Name: Siemens SINUMERIK 828D
Brand: Siemens
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P4: PLC for SINUMERIK 828D

14.6 Function interface

Basic Functions

1198 Function Manual, 09/2011, 6FC5397-0BP40-2BA0

Preface3
Table of Contents9
A2: Various NC/PLC Interface Signals and Functions35
Brief Description35
NC/PLC Interface Signals36
General36
Ready Signal to PLC38
Status Signals to PLC38
Signals To/From Panel Front39
Signals to Channel41
Signals to Axis/Spindle41
Signals from Axis/Spindle50
Signals to Axis/Spindle (Digital Drives)51
Signals from Axis/Spindle (Digital Drives)53
Functions55
Screen Settings55
Settings for Involute Interpolation - Only 840D Sl56
Activate DEFAULT Memory59
Read/Write PLC Variable59
Access Protection Via Password and Keyswitch63
Password64
Keyswitch Settings (DB10, DBX56.4 to 7)65
Parameterizable Protection Levels66
Examples67
Data Lists69
Machine Data69
Display Machine Data69
NC-Specific Machine Data70
Channelspecific Machine Data70
Axis/Spindlespecific Machine Data71
System Variables72
Signals72
Signals to NC72
Signals from NC72
Signals to Operator Panel Front73
Signals from Operator Panel Front73
Signals to Channel73
Signals from Channel74
Signals to Axis/Spindle74
Signals from Axis/Spindle74
A3: Axis Monitoring, Protection Zones77
Brief Description77
Axis Monitoring Functions77
Protection Zones77
Axis Monitoring78
Contour Monitoring78
Contour Error78
Following Error Monitoring78
Positioning, Zero Speed and Clamping Monitoring81
Correlation between Positioning, Zero-Speed and Clamping Monitoring81
Positioning Monitoring81
Zero Speed Monitoring83
Exact Stop and Standstill Tolerance Dependent on the Parameter Set84
Clamping Monitoring84
Speed-Setpoint Monitoring91
Actual Velocity Monitoring93
Measuring-System Monitoring (Systems with PROFIBUS Drives)94
Limit Switches-Monitoring95
Hardware Limit Switches95
Software Limit Switch96
Monitoring of the Working Area Limitation98
General98
Working Area Limitation in BKS100
Working Area Limitation in WKS/ENS102
Deactivating All Monitoring Functions: "Parking106
Protection Zones107
General107
Types of Protection Zone108
Definition Via Part Program Instruction111
Definition Via System Variable114
Activation and Deactivation of Protection Zones116
Protection-Zone Violation and Temporary Enabling of Individual Protection Zones120
Restrictions in Protection Zones125
Supplementary Conditions127
Axis Monitoring Functions127
Examples128
Axis Monitoring128
Working Area Limitation in WKS/ENS128
Protection Zones130
Definition and Activation of Protection Zones130
Data Lists141
Machine Data141
NC-Specific Machine Data141
Channelspecific Machine Data141
Axis/Spindlespecific Machine Data142
Setting Data143
Axis/Spindlespecific Setting Data143
Signals144
Signals to Channel144
Signals from Channel144
Signals to Axis/Spindle145
B1: Continuouspath Mode, Exact Stop, Lookahead147
Brief Description147
Exact Stop Mode150
Continuous-Path Mode154
General Functionality154
Velocity Reduction According to Overload Factor156
Blending158
Rounding According to a Path Criterion (G641)161
Rounding in Compliance with Defined Tolerances (G642/G643)163
Rounding with Maximum Possible Axial Dynamic Response (G644)166
Rounding of Tangential Block Transitions (G645)169
Lookahead171
Standard Functionality171
Free-Form Surface Mode: Extension Function176
Dynamic Adaptations180
Smoothing the Path Velocity180
Adaptation of the Dynamic Path Response183
Determination of the Dynamic Response Limiting Values187
Interaction between the "Smoothing of the Path Velocity" and "Adaptation of the Path Dynamic Response" Functions188
Dynamic Response Mode for Path Interpolation191
Free-Form Surface Mode: Basic Functions193
Compressor Functions197
NC Block Compression197
Combining Short Spline Blocks (Option for 828D)201
Contour/Orientation Tolerance203
Tolerance and Compression of G0 Blocks206
RESET Response209
Supplementary Conditions210
Block Change and Positioning Axes210
Block Change Delay210
Rounding and Repositioning (REPOS)210
Data Lists212
Machine Data212
General Machine Data212
Channelspecific Machine Data212
Axis/Spindlespecific Machine Data213
Setting Data213
Channelspecific Setting Data213
Signals214
Signals from Channel214
Signals from Axis/Spindle214
B2: Acceleration215
Brief Description215
General215
Features215
Functions217
Acceleration and Jerk for Positioning Motion to Fixed Points217
General Information217
Parameterization217
Acceleration Without Jerk Limitation (BRISK/BRISKA) (Channel-/Axis-Specific)218
General Information218
Programmable Maximum Value (Axis-Specific)219
Parameterization219
Programming220
Constant Travel Time (Channel-Specific)221
General Information221
Parameterization222
Acceleration Matching (ACC) (Axis-Specific)223
General Information223
Programming223
Acceleration Margin (Channel-Specific)224
General Information224
Parameterization224
Path-Acceleration Limitation (Channel-Specific)224
Programming225
Path Acceleration for Real-Time Events (Channel-Specific)226
General Information226
Programming227
Acceleration with Programmed Rapid Traverse (G00) (Axis-Specific)228
General Information228
Parameterization228
Acceleration with Active Jerk Limitation (SOFT/SOFTA) (Axis-Specific)229
General Information229
Parameterization229
Excessive Acceleration for Non-Tangential Block Transitions (Axis-Specific)229
Parameterization230
Acceleration Margin for Radial Acceleration (Channel-Specific)230
General Information230
Parameterization231
Jerk Limitation with Path Interpolation (SOFT) (Channel-Specific)232
General Information232
Maximum Jerk Value (Axis-Specific)234
Maximum Jerk Value (Channel-Specific)234
Parameterization234
Programming234
Jerk Limitation with Single-Axis Interpolation (SOFTA) (Axis-Specific)235
General Information235
Parameterization235
Programming236
Path-Jerk Limitation (Channel-Specific)236
General Information236
Parameterization237
Programming237
Path Jerk for Real-Time Events (Channel-Specific)238
General Information238
Programming239
Jerk with Programmed Rapid Traverse (G00) (Axis-Specific)240
General Information240
Parameterization240
Excessive Jerk for Block Transitions Without Constant Curvature (Axis-Specific)240
Parameterization241
Velocity-Dependent Jerk Adaptation (Axisspecific)241
Jerk Filter (Axis-Specific)243
General Information243
Parameterization246
Kneeshaped Acceleration Characteristic Curve247
Adaptation to the Motor Characteristic Curve247
Effects on Path Acceleration249
Substitute Characteristic Curve249
Parameterization252
Programming253
Boundary Conditions254
Examples256
Acceleration256
Path Velocity Characteristic256
Jerk258
Path Velocity Characteristic258
Acceleration and Jerk259
Kneeshaped Acceleration Characteristic Curve261
Activation261
Data Lists263
Machine Data263
Channelspecific Machine Data263
Axis/Spindlespecific Machine Data263
Setting Data264
Channelspecific Setting Data264
System Variables264
D1: Diagnostics Tools265
Brief Description265
Description of Diagnostic Tools266
Service Overview269
Axis/Spindle Service Display269
Drive Service Display (for Digital Drives Only)276
Service Display PROFIBUS DP 840Di287
Communication Log291
PLC Status292
Identifying Defective Drive Modules293
Data Lists296
Machine Data296
Drive-Specific Machine Data296
NC-Specific Machine Data296
Axis/Spindlespecific Machine Data297
Setting Data297
Axis/Spindle-Specific Setting Data297
Signals297
Signals to Axis/Spindle297
Signals from Axis/Spindle297
F1: Travel to Fixed Stop299
Product Brief299
General Functionality300
Functional Sequence, Programming, Parameterization300
Response to RESET and Function Abort307
Block Search Response308
Miscellaneous312
Supplementary Conditions for Expansions315
Travel with Limited Torque/Force FOC (Option for 828D)317
Travel to Fixed Stop320
Examples324
Data Lists326
Machine Data326
Axis/Spindlespecific Machine Data326
Setting Data326
Axis/Spindle-Specific Setting Data326
Signals326
Signals to Axis/Spindle326
Signals from Axis/Spindle327
G2: Velocities, Setpoint / Actual Value Systems, Closed-Loop Control329
Brief Description329
Velocities, Traversing Ranges, Accuracies330
Velocities330
Traversing Ranges332
Positioning Accuracy of the Control System333
Block Diagram of Resolutions and Scaling Values333
Input/Display Resolution, Computational Resolution335
Scaling of Physical Quantities of Machine and Setting Data336
Metric/Inch Measuring System340
Conversion of Basic System by Parts Program340
Manual Switchover of the Basic System344
FGROUP and FGREF349
Setpoint/Actual-Value System353
General353
Setpoint and Encoder Assignment356
Adapting the Motor/Load Ratios359
Speed Setpoint Output361
Actual-Value Processing363
Adjustments to Actual-Value Resolution366
Closed-Loop Control374
General374
Parameter Sets of the Position Controller377
Optimization of the Control380
Position Controller, Position Setpoint Filter: Balancing Filter380
Position Controller, Position Setpoint Filter: Jerk Filter383
Position Control with Proportional-Plus-Integral-Action Controller386
Data Lists388
Machine Data388
Displaying Machine Data388
NC-Specific Machine Data388
Channelspecific Machine Data388
Axis/Spindlespecific Machine Data389
H2: Auxiliary Function Outputs to PLC391
Brief Description391
Function391
Definition of an Auxiliary Function392
Overview of Auxiliary Functions393
Predefined Auxiliary Functions400
Overview: Predefined Auxiliary Functions400
Overview: Output Behavior412
Parameter Assignment415
Group Assignment415
Type, Address Extension and Value416
Output Behavior417
Userdefined Auxiliary Functions422
Parameter Assignment423
Maximum Number of User-Defined Auxiliary Functions423
Group Assignment423
Type, Address Extension and Value424
Output Behavior425
Associated Auxiliary Functions426
Type-Specific Output Behavior428
Priorities of the Output Behavior for Which Parameters Have Been Assigned430
Programming an Auxiliary Function431
Programmable Output Duration433
Auxiliary Function Output to the PLC435
Auxiliary Functions Without Block Change Delay436
M Function with an Implicit Preprocessing Stop437
Response to Overstore438
Block-Search Response439
Auxiliary Function Output During Type 1, 2, and 4 Block Searches439
Assignment of an Auxiliary Function to a Number of Groups440
Time Stamp of the Active M Auxiliary Function442
Determining the Output Sequence442
Output Suppression of Spindle-Specific Auxiliary Functions444
Auxiliary Function Output with a Type 5 Block Search (SERUPRO)447
ASUB at the End of the SERUPRO452
Implicitly Output Auxiliary Functions459
Information Options460
Group-Specific Modal M Auxiliary Function Display460
Querying System Variables461
Supplementary Conditions464
General Constraints464
Output Behavior465
Examples467
Extension of Predefined Auxiliary Functions467
Defining Auxiliary Functions469
Data Lists473
Machine Data473
NC-Specific Machine Data473
Channelspecific Machine Data473
Signals474
Signals to Channel474
Signals from Channel474
Signals to Axis/Spindle476
Signals from Axis/Spindle476
K1: Mode Group, Channel, Program Operation, Reset Response477
Product Brief477
Mode Group (MG)480
Mode Group Stop482
Mode Group RESET483
Mode Types and Mode Type Change484
Monitoring Functions and Interlocks of the Individual Modes490
Mode Change490
Channel492
Global Start Disable for Channel495
Program Test496
Program Execution Without Setpoint Outputs496
Program Execution in Singleblock Mode498
Program Execution with Dry Run Feedrate500
Skip Part-Program Blocks501
Workpiece Simulation503
Block Search504
Sequence for Block Search of Type 1, 2 and 4505
Block Search in Connection with Other NCK Functions507
ASUB after and During Block Search507
PLC Actions after Block Search508
Spindle Functions after Block Search509
Reading System Variables for a Block Search510
Automatic Start of an ASUB after a Block Search510
Cascaded Block Search512
Examples of Block Search with Calculation514
Block Search Type 5 SERUPRO518
Repos524
Continue Machining after SERUPRO Search Target Found525
Repositioning on Contour with Controlled REPOS534
Acceleration Measures Via MD537
Serupro Asup538
Selfacting SERUPRO541
Inhibit Specific Part of the Program in the Part Program for SERUPRO542
Special Features in the Part-Program Target Block546
STOPRE in the Part-Program Target Block546
SPOS in Target Block547
Behavior During POWER ON, Mode Change and RESET547
Special Features of Functions Supported During SERUPRO548
Travel to Fixed Stop (FXS)548
Force Control (FOC)549
Synchronous Spindle549
Couplings and Master-Slave550
Axis Functions553
Gear Stage Change554
Superimposed Motion554
REPOS Offset in the Interface555
Making the Initial Settings more Flexible555
System Variables and Variables for SERUPRO Sequence556
Restrictions557
Program Operation Mode558
Initial Settings558
Selection and Start of Part Program or Part-Program Block561
Part-Program Interruption563
RESET Command564
Program Status565
Channel Status566
Responses to Operator or Program Actions567
Part-Program Start568
Example of Timing Diagram for a Program Run569
Program Jumps570
Jump Back to Start of Program570
Program Section Repetitions572
Overview572
Individual Part Program Block572
A Part Program Section after a Start Label573
A Part Program Section between a Start Label and End Label574
A Part Program Section between a Start Label and the Key Word: ENDLABEL575
Eventdriven Program Calls576
Function576
Parameter Assignment581
Programming585
Boundary Conditions586
Examples586
Influencing the Stop Events through Stop Delay Area588
Asynchronous Subroutines (Asubs), Interrupt Routines591
Function591
General Functionality591
Sequence of an Interrupt Routine in Program Operation593
Interrupt Routine with REPOSA594
NC Response595
Parameter Assignment596
Programming601
Restrictions603
Examples603
User-Specific ASUB for RET and REPOS604
Function604
Parameter Assignment604
Programming605
Single Block607
Decoding Single Block SBL2 with Implicit Preprocessing Stop608
Single Block Stop: Suppression Using SBLOF608
Single Block Stop: Inhibit According to Situation611
Single-Block Behavior in Mode Group with Type A/B612
Program Control614
Function Selection (Via Operator Panel Front or PLC)614
Activation of Skip Levels615
Adapting the Size of the Interpolation Buffer616
Program Display Modes Via an Additional Basic Block Display618
Basic Block Display for Shopmill/Shopturn619
Structure for a DIN Block621
Execution from External624
Execution from External Subroutines625
System Settings for Power-Up, Reset/Part-Program End and Part-Program Start628
Tool Withdrawal after POWER off with Orientation Transformation633
Replacing Functions by Subprograms636
Overview636
Replacement of M, T/TCA and D/DL Functions637
Replacement of M Functions637
Replacing T/TCA and D/DL Functions639
System Variable641
Example: Replacement of an M Function643
Example: Replacement of a T and D Function645
Behavior in the Event of a Conflict647
Replacement of Spindle Functions648
General648
Replacement of M40 - M45 (Gear Stage Change)650
Replacement of SPOS, SPOSA, M19 (Spindle Positioning)651
System Variable652
Example: Gear Stage Change653
Example: Spindle Positioning655
Properties of the Subprograms658
Restrictions660
Program Runtime / Part Counter661
Program Runtime661
Workpiece Counter668
Data Lists673
Machine Data673
General Machine Data673
Channelspecific Machine Data674
Axis/Spindlespecific Machine Data677
Setting Data677
Channelspecific Setting Data677
Signals678
Signals to NC678
Signals to NC679
Signals from Channel679
Signals to NC681
Signals from Axis/Spindle681
K2: Axis Types, Coordinate Systems, Frames683
Brief Description683
Axes683
Coordinate Systems685
Frames687
Axes691
Overview691
Machine Axes692
Channel Axes693
Geometry Axes693
Replaceable Geometry Axes694
Special Axes698
Path Axes699
Positioning Axes699
Main Axes700
Synchronized Axes701
Axis Configuration703
Link Axes705
Zeros and Reference Points706
Reference Points in Working Space706
Position of Coordinate Systems and Reference Points708
Coordinate Systems709
Overview709
Machine Coordinate System (MCS)712
Basic Coordinate System (BCS)713
Additive Offsets715
Basic Zero System (BZS)718
Settable Zero System (SZS)720
Workpiece Coordinate System (WCS)721
Frames722
Frame Types722
Frame Components723
Translation723
Fine Offset724
Rotations for Geometry Axes725
Scaling729
Mirroring729
Chain Operator730
Programmable Axis Identifiers730
Coordinate Transformation731
Frames in Data Management and Active Frames731
Overview731
Activating Data Management Frames733
NCU Global Frames734
Frame Chain and Coordinate Systems735
Overview735
Relative Coordinate Systems736
Configurable SZS738
Manual Traverse in the SZS Coordinate System739
Suppression of Frames740
Frame Chain Frames742
Overview742
Settable Frames $P_Uifr[N]742
Channel Basic Frames $P_Chbfr[N]743
NCU Global Basic Frames $P_Ncbfr[N]744
Complete Basic Frame $P_ACTBFRAME745
Programmable Frame $P_PFRAME746
Channelspecific System Frames748
Implicit Frame Changes752
Frames and Switchover of Geometry Axes752
Frame for Selection and Deselection of Transformations755
Adapting Active Frames771
Mapped Frames772
Predefined Frame Functions776
Inverse Frame776
Additive Frame in Frame Chain779
Functions781
Setting Zeros, Workpiece Measuring and Tool Measuring781
Zero Offset External Via System Frames781
Toolholder782
Subprograms with SAVE Attribute (SAVE)793
Data Backup794
Positions in the Coordinate System794
Control System Response795
1Power on795
2Mode Change795
3RESET, End of Part Program796
4Part Program Start799
5Block Search799
6Repos799
Workpiecerelated Actualvalue System800
Overview800
Use of Workpiecerelated Actual-Value System800
Special Reactions802
Restrictions804
Examples804
Axes804
Coordinate Systems807
Frames808
Data Lists811
Machine Data811
Displaying Machine Data811
NC-Specific Machine Data811
Channelspecific Machine Data812
Axis/Spindlespecific Machine Data813
Setting Data813
Channelspecific Setting Data813
System Variables813
Signals815
Signals from Channel815
Signals to Axis/Spindle815
Signals from Axis/Spindle815
N2: Emergency Stop817
Brief Description817
Relevant Standards818
Emergency Stop Control Elements819
Emergency Stop Sequence820
Emergency Stop Acknowledgement822
Data Lists824
Machine Data824
Drive-Specific Machine Data824
Axis/Spindlespecific Machine Data824
Signals824
Signals to NC824
Signals from NC824
Signals to BAG824
P1: Transverse Axes825
Brief Description825
Defining a Geometry Axis as Transverse Axis828
Dimensional Information for Transverse Axes830
Data Lists836
Machine Data836
Channelspecific Machine Data836
Axis/Spindlespecific Machine Data836
P3: Basic PLC Program for SINUMERIK 840D Sl837
Brief Description837
Key Data of the PLC-Cpus for 840D Sl and 840Di Sl839
Reserve Resources (Timers, Counters, FC, FB, DB, I/O)846
Startup Hardware Configuration of the PLC-Cpus847
Starting up the PLC Program852
Installation of the Basic Program852
Application of Basic Program852
Version Codes853
Machine Program853
Data Backup854
PLC-Series Startup, PLC Archive854
Software Upgrade856
I/O Modules (FM, CP Modules)857
Troubleshooting858
Coupling of the PLC Cpus859
General859
Features of PLC Cpus859
Interface with Integrated PLC859
Diagnostic Buffer on PLC861
Interface Structure862
PLC/NCK Interface862
Interface PLC/HMI868
PLC/MCP/HHU Interface873
Structure and Functions of the Basic Program875
Startup and Synchronization of NCK PLC877
Cyclical Mode (ob 1)877
Time-Interrupt Processing (ob 35)879
Process Interrupt Processing (ob 40)879
Diagnostic Interrupt, Module Failure Processing (ob 82, ob 86)880
Response to NCK Failure880
Functions of the Basic Program Called from the User Program881
Symbolic Programming of User Program with Interface DB884
M Decoding Acc. to List886
PLC Machine Data890
Configuration Machine Control Panel, Handheld Unit, Direct Keys894
Switchover of Machine Control Panel, Handheld Unit902
SPL for Safety Integrated905
Assignment Overview906
Assignment: NCK/PLC Interface906
Assignment: FB/FC906
Assignment: DB907
Assignment: Timers908
Memory Requirements of the Basic PLC Program909
Basic Conditions and NC VAR Selector912
Supplementary Conditions912
1Programming and Parameterizing Tools912
2SIMATIC Documentation Required913
3Relevant SINUMERIK Documents914
NC VAR Selector914
1Overview914
2Description of Functions916
3Startup, Installation924
Block Descriptions925
FB 1: RUN_UP Basic Program, Startup Section925
FB 2: Read GET NC Variable933
FB 3: PUT Write NC Variables940
FB 4: PI_SERV PI Services946
1Overview of Available PI Services948
2General PI Services950
3PI Services of Tool Management954
FB 5: GETGUD Read GUD Variable970
FB 7: PI_SERV2 PI-Services977
FB 9: Mton Control Unit Switchover981
FB 10: Safety Relay (si Relay)986
FB 11: Brake Test989
13.13.10 FB 29: Signal Recorder and Data Trigger Diagnostics994
13.13.11 FC 2: GP_HP Basic Program, Cyclic Section998
13.13.12 FC 3: GP_PRAL Basic Program, Interruptdriven Section999
13.13.13 FC 5: GP_DIAG Basic Program, Diagnostic Alarm, and Module Failure1001
13.13.14 FC 6: TM_TRANS2 Transfer Block for Tool Management and Multitool1004
13.13.15 FC 7: TM_REV Transfer Block for Tool Change with Revolver1005
13.13.16 FC 8: TM_TRANS Transfer Block for Tool Management1008
13.13.17 FC 9: ASUB Startup of Asynchronous Subprograms1015
13.13.18 FC 10: AL_MSG Error and Operating Messages1017
13.13.19 FC 12: AUXFU Call Interface for User with Auxiliary Functions1019
13.13.20 FC 13: Bhgdisp Display Control for Handheld Unit1020
13.13.21 FC 17: Ydelta Star-Delta Changeover1025
13.13.22 FC 18: Spinctrl Spindle Control1028
13.13.23 FC 19: MCP_IFM Transmission of MCP Signals to Interface1039
13.13.24 FC 21: Transfer PLC NCK Data Exchange1045
13.13.25 FC 22: TM_DIR Direction Selection for Tool Management1053
13.13.26 FC 24: MCP_IFM2 Transmission of MCP Signals to Interface1055
13.13.27 FC 25: MCP_IFT Transfer of MCP/OP Signals to Interface1059
13.13.28 FC 26: HPU_MCP Transmission of HT8 Signals to Interface1061
1Overview of the NC/PLC Interface Signals of HT 81066
2Overview of the NC/PLC Interface Signals of HT 81067
13.13.29 FC 19, FC 24, FC 25, FC 26 Source Code Description1067
13.13.30 FC 1005: AG_SEND Transfers Data to Ethernet CP1069
13.13.31 FC 1006: AG_RECV Receives Data from the Ethernet CP1070
Signal/Data Descriptions1072
Interface Signals NCK/PLC, HMI/PLC, MCP/PLC1072
Decoded M Signals1072
G Functions1073
Message Signals in DB 21075
Programming Tips with STEP 71076
Copying Data1076
ANY and POINTER1076
1Use of POINTER and any in FC1077
2Use of POINTER and any in FB1078
3POINTER or any Variable for Transfer to FC or FB1079
Multiinstance DB1082
Strings1083
Determining Offset Addresses for Data Block Structures1083
FB Calls1084
Data Lists1086
Machine Data1086
1NC-Specific Machine Data1086
2Channelspecific Machine Data1086
P4: PLC for SINUMERIK 828D1087
Overview1087
PLC Firmware1087
PLC User Interface1087
Data that Are Cyclically Exchanged1089
Alarms and Messages1089
Retentive Data1089
Non-Retentive Data1089
PLC Machine Data1090
PLC Key Data1090
PLC I/O, Fast Onboard Inputs/Outputs1091
PLC Toolbox1091
Star/Delta Changeover1091
Programming Tool PLC8281092
Programming1093
Introduction1093
Important Terms1093
Create/Open a Project1096
Program Organization Using the the Programming Tool1097
Fast Onboard Inputs and Outputs1099
Target System Memory1099
Type of Memory1099
Addressing Range of the Target System1100
Addressing1102
Data Types1104
Constants1106
Data Blocks1108
Special Bit Memories and Their Functions1118
Operation Set1119
Data Classes1119
Defining Data Classes1119
Assigning a Block to a Data Class1121
Load Data Class(Es) into the CPU1123
Load Data Class(Es) from CPU1125
Comparison between Online and Offline Projects1126
Delete in the Target System1127
Rewire Addresses1127
Test and Diagnostic Functions1131
Program Status1131
Status Definition1131
Preconditions of the Status Update1132
Influence of the Operating State on the Target System1132
Communication and Cycle1132
Status Update1133
Simulating Process Conditions1133
Checking Cross References and the Elements Used1133
Program Status in the LAD Program Editor1134
Display Program Status1134
Display Properties1136
Restrictions1137
Adapting the Program Status Display1137
Displaying the Status in a Status Chart1138
Properties of a Status Chart1138
Open Status Chart1140
Working with Several Status Charts1140
Creating a Status Chart1141
Editing the Status Chart1142
Data Formats1143
Enabling the Status Table1144
Working with Test Functions in the Status Chart1145
Execute Cycles1145
Data Interface1147
PLC-NCK Interface1147
Mode Signals1147
NC Channel Signals1148
Axis and Spindle Signals1149
General NCK Signals1150
Fast Data Exchange PLC-NCK1151
PLC-HMI Interface1152
Function Interface1153
Read/Write NC Variables1153
User Interface1153
Operable Variables1157
Program Instance Services (PI Services)1163
User Interface1163
PI Services1166
PLC User Alarms1168
User Interface1168
PLC Axis Control1171
Overview1171
User Interface1172
Spindle Positioning1175
Rotate Spindle1176
Oscillate Spindle1178
Indexing Axis1180
Positioning Axis Metric1182
Positioning Axis Inch1184
Positioning Axis Metric with Handwheel Override1185
10Positioning Axis Inch with Handwheel Override1187
11Rotate Spindle with Automatic Gear Stage Selection1189
12Rotate Spindle with Constant Cutting Rate [M/Min]1190
13Rotate Spindle with Constant Cutting Rate [Feet/Min]1192
14Error Messages1193
Starting Asubs1195
The ASUB up Interface1196
Signal Flow1197
R1: Reference Point Approach1199
Brief Description1199
Axisspecific Referencing1200
Channelspecific Referencing1203
Reference Point Appraoch from Part Program (G74)1205
Referencing with Incremental Measurement Systems1206
Zero Mark Selection with BERO1206
Chronological Sequence1207
Phase 1: Traversing to the Reference Cam1208
Phase 2: Synchronization with the Zero Mark1210
Phase 3: Traversing to the Reference Point1216
Restoration of Position after POWER off1218
Buffered Actual Value1219
Position Restoration with POWER on1220
Referencing with Distancecoded Reference Marks1222
General Overview1222
Basic Parameter Assignment1222
Chronological Sequence1224
Phase 1: Travel Across the Reference Marks with Synchronization1224
Phase 2: Travel to Fixed Stop1226
Referencing by Means of Actual Value Adjustment1229
Actual Value Adjustment to the Referencing Measurement System1229
Actual Value Adjustment to the Referenced Measurement System1229
Actual Value Adjustment for Measuring Systems with Distance-Coded Reference Marks1230
Referencing in Followup Mode1232
Referencing with Absolute Value Encoders1235
Information about Calibration1235
Calibration by Entering a Reference Point Offset1237
Adjustment by Entering a Reference Point Value1238
Automatic Calibration with Probe1239
Calibration with BERO1241
Reference Point Approach with Absolute Encoders1242
Reference Point Approach in Rotary Absolute Encoders with External Zero Mark1242
Automatic Encoder Replacement Detection1245
Enabling the Measurement System1246
Referencing Variants that Are Not Supported1247
Supplementary Conditions1248
Large Traverse Range1248
Data Lists1250
Machine Data1250
1NC-Specific Machine Data1250
2Channelspecific Machine Data1250
3Axis/Spindlespecific Machine Data1250
Signals1251
1Signals to BAG1251
2Signals from BAG1251
3Signals to Channel1252
4Signals from Channel1252
5Signals to Axis/Spindle1252
6Signals from Axis/Spindle1252
S1: Spindles1253
Brief Description1253
Operating Modes1254
Overview1254
Mode Change1255
Control Mode1256
Oscillation Mode1259
Positioning Mode1259
General Functionality1259
Positioning from Rotation1267
Positioning from Standstill1271
Spindle in Position" Signal for Tool Change1275
Axis Mode1276
General Functionality1276
Implicit Transition to Axis Mode1280
Initial Spindle State1283
Reference / Synchronize1284
Configurable Gear Adaptation1289
Gear Steps for Spindles and Gear Step Change1289
Spindle Gear Stage 01300
Determining the Spindle Gear Stage1303
Parameter Set Selection During Gear Step Change1304
Intermediate Gear1306
Nonacknowledged Gear Step Change1307
Gear Step Change with Oscillation Mode1308
Gear Step Change at Fixed Position1315
Configurable Gear Step in M701320
Suppression of the Gear Stage Change for Dryrun, Program Test and SERUPRO1322
Additional Adaptations to the Spindle Functionality that Can be Configured1325
Selectable Spindles1326
Programming1330
Programming from the Part Program1330
Programming Via Synchronized Actions1334
Programming Spindle Controls Via PLC with FC18 - Only 840D Sl1334
Special Spindle Movements Via PLC Interface1335
External Programming (PLC, HMI)1339
Spindle Monitoring1341
Permissible Speed Ranges1341
Axis/Spindle Stationary1342
Spindle in Setpoint Range1342
Minimum / Maximum Speed of the Gear Stage1344
Diagnosis of Spindle Speed Limitation1345
Maximum Spindle Speed1347
Maximum Encoder Limit Frequency1348
End Point Monitoring1349
M40: Automatic Gear Stage Selection for Speeds Outside the Configured Switching Thresholds1351
Spindle with SMI 24 (Weiss Spindle)1353
General Information1353
Sensor Data1353
Clamped State1355
Additional Drive Parameters1356
Examples1357
Automatic Gear Step Selection (M40)1357
Data Lists1358
Machine Data1358
1NC-Specific Machine Data1358
2Channelspecific Machine Data1358
3Axis/Spindlespecific Machine Data1358
Setting Data1360
1Channelspecific Setting Data1360
2Axis/Spindle-Specific Setting Data1360
Signals1361
1Signals to Axis/Spindle1361
2Signals from Axis/Spindle1361
V1: Feedrates1363
Brief Description1363
Path Feedrate F1366
General1366
Type of Feedrate G93, G94, G951368
Type of Feedrate G96, G961, G962, G97, G9711370
Feedrate with G33, G34, G35 (Thread Cutting)1374
General1374
Programmable Run-In and Run-Out Path for G33, G34 and G351376
Linear Progressive/Degressive Thread-Lead Change with G34 and G351378
Stop for Thread Cutting1381
Feedrate for G331/G332, Rigid Tapping1385
Feedrate for G63, Tapping with Compensation Chuck1386
Feedrate FA for Positioning Axes1387
Feedrate Control1389
General1389
Feedrate Disable and Feedrate/Spindle Stop1390
Feedrate Override on Machine Control Panel1391
Programmable Feedrate Override1395
Dry Run Feedrate1396
Multiple Feedrate Values in One Block1398
Fixed Feedrate Values1402
Feedrate for Chamfer/Rounding FRC, FRCM1404
Non-Modal Feedrate FB1405
Programmable Singleaxis Dynamic Response1406
Supplementary Conditions1411
General Boundary Conditions1411
Supplementary Conditions for Feedrate Programming1411
Examples1413
Feedrate Programming for Chamfer/Rounding FRC, FRCM1413
Data Lists1415
Machine Data1415
NC-Specific Machine Data1415
Channelspecific Machine Data1415
Axis/Spindle-Specific Machine Data1416
Setting Data1416
Channelspecific Setting Data1416
Axis/Spindle-Specific Setting Data1416
Signals1417
Signals to Channel1417
Signals from Channel1417
Signals to Axis/Spindle1417
Signals from Axis/Spindle1418
W1: Tool Offset1419
Short Description1419
Tool1422
General1422
Compensation Memory Structure1424
Calculating the Tool Compensation1426
Address Extension for NC Addresses T and M1426
Free Assignment of D Numbers1428
Compensation Block in Case of Error During Tool Change1434
Definition of the Effect of the Tool Parameters1437
Flat D Number Structure1438
General1438
Creating a New D Number (Compensation Block)1438
D Number Programming1439
Programming the T Number1441
Programming M61441
Program Test1442
Tool Management or "Flat D Numbers1442
Tool Cutting Edge1444
General1444
Tool Parameter 1: Tool Type1446
Tool Parameter 2: Cutting Edge Position1449
Tool Parameters 3 - 5: Geometry - Tool Lengths1450
Tool Parameters 6 - 11: Geometry - Tool Shape1452
Tool Parameters 12 - 14: Wear - Tool Lengths1454
Tool Parameters 15 - 20: Wear - Tool Shape1454
Tool Parameters 21 - 23: Tool Base Dimension/Adapter Dimension1454
Tool Parameter 24: Undercut Angle1456
Tools with a Relevant Tool Point Direction1457
Tool Radius Compensation 2D (TRC)1458
General1458
Selecting the TRC (G41/G42)1459
Approach and Retraction Behavior (NORM/KONT/KONTC/KONTT)1460
Smooth Approach and Retraction1464
Function1464
Parameters1465
Velocities1472
System Variables1474
Supplementary Conditions1475
Examples1476
Deselecting the TRC (G40)1479
Compensation at Outside Corners1479
Compensation at Inside Corners1483
Collision Detection and Bottleneck Detection1485
Blocks with Variable Compensation Value1487
Keep Tool Radius Compensation Constant1489
Alarm Behavior1492
Intersection Procedure for Polynomials1493
G461/G462 Approach/Retract Strategy Expansion1493
Toolholder with Orientation Capability1497
General1497
Kinematic Interaction and Machine Design1504
Oblique Machining with 3 + 2 Axes1511
Machine with Rotary Work Table1512
Procedure When Using Toolholders with Orientation Capability1516
Programming1520
Supplementary Conditions and Control System Response for Orientation1521
Cutting Data Modification for Tools that Can be Rotated1524
Function1524
Determination of Angle of Rotation1524
Cutting Edge Position, Cut Direction and Angle for Rotary Tools1525
Modifications During the Rotation of Turning Tools1527
Cutting Edge Position for Milling and Tapping Tools1530
Modifications During Rotation of Milling and Tapping Tools1531
Parameter Assignment1531
Programming1532
Example1536
Incrementally Programmed Compensation Values1538
G91 Extension1538
Machining in Direction of Tool Orientation1539
Basic Tool Orientation1541
Special Handling of Tool Compensations1545
Relevant Setting Data1545
Mirror Tool Lengths (SD42900 $SC_MIRROR_TOOL_LENGTH)1546
Mirror Wear Lengths (SD42920 $SC_WEAR_SIGN_CUTPOS)1547
Tool Length and Plane Change (SD42940 $SC_TOOL_LENGTH_CONST)1548
Tool Type (SD42950 $SC_TOOL_LENGTH_TYPE)1549
Temperature Offsets in Tool Direction (SD42960 $SC_TOOL_TEMP_COMP)1550
Tool Lengths in the WCS, Allowing for the Orientation1550
Tool Length Offsets in Tool Direction1551
Sum Offsets and Setup Offsets1556
General1556
Description of Function1557
Activation1560
Examples1565
Upgrades for Tool Length Determination1566
18.11.5.2Functionality of the Individual Wear Values1570
Working with Tool Environments1574
General1574
Saving with TOOLENV1574
Delete Tool Environment1576
How Many Environments and Which Ones Are Saved1578
Read T, D, DL from a Tool Environment1578
Read Tool Lengths, Tool Length Components1579
Changing Tool Components1585
Tool Lengths L1, L2, L3 Assignment: LENTOAX1591
Supplementary Conditions1594
Flat D Number Structure1594
SD42935 Expansions1594
Examples1595
Toolholder with Orientation Capability1595
1Example: Toolholder with Orientation Capability1595
2Example of Toolholder with Orientation Capability with Rotary Table1596
3Basic Tool Orientation Example1598
4Calculation of Compensation Values on a Location-Specific and Workpiece-Specific Basis1599
Examples 3-6: SETTCOR Function for Tool Environments1601
Data Lists1608
Machine Data1608
1NC-Specific Machine Data1608
2Channelspecific Machine Data1608
3Axis/Spindlespecific Machine Data1609
Setting Data1610
1Channelspecific Setting Data1610
Signals1610
1Signals from Channel1610
Z1: NC/PLC Interface Signals1611
Various Interface Signals and Functions (A2)1611
Signals from PLC to NC (DB10)1611
Selection/Status Signals from HMI to PLC (DB10)1611
Signals from the NC to the PLC (DB10)1612
Signals to Operator Panel (DB19)1616
Signals from Operator Control Panel (DB19)1620
Signals to Channel (DB211623
Signals from Channel (DB211624
Signals to Axis/Spindle (DB311625
Signals from Axis/Spindle (DB311637
Axis Monitoring, Protection Zones (A3)1652
Signals to Channel (DB211652
Signals from Channel (DB211653
Signals to Axis/Spindle (DB311654
Signals from Axis/Spindle (DB311656
Continuouspath Mode, Exact Stop and Lookahead (B1)1657
Signals from Channel (DB211657
Signals from Axis/Spindle (DB311657
Travel to Fixed Stop (F1)1659
Signals to Axis/Spindle (DB311659
Signals from Axis/Spindle (DB311660
Help Function Output to PLC (H2)1662
Signals to Channel (DB211662
Signals from Channel (DB211662
Signals from Axis/Spindle (DB311666
Mode Group, Channel, Program Operation, Reset Response (K1)1667
Signals to Mode Group (DB11)1667
Signals from the Mode Group (DB11)1671
Signals to Channel (DB211675
Signals from Channel (DB211679
Signals to Axis/Spindle (DB311692
Signals from Axis/Spindle (DB311692
Axis Types, Coordinate Systems, Frames (K2)1695
Signals to Axis/Spindle (DB311695
Emergency Stop (N2)1696
Signals to NC (DB10)1696
Signals from NC (DB10)1697
PLC Basic Program (P3)1697
Reference Point Approach (R1)1698
Signals to Channel (DB211698
Signals from Channel (DB211699
Signals to Axis/Spindle (DB311699
Signals from Axis/Spindle (DB311700
Spindles (S1)1702
Signals to Axis/Spindle (DB311702
Signals from Axis/Spindle (DB311708
Feeds (V1)1718
Signals to Channel (DB211718
Signals to Axis/Spindle (DB311727
Signals from Axis/Spindle (DB311733
Signals from Axis/Spindle (DB311742
Appendix1743
List of Abbreviations1743
Overview1751
Glossary1753

Control Type	CNC
Operating System	Windows Embedded
Processor	Intel Atom
Display	10.4" color TFT display
Interfaces	Ethernet, USB
Programming	ShopMill, ShopTurn
Operation Panel Size	10.4"
Protection Class	IP65
PLC Memory	2 MB
Spindle Capacity	4 spindles
Hard Drive	CompactFlash

Siemens SINUMERIK 828D Function Manual

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