traversing request is provided for an axis for which ”Feed Stop” is provided, this will
remain stored. This traversing request will be carried out directly at the moment when
”Feed Stop” is canceled.
If the axis interpolates with other axes, this will also apply to these axes.
Spindle Stop:
 The spindle will be decelerated to a standstill along its deceleration characteristic.
 In positioning mode, the positioning process will be aborted by setting the signal ”Spindle
Stop”. The behavior above applies to single axes.
Signal state 0 or edge Feed Stop:
change 1 ---> 0  The feed for the axis is enabled.
 If a traversing request (”traversing command”) is provided for the axis when ”Feed Stop”
is canceled, this will be carried out directly.
Spindle Stop:
 The speed is enabled for the spindle.
 If “Spindle Stop” is canceled, the spindle is accelerated to the previous speed setpoint
along its acceleration constant or, in positioning mode, the positioning is continued.
Application example(s) Feed Stop:
 The traversing movements of the machine axes will not be started with “Feed Stop” if,
e.g. certain operating states are provided on the machine which do not allow an axis
movement (e. g. door not closed).
Spindle Stop:
 to carry out a tool change.
Special cases, errors, ....

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Feed (V1)

11.6 Data fields, lists

11.6.1 Interface signals

Number .Bit Name Ref.

Channel–specific
V3200 0000 .6 Enable dry run feed
V3200 0004 – Feed override
V3200 0005 Rapid traverse override
V3200 0006 .0 Feed disable
V3200 0006 .6 Rapid traverse override active
V3200 0006 .7 Feed override active
V3200 1000 .3 Feed stop, geometry axis 1
V3200 1004 .3 Feed stop, geometry axis 2
V3200 1008 .3 Feed stop, geometry axis 3
V1700 0000 .6 Dry run feed selected
V1700 0001 .3 Feed override selected for rapid traverse
V3300 0001 .2 Revolutional feed active
Axis/spindle–specific
VB380x 0000 – Feed override
VB380x 2003 – Spindle override
V380x 0001 .7 Override active
V380x 2001 .0 Feed override for spindle active
V380x 0004 .3 Feed Stop / Spindle Stop
V390x 2002 .0 Constant cutting rate active (spindle) S1
V390x 2002 .3 Rigid tapping active (spindle) S1

11.6.2 Machine data/setting data

Number Identifier Name Ref.

General machine data
10240 SCALING_SYSTEM_IS_METRIC Scaling system, metric G1
Axis–specific machine data
32000 MAX_AX_VELO Maximum axis velocity G1
35100 SPIN_VELO_LIMIT Maximum spindle speed S1
Channel–specific setting data
42100 DRY_RUN_FEED Dry run feed K1
42110 DEFAULT_FEED Default value for feedrate

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Continuous–Path Mode, Exact Stop
and LookAhead (B1) 12
12.1 Brief description

In continuous–path mode, the CNC executes a part program block by block. Only if the functions of
the block currently executed have been completed, the next block is started. Various demands pla-
ced on machining and positoning require various block change criteria. Two behaviors are to be
found at the block borders for the path axes.
The first type, “Exact stop”, means that all path axes must have reached the given target position
depending on an exact stop criterion before the next block change is initiated. To be able to fulfill
this criterion, the path axes must reduce their tool path velocity what, however, will result in a delay
of the block change. The second type, “Continous–path mode”, is used to try to avoid decelerating
of the tool path rate at the block border to be able to change to the next block at the same tool path
velocity (if possible).
“LookAhead” is a method, which is used in continuous–path mode to determine a velocity control
looking ahead for several NC program blocks.

12.2 General

Interpolating machine axes must have the same dynamic behavior, i.e. the same following error
must occur at a the same velocity.

Path axes are all machining axes that are controlled by an interpolator that determines the path
points so that

 all involved axes will start at the same time;

 each involved axis will traverse at the correct velocity ratio;
 all axes will reach the programmed target position at the same time.
The accelerations of the individual axes may be different depending on the path to be traversed,
such as a circle.
Path axes may be geometry axes or supplementary axes (e.g. workpiece rotary axes involved in the
workpiece machining).

Velocity at zero–cycle blocks

Zero–cycle blocks are blocks whose path length is shorter than the path that can be covered using
the programmed set feedrate and the interpolation cycle (time). For accuracy reasons, the velocity
is reduced such that traversing along the path takes at least one interpolator cycle. The velocity is
thus equal to or less than the quotient of the path length of the block divided by the IPO cycle.

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Continuous–Path Mode, Exact Stop and LookAhead (B1)

Stopping for synchronization

Irrespective of whether exact stop or continuous–path mode is selected, the block change may be
delayed by synchronization processes and can thus cause a stop of the path axis. In exact stop
mode, the path axes are stopped at the end point of the current block. In continuous path mode, the
path axes are stopped in this situation at the next block end point, where they can be braked kee-
ping their acceleration limits. A stop is carried out for synchronization
 on PLC acknowledgement.
If the acknowledgement by the PLC is required for an auxiliary function output before or after the
end of a motion, the stop is carried out at block end.
 if there are no more following blocks.
If following blocks cannot or not quickly enough be prepared (e.g. “Execution from external
source”), the stop is carried out at the last approachable block limit.
 when emptying the buffer.
If it is required in the NC part program to synchronize the initial part of the program with the main
run (empty buffer, e.g. STOPRE), a block–related velocity reduction and/or an exact stop is impli-
citly connected with it.
No contour errors occur when stopping for synchronization. However, the stop is not desired espe-
cially in contiuous path mode, since a relief cut can occur.

12.3 Exact Stop

The Exact Stop function (G60, G9) is used to wait for the path axes running in to the programmed
block end point. If all path axes have reached the exact stop criterion, the block change is carried
out. The velocity at the block transition is nearly zero.

This means:
 that the path axes at the block end point come nearly to a standstill without overshooting.
 the machining time is exceeded due to the waiting time to achieve the exact stop criterion.
 relief cutting may occur due to the waiting time to achieve the exact stop criterion.
The exact stop function is suited for exact traversing along contours.

Exact stop is not recommended if

 the exact curve within the framework of a criterion (e.g. exact stop fine) may deviate from the
programmed criterion to make the machining faster.

 absolute velocity tolerance is required.

Enabling Excact Stop

The Exact Stop function can be selected in the NC part program using the command G60 or G9.
G60 is modally active, G9 non–modal. G09 is used to interrupt continuous path mode. The two ex-
act stop functions are only active with the selected exact stop criterion (G601, G602). The exact
stop function is deselected using the continuous path mode function G64.

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 Continuous–Path Mode, Exact Stop and LookAhead (B1)

Exact stop criteria

 Exact stop fine: G601
This criterion is used to monitor whether the distance of axis actual position from the set position
is within a certain range. The size of this distance is defined in MD 36010: STOP_LIMIT_FINE
(exact stop fine).
 Exact stop coarse: G602
The same functionality as exact stop fine, but the monitoring window is defined in MD 36000:
STOP_LIMIT_COARSE (exact stop coarse). To achieve a faster block change compared with
the criterion ’exact stop fine’, the exact stop coarse window must be parameterized larger than
the exact stop fine window.

Block change times

v t1=interpolator end
Actual value with G602
with G601

Set value
Exact stop coarse > Exact stop fine

t1 t

Fig. 12-1 Block change according to the exact stop criteria

Interpolator end
The interpolator end is reached when the interpolator has calculated the setpoint velocity of the
axes to the amount of zero for one interpolation clock pulse. However, the actual positions of the
path axes have not reached the target (following error).
The auxiliary functions contained in the block are transferred to the PLC with interpolator end, irres-
pective of the continuous path mode and/or the active exact stop criterion of the exact stop function,
provided that these auxiliary functions are output after end of motion.

12.4 Continuous path mode

12.4.1 General

In continuous path mode, the path velocity is not decelerated for block change at the end of block to
a velocity which allows to reach the exact stop criterion. The objective is to avoid a major braking of
the path axes at the block change point in order to switch over to the next block at the same tool
path velocity if possible. In order to achieve this objective, the LookAhead function is activated in
addition to the selection of the continuous path mode (G64) (refer to Section 12.5).

The continuous path mode causes :

 a rounding of the contour.
 shorter processing times due to missing braking and acceleration procedures, which are requi-
red for reaching the exact stop criterion.
 better cutting conditions due to the more uniform velocity characteristic.
Continuous path mode is useful if a contour is to be traversed rapidly.

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Continuous–Path Mode, Exact Stop and LookAhead (B1)

Continuous path mode is not useful if:

 a contour is to be traversed exactly.

 an absolute constant velocity is required.

Implied exact stop

In some cases, an exact stop must be generated in continuous path mode to be able to carry out
the following actions. In such situations, the path velocity is braked down to zero.
 If auxiliary functions are output prior to the traversing motion, the previous block is only comple-
ted when the selected exact stop criterion is reached.
 If auxiliary functions are output after the traversing motion, these are output after interpolator end
of the block.
 If an executable block does not contain any traversing information for the path axes, the pre-
vious block is completed when the selected exact stop criterion is reached.
 A block is completed at interpolator end, if the switch–over of the acceleration profile BRISK/
SOFT is carried out in the following block.
 If the function “Empty buffer” (STOPRE) is programmed in the part program, the previous block
is completed when the selected exact stop criterion is reached.

Velocity = 0 in continuous path mode

Irrespective of the implied exact stop, the path motion is braked down to zero at the block end, if:
 the time for the positioning of a spindle is longer using SPOS than the traversing time of the path
axes. The block change is carried out when the exact stop fine of the spindle to be positioned is
reached.
 a synchronization is required (see Section 12.2).

Auxiliary function output during traversing

If the traversing time is not sufficient due to the programmed path length and the velocity of the
block with auxiliary function output, the tool path velocity for the block is pre–emptively reduced in
such a way that the acknowledgement of the auxiliary function can be provided within a PLC cycle
time. If the acknowledgement is not carried out within a PLC cycle time, the following prepared block
cannot be executed, and the axes are stopped immediately with setpoint specification = 0 (without
taking into account the acceleration limits). If also in long blocks the velocity acknowledgement is
not provided by the end of the block, in which it was not necessary to reduce the velocity due to the
PLC acknowledgement time, the velocity is retained by the end of the block and is reduced as des-
cribed above. If the acknowledgement is provided during the braking process, no acceleration to the
desired speed is carried out.

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 Continuous–Path Mode, Exact Stop and LookAhead (B1)

12.4.2 Velocity reduction according to the overload factor

Function
This function reduces the traversing rate in continuous path mode such that the non–tangential
block transition can be overrun in one interpolator clock pulse, keeping the acceleration limit and
taking into account the overload factor. The velocity reduction causes sudden axis–specific velocity
changes if the contour characteristic at the block end is not tangential. The synchronous axes invol-
ved in traversing will also be involved in these sudden velocity changes. The sudden velocity chan-
ge avoids a reduction of the traversing rate to zero. The sudden velocity change is carried out if the
axial velocity with the axis acceleration has been reduced to a velocity from which the new setpoint
value can be reached by the sudden velocity change. The amount of the sudden change of the set-
point can be limited using the overload factor criterion. Since the amount of the sudden change is
axis–related, the smallest amount of the sudden change is taken into account at the block transition
of the path axes active during block change. In case of an almost tangential block transition, the
path velocity is not reduced, if the admissible axes accelerations are not exceeded. This allows to
overrun very small bends in the contour.

Overload factor
The overload factor limits the sudden velocity change (further referred to as ’velocity jump’) of the
machine axis at the block transition. To make sure that the velocity jump does not exceed the axis
load, the jump is deduced from the acceleration of the axis. The overload factor specifies by what
amount the acceleration of the machine axis can be exceeded for an IPO clock pulse, which is sto-
red in MD 32300: MAX_AX_ACCEL (axis acceleration). The velocity stroke is the product of the axis
acceleration * (overload factor –1) * interpolator clock pulse. The overload factor is 1.2.
Factor 1.0 means that only tangential transitions can be overrun at an endless velocity. In the case
of any other transitions, the velocity will be reduced to zero due to the setpoint settings.

Selection and deselection of the velocity reduction

The modal selection of continuous path mode with velocity reduction can be carried out according to
the overload factor in each NC part program block using program code G64 (BRISK active, not
SOFT).
The continuous path mode G64 can be
 interrupted by selecting the exact stop G9 block by block;
 deselected by selecting exact stop G60.

12.4.3 Velocity reduction for jerk limitation on the path

Introduction
The jerk limitation on the path is another method for controling the continuous path mode. Whereas
”Velocity reduction according to overload factor” (see Section 12.4.2) limits the change in the veloci-
ty, the ”Jerk limitation on the path” as described here limits acceleration jumps (jerks).

In contour elements consisting of partial pieces (e.g. circle – straight line transitions), acceleration
jumps occur at the block transition in continuous path mode.
References: Section ”Acceleration”.

SINUMERIK 802DDescription of Funktions

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Continuous–Path Mode, Exact Stop and LookAhead (B1)

Jerk reduction
Jerks can be reduced by reducing the tool path velocity at block transitions with path elements ha-
ving various bends of different kind. A smoother transition is achieved between the contour ele-
ments.

Jerk limit
The user defines the maximum jerk using MD 32432: PATH_TRANS_JERK_LIM (maximum axis–
specific jerk of a path axis at the block transition), which is allowed to occur in a path axis at block
transition.

Enabling
The jerk limitation at block transitions becomes active if continuous path mode with G64 and acce-
leration behavior SOFT are programmed. MD 32432: PATH_TRANS_JERK_LIM must have a posi-
tive value.

12.4.4 Machine axis–specific jerk limitation

Function
The axis–specific machine data MD 32431: MAX_AX_JERK[..] can be used to set the acceleration
change for each machine axis separately, as it is already done for the acceleration limitation using
machine data MD 32300: MAX_AX_ACCEL[..]. MD 32431: MAX_AX_JERK[..] is active for the axes
interpolated by the path and for which SOFT (jerk–free acceleration curve) is active within the
block.
Generally, a distinction is made between the axis acceleration curve within a block and at the transi-
tion between two blocks.

Advantages
To use axis–specific machine data for the path has the following advantages:

 The dynamic properties of the axes are directly taken into account by interpolation and can be
utilized completely for each indiividual axis.
 The limitation of the jerk per axis is kept not only in linear blocks, but also in curved contours.
References: Section ”Acceleration”.

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 Continuous–Path Mode, Exact Stop and LookAhead (B1)

12.5 LookAhead

Function
LookAhead is a procedure in continuous path mode (G64), which can pre–emptively determine the
velocity control beyond the current block for several NC part program blocks.
Without LookAhead: If the programmed blocks contained only very small distances to be traversed,
a velocity was reached per block which allowed braking of the axes at the block end point, obser-
ving the acceleration limits. This meant that the programmed velocity was not reached at all,
although a sufficient number of prepared blocks with almost tangential path transitions was present.
With LookAhead function: It is possible to carry out the acceleration and deceleration phases over
several blocks with almost tangential block transitions and thus to obtain a higher feedrate for small
distances. In this way, there is a pre–emptive braking with regard to the velocity limitations, so that a
violation of the acceleration and velocity limits is avoided.

Feed
G64 continuous path mode with Look Ahead

Programmed feed F
F1

G60 – exact stop

N1 N2 N3 N4 N5 N6 N7 N8 N9 N10 N11 N12 Block distance

Fig. 12-2 Comparison of the velocity behavior G60 and G64 with short paths in the blocks

LookAhead takes into account foreseeable velocity limitations such as

 velocity limitation in the block

 acceleration limitation in the block
 velocity limitation at the block transition
 synchronization with block change at the block transition
 exact stop at the block end upon completion

Method of operation
The LookAhead functionality is only available for the path axes and not for the spindle.

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Continuous–Path Mode, Exact Stop and LookAhead (B1)

For safety reasons, the velocity at the block end of each block prepared is first deemed to be zero,
since the following block or an exact stop block could be very small and the axes are to have re-
ached standstill at the block end point. In a sequence of blocks with a high setpoint velocity and
very short path distances, the velocity in the individual blocks can be increased depending on the
current predicted velocity value, in order to reach the required setpoint velocity, and can then be
reduced again, to allow the velocity at the block end point of the last predicted following block to
become zero. In this way, you will get a saw–tooth velocity profile, which can be avoided by redu-
cing the setpoint velocity in the predicted block number (firmly preset).

Velocity profiles
Apart from the firmly foreseeable velocity limitations, LookAhead can also include the programmed
velocity. This allows to pre–emptively attain the smaller velocity beyond the current block.

Following block velocity

A possible velocity profile includes the detection of the following block velocity. On the basis of the
information from the current and the following NC blocks, a velocity profile is calculated, from which
the required velocity reductions for the current override are deducted. The maximum value of the
velocity profile found is limited by the maximum path velocity. This function allows to start a velocity
reduction in the current block taking into account the override, so that the smaller velocity of the fol-
lowing block can be reached at the beginning of the following block. If the reduction of the velocity
takes longer than the traversing time of the current block, the speed is further reduced in the follo-
wing block. The velocity control is always only taken into account only for the following block.

Selection and deselection of LookAhead

LookAhead is selected by selecting continuous path mode G64 and canceled by G60/G9.

12.6 Data descriptions (MD, SD)

12.6.1 Channel–specific machine data

29000 LOOKAH_NUM_CHECKED_BLOCKS
MD number Number of LookAhead blocks
Default: 10 Min. input limit: *** Max. input limit: ***
Change valid after NEW_CONF Protection level: 1/7 Unit: –
Data type: DWORD Valid from SW release:
Meaning: Max. number of blocks used with LookAhead for pre–emptive velocity control
Related to ....

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 Continuous–Path Mode, Exact Stop and LookAhead (B1)

12.6.2 Axis–specific machine data

32432 PATH_TRANS_JERK_LIM
MD number Max. axis–specific jerk with path movement at the block transition
Default: 1000.00 m/s3 Min. input limit: 0.0 Max. input limit: ***
2777.77 rev./s3
Change valid after NEW_CONF Protection level: 3/3 Unit: m/s3, rev./s 3
Data type: DOUBLE Valid from SW release:
Meaning: The control system will limit the jerk (acceleration jump) at the block transition from discontinuously
curved contour elements to the preset value.
MD inapplicable ...... Exact stop
Application example(s)
Related to .... Continuous path mode, acceleration type SOFT
MD 32431: MAX_AX_JERK (max. axis–specific jerk with path movement)
It is recommended to set both MDs to the same value.

12.7 Signal descriptions

12.7.1 Channel–specific signals

V3300 00004.3 All axes are stopped

Data block Signal(s) from channel (NCK –> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge All axes of the channel are stopped with interpolator end. No further traversing motions are
change 0 –––> 1 present.

12.7.2 Axis–specific signals

V390x 0000.6 Position reached with exact stop coarse

Data block Signal(s) from axis/spindle (NCK –> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The axis is at the appropriate exact stop and no interpolator is active for the axis; furthermore,
change 0 –––> 1 – the control system is in reset state (Reset key and/or program end).
– the axis has been programmed last as a positioning spindle.
– the path movement has been terminated by NC stop.
– the spindle is in position–controlled mode and at a standstill.
– the axis is switched from speed–controlled mode to position–controlled mode using the IS
“Position measuring system“.
Signal state 0 or edge The axis is not at the appropriate exact stop or the interpolator is active for the axis or
change 1 –––> 0 – the path movement has been terminated by NC stop.
– the spindle is in speed–controlled mode.
– Parking mode is active for the axis.
– the axis is switched from position–controlled mode to speed–controlled mode using the IS
“Position measuring system“.
Signal inapplicable .....
Related to .... MD 36000: STOP_LIMIT_COARSE (exact stop coarse)

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Continuous–Path Mode, Exact Stop and LookAhead (B1)

V390x0000.7 Position reached with exact stop fine

Data block Signal(s) from axis/spindle (NCK –> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge See IS ”Position reached with exact stop coarse”.
change 0 –––> 1
Signal state 0 or edge See IS ”Position reached with exact stop coarse”
change 1 –––> 0
Signal inapplicable ...
Related to .... MD 36010: STOP_LIMIT_FINE (exact stop fine)

12.8 Data fields, lists

12.8.1 Interface signals

Number .Bit Name Ref.

Channel–specific
V33000004 .3 All axes are at standstill
Axis/spindle–specific
V390x0000 .6 Position reached with exact stop coarse
V390x0000 .7 Position reached with exact stop fine

12.8.2 Machine data

Number Identifier Name Ref.

Channel–specific
29000 LOOKAH_NUM_CHECKED_BLOCKS Number of LookAhead blocks
Axis/spindle specific
32431 MAX_AX_JERK Max. axis–specific jerk for path movement B2
32432 PATH_TRANS_JERK_LIM Max. axis–specific jerk for path movement at
block transition
36000 STOP_LIMIT_COARSE Exact stop coarse A3
36010 STOP_LIMIT_FINE Exact stop fine A3
36020 POSITIONING_TIME Delay time for exact stop fine A3

SINUMERIK 802DDescription of Funktions

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Output of Auxiliary Functions to the PLC (H2) 13
13.1 Brief description

Auxiliary functions
In addition to axis positions and interpolation types, technological functions (feed, spindle speed,
gear step) and functions to control any additional facilities on the machine tool (sleeve forward, open
gripper, clamp chuck) can be specified for the machining of workpieces in the part program. To this
aim, auxiliary functions are provided.

Auxiliary functions divide into:

 Miscellaneous function M
 Spindle function S
 Auxiliary function H
 Tool number T
 Tool offset D
 Feed F (With SINUMERIK 802D, F is not output to the PLC.)

Output of auxiliary functions to the PLC

The auxiliary function output is used to tell the PLC in due time when the part program wants to per-
form, e.g. certain switching actions on the machine tool to be carried out by the PLC. This is carried
out by transferring the appropriate auxiliary functions, including their parameters, to the PLC. The
processing of the values and signals transferred must be carried out by the PLC user program. The
individual forms of auxiliary function configuration, programming and modes of functioning will be
described in the following Section.

Auxiliary function groups

Auxiliary functions can be summarized in groups.

13.2 Programming of auxiliary functions

General structure of an auxiliary function

Identifier[address extension]=value

The identifiers permitted for auxiliary functions are:

M, S, H, T, D, F.

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Output of Auxiliary Functions to the PLC (H2)

An address extension is only provided for the H function. The address extension must be integer.
With direct specification of the address extension using a numerical value, the brackets may be
omitted.
The value for the individual auxiliary functions is defined differently (INT = integer or REAL = fractio-
nal decimal number (floating point)).

Table 13-1 Overview of auxiliary functions; programming

Func- Address extension Value Explanation Num-

tion (integer) ber per
block
Meaning: Range Range Type Meaning:
M – – 0–99 INT Function Certain numbers is assi- 5
gned a fixed function
S – – 0– 3.4028 ex 38 REAL Spindle speed 1

H any 0–99 ±3.4028 ex 38 REAL any These functions have no 3

effect in the NCK and
must be realized exclusi-
vely by the PLC.
T – – 0–32000 INT Tool selection 1

D – – 0–9 INT Tool offset se- D0 deselection, 1

lection default value D1
F – – 0.001– REAL Feedrate 1
999 999.999

Max. 10 auxiliary functions may be programmed in a block. If the specified ranges or values for ad-
dress extension are exceeded or a wrong data type is taken into account, alarm 14770 ”Auxiliary
functions incorrectly programmed” is output. The following Table shows some programming exam-
ples for H functions.

If the permissible number of auxiliary functions per block is exceeded, alarm 12010 is output.

Table 13-2 Programming examples for H functions

Programming H function output to the PLC

H5 H0=5.0
H=5.379 H0=5.379
H17=3.5 H17=3.5
H5.3=21 Error, alarm 14770

Block change
The NCK can carry out a new auxiliary function output to the PLC only after the PLC has acknow-
ledged all auxiliary functions transferred.
A block is only considered completed if the programmed movement has been completed and the
auxiliary function has been acknowledged. To this aim, the NCK stops the execution of the part pro-
gram (if necessary) to ensure that no auxiliary functions get lost from the view of the PLC user pro-
gram.

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 Output of Auxiliary Functions to the PLC (H2)

13.3 Transfer of values and signals to the PLC interface

Transfer time
Auxiliary functions output at the end of the block (e.g. M2) are only output if all axes and SPÜS mo-
vements of the spindle are completed.
If several auxiliary functions with different output types (prior to, during, at the end of the movement)
are programmed in a block that contains movements, the individual auxiliary functions are output
depending on their particular output type.

In a block without traversing movements, the auxiliary functions are output immediately as a block.

Continuous–path mode
A path movement only remains continuously if the auxiliary function is output during the movement
and has been acknowledged from the PLC prior to the end of the path.
References: Chapter ”Continuous–Path Mode, Exact Stop, LookAhead”

Interface signals
Provision of the signals from the NCK to the PLC: see Section 13.8 “Signal descriptions”

13.4 Division of auxiliary functions into groups

Functionality
The auxiliary functions of the M, H, D, T and S types, which are to be output, can be divided into
auxiliary function groups using machine data.

One auxiliary function may be assigned only one group.

Only one auxiliary function may be programmed per group. Otherwise, alarm 14760 is output.

Configuration
A max. of 64 auxiliary function groups can be defined.
These 64 auxiliary functions groups can be assigned max. 64 auxiliary functions. The auxiliary func-
tions that are assigned default values (groups 1 to 3) will not be taken into account.
The actual number of auxiliary functions, which have been distributed over the groups, are entered
in the NCK–specific MD 11100: AUXFU_MAXNUM_GROUP_ASSIGN (number of auxiliary func-
tions distributed over the AUXFUNC groups). To this aim, level 2 password must be set. Then the
control system must be turned off and turned on again (POWER ON). Only now the following ma-
chine data with index n greater than zero are available, and further values can be entered.

An auxiliary function assigned is defined in the following machine data:

MD 22000: AUXFU_ASSIGN_GROUP[n] Auxiliary function group
MD 22010: AUXFU_ASSIGN_TYPE[n] Auxiliary function type
MD 22020: AUXFU_ASSIGN_EXTENSION[n] Auxiliary function extension
MD 22030: AUXFU_ASSIGN_VALUE[n] Auxiliary function value

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Output of Auxiliary Functions to the PLC (H2)

Defaulted auxiliary function groups

Group 1:
The auxiliary functions M0, M1 and M2 (M17, M30) are assigned to group 1 by default. The output is
always carried out at the block end.

Group 2:
The M functions M3, M4 and M5 (M70) are assigned to group 2 by default. The output is always
carried out before the motion.

Group 3:
The S function is assigned to group 3 by default. This group and all further groups are output in pa-
rallel with the movement.

User–defined groups
All further groups (user–defined) are output with the movement.
The output settings can only be modified with Expert mode access (protection level 1).

Non–grouped auxiliary functions

The output of auxiliary functions that are not contained in groups is carried out with the movement.

Configuration sample
Distribute 8 auxiliary functions over 7 groups:

Group 1: M0, M1, M2 (M17, M30) – by default, should be kept

Group 2: M3, M4, M5 (M70) – by default, should be kept
Group 3: S functions – by default, should be kept
Group 4: M78, M79
Group 5: M80, M81
Group 6: H1=10, H1=11 H1=12
Group 7: all T functions
The password for protection level 2 is set. Make the appropriate entry in MD 11100: AUXFU_MAX-
NUM_GROUP_ASSIGN = 8. Then turn off the control system and turn it on again or use the appro-
priate softkey to power up the control and program the remaining machine data; then reboot the
control system..

Table 13-3 Entries in the machine data for the sample above

Index MD 22000 MD 22010 MD22020 MD22030

n (GROUP) (TYPE) (EXTENSION) (VALUE)
0 4 M 0 78
1 4 M 0 79
2 5 M 0 80
3 5 M 0 81
4 6 H 1 10
5 6 H 1 11
6 6 H 1 12
7 7 T 0 –1

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 Output of Auxiliary Functions to the PLC (H2)

13.5 Behavior on block search

Block search with calculation

With block search with calculation, all auxiliary functions assigned to a group are collected and out-
put at the end of the block search prior to the restart block (except for group 1: M0, M1,...).
In any case the last auxiliary function of a group is output.

All auxiliary functions collected are output as normal auxiliary functions in a separate block prior to
the movement.

Important: To collect all auxiliary functions during a block search, they must be assigned to an auxi-
liary function group!

13.6 Description of the auxiliary functions

13.6.1 M function

Application
The M functions can be used to enable most varied switching operations on the machine via part
program.

Scope of functions
 A number of 5 M functions is possible per part program block.
 Range of values of M functions: 0 to 99; integer
 A minor part of M functions is assigned a fixed functionality defined by the control manufacturer
(see User’s Guide “Operation and Programming”). The remaining functions are free for use by
the machine manufacturer.

13.6.2 T function

Application
The T function can be used by the PLC to load the tool required for a certain section of the machi-
ning program. Whether a tool change is to be carried out directly using the T command or using a
following M6 command can be set using MD 22550: TOOL_CHANGE_MODE..

The programmed T function can be interpreted either as a tool number or as a location number.

References: Section ”Tool compensation“

Scope of functions
A maximum of 1 T function is possible per part program block.

Special feature
T0 is reserved for the following function: Remove current tool from the tool holder and do not chan-
ge a new tool.

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Output of Auxiliary Functions to the PLC (H2)

13.6.3 D function

The D function can be used to select the tool compensation for the active tool. The tool compensa-
tions are described in detail:

References: ”Operation and Programming“

13.6.4 H function

Application
The H functions can be used to transfer various values from the part program to the PLC. The as-
signment of the functions is left up to the user.

Scope of functions
 3 H functions are possible per part program block.
 Range of values of the H functions: Floating point data (such as arithmetic parameters R)
 Adreßerweiterung 0 bis 99 (H0=... bis H99=...) möglich

13.6.5 S function

The S function is used to set the speed for the spindle with M3 or M4. For lathes with G96 (constant
cutting rate), the cutting value is set.

References: ”Operation and Programming“

13.7 Data descriptions (MD, SD)

13.7.1 General machine data

11100 AUXFU_MAXNUM_GROUP_ASSIGN
MD number Number of auxiliary functions distributed over the AUXFUNC groups
Default: 1 Min. input limit: 1 Max. input limit: 64
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BYTE Valid from SW release:
Meaning: The number of auxiliary functions, which have been distributed over the groups, are to be
entered in the MD. Only the customer–specific auxiliary functions are taken into account,
not the predefined auxiliary functions.
Application example(s)
Related to .... MD 22010: AUXFU_ASSIGN_TYPE[n]

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 Output of Auxiliary Functions to the PLC (H2)

13.7.2 Channel–specific machine data

22000 AUXFU_ASSIGN_GROUP[n]
MD number Auxiliary function group [ aux. fu. no. in channel ]: 0...63
Default: 1 Min. input limit: 1 Max. input limit: 64
Change valid after Power On Protection level: 2/7 Unit: –
Data type: BYTE Valid from SW release:
Meaning: see MD: AUXFU_ASSIGN_TYPE [n] (auxiliary function type)
Application example(s)

22010 AUXFU_ASSIGN_TYPE[n]
MD number Auxiliary function type [aux. fu. no. in channel]: 0...63
Default: – Min. input limit: – Max. input limit: 1 character
Change valid after Power On Protection level: 2/7 Unit: –
Data type: STRING Valid from SW release:
Meaning: This MD (auxiliary function type), MD 22020: AUXFU_ASSIGN_EXTENSION[n] (auxiliary
function extension), MD 22030: AUXFU_ASSIGN_VALUE[n] (auxiliary function value) and
MD 22000: AUXFU_ASSIGN_GROUP[n] (auxiliary function group) are used to assign an
auxiliary function type (M, H, T, D, S) the appropriate extension and to assign the auxiliary
function value an auxiliary function group.
Example: M 0 = 99 => group 5 (corr. to M100)

Auxiliary function type

Auxiliary function extension
Auxiliary function value
Auxiliary function group
⇒ MD: AUXFU_ASSIGN_TYPE[0] = ”M”
MD: AUXFU_ASSIGN_EXTENSION[0] = 0 ; only for type H; also other values
MD: AUXFU_ASSIGN_VALUE[0] = 99
MD: AUXFU_ASSIGN_GROUP[0] = 5 ; ( 5th group)

M00, M01, M02, (M17 and M30) are assigned to group 1 by default. M3, M4, M5 and are
assigned to group 2 by default.

Index [n] of the machine data always designates the auxiliary function number in the chan-
nel: 0–63.
All auxiliary functions assigned to auxiliary function groups must be numbered in the ascen-
ding order.
[0]⇒1st auxiliary function
[1]⇒ 2nd ,,
...
All machine data required for assigning an auxiliary function to an auxiliary function group
must have the same index [n].
Application example(s) see Section 13.4
Special cases, errors, ...... If the auxiliary function value of an auxiliary function is less than 0, all auxiliary functions of this
type and extension are assigned to a group.
Related to .... MD 11100: AUXFU_MAXNUM_GROUP_ASSIGN

22020 AUXFU_ASSIGN_EXTENSION[n]
MD number Auxiliary function extension [Aux. fu. in channel]: 0...63
Default: 0 Min. input limit: 0 Max. input limit: 99
Change valid after Power On Protection level: 2/7 Unit: –
Data type: BYTE Valid from SW release:
Meaning: See MD 22010: AUXFU_ASSIGN_TYPE [n] (auxiliary function type)
Application example(s)

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22030 AUXFU_ASSIGN_VALUE[n]
MD number Auxiliary function value [Aux. fu. in channel]: 0...63
Default: 0 Min. input limit: *** Max. input limit: ***
Change valid after Power On Protection level: 2/7 Unit: –
Data type: DWORD Valid from SW release:
Meaning: If the value in this MD is less than 0, all auxiliary functions of this type and of this address
extension are assigned to this group.
further see MD 22010: AUXFU_ASSIGN_TYPE[n] (auxiliary function type)
Application example(s) see Section 13.4

13.8 Signal descriptions

V2500 0004. 0 to .4 M funct. changes 1 to 5

V2500 0006.0 S funct. change 1
V2500 0008.0 T funct. change 1
V2500 0010.0 D funct. change 1
V2500 0012.0 to .2 D funct. changes 1 to 3
Interface signal Signal(s) from channel (NCK ––> PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 An M, S ,T, D, H information has been output to the interface together with a new value and the
corresponding change signal. The change signal indicates that the corresponding value is valid.
The change signals are only valid for one PLC cycle, i.e. if the signal is 1, a change is pending
for this cycle.
Signal state 0
The value of the appropriate information is not valid.

VD2500 2000 T function1

Interface signal Signal(s) from channel (NCK ––> PLC)
Edge evaluation: no Signal(s) updated: job–controlled Signal(s) valid from SW release:
from NCK
Signal state 1 Once the T change signal is provided, this machine data provides the T function programmed in
an NC block.
Range of values of T function: 0-32000; integer
The T function remains stored until it is overwritten by a new T function.
Signal state 0 • after power up of the PLC.
• Before a new auxiliary function is entered, the remaining functions are deleted.
Application example(s) Control of automatic tool selection.
Special cases, errors, With T0, the current tool is removed from the tool mount and no new tool is changed (default
...... configuration of machine manufacturer).

VB2500 1000 to
VB2500 1012 Decoded M signals: M0 - M99
Interface signal Signal(s) from channel (NCK ––> PLC) Synchronous actions (S5)|Signals
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 The dynamic M signal bits are set using decoded M functions.
Signal state 0 In case of a general auxiliary function output, the dynamic M signal bits are acknowledged by
the PLC system program after the user program has been passed completely.
Application example(s) Spindle CW/CCW rotation, coolant ON/OFF.
Related to ... IS “M function for spindle (DINT), axis–specific” (VD370x 0000)

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VD2500 3000 M function 1

VD2500 3008 M function 2
VD2500 3016 M function 3
VD2500 3024 M function 4
VD2500 3032 M function 5
Interface signal Signal(s) from channel (NCK ––> PLC)
Edge evaluation: no Signal(s) updated: job–controlled from Signal(s) valid from SW release:
NCK
Signal state 1 This machine data provides up to 5 M functions programmed in a block at a time once the M
change signals are provided.
Range of values of the M functions: 0 to 99; integer
Range of values of the extended address: 0; integer
The M functions remain stored until they are overwritten by new M functions.
Signal state 0 • after power up of the PLC.
• Before a new auxiliary function is entered, the remaining functions are deleted.
Related to .... IS “M function for the spindle (DINT), axis–specific“ (VD370x 0000)

VD2500 4000 S function 1

Interface signal Signal(s) from channel (NCK ––> PLC)
Edge evaluation: no Signal(s) updated: job–controlled from Signal(s) valid from SW release:
NCK
Signal state 1 The programmed S function is made available here in an NC block (speed or cutting value for
G96), as soon as the S change signal is present.
Range of values of S function: floating point (REAL format/4–byte))
The S function is kept, until it is overwritten by a new S function.
Signal state 0 • after power up of the PLC.
• Before a new auxiliary function is entered, the remaining functions are deleted.
Related to .... IS “S function for the spindle (REAL), axis–specific“ (VD370x 0004)

VD2500 5000 D function 1

Interface signal Signal(s) from channel (NCK ––> PLC)
Edge evaluation: no Signal(s) updated: job–controlled from Signal(s) valid from SW release:
NCK
Signal state 1 Once the D change signal is provided, this machine data provides the D function programmed in
an NC block.
Range of values of D function: 0–9; integer
The D function remains stored until it is overwritten by a new D function.
Signal state 0 • after power up of the PLC.
• Before a new auxiliary function is entered, the remaining functions are deleted.
Application example(s)
Special cases, errors, ...... D0 is reserved for the deselection of the current tool offset.

VD2500 6000 H function 1

VD2500 6008 H function 2
VD2500 6016 H function 3
VD2500 6004 Extended address of H function 1
VD2500 6012 Extended address of H function 2
VD2500 6020 Extended address of H function 3
Interface signal Signal(s) from channel (NCK ––> PLC)
Edge evaluation: no Signal(s) updated: job–controlled from Signal(s) valid from SW release:
NCK
Signal state 1 This machine data provides up to 3 H functions programmed in a block at a time once the H
change signals are provided.
Range of values of H function: Floating point (REAL–Format/4–byte)
Range of values of the extended address: 0 to 99; integer
The H functions remain stored until it is overwritten by a new H function.
Signal state 0 • after power up of the PLC.
• Before a new auxiliary function is entered, the remaining functions are deleted.
Application example(s) Switching operations on the machine.

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Output of Auxiliary Functions to the PLC (H2)

13.9 Data fields, lists

13.9.1 Interface signals

Number .Bit Name Ref.

Channel–specific
V2500 0000 .0 to .4 M function 1 change to M function 5 change
V2500 0006 .0 S function 1 change
V2500 0008 .0 T function 1, change
V2500 0010 .0 D function 1, change
V2500 0012 .0 to .2 H function 1 change to H function 3 change
VD2500 2000 T function 1 (DInt)
VD2500 3000 M function 1 (DInt)
VD2500 3008 M function 2 (DInt)
VD2500 3016 M function 3 (DInt)
VD2500 3024 M function 4 (DInt)
VD2500 3032 M function 5 (DInt)
VD2500 4000 S function 1 (REAL format)
VD2500 5000 D function 1 (DInt)
VB2500 6004 Extended address of H function 1 (dual)
VD2500 6000 H function 1 (REAL format)
VB2500 6012 Extended address of H function 2 (dual)
VD2500 6008 H function 2 (REAL format)
VB2500 6020 Extended address of H function 3 (dual)
VD2500 6016 H function 3 (REAL format)
V2500 1000 .0 – .7 Dynamic M function: M00–M07
V2500 1001 .0 – .7 Dynamic M function: M08–M15
to
V2500 1012 .0 – .7 Dynamic M function: M96- M99
VD370x 0000 – M function for the spindle (DINT), axis–specific S1
VD370x 0004 – S function for the spindle (REAL), axis–specific S1

13.9.2 Machine data

Number Identifier Name Ref.

11100 AUXFU_MAXNUM_GROUP_ASSIGN Number of auxiliary functions distributed over the AUX-
FUNC groups
22000 AUXFU_ASSIGN_GROUP[n] Auxiliary function group
22010 AUXFU_ASSIGN_TYPE[n] Auxiliary function type
22020 AUXFU_ASSIGN_EXTENSION[n] Auxiliary function extension
22030 AUXFU_ASSIGN_VALUE[n] Auxiliary function value

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Tool Compensation (W1) 14
14.1 Overview: Tool and tool compensation

Characteristics
With the SINUMERIK 802D control system, tool compensation data can be taken into account for
various tool types (drill, milling tool, turning tool, ...).

 Length compensation
 Radius compensation
 Storage of the tool compensation data in the tool offset memory
– Tool identification by T numbers from 0 to 32000
– Definition of a tool with a maximum of 9 cutting edges (compensation data blocks) using a T
number
– Cutting edge is described by tool parameters:
- Tool type
- Geometry: Length Wear: Length
- Geometry: Radius Wear: Radius
- Cutting edge position (with turning tools)
 Tool change can be selected: either immediately using a T command or using M6
 Tool radius compensation
– The compensation is active for all interpolation types: Linear and circular
– The compensation can be selected on external corners: Transition circle (G450) or intersec-
tion point of the equidistants (G451)
– Automatic detection of outer/inner corners
Detailed description:

References: ”Operation and Programming“

14.2 Tool

Selecting a tool
The T function is used to select a tool in the program. Whether the new tool is loaded immediately
using the T function or using M6, depends on the setting in MD 22550: TOOL_CHANGE_MODE
(new tool compensation with M function).

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Tool Compensation (W1)

Range of values for T

The T function may have integer values from T0 (no tool) to T32000 (tool with number 32000).
A maximum of 32 tools can be stored in the CNC at a time.

14.3 Tool compensation

Tool compensation using the D function

A tool may have up to 9 cutting edges. The 9 cutting edges are assigned to the D functions D1 to
D9.
A maximum of 64 tool compensation data blocks can be stored, which divide over the individual
tools.

The cutting edge is programmed using D1 (edge 1) to D9 (edge 9). The tool cutting edge always
refers to the tool currently active. An active tool cutting edge (D1 to D9) without active tool (T0) will
not be active. A cutting edge D0 will cancel all tool compensations of the tool currently active.

Edge selection during tool change

After programming a new tool (new T number) and changing this tool, the cutting edge can be se-
lected using the following options:
1. Programm the cutting edge number.
2. Do not program the cutting edge number. D1 is active automatically.

Enabling the tool compensation

D1 to D9 are used to enable the tool compensation for the tool edge of the tool currently active. The
tool length compensation and the tool radius compensation, however, come into effect at different
times:

 The tool length compensation (TLC) will be realized with the first traversing movement of the
axis for which the TLC is to be active. This traversing movement must be a linear interpolation
(G0, G1).
 The tool radius compensation (TRC) will be active by programming G41/G42 in the active plane
(G17, G18 or G19). The TRC with G41/G42 may only be carried out in a program block that con-
tains G0 (rapid traverse) or G1 (linear interpolation).
For a detailed description of the tool compensation including tool radius compensation, see:

References: ”Operation and Programming”, Chapter “Tool and Tool Compensation”

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14.4 Data descriptions (MD, SD)

22550 TOOL_CHANGE_MODE
MD number New tool compensation with M function
Default: 0 Min. input limit: 0 Max. input limit: 1
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BYTE Valid from SW release:
Meaning: A tool is selected in the program using the T function. Whether the new tool is changed
immediately using the T function, depends on the setting in this MD:
0:
The new tool is loaded immediately using the T function. For turning machines with tool
revolver, in most cases, this setting is used.

1:
The new tool is prepared for loading using the T function. In case of machines equipped with
a tool magazine, this setting is used mainly to bring the new change to the tool change
position in parallel to the machining time (without interrupting the machining time). The M
function is used to remove the old tool from the spindle and to load the new tool into the
spindle. According to DIN 66025, this tool change is programmed using the M function M6.
Related to ....

14.5 Data fields, lists

14.5.1 Interface signals

Number .Bit Name Ref.

Channel–specific
V2500 0008 .0 T function 1, change H2
V2500 0010 .0 D function 1, change H2
VD2500 2000 – T function 1 H2
VD2500 5000 – D function 1 H2
V25001000 .6 M6 H2

14.5.2 Machine data

Number Identifier Name Ref.

Channel–specific
22550 TOOL_CHANGE_MODE New tool compensation with M function

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Measuring (M5) 15
(This function is available soon.)

15.1 Brief description

Channel–specific measuring
In a part program block, a trigger event is programmed, which will initiate the measuring process,
and a measuring mode is defined in which the measurement is carried out. The statements will ap-
ply to all axes programmed in this block.

15.2 Hardware requirements

15.2.1 Probes that can be used

General
To acquire tool and workpiece dimensions, a switching sensing probe is required, which provides a
constant signal (no pulse) in case of a deflection.

The probe must switch nearly free from bouncing. This is generally possible by a mechanical adjust-
ment of the probe.
Various manufacturers offer different designs of probes on the market. The probes are therefore
divided into three groups, depending on the number of directions in which a probe can be deflected
(see Fig. 15–1).

Multi–directional Bi–directional Mono–directional

probe probe probe

Fig. 15-1 Probe types

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Measuring (M5)

Table 15-1 Probe assignment

Tracer type Turning machines Milling and machining

centers
Tool measurement Workpiece measurement Workpiece measurement
multi–directional X X X
bi–directional _ X X
mono–directional _ _ X

Whereas for turning machines a bi–directional probe can be used, for milling and machining centers
a mono–probe can also be used for workpiece measurement.

Multi–directional probes (3D)

This type can be used for tool and workpiece measurement without any restrictions.

Bi–directional probes
For the workpiece measurement in milling and machining centers, this type is treated as a mono–
probe. For turning machines, this type can be used for workpiece measurement.

Mono–directional probes
On milling and machining centers, this type can be used for workpiece measurement with slight re-
strictions.

Spindle position with mono–probe

To allow utilization of this type for milling and machining centers, it is required that the spindle can be
positioned by means of the NC function SPOS and that the switching signal of the key can be trans-
ferred over 360 degrees to the receiving station (on the column of the machine).
The probe in the spindle must be mechanically aligned such that in spindle position 0 degrees mea-
suring is possible in the following directions:

Table 15-2 Spindle positions for probe alignment

Measurement at a spindle position of

0 degrees
X–Y plane G17 Positive X direction
Z–X plane G18 Positive Z direction
Y Z plane G19 Positive Y direction

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15.2.2 Connecting the probe

Connection to the 802D/drive 611UE

With the SINUMERIK 802D, the probe is connected to the drive 611UE on the terminals X453 (in-
put I0.A) for drive A and/or on X454 (input I0.B) for drive B in case of two–axis modules. For single–
axis modules, only drive A is available.
All measuring inputs of the axis drive modules must be linked and connected to the probe.
Parameterize the input of each axis drive using the function “Probe“ when starting up the drive.

The connection including the reference potential, is explained and described in detail in:
References: “Start–Up Guide”
References: “SIMODRIVE 611 UE, Description of Functions”

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Measuring (M5)

Motor enco- Motor enco-

der der
Drive A Drive B
Button for X411 X412
FAULT
POWER
LED rot
ON–RESET

Option module
Signaling terminals X423
PROFIBUS–DP3
AS1 X421
AS2

Terminals for supply and Terminals drive B

pulse enable
56.B
P24 X454 14.B
M24 24.B
20.B
9 65.B
9
663
I0.B
X431
19 I1.B
O0.B
Analog outputs O1.B

75.A
X441 Encoder interface TTL enco-
16.A
der 1 P_Encoder
75.B X472
16.B 2 M_Encoder
15 3 A
(refe- 4 *A
rence) 5 reserved
6 B
X34 7 *B
8 reserved
M DAU1 DAU2 9 P_Encoder
10 R
Terminals of drive A 11 M_Encoder
56.A 12 *R
14.A 13 reserved
24.A 14 reserved
20.A 15 reserved
X453
65.A
9
I0.A Display
I1.A and
O0.A Serial operating unit
O1.A interface
(RS232)
X471 Unit bus
X351

Fig. 15-2 Elements on the front panel “SIMODRIVE 611 UE”; the sensing probe is connected to
X453/X454

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15.3 Channel–specific measuring

15.3.1 Measuring mode

Measuring commands MEAS and MEAW

The measuring process is enabled from the part program. A trigger event and a measuring mode
are programmed. Two measuring modes are provided:

 MEAS: Measuring with deletion of the distance to go

Example:
N10 G1 F300 X300 Z200 MEAS=–1
Trigger event is the falling edge (–) of the probe (1).
 MEAW: Measuring without deleting the distance to go
Example:
N20 G1 F300 X300 Y100 MEAW=1
Trigger event is the rising edge (+) of the probe (1).
The measuring block is completed when the sensing probe signal is arrived (or the position is re-
ached). The measuring job can be canceled using RESET.

References: “Operation and Programming”

Note
If a geometry axis (axis in WCS) is programmed in a measuring block, the measured va-
lues for all geometry axes will be stored.

15.3.2 Measurement results

Reading measurement results in the program

The results of the measurement command can be read in the part program using system variables.
 System variable $AC_MEA[1]
Polling the status signal of the measuring job.
The variable is deleted at the beginning of a measurement. Once the probe reaches the trigger
criterion (rising or falling edge), the variable is set. Thus the realization of the measuring job can
be checked in the part program.
 System variable $AA_MM[<axis>]
Access to the result of measurement in the machine coordinate system.
Reading in the part program and in the synchronous actions. <axis> stands for the name of the
measuring axis (X, Y, ...).
 System variable $AA_MW[axis]
Access to the measurement result in the workpiece coordinate system. Reading in the part pro-
gram and in the synchronous actions. <axis> stands for the name of the measuring axis
(X, Y, ...).
References: “Operation and Programming”

PLC service display

The measuring signal can be checked using the diagnostics menu ”PLC status”:
IS “Probe 1 actuated” (V2700 0001.0).

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Measuring (M5)

The IS “Measurement active” (V390x 0002.3) can be used to display the current measuring status
of the axis (measuring block with this axis running).

15.4 Measuring accuracy and testing

15.4.1 Measuring accuracy

Accuracy:
The runtime of the measuring signal is determined by the hardware used. The delay times are in the
µs range, plus reaction time of the probe when using the SIMODRIVE 611UE.

The measuring uncertainty results from:

Measuring uncertainty = runtime of measuring signal x traversing velocity

Correct results can only be guaranteed for traversing velocities, at which not more than 1 trigger
signal per position controller cycle arrives.

15.4.2 Sensing probe function test

Example of a function test

It is recommended to carry out the function test of the snesing probe using an NC program.
%_N_PRUEF_MESSTASTER_MPF
;test program for probe connection
N10 ;R10 Flag for selection state
N20 ;R11 MESSWERT_IN_X
N30 G17 T1 D1 ;Preselect tool compensation for probe
N40 ANF: G0 G90 X0 F150 ;Start position and measuring velocity
N50 MEAS=1 G1 X100 ;Measuring at measuring input 1 in the X axis
N60 STOPRE
N70 R10=$AC_MEA[1] ;Switching signal at 1st measuring input
N80 IF R10==0 GOTOF FEHL1 ;Evaluation of the signal
N90 R11=$AA_MW[X] ;Reading in the meas. value in the workpiece coordinates
N95 M0
N100 M2
N110 FEHL1: MSG (”Probe does not switch!”)
N120 M0
N130 M2

Example: Repeat accuracy

This program allows to determine the measuring scatterband (repeat accuracy or repeatability) of
the entire measuring system (machine–probe–signal transmission).

In the example, the X axis is measured 10 times and the measured value is taken over into the
workpiece coordinates.

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 Measuring (M5)

So–called “random size deviations” can be noticed, which are not subject to a particular trend.

%_N_PRUEF_GENAU_MPF
N05 ;R11 Switching signal
N06 R12=1 ;Counter
N10 ; R1 bis R10 MEASURED VALUE_IN_X
N15 G17 T1 D1 ;Initial conditions, preselect tool compensation
for probe
N20 ANF: G0 X0 F150 ;Prepositioning in the measuring axis
N25 MEAS=+1 G1 X100 ;Measuring at the 1st measuring input on rising
switching edge, in the X axis
;N30 STOPRE ;Stop decoding for later evaluation of the result
(is carried out automatically when reading MEA)
N35 R11= $AC_MEA[1] ;Switching signal at 1st read measuring input
N37 IF R11==0 GOTOF FEHL1 ;Check switching signal
N40 R[R12]=$AA_MW[X] ;Read measured value in workpiece coordinates
N50 R12=R12+1
N60 IF R12<11 GOTOB ANF ;Repeat 10 times
N65 M0
N70 M02
N80 FEHL1: MSG (”Probe does not switch”)
N90 M0
N95 M02

After selecting the parameter display, the results of the measurement R1 to R10 can be read.

15.5 Boundary conditions

Use of SIMODRIVE 611 UE drives

15.6 Data descriptions (MD, SD)

13200 MEAS_PROBE_LOW_ACTIVE
MD number Switching behavior of probe
Default: 0 Min. input limit: 0 Max. input limit: 1
Change valid after Power On Protection level: 2/2 Unit: –
Data type: BOOLEAN Valid from SW release:
Meaning: 0: when not deflected 0V
when deflected 24 V
1: when not deflected 24 V
when deflected 0V

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15.7 Signal descriptions

V390x 0002.3 Measurement active

Interface signal Signal(s) from axis/spindle (NCK → PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge The function ”Measuring“ is active.
change 0 –––> 1
This shows the current measuring status of the axis (measuring block with this axis running).
Signal state 0 or edge The function ”Measuring“ is not active.
change 1 –––> 0

V2700 0001.0 Probe 1 actuated

Interface signal Signal(s) from axis/spindle (drive → PLC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge Probe 1 is actuated.
change 0 –––> 1
Signal state 0 or edge Probe 1 is not actuated.
change 1 –––> 0

15.8 Data fields, lists

15.8.1 Interface signals

Number .Bit Name Ref.

General (from NCK to PLC)
V2700 0001 .0 Probe 1 actuated.
Axis/spindle–specific (from axis to PLC)
V390x 0002 .3 Measurement active

15.8.2 Machine data

Number Identifier Name Ref.

General machine data
13200 MEAS_PROBE_LOW_ACTIVE Switching behavior of probe

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Compensation (K3) 16
16.1 Brief description

Compensations
With the SINUMERIK 802D, the following compensations can be enabled axis–specifically:
 Backlash compensation
 Interpolatory compensation LEC
(compensation of leadscrew error and measuring system error)
 Following error compensation (dynamic feedforward control)
The compensation functions can be set for each machine separately using axis–specific machine
data.

Position display
The standard actual and set value display does not take into account the compensation values and
displays the position values of an ”ideal machine”. The compensation values are displayed in the
operating area ”System” in the screen form ”Service Axes” under “Abs. comp. value meas.
system 1”.

16.2 Backlash compensation

Effect
With axes/spindles provided with indirect measuring systems, the mechanical backlash results in a
falsification of the distance to be traversed. For example, with direction reversal, an axis travels will
traverse too few or too much by the amount of the backlash (see Fig. 16–1).

Compensation
To compensate the backlash, the axis–specific actual value is corrected by the backlash amount
with each direction reversal of the axis/spindle.

During the start–up, this amount can be entered in

MD 32450: BACKLASH (backlash) for each axis/spindle.

Activation
After reference point approach, the backlash compensation is always active in all operating modes.

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Compensation (K3)

Positive backlash
The encoder advances the machine part (e.g. table). To make sure that the actual position acquired
by the encoder advances the real position of the table, the table traverses too shortly (see Fig.
16–1). In this case, a positive backlash compensation value must be entered (= normal case).

Table
Back–

ÉÉÉ ÉÉÉÉÉ
lash

Encode M
r
Encoder actual value advances the real actual value (ta-
ble): Table traverses too short

Fig. 16-1 Positive backlash (normal case)

Negative backlash
The encoder lags behind the machine part (e.g. table); the table travels too far. A negative compen-
sation value must be entered.

Large backlash compensation values

In case of direction reversal of the axis concerned, the user may provide the backlash compensa-
tion value divided into several segments. This avoids that a sudden setpoint change on the axes
results in specific axis errors.

The contents of the axis–specific MD 36500: ENC_CHANGE_TOL determine the increment, by

which the backlash compensation value (MD 32450: BACKLASH) is added.

Note that the backlash compensation will only be taken into account after n servo cycles ( n=
MD32450 / MD 36500). If the time is too long, zero speed monitoring alarms may result.

If MD 36500: ENC_CHANGE_TOL is greater than MD 32450: BACKLASH, the compensation is

carried out in one servo cycle.

16.3 Interpolatory compensation

16.3.1 General

Terms and definitions

Compensation value: Difference between the axis position measured by the position encoder and
the desired programmed axis position (= axis position of the ideal machine). The compensation va-
lue is often also called offset value.

Intermediate point: A position of the axis and the related compensation value.
Compensation table: Table of intermediate points

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Compensation table
Since measurement deviations of ball screw spindle and measuring system have a direct influence
on the accuracy of the workpiece machining, they must be compensated by appropriate position–
dependent compensation values. The compensation values are determined according to the mea-
sured error curve and entered in the control system in the form of compensation tables during the
start–up. For each compensation relation, a separate table must be created.
The input of compensation values and additional table parameters are carried out using special sy-
stem variables.

Input of the compensation table

The compensation tables can be loaded into the buffered NC user memory in two different ways:

 The compensation values are loaded by starting an NC program that contains the compensation
tables.
 The compensation data can also be loaded by transferring the compensation tables from a PC
via the serial interface of the HMI.

Note
The compensation tables can be output via the serial interface of the HMI from the ope-
rating area ”System” –> “Data I/O” –> “Data selection” / Data ... / Compensation: Leads-
crew error” and downloaded after editing.

Linear interpolation between intermediate points

The traversing distance to be compensated and defined by start and end positions will be divided
into several segments of the same size (the number depends on the error curve form) (see Fig.
16–2). In the following, the actual positions limiting these segments will be referred to as ”interme-
diate points”. During the start–up, the corresponding offset value must be entered for each interme-
diate point. The offset (or compensation) value acting between 2 intermediate points is generated
from the corresponding compensation values of the adjacent intermediate points (i.e. adjacent
points are linked by a straight line) by a linear interpolation.

Compensation Error curve

value Compensation curve

Linear interpolation

n n+1 n+2 n+3 Position of

Intermediate point the axis

Fig. 16-2 Linear interpolation between the intermediate points

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Compensation (K3)

Compensation value at the reference point

The compensation table should be structured such that the compensation value is zero at the refe-
rence point.

16.3.2 Leadscrew error compensation (LEC)

Function
The leadscrew error compensation / measuring system error compensation (LEC) is an axis–speci-
fic compensation.

With the LEC, the axis–specific actual position value is modified by the corresponding compensa-
tion value at the interpolation cycle and directly traversed by the machine axis. A positive compen-
sation value results in a movement of the corresponding machine axis in the negative direction.

The size of the compensation value is not limited and is not monitored. To avoid inadmissible high
velocities and accelerations of the machine axis due to the compensation, the compensation value
should be selected correspondingly small. Otherwise, in case of large compensation values, other
axis monitoring functions may result in alarm messages (e.g. contour monitoring, speed setpoint
limitation).

Activation
 The compensation values are stored in the NC user memory and are active after Power ON.
 The function has been activated for the machine axis desired
(MD 32700: ENC_COMP_ENABLE [0] = 1). .
 The axis has been referenced (IS ”Referenced/synchronized 1“ V390x0000.4 set).
If these conditions are fulfilled, the axis–specific actual position value will be modified by the corres-
ponding compensation value and traversed by the machine axis immediately.

If the reference is then lost, e.g. since the encoder frequency has been exceeded (IS ”Referenced/
synchronized 1 “ = ‘0’), the compensation processing will be switched off.

Compensation table
The position–related compensations for the corresponding axis are stored in the compensation ta-
ble in the form of system variables. A maximum of 125 intermediate points (N = 0...124) is possible.
To this aim, the following measuring–system specific parameters must be defined for the table (see
Fig.16-3):

 Compensation value for intermediate point N of the compensation table:

$AA_ENC_COMP [0,N,AXi]= ...
with: AXi = machine axis name, e.g. X1, Y1, Z1 ; N = intermediate point index
The compensation value for each individual intermediate point (axis position) must be entered in
the table. The size of the compensation value is not limited.

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Note
The first and the last compensation values remain active over the entire traversing range, i.e. these
compensation values should be ”0” if the compensation table does not extend over the entire traver-
sing range.

 Intermediate point spacing: $AA_ENC_COMP_STEP[0,AXi]= ...

The intermediate point spacing defines the spacing between the compensation values of the
corresponding compensation table (AXi, see above).
 Starting position: $AA_ENC_COMP_MIN[0,AXi]= ...
The starting position is the axis position at which the compensation table for the axis in question
starts (intermediate point 0).
The compensation value pertaining to the starting position is $AA_ENC_COMP[0,0,AXi]
For all positions less than the starting position, the compensation value of intermediate point 0 is
used (does not apply to tables with module).
 End position: $AA_ENC_COMP_MAX[0,AXi]= ...
The end position is the axis position at which the compensation table for the corresponding axis
ends (intermediate point k < 125).
The compensation value pertaining to the end position is $AA_ENC_COMP[0,k,AXi)]
For all positions greater than the end position, the compensation value of intermediate point k is
used (exception: table with modulo function). Compensation values greater than k are inactive.
 Compensation with modulo function: $AA_ENC_COMP_IS_MODULO[0,AXi] = 1
If the compensation with modulo function is activated, the compensation table is repeated cycli-
cally, i.e. the compensation value at $AA_ENC_COMP_MAX (
intermediate point
$AA_ENC_COMP[0,k,AXi]) is directly followed by the compensation value at
$AA_ENC_COMP_MIN (
intermediate point $AA_ENC_COMP[0,0,AXi]).
In case of rotary axes with modulo 360, it is recommended to use 0 degrees as the starting
position ($AA_ENC_COMP_MIN) and 360 degrees as the end position
($AA_ENC_COMP_MAX). These two compensation values must be entered with the same
amount.

Caution
! When entering the compensation values, it should be made sure that all intermediate points is assi-
gned a compensation value within the defined range (i.e. that no gaps occur). Otherwise, for these
intermediate points the compensation value will be used, which has remained from previous entries
in these places.

Note
 In MD 10240: SCALING_SYSTEM_IS_METRIC=0, table parameters that contain positional
information are interpreted in inches.
An automtic conversion of the position data can be achieved by manual switch–over (see Sec-
tion 3.2.2 “Switching over the scaling system manually“).
 The compensation table can only be loaded if MD 32700: ENC_COMP_ENABLE=0 is set. If this
value is set =1, the compensation will be enabled, thus enabling write protection (output of alarm
17070).

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Compensation (K3)

Example
The following example shows the specification of compensation values for machine axis X1 as a
program.

%_N_AX_EEC_INI
CHANDATA (1)
$AA_ENC_COMP[0,0,X1]= 0.0 ;1st compensation value (intermediate point 0) +0mm
$AA_ENC_COMP[0,1,X1]= 0.01 ;2nd compensation value (intermediate point 1) +10mm
$AA_ENC_COMP[0,2,X1]= 0.012 ;3rd compensation value (intermediate point 2) +12mm
...
$AA_ENC_COMP[0,120,X1]= 0.0 ;last compensation value (intermediate point 120)

$AA_ENC_COMP_STEP[0,X1]= 2.0 ;intermediate point spacing 2.0 mm

$AA_ENC_COMP_MIN[0,X1]= –200.0 ;compensation starts at –200.0 mm
$AA_ENC_COMP_MAX[0,X1]= 40.0 ;compensation ends at +40.0 mm
$AA_ENC_COMP_IS_MODULO[0,X1] = 0 ;compensation without modulo function
M17

Values for more than 125 interpolation points will cause alarm 12400 ”Element missing“.

Error curve
Compensation curve
Compensation value (linear interpolation between the intermediate points)
Compensation values of compensation table
Start position End position
($AA_ENC_COMP_MIN) ($AA_ENC_COMP_MAX)

Compensation value of
Intermediate point spacing intermediate point 5
($AA_ENC_COMP)
Reference point
–200–207
–198 –196 –194 38 40 Axis position
0 1 2 3 4 5 119 120
Intermediate points
Linear interpolation

Fig.
16-3 Parameters of the compensation table (system variables for LEC)

16.3.3 Special features of interpolatory compensation

Measuring
The function ”Measuring” provides the compensated actual positions (ideal machine) required by
the user or programmer.

Software limit switches

The software limit switches also monitor the ideal position values (i.e. the actual position values cor-
rected by the LEC and the backlash compensation).

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 Compensation (K3)

16.4 Following error compensation (feedforward control)

16.4.1 General

Axis–specific following errors

The feedforward control allows to reduce the following error nearly to zero. The feedforward control
is therefore also called ”following error compensation”.
In particular, in case of acceleration processes at contour bends, e.g. circles and corners, this follo-
wing error results in an undesired velocity–dependent contour error.
The SINUMERIK 802D control system uses feedforward control type “Speed feedforward control”.

Enabling/disabling the feedforward control in the part program

The feedforward control can be enabled/disabled in the part program using the following high–level
language elements:

FFWON Feedforward control ON

FFWOF Feedforward control OFF (default position when turning on the control system)
MD 32630: FFW_ACTIVATION_MODE defines axis–specifically whether the feedforward control
can be enabled by FFWON for this axis and/or whether it can be disabled by FFWOF.

FFWON and FFWOF are used to enable/disable the feedforward control for all axes/spindles for
which MD 32630: FFW_ACTIVATION_MODE = 1 is set.

For interpolating axes, MD 32630: FFW_ACTIVATION_MODE should therefore be set to the same
value.

To avoid jerks, the feedforward control should only be enabled/disabled when the axis/spindle is at a
standstill. This must be observed and guaranteed by the programmer.

Prerequisites
When using the feedforward control, make sure that the following is observed:
 rigid machine behavior
 exact knowledge of the machine dynamic properties required
 no sudden position and speed setpoint changes

Optimizing the control loop

The feedforward control is set axis/spindle–specifically. First, current, speed and position control
loop must be set for the corresponding axis/spindle to an optimum value.

References: “Start–Up Guide“

Defining the parameters

Then the feedforward control parameters must be entered for the corresponding axis/spindle and
entered in the machine data (refer to the following Section).

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Compensation (K3)

16.4.2 Speed feedforward control

With the speed feedforward control, a speed setpoint is provided to the input of the speed controller
as an additional setpoint (see Fig. 16–4).

To achieve a speed feedforward control set correctly, the equivalent time constant of the speed con-
trol loop must be determined exactly and entered as a machine data.

NCK Drive

+
Set value Feedforward Position Speed
control
(Reference input controller controller
variable) –

Actual position value

MD 32810: EQUIV_SPEEDCTRL_TIME

Fig. 16-4 Speed feedforward control

Parameters

On start–up, the following axis–specific MD must be defined for the speed feedforward control:
MD 32810: EQUIV_SPEEDCTRL_TIME “Equivalent time constant of the connected speed control
loop”).

16.5 Data descriptions (MD, SD)

Axis–specific machine data

32450 BACKLASH[n]
MD number Backlash
Default: 0.0 Min. input limit: *** Max. input limit: ***
Change valid after NEW_CONF Protection level: 2/2 Unit: mm and/or degrees
Data type: DOUBLE Valid from SW release:
Meaning: Backlash between positive and negative traversing dircetions.
The input of the compensation value is
S positive if the encoder advances the machine part (normal case)
S negative if the encoder follows the machine part.
If ”0” is entered, the compenation value is disabled.
The backlash compensation is always active in all operating modes after reference point appro-
ach.
Index [n] is coded as follows: [Encoder No.]: 0
Special cases, errors, ......
Related to .... MD 36500: ENC_CHANGE_TOL (backlash compensation segment)

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 Compensation (K3)

32630 FFW_ACTIVATION_MODE
MD number Feedforward control can be enabled from the program
Default: 1 Min. input limit: 0 Max. input limit: 1
Change valid after RESET Protection level: 2/2 Unit: –
Data type: Byte Valid from SW release:
Meaning: This MD can be used to define whether the feedforward control for this axis/spindle can be ena-
bled/disabled from the part program.
0: The feedforward control cannot be enabled/disabled by FFWON and/or FFWOF.
1: The feedforward control can be enabled/disabled by FFWON and/or FFWOF from the part
program.
The status last valid remains also active after RESET (and thus also in JOG mode).
Since FFWON and/or FFWOF is used to enable/disable the feedforward control of all axes of the
channel, this MD should be set to the same value for axes that interpolate with each other.
Related to ....
Further references ”Operation and Programming”

32700 ENC_COMP_ENABLE[n]
MD number Encoder/leadscrew error compensation (LEC)
Default: 0 Min. input limit: 0 Max. input limit: 1
Change valid after NEW_CONF Protection level: 2/2 Unit: –
Data type: BOOLEAN Valid from SW release:
Meaning: 1: The LEC is enabled for the axis/measuring system.
The LEC can be used to compensate leadscrew errors and measuring system errors.
The function will internally only be enabled if the corresponding measuring system is referen-
ced (IS: “Referenced/synchronized 1” = 1).
Write–protection function (compensation values) active.
0: The LEC is not active for the axis/measuring system in question.

Index [n] is coded as follows: [Encoder No.]: 0

Related to .... IS “Referenced/synchronized 1 ”

32810 EQUIV_SPEEDCTRL_TIME[n] n = control parameter record No.: 0 ... 5

MD number Equivalent time constant of speed control loop
Default: Min. input limit: 0.0 Max. input limit: ***
(0.0005, 0.0005, ... , 0.0005)
Change valid after NEW_CONF Protection level: 2/2 Unit: s
Data type: DOUBLE Valid from SW release:
Meaning: This equivalent time constant is required for the function “Speed feedforward control”.
The value must correspond to the equivalent time constant of the closed speed control loop.
Setting aid: Orientation value is the time constant of the setpoint smoothing in the drive.
Related to .... MD 36400: CONTOUR_TOL (tolerance band of contour monitoring)

36500 ENC_CHANGE_TOL
MD number Backlash compensation segment / tolerance of position actual–value switchover
Default: 0.1 Min. input limit: 0.0 Max. input limit: ***
Change valid after NEW_CONF Protection level: 2/2 Unit: mm or degrees
Data type: DOUBLE Valid from SW release:
Meaning: Segment for backlash compensation input
This MD is used to manage large backlash compensation values. In this case, the backlash will
not be provided to the actual value at a time, but in ”n” steps having a step size of
MD: ENC_CHANGE_TOL. The calculation of the backlash thus lasts ”n” servo cycles. If the time
required to calculate the backlash completely is too large, standstill monitoring alarms can be out-
put.
This MD is only active if MD: ENC_CHANGE_TOL is greater than MD: BACK_LASH.
Related to .... MD 32450: BACKLASH[0] (backlash compensation)

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Compensation (K3)

38000 MM_ENC_COMP_MAX_POINTS[n] (MD can only be displayed)

MD number Number of intermediate points for encoder/spindle compensation (LEC)
Default: 125 Min. input limit: – Max. input limit: –
Change valid after Power On Protection level: 0/7 Unit: –
Data type: DWORD Valid from SW release:
Meaning: With the LEC, the maximum number of intermediate points per axis/measuring system is 125.
The required number k can be calculated as follows using to the specified parameters:
$AA_ENC_COMP_MAX – $AA_ENC_COMP_MIN
k = ––––––––––––––––––––––––––––––––––––––––––– + 1
$AA_ENC_COMP_STEP

$AA_ENC_COMP_MIN starting position (system variable)

$AA_ENC_COMP_MAX end position (system variable)
$AA_ENC_COMP_STEP intermediate point distance (system variable)

Index [n] is coded as follows: [encoder No.]: 0

Related to .... MD 32700: ENC_COMP_ENABLE[n] LEC active

16.6 Data fields, lists

16.6.1 Interface signals

Number .Bit Name Ref.

Axis/spindle–specific
V390x0000 .4 Referenced/synchronized 1 R1

16.6.2 Machine data

Number Identifier Name Ref.

General
10240 SCALING_SYSTEM_IS_METRIC Scaling system metric G2
Axis–specific
32450 BACKLASH[n] Backlash
32630 FFW_ACTIVATION_MODE Feedforward control can be enabled from the pro-
gram
32700 ENC_COMP_ENABLE[n] Interpolatory compensation active
32810 EQUIV_SPEEDCTRL_TIME[n] Equivalent time constant of speed control loop
36500 ENC_CHANGE_TOL Backlash compensation segment
38000 MM_ENC_COMP_MAX_POINTS[n] Intermediate points for encoder/spindle compen-
sation (LEC) (only for display)

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Various Interface Signals (A2) 17
17.1 General

Brief description
This Description of Functions describes the functionalities of various interface signals that are of
general importance and are not described in other Descriptions of Functions.

Interfaces
The exchange of signals and data between the PLC user program and

 NCK (Numerical Control Kernel)

 HMI (display unit)
is carried out via various data areas. The PLC user program need not take care of the exchange.
From the user’s view, this is carried out automatically.

NCK General PLC

Signals to NC
General

Signals from NC
User
program
Operating Modes

Signals to NCK
Operating
Modes
Signals from NCK

Channel
Signals to NCK
Signals to NCK
Chan- Signals from NCK
nel Signals from NCK

Spindle (n+1)
Axis n
Axis 2
Axis, Axis 1
spindle
Signals to NCK

Signals from NCK

Fig. 17-1 PLC/NCK interface

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Various Interface Signals (A2)

Cyclic signal exchange

The control and status signals of the PLC/NCK interface are updated cyclically.
They can be divided into the following groups (see Fig. 17–1):

 General signals
 Mode signals
 Channel signals
 Axis/spindle signals

17.2 Signals from PLC to NCK

Access rights
The access to programs, data and functions is protected user–oriented by 8 hierarchical protection
levels. These protection levels are divided into:
 4 password protection levels for Siemens, machine manufacturer (2x) and end user
 4 protection levels for end users (interface signals V26000000.4 to .7)
This provides a safety concept to manage the access rights, which contains several levels.

See also Start–Up Guide, Section “Access rights”

Table 17-1 Access protection

Protection level: Type User Access to (examples)

0 Pass– SIEMENS, reserved

word

1 Pass– Expert mode defined functions, programs and data;

word

2 Pass– Machine manufacturer defined functions, programs and data;

word for standard start–up

3 Pass– End user assigned functions, programs and data;

word

4 IS End user: less than protection levels 0 to 3;

V2600 Programmer defined either by machine manufacturer or
0000.7 Setter end user

5 IS End user: less than protection levels 0 to 3;

V2600 Qualified operator, defined by end user fewer
0000.6 who will not program access
rights
6 IS End user: Example:
V2600 Trained operator only program selection, input of tool wear
0000.5 who will not program and zero offsets

7 IS End user: Example:

V2600 Semi–skilled operator No inputs, no program selection
0000.4 only possible if the machine control
panel can be operated

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 Various Interface Signals (A2)

Deleting the distance to go – channel–specific (V3200 0006.2)

The IS ”Delete distance to go (channel–specific)” is only active for path axes.
The distance to go is deleted for all axes of the geometry group with the rising edge of the interface
signal, and it is immediately stopped by ramp stop. Then, the next program block is started.

Axis/spindle lock (V380x 0001.3)

The IS ”Axis/spindle lock” can be used for testing purposes.

Axis lock (for axis):

If the IS ”Axis lock” is provided, no more partial position setpoints are output to the position controller
of this axis; the traversing movement of this axis is thus disabled. The position control loop remains
closed and the remaining following error will be compensated. If an axis is traversed with axis lock,
the actual value position display will show the set position, and the velocity actual value display will
show the setpoint velocity, whereby the machine axis does not actually travel. The IS “RESET”
(V3000 0000.7) is used to set the position actual value display to the real actual value of the
machine. The traversing commands for this axis are still output to the PLC. If the interface signal is
canceled, the corresponding axis can be traversed normally again. If the interface signal ”Axis lock”
is provided for a traversing axis, the axis will be stopped with ramp stop.
Spindle interlocking (for spindle):
If the IS ”Spindle lock“ is provided, no more speed setpoint values are output to the speed controller
for this spindle in control mode and no more position partial setpoint values are output to the
position controller in positioning mode. The spindle motion is thus locked. The speed actual value
display will display the speed setpoint. The spindle locking is canceled by ”Reset” or program end
(M2) and restarting the program. If the interface signal ”Spindle lock” is provided for a rotating
spindle, the spindle is stopped according to its acceleration characteristic.

The cancellation of ”Axis/spindle lock” (edge change 1 → 0) will only come into effect if the axis/
spindle is at a standstill (i.e. if the interpolation setpoint is no longer present). The new movement
starts with new setpoints. (e.g.: new program block with movement settings in AUTOMATIC mode).
Note: Different actual values between simulated and real axes!

Follow–up mode (V380x 0001.4)

If an axis/spindle is in follow–up mode, its setpoint position will follow the current actual position. In
follow–up mode, the position setpoint value is not provided from the interpolator, but is derived from
the current actual position. Since the position actual value of the axis is continued to be acquired,
re–referencing of the axis is not necessary after canceling the follow–up mode.
Zero speed, clamping and positioning monitoring are not active in follow–up mode.

Effect:
The IS ”Follow–up mode” is only applicable if the servo enable of the drive has been canceled (e.g.
by the IS ”Servo enable” = 0 signal or inside the control system due to a fault), and/or servo enable
is provided again.

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Various Interface Signals (A2)

IS ”Follow–up mode” = 1:
If the IS ”Servo enable” is canceled, the position setpoint value of the relevant axis is followed up the
actual value continuously. This state is signaled to the PLC using the IS ”Follow–up active”
(V390x 0001.3). If the IS ”Servo enable” is then set again, a repositioning to the last programmed
position is carried out internally in the control system if a part program is active (REPOSA: Approach
on a straight path with all axes).
Otherwise:
the axis motion will start at the new actual position possibly changed.

IS ”Follow–up mode” = 0:
If the IS ”Servo enable” is canceled, the old position setpoint value is maintained. If the axis is
pushed off its position, a following error between the position setpoint value and the position actual
value occurs, which is compensated by the control system when the IS ”Servo enable” is set. The
axis motion starts at the setpoint position which existed before ”Servo enable” was canceled.
In ”Stop” state, the IS ”Follow–up active” (V390x 0001.3) is at 0.
Clamping or zero speed monitoring are active.

Position measuring system 1 (V380x 0001.5)

A position encoder can be connected to the spindle. In this case, the signal for the spindle must be
set.
This signal is in any case required for the axes. A position encoder must be provided.

Servo enable (V380x 0002.1)

If Servo Enable is provided for the drive, the position control loop of the axis/spindle will be closed.
The axis/spindle is thus in position control.
If Servo Enable is disabled, the position control loop will be opened, and the speed control loop of
the axis/spindle will be opened with delay.
IS ”Position controller active” (V390x 0001.5) will be set to 0–signal (checkback signal).

Enabling:
Servo Enable for the drive can be set and disabled from the following points:

1. from the PLC user program using the interface signal ”Servo enable” (normal case)
Application: Disabling of Servo Enable prior to clamping an axis/spindle.
2. Internally in the control system, servo enable is disabled in case of various faults on the ma-
chine, the drive, the position encoder or the control system (fault).
Application: In case of a fault, all axes moving must be stopped by rapid stop.
3. internally in the control system in case of the following events: IS ”EMERGENCY STOP”
(V2600 0000.1) is present

Disabling servo enable for a moving axis/spindle:

 The spindle is decelerated to standstill using rapid stop, taking into account
MD 36610: AX_EMERGENCY_STOP_TIME (duration of brake ramp in case of errors). Then
alarm 21612 ”Servo enable reset during the movement” is output.
 The position control loop of the axis/spindle will be opened. Checkback message to the PLC
usng IS ”Position controller active” (V390x0001.5) = 0 signal. In addition, the timer for the time
delay of servo enable (MD 36620: SERVO_DISABLE_DELAY_TIME (servo disable delay time)
is started.

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 Various Interface Signals (A2)

 Once the actual velocity reaches the standstill range, Servo Enable will be canceled. Checkback
message to PLC with IS ”Speed controller active” (V390x0001.6) = 0 signal. The servo enable of
the drive is canceled at the latest after expiration of the time defined in
MD 36620: SERVO_DISABLE_DELAY_TIME.
Caution: If you have set the servo enable shutdown delay too small, servo enable will be disa-
bled even if the axis/spindle is still traversing/rotating. It will then suddenly be stopped with set-
point 0.
 The actual position value of the axis/spindle will still be acquired by the control system.
This state of the axis/spindle can only be changed after RESET.
Interpolation axis group:
All axes involved in the interpolation will be stopped if Servo Enable is disabled for one of the axes
involved.

The axes are stopped as described above. All axes of the geometry group will be stopped with rapid
stop. In addition, alarm 21612 ”Servo enable reset during the movement” is output. An execution of
the NC program is then no longer possible.

Signals for digital drives, to axis/spindle

Ramp function generator rapid stop (V380x 4000.1)

Rapid stop is requested by the PLC user program for the drive. The drive is then stopped without a
ramp function (with speed setpoint 0). Servo enable remains stored.

Speed setpoint smoothing (V380x 4000.3)

The PLC user program requests a filter for smoothing the speed setpoint for the axis/spindle. The
smoothing is enabled in the drive module only under certain conditions.

Drive parameter record selection A, B, C (V380x 4001.0 to .2)

With SIMODRIVE 611UE, the bit combination A, B, C can be used to select up to 8 different drive
parameter records from the PLC user program.

Integrator disabled for speed controller (V380x 4001.6)

The PLC user program disables the integrator of the speed controller for the drive. The speed
controller is thus switched over from a PI to a P controller.

Pulse enable (V380x 4001.7)

The PLC user program provides pulse enable for the axis/spindle. Pulse enable for the drive module
is only carried out if all enable signals are present.

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Various Interface Signals (A2)

17.3 Signals from NCK to PLC

Drives in cyclic mode (V2700 0002.5)

The NCK signals to the PLC that all existing drives are in cyclic mode.

Drive ready (V2700 0002.6)

A signal is provided from the NCK to the PLC that all existing drives are ready for operation. The IS
”Drive Ready” is provided from all axes/spindles (group signal).

NCK alarm is present (V2700 0003.0)

A signal is provided from the control system to the PLC that at least one NCK alarm is present. The
channel–specific interface (V3300 0004.7) can be interrogated whether a standstill of machining has
been initiated.

Air temperature alarm (V2700 0003.6)

The ambient temperature or fan monitoring function has responded.

Channel–specific NCK alarm is present (V3300 0004.6)

A signal is provided from the control system to the PLC that at least one NCK alarm is present for
the channel. The IS ”NCK alarm with program standstill present” (V33000004.7) can be used to
make a conclusion on the extent the current program execution has been interrupted and/or abor-
ted.

External language mode active (V3300 4001.0)

The control system signals to the PLC that the active program language for the part program is not a
SIEMENS language. A language switch–over has been carried out using G291.

NCK alarm with program stop present (V3300 0004.7)

The control system signals to the PLC that at least one NCK alarm is present for the channel which
has interrupted and/or aborted the current program execution (program standstill).

Follow–up active (V390x 0001.3)

Follow–up mode is active for this axis.
(”Follow–up” in detail: refer to the IS “Follow–up mode” (V380x0001.4))

Axis/spindle stopped (V390x 0001.4)

The current actual velocity of the axis and/or the actual speed of the spindle is within the range defi-
ned as the standstill. This range is defined by MD 36060: STANDSTILL_VELO_TOL (max. velocity/
speed for the signal ”Axis/spindle stopped”).

Position controller active (V390x 0001.5)

The position controller for the axis/spindle is closed; the position control is active.

Speed controller active (V390x 0001.6)

The speed controller for the axis/spindle is closed; the speed control is active.

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 Various Interface Signals (A2)

Current controller active (V390x 0001.7)

The current controller for the axis/spindle is closed; the current control is active.

Lubrication pulse (V390x 1002.0)

The IS ”Lubrication pulse” is sent by NCK and changes its state, as soon as the axis/spindle has
traveled a distance longer than defined by MD 33050: LUBRICATION_DIST (distance to be traver-
sed for lubrication from PLC).

Signals for digital drives, from axis/spindle

Ramp function generator disabling active (V390x 4000.1)

The drive feeds back to the PLC that ramp function generator quick stop is active. This will stop the
drive without a ramp function (with speed setpoint 0).

Speed setpoint smoothing active (V390x 4000.3)

The PLC user program requests a filter for smoothing the speed setpoint for the axis/spindle. The
smoothing is activated in the drive module only under certain conditions.

Active drive parameter records A, B, C (V390x 4001.0 to .2)

The drive module feeds back to the PLC which drive parameter block is currently active. With
SIMODRIVE 611UE, the bit combinations A, B, C can be used to select 8 different drive parameter
records from the PLC.

DRIVE ready (V390x 4001.5)

Response that the drive is ready for operation. Thus, the preconditions of the drive for traversing the
axis/spindle are given.

Integrator of speed controller disabled (V390x 4001.6)

The intergrator of the speed controller is interlocked. The speed controller has thus been switched
over from a PI to a P controller.

Pulses enabled (V390x 4001.7)

Pulse enable for the drive module is provided. The axis/spindle can thus be traversed.

Motor temperature prewarning (V390x 4002.0)

The drive module signals to the PLC that the motor temperature has exceeded the warning
threshold. If the motor temperature remains too high, the drive is stopped after expiration of a
defined time (drive MD) and pulse enable is disabled.

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Various Interface Signals (A2)

Heat sink temperature prewarning (V390x 4002.1)

The drive module signals to the PLC that the heat sink temperature has exceeded the warning
threshold. After 20 seconds, pulse enable is canceled for the drive module concerned.

Acceleration process completed (V390x 4002.2)

The signal signals that the speed actual value has reached the new setpoint value taking into
account the tolerance band set on the drive. Thus, the acceleration process is completed. Following
speed variations due to load changes have no effect on the interface signal.

|Md| < Mdx (V390x 4002.3)

The signal signals that the current torque |Md| is less than the threshold torque set in the drive Mdx.

|nact| < nmin (V390x 4002.4)

The signal signals that the speed actual value |nist| is less than the set minimum speed nmin.

nact| < nx (V390x 4002.5)

The signal signals that the speed actual value |nact| is less than the set threshold speed nx.

nact = nset (V390x 4002.6)

It is signaled to the PLC that the speed actual value nact has reached the new setpoint value, taking
into account the tolerance band set on the drive, and that this value continues to be within the
tolerance band.

Variable signaling function (V390x 4002.7)

Using the variable signaling function, the SIMODRIVE 611UE can monitor any parameter for excee-
ding a defined threshold and feed it back to the PLC as an interface signal.
The quantity to be monitored is defined using 611UE machine data.

DC link < warning threshold (V390x 4003.0)

The drive signals to the PLC that the DC link voltage (UZK) is less than the DC link low voltage
threshold.

17.4 Signals from PLC to HMI

OP key lock (V1900 5000.2)

The IS ”OP key lock” can be used to disable (1 signal) or enable (0 signal) the operator panel key-
board for the operator.

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PLC User Interface 18
18.1 Address ranges

Operand identifier Description Range

V Data V0.0 to V79999999.7 (see below)
T Timers T0 to T31
C Counters C0 to C31
I Image of digital inputs I0.0 to I17.7
Q Image of digital outputs Q0.0 to Q11.7
M Flags M0.0 to M255.7
SM Special flags SM0.0 to SM 0.6 (see below)
A ACCU (logics) AC0, AC1 (UDword)
A ACCU (arithmetics) AC2, AC3 (Dword)

Generating the V range address:

Type ID Range No. Subrange Offset Addressing
(DB No.) (Channel, axis No.)
10 00 0 000 symbolic
(10–79) (00–99) (0–9) (000–999) (8 digits)

Special flags SM bit definition (read–only):

SM bits Description
SM 0.0 Flag with defined ONE signal
SM 0.1 Default setting: first PLC cycle ‘1’, following cylces ‘0’
SM 0.2 Buffered data lost – valid only in the first PLC cycle (‘0’ – data o.k., ‘1’ – data lost)
SM 0.3 Power On: first PLC cycle ‘1’, following cycles ‘0’
SM 0.4 60 s clock (alternating ‘0’ for 30 s, then ‘1’ for 30 s)
SM 0.5 1 s clock (alternating ‘0’ for 0.5 s, then ‘1’ for 0.5 s)
SM 0.6 PLC cycle clock (alternating a cycle ‘0’, then a cycle ‘1’)

Note
All empty fields in the user interface are “Reserved for Siemens” and may not be filled out
or evaluated!
Fields marked with “0” must always be loaded with the value “logic 0”.
Anny references on the description of the interface signals always refer to the appropriate
Chapters/Sections of the Description of Functions and are specified with [F “Chapter/Sec-
tion No.”].

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Access rights to variables:

[r] marks a read–only area
[r/w] marks a random access area
plus specification of data format
1: BIT
8: BYTE
16: INT / WORD
32: DINT / DWORD / REAL

no data format specified: all data formats specified can be read or written

18.2 User data

18.2.1 User data 1

1000 Data 1 [r/w]

Data block
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
User data
1000 0000
to
User data
1000 0011

18.2.2 User Data 2

1100 Data 2 [r/w]

Data block
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
User data
1100 0000
to
User data
1100 0007

18.2.3 Battery–backed data range

1400 Battery–backed data [r/w]

Data block
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
User data
1400 0000
to
User data
1400 0127

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18.3 User alarm

Note: For information on PLC alarms including the configuration of user alarms, please refer to:
References: “Start–up Gude“, Section “PLC alarms”

18.3.1 User alarm: Enabling

1600 Enable alarm [r/w]

Data block Interface PLC –––––> HMI
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Enable alarm No.
1600 0000 700007 700006 700005 700004 700003 700002 700001 700000
Enable alarm No.
1600 0001 700015 700014 700013 700012 700011 700010 700009 700008
Enable alarm No.
1600 0002 700023 700022 700021 700020 700019 700018 700017 700016
Enable alarm No.
1600 0003 700031 700030 700029 700028 700027 700026 700025 700024

18.3.2 Variable for alarm

1600 Variable for alarm [r32/w32]

Data block Interface PLC –––––> HMI
Byte
1600 1000 Variable for alarm 700000 (4–byte)
1600 1004 Variable for alarm 700001 (4–byte)
1600 1008 Variable for alarm 700002 (4–byte)
... ...
1600 1116 Variable for alarm 700029 (4–byte)
1600 1120 Variable for alarm 700030 (4–byte)
1600 1124 Variable for alarm 700031 (4–byte)

18.3.3 Active alarm reaction

1600 Active alarm reaction [r]

Data block Interface PLC –––––> HMI
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
1600 2000 PLC STOP EMER- Feed lock Read–in NC start in-
GENCY of all disable hibited
STOP axes
1600 2001
1600 2002
1600 2003

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18.4 Signals from/to HMI

18.4.1 Program control signals from HMI (battery–backed range)

1700 HMI signals [r]
Data block Interface HMI –––––> PLC
DBB Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
1700 0000 Dry run M01 selec- DRF selec-
feed selec- ted ted
ted [F10.8.2] [F10.8.2]
[F10.8.2]
1700 0001 Program Feed over-
test selec- ride for ra-
ted pid traverse
[F10.8.2] selected
[F10.8.2]
[F11.5.1]
1700 0002 Block skip
selected
[F10.8.2]
1700 0003

1900 HMI signals [r/w]

Data block Interface HMI –––––> PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
1900 0000 Simulation
active
[F10.8.2]
1900 0001
1900 0002
1900 0003

18.4.2 General selection/status signals from MMC (battery–backed range)

1900 HMI signals [r]

Data block Interface HMI –––––> PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
1900 1000
1900 1001
1900 1002
Axis number for handwheel 1
1900 1003 Machine C B A
axis [F9.6.1] [F9.6.1] [F9.6.1]
[F9.6.1]

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Axis number for handwheel 2

1900 1004 Machine C B A
axis [F9.6.1] [F9.6.1] [F9.6.1]
[F9.6.1]
Axis number for handwheel 3
1900 1005 Machine C B A
axis [F9.6.1] [F9.6.1] [F9.6.1]
[F9.6.1]
1900 1006
1900 1007

18.4.3 General selection/status signals to MMC (battery–backed range)

1900 Signals to operator panel [r/w]

Data block Interface PLC –––––> HMI
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
1900 5000 OP key
lock
[F17.4]
1900 5001
1900 5002
1900 5003

18.5 Auxiliary function transfer from NC channel

2500 Auxiliary functions from NCK channel[r]

Data block PLC interface
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
2500 0000
to
2500 0003
2500 0004 M funct. 5 M funct. 4 M funct. 3 M funct. 2 M funct. 1
change change change change change
[F13.8] [F13.8] [F13.8] [F13.8] [F13.8]
2500 0005
2500 0006 S func. 1
change
[F13.8]
2500 0007
2500 0008 T func. 1
change
[F13.8]
2500 0009
2500 0010 D func. 1
change
[F13.8]

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2500 0011
2500 0012 H func. 3 H func. 2 H func. 1
change change change
[F13.8] [F13.8] [F13.8]
2500 0013
to
2500 0019

18.5.1 Decoded M signals (M0 – M99)

2500 M functions from NCK channel [r]

Data block NCK interface
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Dynamic M functions [F13.8]
2500 1000 M7 M6 M5 M4 M3 M2 M1 M0
Dynamic M functions [F13.8]
2500 1001 M15 M14 M13 M12 M11 M10 M9 M8
Dynamic M functions [F13.8]
2500 1002 M23 M22 M21 M20 M19 M18 M17 M16
...

Dynamic M functions [F13.8]

2500 1012 M99 M98 M97 M96
2500 1013
to
2500 1015
Note: The signals are output for the duration of one PLC cycle.

18.5.2 T functions transferred

2500 T functions from NCK channel [r]

Data block PLC interface
Start byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
2500 2000 T function 1 (DINT) [F13.8]
2500 2004
to
25002007

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18.5.3 M functions transferred

2500 M functions from NCK channel [r]

Data block PLC Interface
Start byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
2500 3000 M function 1 (DINT) [F13.8]
2500 3004
2500 3008 M function 2 (DINT) [F13.8]
2500 3012
2500 3016 M function 3 (DINT) [F13.8]
2500 3020
2500 3024 M function 4 (DINT) [F13.8]
2500 3028
2500 3032 M function 5 (DINT) [F13.8]
2500 3036

18.5.4 S functions transferred

2500 S functions from NCK channel [r]

Data block PLC interface
Start byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
2500 4000 S function 1 (REAL) [F13.8]
25004004
to
2500 4020

18.5.5 D functions transferred

2500 D functions from NCK channel [r]

Data block Interface PLC
Start byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

2500 5000 D function 1 (DINT) [F13.8]

2500 5004

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18.5.6 H functions transferred

2500 H functions from NCK channel [r]

Data block Interface PLC
Start byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

2500 6000 H function 1 (REAL) [F13.8]

2500 6004 Extended address of H function 1 (byte) [F13.8]
2500 6008 H function 2 (REAL)
2500 6012 Extended address of H function 2 (byte) [F13.8]
2500 6016 H function 3 (REAL) [F13.8]
2500 6020 Extended address of H function 3 (byte) [F13.8]

18.6 NCK signals

2600 General signals to NCK [r/w]

Data block Interface PLC –––––> NCK
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
2600 0000 Protection level [F17.2] Acknow- EMER-
ledge GENCY
EMER- STOP
GENCY [F1.5]
4 5 6 7 STOP
[F1.5]

2600 0001 INC inputs

in mode
group area
active 1)
[F9.6.2]

2600 0002

2600 0003
Notes: 1) see operating mode signals

2700 General signals from NCK [r]

Data block Interface NCK –––––> PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
2700 0000 EMER-
GENCY
STOP ac-
tive
[F1.5]
2700 0001 INCH di- Sensor 1 is
mension actuated.
system [F15.7]
[F3.6]

SINUMERIK 802DDescription of Funktions

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2700 0002 Drive Drives in

ready cyclic
[F17.3] mode
[F17.3]
2700 0003 Air tempe- NCK alarm
rature is present
alarm [F17.3]
[F17.3]

3000 Operating mode signals to NCK [r/w]

Data block Interface PLC –––––> NCK
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Reset Operating Operating mode
[F10.8.1] mode
3000 0000 Change JOG MDA AUTOM.
lock [F10.8.1] [F10.8.1] [F10.8.1]
[F10.8.1]
Machine function
3000 0001 REF
[F10.8.1]
Machine function 1) [F9.6.2]
3000 0002 Continuous NCvar. INC10 000 INC 1000 INC 100 INC 10 INC 1
traversing
3000 0003
Note:
1) To
be be able use the machine function signals in VB3000 0002, set the signal ”INC inputs in mode group area active”
(V2600 0001.0) to ”1”.
The machine function INC10 000 is not supported by all machine control panels.

3100 Operating mode signals from NCK [r]

Data block Interface NCK –––––> PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Active mode
3100 0000 802– JOG MDA AUTOM.
READY [F10.8.1] [F10.8.1] [F10.8.1]
[F10.8.1]
Active machine function
3100 0001 REF
[F10.8.1]
3100 0002
3100 0003

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18.7 Channel signals

18.7.1 Signals to NC channel

Control signals to NC channels

3200 Signals to NCK channel [r/w]

Data block Interface PLC –––––> NCK
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
3200 0000 Enable dry Enable Enable sin-
run feed M01 gle block 4)
[F11.5.1] [F10.8.2] [F10.8.2]
3200 0001 Enable pro- Enable re-
gram test ferencing
[F10.8.2] [F8.6]

3200 0002 Enable

block skip
[F10.8.2]
3200 0003
3200 0004 Feed override2) [F11.5.1]
H G F E D C B A
3200 0005 Rapid traverse override3) [F11.5.1]
H G F E D C B A
3200 0006 Feed over- Feed over- Program le- Delete di- Read–in di- Feed disa-
ride1) active ride active vel abortion stance to sable ble
[F11.5.1] [F11.5.1] [F10.8.2] go [F10.8.2] [F11.5.1]
[17.2]
3200 0007 NC Stop fpr NC Stop NC Stop at NC Start NC Start in-
axes plus block bor- hibited
spindle der
[F10.8.2] [F10.8.2] [F10.8.2] [F10.8.2] [F10.8.2]
Note:
1)+ Feed override active Even if feed override is not active (=100%), the position 0% is nevertheless
active.
2)+ Feed override 31 positions (Gray code)
3)+ Rapid traverse override 31 positions (Gray code)
4)+ Single block Use softkey for Single block type selection (SBL1/SBL2) (see ”User’s Guide”)

Control signals to geometry axes (axes in WCS)

3200 Signals to NCK channel [r/w]

Data block Interface PLC –––––> NCK
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Geometry axis 1 (axis 1 in WCS)
3200 1000 Traversing keys Rapid tra- Traversing Feed stop Enable handwheel
verse overri- key lock
+ – de 3 2 1
[F9.6.3] [F9.6.3] [F9.6.3] [F9.6.3] [F11.5.1] [F9.6.3] [F9.6.3] [F9.6.3]

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Geometry axis 1 (axis 1 in WCS)

3200 1001 Machine function 1) [9.6.3]
Continuous INCvar. INC10 000 INC1000 INC100 INC10 INC1
traversing [
32001002
32001003
Geometry axis 2 (axis 2 in WCS)
3200 1004 Traversing keys Rapid tra- Traversing Feed stop[ Activate handwheel
verse overri- key lock [F11 5 1]
[F11.5.1]
+ – de 3 2 1
[F9.6.3]
[F9.6.3] [F9.6.3] [F9.6.3] [F9.6.3] [F9.6.3] [F9.6.3]

Axis 2 in WCS
3200 1005 Machine functions 1) [9.6.3]
Continuous INCvar. INC10 000 INC1000 INC100 INC10 INC1
traversing
3200 1006
3200 1007
Geometry axis 3 (axis in WCS)
3200 1008 Traversing keys Rapid tra- Traversing Feed stop Activate handwheel
verse overri- key lock
+ – de 3 2 1
[F9.6.3] [F9.6.3] [F9.6.3] [F9.6.3] [F11.5.1] [F9.6.3] [F9.6.3] [F9.6.3]

Geometry axis 1 (axis 3 in WCS)

3200 1009 Machine functions 1) [9.6.3]
Continuous INCvar. INC10 000 INC1000 INC100 INC10 INC1
traversing
3200 1010
3200 1011
Notes:
1) Machine function settings for the machine function in VB3200 1001, VB3200 1005, VB3200 1009 only if signal
”INC inputs in mode group area active” (V2600 0001.0) is not set.
The machine function INC10 000 is not supported by all machine control panels.

18.7.2 Signals from NC channel

Status signals from NC channel

3300 Signals from NCK channel [r]

Data block Interface NCK –––––> PLC
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
3300 0000 Last action M0/M1 ac- Approach Action
block ac- tive block active block active
tive
[F10.8.2] [F10.8.2] [F10.8.2] [F10.8.2]
3300 0001 Program M2/M30 ac- Block Revolutio- Referen-
test active tive search ac- nal feed ac- cing active
tive tive
[F10.8.2] [F10.8.2] [F10.8.2] [F11.5.1] [F8.6]

SINUMERIK 802DDescription of Funktions

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3300 0002
Channel status Program status
3300 0003 Reset Interrupted Active Aborted Interrupted Stopped Running
[F10.8.2] [F10.8.2] [F10.8.2] [F10.8.2] [F10.8.2] [F10.8.2] [F10.8.2]
3300 0004 NCK alarm Channel– All axes All axes re-
with por- specific stopped ferenced
cessing NCK alarm [F12.7] [F8.6]
stop is pre- is present
sent
[F17.3] [F17.3]
3300 0005
3300 0006
3300 0007

Status signals of geometry axes (axes in WCS)

3300 Signals from NCK channel [r]

Data block Interface NCK –––––> PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Geometry axis 1 (axis 1 in WCS)
3300 1000 Travel command Handwheel active
plus minus 3 2 1
[F9.6.3] [F9.6.3] [F9.6.3] [F9.6.3] [F9.6.3]
Active machine function [9.6.3]
3300 1001 Continuous INCvar. INC10 000 INC1000 INC100 INC10 INC1
traversing
3300 1002
3300 1003
Geometry axis 2 (axis 2 in WCS)
3300 1004 Travel command Handwheel active
plus minus 3 2 1
[F9.6.3] [F9.6.3] [F9.6.3] [F9.6.3] [F9.6.3]
3300 1005 Active machine function [9.6.3]
Continuous INCvar. INC10 000 INC1000 INC100 INC10 INC1
traversing
3300 1006
3300 1007
Geomery axis 3 (axis 3 in WCS)
3300 1008 Travel command Handwheel active
plus minus 3 2 1
[F9.6.3] [F9.6.3] [F9.6.3] [F9.6.3] [F9.6.3]
3300 1009 Active machine function [9.6.3]
Continuous INCvar. INC10 000 INC1000 INC100 INC10 INC1
traversing
3300 1010
3300 1011

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3300 Signals from NCK channel [r]

Data block Interface NCK –––––> PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
3300 4000
3300 4001 Workpiece External
setpoint re- language
ached mode ac-
tive
[F10.8.2] [F17.3]
3300 4002
3300 4003

18.8 Axis/spindle signals

18.8.1 Transferred M/S functions, axis–specific

3700...3704 M/S functions [r]
Data block Interface PLC –––––> NCK
Start byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

370x 0000 M function for spindle (DINT) [F5.9]

370x 0004 S function for spindle (REAL) [F5.9]

18.8.2 Signals to axis/spindle

Common signals to axis/spindle

3800...3804 Signals to axis/spindle [r/w]
Data block Interface PLC –––––> NCK
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Feed override [F11.5.2]
380x 0000 H G F E D C B A
380x 0001 Override Position en- Follow–up Axis/
active coder 1 mode spindle
lock
[F11.5.2] [F17.2] [F17.2] [F17.2]
380x 0002 Clamping Distance to Servo
process go/spindle enable
running reset
[F2.7] [F5.9] [F17.2]
380x 0003 Velocity/
speed limi-
tation
[F2.7]
Traversing keys Rapid tra- Traversing Feed stop Enable handwheel
verse over- key lock Spindle Stop
380x 0004 plus minus ride 3 2 1
[F9.6.4] [F9.6.4] [F11.5.2] [F9.6.4] [F9.6.4] [F9.6.4]
[F9.6.4] [F9.6.4]

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Machine functions 1)
380x 0005 Continuous INCvar INC10 000 INC1000 INC100 INC10 INC1
traversing
380x 0006
to
380x 0011
Notes: 1) Machine function settings for the machine function in VB38x 0005 only if signal ”INC inputs in mode group range
active” (V2600 0001.0) is not set.
The machine function INC10 000 is not supported by all machine control panels.

Signals to axis

3800...3804 Signals to axis [r/w]

Data block Interface PLC –––––> NCK
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Delayed re- 2nd software limit switch Hardware limit switch
ference
380x 1000 point ap- plus minus plus minus
(axis) proach
[F2.7] [F2.7] [F2.7] [F2.7]
[F8.6]
380x 1001
to
380x 1003

Signals to spindle

3800...3804 Signals to spindle [r/w]

Data block Interface PLC –––––> NCK
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Gear is Actual gear stage
switched
380x 2000 over C B A
(spindle) [F5.9] [F5.9] [F5.9] [F5.9]

Invert Resynchro- Feed overri-

M3/M4 nization de valid for
380x 2001 when posi- spindle
(spindle) [F5.9] tioning 1 [F11.5.2]
[F5.9]
Set direction of rotation Oscillation Oscillation
380x 2002 CCW CW speed d f
from PLC
(spindle) [F5.9] [F5.9] [F5.9] [F5.9]
380x 2003 Spindle override [F11.5.2]
(spindle) H G F E D C B A

SINUMERIK 802DDescription of Funktions

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Signals to drive

3800...3804 Signals to axis/spindle [r/w]

Data block Interface PLC –––––> NCK
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
380x 4000 Speed set- HLGSS
point smoo- [F17.2]
thing
[F17.2]

380x 4001 Pulse Integrator Parameter record selection [F17.2]

enable lock n con-
[F17 2]
[F17.2] troller
C B A
[F17.2]
380x 4002

380x 4003

18.8.3 Signals from axis/spindle

General signals from axis/spindle

3900...3904 Signals from axis/spindle [r]

Data block Interface NCK –––––> PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Position reached Referen- Encoder fre- Spindle/no
390x 0000 with exact with exact ced/syn-
d/ quency ex- axis
i
stop fine stop coarse chronized 1 ceeded 1 [F5.9]
[F12.7] [F12.7] [F8.6] [F2.7]
390x 0001 Current Speed con- Position Axis/ Follow–up
controller troller ac- controller spindle active
acitve tive active stopped (n [F17.3]
[F17.3] [F17.3] [F17.3] < nmin)

[F17.3]
390x 0002 Measuring
active
[F15.7]
390x 0003
Traversing command Handwheel active
390x 0004 plus minus 3 2 1
[F9.6.4] [F9.6.4] [F9.6.4] [F9.6.4] [F9.6.4]
Active machine function [9.6.4]
390x 0005 continuous NCvar. INC10 000 INC1000 INC100 INC10 INC1
390x 0006
to
390x 0011

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Signals from axis

3900...3904 Signals from axis [r]

Data block Interface NCK –––––> PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
390x 1000
390x 1001
390x 1002 Lubrication
pulse
[F17.3]
390x 1003

Signals from spindle

3900...3904 Signals from spindle [r]

Data block Interface NCK –––––> PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Switch over Set gear stage
390x 2000 gear C B A
(spindle) [F5.9] [F5.9] [F5.9] [F5.9]
390x 2001 Actual di- Spindle Setpoint Setpoint Speed limit
(spindle) rection of in setpoint speed in- speed limi- exceeded
rotation CW range creased ted [F5.9]
[F5.9] [F5.9] [F5.9] [F5.9]
Active spindle mode Rigid
g tap- Constant
390x 2002 Control Oscillation Positioning ping
i cutting
tti ratet
mode mode mode [F5.9] active
(spindle)
[F5.9] [F5.9] [F5.9] [F5.9]

390x 2003

Signals from drive

3900...3904 Signals from axis/spindle [r]

Data block Interface NCK PLC –––––> PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
390x 4000 Speed set- Ramp–
point smoo- function ge-
thing nerator en-
active coder lock
[F17.3] active
[F17.3]
390x 4001 Pulses Integrator Drive Active parameter record [F17.3]
enabled of n control- readyy
[F17.3] ler disabled [F17.3] C B A
[F17.3]
390x 4002 Variable nact = nset nact<nx nact < nmin Md < Mdx Accelera- Temperature prewarning
signaling
g g [F17.3] [F17.3] [F17.3] [F17.3] tion pro-
function 1 cess com- Heat sink Motor
[F17.3] pleted
[F17.3] [F17.3]
[F17.3]
390x 4003 UZK<war-
ning thres-
hold
[F17.3]

SINUMERIK 802DDescription of Funktions

18-296 6FC5 697–2AA10–0BP0 (04.00)
 PLC User Interface

18.9 PLC machine data

18.9.1 INT values (MD 14510 USER_DATA_INT)

4500 Signals from NCK [r16]

Data block Interface NCK –––––> PLC
Byte
4500 0000 Int value (WORD/ 2 byte)
4500 0002 Int value (WORD/ 2 byte)
4500 0004 Int value (WORD/ 2 byte)
to
4500 0062 Int value (WORD/ 2 byte)

18.9.2 HEX values (MD 14512 USER_DATA_HEX)

4500 Signals from NCK [r8]

Data block Interface NCK –––––> PLC
Byte
4500 1000 Hex value (BYTE)
4500 1001 Hex value (BYTE)
to
45001031 Hex value (BYTE)

18.9.3 FLOAT values (MD 14514 USER_DATA_FLOAT)

4500 Signals from NCK [r32]

Data block Interface NCK –––––> PLC
Start byte

4500 2000 Float value (REAL/ 4–byte)

4500 2004 Float value (REAL/ 4–byte)
to
4500 2028 Float value (REAL/ 4–byte)

SINUMERIK 802DDescription of Funktions

6FC5 697–2AA10–0BP0 (04.00) 18-297
PLC User Interface

18.9.4 User alarm: Configuration (MD 14516 USER_DATA_PLC_ALARM)

4500 Signals from NCK [r8]

Data block Interface NCK –––––> PLC
Byte
4500 3000 Alarm reaction/reset criterion for alarm 700000
4500 3001 Alarm reaction/reset criterion for alarm 700001
to
4500 3031 Alarm reaction/reset criterion for alarm 700031

Note: For information on PLC alarms including the configuration of user alarms, please refer to:
References: “Start–up Guide”, Section “PLC alarms”

SINUMERIK 802DDescription of Funktions

18-298 6FC5 697–2AA10–0BP0 (04.00)
Various Machine Data 19
This Chapter describes machine data that are of general importance, but for which no topic–related
Chapters/Sections are included in this Description of Functions.

19.1 Display machine data

202 FIRST_LANGUAGE
MD number First language
Default: 1 Min. input limit: 1 Max. input limit: 2
Change valid: immediately Protection level: 2/3 Unit: –
Date type: BYTE Valid from SW release:
Meaning: This machine data can be used to set the language (1 or 2) automatically displayed after each
system power up.
With the SINUMERIK 802D, 2 languages can be used at a time. Other languages implemented
in the control system in the delivery status can be loaded during start–up.
It is also possible to switch over the language temporarily using the appropriate softkey in the
“System” operating area. After Power On, the language set using this MD will be active again.
Further references ”Operation and Programming“

203 DISPLAY_RESOLUTION
MD-Nummer Display resolution
Default: 3 Min. input limit: 0 Max. input limit: 5
Change valid: immediately Protection level: 2/3 Unit: –
Date type: BYTE Valid from SW release:
Meaning: This machine data is used to define the number of decimal places for the position display of
linear axes if a metric system is used and, generally, for rotary axes.
Spindle positions are treated as rotary axes positions.
The position is displayed with a maximum of 10 characters including sign and decimal point.
A positive sign is not displayed.
By default, 3 places after the decimal point are displayed
MD value=3: Display unit = 10–3 [mm] or [degrees]
Related to .... MD 10200: INT_INCR_PER_MM bzw. MD 10210: INT_INCR_PER_DEG

204 DISPLAY_RESOLUTION_INCH
MD number Display unit for inch scaling system
Default: 4 Min. input limit: 0 Max. input limit: 5
Change valid: immediately Protection level: 2/3 Unit: –
Date type: BYTE Valid from SW release:
Meaning: This machine data is used to define the number of decimal places for linear axes if an inch sca-
ling system is used.
The position is displayed with a maximum of 10 characters including sign and decimal point. A
positive sign is not displayed.
By default, 4 places after the decimal point are displayed
MD value=4: Display unit = 10–4 [inch]
For rotary axes and spindle positions, the display remains as defined acc. to MD 203.
Related to .... MD 10200: INT_INCR_PER_MM, MD 203: DISPLAY_RESOLUTION

SINUMERIK 802DDescription of Funktions

6FC5 697–2AA10–0BP0 (04.00) 19-299
Various Machine Data

205 DISPLAY_RESOLUTION_SPINDLE
MD number: Display unit for spindle values
Default: 1 Min. input limit: 0 Max. input limit: 5
Change valid: immediately Protection level: 2/3 Unit: –
Date type: BYTE Valid from SW release:
Meaning: This machine data defines the number of decimal places for the display of the spindle speed.
The display is carried out with a max. of 10 characters including sign and decimal point. A posi-
tive sign is not displayed.
By default 1 place after the decimal point is displayed
MD value=1: display resolution = 10–1

19.2 General machine data

10000 AXCONF_MACHAX_NAME_TAB[0]...[4]
MD number Machine axis name
Default: Min. input limit: a letter Max. input limit: 15 characters
Drehen: (”X1”, “Z1”, “SP”, “A1”, “B1”) starting with a letter,
Fräsen: (”X1”, “Y1”, “Z1”, “SP”, “A1”) 16th character reserved (end of string)
Change valid after Power On Protection level: 2/2 Unit: –
Date type: STRING Valid from SW release:
Meaning: The name of the machine axis is entered in this machine data.

An axis identifier consists of a valid address letter (A, B, C, Q, U, V, W, X, Y, Z) followed by

an optional numerical extension; (1–99) should be used preferably.
The selected machine axis identifier must differ from the designation of geometry axes (X, Y,
Z) and further channel axes (MD 20080: AXCONF_CHANAX_NAME_TAB – if a transformation
is intended (e.g.: TRANSMITT).
Note: Transformations are not implemented in SW release P1 of the SINUMERIK 802D.

A “free” machine axis identifier that has been entered (axis name) may not be a name,
address, vocabulary word or predefined identifier already used by the control system or
which is reserved for a different functionality (e.g.: SPOS, DIAMON, ...).
Note: Not the entire functionality of the SINUMERIK 802D control system is documented; a free
axis name may therefore only be used conditionally.
Special cases, errors, ...... For machine axes, the following is recommended:
X1, Y1, Z1, U1, V1, W1, Q1 for linear axes,
A1, B1, C1 for rotary axes
Related to .... MD 20060: AXCONF_GEOAX_NAME_TAB (geometry axis name)
MD 20080 :AXCONF_CHANAX_NAME_TAB (channel axis name)

10074 PLC_IPO_TIME_RATIO
MD number Factor of PLC task for power up (IPO)
Default: 2 Min. input limit: 1 Max. input limit: 50
Change valid after: Power On Protection level: 2/2 Unit: –
Date type: DWORD Valid from SW release:
Meaning: Division ratio between IPO and PLC task.
For example, a value of 2 means that the PLC task is only processed in every second IPO cy-
cle. The PLC cycle time thus amounts to 2 IPO times. Thus, more runtime is provided for the
other tasks.
The PLC runtime may not exceed this PLC cycle time; otherwise, an alarm is generated with
PLC STOP.
Application example(s)

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 Various Machine Data

11210 UPLOAD_MD_CHANGES_ONLY
MD-Nummer Saving of modified MDs only
Default: 0x0F Min. input limit: 0x00 Max. input limit: 0x0FF
Change valid: immediately Protection level: 2/2 Unit: –
Date type: BYTE Valid from SW release:
Meaning: Differential MD upload selection:
Bit0(LSB) Activation of differential upload with TEA files (machine data files)
0: All data are output
1: Only MDs that have been changed compared with the compiled value are ouput.
Bit1 Activation of differential upload with INI files
0: All data are output
1: Only MDs that have been changed compared with the compiled value are ouput.
Bit2 Change of a field element
0: The complete array is output.
1: Only the modified field elements of an array are output.
Bit3 R parameters (only for INI files)
0: All R parameters are output.
1: Only R parameters unequal to ’0’ are output.
Bit4 Frames (only for INI files)
0: All frames are output.
1: Only frames that are no zero frames are output.
Bit5 Tool data (cutting edge parameters) (only for INIfiles)
0: All tool data are output.
1: Only tool data unequal to ’0’ are output.

14510 USER_DATA_INT[0]...[31]
MD number User data (INT)
Default: 0 Min. input limit: –32768 Max. input limit: 32767
Change valid after Power On Protection level: 3/7 Unit: –
Date type: DWORD Valid from SW release:
Meaning: User machine data; evaluation in PLC (display as an integer number, decimal)

14512 USER_DATA_HEX[0]...[31]
MD number User data (HEX)
Default: 0 Min. input limit: 0 Max. input limit: 0x0FF
Change valid after Power On Protection level: 3/7 Unit: –
Date type: BYTE Valid from SW release:
Meaning: User machine data; evaluation in PLC (display in HEX format)

14514 USER_DATA_FLOAT[0]...[7]
MD number User data (FLOAT)
Default: 0.0 Min. input limit: –3.40e38 Max. input limit: 3.40e38
Change valid after Power On Protection level: 3/7 Unit: –
Date type: DOUBLE Valid from SW release:
Meaning: User machine data; evaluation in the PLC (floating point format, in the PLC limited to the 32–bit
IEEE format)

SINUMERIK 802DDescription of Funktions

6FC5 697–2AA10–0BP0 (04.00) 19-301
Various Machine Data

14516 USER_DATA_PLC_ALARM[0]...[31]
MD number User data (HEX)
Default: 0 Min. input limit: *** Max. input limit: ***
Change valid after Power On Protection level: 3/7 Unit: –
Date type: BYTE Valid from SW release:
Meaning: User data; evaluation in PLC (display in HEX format)

19.3 Channel–specific machine data

20050 AXCONF_GEOAX_ASSIGN_TAB[0]...[2]
MD number Assignment ’Geometry axis / channel axis’
Default: Min. input limit: 0 Max. input limit: 5
Drehen: (1, 0, 2) (0 means that the geometry axis is assi-
Fräsen: (1, 2, 3) gned to none channel axis)
Change valid after Power On Protection level: 2/2 Unit: –
Date type: BYTE Valid from SW release:
Meaning: This MD is used to assigne a geometry axis a channel axis.
The assignment must be made for all 3 geometry axes (X, Y, Z). If no assignment is made for a
geometry axis, value “0” must be entered. Thus, the geometry axis does not exist and cannot be
programmed. For example, with the “Turning” technology, the 2nd geometry axis Y need not be
programmed –> entry: value 0 (see default for turning).
Special cases, errors, ...... It is recommended to assign the first channel axes to the geometry axes.

20070 AXCONF_MACHAX_USED[0]...[4]
MD number Machine axis number valid in the channel
Default: Min. input limit: 0 Max. input limit: 5
Turning: (1, 2, 3, 0, 0) (0 means that the machine axis is assi-
Milling: (1, 2, 3, 4, 5) gned to none channel axis)
Change valid after Power On Protection level: 2/2 Unit: –
Date type: BYTE Valid from SW release:
Meaning: This MD is used to assign a channel axis a machine axis.
SINUMERIK 802D has 5 channel axes.
For the axes enabled in the channel, channel identifiers must be specified in
MD 20080: AXCONF_CHANAX_NAME_TAB. These axes can be programmed.

A machine axis that has been assigned to none channel axis is not active, i.e. no axis control, no
display on the screen.
Special cases, errors, ...... Each geometry axis that is to be programmed must be assigned a channel axis und thus indirectly
a machine axis. The remaining axes in the channel (apart from the geometry axes) are the addi-
tional axes; these can also be programmed.
Application example(s) Example of assignments of the machine axes (MA) to channel axes:
AXCONF_MACHAX_USED [0] = 3 ;3rd MA is the 1st axis in the channel
AXCONF_MACHAX_USED [1] = 1 ;1st MA is the 2nd axis in the channel
AXCONF_MACHAX_USED [2] = 5 ;5th MA is the 3rd axis in the channel
AXCONF_MACHAX_USED [3] = 0 ; no assignment
Note: Do not leave gaps!, error example:
AXCONF_MACHAX_USED [0] = 1 ;1st MA is the 1st axis in the channel
AXCONF_MACHAX_USED [1] = 2 ;2nd MA is the 2nd axis in the channel
AXCONF_MACHAX_USED [2] = 0 ;gap in the list ...
AXCONF_MACHAX_USED [3] = 3 ;... of channel axes
Related to .... MD 20080: AXCONF_CHANAX_NAME_TAB[0]...[4] (channel axis name)

SINUMERIK 802DDescription of Funktions

19-302 6FC5 697–2AA10–0BP0 (04.00)
 Various Machine Data

20080 AXCONF_CHANAX_NAME_TAB[0]...[4]
MD number Channel axis name
Default: Min. input limit: Max. input limit: 15 characters,
Turning: (”X”, “Z”, “SP”, “ ”, “ ”) a letter or space starting with a letter,
Milling: (”X”, “Y”, “Z”, “SP”, “A”) 16th character reserved (end of string)
Change valid after Power On Protection level: 2/2 Unit: –
Date type: STRING Valid from SW release:
Meaning: The name of the channel axis is entered in this MD.
A channel axis is displayed in the WCS (workpiece coordinate system) using this name. This
name is also used in the program.
As a rule, the first two or three channel axes are used as geometry axes (see also MD 20050:
AXCONF_GEOAX_ASSIGN_TAB). The remaining channel axes are designated as additional
axes.
The SINUMERIK 802D has 5 channel axes.
Special cases, errors, ...... The following is recommended for channel axis names:
X, Y, Z, U, V, W, Q for linear axes,
A, B, C for rotary axes
In case of any deviations from the recommendations above, observe the rules for generating the
axis identifiers (see MD 10000: AXCONF_MACHAX_NAME_TAB).

27800 TECHNOLOGY_MODE
MD number Technology in the channel
Default: Min. input limit: 0 Max. input limit: 1
Turning: 1
Milling: 0
Change valid after NEW_CONF Protection level: 2/2 Unit: –
Date type: BYTE Valid from SW release:
Meaning: Selection of the technology for display and operating purposes (HMI)
0: Milling
1: Turning
It is used to provide technology–dependent screen forms and softkeys in HMI.
Special cases, errors, ......

19.4 Axis–specific machine data

30600 FIX_POINT_POS
MD number Fixed–value positions of the axes with G75
Default: 0.0 Min. input limit: *** Max. input limit: ***
Change valid after Power On Protection level: 2/2 Unit: mm, degrees
Date type: DOUBLE Valid from SW release:
Meaning: This machine data is used to specify the fixed–point position approached when programming
G75.
Application example(s) Travel to fixed point: G75 X1=0
In this case, the machine axis identifier is programmed! The axis must be specified a dummy
value, in this case 0.
Further reference ”Operation and Programming”

SINUMERIK 802DDescription of Funktions

6FC5 697–2AA10–0BP0 (04.00) 19-303
Various Machine Data

33050 LUBRICATION_DIST
MD number Distance to be traversed for the PLC signal lubrication pulse
Default: 100 000 000 Min. input limit: 0.0 Max. input limit: ***
Change valid after: Power On Protection level: 2/7 Unit: mm, degrees
Date type: DOUBLE Valid from SW release:
Meaning: Distance to be traversed to trigger the lubrication pulse
After the distance traversed for the appropriate axis, the status of the axis–specific IS: “Lubrica-
tion pulse“ (V390x 1002.0) is changed. It is thus possible to control a lubrication unit for an axis
from the PLC program depending on the traversed distance.
From Power On, the traversed distance is summed up.
Related to .... IS: “Lubrication pulse” (V390x 1002.0)

SINUMERIK 802DDescription of Funktions

19-304 6FC5 697–2AA10–0BP0 (04.00)
 Index

Index
A Decoding single block, 10-183
Display resolution, 3-49
Acceleration, 9-147 Dry run feed, 10-183
Acceleration profiles, 4-75
Jerk–limited acceleration, 4-75
Sudden acceleration, 4-75
Accuracy, 15-260 E
ACN, 6-120 Edge selection during tool change, 14-252
Action single block, 10-183 EMERGENCY STOP
Actual values, 2-27 Acknowlededgement, 1-17
Actual–value assignment, 3-59 Interface signal, 1-16
Actual–value processing, 3-61 Sequence, 1-16
Actual–value resolution, 3-61 Encoder monitoring functions, 2-28
Actual–value system, 3-55 Encoder frequency, 2-28
Auxiliary function groups Zero marks, 2-29
Defaulted, 13-244 Exact stop, 12-232
Non–grouped, 13-244 Exact stop criteria, 12-233
Auxiliary function output, Block change, 13-242 Exact stop coarse, 2-23
Auxiliary functions, 13-241 Exact stop fine, 2-24
Description, 13-245 Exact stop criterion, 12-233
Axis monitoring Exact stop limit fine, 2-23
Clamping, 2-25
Contour, 2-21
Axis monitoring
Actual velocity, 2-27 F
Positioning monitoring, 2-22 Feed disable, 11-219
Speed setpoint, 2-26 Feed override, 9-147
Zero speed , 2-24 Feed override switch, 11-220
Axis–related jerk limitation, 4-76 Feed stop, 10-179
Feed/spindle stop, 11-219
Feedrate, 3-48
B Feeds
Feed disable, 11-219
Backlash compensation Feed override, 11-218, 11-219, 11-220
Negative backlash, 16-264 Feed/spindle stop, 11-219
Positive backlash, 16-264 Feedrate F, 11-215
Block change point, 12-233 Spindle override, 11-221
Block search, 10-184, 13-245 Tapping with compensating chuck G63, 11-217
Tapping without compensating chuck G331, G332,
11-217
C Thread cutting G33, 11-216
Following error compensation, 16-269
Channel, 10-169 Parameters, 16-269
Channel status, 10-178
Commands MEAS, MEAW, 15-259
Compensation table, 16-266
Computational resolution, 3-49 H
Connecting the probe, 15-257 Handwheel, traversing in JOG mode, 9-151
Continuous traversing, 9-149 Hardware limit switches, 2-30, 9-148
Contour violation, 2-31
Control, 3-63
Cyclic signal exchange, 17-274
I
Implied exact stop, 12-234
D Inch scaling system, 3-50
Incremental traversing, 9-150
D functions, 14-252

SINUMERIK 802DDescription of Funktions

6FC5 697–2AA10–0BP0 (04.00) Index-305
Index

Input resolution, 3-49 M

Interface signals
2nd software limit switch plus or minus, 2-43 Manual Traversing and Handwheel Traversing (H1),
Activate referencing, 8-142 9-145
Active spindle mode ”Control mode”, 5-113 Machine data, 19-299
Active spindle mode ”Oscillation mode”, 5-113 Metric scaling system, 3-50
Active spindle mode ”Positioning mode”, 5-113 Mode change, 10-170
Actual direction of rotation, 5-111 Mode group, ready to operate, 10-170
Actual gear stages A to C, 5-108 Monitoring of static limitations, 2-30
All axes to be referenced are referenced, 8-142 Motion monitoring functions, 2-21
Clamping process running, 2-42
Delayed reference point approach, 8-143
Dry run feed selected, 11-225 N
Encoder limit frequency exceeded, 2-43
Feed override for rapid traverse selected, 11-226 NC Start, 10-175
Gear is switched, 5-107 NC Stop, 10-179
Hardware limit switch plus and minus, 2-43 Notes for the reader, v
Invert M3/M4, 5-109
Measuring status, 15-262
Oscillation from PLC, 5-110 O
Oscillation speed, 5-109
Probe actuated, 15-262 Operating modes, 10-171
Referencing active, 8-142 Locks, 10-174
Resynchronize spindle when positioning 1 and 2, Monitoring functions, 10-173
5-108 Output of auxiliary function, Block search, 13-245
Revolutional feed active, 11-226 Overload factor, 12-235
Rigid tapping active, 5-114
Set direction of rotation CCW/set direction of rotation
CW, 5-109 P
Set gear steps A to C, 5-111
Parameter blocks of position controller, 3-64
Set speed increased, 5-112
Part program interruption, 10-176
Set speed limited, 5-113
Path–related jerk limitation, 4-75
Speed limit exceeded, 5-113
PATH_TRANS_JERK_LIM, MD 32432, 12-239
Spindle in set range, 5-112
Physical quantities, 3-50
Spindle reset/delete distance to go, 5-107
PLC service display, 15-259
Spindle/no axis, 5-110
PLC user interface, 18-281
Switch gear, 5-111
Axis/spindle signals, 18-293
Velocity/spindle speed limiting, 2-42
Channel signals, 18-290
Interpolatory compensation
PLC machine data, 18-297
Linear interpolation, 16-265
User alarm, 18-283
Methods, 16-264
User data, 18-282
PLC/NCK interface, 17-273
Position control, 3-64
J Position control direction, 2-27
Jerk limit, 12-236 Position control gain, 2-24
Jerk limitation, 12-235 Position control loop, 3-63
Jerk reduction, 12-236 Positioning window, 2-24
Probe assignment, 15-256
Probe types, 15-255
Mono–directional, 15-256
L Probe types
Limit switch monitoring, 2-30 Bi–directional, 15-256
Linear axis, with rotary encoder installed on the motor, Multi–directional, 15-256
3-62
LookAhead, 12-233, 12-237
Following block velocity, 12-238
Selection and deselection, 12-238
Velocity profiles, 12-238

SINUMERIK 802DDescription of Funktions

Index-306 6FC5 697–2AA10–0BP0 (04.00)
 Index

Program control, 10-177 Signals from NCK to PLC, 17-278

DRY, 10-177 Signals from PLC to HMI, 17-280
M01, 10-177 Signals from PLC to NCK, 17-274
PRT, 10-177 Simulation axes, 3-55
ROV, 10-177 Single block, 10-179
SBL1, 10-177 Single block mode, 10-182
SKP, 10-177 Skipping part program blocks, 10-186
Program mode, 10-169, 10-174 Software limit switches, 2-31, 6-118, 9-148
Program status, 10-177 Speed, control, 2-28
Program test, 10-181 Speed control loop, 3-63
Speed setpoint output, 3-60
Spindle (S1) Gear stage change, 5-88
Spindle (S1) Spindle monitoring functions, 5-92
R Spindle (S1) Synchronizing, 5-87
Rapid stop, 2-22, 2-25, 2-26, 2-27, 2-28, 2-29 Spindle override factor, 11-221
Rapid traverse override, 9-147 Spindle position with mono–probe, 15-256
Rapid traverse override switch, 11-220 Spindle speed, 3-48
Read measurement results, 15-259 Spindle stop, 10-179
Read–in lock, 10-179 SPOS, 12-234
Referencing Standardization of Machine and Setting Data, 3-50
axis–specific, 8-128
channel–specific, 8-128
using incremental measuring systems, 8-129
Referencing using absolute encoders, 8-132
T
Reset, 1-17, 10-179 T function, 13-245
Rotary axes Tachogenerator, 2-27
Absolute programming, 6-120, 6-121 Tool, 14-251
Axis adresses, 6-117 Tool compensation, 14-252
Feed, 6-118 Transverse axes
Incremental dimension programming, 6-120 Diameter programming, 7-125
Modulo 360 degrees, 6-119 Geometry axes, 7-125
Software limit switches, 6-118 Traversing ranges, 3-48
Units, 6-118
Rotary axis, 6-117
with rotary encoder installed on the motor, 3-62
V
Velocities, 3-47
Velocity reduction according to the overload factor,
S 12-235
Scaling system, 3-50
Conversion, 3-50
Switching over manually, 3-52
Sensing probe function test, 15-260
W
Setpoint output, 3-55 Work area limiting, 6-118
Setpoint system, 3-55 Working area limitation, 2-32
Signal, Transformation active, 15-262

SINUMERIK 802DDescription of Funktions

6FC5 697–2AA10–0BP0 (04.00) Index-307
Index

SINUMERIK 802DDescription of Funktions

Index-308 6FC5 697–2AA10–0BP0 (04.00)
 To Suggestions

SIEMENS AG Corrections
A&D MC IS For Publication/Manual
Postfach 3180
SINUMERIK 802D
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(Tel. +49 180 / 538 – 8008 [hotline]
Fax +49 9131 / 98 – 1145
Mailto: motioncontrol.docu@erlf.siemens.de) Manufacturer Documentation
Descriptions of Functions
From
Order No.:6FC5697–2AA10–0BP0
Name Edition 04.00
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