siemens 840D User Manual

SINUMERIK

SINUMERIK 840D sl / 828D Extended Functions

Function Manual

Valid for

Controls

SINUMERIK 840D sl / 840DE sl SINUMERIK 828D

Software	version
CNC software	4.5 SP2

03/2013

___________________

Preface

	A4: Digital and analog NCK
		1
	I/Os for SINUMERIK 840D sl
	B3: Distributed systems
		2
	- 840D sl only
	H1: Manual and handwheel
		3
	travel
	K3: Compensations	4
	K5: Mode groups, channels,
		5
	axis interchange
	M1: Kinematic
		6
	transformation
	M5: Measurement	7
	N3: Software cams, position
		8
	switching cycles
	- only 840D sl
	N4: Own channel
		9
	- only 840D sl
	P2: Positioning axes	10
	P5: Oscillation - only 840D sl	11
	R2: Rotary axes	12
	S3: Synchronous spindle	13
	S7: Memory configuration	14
	T1: Indexing axes	15
	W3: Tool change	16
	W4: Grinding-specific tool
		17
	offset and tool monitoring
	Z2: NC/PLC interface signals	18
	Appendix	A

6FC5397-1BP40-3BA1

Legal information

Warning notice system

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.

DANGER

indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING

indicates that death or severe personal injury may result if proper precautions are not taken.

CAUTION

indicates that minor personal injury can result if proper precautions are not taken.

NOTICE

indicates that property damage can result if proper precautions are not taken.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

Qualified Personnel

The product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.

Proper use of Siemens products

Note the following:

WARNING

Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks

All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of Liability

We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AG	Order number: 6FC5397-1BP40-3BA1	Copyright © Siemens AG 1994 - 2013.
Industry Sector	05/2013 Technical data subject to change	All rights reserved
Postfach 48 48
90026 NÜRNBERG
GERMANY

Preface

SINUMERIK documentation

The SINUMERIK documentation is organized in the following categories:

●General documentation

●User documentation

●Manufacturer/service documentation

Additional information

You can find information on the following topics at www.siemens.com/motioncontrol/docu:

●Ordering documentation/overview of documentation

●Additional links to download documents

●Using documentation online (find and search in manuals/information)

Please send any questions about the technical documentation (e.g. suggestions for improvement, corrections) to the following address:

[e-mail]

My Documentation Manager (MDM)

Under the following link you will find information to individually compile OEM-specific machine documentation based on the Siemens content:

www.siemens.com/mdm

Training

For information about the range of training courses, refer under:

●www.siemens.com/sitrain

SITRAIN - Siemens training for products, systems and solutions in automation technology

●www.siemens.com/sinutrain

SinuTrain - training software for SINUMERIK

FAQs

You can find Frequently Asked Questions in the Service&Support pages under Product Support. http://support.automation.siemens.com

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Preface

SINUMERIK

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

Target group

This publication is intended for:

●Project engineers

●Technologists (from machine manufacturers)

●System startup engineers (Systems/Machines)

●Programmers

Benefits

The function manual describes the functions so that the target group knows them and can select them. It provides the target group with the information required to implement the functions.

Standard version

This documentation only describes the functionality of the standard version. Extensions or changes made by the machine tool manufacturer are documented by the machine tool manufacturer.

Other functions not described in this documentation might be executable in the control. This does not, however, represent an obligation to supply such functions with a new control or when servicing.

Further, for the sake of simplicity, this documentation does not contain all detailed information about all types of the product and cannot cover every conceivable case of installation, operation or maintenance.

Technical Support

You will find telephone numbers for other countries for technical support in the Internet under http://www.siemens.com/automation/service&support

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Preface

Information on structure and contents

Installation

Structure of this Function Manual:

●Inner title (page 3) with the title of the Function Manual, the SINUMERIK controls as well as the software and the version for which this version of the Function Manual is applicable and the overview of the individual functional descriptions.

●Description of the functions in alphabetical order (e.g. A2, A3, B1, etc.)

●Appendix with:

–List of abbreviations

–Documentation overview

●Index of terms

Note

For detailed descriptions of data and alarms see:

•For machine and setting data:

Detailed description of machine data (only electronically on DOConCD or DOConWEB)

•For NC/PLC interface signals:

–Function Manual, Basic Functions; NC/PLC Interface Signals (Z1)

–Function Manual, Basic Functions; NC/PLC Interface Signals (Z2)

–Function Manual, Special Functions; NC/PLC Interface Signals (Z3)

•For alarms: Diagnostics Manual

Notation of system data

The following notation is applicable for system data in this documentation:

Signal/Data	Notation	Example
NC/PLC interface	... NC/PLC interface signal:	When the new gear stage is engaged, the following NC/PLC
signals	<signal address> (<signal name>)	interface signals are set by the PLC program:
		DB31, ... DBX16.0-2 (actual gear stage A to C)
		DB31, ... DBX16.3 (gear is changed)
Machine data	... machine data:	Master spindle is the spindle stored in the machine data:
	<Type><Number> <Complete	MD20090 $MC_SPIND_DEF_MASTER_SPIND (position of
	Designator> (<Meaning>)	deletion of the master spindle in the channel)
Setting data	... setting data:	The logical master spindle is contained in the setting data:
	<Type><Number> <Complete	SD42800 $SC_SPIND_ASSIGN_TAB[0] (spindle number
	Designator> (<Meaning>)	converter)

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Preface

Note

Signal address

The description of functions include as <signal address> of an NC/PLC interface signal, only the address valid for SINUMERIK 840D sl. The signal address for SINUMERIK 828D should be taken from the data lists "Signals to/from ..." at the end of the particular description of functions.

Quantity structure

Explanations concerning the NC/PLC interface are based on the absolute maximum number of sequential components:

●Mode groups (DB11)

●Channels (DB21, etc.)

●Axes/spindles (DB31, etc.)

Data types

The control provides the following data types that can be used for programming in part programs:

Type	Meaning	Range of values
INT	Signed integers	-2.147.483.648 ... +2.147.483.647
REAL	Numbers with decimal point	≈ ±5,0*10-324 … ≈ ±1,7*10+308
BOOL	Boolean values	TRUE (≠0) , FALSE (0)
CHAR	ASCII characters and bytes	0 ... 255 or -128 ... 127
STRING	Character string, null-terminated	Maximum of 400 characters + /0
		(no special characters)
AXIS	Axis names	All axis names available in the control
		system
FRAME	Geometrical parameters for moving, rotating, scaling, and	---
	mirroring

Note

Arrays can only be formed from similar elementary data types. Up to 3-dimensional arrays are possible.

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Contents

	Preface	......................................................................................................................................................	3
1	A4: Digital .......................................................................and analog NCK I/Os for SINUMERIK 840D sl		25
	1.1 ..................................................................................................................................	Introduction	25
	1.2 ............................................................................................................................	Access via PLC	27
	1.2.1 ...........................................................................................................................	Brief description	27
	1.2.2 .....................................................................................................	Configuration of the NCK I/Os	28
	1.2.3 ............................................................................................................	NCK digital inputs/outputs	31
	1.2.3.1 ........................................................................................................................	NCK digital inputs	31
	1.2.3.2 ......................................................................................................................	NCK digital outputs	32
	1.2.3.3 ............................................................	Connection and logic operations of fast digital NCK I/Os	35
	1.2.4 ..........................................................................................................................	NCK analog I/Os	37
	1.2.4.1 .......................................................................................................................	NCK analog inputs	37
	1.2.4.2 .....................................................................................................................	NCK analog outputs	39
	1.2.4.3 ...............................................................	Representation of the NCK analog input/output values	43
	1.2.5 .......................................................................................................................	Comparator inputs	45
	1.2.6 ..................................................................................	Direct PLC I/Os, addressable from the NC	48
	1.2.6.1 .......................................................................................................................................	Function	48
	1.2.6.2 ............................................................................................................	Supplementary conditions	51
	1.2.6.3 .....................................................................................................................................	Examples	52
	1.3 ................................................................................................................	Access via PROFIBUS	54
	1.3.1 ...........................................................................................................................	Brief description	54
	1.3.2 ....................................................................................................	Configuration of the I/O ranges	56
	1.3.3 .............................................................................................................................	Data exchange	58
	1.3.3.1 .............................................................	Communication via part programs/synchronous actions	58
	1.3.3.2 ..............................................................................................	Communication via compile cycles	61
	1.3.4 ............................................................................................................	Supplementary conditions	62
	1.3.5 .....................................................................................................................................	Examples	63
	1.3.5.1 ..................................................................................................	PROFIBUS - I/O in write direction	63
	1.3.5.2 ..................................................................................................	PROFIBUS - I/O in read direction	65
	1.3.5.3 .....................................	Query of the RangeIndex in case of "PROFIBUS - I/O in write direction"	66
	1.4 ......................................................................................................................................	Data lists	68
	1.4.1 ................................................................................................................................	Machine data	68
	1.4.1.1 ..................................................................................................................	General machine data	68
	1.4.1.2 .....................................................................................................	Channelspecific machine data	69
	1.4.2 ..................................................................................................................................	Setting data	69
	1.4.2.1 .....................................................................................................................	General setting data	69
	1.4.3 .........................................................................................................................................	Signals	69
	1.4.3.1 ...............................................................................................................................	Signals to NC	69
	1.4.3.2 ...........................................................................................................................	Signals from NC	70

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Contents

2	B3: Distributed systems - 840D sl only ....................................................................................................		71
	2.1	Brief description ..........................................................................................................................	71
	2.1.1	Several operator panels on several NCUs (T:M:N)....................................................................	71
	2.1.2	NCU link......................................................................................................................................	74
	2.1.2.1	Link communication ....................................................................................................................	74
	2.1.2.2	Link variables..............................................................................................................................	75
	2.1.2.3	Link axes.....................................................................................................................................	75
	2.1.2.4	Lead link axes.............................................................................................................................	76
	2.1.2.5	Dependencies.............................................................................................................................	76
	2.1.2.6	Application example: Rotary indexing machine..........................................................................	77
	2.2	NCU link......................................................................................................................................	79
	2.2.1	Link communication ....................................................................................................................	79
	2.2.1.1	General information.....................................................................................................................	79
	2.2.1.2	Link module.................................................................................................................................	83
	2.2.1.3	Parameter assignment: NC system cycles.................................................................................	83
	2.2.1.4	Parameter assignment: Link communication..............................................................................	85
	2.2.1.5	Configuration...............................................................................................................................	85
	2.2.1.6	Wiring the NCUs .........................................................................................................................	86
	2.2.1.7	Activation.....................................................................................................................................	86
	2.2.2	Link variables..............................................................................................................................	87
	2.2.2.1	Properties of the link variables memory......................................................................................	88
	2.2.2.2	Properties of the link variables....................................................................................................	88
	2.2.2.3	Write elements............................................................................................................................	89
	2.2.2.4	Dynamic response during write...................................................................................................	90
	2.2.2.5	System variable...........................................................................................................................	90
	2.2.2.6	Synchronization of a write request..............................................................................................	91
	2.2.2.7	Example: Structure of the link variables memory .......................................................................	91
	2.2.2.8	Example: Read drive data...........................................................................................................	93
	2.2.3	Link axes.....................................................................................................................................	94
	2.2.3.1	General information.....................................................................................................................	94
	2.2.3.2	Name of a link axis......................................................................................................................	96
	2.2.3.3	Parameterization.........................................................................................................................	96
	2.2.3.4	Auxiliary function output for spindles ..........................................................................................	97
	2.2.3.5	Supplementary conditions...........................................................................................................	98
	2.2.4	Axis container............................................................................................................................	100
	2.2.4.1	General information...................................................................................................................	100
	2.2.4.2	Parameterization.......................................................................................................................	103
	2.2.4.3	Programming.............................................................................................................................	110
	2.2.4.4	System variable.........................................................................................................................	111
	2.2.4.5	Machining with axis container (schematic) ...............................................................................	112
	2.2.4.6	Behavior in different operating states .......................................................................................	113
	2.2.4.7	Behavior when withdrawing the release for axis container rotation..........................................	113
	2.2.4.8	Supplementary conditions.........................................................................................................	115
	2.2.5	Lead link axes...........................................................................................................................	118
	2.2.5.1	General information...................................................................................................................	118
	2.2.5.2	Parameterization.......................................................................................................................	119
	2.2.5.3	System variables to enter a leading value................................................................................	120
	2.2.5.4	Supplementary conditions.........................................................................................................	121
	2.2.5.5	Example ....................................................................................................................................	121
	2.2.6	System of units within a link group............................................................................................	121
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	2.3	Examples ...................................................................................................................................	122
	2.3.1	Link axis.....................................................................................................................................	122
	2.3.2	Axis container coordination........................................................................................................	123
	2.3.2.1	Axis container rotation without a part program wait...................................................................	123
	2.3.2.2	Axis container rotation with an implicit part program wait..........................................................	124
	2.3.2.3	Axis container rotation by one channel only (e.g. during power up)..........................................	124
	2.3.3	Evaluating axis container system variables...............................................................................	124
	2.3.3.1	Conditional branch.....................................................................................................................	124
	2.3.3.2	Static synchronized action with $AN_AXCTSWA......................................................................	124
	2.3.3.3	Wait for certain completion of axis container rotation................................................................	125
	2.3.4	Configuration of a multi-spindle turning machine.......................................................................	126
	2.3.5	Lead link axis.............................................................................................................................	135
	2.3.5.1	Configuration..............................................................................................................................	135
	2.3.5.2	Programming..............................................................................................................................	137
	2.4	Data lists ....................................................................................................................................	138
	2.4.1	Machine data..............................................................................................................................	138
	2.4.1.1	General machine data................................................................................................................	138
	2.4.1.2	Channelspecific machine data...................................................................................................	138
	2.4.1.3	Axis/spindlespecific machine data.............................................................................................	139
	2.4.2	Setting data................................................................................................................................	139
	2.4.2.1	General setting data...................................................................................................................	139
	2.4.2.2	Axis/spindle-specific setting data...............................................................................................	139
	2.4.3	Signals .......................................................................................................................................	139
	2.4.3.1	Signals from NC.........................................................................................................................	139
	2.4.3.2	Signals from HMI/PLC ...............................................................................................................	140
	2.4.3.3	General online interface.............................................................................................................	140
	2.4.3.4	Signals from axis/spindle...........................................................................................................	142
	2.4.4	System variables........................................................................................................................	142
3	H1: Manual and handwheel travel .........................................................................................................		143
	3.1	Introduction ................................................................................................................................	143
	3.1.1	Overview....................................................................................................................................	143
	3.1.2	General characteristics when traversing in the JOG mode.......................................................	144
	3.1.3	Control of manual-travel functions via PLC interface.................................................................	147
	3.2	Continuous (JOG CONT)...........................................................................................................	148
	3.2.1	General functionality..................................................................................................................	148
	3.2.2	Distinction between inching mode continuous mode.................................................................	149
	3.2.3	Supplementary conditions..........................................................................................................	150
	3.3	Incremental (JOG INC)..............................................................................................................	151
	3.3.1	General functionality..................................................................................................................	151
	3.3.2	Distinction between jogging mode and continuous mode .........................................................	152
	3.3.3	Supplementary conditions..........................................................................................................	153
	3.4	Handwheel travel in JOG...........................................................................................................	154
	3.4.1	Function .....................................................................................................................................	154
	3.4.2	Parameter assignment...............................................................................................................	161
	3.4.3	Travel request............................................................................................................................	166
	3.4.4	Double use of the handwheel ....................................................................................................	169

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Contents

3.5	Handwheel override in automatic mode....................................................................................	170
3.5.1	General functionality .................................................................................................................	170
3.5.2	Programming and activating handwheel override.....................................................................	175
3.5.3	Special features of handwheel override in automatic mode.....................................................	177
3.6	Contour handwheel/path input using handwheel (option).........................................................	178
3.7	DRF offset.................................................................................................................................	180
3.8	Approaching a fixed point in JOG.............................................................................................	183
3.8.1	Introduction ...............................................................................................................................	183
3.8.2	Functionality..............................................................................................................................	184
3.8.3	Parameterization.......................................................................................................................	186
3.8.4	Programming.............................................................................................................................	188
3.8.5	Supplementary Conditions........................................................................................................	188
3.8.6	Application example..................................................................................................................	189
3.9	Retraction in the tool direction (JOG retract) ............................................................................	190
3.9.1	Overview...................................................................................................................................	190
3.9.2	Parameter assignment..............................................................................................................	191
3.9.3	Selection....................................................................................................................................	193
3.9.4	Tool retraction...........................................................................................................................	195
3.9.5	Deselection ...............................................................................................................................	196
3.9.6	Repeated selection ...................................................................................................................	196
3.9.7	Continuing machining................................................................................................................	197
3.9.8	State diagram............................................................................................................................	198
3.9.9	System data..............................................................................................................................	198
3.9.10	Supplementary conditions.........................................................................................................	199
3.10	Start-up: Handwheels................................................................................................................	200
3.10.1	General information...................................................................................................................	200
3.10.2	Connection via PPU (only 828D)..............................................................................................	201
3.10.3	Connection via PROFIBUS (828D)...........................................................................................	202
3.10.4	Connection via PROFIBUS (840D sl).......................................................................................	203
3.10.5	Connected via Ethernet (only 840D sl).....................................................................................	206
3.11	Special features relating to manual and handwheel travel.......................................................	209
3.11.1	Manual travel of geometry/orientation axes..............................................................................	209
3.11.2	Spindle manual travel................................................................................................................	211
3.11.3	Monitoring functions..................................................................................................................	213
3.11.4	Other .........................................................................................................................................	214
3.12	Data lists....................................................................................................................................	215
3.12.1	Machine data.............................................................................................................................	215
3.12.1.1	General machine data...............................................................................................................	215
3.12.1.2	Channel-specific machine data.................................................................................................	216
3.12.1.3	Axis/spindlespecific machine data............................................................................................	216
3.12.2	Setting data...............................................................................................................................	217
3.12.2.1	General setting data..................................................................................................................	217
3.12.3	Signals.......................................................................................................................................	218
3.12.3.1	Signals from NC........................................................................................................................	218
3.12.3.2	Signals to mode group..............................................................................................................	218
3.12.3.3	Signals from mode group..........................................................................................................	218
3.12.3.4	Signals to channel.....................................................................................................................	219
3.12.3.5	Signals from channel.................................................................................................................	220
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	3.12.3.6	Signals to axis/spindle ...............................................................................................................	221
	3.12.3.7	Signals from axis/spindle...........................................................................................................	221
	3.12.4	System variable..........................................................................................................................	222
	3.12.4.1	System variable..........................................................................................................................	222
	3.12.5	OPI variable ...............................................................................................................................	222
	3.12.5.1	OPI variable ...............................................................................................................................	222
4	K3: Compensations ...............................................................................................................................		223
	4.1	Introduction ................................................................................................................................	223
	4.2	Temperature compensation.......................................................................................................	224
	4.2.1	Description of functions..............................................................................................................	224
	4.2.2	Commissioning...........................................................................................................................	227
	4.2.3	Example.....................................................................................................................................	229
	4.2.3.1	Commissioning the temperature compensation for the Z axis of a lathe ..................................	229
	4.3	Backlash compensation.............................................................................................................	231
	4.3.1	Mechanical backlash compensation..........................................................................................	231
	4.3.1.1	Description of functions..............................................................................................................	231
	4.3.1.2	Commissioning...........................................................................................................................	233
	4.3.2	Dynamic backlash compensation..............................................................................................	234
	4.3.2.1	Description of functions..............................................................................................................	234
	4.3.2.2	Commissioning...........................................................................................................................	235
	4.4	Interpolatory compensation........................................................................................................	235
	4.4.1	General properties.....................................................................................................................	235
	4.4.2	Compensation of leadscrew errors and measuring system errors............................................	238
	4.4.2.1	Measuring system error compensation (MSEC)........................................................................	238
	4.4.2.2	Commissioning...........................................................................................................................	239
	4.4.2.3	Example.....................................................................................................................................	242
	4.4.3	Compensation of sag and angularity errors...............................................................................	243
	4.4.3.1	Description of functions..............................................................................................................	243
	4.4.3.2	Commissioning...........................................................................................................................	247
	4.4.3.3	Examples ...................................................................................................................................	251
	4.4.4	Direction-dependent leadscrew error compensation.................................................................	259
	4.4.4.1	Description of functions..............................................................................................................	259
	4.4.4.2	Commissioning...........................................................................................................................	260
	4.4.4.3	Example.....................................................................................................................................	264
	4.4.5	Extension of the sag compensation with NCU link - only 840D sl.............................................	267
	4.4.6	Special features of interpolatory compensation.........................................................................	277
	4.5	Dynamic feedforward control (following error compensation) ...................................................	278
	4.5.1	General properties.....................................................................................................................	278
	4.5.2	Speed feedforward control.........................................................................................................	280
	4.5.3	Torque feedforward control........................................................................................................	282
	4.5.4	Dynamic response adaptation ...................................................................................................	283
	4.5.5	Forward feed control for commandand PLC axes...................................................................	284
	4.5.6	Secondary conditions.................................................................................................................	286
	4.6	Friction compensation (quadrant error compensation)..............................................................	287
	4.6.1	General function description......................................................................................................	287
	4.6.2	Supplementary conditions..........................................................................................................	288
	4.6.3	Friction compensation with a constant compensation value .....................................................	288
	4.6.3.1	Function activation.....................................................................................................................	288
	4.6.3.2	commissioning ...........................................................................................................................	289
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Contents

	4.6.4	Friction compensation with acceleration-dependent compensation value	............................... 294
	4.6.4.1	Description of functions.............................................................................................................	294
	4.6.4.2	Function activation....................................................................................................................	295
	4.6.4.3	commissioning ..........................................................................................................................	295
	4.6.5	Compensation value for short traversing blocks.......................................................................	296
	4.7	Measures for hanging (suspended axes)..................................................................................	297
	4.7.1	Electronic counterweight...........................................................................................................	297
	4.7.2	Reboot delay.............................................................................................................................	299
	4.8	Data lists....................................................................................................................................	301
	4.8.1	Machine data.............................................................................................................................	301
	4.8.1.1	General machine data...............................................................................................................	301
	4.8.1.2	Channelspecific machine data..................................................................................................	301
	4.8.1.3	Axis/spindlespecific machine data............................................................................................	301
	4.8.2	Setting data...............................................................................................................................	302
	4.8.2.1	General setting data..................................................................................................................	302
	4.8.2.2	Axis/spindle-specific setting data..............................................................................................	303
	4.8.3	Signals.......................................................................................................................................	303
	4.8.3.1	Signals from NC........................................................................................................................	303
	4.8.3.2	Signals from mode group..........................................................................................................	303
	4.8.3.3	Signals from channel.................................................................................................................	303
	4.8.3.4	Signals to axis/spindle...............................................................................................................	303
	4.8.3.5	Signals from axis/spindle ..........................................................................................................	304
5	K5: Mode groups, channels, axis interchange .......................................................................................		305
	5.1	Brief description ........................................................................................................................	305
	5.2	Mode groups - only 840D sl......................................................................................................	306
	5.3	Channels - only 840D sl............................................................................................................	307
	5.3.1	Channel synchronization (program coordination).....................................................................	308
	5.3.2	Channel synchronization: Conditional wait in path controlled operation ..................................	311
	5.3.3	Running-in channel-by-channel................................................................................................	315
	5.4	Axis/spindle replacement..........................................................................................................	320
	5.4.1	Introduction ...............................................................................................................................	320
	5.4.2	Example of an axis replacement...............................................................................................	322
	5.4.3	Axis replacement options..........................................................................................................	323
	5.4.4	Replacement behavior NC program .........................................................................................	324
	5.4.5	Transition the axis into the neutral state (RELEASE)...............................................................	325
	5.4.6	Transferring an axis or spindle into the part program (GET, GETD)........................................	326
	5.4.7	Automatic axis replacement......................................................................................................	327
	5.4.8	Axis replacement via PLC.........................................................................................................	329
	5.4.9	Set axis replacement behavior variable....................................................................................	332
	5.4.10	Axis interchange via axis container rotation..............................................................................	333
	5.4.11	Axis replacement with and without preprocessing stop............................................................	333
	5.4.12	Axis exclusively controlled from the PLC..................................................................................	335
	5.4.13	Axis permanently assigned to the PLC.....................................................................................	336
	5.4.14 Geometry axis in rotated frame and axis replacement.............................................................		337
	5.4.15	Axis replacement from synchronized actions............................................................................	338
	5.4.16	Axis interchange for leading axes (gantry)................................................................................	341
	5.5	Marginal conditions...................................................................................................................	341
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	5.6	Data lists ....................................................................................................................................	343
	5.6.1	Machine data..............................................................................................................................	343
	5.6.1.1	General machine data................................................................................................................	343
	5.6.1.2	Channel-specific machine data..................................................................................................	343
	5.6.1.3	Axis/spindlespecific machine data.............................................................................................	345
	5.6.2	Setting data................................................................................................................................	346
	5.6.2.1	Channelspecific setting data......................................................................................................	346
	5.6.3	Signals .......................................................................................................................................	346
	5.6.3.1	Signals to/from BAG ..................................................................................................................	346
	5.6.3.2	Signals to/from Channel.............................................................................................................	346
6	M1: Kinematic transformation................................................................................................................		347
	6.1	Brief description.........................................................................................................................	347
	6.1.1	TRANSMIT (option) ...................................................................................................................	347
	6.1.2	TRACYL (option)........................................................................................................................	348
	6.1.3	TRAANG (option).......................................................................................................................	349
	6.1.4	Chained transformations............................................................................................................	349
	6.1.5	Activating transformation machine data via parts program/softkey...........................................	350
	6.2	TRANSMIT face end transformation (option) ............................................................................	350
	6.2.1	Specific settings.........................................................................................................................	351
	6.2.2	Switch on....................................................................................................................................	354
	6.2.3	Deactivation ...............................................................................................................................	354
	6.2.4	Applications................................................................................................................................	355
	6.2.5	Working area limitations.............................................................................................................	361
	6.2.6	Overlaid motions with TRANSMIT.............................................................................................	362
	6.2.7	Monitoring of rotary axis rotations over 360º.............................................................................	362
	6.2.8	Constraints.................................................................................................................................	362
	6.2.9	Example: Axis configuration.......................................................................................................	363
	6.3	TRACYL cylinder surface transformation (option).....................................................................	366
	6.3.1	Preconditions.............................................................................................................................	368
	6.3.2	Specific settings.........................................................................................................................	371
	6.3.3	Switch on....................................................................................................................................	375
	6.3.4	Deactivation ...............................................................................................................................	376
	6.3.5	Boundary conditions ..................................................................................................................	376
	6.4	TRAANG oblique angle transformation (option)........................................................................	378
	6.4.1	Preconditions.............................................................................................................................	379
	6.4.2	Specific settings.........................................................................................................................	381
	6.4.3	Switch on....................................................................................................................................	383
	6.4.4	Deactivation ...............................................................................................................................	383
	6.4.5	Boundary conditions ..................................................................................................................	384
	6.4.6	Programming (G05, G07) ..........................................................................................................	385
	6.5	Chained transformations............................................................................................................	387
	6.5.1	Activating chained transformations............................................................................................	389
	6.5.2	Switching off a chained transformation......................................................................................	389
	6.5.3	Special characteristics of chained transformations....................................................................	389
	6.5.4	Persistent transformation...........................................................................................................	390
	6.5.5	Axis positions in the transformation chain .................................................................................	395
	6.6	Cartesian PTP travel..................................................................................................................	398
	6.6.1	Programming of position............................................................................................................	401
	6.6.2	Overlap areas of axis angles .....................................................................................................	402
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Contents

	6.6.3	Examples of ambiguities of position..........................................................................................	403
	6.6.4	Example of ambiguity in rotary axis position.............................................................................	404
	6.6.5	PTP/CP switchover in JOG mode.............................................................................................	404
	6.7	Cartesian manual travel (optional)............................................................................................	405
	6.8	Activating transformation machine data via part program/softkey............................................	412
	6.8.1	Functionality..............................................................................................................................	412
	6.8.2	Constraints................................................................................................................................	413
	6.8.3	Control response to power ON, mode change, RESET, block search, REPOS ......................	415
	6.8.4	List of machine data affected....................................................................................................	415
	6.9	Constraints................................................................................................................................	418
	6.9.1	Chained transformations...........................................................................................................	418
	6.10	Examples...................................................................................................................................	419
	6.10.1	TRANSMIT................................................................................................................................	419
	6.10.2	TRACYL....................................................................................................................................	420
	6.10.3	TRAANG ...................................................................................................................................	426
	6.10.4	Chained transformations...........................................................................................................	427
	6.10.5	Activating transformation MD via a part program......................................................................	431
	6.10.6	Axis positions in the transformation chain.................................................................................	432
	6.11	Data lists....................................................................................................................................	435
	6.11.1	Machine data.............................................................................................................................	435
	6.11.1.1	TRANSMIT................................................................................................................................	435
	6.11.1.2	TRACYL....................................................................................................................................	436
	6.11.1.3	TRAANG ...................................................................................................................................	438
	6.11.1.4	Chained transformations...........................................................................................................	439
	6.11.1.5	Non transformation-specific machine data................................................................................	439
	6.11.2	Signals.......................................................................................................................................	439
	6.11.2.1	Signals from channel.................................................................................................................	439
7	M5: Measurement..................................................................................................................................		441
	7.1	Brief description ........................................................................................................................	441
	7.2	Hardware requirements.............................................................................................................	442
	7.2.1	Probes that can be used...........................................................................................................	442
	7.3	Channel-specific measuring......................................................................................................	444
	7.3.1	Measurement............................................................................................................................	444
	7.3.2	Measurement results.................................................................................................................	445
	7.4	Axial measurement ...................................................................................................................	446
	7.4.1	Measurement............................................................................................................................	446
	7.4.2	Telegram selection....................................................................................................................	449
	7.4.3	Measurement results.................................................................................................................	449
	7.5	Setting zeros, workpiece measuring and tool measuring.........................................................	451
	7.5.1	Preset actual value memory and scratching.............................................................................	451
	7.5.2	Workpiece measuring ...............................................................................................................	452
	7.5.2.1	Input values...............................................................................................................................	452
	7.5.2.2	Measurement selection.............................................................................................................	459
	7.5.2.3	Output values............................................................................................................................	460
	7.5.2.4	Calculation method ...................................................................................................................	461
	7.5.2.5	Units of measurement and measurement variables for the calculation....................................	464
	7.5.2.6	Diagnostics................................................................................................................................	465
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Contents

	7.5.3	Types of workpiece measurement.............................................................................................	466
	7.5.3.1	Measurement of an edge (measurement type 1, 2, 3) ..............................................................	466
	7.5.3.2	Measurement of an angle (measurement type 4, 5, 6, 7)..........................................................	470
	7.5.3.3	Measurement of a hole (measurement type 8)..........................................................................	473
	7.5.3.4	Measurement of a shaft (measurement type 9).........................................................................	476
	7.5.3.5	Measurement of a groove (measurement type 12)....................................................................	477
	7.5.3.6	Measurement of a web (measurement type 13)........................................................................	480
	7.5.3.7	Measurement of geo axes and special axes (measurement type 14, 15).................................	481
	7.5.3.8	Measurement of an oblique edge (measurement type 16)........................................................	483
	7.5.3.9	Measurement of an oblique angle in a plane (measurement type 17)......................................	485
	7.5.3.10	Redefine measurement around a WCS reference frame (measurement type 18)....................	488
	7.5.3.11	Measurement of a 1-, 2- and 3-dimensional setpoint selection (measurement type 19, 20,
		21)..............................................................................................................................................	492
	7.5.3.12	Measuring a measuring point in any coordinate system (measurement type 24).....................	496
	7.5.3.13	Measurement of a rectangle (measurement type 25)................................................................	500
	7.5.3.14	Measurement for saving data management frames (measurement type 26)............................	501
	7.5.3.15	Measurement for restoring backed-up data management frames (measurement type 27)......	502
	7.5.3.16	Measurement for defining an additive rotation for taper turning (measurement type 28)..........	503
	7.5.4	Tool measuring..........................................................................................................................	504
	7.5.5	Types of workpiece measurement.............................................................................................	505
	7.5.5.1	Measurement of tool lengths (measurement type 10)...............................................................	505
	7.5.5.2	Measurement of tool diameter (measurement type 11).............................................................	507
	7.5.5.3	Measurement of tool lengths with zoom-in function (measurement type 22)............................	508
	7.5.5.4	Measuring a tool length with stored or current position (measurement type 23).......................	509
	7.5.5.5	Measurement of a tool length of two tools with the following orientation: .................................	511
	7.6	Measurement accuracy and functional testing ..........................................................................	523
	7.6.1	Measurement accuracy..............................................................................................................	523
	7.6.2	Probe function test.....................................................................................................................	524
	7.7	Simulated measuring.................................................................................................................	525
	7.7.1	General functionality..................................................................................................................	525
	7.7.2	Position-related switch request..................................................................................................	525
	7.7.3	External switch request..............................................................................................................	527
	7.7.4	System variable..........................................................................................................................	528
	7.8	Channels - only 840D sl.............................................................................................................	528
	7.8.1	Measuring mode 1.....................................................................................................................	528
	7.8.2	Measuring mode 2.....................................................................................................................	529
	7.8.3	Continuous measurement..........................................................................................................	529
	7.8.4	Functional test and repeat accuracy..........................................................................................	531
	7.9	Data lists ....................................................................................................................................	532
	7.9.1	Machine data..............................................................................................................................	532
	7.9.1.1	General machine data................................................................................................................	532
	7.9.1.2	Channel-specific machine data..................................................................................................	533
	7.9.2	System variables........................................................................................................................	533
8	N3: Software cams, position switching cycles - only 840D sl.................................................................		535
	8.1	Brief Description.........................................................................................................................	535
	8.2	Cam signals and cam positions.................................................................................................	536
	8.2.1	Generation of cam signals for separate output..........................................................................	536
	8.2.2	Generation of cam signals with gated output.............................................................................	539
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Contents

	8.2.3	Cam positions ...........................................................................................................................	543
	8.2.4	Lead/delay times (dynamic cam)..............................................................................................	545
	8.3	Output of cam signals ...............................................................................................................	546
	8.3.1	Activating...................................................................................................................................	546
	8.3.2	Output of cam signals to PLC...................................................................................................	547
	8.3.3	Output of cam signals to NCK I/Os in position control cycle.....................................................	547
	8.3.4	Timer-controlled cam signal output...........................................................................................	549
	8.3.5	Independent, timer-controlled output of cam signals................................................................	550
	8.4	Position-time cams....................................................................................................................	551
	8.5	Supplementary Conditions........................................................................................................	553
	8.6	Data lists....................................................................................................................................	553
	8.6.1	Machine data.............................................................................................................................	553
	8.6.1.1	General machine data...............................................................................................................	553
	8.6.2	Setting data...............................................................................................................................	554
	8.6.2.1	General setting data..................................................................................................................	554
	8.6.3	Signals.......................................................................................................................................	554
	8.6.3.1	Signals to axis/spindle...............................................................................................................	554
	8.6.3.2	Signals from axis/spindle ..........................................................................................................	554
9	N4: Own channel - only 840D sl ............................................................................................................		555
	9.1	Brief Description........................................................................................................................	555
	9.2	Stroke control............................................................................................................................	555
	9.2.1	General information...................................................................................................................	555
	9.2.2	High-speed signals....................................................................................................................	556
	9.2.3	Criteria for stroke initiation ........................................................................................................	558
	9.2.4	Axis start after punching............................................................................................................	560
	9.2.5	PLC signals specific to punching and nibbling..........................................................................	561
	9.2.6	Punching and nibbling-specific reactions to standard PLC signals..........................................	561
	9.2.7	Signal monitoring ......................................................................................................................	562
	9.3	Activation and deactivation .......................................................................................................	562
	9.3.1	Language commands................................................................................................................	562
	9.3.2	Functional expansions ..............................................................................................................	567
	9.3.3	Compatibility with earlier systems.............................................................................................	571
	9.4	Automatic path segmentation....................................................................................................	573
	9.4.1	General information...................................................................................................................	573
	9.4.2	Operating characteristics with path axes..................................................................................	575
	9.4.3	Response in connection with single axes.................................................................................	579
	9.5	Rotatable tool............................................................................................................................	584
	9.5.1	General information...................................................................................................................	584
	9.5.2	Coupled motion of punch and die.............................................................................................	585
	9.5.3	Tangential control......................................................................................................................	586
	9.6	Protection zones .......................................................................................................................	590
	9.7	Supplementary conditions.........................................................................................................	590
	9.8	Examples...................................................................................................................................	591
	9.8.1	Examples of defined start of nibbling operation........................................................................	591
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	9.9	Data lists ....................................................................................................................................	596
	9.9.1	Machine data..............................................................................................................................	596
	9.9.1.1	General machine data................................................................................................................	596
	9.9.1.2	Channelspecific machine data...................................................................................................	596
	9.9.2	Setting data................................................................................................................................	596
	9.9.2.1	Channelspecific setting data......................................................................................................	596
	9.9.3	Signals .......................................................................................................................................	597
	9.9.3.1	Signals to channel......................................................................................................................	597
	9.9.3.2	Signals from channel .................................................................................................................	597
	9.9.4	Language commands ................................................................................................................	597
10	P2: Positioning axes..............................................................................................................................		599
	10.1	Product brief...............................................................................................................................	599
	10.2	Own channel, positioning axis or concurrent positioning axis...................................................	601
	10.2.1 Own channel - only 840D sl.......................................................................................................		602
	10.2.2	Positioning axis..........................................................................................................................	602
	10.2.3	Concurrent positioning axis........................................................................................................	605
	10.3	Motion behavior and interpolation functions..............................................................................	606
	10.3.1 Path interpolator and axis interpolator.......................................................................................		606
	10.3.2	Interpolation response of path axis in G0..................................................................................	606
	10.3.3	Autonomous singleaxis operations............................................................................................	608
	10.3.4	Autonomous single-axis functions with NC-controlled ESR......................................................	613
	10.4	Positioning axis dynamic response............................................................................................	615
	10.5	Programming..............................................................................................................................	617
	10.5.1	General ......................................................................................................................................	617
	10.5.2	Revolutional feed rate in external programming........................................................................	620
	10.6	Block change..............................................................................................................................	621
	10.6.1	Settable block change time........................................................................................................	623
	10.6.2	End of motion criterion with block search..................................................................................	628
	10.7	Control by the PLC.....................................................................................................................	629
	10.7.1	Starting concurrent positioning axes from the PLC ...................................................................	631
	10.7.2	PLC-controlled axes...................................................................................................................	632
	10.7.3	Control response of PLC-controlled axes..................................................................................	633
	10.8	Response with special functions................................................................................................	635
	10.8.1	Dry run (DRY RUN) ...................................................................................................................	635
	10.8.2	Single block................................................................................................................................	635
	10.9	Examples ...................................................................................................................................	636
	10.9.1	Motion behavior and interpolation functions..............................................................................	636
	10.9.1.1	Traversing path axes without interpolation with G0...................................................................	637
	10.10	Data lists ....................................................................................................................................	637
	10.10.1	Machine data..............................................................................................................................	637
	10.10.1.1	NC-specific machine data.....................................................................................................	637
	10.10.1.2	Channelspecific machine data..............................................................................................	637
	10.10.1.3	Axis/spindlespecific machine data........................................................................................	638
	10.10.2	Setting data................................................................................................................................	638
	10.10.2.1	Axis/spindle-specific setting data..........................................................................................	638
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Contents

	10.10.3		Signals.......................................................................................................................................	638
	10.10.3.1		Signals to channel................................................................................................................	638
	10.10.3.2		Signals from channel ...........................................................................................................	639
	10.10.3.3		Signals to axis/spindle .........................................................................................................	639
	10.10.3.4		Signals from axis/spindle.....................................................................................................	639
11	P5: Oscillation - only 840D sl.................................................................................................................			641
	11.1		Brief description ........................................................................................................................	641
	11.2		Asynchronous oscillation...........................................................................................................	642
	11.2.1		Influences on asynchronous oscillation ....................................................................................	643
	11.2.2		Asynchronous oscillation under PLC control ............................................................................	650
	11.2.3		Special reactions during asynchronous oscillation...................................................................	650
	11.3		Oscillation controlled by synchronized actions .........................................................................	653
	11.3.1		Infeed at reversal point 1 or 2...................................................................................................	656
	11.3.2		Infeed in reversal point range....................................................................................................	657
	11.3.3		Infeed at both reversal points....................................................................................................	659
	11.3.4		Stop oscillation movement at the reversal point.......................................................................	660
	11.3.5		Oscillation movement restarting................................................................................................	661
	11.3.6		Do not start partial infeed too early...........................................................................................	662
	11.3.7		Assignment of oscillation and infeed axes OSCILL..................................................................	662
	11.3.8		Definition of infeeds POSP........................................................................................................	663
	11.3.9		External oscillation reversal ......................................................................................................	664
	11.4		Marginal conditions...................................................................................................................	665
	11.5		Examples...................................................................................................................................	665
	11.5.1	Example of asynchronous oscillation........................................................................................		666
	11.5.2	Example 1 of oscillation with synchronized actions..................................................................		667
	11.5.3	Example 2 of oscillation with synchronized actions..................................................................		670
	11.5.4		Examples for starting position...................................................................................................	672
	11.5.4.1 Define starting position via language command.......................................................................			672
	11.5.4.2		Start oscillation via setting data ................................................................................................	672
	11.5.4.3		Non-modal oscillation (starting position = reversal point 1)......................................................	673
	11.5.5		Example of external oscillation reversal....................................................................................	676
	11.5.5.1		Change reversal position via synchronized action with "external oscillation reversal".............	676
	11.6		Data lists....................................................................................................................................	676
	11.6.1		Machine data.............................................................................................................................	676
	11.6.1.1		General machine data...............................................................................................................	676
	11.6.2		Setting data...............................................................................................................................	677
	11.6.2.1		Axis/spindle-specific setting data..............................................................................................	677
	11.6.3		Signals.......................................................................................................................................	677
	11.6.3.1		Signals to axis/spindle...............................................................................................................	677
	11.6.3.2		Signals from axis/spindle ..........................................................................................................	677
	11.6.4		System variables.......................................................................................................................	678
	11.6.4.1		Main run variables for motion-synchronous actions .................................................................	678
12	R2: Rotary axes.....................................................................................................................................			681
	12.1		Brief Description........................................................................................................................	681
	12.2		Modulo 360 degrees .................................................................................................................	685

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	12.3	Programming rotary axes...........................................................................................................	688
	12.3.1	General information ...................................................................................................................	688
	12.3.2	Rotary axis with active modulo conversion (continuously-turning rotary axis)..........................	688
	12.3.3	Rotary axis without modulo conversion.....................................................................................	694
	12.3.4	Other programming features relating to rotary axes..................................................................	696
	12.4	Activating rotary axes.................................................................................................................	697
	12.5	Special features of rotary axes ..................................................................................................	698
	12.6	Examples ...................................................................................................................................	699
	12.7	Data lists ....................................................................................................................................	700
	12.7.1	Machine data..............................................................................................................................	700
	12.7.1.1	General machine data................................................................................................................	700
	12.7.1.2	Axis/spindlespecific machine data.............................................................................................	700
	12.7.2	Setting data................................................................................................................................	700
	12.7.2.1	General setting data...................................................................................................................	700
	12.7.2.2	Axis/spindle-specific setting data...............................................................................................	700
	12.7.3	Signals .......................................................................................................................................	701
	12.7.3.1	Signals to axis/spindle ...............................................................................................................	701
	12.7.3.2	Signals from axis/spindle...........................................................................................................	701
13	S3: Synchronous spindle.......................................................................................................................		703
	13.1	Brief description.........................................................................................................................	703
	13.1.1	Function .....................................................................................................................................	703
	13.1.2	Synchronous mode....................................................................................................................	705
	13.1.3	Prerequisites for synchronous mode.........................................................................................	711
	13.1.4	Selecting synchronous mode for a part program.......................................................................	712
	13.1.5	Deselecting the synchronous mode for the part program..........................................................	714
	13.1.6	Controlling synchronous spindle coupling via PLC....................................................................	716
	13.1.7	Monitoring of synchronous operation.........................................................................................	718
	13.2	Programming..............................................................................................................................	720
	13.2.1	Definition (COUPDEF)...............................................................................................................	721
	13.2.2	Switch the coupling (COUPON, COUPONC, COUPOF) on and off..........................................	724
	13.2.3	Axial system variables for synchronous spindle........................................................................	726
	13.2.4	Automatic selection and deselection of position control............................................................	727
	13.3	Configuration..............................................................................................................................	728
	13.3.1	Response of the synchronous-spindle coupling for NC Start....................................................	729
	13.3.2	Behavior of the synchronous-spindle coupling for reset............................................................	729
	13.4	Points to note.............................................................................................................................	730
	13.4.1	Special features of synchronous mode in general.....................................................................	730
	13.4.2	Restore synchronism of following spindle..................................................................................	732
	13.4.3	Synchronous mode and NC/PLC interface signals....................................................................	734
	13.4.4	Differential speed between leading and following spindles.......................................................	738
	13.4.5	Behavior of synchronism signals during synchronism correction..............................................	743
	13.4.6	Delete synchronism correction and NC reset............................................................................	743
	13.4.7	Special points regarding start-up of a synchronous spindle coupling........................................	743
	13.5	Boundary conditions ..................................................................................................................	749
	13.6	Examples ...................................................................................................................................	749
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Contents

	13.7	Data lists....................................................................................................................................	750
	13.7.1	Machine data.............................................................................................................................	750
	13.7.1.1	NC-specific machine data.........................................................................................................	750
	13.7.1.2	Channelspecific machine data..................................................................................................	750
	13.7.1.3	Axis/spindlespecific machine data............................................................................................	751
	13.7.2	Setting data...............................................................................................................................	751
	13.7.2.1	Channelspecific setting data.....................................................................................................	751
	13.7.3	Signals.......................................................................................................................................	752
	13.7.3.1	Signals to channel.....................................................................................................................	752
	13.7.3.2	Signals from channel.................................................................................................................	752
	13.7.3.3	Signals to axis/spindle...............................................................................................................	752
	13.7.3.4	Signals from axis/spindle ..........................................................................................................	753
	13.7.4	System variables.......................................................................................................................	753
14	S7: Memory configuration......................................................................................................................		755
	14.1	Brief description ........................................................................................................................	755
	14.2	Memory organization.................................................................................................................	756
	14.2.1	Active and passive file system..................................................................................................	756
	14.2.2	Reconfiguration.........................................................................................................................	757
	14.3	Configuration of the static user memory...................................................................................	758
	14.3.1	Division of the static NC memory..............................................................................................	758
	14.3.2	Commissioning..........................................................................................................................	761
	14.4	Configuration of the dynamic user memory..............................................................................	762
	14.4.1	Division of the dynamic NC memory.........................................................................................	762
	14.4.2	Commissioning..........................................................................................................................	763
	14.5	Data lists....................................................................................................................................	764
	14.5.1	Machine data.............................................................................................................................	764
	14.5.1.1	General machine data...............................................................................................................	764
	14.5.1.2	Channelspecific machine data..................................................................................................	767
	14.5.1.3	Axis/spindlespecific machine data............................................................................................	769
15	T1: Indexing axes ..................................................................................................................................		771
	15.1	Brief Description........................................................................................................................	771
	15.2	Traversing of indexing axes......................................................................................................	771
	15.2.1	Traversing of indexing axes in the JOG mode..........................................................................	772
	15.2.2	Traversing of indexing axes in the AUTOMATIC mode............................................................	774
	15.2.3	Traversing of indexing axes by PLC.........................................................................................	775
	15.3	Parameterization of indexing axes............................................................................................	775
	15.4	Programming of indexing axes..................................................................................................	777
	15.5	Equidistant index intervals........................................................................................................	782
	15.5.1	Features....................................................................................................................................	782
	15.5.2	Hirth tooth system.....................................................................................................................	783
	15.5.3	Response of the Hirth axes in particular situations...................................................................	784
	15.5.4	Restrictions ...............................................................................................................................	785
	15.5.5	Modified activation of machine data..........................................................................................	786
	15.6	Starting up indexing axes..........................................................................................................	786
	15.7	Special features of indexing axes.............................................................................................	790
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			Contents
	15.8	Examples ...................................................................................................................................	791
	15.8.1	Examples of equidistant indexes...............................................................................................	791
	15.9	Data lists ....................................................................................................................................	793
	15.9.1	Machine data..............................................................................................................................	793
	15.9.1.1	General machine data................................................................................................................	793
	15.9.1.2	Axis/spindlespecific machine data.............................................................................................	793
	15.9.2	Setting data................................................................................................................................	793
	15.9.2.1	General setting data...................................................................................................................	793
	15.9.3	Signals .......................................................................................................................................	794
	15.9.3.1	Signals from axis/spindle...........................................................................................................	794
	15.9.4	System variables........................................................................................................................	794
16	W3: Tool change....................................................................................................................................		795
	16.1	Brief Description.........................................................................................................................	795
	16.2	Tool magazines and tool change equipments...........................................................................	795
	16.3	Tool change times......................................................................................................................	796
	16.4	Cut-to-cut time............................................................................................................................	796
	16.5	Starting the tool change.............................................................................................................	796
	16.6	Tool change point ......................................................................................................................	797
	16.7	Supplementary Conditions.........................................................................................................	798
	16.8	Examples ...................................................................................................................................	798
	16.9	Data lists ....................................................................................................................................	800
	16.9.1	Machine data..............................................................................................................................	800
	16.9.1.1	General machine data................................................................................................................	800
	16.9.1.2	Channelspecific machine data...................................................................................................	800
	16.9.1.3	Axis-/spindlespecific machine data............................................................................................	800
	16.9.2	Signals .......................................................................................................................................	800
	16.9.2.1	Signals from channel .................................................................................................................	800
17	W4: Grinding-specific tool offset and tool monitoring.............................................................................		801
	17.1	Tool offset for grinding operations.............................................................................................	801
	17.1.1	Structure of tool data..................................................................................................................	801
	17.1.2	Edge-specific offset data............................................................................................................	803
	17.1.3	Tool-specific grinding data.........................................................................................................	806
	17.1.4	Examples of grinding tools.........................................................................................................	812
	17.2	Online tool offset........................................................................................................................	816
	17.2.1	General information ...................................................................................................................	816
	17.2.2	Write online tool offset: Continuous...........................................................................................	818
	17.2.3	Activate/deactivate online tool offset .........................................................................................	820
	17.2.4	Example of writing online tool offset continuously.....................................................................	821
	17.2.5	Write online tool offset discretely...............................................................................................	823
	17.2.6	Information about online offsets.................................................................................................	823
	17.3	Online tool radius compensation................................................................................................	824
	17.4	Grinding-specific tool monitoring................................................................................................	825
	17.4.1	General information ...................................................................................................................	825
	17.4.2	Geometry monitoring .................................................................................................................	826
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Contents

	17.4.3	Speed monitoring......................................................................................................................	827
	17.4.4	Selection/deselection of tool monitoring ...................................................................................	828
	17.5	Constant grinding wheel peripheral speed (GWPS).................................................................	829
	17.5.1	General information...................................................................................................................	829
	17.5.2	Selection/deselection and programming of GWPS, system variable .......................................	830
	17.5.3	GWPS in all operating modes...................................................................................................	831
	17.5.4	Programming example for GWPS.............................................................................................	832
	17.6	Supplementary Conditions........................................................................................................	833
	17.6.1	Tool changes with online tool offset..........................................................................................	833
	17.7	Data lists....................................................................................................................................	834
	17.7.1	Machine data.............................................................................................................................	834
	17.7.1.1	General machine data...............................................................................................................	834
	17.7.1.2	Channelspecific machine data..................................................................................................	834
	17.7.1.3	Axis/spindlespecific machine data............................................................................................	834
	17.7.2	Signals.......................................................................................................................................	834
	17.7.2.1	Signals from axis/spindle ..........................................................................................................	834
18	Z2: NC/PLC interface signals.................................................................................................................		835
	18.1	Digital and analog NCK I/Os (A4).............................................................................................	835
	18.1.1	Signals to NC (DB10)................................................................................................................	835
	18.1.2	Signals from NC (DB10)............................................................................................................	843
	18.2	Distributed systems (B3)...........................................................................................................	846
	18.2.1	Defined logical functions/defines ..............................................................................................	846
	18.2.2	Interfaces in DB19 for M:N........................................................................................................	849
	18.2.3	Signals from NC (DB10)............................................................................................................	856
	18.2.4	Signals from axis/spindle (DB31, ...).........................................................................................	857
	18.3	Manual and Handwheel Travel (H1).........................................................................................	858
	18.3.1	Signals from NC (DB10)............................................................................................................	858
	18.3.2	Signals to channel (DB21, ...) ...................................................................................................	861
	18.3.3	Signals from channel (DB21, ...)...............................................................................................	867
	18.3.4	Signals with contour handwheel ...............................................................................................	874
	18.3.5	Signals to axis/spindle (DB31, ...).............................................................................................	876
	18.3.6	Signals from axis/spindle (DB31, ...).........................................................................................	881
	18.4	Compensations (K3) .................................................................................................................	884
	18.5	Mode Groups, Channels, Axis Replacement (K5)....................................................................	885
	18.5.1	Signals to axis/spindle (DB31, ...).............................................................................................	885
	18.5.2	Signals from axis/spindle (DB31, ...).........................................................................................	886
	18.6	Kinematic Transformation (M1).................................................................................................	886
	18.6.1	Signals from channel (DB21, ...)...............................................................................................	886
	18.7	Measurement (M5)....................................................................................................................	887
	18.7.1	Signals from NC (DB10)............................................................................................................	887
	18.7.2	Signals from axis/spindle (DB31, ...).........................................................................................	887
	18.8	Software cams, position switching signals (N3)........................................................................	888
	18.8.1	Signal overview.........................................................................................................................	888
	18.8.2	Signals from NC (DB10)............................................................................................................	889
	18.8.3	Signals to axis/spindle (DB31, ...).............................................................................................	890
	18.8.4	Signals from axis/spindle (DB31, ...).........................................................................................	890
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Contents

	18.9	Punching and Nibbling (N4) .......................................................................................................	891
	18.9.1	Signal overview ..........................................................................................................................	891
	18.9.2	Signals to channel (DB21, ... ) ....................................................................................................	891
	18.9.3	Signals from channel (DB21, ... ) ................................................................................................	893
	18.10	Positioning axes (P2) .................................................................................................................	894
	18.10.1	Signals to axis/spindle (DB31, ... ) ..............................................................................................	894
	18.10.2 Function call - only 840D sl........................................................................................................		898
	18.11	Oscillation (P5) ...........................................................................................................................	898
	18.11.1	Signals to axis/spindle (DB31, ... ) ..............................................................................................	898
	18.11.2	Signals from axis/spindle (DB31, ... ) ..........................................................................................	900
	18.12	Rotary axes (R2) ........................................................................................................................	902
	18.12.1	Signals to axis/spindle (DB31, ... ) ..............................................................................................	902
	18.12.2	Signals from axis/spindle (DB31, ... ) ..........................................................................................	902
	18.13	Synchronous Spindles (S3) .......................................................................................................	903
	18.13.1	Signals to axis/spindle (DB31, ... ) ..............................................................................................	903
	18.13.2	Signals from axis/spindle (DB31, ... ) ..........................................................................................	903
	18.14	Memory Configuration (S7) ........................................................................................................	906
	18.15	Indexing Axes (T1) .....................................................................................................................	906
	18.15.1	Signals from axis/spindle (DB31, ... ) ..........................................................................................	906
	18.16	Tool Change (W3) ......................................................................................................................	907
	18.17	Grinding - specific tool offset and tool monitoring (W4) ...............................................................	908
	18.17.1	Signals from axis/spindle (DB31, ... ) ..........................................................................................	908
A	Appendix	................................................................................................................................................	909
	A.1	List of abbreviations ...................................................................................................................	909
	A.2	Overview ....................................................................................................................................	918
	Glossary ................................................................................................................................................		919
	Index......................................................................................................................................................		941

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A4: Digital and analog NCK I/Os for SINUMERIK	1
840D sl

1.1Introduction

Function

Signals can be read and output in the interpolation cycle via the inputs/outputs of the fast digital and analog NCK I/Os. The following functions can be executed with these signals, for example:

●Several feedrate values in one block

●Several auxiliary functions in one block

●Rapid retraction on final dimension

●Axis-specific delete distance-to-go

●Program branches

●Rapid NC Start

●Analog calipers

●Position switching signals

●Punching/nibbling functions

●Analog-value control

Hardware

The SINUMERIK 840D sl hardware has three 14-pin I/O interfaces X122, X132 and X142 on the NCU on-board. Only X142 is available as a fast NCK I/O.

There are four fast digital inputs and four outputs on the X142 that can be addressed via the first address byte and via the $A_IN[1...4] and $A_OUT[1...4] system variables.

ET 200 modules can also be connected to the PROFIBUS DP/MPI interfaces X126 and X136. This enables the number of digital and analog NCK I/Os to be expanded by 32 and 8 respectively. These NCK I/Os are called external NCK I/Os in the following.

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A4: Digital and analog NCK I/Os for SINUMERIK 840D sl

1.1 Introduction

Table 1- 1 Maximum number of digital and analog NCK I/Os

	Total	NCU on-board	External NCK I/Os
Digital inputs	36	4	32
Digital outputs	36	4	32
Analog inputs	8	-	8
Analog outputs	8	-	8

References:

For further information about the hardware specification, refer to:

●SINUMERIK 840D sl NCU Manual

●SIMATIC ET 200S FC Operating Instructions

Access to NCK I/Os:

The fast digital and analog NCK I/Os can be accessed in the following ways:

●Access via PLC (Page 27) (for on-board I/Os and PROFIBUS I/Os)

●Access via PROFIBUS (Page 54) (for PROFIBUS I/Os)

Monitoring

The following monitoring functions are active for the external NCK I/Os:

●During run-up:

–Check whether the arrangement of components of the I/O modules in the ET 200 modules matches the MD assignments.

●During cyclic operation:

–Sign-of-life monitoring in interpolation cycles

–Module monitoring in interpolation cycles

–Temperature monitoring

In the event of a fault, NC-Ready is canceled and an alarm is output.

Response to faults

The digital and analog NCK outputs are switched to a safe status (0 V at output) in the event of faults (e.g. NC-Ready = 0) in the NCU or power failures.

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A4: Digital and analog NCK I/Os for SINUMERIK 840D sl

1.2 Access via PLC

1.2Access via PLC

1.2.1Brief description

Configuring NCK I/Os

During commissioning, the number and the hardware assignment of the addressable digital and analog NCK I/Os and their assignment to NC functions is defined via machine data.

For further information, see "Configuration of the NCK I/Os (Page 28)".

Data exchange

The signals and analog values of the digital and analog I/Os are available in the NC (part program, ASUB, synchronized action, etc.) in the form of system variables.

•	$A_IN [<n>]	Read digital NCK input <n> (where <n> = 1...4 and 9...40)
		For further information, see "NCK digital inputs (Page 31)".
•	$A_OUT [<n>]	Read/write digital NCK output <n> (where <n> = 1...4 and 9...40)
		For further information, see "NCK digital outputs (Page 32)".
•	$A_INA [<n>]	Read analog NCK input <n> read (where <n> = 1...8)
		For further information, see "NCK analog inputs (Page 37)".
•	$A_OUTA [<n>]	Read/write analog NCK output <n> read (where <n> = 1...8)
		For further information, see "NCK analog outputs (Page 39)".

<n> = number of the NCK input/output

Note

When these system variables are read by the part program, a preprocessing stop (STOPRE) is initiated inside the control.

Comparator inputs

In addition to the digital and analog NCK inputs, 16 internal comparator inputs (comparator input bytes 1 and 2) are also available.

The signal state of a comparator input is formed by comparing an analog input signal with a threshold value within a setting data.

For further information, see "Comparator inputs (Page 45)".

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A4: Digital and analog NCK I/Os for SINUMERIK 840D sl

1.2 Access via PLC

PLC I/Os for direct addressing by NCK

Up to 32 bytes for digital input signals and analog input values, and up to 32 bytes for digital output signals and analog output values can be addressed directly by the part program. These bytes must be taken into account when the PLC is configured. They are processed directly by the PLC operating system. As a result, the time taken to transfer signals between the NC and PLC I/O modules is of an order of magnitude of 0.5 ms.

Note

The output bytes specified for the NCK may not be write-accessed by the PLC user program, as the access operations between the NCK and PLC would be uncoordinated.

For further information, see "Direct PLC I/Os, addressable from the NC (Page 48)".

1.2.2Configuration of the NCK I/Os

Number of active NCK I/Os

The number of addressable digital NCK I/O bytes and analog I/Os is defined with the machine data:

•MD10350 $MN_FASTIO_DIG_NUM_INPUTS

•MD10360 $MN_FASTIO_DIG_NUM_OUTPUTS

•MD10300 $MN_FASTIO_ANA_NUM_INPUTS

•MD10310 $MN_FASTIO_ANA_NUM_OUTPUTS

Number of active digital NCK input bytes (max. 5)

Number of active digital NCK output bytes (max. 5)

Number of active analog NCK inputs (max. 8)

Number of active analog NCK outputs (max. 8)

Corresponding alarms are generated if the part program addresses I/Os that have not been defined in the above machine data.

The NCK I/Os do not have to actually exist in the hardware. In this case the signal states or the binary analog values are set to "zero" in a defined way inside the NCK. However, these values can be changed by the PLC.

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A4: Digital and analog NCK I/Os for SINUMERIK 840D sl

1.2 Access via PLC

Hardware assignment of the external NCK I/Os

The assignment of the I/O signal modules or I/O modules to the external NCK I/Os is performed via the machine data:

•	MD10366 $MN_HW_ASSIGN_DIG_FASTIN[<n>]	HW assignment for external
		digital inputs
•	MD10368 $MN_HW_ASSIGN_DIG_FASTOUT[<n>]	HW assignment for external
		digital outputs
•	MD10362 $MN_HW_ASSIGN_ANA_FASTIN[<n>]	HW assignment for external
		analog inputs
•	MD10364 $MN_HW_ASSIGN_ANA_FASTOUT[<n>]	HW assignment for external
		analog outputs

<n> = Index for addressing the external digital I/O bytes (0 ... 3) or the external analog I/Os (0 ... 7)

Example:

Two additional input bytes and one additional output byte are configured in the NC for the data exchange with the digital I/Os of an external PROFIBUS module.

Hardware assignment:

MD10366 $MN_HW_ASSIGN_DIG_FASTIN[0]='H5000200' ; for $A_IN[9] ... [16] MD10366 $MN_HW_ASSIGN_DIG_FASTIN[1]='H5000201' ; for $A_IN[17] ... [20] MD10368 $MN_HW_ASSIGN_DIG_FASTOUT[0]='H5000200' ; for $A_OUT[9] ... [16] 'H5000000' specifies that the input/output is on the PROFIBUS.

The lower-order digits specify the start address of the assigned module as a logical PROFIBUS address in hexadecimal format.

For the configuration in the SIMATIC Manager, the same logical address is assigned in decimal format (e.g. the value 'H202' corresponds to the logical address '514').

Number of active NCK I/O bytes:

MD10350 $MN_FASTIO_DIG_NUM_INPUTS = 3

MD10360 $MN_FASTIO_DIG_NUM_OUTPUTS = 2

Note

The on-board byte must also be counted for the configuration of MD10350 or MD10360!

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A4: Digital and analog NCK I/Os for SINUMERIK 840D sl

1.2 Access via PLC

Weighting factor for the analog NCK I/Os

The weighting factor can be used to adapt each individual NCK I/O to the AD or DA converter of the analog I/O module used:

• MD10320 $MN_FASTIO_ANA_INPUT_WEIGHT[<n>] Weighting factor for the analog NCK inputs

For further information, see "NCK analog inputs (Page 37)".

• MD10330 $MN_FASTIO_ANA_OUTPUT_WEIGHT[<n>] Weighting factor for the analog NCK outputs

For further information, see "NCK analog outputs (Page 39)".

Assignment to NC functions

Several NC functions are dependent on the functionality of the NCK I/Os.

The assignment of the NCK I/Os used for these NC functions is performed functionspecifically via machine data, e.g. for the "Multiple feedrates in one block" function via the machine data:

MD21220 $MC_MULTFEED_ASSIGN_FASTIN

A byte address should be specified in the machine data for digital inputs/outputs. The assignment is always byte-by-byte.

Byte address	Assignment for the digital NCK I/Os
0	None
1	1 to 4 (on-board I/O)	and	5 to 8	(NCK output without hardware)
2	9	to	16	(external NCK I/Os)
3	17	to	24	(external NCK I/Os)
4	25	to	32	(external NCK I/Os)
5	33	to	40	(external NCK I/Os)
128	Inputs 1 to 8 of comparator byte 1
129	Inputs 9 to 16 of comparator byte 2

Note

Multiple assignments

Multiple assignments of inputs are not monitored.

Multiple assignments of outputs are checked during run-up and indicated by an alarm.

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