802Dsl FB 0505 en

Description of Functions 05/05 Edition
sinumerik
Turning, Milling
SINUMERIK 802D sl
EMERGENCY STOP (N2) 1
Axis Monitoring (A3)

2
Velocities, Setpoint/Actual
Value Systems, Closed-Loop
Control (G2) 3
Acceleration (B2) 4
SINUMERIK 802D sl 5
Spindle (S1)
Rotary Axes (R2) 6

Description of Functions
Turning, Milling Transverse Axes (P1) 7
Reference Point
Approach (R1) 8
Manual and Handwheel
Travel (H1) 9
Operating Modes, Program
Operation (K1) 10
Feed (V1) 11
Continuous Path Mode, Exact
Stop and LookAhead (B1) 12
Auxiliary Function Output to
PLC (H2) 13
Tool: Compensation and
Monitoring (W1) 14
Measurement (M5)
15
Valid for Compensation (K3) 16
Control system Software version
Travel to Fixed Stop (F1)
17
SINUMERIK 802D sl 1
Kinematic
Transformations (M1) 18
Tangential Control (T3) 19
Various Interface Signals (A2) 20
PLC User Interface 21
Various Machine Data

22
Edition 05/2005
Safety-related information
This manual contains important information related to your personal safety and the protection of equipment.
The notices referring to your personal safety are highlighted in the manual by a triangular safety alert
symbol, notices referring to property damage only 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
! with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
Caution
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
Attention
indicates that an undesirable event or state may arise if the relevant note is not observed.
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 warning symbol may also include a warning relating
to property damage.
Qualified personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Qualified persons as far as
the safety instructions given in this documentation are concerned are those who have the necessary
authorization to commission, ground and identify equipment, systems and circuits in accordance with the
relevant safety standards.
Use as prescribed
Note the following:
Warning
! This device and its components may only be used for the applications described in the catalog or in the
technical descriptions, and only in combination with third-party devices and components which have been
approved or recommended by Siemens. This product can only function correctly and safely if it is
transported, stored, set up, and installed correctly, and operated and maintained as recommended.
Trademarks
All designations with the trademark symbol  are registered trademarks of Siemens AG. Other designations
in this documentation may be trademarks whose use by third parties for their own purposes may infringe the
rights of the owner.
Disclaimer of liability
We have checked the contents of this manual for agreement with the hardware and software described.
Since discrepancies cannot be precluded entirely, we cannot guarantee full agreement. The information
given in this publication is reviewed at regular intervals and any corrections that might be necessary are
made in the subsequent editions.
Siemens AG Copyright (E) Siemens AG 2005.

Automation and Drives 6FC5397-1CP10-1BA0
Postfach 4848
D–90437 NUREMBERG Siemens AG 2005
FEDERAL REPUBLIC OF GERMANY Subject to change without prior notice.
Foreword
SINUMERIK Documentation
The SINUMERIK documentation is organized in 3 parts:
S General documentation
S User documentation
S Manufacturer/Service documentation
More detailed information about other publications concerning SINUMERIK 802D sl
and publications that apply to all SINUMERIK control systems (e.g., Universal Inter-
face, Measuring Cycles, etc.) can be obtained from your local Siemens branch office.
A list of documents, updated on a monthly basis, is available on the Internet for the
available languages at:
http://www.siemens.com/motioncontrol
Select “Support”/“Technical Documentation”/“Overview of Documents”.
The Internet version of the DOConCD (DOConWEB) is available at:
http://www.automation.siemens.com/doconweb.
Target readership of this documentation

This document is designed for machine tool manufacturers. This publication provides
detailed information that the user requires for strating up SINUMERIK 810Dsl control
systems.
Standard version
The present Instruction Manual describes the functionality of the standard scope. Ex-
tensions or changes made by the machine manufacturer are documented by the ma-
chine 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.
Hotline
If you have any questions, do not hesitate to call our hotline:
A&D Technical Support
Tel.: +49 (0) 180 / 5050 – 222
Fax: +49 (0) 180 / 5050 – 223
Internet: http://www.siemens.de/automation/support–request
If you have any comments, suggestions, or corrections regarding this documentation,
please fax or e-mail them to:
Fax: +49 (0) 9131 / 98 – 63315
E-mail: motioncontrol.docu@siemens.com
Fax form: See the reply form at the end of the brochure.
SINUMERIK 802D sl Description of Functions (FB), 05/05 Edition

6FC5397-1CP10-1BA0 iii
Foreword
Internet address
http://www.siemens.com/motioncontrol
Notes for the reader

The function descriptions are only valid for the specific software version or up to the software
version specified. You should request valid function descriptions for new software versions.
Old function descriptions are only partly applicable for new software versions.
Note
It may be possible to run functions that are not described in this document in your controller.
This does not, however, represent an obligation to supply such functions with a new delivery
or when servicing, and no support can be provided in case of error.
Technical Information
Notations
The following notation and abbreviations are used in this documentation:
S PLC interface signals –> IS “Signal designation” (Signal date)
Example: IS “Feed override” (VB380x 0000)
The variable byte is located in the “to axis” range, x stands for the axis: 0 axis 1
1 axis 2
n axis n+1.
S Machine data –> MD MD_NR: MD_NAME
S Setting data –> SD SD_NR: SD_NAME
S The chapter titles are supplemented by a brief description in brackets (e.g. Chapter 1:
EMERGENCY STOP (N2). This brief description is used in cross references to other
chapters.
Explanation of the brief description

Chapters of each Description of Functions describe the data and signals which are significant
for the respective function. Certain terms and abbreviations, which are used in these tabular
descriptions, are explained here.
Default value:
The machine/setting data are initialized with this value when loading the default machine data.
Range of values (minimum/maximum value):
Specifies the input limits. If no range of values is specified, the data type determines the input
limits and the field is marked with “***”.

iv 6FC5397-1CP10-1BA0
Foreword
Activation of changes:
Changes in machine data, setting data etc. come not into effect immediately. The conditions
for activation are therefore always specified. The possibilities are shown in the following list in
order of their priority:
S POWER ON (po) Disconnection and reconnection of power supply
or softkey “StartUp/Normal” at HMI
S NEW_CONF (cf) “RESET” key on control unit
S RESET (re) “RESET” key on control unit
S IMMEDIATE (so) After entry of value
Protection level:
Protection levels 0 to 7 have been used. The lock for protection levels 1 to 3 (4 to 7) can be
canceled by entering the correct password and 4 to 7 via IS “Protection level” (e.g. keyswitch
position). Protection level 0 is not accessible. (See chapter “Various Interface Signals”)
The operator only has access to information protected by one particular level and the levels
below it. Various protection levels are assigned to the machine data by default and are mar-
ked with a write/read value (e.g. 4/7).
Note: Machine and setting data of protection levels 2 to 7 are described in this document.
Protection level 1 machine data is only referred to in special cases (expert mode).
Unit:
The unit refers to the default setting (see Section “Velocities, setpoint/actual value systems,
closed-loop control”.
If the MD is not based on a physical unit, the relevant field contains a “–”.
Data type:
The following data types are used in the control system:
S DOUBLE
Floating point value (64-bit value)
Input limits from +/–4.19*10–307 to +/–1.67*10308
S DWORD
Integer value (integer values, 32 bit value)
Input limits from –2 147 483 648 to +2 147 483 648 (decimal),
as hex value: 0000 through FFFF
S BYTE
Integer value (integer values, 8 bit value)
Input limits from –128 to +127 (decimal), as hex value: 00 through FF
S BOOLEAN
Boolean value: TRUE (1) or FALSE (0)
S STRING
Consisting of max. 16 ASCII characters (upper case letters, numbers and underscore)

6FC5397-1CP10-1BA0 v
Foreword
Machine date example

36210 CTRLOUT_LIMIT[0]
MD number Maximum speed setpoint
Default setting: 110.0 Minimum input limit: 0.0 Maximum input limit: 200.0
Changes effective after NEW_CONF Protection level: 2/7 Unit: %
Data type: DOUBLE Applies from SW:
Meaning:
Alarms
Detailed explanations of alarms that may occur can be found in
References: “Diagnostics Guide”.

vi 6FC5397-1CP10-1BA0
Contents
Contents
1 EMERGENCY STOP (N2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.1 Brief Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.2 EMERGENCY STOP sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.3 EMERGENCY STOP acknowledgment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.4 Data Descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.5 Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.6 Data Fields, Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.6.1 Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.6.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
2 Axis Monitoring (A3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.1 Overview of monitoring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.2 Motion monitoring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2.2.1 Contour monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2.2.2 Positioning monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2.2.3 Zero-speed monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2.2.4 Clamping monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2.2.5 Speed setpoint monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2.2.6 Actual velocity monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
2.3 Encoder monitoring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
2.3.1 Encoder limit frequency monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
2.3.2 Zero-mark monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2.4 Monitoring of static limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
2.4.1 Limit switch monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
2.4.2 Working area limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
2.5 Supplementary conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
2.6.1 Channel-specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
2.6.2 Axis-specific/spindle-specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
2.6.3 Axis/spindle-specific setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
2.7 Signal Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
2.7.1 Axis/spindle-specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
2.8.1 Axis/spindle-specific interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
2.8.2 Axis/spindle-specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
2.8.4 Axis/spindle-specific setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
3 Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2) . . . . . . . . . . 3-47
3.1 Velocities, traversing ranges, accuracies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
3.1.1 Velocities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
3.1.2 Traversing ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.1.3 Input/display resolution, computational resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3.1.4 Standardizing physical quantities of machine and setting data . . . . . . . . . . . . . . . . . . . . . 3-49
3.2 Metric/inch measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
3.2.1 Conversion of basic system by part program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
3.2.2 Manual changing the basic system changeover of the basic system . . . . . . . . . . . . . . . . 3-53
3.3 Setpoint/actual-value system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
3.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

6FC5397-1CP10-1BA0 vii
Contents
3.3.2 Drives with DRIVE-QLiQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

3.3.3 Speed setpoint and actual-value routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
3.3.4 Speed setpoint output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
3.3.5 Actual-value processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
3.4 Closed-loop control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
3.5 Data Description (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
3.5.1 General machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
3.5.3 Axis-specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
3.6 Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
3.7 Data fields, data lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
3.7.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
4 Acceleration (B2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
4.1 Acceleration profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
4.2 Jerk limitation on interpolator level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78
4.3 Jerk limitation in JOG mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
4.4 Percentage acceleration correction, ACC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
4.5 Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
4.6 Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
5 Spindle (S1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
5.1 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
5.2 Spindle modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84
5.2.1 Spindle control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85
5.2.2 Spindle oscillation mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86
5.2.3 Spindle positioning mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88
5.2.4 Spindle mode axis mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5.3 Synchronizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93
5.4 Gear stage change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94
5.5 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99
5.6 Spindle monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100
5.6.1 Axis/spindle stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100
5.6.2 Spindle in setpoint range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101
5.6.3 Maximum spindle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101
5.6.4 Minimum/maximum speed for gear stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101
5.6.5 Max. encoder limit frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-102
5.6.6 Target point monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103
5.7 2nd spindle/master spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-104
5.8 Analog spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105
5.9.3 Spindle-specific setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
5.11.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-126

viii 6FC5397-1CP10-1BA0
Contents
5.11.3 Setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-127

6 Rotary Axes (R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-129
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-129
6.2 Modulo 360 degrees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-131
6.3 Programming of rotary axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-132
6.3.1 Rotary axis with active modulo conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-132
6.3.2 Rotary axis without modulo conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-133
6.5.1 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-136
6.5.2 Setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-136
7 Transverse Axes (P1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-137
7.1 Transverse axis definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-137
7.2 Diameter programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-137
7.3 Constant cutting rate: G96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-138
8 Reference Point Approach (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-139
8.1 Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-139
8.2 Referencing with incremental measuring systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-142
8.3 Referencing with absolute value encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-146
8.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-146
8.3.2 Operator-assisted calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-146
8.4 Secondary conditions for absolute encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-148
8.4.1 Calibrating absolute encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-148
8.6.1 Channel-specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-157
8.7.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-159
9 Manual and Handwheel Travel (H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-161
9.1 General characteristics of traversing in JOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-161
9.2 Continuous jogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-165
9.3 Incremental jogging (INC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-166
9.4 Handwheel traversal in JOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-167
9.5.3 General setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-171
9.6.1 HMI signals to the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-173
9.6.2 NCK signals and signals in the operating mode range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-174

6FC5397-1CP10-1BA0 ix
Contents

9.7.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-183
9.7.3 Setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-183
10 Operating Modes, Program Mode (K1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-185
10.2 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186
10.2.1 Mode change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-187
10.2.2 Functional possibilities in the individual modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-188
10.2.3 Monitoring functions in the individual modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-189
10.2.4 Interlocks in the individual modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190
10.3 Processing a part program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-191
10.3.1 Program mode and part program selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-191
10.3.2 Start of part program or part program block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-191
10.3.3 Part program interruption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-192
10.3.4 RESET command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-193
10.3.5 Program control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194
10.3.6 Program status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194
10.3.7 Channel status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-195
10.3.8 Responses to operator or program actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-196
10.3.9 Example of timing diagram for a program run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-197
10.4 Program testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-198
10.4.1 General notes on the program test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-198
10.4.2 Program processing without axis movements (PRT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-198
10.4.3 Program processing in single block mode (SBL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-199
10.4.4 Program processing with dry run feedrate (DRY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200
10.4.5 Block search: Processing of selected program sections . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-201
10.4.6 Skip part program blocks (SKP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-203
10.4.7 Graphic simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-204
10.5 Timers for program execution time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-206
10.6 Workpiece counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-207
10.7.1 Machine data display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-209
10.7.3 Channel-specific setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-214
10.8.1 Operating mode signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-216
10.9.2 Channel-specific setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-230
11 Feed (V1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-233
11.1 Path feedrate F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-233
11.1.1 Feedrate with G33, G34, G35 (Thread cutting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-235
11.1.2 Feedrate for G63 (tapping with compensation chuck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-237
11.1.3 Feedrate for G331, G332 (rigid tapping) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-237
11.1.4 Feedrate for chamfer/rounding: FRC, FRCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-238
11.2 Rapid traverse G0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-239
11.3 Feedrate control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-240
11.3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-240

x 6FC5397-1CP10-1BA0
Contents
11.3.2 Feed disable and feed/spindle stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-240

11.3.3 Feedrate override on a machine control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-241
11.6.2 Machine data/setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-252
12 Continuous Path Mode, Exact Stop and LookAhead (B1) . . . . . . . . . . . . . . . . . . . . . . 12-253
12.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-254
12.3 Exact stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-255
12.4 Continuous path mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-256
12.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-256
12.4.2 Velocity reduction according to overload factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-257
12.4.3 Jerk limiting along the path through velocity reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-258
12.4.4 Machine axis-specific jerk limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-259
12.5 LookAhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-260
12.6.2 Axis-specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-262
12.7.2 Axis-specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-263
12.8.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-264
13 Auxiliary Function Output to PLC (H2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-265
13.2 Programming of auxiliary functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-266
13.3 Transfer of values and signals to the PLC interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-267
13.4 Grouping of auxiliary functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-268
13.5 Block search response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-269
13.6 Description of the auxiliary functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-270
13.6.1 M function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-270
13.6.2 T function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-270
13.6.3 D function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-270
13.6.4 H function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-271
13.6.5 S function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-271
13.9.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-277

6FC5397-1CP10-1BA0 xi
Contents
14 Tool: Compensation and Monitoring (W1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-279

14.1 Tool and tool compensation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-279
14.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-280
14.3 Tool compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-281
14.4 Tool monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-282
14.4.1 Tool monitoring overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-282
14.4.2 Service life monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-284
14.4.3 Workpiece count monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-285
14.4.4 Examples for the service life monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-286
14.5 Special handling of tool compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-287
14.8.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-293
15 Measurement (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-295
15.2 Hardware requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-296
15.2.1 Suitable probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-296
15.2.2 Probe connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-297
15.3 Channel-specific measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-298
15.3.1 Measuring mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-298
15.3.2 Measurement results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-298
15.4 Measuring accuracy and functional testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-299
15.4.1 Measuring accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-299
15.4.2 Probe functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-299
15.5 Tool measuring in JOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-301
15.8.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-308
16 Compensation (K3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-309
16.2 Backlash compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-310
16.3 Interpolatory compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-311
16.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-311
16.3.2 LEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-312
16.3.3 Special features of interpolatory compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-315
16.4 Following error compensation (feedforward control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-316
16.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-316
16.4.2 Speed feedforward control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-317
16.6.2 Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-320

xii 6FC5397-1CP10-1BA0
Contents
17 Travel to Fixed Stop (F1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-321

17.2 Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-322
17.3 Response to RESET and function abort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-328
17.4 Block search response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-328
17.5 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-329
18 Kinematic Transformations (M1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-339
18.2 TRANSMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-340
18.2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-340
18.2.2 TRANSMIT configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-341
18.3 TRACYL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-345
18.3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-345
18.3.2 TRACYL configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-348
18.3.3 Programming example, TRACYL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-352
18.4 Special features of TRANSMIT and TRACYL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-354
18.7 Data Fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-360
19 Tangential Control (T3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-361
19.2 Characteristics of “Tangential control” function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-362
19.3 Use of “Tangential control” function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-363
19.3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-363
19.3.2 Definition of axis coupling: TANG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-364
19.3.3 Switching-in the axis coupling: TANGON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-365
19.3.4 Response at corners, activation “with intermediate block”: TLIFT . . . . . . . . . . . . . . . . . . . 19-365
19.3.5 De-activation of axis coupling: TANGOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-365
19.3.6 De-activate corner response “with intermediate block” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-366
19.3.7 Deleting the definition of axis coupling: TANGDEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-366
19.3.8 Programming examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-366
19.4 Limit angle for reversal of path direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-367
20 Various Interface Signals (A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-369
20.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-369
20.2 Signals from PLC to NCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-370
20.3 Signals from NCK to PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-374

6FC5397-1CP10-1BA0 xiii
Contents
20.4 Signals from PLC to HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-377

20.5 Signals from HMI to PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-378
20.6 Reading/writing NC variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-379
20.6.1 User interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-379
20.6.2 NC variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-381
20.7 Signals from PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-384
21 PLC User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-385
21.1 Address ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-385
21.2 User data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-387
21.2.1 User data 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-387
21.2.2 User data 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-387
21.2.3 Reading/writing NC data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-387
21.2.4 Retentive data area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-388
21.3 User alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-389
21.3.1 User alarm: Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-389
21.3.2 Variable for alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-389
21.3.3 Active alarm reaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-390
21.4 Signals from/to HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-390
21.4.1 Program control signals from HMI (retentive area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-390
21.4.2 General selection/status signals from HMI (retentive area) . . . . . . . . . . . . . . . . . . . . . . . . 21-392
21.4.3 General selection/status signals to HMI (retentive area) . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-392
21.5 Auxiliary function transfer from NC channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-393
21.5.1 Decoded M signals: (M0–M99) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-393
21.5.2 Transferred T functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-394
21.5.3 Transferred M functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-394
21.5.4 Transferred S functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-395
21.5.5 Transferred D functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-395
21.5.6 Transferred H functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-395
21.6 NCK signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-396
21.7 Channel signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-398
21.7.1 Signals to NC channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-398
21.7.2 Signals from NC channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-400
21.8 Axis/spindle signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-402
21.8.1 Transferred M/S functions, axis-specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-402
21.8.2 Signals to axis/spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-402
21.8.3 Signals from axis/spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-404
21.9 PLC machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-406
21.9.1 INT values (MD 14510 USER_DATA_INT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-406
21.9.2 HEX values (MD 14512 USER_DATA_HEX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-406
21.9.3 FLOAT values (MD 14514 USER_DATA_FLOAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-406
21.9.4 User alarm: Configuration (MD 14516 USER_DATA_PLC_ALARM) . . . . . . . . . . . . . . . . 21-407
21.10 Reading and writing PLC variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-407
21.11 Tool management functions from NC channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-408
21.12 Axis actual values and distances-to-go . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-409
22 Various Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-411
22.1 Display machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-411
22.2 General machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-412
22.3 Channel-specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-414
22.4 Axis-specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-416

xiv 6FC5397-1CP10-1BA0
EMERGENCY STOP (N2) 1
1.1 Brief Description
Important
It is the duty of the machine manufacturer to observe national and international standards
(see the notes on standards in the following paragraph). The SINUMERIK 802D supports the
machine manufacturer in the implementation of the EMERGENCY STOP function in
accordance with the specifications in this Description of Functions. The responsibility for the
EMERGENCY STOP function (its triggering, execution and acknowledgment) rests
exclusively with the machine manufacturer.
Note
Particular reference should be made to the following standards for the EMERGENCY STOP
function:
S EN 292 Part 1
S EN 292 Part 2
S EN 418
S EN 60204 Part 1:1992 Section 10.7
VDE 0113 Part 1 is only valid for a transitional period and will be superseded by EN 60204.
EMERGENCY STOP in the control system

The control system supports the machine manufacturer in implementing an EMERGENCY
STOP function on the basis of the following features:
S Activation of EMERGENCY STOP sequence in the NC via a PLC input.
S The EMERGENCY STOP procedure in the NC reduces the speed of all axes and spindles
as quickly as possible.
S The EMERGENCY STOP state is not canceled when the EMERGENCY STOP button is
released. Resetting the control device does not restart the machine.
S After the EMERGENCY STOP state has been canceled, it is not necessary to reference
axes or synchronize spindles (positions are corrected).

6FC5397-1CP10-1BA0 1-15
EMERGENCY STOP (N2)
1.2 EMERGENCY STOP sequence
EMERGENCY STOP pushbutton

The Siemens machine control panel (MCP) for 802D is equipped with a mushroomhead push-
button (with one NC and one NO contact each) referred to below as the EMERGENCY STOP
pushbutton.
1.2 EMERGENCY STOP sequence
Prerequisite
Actuation of the EMERGENCY STOP pushbutton or a signal derived directly from the button
must be transferred to the control system (PLC) as a PLC input. In the PLC user program, this
PLC input must be transferred to IS “EMERGENCY STOP” (V2600 0000.1) in the NC.
The reset of the EMERGENCY STOP button, or a signal generated directly from its reset,
must be transferred to the programmable controller (PLC) in the form of a PLC input signal. In
the PLC user program, this PLC input must be transferred to IS “Acknowledge EMERGENCY
STOP” (V2600 0000.2) in the NC.
Sequence in the NC
The predefined (in EN 418) sequence of internal functions implemented to reach the
EMERGENCY STOP state is as follows in the control system:
1. Part program execution is interrupted. All axes and spindles are braked according to
MD 36610: AX_EMERGENCY_STOP_TIME, defined braking ramp.
2. The IS “802-READY” (V3100 0000.3) is reset.
3. The IS “EMERGENCY STOP active” (V2700 0000.1) is set.
4. Alarm 3000 is set.
5. On expiry of a delay that is set for specific axes/spindles in MD 36620: SERVO_DIS-
ABLE_DELAY_TIME (shutdown delay, controller enable) – the controller enable is with-
drawn after an adjustable axis/spindle-specific time. In this case, it must be noted, that
MD 36620: SERVO_DISABLE_DELAY_TIME must be entered at least as long as in
MD 36610: AX_EMERGENCY_STOP_TIME.
Sequence on the machine

The sequence of EMERGENCY STOP functions on the machine is determined solely by the
machine manufacturer. The following should be noted with respect to the sequence in the NC:
S The sequence of operations in the NC is started with IS “EMERGENCY STOP” (V2600
0000.1). When the axes and spindles have come to a halt, the power supply must be
interrupted, in compliance with EN 418.
S The PLC I/Os (digital outputs) are not affected by the sequence in the NC. If individual out-
puts are required to attain a particular state in the event of an EMERGENCY STOP, the
machine manufacturer must include functions for this purpose in the PLC user program.

1-16 6FC5397-1CP10-1BA0
EMERGENCY STOP (N2)
1.3 EMERGENCY STOP acknowledgment
Important
The interruption of the power feed to the equipment is the responsibility of the machine
manufacturer.
If the internal functions in the NC should not be executed in the predetermined sequence in
the event of an EMERGENCY STOP, then IS EMERGENCY STOP (V2600 0000.1) may not
be set at any time up to the point that an EMERGENCY STOP defined by the machine
manufacture in the PLC user program is reached. As long as the EMERGENCY STOP
interface signal has not been set and no other alarm is active, all interface signals are
effective in the NC. Any EMERGENCY STOP state defined by the manufacturer can
therefore be assumed.
1.3 EMERGENCY STOP acknowledgment
Acknowledge EMERGENCY STOP

The EMERGENCY STOP state is reset only if IS “Acknowledge EMERGENCY STOP”
(V2600 0000.2) followed by IS “Reset” (V3000 0000.7) are set. It must be noted in this respect
that IS “Acknowledge EMERGENCY STOP” and IS “Reset” must be set (together) for a long
enough period for IS “EMERGENCY STOP active” (V2700 0000.1) to be reset (see Fig. 1-1).
IS “EMERGENCY STOP”
V2600 0000.1 1
IS “Acknowledge
EMERGENCY STOP”
V2600 0000.2
IS “EMERGENCY STOP active”

V2700 0000.1 2
IS “RESET”
V3000 0000.7 3
1 IS “Acknowledge EMERGENCY STOP” has no effect
2 IS “Reset” has no effect
3 IS “Acknowledge EMERGENCY STOP” and
“RESET” reset “EMERGENCY STOP active”
Fig. 1-1 Reset EMERGENCY STOP
Resetting the EMERGENCY STOP state has the following effects:

S the “EMERGENCY STOP active” interface signal is reset
S the servo enable is switched in.
S IS “Position control active” is set.
S the IS “802-READY” is set.
S Alarm 3000 is canceled.
S the part program is aborted.

6FC5397-1CP10-1BA0 1-17
EMERGENCY STOP (N2)
1.4 Data Descriptions (MD, SD)
PLC I/Os
The PLC user program must switch the PLC I/Os to the correct state for operation of the
machine.
Reset
The EMERGENCY STOP state cannot be reset solely by IS “Reset” (V3000 0000.7) (see
diagram above).
Power off/on
Power off/on resets the EMERGENCY STOP state unless IS “EMERGENCY STOP”
(V2600 0000.1) is still set.
Axis-specific machine data
36620 SERVO_DISABLE_DELAY_TIME
MD number Cutout delay servo enable
Default setting: 0.1 Minimum input limit: 0.02 Maximum input limit: ***
Changes effective after NEW_CONF Protection level: 2/2 Unit: s
Meaning: Maximum delay time for removal of “controller enable” after a fault.
If the axis/spindle is still moving the speed enable (controller enable) of the drive is removed by the
control at the latest after the delay time set.
The entered delay time is activated in the following events:
S For faults which cause the axes to stop immediately
S If IS “controller enable” is removed by the PLC
As soon as the actual speed has reached the zero speed range
(MD 36060: STANDSTILL_VELO_ TOL) “Servo enable” is removed for the drive.
The time set must be long enough to allow the axis/spindle to be brought to zero speed from maxi-
mum traversing velocity/speed.
If the axis/spindle is stationary, “controller enable” is removed for the drive immediately.
Application example(s) The drive speed control should be maintained long enough for the axis/spindle to come to a stand-
still from maximum traversing speed. Removal of “controller enable” for a moving axis/spindle must
be delayed until this has happened.
Special cases, errors, ... ... Caution: If the setting for the controller enable shutdown delay is too small the servo enable will
be removed even though the axis/spindle is still moving. The axis/spindle is then stopped abruptly
with setpoint 0.
The time in this MD should therefore be greater than the duration of the brake ramp in error states
(MD 36610: AX_EMERGENCY_STOP_TIME).
Related to .... IS “controller enable” (V380x 0002.1)
MD 36610: AX_EMERGENCY_STOP_TIME (Time for braking ramp when an error occurs)

1-18 6FC5397-1CP10-1BA0
EMERGENCY STOP (N2)
1.5 Signal Descriptions
General signals
V2600 0000.1 EMERGENCY STOP

Interface signal Signal(s) to NC (PLC –––> NC)
Edge evaluation: no Signal(s) updated: cyclic Signal(s) valid from SW:
Signal state 1 or signal The NC is switched to the EMERGENCY STOP state and the EMERGENCY STOP procedure
transition 0 –––> 1 is started on the NC.
Signal state 0 or signal S The NC is not in the EMERGENCY STOP state.
transition 1 –––> 0 S The EMERGENCY STOP state is (still) active but can be reset with IS “Acknowledge
EMERGENCY STOP” and IS “reset”.
Related to .... IS “Acknowledge EMERGENCY STOP” (V2600 0000.2)
IS “EMERGENCY STOP active” (V2700 0000.1)
V2600 0000.2 Acknowledge EMERGENCY STOP

Signal state 1 or signal The EMERGENCY STOP state is reset only if IS “Acknowledge EMERGENCY STOP” followed
transition 0 –––> 1 by IS “Reset” (V3000 0000.7) are set. It must be noted in this respect that IS “Acknowledge
EMERGENCY STOP” and IS “Reset” must be set (together) for a long enough period for
IS “EMERGENCY STOP active” (V2600 0000.1) to be reset.
By resetting the EMERGENCY STOP state:
S the “EMERGENCY STOP active” interface signal is reset
S the controller enable is switched in
S IS “Position control active” is set
S the IS “802-Ready” is set
S Alarm 3000 is canceled
S the part program is no longer processed
Related to .... IS “EMERGENCY STOP” (V2600 0000.1)
IS “EMERGENCY STOP active” (V2700 0000.1)
IS “Reset” (V3000 0000.7)
V2700 0000.1 EMERGENCY STOP active

Signal state 1 or signal The NC is in the EMERGENCY STOP state.
transition 0 –––> 1
Related to .... IS “EMERGENCY STOP” (V2600 0000.1)
IS “Acknowledge EMERGENCY STOP” (V2600 0000.2)

6FC5397-1CP10-1BA0 1-19
EMERGENCY STOP (N2)
1.6 Data Fields, Lists
1.6.1 Interface signals
Number .Bit Name Refe-

rence
General
V2600 0000 .1 EMERGENCY STOP
V2600 0000 .2 Acknowledge EMERGENCY STOP
V2700 0000 .1 EMERGENCY STOP active
Operating mode signal area
V3000 0000 .7 Reset K1
1.6.2 Machine data
Number Identifiers Name Refe-

rence
Axis-specific
36610 AX_EMERGENCY_STOP_TIME Length of the braking ramp for error states A3
36620 SERVO_DISABLE_DELAY_TIME Cutout delay servo enable

1-20 6FC5397-1CP10-1BA0
Axis Monitoring (A3) 2
2.1 Overview of monitoring functions
S Motion monitoring functions
– Contour monitoring
– Positioning monitoring
– Zero-speed monitoring
– Clamping monitoring
– Speed setpoint monitoring
– Actual velocity monitoring
– Encoder monitoring functions
S Monitoring static limits
– Limit switch monitoring
– Working area limiting

6FC5397-1CP10-1BA0 2-21
2.2 Motion monitoring functions
2.2.1 Contour monitoring
Functions
The principle on which the contour monitoring function works is constant comparison of the
following error measured and that calculated in advance from the NC position setpoint. For
the precalculation of the following error, a model is used that simulates the dynamics of the
position control including feedforward control.
So that the monitoring function does not respond incorrectly on slight speed fluctuations
(caused by changes of load) a tolerance band is allowed for the max. contour deviation.
If the speed entered in MD 36400: CONTOUR_TOL (tolerance band contour monitoring) is
exceeded, an alarm is signaled and the axes are stopped.
Activation
Contour monitoring is active for axes and position-controlled spindles.
Activation
If the contour deviation is too large, this has the following effect:
S Alarm 25050 “Contour monitoring” is triggered
S The axis/spindle in question is brought to a standstill with rapid stop (open position control
loop) via a set speed ramp. The braking
ramp time is set in
MD 36610: AX_EMERGENCY_STOP_TIME (duration of the braking ramp on error
states).
S If the axis/spindle is involved in interpolation with other axes/spindles, these are brought
to a standstill with rapid stop with following error reduction (position setpoint = constant).
Remedy
S Increase tolerance band of monitoring in MD 36400
S The actual “servo gain factor” must correspond to the desired servo gain factor set in
MD 32200: POSCTRL_GAIN (servo gain factor)
On analog spindles:
MD 32260: RATED_VELO (rated motor speed) and
MD 32250: RATED_OUTVAL (rated output voltage) must be checked.
S Check optimization of the speed controller
S Check smooth running of the axes
S Check machine data for traversing movements
(feed override, acceleration, max. speeds, ...)

2-22 6FC5397-1CP10-1BA0
2.2.2 Positioning monitoring
Functions
In order to ensure that an axis reaches the required position within a specified time period,
the timer that can be configured in MD 36020: POSITIONING_TIME (time delay exact stop
fine) is started at the end of each motion block (setpoint has reached destination) and, when
the timer runs out, a check made to ascertain whether the axis has reached its setpoint within
the tolerance of MD 36010: STOP_ LIMIT_FINE (exact stop fine).
For details on “Exact stop coarse and fine” see:
References: Chapter “Continuous Path Mode, Exact Stop and Look-Ahead”
V or s 8 Effective tolerance for zero speed

or clamping monitoring
Actual value Interface signal

“Clamping in
progress”
(V380x 0002.3)
MD: CLAMP_POS_TOL
Setpoint
MD:
STANDSTILL_POS_TOL
MD: STOP_LIMIT_COARSE
MD: STOP_LIMIT_FINE
t
MD: “Exact stop fine” – interface signal
STANDSTILL_ “Exact stop course” – interface signal
DELAY_TIME
MD: POSITIONING_TIME
Fig. 2-1 Correlation between positioning, zero-speed and clamping monitoring
Activation
Positioning monitoring is always activated after termination of motion blocks “according to the
setpoint” (setpoint has reached destination).
Position monitoring is active for axes and position-controlled spindles.
Deactivation
When the programmed “Exact stop limit fine” has been reached or a new setpoint output
(e.g. for positioning according to “Exact stop coarse” followed by block change), the positio-
ning monitor is switched off.

6FC5397-1CP10-1BA0 2-23
Effect
If the limit value for “exact stop fine” is not yet reached when the positioning monitoring time
has elapsed, the following action is performed:
S Output of alarm 25080 “Positioning monitoring”
loop) via a set speed ramp.
The braking ramp time is set in MD 36610: AX_EMERGENCY_STOP_TIME (duration of
the braking ramp on error states).
S If the axis/spindle is involved in interpolation with other axes/spindles, these are stopped
by rapid stop with following error reduction (default for position partial setpoint = 0).
Cause of error/ remedy

S Position controller gain too low –– > alter machine data for position control gain
MD 32200: POSCTRL_GAIN (KV factor)
S Positioning window (Exact stop fine), positioning monitoring time and position control gain
have not been coordinated –– > alter machine data:
MD 36010: STOP_LIMIT_FINE (exact stop fine),
MD 36020: POSITIONING_TIME (exact stop fine delay time),
MD 32200: POSCTRL_GAIN (KV factor)
Rule of thumb
S Positioning window large ––> max. positioning monitoring time can be set to a relatively
short value
S Positioning window small ––> max. positioning monitoring time must be set relatively long
S Position controller gain low ––> max. positioning monitoring time must be selected to be
relatively long
S Position control gain high ––> max. positioning monitoring time can be set to a relatively
short value
Note
The size of the positioning window affects the block change time. The smaller the tolerances
that are selected, the longer the positioning task will take, which in turn means a longer time
before the next command can be executed.

2-24 6FC5397-1CP10-1BA0
2.2.3 Zero-speed monitoring
Functions
At the end of a motion block (position setpoint has reached the target), monitoring checks
whether the axis is not more than the distance specified in
MD 36040: STANDSTILL_DELAY_TIME (zero-speed monitoring delay time) away from its
setpoint after the configurable delay time in MD 36060: STANDSTILL_POS_TOL (zero speed
tolerance) has expired. Otherwise, an alarm will be triggered.
See Fig. 2-1
Activation
Zero-speed monitoring is always active after “Zero-speed monitoring delay time” active has
expired, as long as no new travel command is present.
Zero-speed monitoring is active on axes and position-controlled spindles.
Effect
When the monitoring function responds it has the effects:
S Alarm 25040 “Zero-speed monitoring” is triggered
S The affected axis/spindle is brought to a standstill with rapid stop (with open position con-
trol loop) along a speed setpoint ramp. The braking ramp time is set in
MD 36610: AX_EMERGENCY_STOP_TIME (duration of the braking ramp on error
states).
Cause of error/ remedy

S Position control gain too high (control loop oscillation) ––> alter machine data for control-
ler gain MD 32200: POSCTRL_GAIN (servo gain factor)
S Zero-speed window too small ––> alter machine data
MD 36030: STANDSTILL_POS_TOL (zero-speed tolerance)
S Axis is mechanically “pushed” out of position ––> eliminate cause
2.2.4 Clamping monitoring
Functions
If the axis must be clamped once it has been positioned, the clamping monitoring function
can be activated via IS “Clamping in progress” (V380x 0002.3).

6FC5397-1CP10-1BA0 2-25
This may be necessary if the axis can be pressed further from the setpoint than the zero-
speed tolerance permits during the clamping process. The amount by which the axis may
travel from the setpoint position is set in MD 36050: CLAMP_POS_TOL (clamping tolerance
for “Clamping active” interface signal).
See Fig. 2-1
Activation
Clamping monitoring is activated by the interface signal “Clamping active”. It replaces zero-
speed monitoring during clamping.
Clamping monitoring is active on axes and position-controlled spindles.
Effect
If the axis is pushed out of position beyond the clamping tolerance during clamping the
following occurs:
S Alarm 26000 “Clamping monitoring” is triggered
MD 36610: AX_EMERGENCY_STOP_TIME (duration of the braking ramp when fault
states exist).
S If the axis/spindle is assigned to an interpolatory grouping with other axes/spindles, then
these are also braked by rapid stop with following error reduction (default for partial posi-
tion setpoint = 0).
2.2.5 Speed setpoint monitoring
Functions
Speed setpoint monitoring checks whether the setpoint specification does not exceed the
maximum permissible drive speed in MD 36210: CTRLOUT_LIMIT (maximum speed set-
point). The speed may be limited to this value and the axis/ spindle brought to a halt and an
alarm output.
The maximum speed on the axes (in percent) exceeds the speed at which the velocity in
MD 3200: MAX_AX_VELO is reached (100%). This also determines the control margin.
On an analog spindle the maximum speed that can be output must not exceed the speed
reached at the maximum setpoint output voltage of 10V (100%).
The speed setpoint consists of the speed setpoint of the position controller and the feedfor-
ward control parameter (if feedforward control is active).

2-26 6FC5397-1CP10-1BA0
Feedforward control value
+ To
KV
Following speed
error controller
Speed setpoint
monitoring
Position controller
Fig. 2-2 Speed setpoint calculation
Activation
The speed setpoint monitoring is always active for axes and spindles.
Effect
The following occurs if the maximum speed setpoint value is exceeded:
S Alarm 25060 “Speed setpoint limiting” is triggered
loop) via a set speed ramp.
The braking ramp time is set in MD 36610: AX_EMERGENCY_STOP_TIME (duration of
the braking ramp when fault states exist).
Note: in “Expert mode” access level (protection level 1),
MD 36220: CTRLOUT_LIMIT_TIME can be used to set a delay time, after the expiration of
which an alarm is output and the axes are brought to a halt. The default value of this time is
zero.
The use of a speed setpoint limiting will turn the control loop into a non-linear control loop.
This generally causes contour deviations if an axis remains in the set speed limiting. A
control margin must therefore be set (see Section 3.3.4 “Speed setpoint output”).
Error causes
S A control loop or drive error is present.
S Setpoints are too high (accelerations, velocities, reducing factors)
S Obstacle in work area (e.g. positioning on a working table)
S Tachogenerator compensation has not been performed correctly for analog spindles, or a
measuring circuit error or drive fault has occurred.

6FC5397-1CP10-1BA0 2-27
2.2.6 Actual velocity monitoring
Functions
This function monitors the actual velocity for exceeding a permissible limit value programmed
in MD 36200: AX_VELO_LIMIT (threshold value for velocity monitoring).
Activation
The actual velocity monitor is operative whenever the active measuring circuit activated via
“Position measuring system 1” interface signal (V380x 0001.5) is supplying actual values, i.e.
still operating below the limit frequency.
The actual velocity monitoring is active for axes and spindles.
Effect
If the “Threshold for velocity monitoring” is exceeded the following occurs:
S Alarm 25030 “Actual velocity alarm limit” is triggered
S The axis/spindle is brought to a standstill via a speed setpoint ramp with rapid stop (with
open position control loop).
The braking ramp time is set in MD 36610: AX_EMERGENCY_STOP_TIME (braking
ramp time for error states).
S If the axis/spindle is assigned to an interpolatory grouping with other axes/spindles, then
these are also braked by rapid stop with following error reduction (default for partial posi-
tion setpoint = 0).
Troubleshooting tips
S Check actual values
S Check position control direction (control sense)
S MD 36200: AX_VELO_LIMIT (threshold value for velocity monitoring)
S Check speed setpoint cable for analog spindles

2-28 6FC5397-1CP10-1BA0
2.3 Encoder monitoring functions
2.3.1 Encoder limit frequency monitoring
Functions
If the permissible limit frequency of a measuring system entered in MD 36300:
ENC_FREQ_LIMIT (encoder limit frequency) is exceeded, the positional synchronization
(reference point) between the machine and control system will be lost. Correct position con-
trol is no longer possible. This state is signaled to the PLC.
Activation
The encoder limit frequency monitoring is always active when the encoder is switched on
and is active on axes and spindles.
Effect
When the limit frequency of an encoder is exceeded the following occurs:
S The “Encoder limit frequency exceeded 1” interface signal (V390x 0000.2) is set.
S The spindle continues running with speed control.
If the spindle speed is reduced such that the encoder frequency falls below the value of
MD 36302: ENC_FREQ_LIMIT_LOW (% value of MD 36300: ENC_FREQ_LIMIT), the
spindle automatically synchronizes itself with the reference system of the encoder.
S If the limit frequency is exceeded while the measuring system of a position controlled axis/
spindle is active, alarm 21610 “Frequency is exceeded” is signaled.
MD 36610: AX_EMERGENCY_STOP_TIME (duration of the braking ramp when fault
states exist).
S If the axis is assigned to an interpolatory grouping with other axes, then these are also
braked by rapid stop with following error reduction (default for partial position setpoint
= 0).
Error Correction
S After the axes have stopped, the position control is automatically resumed.
Note
The axis affected must be re-referenced.

6FC5397-1CP10-1BA0 2-29
2.3.2 Zero-mark monitoring
Functions
The zero-mark monitoring checks whether pulses were lost between two zero mark passes of
the position actual value encoder. Enter the number of identified zero-mark errors at which
the monitoring function should respond MD 36310: ENC_ZERO_MONITORING (zero-mark
monitoring).
Activation
The monitoring function is activated in MD 36310: ENC_ZERO_MONITORING.
The zero-mark error count starts with “0” each time the encoder is switched on.
Effect
If the number of zero-mark errors entered in MD 36310: ENC_ZERO_MONITIORING is
reached for a measuring system, alarm 25020 “Zero-mark monitoring” is triggered.
The affected axis/spindle is brought to a standstill with rapid stop (with open position control
loop) along a speed setpoint ramp. The braking ramp time is set in
MD 36610: AX_EMERGENCY_STOP_TIME.
If the axis is assigned to an interpolatory grouping with other axes, then these are also
braked by rapid stop with following error reduction (default for partial position setpoint = 0).
Error causes
S MD 36300: ENC_FREQ_LIMIT (encoder limit frequency) set too high.
S Encoder cable damaged.
S Encoder or encoder electronics defective.
Note
When a fault occurs in the measuring circuit, interface signal “Referenced/synchronized 1”
(V390x 0000.4) is canceled, i.e. the axis must be re-referenced.

2-30 6FC5397-1CP10-1BA0
2.4 Monitoring of static limits
2.4.1 Limit switch monitoring
2nd software limit switch Hardware limit Mechanical

(can be activated via PLC) switch traversing limit
1st software limit switch EMERGENCY STOP
Fig. 2-3 Overview of travel limits of linear axes
Hardware limit switches
Functions
Every axis has a hardware limit switch for each traversing direction, which can be used to
prevent the slide from moving out of the slide bed.
When the hardware limit switch is passed, the PLC sends a signal to the NC in the “Hardware
limit switch plus/minus” interface signal (V380x 1000.1 or .0) and the movement of all axes is
stopped.
The braking method can be selected in MD 36600: BRAKE_MODE_CHOICE (deceleration
behavior on hardware limit switch).
Activation
HW limit switch monitoring is active after the control has started up in all modes.
Effect
S When a hardware limit switch is passed in either direction, alarm 21614 “Hardware limit
switch + or –” is triggered.
S The axis is brought to a standstill according to the setting in MD 36600:
BRAKE_MODE_CHOICE (deceleration behavior on hardware limit switch).
S If the axis is assigned to an interpolatory grouping with other axes, then these are also
braked according to the method selected in MD 36600: BRAKE_MODE_CHOICE (decele-
ration behavior on hardware limit switch).
S The direction keys in the approach direction are disabled.

6FC5397-1CP10-1BA0 2-31
Remedy
S Reset
S Move in the opposite direction (in JOG mode)
S Correct the program.
Software limit switch
Functions
These are used to limit the maximum traversing range on each individual axis.
There are 2 pairs of software limit switch for each machine axis. They are defined in the
machine axis system using the following machine data:
MD 36100: POS_LIMIT_MINUS (1st software limit switch minus)
MD 36110: POS_LIMIT_PLUS (1st software limit switch plus)
MD 36120: POS_LIMIT_MINUS2 (2nd software limit switch minus)
MD 36130: POS_LIMIT_PLUS (2nd software limit switch plus)
Activation
S Software limit switch monitoring is activated after reference point approach in all modes.
S The position of the software limit switch can be approached.
S The 2nd software limit switch can be activated via the “2nd software limit switch plus/mi-
nus” interface signal (V380x 1000.3 or .2) from the PLC. The change becomes active im-
mediately. The 1st software limit switch plus/minus is then de-activated.
S The SW limit switch monitor does not operate for endlessly turning rotary axes, i.e. if
MD 30310: ROT_IS_MODULO = 1. (modulo conversion for rotary axis and spindle)
Effects/Reactions
Depending on the mode, different responses to an attempted software limit switch violation
are possible:
AUTO, MDA:
– The block that would violate the software limits switches is not started. The previous
block is terminated properly.
– Program execution is terminated.
– Alarm 10720 “Software limit switch + or –” is signaled.
JOG:
– The axis stops at the software limit switch position.
– Alarm 10621 “Axis at software limit switch + or –” is signaled.
– The direction keys in the approach direction are disabled.

2-32 6FC5397-1CP10-1BA0
Special situations:
– Switching over the software limit switch:
If the current position lies behind the new software limit switch when the software limit
switch is changed over, the axis is decelerated with the maximum permissible axial
acceleration. If an axis is involved in interpolation with other axes, these are also dece-
lerated. A contour violation may occur.
Remedy
S Reset
S Correct the program.
2.4.2 Working area limits
Functions
Working area limits describe the area in which machining is possible. They enable the user to
limit the traversing range of the axes in addition to the limit switches.
References: “Operator control and programming”.
A check is made to see whether the tool tip P is within the protected working area. The value
entered for the working area limit is the last permissible position of the axis.
Via the MD 21020: WORKAREA_WITH_TOOL_RADIUS (allowance for tool radius with
working area limits) can be set to determine whether the monitor is to take account of the tool
radius.
One pair of values (minus/plus) is possible for each axis to describe the protected working
area.
Define working area limits

The working area limits can be defined or changed in two ways:
S Via the operator panel in the “Parameters” operator area using the following setting data:
SD 43430: WORKAREA_LIMIT_MINUS (working area limit minus)
SD 43420: WORKAREA_LIMIT_PLUS (working area limit plus)
Changes in Automatic mode are only possible in the Reset state and then apply
immediately.
Changes are always possible in JOG mode but they do not apply until a new movement is
commenced.
S In a program with G25/G26. Changes are effective immediately.
A programmed motion has priority, it overwrites the value entered in the setting data and
is retained after RESET and End of Program.

6FC5397-1CP10-1BA0 2-33
Xmachine
G26
Xmax
Tool tip
Working area
W Zmachine
G25
Xmin
G25 G26
Zmin Zmax
Fig. 2-4 Working area limitation using the example of the turning machine
Activation
S The working area limitation can be activated via
MD 43410: WORKAREA_MINUS_ENABLE, SD 43400: WORKAREA_PLUS_ENABLE
(working area limitation in the negative or positive direction active). Scanning begins after
reference point approach.
S During program execution, the working area limitation can be activated with the modal
G code “WALIMON” and deactivated with “WALIMOF”.
S The working area limitation is not active with endlessly turning axes, i.e. when MD 30310:
ROT_IS_MODULO = 1 (modulo conversion for rotary axis and spindle).
Effect/Reaction
Depending on the mode, the response to an attempted violation of the working area limitation
can be different:
AUTO, MDA:
– The block that violates the working area limitation is not started. The previous block is
terminated properly.
– Program execution is terminated.
– Alarm 10730 “Work area limitation + or –” is set.
JOG:
– The axis is positioned at the working area limitation and then stopped.
– Alarm 10631 10631 “Axis at software limit switch + or –” is signaled.
– The direction keys in the approach direction are disabled.

2-34 6FC5397-1CP10-1BA0
2.5 Supplementary conditions
Remedy
S Reset
S Check the working area limit in the part program (G25/G26) or in the setting data.
2.5 Supplementary conditions

To ensure that the monitoring functions respond correctly, it is important that the correct
values are entered in the following machine data:
S MD 31030: LEADSCREW_PITCH (leadscrew pitch)
S Gear ratio (load gearbox)
MD 31050: DRIVE_AX_RATIO_DENOM(load gearbox denominator)
MD 31060: DRIVE_AX_RATIO_NUMERA (load gearbox numerator)
Gear ratio (encoder), possibly at spindle:
MD 31070: DRIVE_ENC_RATIO_DENOM (measuring gearbox denominator)
MD 31080: DRIVE_ENC_RATIO_NUMERA (measuring gearbox numerator)
S MD 32810: EQUIV_SPEEDCTRL_TIME
(equivalent time constant speed control loop for feedforward control)
S Relationship between output voltage/output speed
(applies only to analog spindles)
MD 32260: RATED_VELO (rated motor speed)
MD 32250: RATED_OUTVAL (rated output voltage)
S Encoder resolution
The associated machine data is described in:
References: Chapter “Velocities, Setpoint/Actual Value Systems, Closed-Loop Control”

6FC5397-1CP10-1BA0 2-35
2.6.1 Channel-specific machine data
21020 WORKAREA_WITH_TOOL_RADIUS
MD number Allowance for tool radius with working area limiting
Default setting: 0 Minimum input limit: 0 Maximum input limit: 1
Changes effective after RESET Protection level: 2/2 Unit: –
Data type: BOOLEAN Applies from SW:
Meaning: 0: The tool radius is not taken into account.
1: The tool radius is taken into account with respect to the working area limit.
2.6.2 Axis-specific/spindle-specific machine data
36000 STOP_LIMIT_COARSE
MD number Exact stop coarse
Changes effective after NEW_CONF Protection level: 2/2 Unit: mm, degrees
Meaning: An NC block has been completed when the distance in between the actual position of the path
axes and the setpoint (reference) position is the exect stop limit that has been entered. If the
actual position of a path axis is not within these limits, the NC block is not considered complete
and continued part program processing is not possible. Transition to the next block can be in-
fluenced by the value entered. The larger the value, the earlier block change can be initiated. If
the defined exact stop limit is not reached,
– the block is not considered completed,
– it is not possible to continue traversing the axis,
– alarm 25080 positioning monitoring is triggered after the time in MD 36020: POSITIO-
NING_TIME (monitoring time exact stop fine) has elapsed,
– the direction of movement +/– is displayed for the axis in the positioning display. The exact
stop window is also evaluated for spindles in position control mode.
Special cases, errors, ... ... This MD may not be smaller than the setting in MD 36010: STOP_LIMIT_FINE (exact stop fine).
In order to achieve the same block change behavior as for exact stop, the exact stop coarse
window can be the same as that for exact stop fine.
This MD may not be equal to or larger than the setting in MD 36030: STANDSTILL_POS_TOL
(zero-speed tolerance).
Related to .... MD 36020: POSITIONING_TIME (exact stop fine delay time)
36010 STOP_LIMIT_FINE
MD number Exact stop fine
Meaning: See MD 3600: STOP_LIMIT_COARSE (exact stop coarse)
Special cases, errors, ... ... This MD must not be greater than the setting in MD 36000: STOP_LIMIT_COARSE (exact stop
coarse).
This MD must not be equal to or greater than the setting in MD 36030: STANDSTILL_POS_TOL
(zero-speed tolerance).
Related to .... MD 36020: POSITIONING_TIME (exact stop fine delay time)

2-36 6FC5397-1CP10-1BA0
36020 POSITIONING_TIME
MD number Time delay exact stop fine
Meaning: This MD defines the time after which the following error must have reached the limit value for
exact stop fine when approaching a position (position setpoint has reached the target). If this is
not the case, alarm 25080 “Positioning monitoring” is set and the relevant axis is stopped.
The MD setting should be large enough that the monitoring function does not respond during
normal operation, as the complete traversing operation (acceleration, constant travel, decelera-
tion) is monitored by other functions.
Related to .... MD 36010: STOP_LIMIT_FINE (exact stop fine)
36030 STANDSTILL_POS_TOL
MD number Zero-speed tolerance
Meaning: At the end of a motion block (position setpoint has reached the target), monitoring checks whe-
ther the axis is not more than the distance specified in MD 36040:
STANDSTILL_DELAY_TIME (zero-speed monitoring delay time) from its setpoint after the confi-
gurable delay time in MD 36060: STANDSTILL_POS_TOL (zero-speed tolerance) has expired.
If the setpoint position zero-speed tolerance has been violated in any direction, alarm 25040
“Zero-speed monitoring” is triggered and the axis is brought to a standstill.
Special cases, errors, ... ... The zero-speed tolerance must be greater than the “Exact stop limit coarse”.
Related to .... MD 36040: STANDSTILL_DELAY_TIME (zero-speed monitoring delay time)
36040 STANDSTILL_DELAY_TIME
MD number Zero-speed monitoring delay time
Meaning: See MD 36030: STANDSTILL_POS_TOL (zero-speed tolerance)
Related to .... MD 36030: STANDSTILL_POS_TOL (zero-speed tolerance)
36050 CLAMP_POS_TOL
MD number Clamping tolerance with interface signal “Clamping active”
Meaning: The clamping monitor is activated by “Clamping active” interface signal (V380x 0002.3). If the
monitored axis has been pushed out of the setpoint position (exact stop limit) by more than the
clamping tolerance, alarm 26000 “Clamping monitoring” is triggered and the axis is stopped.
Special cases, errors, ... ... The clamping tolerance must be larger than the “Exact stop limit coarse”.
Related to .... IS “Clamping in progress”

6FC5397-1CP10-1BA0 2-37
36060 STANDSTILL_VELO_TOL
MD number Maximum velocity/speed “Axis/spindle stationary”
Default setting: 5.0 mm/min, Minimum input limit: 0.0 Maximum input limit: ***
0.0138 rpm
Changes effective after NEW_CONF Protection level: 2/2 Unit:
Linear axis: mm/min
Rotary axis: rpm
Meaning: The zero-speed range for the axis velocity and spindle speed is set in this machine data.
If the actual velocity of the axis or the actual speed of the spindle is smaller than the value ent-
ered, and if no more setpoints are being output to the axis/ spindle, interface signal “Axis/spindle
stationary” (V390x 0001.4) is set.
Vact
MD:STANDSTILL_VELO_TOL
Vzero
t
1
IS
”Axis/ Spindle stationary”
0
Application example(s) The pulse enable should not be removed until the axis/spindle is stationary to ensure that the
axis/spindle is stopped in a controlled manner. Otherwise the axis will coast to rest.
Related to .... “Axis/ spindle stationary” interface signal (V390x 0001.4)
36100 POS_LIMIT_MINUS
MD number 1st Software limit, switch minus
Default setting: – 100 000 000 Minimum input limit: *** Maximum input limit: ***
Changes effective after NEW_CONF Protection level: 2/2 Unit: mm; degrees
Meaning: Same meaning as 1st software limit switch but applies to the traversing limit in the negative
direction.
The MD is effective after reference point approach if PLC interface signal
“2nd software limit switch minus” is not set.
MD irrelevant for ... ... If axis is not referenced.
Related to .... “2nd software limit switch minus” interface signal
36110 POS_LIMIT_PLUS
MD number 1st Software limit, switch plus
Default setting: 100 000 000 Minimum input limit: *** Maximum input limit: ***
Meaning: A software limit switch can be activated in addition to a hardware limit switch. The absolute posi-
tion, in the machine coordinate system, of the positive range limit is entered for each axis.
The MD is effective after reference point approach if interface signal “2nd software limit switch
plus” is not enabled.
Related to .... “2nd software limit switch plus” interface signal

2-38 6FC5397-1CP10-1BA0
36120 POS_LIMIT_MINUS2
MD number 2nd software limit, switch minus
Meaning: Same meaning as 2nd software limit switch plus, but applies to the traversing limit in the nega-
tive direction.
An interface signal can be used to select from the PLC which of the software limit switches 1 or 2
is to apply.
e.g. V380x 1000 Bit 2 = 0 “1st software limit switch minus” active for 1st axis
Bit 2 = 1 “2nd software limit switch minus” active for 1st axis.
Related to .... “2nd software limit switch minus” interface signal
36130 POS_LIMIT_PLUS2
MD number 2nd software limit, switch plus
Meaning: This machine data can be used to specify a 2nd software limit switch position in the positive
direction in the machine axis system.
An interface signal can be used to select from the PLC which of the software
limit switches 1 or 2 is to apply.
e.g.: V380x 1000 Bit 3 = 0 “1st software limit switch plus” active for 1st axis
Bit 3 = 1 “2nd software limit switch plus” active for 1st axis.
Related to .... “2nd software limit switch plus” interface signal
36200 AX_VELO_LIMIT[0]...[5]
MD number Threshold value for velocity monitoring
Default setting: 11,500 mm/min, Minimum input limit: 0.0 Maximum input limit: ***
31,944 rpm
Changes effective after NEW_CONF Protection level: 2/2 Unit: mm/min,
rpm
Meaning: The threshold value for the actual velocity monitoring function is entered in this MD.
If the axis has at least one active encoder and this is operating below its limit frequency,
alarm 25030 “Actual velocity alarm limit” is activated and the axes brought to a standstill when
the threshold value is exceeded.
Settings
S For axes, a value that lies 10–15% above
MD 32000: MAX_AX_VELO (maximum axis velocity) should be chosen.
S For spindles, a value should be selected for each gear stage which is 10–15% higher than
MD 35110: GEAR_STEP_MAX_VELO_LIMIT[n] (maximum speed of gear stage).
Machine data index has the following code:
[control parameter set number]: 0–5
Please refer to the following for the effect of control parameters sets:
References: Chapter “Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control”

6FC5397-1CP10-1BA0 2-39
36300 ENC_FREQ_LIMIT[0]
MD number Encoder limit frequency
Default setting: 300000 Minimum input limit: 0.0 Maximum input limit: ***
Changes effective after POWER ON Protection level: 2/2 Unit: Hz
Meaning: The encoder frequency is entered into this MD.
The active encoder is defined via the “Position measuring system 1” interface signal
(V380x 0001.5).
Related to .... MD 36302: ENC_FREQ_LIMIT_LOW
36310 ENC_ZERO_MONITORING[0]
MD number Zero-mark monitoring
Default setting: 0 Minimum input limit: 0 Maximum input limit: ***
Changes effective after NEW_CONF Protection level: 2/2 Unit: –
Data type: DWORD Applies from SW:
Meaning: This machine data activates the zero-mark monitoring and determines the number of inadmissi-
ble zero marks.
0: Zero-mark monitoring OFF, encoder hardware monitoring ON
1–99, > 100: Number of identified zero-mark errors at which the monitoring
should be activated
100: Zero-mark monitoring OFF, encoder hardware monitoring OFF
Examples: MD value = 1: monitoring is activated at the 1st error.
MD value = 2: the 1st error is tolerated. Monitoring is activated at the 2nd error.
MD value = 3: the 1st and 2nd errors are tolerated. Monitoring is activated at the 3rd error.
The error count always begins at zero when the encoder is switched on.
Special cases, errors, ... ... The zero-mark monitoring on absolute value encoders must be switched off with value = 0!
36400 CONTOUR_TOL
MD number Contour monitoring tolerance band
Meaning: Tolerance band for max. contour deviation.
The maximum difference between the real and expected actual value is entered in this MD.
The input of a tolerance band is designed to prevent the contour monitoring function from re-
sponding erroneously due to slight fluctuations in speed resulting from normal control procedures
(e.g. during first cut).
This MD must be adapted to the position controller gain and, in the case of feedforward control,
to the accuracy of the loop model MD 32810: EQUIV_SPEEDCTRL_TIME (equivalent time con-
stant for speed loop feedforward control) and to the permissible acceleration rates and velocities.
References See Section 2.2.1
36600 BRAKE_MODE_CHOICE
MD number Deceleration behavior on hardware limit switch
Changes effective after POWER ON Protection level: 2/2 Unit: –
Data type: BYTE Applies from SW:
Meaning: If a rising signal edge is detected at the axis-specific hardware limit switch, the axis is decelera-
ted immediately.
The type of deceleration is specified via machine data:
0: controlled deceleration according to the acceleration ramp defined by

MD 32300: MAX_AX_ACCEL (axis acceleration).
1: fast deceleration (setpoint default = 0) with reduction of following error.
Related to .... “Hardware limit switch plus or minus” interface signal (V380x 1000.1 or V380x 1000.0)

2-40 6FC5397-1CP10-1BA0
36610 AX_EMERGENCY_STOP_TIME
MD number Length of the braking ramp for error states
Default setting: 0.05 Minimum input limit: 0.02 Maximum input limit: 1000

Meaning: For axis: when the following monitoring functions respond, the affected axis is brought to a
standstill with rapid stop (with open position control loop) along a braking ramp of the speed
setpoint:
S EMERGENCY STOP
S Following error monitoring
S Positioning monitoring
S Zero-speed monitoring
S Clamping monitoring
S Speed setpoint monitoring
S Actual velocity monitoring
S Encoder limit frequency monitoring (except on speed-controlled spindles)
S Zero-mark monitoring
S Contour tunnel monitoring
If the encoder limit frequency is exceeded, the speed setpoint is displayed as the actual value in
the basic NC display.
The time for the reduction of the speed setpoint from the maximum speed setpoint to setpoint
= 0 should be entered in MD 36610. The time taken to stop the axis depends on the actual
speed setpoint at the time the monitoring responds.
Speed setpoint
MD 36210:
CTRLOUT_LIMIT
e.g. current
speed setpoint
Current time until t [s]

axis stops
MD 36610:
AX_EMERGENCY_STOP_TIME
Fig. 4-1 Braking ramp for error states
For spindle: In the case of spindles without an active position control, the speed-controlled
spindle may continue to rotate with no rapid stop braking response when the encoder frequency
monitoring function responds (i.e. no valid actual value information available). The speed
setpoint monitor is active, but not the actual velocity monitor (MD 36200) when the encoder is
active. The spindle speed setpoint limit is just limeted (no alarm); the setpoint is limited to the
max. chuck speed (MD 35100) and displayed in IS “Programmed speed too high”.
The current speed is not displayed as no valid actual value is available at this point in time.
Meaning: Where interpolating axes are involved, maintenance of the contour during the deceleration phase
cannot be guaranteed.
Notice: If the value for the duration of the braking ramp for error states has been set too
high, controller enable is canceled even though the axis/spindle is still traversing. It
is then stopped abruptly with speed setpoint 0. The time set in
MD 36610: AX_EMERGENCY_STOP_TIME should therefore be less than the time
set in MD 36620: SERVO_DISABLE_DELAY_TIME (shutdown delay contoller
enable).
Related to .... MD 36620: SERVO_DISABLE_DELAY_TIME Shutdown delay servo enable
MD 36210: CTRLOUT_LIMIT Maximum speed setpoint

6FC5397-1CP10-1BA0 2-41
2.6.3 Axis/spindle-specific setting data
43400 WORKAREA_PLUS_ENABLE
SD number Working area limiting active in positive direction
Changes effective after: immediately Protection level: 7/7 Unit: –
Meaning: 0: The working area limit of the axis is de-activated in the positive direction.
1: The working area limit of the axis is active in the positive direction.
The setting data is parameterized using the operator panel in the “Parameter” area by activating/
de-activating the working area limitation.
SD irrelevant for ... ... G code: WALIMOF
43410 WORKAREA_MINUS_ENABLE
SD number Working area limiting active in negative direction
Changes effective after: immediately Protection level: 7/7 Unit: –
Meaning: 0: The working area limit of the axis is de-activated in the negative direction.
1: The working area limit of the axis is active in the negative direction.
The setting data is parameterized using the operator panel in the “Parameter” area by activating/
de-activating the working area limitation.
43420 WORKAREA_LIMIT_PLUS
SD number Working area, limiting plus
Changes effective after: immediately Protection level: 7/7 Unit: mm, degrees
Meaning: The working area limits can be used to restrict the working area in the MCS in the positive direc-
tion of the corresponding axis.
The setting data can be changed via the operator panel in the “Parameter” operating area.
The positive working area limit can be changed in the program with G26.
Related to .... SD 43400: WORKAREA_PLUS_ENABLE
43430 WORKAREA_LIMIT_MINUS
SD number Working area, limiting minus
Changes effective after: immediately Protection level: 7/7 Unit: mm, degrees
Meaning: The working area limitation can be used to restrict the working area in the MCS in the negative
direction of the corresponding axis.
The setting data can be changed via the operator panel in the “Parameter” operating area.
The negative working area limit can be changed in the program with G25.
Related to .... SD 43410: WORKAREA_MINUS_ENABLE

2-42 6FC5397-1CP10-1BA0
2.7 Signal Description
2.7.1 Axis/spindle-specific signals
.
Signals to axis (V380x ....) . Signals from axis (V390x ....)
.
x=0 –> axis 1, Axis 3 x=0 –> axis 1,
x=1 –>axis 2, ... Axis 2 x=1 –>axis 2, ...
Axis 1
Clamping in progress (V380x 0002.3)
Hardware limit switch plus (V380x 1000.1) Axis

monitoring
Hardware limit switch minus (V380x 1000.0) functions Encoder frequency exceeded 1
(V390x 0000.2)
2nd software limit switch plus (V380x 1000.3)
2nd software limit switch minus (V380x 1000.2)
Fig. 2-5 PLC interface signals for axis monitoring functions
Signals to axis/spindle
V380x 0002.3 Clamping in progress

Data block Signal(s) to axis/spindle (PLC –––> NCK)
Signal state 1 or signal Clamping in progress
transition 0 –––> 1 The clamping monitoring function is activated.
Signal state 0 or signal Clamping terminated.
transition 1 –––> 0 The zero-speed monitoring function takes over from the clamping monitoring function.
Related to .... MD 36050: CLAMP_POS_TOL (clamping tolerance)
References Section 2.2.4
V380x 0003.6 Velocity/spindle speed limitation

Data block Signal(s)
Signal state 1 or signal The NCK limits the velocity/spindle speed to the limit value set in
transition 0 –––> 1 MD 35160: SPIND_EXTERN_VELO_LIMIT.
Signal state 0 or signal No limiting active.
Related to .... MD 35100: SPIND_VELO_LIMIT (max. spindle speed)
SD 43220: SPIND_MAX_VELO_G26 (prog. spindle speed limiting G26)
SD 43230: SPIND_MAX_VELO_LIMIT (prog. spindle speed limiting G96)

6FC5397-1CP10-1BA0 2-43
V380x 1000.1 and .0 Hardware limit switches plus and minus

Signal state 1 or signal A switch can be mounted at each end of the travel range of a machine axis which will cause a
transition 0 –––> 1 signal “Hardware limit switch plus or minus” to be signaled to the NC via the PLC if it is
approached.
If the signal is recognized as set, alarm 021614 “Hardware limit switch + or –” is output and the
axis is decelerated immediately. The braking mode is defined in
MD 36600: BRAKE_MODE_CHOICE (deceleration behavior on hardware limit switch).
Signal state 0 or signal Normal condition, hardware limit switch not triggered.
Related to .... MD 36600: BRAKE_MODE_CHOICE (deceleration behavior on hardware limit switch)
V380x1000.3 or .2 2nd software limit switch plus or minus

Signal state 1 or signal 2nd software limit switch for the plus or minus direction is active.
transition 0 –––> 1 1st software limit switch for the plus or minus direction is not active.
The 2nd software limit switches (plus and minus) can be activated in addition to the 1st software
limit switches (plus and minus) via this interface signal.
The position is defined by MD 36130: POS_LIMIT_PLUS2,
MD 36120: POS_LIMIT_MINUS2 (2nd software limit switch plus, 2nd software limit switch
minus).
Signal state 0 or signal 1st software limit switch for the plus or minus direction is active.
transition 1 –––> 0 2nd software limit switch for the plus or minus direction is not active.
Related to .... MD 36110: POS_LIMIT_PLUS, MD 36130: POS_LIMIT_PLUS2,
MD 36100: POS_LIMIT_MINUS, MD 36120: POS_LIMIT_MINUS2, (software limit switch plus,
software limit switch minus)
Signals from axis/spindle
V390x 0000.2 Encoder limit frequency exceeded 1

Data block Signal(s) from axis/spindle (NCK –––> PLC)
Signal state 1 or signal The axis velocity defined in MD 36300: ENC_FREQ_LIMIT (encoder limit frequency) has been
transition 0 –––> 1 exceeded. The reference point for the position measuring system concerned
has been lost (IS: Referenced/synchronized is in signal state 0). Proper position closed loop
control is no longer possible. The spindles continue to run with speed control.
The axes are brought to a standstill with rapid stop (with open position control loop) along a
speed setpoint ramp.
Signal state 0 or signal The axis velocity defined in MD 36300: ENC_FREQ_LIMIT is no longer exceeded.
transition 1 –––> 0 For the edge change 1 ––>, the encoder frequency must have dropped below the setting in
MD 36302: ENC_FREQ_LIMIT_LOW (% value of MD 36300: ENC_FREQ_LIMIT).

2-44 6FC5397-1CP10-1BA0
2.8.1 Axis/spindle-specific interface signals

rence
Axis/spindle-specific
V380x 0001 .5 Position measuring system 1 A2
V380x 0002 .3 Clamping in progress
V380x 0003 .6 Velocity/spindle speed limiting
V380x 1000 .0 / .1 Hardware limit switch minus/hardware limit switch plus
V380x 1000 .2 / .3 2nd software limit switch minus/2nd software limit switch plus
V390x 0000 .2 Encoder limit frequency exceeded 1
V390x 0000 .4 Referenced/synchronized 1 R1
2.8.2 Axis/spindle-specific machine data

rence
Axis/spindle-specific ($MA_ ... )
30310 ROT_IS_MODULO Modulo conversion for rotary axis and spindle R2
32000 MAX_AX_VELO Maximum axis velocity G2
32200 POSCTRL_GAIN [n] Servo gain factor G2
32250 RATED_OUTVAL Rated output voltage S1
32260 RATED_VELO Rated motor speed S1
32300 MAX_AX_ACCEL Axis acceleration B2
32810 EQUIV_SPEEDCTRL_TIME [n] Equivalent time constant speed control loop for K3
feedforward control
35160 SPIND_EXTERN_VELO_LIMIT Spindle speed limiting via PLC S1
36000 STOP_LIMIT_COARSE Exact stop coarse
36010 STOP_LIMIT_FINE Exact stop fine
36020 POSITIONING_TIME Time delay exact stop fine
36030 STANDSTILL_POS_TOL Zero-speed tolerance
36040 STANDSTILL_DELAY_TIME Zero-speed monitoring delay time
36050 CLAMP_POS_TOL Clamping tolerance with “Clamping active” inter-
face signal
36060 STANDSTILL_VELO_TOL Maximum velocity/speed “Axis/spindle stationary”
36100 POS_LIMIT_MINUS 1st software limit switch minus
36110 POS_LIMIT_PLUS 1st software limit switch plus
36120 POS_LIMIT_MINUS2 2nd software limit switch minus
36130 POS_LIMIT_PLUS2 2nd software limit switch plus

6FC5397-1CP10-1BA0 2-45

rence
36200 AX_VELO_LIMIT [n] Threshold value for velocity monitoring
36210 CTRLOUT_LIMIT[n] Maximum speed setpoint G2
36300 ENC_FREQ_LIMIT[n] Encoder limit frequency
36302 ENC_FREQ_LIMIT_LOW Encoder limit frequency re-synchronization R1
36310 ENC_ZERO_MONITORING [n] Zero-mark monitoring
36400 CONTOUR_TOL Contour monitoring tolerance band
36500 ENC_CHANGE_TOL High backlash values/ K3
Maximum tolerance for position actual value
changeover
36600 BRAKE_MODE_CHOICE Deceleration behavior on hardware limit switch
36610 AX_EMERGENCY_STOP_TIME Length of the braking ramp for error states
36620 SERVO_DISABLE_DELAY_TIME Cutout delay servo enable N2

rence
Channel-specific ($MC_ ... )
21020 WORKAREA_WITH_TOOL_RADIUS Allowance for tool radius with working area
limiting
2.8.4 Axis/spindle-specific setting data

rence
Axis/spindle-specific ($SA_ ... )
43400 WORKAREA_PLUS_ENABLE Working area limiting active in positive direction
43410 WORKAREA_MINUS_ENABLE Working area limiting active in negative direction
43420 WORKAREA_LIMIT_PLUS Working area limiting plus
43430 WORKAREA_LIMIT_MINUS Working area limiting minus

2-46 6FC5397-1CP10-1BA0
Velocities, Setpoint/Actual Value Systems,
Closed-Loop Control (G2) 3
3.1 Velocities, traversing ranges, accuracies
3.1.1 Velocities
The maximum path/axis velocities and spindle speed are influenced by the machine design,
the dynamic response of the drive and the limit frequency of the actual-value acquisition sy-
stem (encoder limit frequency).
The maximum axis velocity is defined in MD 32000: MAX_AX_VELO (maximum axis
velocity).
The maximum permissible spindle speed is preset in MD 35100: SPIND_VELO_LIMIT (maxi-
mum spindle speed).
References: Chapter “Spindle”
As well as the limit by MD 32000: MAX_AX_VELO, the control also limits the maximum path
velocity depending on the situation according to the following formula:
progr. path length in a part program block [mm or degrees]

Vmax v * 0, 9
IPO cycle [s]
With a high feedrate (resulting from program and feedrate override), the maximum path velo-
city is limited to Vmax.
This automatic feedrate limiting can lead to a drop in velocity over several blocks with pro-
grams generated by CAD systems with extremely short blocks.
Example:
IPO cycle = 12 ms
N10 G0 X0 Y0; [mm]
N20 G0 X100 Y100; [mm]
⇒ programmed path length in block = 141.42 mm
⇒ Vmax = (141.42 mm / 12 ms) * 0.9 = 10606.6 mm/s = 636.39 m/min

The following restriction applies to the minimum path or axis velocity:
Vmin w 10 *3
calculation resolution[mm orincr.
degrees
] * IPO cycle [s]

6FC5397-1CP10-1BA0 3-47
Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2)
The calculation resolution is defined in MD 10200: INT_INCR_PER_MM (calculation resolu-

tion for linear positions) or MD 10210: INT_INCR_PER_DEG (calculation resolution for angu-
lar positions). It is described in more detail on the following pages.
If Vmin is not reached, no traversing movement is carried out.
Example: MD 10200: INT_INCR_PER_MM = 1000 [incr./mm] ;
IPO cycle = 12 ms;
⇒Vmin = 10 –3/(1000 incr/mm x 12 ms) = 0.005 mm/min;
The value range of the feedrates depends on the calculation resolution selected. With the de-
fault settings of MD 10200: INT_INCR_PER_MM (calculation resolution for linear positions)
(1000 incr./mm) or MD 10210: INT_INCR_PER_DEG (calculation resolution for angular posi-
tions) (1000 incr./degrees), the following value range can be programmed with the specified
resolution:
Value range for path feed F: metric system:
0.001 v F v 999.999,999 [mm/min, mm/rev, degree/min, degree/rev]
Value range for spindle speed S:
0,001 v S v 999,999.999 [rpm]
If the calculation resolution is increased/decreased by a factor of 10, the value ranges change
accordingly (maximum number of decimal points is constant).
3.1.2 Traversing ranges
The value range of the traversing area depends on the calculation resolution selected.
With the default settings of MD 10200: INT_INCR_PER_MM (calculation resolution for linear
positions) (1000 incr./mm) or MD 10210: INT_INCR_PER_DEG (calculation resolution for an-
gular positions) (1000 incr./degrees), the following value range can be programmed with the
specified resolution:
Table 3-1 Traversing ranges of axes
G71 [mm, degrees] G70 [inch, degrees]

Area Area
Linear axes X, Y, Z, ... " 999.999,999 " 399.999,999
Rotary axes A, B, C, ... " 999.999,999 " 999.999,999
Interpolation parameters I, J, K " 999.999,999 " 399.999,999
The unit of measurement of rotary axes is always degrees.

If the calculation resolution is increased/decreased by a factor of 10, the value ranges change
accordingly (maximum number of decimal points is constant).
The travel range can be limited by software limit switches and working areas.
References: Chapter “Axis monitoring functions”
The travel range for rotary axes can be limited via machine data.
References: Chapter “Rotary axes”

3-48 6FC5397-1CP10-1BA0
3.1.3 Input/display resolution, computational resolution
The following types of resolution, e.g. resolution of linear and angular positions, velocities,
accelerations and jerk, must be differentiated as follows:
S The input resolution, i.e. the input of data via the operator panel or by means of part
programs.
S The display resolution, i.e. display of data on the operator panel.
S The calculation resolution, i.e. the internal representation of data entered via the operator
panel or part program.
The input and display resolution are determined by the control panel used (display machine
data), whereby the display resolution for position values/spindle speed can be modified using
MD 203: DISPLAY_RESOLUTION (display resolution, metric linear position, general angular
position) or MD 205: DISPLAY_RESOLUTION (display resolution for spindle speed).
Via the MD 204: DISPLAY_RESOLUTION_INCH can be used to configure the display resolu-
tion for linear position values in inches.
For the programming of part programs, the input resolutions listed in the Programming Guide
apply.
The desired calculation resolution is defined in MD 10200: INT_INCR_PER_MM (calculation
resolution for linear positions) and MD 10210: INT_INCR_PER_DEG (calculation resolution
for angular positions). It is independent of the input/display resolution but should have at least
the same resolution.
The max. number of places after the decimal point for position values, velocities etc. in the
part program and the number of places after the decimal point for tool offsets, zero offsets etc.
(and therefore also for the maximum possible accuracy) are defined with the calculation
resolution.
The precision of the angular and linear position input is limited to the calculation resolution by
rounding the product of the programmed value and the calculation resolution to an integer
value.
In order to keep the rounding-off easily reproducible, it is advisable to use powers of 10 for the
calculation resolution.
Example of rounding:
Calculation resolution: 1,000 increments/mm
Programmed path: 97.3786 mm
Effective value = 97.379 mm
3.1.4 Standardizing physical quantities of machine and setting data
Machine and setting data that possess a physical quantity are interpreted in the input/output
units below depending on whether the metric or inch system is selected:

6FC5397-1CP10-1BA0 3-49
Physical quantity: Input/output units

for standard basic system:
Metric Inch
Linear position 1 mm 1 inch

Angular position 1 degree 1 degree
Linear velocity 1 mm/min 1 inch/min
Angular velocity 1 rpm 1 rpm
Linear acceleration 1 m/s2 1 inch/s2
Angular acceleration 1 rev./s2 1 rev./s2
Linear jerk 1 m/s3 1 inch/s3
Angular jerk 1 rev./s3 1 rev./s3
Time 1s 1s
Position controller gain 1/s 1/s
Revolution feedrate 1 mm/rev. 1 inch/rev.
Compensation value linear position 1 mm 1 inch
Compensation value angular position 1 degree 1 degree

3-50 6FC5397-1CP10-1BA0
3.2 Metric/inch measuring system

The control system can operate with the inch or the metric measurement system. The initial
setting is defined in MD 10240: SCALING_SYSTEM_IS_METRIC (basic metric system). De-
pending on the setting in the MD, all geometric values are interpreted either as metric or inch
values. All manual settings also refer to this basic setting (e.g. handwheel, INC, JOG feed-
rate), as do zero offsets, tool offsets, etc. and the associated displays.
The setting MD 10260: CONVERT_SCALING_SYSTEM=1 makes it considerably easier to
change the dimension system.
S Availability of an MMC softkey for change dimension system.
S Automatic conversion of NC active data when the dimension system is changed-over.
S Data backup is performed with the actual dimension system identifier.
S The scope of MD 10240: SCALING_SYSTEM_IS_METRIC is reset.
3.2.1 Conversion of basic system by part program
When programming, it is possible to change over between dimension systems for some
workpiece-related specifications with G70/G71 and with G700/G710. Data influenced by
G70/G71/G700/G710 is described in the Programming Guide.
When changing the dimension system via MMC soft key, these initial settings are automati-
cally initialized for the dimension system with G700 or G710.
Application:
With this function it is possible, for example, with a metric system as basis, to machine an
inch thread in a metric part program. Tool offsets, zero offsets and feedrates remain metric.
Machine data are output to the screen in the basic system selected in MD 10240: SCA-
LING_SYSTEM_IS_METRIC (basic system metric).
Machine coordinates, tool data and zero offsets are always displayed in the initial setting,
workpiece coordinate displays are in the current setting.
Note:
If programs including data sets (zero offsets, tool offset) – programmed in a dimension system
other than the basic system – are read in from an external source, then the initial setting must
first be changed using MD 10240: SCALING_SYSTEM_IS_METRIC.
Data exchange with the PLC of interface signals containing dimension information, e.g. feed-
rate for path and positioning axes, is always carried out in the selected basic system.
G700/G710 extends the functionality of G70/G71 as follows:
1. The feed is interpreted in the programmed dimension system:
– G700: length parameters [inch]; feedrates [inch/min]
– G710: length parameters [mm]; feedrates [mm/min]

6FC5397-1CP10-1BA0 3-51
The programmed feed is modal and therefore remains active after subsequent
G70/G71/G700/G710 commands. If the feedrate is to apply in the new
G70/G71/G700/G710 context, it must be re-programmed.
2. System variables and machine data specifying lengths in the part program are read and
written in the programmed dimension system.
This allows you to implement part programs that are independent of the default dimension
system.
Comparison of the effect of G70 and G700 on machine data and system variables in the part
program:
S with G70: reading/writing in the basic system
S with G700: reading/writing in the programmed dimension system
Comparison: G70/G71–G700/G710
Meanings:
P: data read/write operations performed in programmed dimension system
G: data read/write operations perfomed in basic system
(MD 10240: SCALING_SYSTEM_IS_METRIC)
R/W: read/write
Table 3-2 Comparison
Area G70/G71 G700/G710

Part program Part program
Display, decimal places (WCS) P/P P/P
Display, decimal places (MCS) G/G G/G
Feedrates G/G P/P
Positional data X, Y, Z P/P P/P
Interpolation parameters I, J, K P/P P/P
Circle radius (CR) P/P P/P
Polar radius (RP) P/P P/P
Pitch P/P P/P
Programmable offset, rotation,... P/P P/P
Programmable offset G54, G55, etc. G/G P/P
Working area limits (G25/G26) G/G P/P
Tool offsets G/G P/P
Length-related machine data G/G P/P
Length-related setting data G/G P/P
Length-related system variables G/G P/P
R parameters G/G G/G
Siemens cycles P/P P/P
Jog/handwheel increment factor G/G G/G

3-52 6FC5397-1CP10-1BA0
3.2.2 Manual changing the basic system changeover of the basic system
General
The dimension system for the whole machine is done changed using an MMC softkey “Switch
to mm > inch” or “Switch to inch > mm” located in the “POSITION” –> “Settings” area.
The softkey can only be accessed in JOG or MDA mode. The change is only accepted if:
S The channel is in reset status
S The axes are not being traversed.
Actions such as NC start or mode change are disabled for the duration of the changeover.
If the changeover cannot be performed, this is indicated by a message at the user interface.
These measures ensure that a consistent set of data is always used for a running program
with reference to the dimension system.
The actual changeover of the dimension system is performed internally by writing all the ne-
cessary machine data and subsequently activating them with a Reset.
MD 10240: SCALING_SYSTEM_IS_METRIC and the corresponding G70/G71/G700/G710
settings in MD 20150: GCODE_RESET_VALUES are changed over automatically and con-
sistently. Note: MD 20150 can only be read/ written in expert mode (protection level 1).
The value of MD 20150: GCODE_RESET_VALUES[12] changes between G700 and G710.
That is, the start-up setting of the G commands changes between G700 and G710.
This process takes place independently of the protection level currently set.
System Data
When changing over the dimension system, from the view of the user, all length-related speci-
fications are converted to the new dimension system automatically. These include:
S Positions
S Feedrates
S Acceleration rates
S Jerk
S Tool offsets
S Compensation values
S Machine data
S Jog and handwheel factors
After the changeover, all of the above data is available in the physical magnitudes described
in Subsection 3.1.4.
Data for which no unique physical units are defined, such as:
S R parameters

6FC5397-1CP10-1BA0 3-53
are not converted automatically. In this case, the user must allow for the current dimension
system in MD 10240: SCALING_SYSTEM_IS_METRIC.
The current dimension system setting can be read at the PLC interface via the “inch system”
signal V2700 0001.7.
Reference point
The reference point is retained. It is not necessary to repeat referencing.
Input resolution and calculation resolution

The input/calculation resolution is set in the PLC using MD 10200: INT_INCR_PER_MM. The
default setting for a metric system is 1000 (0.001 mm). inches is required for an inch system.
Example:
1 inch = 25.4mm ⇒ 0.0001 inch = 0.00254 mm = 2.54 µm
In order to program and represent the last 40 nm, a value of 100000 must be entered in
MD 10200.
Only with this identical setting for both dimension systems is it possible to change the system
of measurement without a significant loss of accuracy. Once MD 10200 has been set as
above, it no longer has to be changed for each dimension system changeover.
Jog and increment weighting

MD 31090: JOG_INCR_WEIGHT consists of two values containing axis-specific increment
weighting factors for each of the two dimension system. The control automatically selects the
correct value depending on the setting in MD 10240: SCALING_SYSTEM_IS_METRIC.
Note: MD 31090: JOG_INCR_WEIGHT can only be read/ written in “expert mode” access
level (protection level 1)!
Default setting for each axis:
S Metric: MD 31090: JOG_INCR_WEIGHT[0]=0.001 mm
S Inch: MD 31090: JOG_INCR_WEIGHT[1]=0.00254 mm => 0.0001 inch
Data backup
Data sets which can be read out separately from the control and which contain data relating
the dimension system are given an INCH or METRIC identifier corresponding to
MD 10240: SCALING_SYSTEM_IS_METRIC. This records a dimension system in which the
data were originally read out.
This information is intended to prevent data sets from being read into the control system with
a dimension system of which is different from the active system. In this case, alarm 15030 is
triggered and the write process is interrupted.

3-54 6FC5397-1CP10-1BA0
3.3 Setpoint/actual-value system
Since the language instruction is also evaluated in part programs, these can also be “protec-
ted” against operator errors as described above. You can therefore prevent part programs
containing e.g. only metric data from running on an inch dimension system.
3.3.1 General
Block diagram
A control loop with the following structure can be configured for every closed-loop controlled
axis/spindle:
Motor
Speed setpoint Speed setpoint
Closed–loop M
control output routing
MD 30130:
CTRLOUT_TYPE=0 (SIMULATION)
IS Position measuring
system 1 MD 30240:
ENC_TYPE=0 (SIMULATION)
Actual-value Encoder
Actual–value assignment
processing G
Fig. 3-1 Block diagram of a control loop
Setpoint output
A setpoint can be output for each axis/spindle. The setpoint output to the sensor is done digi-
tally or, in the case of analog spindles 10 V unidirectionally or bidirectionally.
Simulation axes
The speed control loop of an axis can be simulated for test purposes. The axis “traverses”
with a following error, similar to a real axis.
A simulation axis can be defined by setting the two machine data MD 30130:
CTRLOUT_TYPE[n] (setpoint output mode) and MD 30240: ENC_TYPE[n] (actual-value
assignment type) to “0”.
As soon as the standard machine data have been loaded, the axes become simulation axes.
The setpoint and actual value can be set to the reference point value with reference point
approach.

6FC5397-1CP10-1BA0 3-55
Via the MD 30350: SIMU_AX_VDI_OUTPUT (output of axis signals for simulation axes) can
be set to define whether axis-specific interface signals are output to the PLC during the simu-
lation process.
3.3.2 Drives with DRIVE-QLiQ
General
With the 802D system, the SINAMICS_I controller is integrated into the control system.
From this integrated controller, the connection to further SINAMICS modules is realized via
DRIVE-QLiQ. This connection can extend up to motors with SMI interface. The topology is
identified automatically when starting up the SINAMICS drive (see Instruction Manual)
Configuring drives with SINUMERIK 802 D sl using SINAMICS components

The control system provides preconfigured system data blocks for various drive configurati-
ons. These configurations are set via MD 11240 [2]: PROFIBUS_SBD_ NUMBER.
Notice
Do not change MD 11240 [1], [3]. They are reserved for Siemens.
See the comprehensive machine data description in the Chapter “Data description” for the full
range of selection options.
The drive is assigned a drive number via the slot in the DRIVE-QLiQ system. Please note that
the ALM (Active Line Modul) is also assigned a number in this system. These numbers are
displayed in the screen of the drive machine data after starting up the SINAMICS drives.
This drive number is used for assignment of the NC axes to the drives. The relevant values
are entered in the machine data 30110 and 30220 (see also next Section “Speed setpoint and
actual value assignment”).

3-56 6FC5397-1CP10-1BA0
Example
The following modules are used for a 3-axis milling machine with spindle:
S one active line module (ALM)
S two one-axis modules (for spindle and Z axis)
S one double-axis module(for X and Y axes)
802 D sl
X1
Measuring system connections

X200
X201
X200
X202
X201
X200
X202
X201
X200
X202
X203
ALM Motor Motor Double
SINAMICS
module module motor

module
Spindle Z X and Y
Fig. 3-2 Example: Milling machine with 3 axes and spindle
The configuration is performed via machine data.
Table 3-3 Configuration
MD X Y Z SP
30100 5 5 5 5
30110 3 4 2 1
30120 1 1 1 1
30130 1 1 1 1
30134 0 0 0 0
30200 1 1 1 1
30230 1 1 1 1
30220 3 4 2 1
Note
In the case of dual-axis power modules, both drives (A and B) are each assigned to an axis.

6FC5397-1CP10-1BA0 3-57
The commissioning of the drives is performed via the drive machine data. Thus, the topology
can be identified and the motor data set up.
Via the MD 13060: DRIVE_TELEGRAM_TYPE[n] is used to set the default message frame
type for communication with each drive. When using the SINAMICS drive, the required value
= 102 is already set by default. The message frame type 102 must also be set in SINAMICS.
For the relevant procedure, please refer to the Start-up Guide.
The SINAMICS is thus ready for traversing. Further fine optimization can be performed later
via the V24 connection using the Starter tool. The V24 connection must be activated for the
connection using the SYSTEM > PLC > STEP 7 connection menu item.
3.3.3 Speed setpoint and actual-value routing
Prerequisite for routing

All NC machine axes must be uniquely defined in
MD 10000: AXCONF_MACHAX_NAME_TAB[n] (machine axis name). This name must be
unique across the whole system.
Note
To connect an analog (instead of a digital) spindle, install the MCPA module. When doing so,
various additional notes must be observed. Please refer to the “Spindle” Chapter in the
Start-up Guide.
Speed setpoint routing

The speed setpoint assignment is illustrated in the diagram below.
802 D sl
X1
Measuring system connections

X200
X201
X200
X202
X201
X200
X202
X201
X200
X202
X201
X200
X202
ALM Motor Motor Motor Motor

SINAMICS
module module module module
Spindle X Y Z
Drive1 Drive2 Drive3 Drive4
Fig. 3-3 Speed setpoint routing, example

3-58 6FC5397-1CP10-1BA0
The following machine data of each machine axis must be parameterized:

S MD 30110: CTRLOUT_MODULE_NR[0] Assignment of the drive number
S MD 30130: CTRLOUT_TYPE[0] Setpoint output type; the type of the
speed setpoint output is entered here.
S SP – spindle = machine axis 4: CTRLOUT_MODULE_NR = 1 –>Drive number 1
S X1 – axis= machine axis 1: CTRLOUT_MODULE_NR = 2 –>Drive number 2
S Y1 – axis = machine axis 2: CTRLOUT_MODULE_NR = 3 –>Drive number 3
S Z1 – axis = machine axis 3: CTRLOUT_MODULE_NR = 4 –>Drive number 4
S A1 – axis = machine axis 5: CTRLOUT_MODULE_NR = 5 –>Drive number 5
Actual-value routing
Due to the fixed assignment of the encoder (measuring system) to the drive, the actual value
assignment must be performed identically to the speed setpoint assignment (the same drive
number). For the actual-value assignment, please refer to the diagram below. The parameteri-
zation is described in the associated machine data: Drive–Qliq measuring system 1
Drive–Qliq measuring system 2

802 D sl
X1
X200
X201
X200
X202
X201
X200
X202
X201
X200
X202
X201
X200
X202
ALM Motor Motor Motor Motor

SINAMICS
module module module module
Spindle X Y Z
Drive1 Drive2 Drive3 Drive4
Fig. 3-4 Actual-value assignment, example
The following machine data of each machine axis must be parameterized:

S MD 30220: ENC_MODULE_NR[0] : Assignment of the drive number
S MD 30240: ENC_TYPE[0] Type of actual-value assignment;
enter the encoder type you are using here.
S SP – Spindle = machine axis 4: ENC_MODULE_NR = 1 –> Drive number 1
S X1 – axis = machine axis 1: ENC_MODULE_NR = 2 –> Drive number 2
S Y1 – axis = machine axis 2: ENC_MODULE_NR = 3 –> Drive number 3
S Z1 – axis = machine axis 3: ENC_MODULE_NR = 4 –> Drive number 4
S A1 – axis = machine axis 5: ENC_MODULE_NR = 5 –> Drive number 5

6FC5397-1CP10-1BA0 3-59
Special points to be noted

MD 30110: CTRLOUT_MODULE_NR[0] and MD 30220: ENC_MODULE_NR[0] of one
machine axis must have the same drive number.
For operation of a digital spindle with a second direct position encoder, the following MDs
must be set for the actual-value assignment. A reloadable SDB must be loaded from the tool-
box, granting access to the message frame type = 103 for the relevant drives. The message
frame type 103 must also be set in SINAMICS.
MD 13060: DRIVE_TELEGRAM_TYPE[0–5] =103
MD 30220: ENC_MODULE_NR[0] =3 Module no. for input of the 2nd spindle system
MD 30230: ENC_INPUT_NR[0] =2 Measuring system slot on the module
The direction can be corrected, e.g. using MD 32110: ENC_FEEDBACK_POL[0] = –1.
3.3.4 Speed setpoint output
MD 32100: AX_MOTION_DIR
ÍÍÍÍÍ
nmotor nspindle
MD 31030: LEADSCREW_PITCH
Controller M
Load
gearbox
ÍÍÍÍÍ Ball screw
For linear axes only
MD 31060: DRIVE_AX_RATIO_NUMERA [n] Number of motor revolutions

=
MD 31050: DRIVE_AX_RATIO_DENOM [n] Number of load revolutions (spindle)
Fig. 3-5 Speed setpoint output
Traversing direction
MD 32100: AX_MOTION_DIR (traversing direction) can be used to reverse the direction of
motion of the axis (without affecting the control sense of the position control).

3-60 6FC5397-1CP10-1BA0
Maximum speed setpoint

The maximum speed setpoint is set with MD 36210: CTRLOUT_LIMIT. The percent value re-
fers to the speed (100%) at which the axis velocity of MD 32000: MAX_AX_VELO is reached.
A value greater than 100% contains the requisite control margin for the position control of
axes.
n Set= Speed setpoint

Max. speed setpoint
MD 36210: CTRLOUT_LIMIT
5–25%
Speed at:
Max. axis velocity
MD 32000: MAX_AX_VELO
t [sec]
Fig. 3-6 Speed setpoint output
If settings beyond the limit are made, the value in MD 36210 is used as the limiter, an alarm is
emitted and the axes brought to a halt. See Chapter “Axis monitoring functions” for more
details.
With an analog spindle the maximum outputtable speed is limited by the maximum setpoint
output voltage of 10V. The value of MD 36210: CTRLOUT_LIMIT should not be greater than
the speed value that is reached at this voltage (100%).
Note
For special situations for controlling a spindle, see Chapter “Spindles”.
3.3.5 Actual-value processing
Actual-value resolution
In order to be able to create a correctly closed position closed-loop control, the control system
must be informed of the valid actual-value resolution.
Depending on the type of axis (linear axis, rotary axis/spindle, analog spindle) and the type of
actual-value resolution (direct, indirect), the following machine data must be parameterized to
calculate the actual-value acquisition for the main applications:
Machine data Linear axis Rotary axis Spindle
Encoder on Encoder on Encoder on Encoder on Without

motor motor motor machine measuring
system
MD 30200: NUM_ENCS 1 1 1 1 0
(Number of encoders)
MD 30300: IS_ROT_AX 0 1 1 1 1
(Rotary axis)

6FC5397-1CP10-1BA0 3-61
MD 31040: ENC_IS_DIRECT[0] 0 0 0 1 1
(Encoder is connected directly at the machine)
MD 31020: ENC_RESOL[0] Pulses/rev Pulses/rev Pulses/rev Pulses/rev –

(Encoder pulses per revolution)
MD 31030: LEADSCREW_PITCH mm/rev. – – – –

(Leadscrew pitch)
MD 31080: 1 1 1 Load revs –

DRIVE_ENC_RATIO_NUMERA[n]
(Measuring gearbox numerator)
MD 31070: 1 1 1 Encoder –
DRIVE_ENC_RATIO_DENOM[n] revs
(Measuring gearbox denominator)
MD 31060: Motor revs Motor revs Motor revs See –

DRIVE_AX_RATIO_NUMERA[n] note *)
(Load gearbox numerator)
MD 31050: Leadscrew Load revs Load revs See –

DRIVE_AX_RATIO_DENOM[n] revs note *)
(Load gearbox denominator)
– = Irrelevant for this combination

The index [n] of the machine data has the following code:
MD: DRIVE_AX_...[Closed-loop control parameter set no.] : 0–5
Note
*) These MD are not required for encoder matching (path evaluation). However, they must be
entered correctly for the setpoint calculation! Otherwise the required servo gain (KV) factor will
not be set.
Variants of actual-value acquisition

The associated machine data for different variants of actual-value acquisition are described
below.

3-62 6FC5397-1CP10-1BA0
Linear axis with rotary encoder on motor
MD: IS_ROT_AX=0
nEncoder
MD: ENC_IS_DIRECT=0
ÍÍÍÍÍ
Table
G M Ball screw
Load
gearbox nSpindle LEADSCREW_PITCH
nMotor
MD: MD: DRIVE_AX_RATIO_NUMERA No. of motor revs
ENC_RESOL =
MD: DRIVE_AX_RATIO_DENOM No. of spindle revs
Fig. 3-7 Linear axis with rotary encoder on motor
Rotary axis with rotary encoder on motor
MD: MD:
n ENC_IS_DIRECT=0 n IS_ROT_AX=1
Encoder Load
G M L Rotary table
Load
Gearbox
n MD: DRIVE_AX_RATIO_NUMERA No. of motor revs
MD: Motor =
ENC_RESOL MD: DRIVE_AX_RATIO_DENOM No. of load revs
Fig. 3-8 Rotary axis with rotary encoder on motor
Spindle with rotary encoder on the machine
n Load
Spindle chuck
MD:
ENC_IS_DIRECT=1
n Encoder
MD:
M L G ENC_RESOL
MD: MD: DRIVE_ENC_RATIO_NUMERA No. of load revs

IS_ROT_AX=1 =
MD: DRIVE_ENC_RATIO_DENOM No. of Encoder revs
Load Measuring
gearbox gearbox
Fig. 3-9 Spindle with rotary encoder on the machine
Note:
With MD 32110: ENC_FEEDBACK_POL (sign of actual value), the leading sign of the actual-
value acquisition and also the control sense of the position control can be changed.

6FC5397-1CP10-1BA0 3-63
3.4 Closed-loop control
General
The closed-loop control of an axis consists of the current and speed control loop of the drive
plus a higher-level position control loop in the NC.
The speed and current control are described in:
References: SINAMICS S120 Start-up Guide
MD 32200: POSCTRL_GAIN
Interpolator/ Feedforward Speed

smoothing control Closed–loop setpoint-
control processing
MD 32100: AX_MOTION_DIR
IS: Position measuring

system 1
Actual–
value
MD 32620: FFW_MODE processing
MD 32630: FFW_ACTIVATION_MODE
MD 32610: VELO_FFW_WEIGHT MD 32110: ENC_FEEDBACK_POL
MD 32810: EQUIV_SPEEDCTRL_TIME MD 32700: ENC_COMP_ENABLE
MD 32450: BACKLASH
Fig. 3-10 Principle of position control for an axis /spindle
For a description of jerk limiting, see:

References: Chapter “Acceleration”
For a description of feedforward control, backlash and leadscrew error compensation see:
References: Chapter “Compensations”
Servo gain factor

A high servo gain factor setting in MD 32200: POSCTRL_GAIN[n] (position controller gain) is
required to prevent the occurrence of significant contour deviations.
The index[n] of the machine data has the following code:
[closed-loop control parameter set no.]: 0 – 5
However, if the servo gain factor is too high, instability, overshoot and possibly impermissibly
high loads on the machine will result.
The maximum permissible servo gain factor depends on the following:
S Design and dynamics of the drive
(rise time, acceleration and deceleration capabilities)
S Quality of the machine (elasticity, vibration clamping)

3-64 6FC5397-1CP10-1BA0
S Position-control cycle
Velocity [mńmin]
KV + ; Unit of servo gain factor as per VDI norm
Following error [mm]
Parameter sets of the position controller

The position control can operate with 6 different parameter sets. This information is used for
S fast adaptation of the position control to altered machine characteristics during operation,
e.g. a gear change of the spindle.
S matching the dynamics of an axis to another axis, e.g. during tapping.
The following machine data can be changed as related units of data by switching over the
parameter set.
MD 31050: DRIVE_AX_RATIO_DENOM[n] (denominator load gearbox)
MD 31060: DRIVE_AX_RATIO_NUMERA[n] (load gearbox numerator)
MD 32200: POSCTRL_GAIN[n] (servo gain factor)
MD 32810: EQUIV_SPEEDCTRL_TIME[n] (equivalent time constant speed control loop for feed-
forward control)
MD 36200: AX_VELO_LIMIT[n] (threshold value for velocity monitoring)
Machine data index[n] has the following code:
[control parameter block number]: 0–5
Spindle parameter sets:
In the case of spindles, each gear stage is assigned its own parameter set. The appropriate
parameter set is activated depending on interface signal “Actual gear stage (V380x 2000.0
to .2).
Note: The machine data that are changed over with the spindle gear stage, are listed in
Chapter “Spindles”.
IS “Actual gear stage” Active parameter set

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

S Parameter set 1 (index=0) is activated for axes not involved in tapping or thread cutting.
S For axes involved in tapping or thread cutting, the same parameter set number as for the
current gear stage of the spindle is activated.

6FC5397-1CP10-1BA0 3-65
3.5 Data Description (MD, SD)
Note
If e.g. a load gearbox is active for an axis, this ratio (numerator, denominator) must be entered
in all other parameter sets used for threads in additon to the parameter set with index=0
The current parameter set is displayed in operating area “Diagnostics” in the “Service axis”
display.
3.5.1 General machine data
10200 ** INT_INCR_PER_MM
MD number Calculation resolution for linear positions
Meaning: The number of internal increments per millimeter is defined in this MD.
The precision of the linear position input is limited to the calculation resolution by rounding-off the
product of the programmed value and the calculation resolution to an integer value.
To make the rounding clear, powers of 10 should be used for the calculation resolution.
Application example(s) The calculation resolution can be increased to u1000 incr./mm for linear axes operating to high
accuracy requirements.
10210 ** INT_INCR_PER_DEG
MD number Calculation resolution for angular positions
Meaning: The number of internal increments per degree is defined in this MD.
The precision of the angular position input is limited to the calculation resolution by rounding-off the
product of the programmed value and the calculation resolution to an integer value.
To make the rounding clear, powers of 10 should be used for the calculation resolution.
Application example(s) The calculation resolution can be changed to u1000 incr./degrees for a high-resolution rotary axis.

3-66 6FC5397-1CP10-1BA0
10240 SCALING_SYSTEM_IS_METRIC
MD number Basic system metric
Meaning: The MD defines the basic system used by the control to scale length-dependent physical quanti-
ties during data input/output.
All related data are stored internally in the basic units 1 mm, 1 degree and 1 sec.
When accessing a part program via the operator panel or from an external device, scaling is in the
following units:
SCALING_SYSTEM_IS_METRIC = 1: normalized to:
mm, mm/min, m/s2, m/s3mm/rev
SCALING_SYSTEM_IS_METRIC = 0: normalized to:
inch, inch/min, inch/s2inch/s3, inch/rev
The selection of the basic system also specifies the interpretation of the programmed F value for
linear axes:
metric inch
G94 mm/min inch/min
G95 mm/rev inch/rev
A power-up is necessary after changing this machine data, as associated machine data that have
physical units will otherwise be normalized incorrectly.
Perform the following steps:
S MD change by manual input
å First perform start-up and then enter the physical units in the related machine
data.
S MD change via machine data file
å First perform start-up and then reload the machine data file
so that the new physical units are activated.
If the machine data are altered, alarm 4070 “Scaling machine data altered” is output.
Application example(s) Installation in the metric system and then conversion to inch system.
11240 PROFIBUS_SDB_NUMBER
MD number SDB1000 number
Default setting: 1 Minimum input limit: –1 Maximum input limit: 6
Data type: BYTE Applies from SW: 1
Meaning: BUS_SDB_NUMBER [0] = 0
Digital inputs and outputs via I/O modules (PP modules)
The assignment is provided via DIL switches. Max. 3 modules with the addresses 9, 8 and 7 are
possible.
PROFIBUS_SDB_NUMBER [2] = X
Number of the system module you are using for configuring the hardware I/Os.
SINUMERIK 802D sl offers the following options to choose from:
0: 2 SINAMICS drives with SLM

4: 3 SINAMICS drives with ALM

Note:
With the SDB reloaded from the toolbox, PROFIBUS_SDB_NUMBER[2] = 0 must be set. This
activates the module.
The machine data PROFIBUS_SDB_NUMBER[1] and PROFIBUS_SDB_NUMBER[3] are
reserved internally for Siemens.

6FC5397-1CP10-1BA0 3-67
13060 DRIVE_TELEGRAM_TYPE[n]
MD number Default message frame type for drives connected to PROFIBUS DP
Default setting: Minimum input limit: 0 Maximum input limit: ***
(102, 102, 102, 102, 102)
Meaning: The message frame type:
102: must be specified for each drive. Standard message frame for SINAMICS actual-value
assignment
103: SINAMICS– Spindle with second direct measuring system
Index [n] of the machine data has the following code: [drive index]:
n=0: Drive number 1
n=1: drive number 2, etc.
20150 GCODE_RESET_VALUES[n]
MD number Initial setting of G groups [G group no.]: 0...59
Default setting: see below Minimum input limit: 0 Maximum input limit: 14
Meaning: Specification of the G codes which come into effect when booting and reset or at the end/start of a
part program.
The index of the G code must be specified as a default value in the appropriate groups.
DesignationGroup Default value
GCODE_RESET_VALUES[0] 1 2 (G01)
GCODE_RESET_VALUES[1] 2 0 (inactive)
GCODE_RESET_VALUES[3] 4 1 (START FIFO)
GCODE_RESET_VALUES[5] 6 1 (G17) for milling
GCODE_RESET_VALUES[15] 16 1 (CFC)
...
References For a list of the G groups with the G functions contained therein, please refer to
References: “Operation and Programming”

3-68 6FC5397-1CP10-1BA0
3.5.3 Axis-specific machine data
30100 CTRLOUT_SEGMENT_NR[n]
MD number Setpoint: Drive type
Meaning: Number of the bus segment via which the output is addressed.
0: Local bus segment for analog output (MCPA)

5: Bus segment for DRIVE-QLiQ output
30110 CTRLOUT_MODULE_NR[n]
MD number Setpoint: Drive number/module number
30110 CTRLOUT_MODULE_NR[n]
MD number Setpoint: Drive number/module number
Meaning: For a standard axis, the drive number must be entered.
Index [n] of the machine data is coded as follows: [setpoint branch]: 0
30120 CTRLOUT_NR[n]
MD number Setpoint: Output to module:
Meaning: The number of the output on a module via which the setpoint output is addressed is entered here.
Index[n] of the machine data is coded as follows: [setpoint branch]: 0
30130 CTRLOUT_TYPE[n]
MD number Output type of setpoint
Meaning: The speed setpoint output type is entered in the MD:
0: Simulation (no HW required)
1: Setpoint output active
The index [n] of the machine data has the following code: [setpoint branch]: 0
Application example(s) Simulation: Machine functions can be simulated even if there is no drive system.
30200 NUM_ENCS
MD number Number of encoders
Meaning: 1: Spindle/axis with measuring system (in the motor or direct)
0: No measuring system (possible for spindles)
30220 ENC_MODULE_NR[n]
MD number Actual value: Drive number/measuring circuit number
Meaning: For a standard axis, the drive number must be entered.
Index [n] of the machine data is coded as follows: [encoder no.]: 0

6FC5397-1CP10-1BA0 3-69
30230 ENC_INPUT_NR[n]
MD number Actual value: Input number on module/ measuring circuit board
Meaning: The number of the input on a module via which the encoder is addressed is entered here.
The index[n] of the machine data has the following code: [encoder no.]: 0
Application example(s) Simulation:
Machine functions can be simulated even if there is no measuring system.
30240 ENC_TYPE[n]
MD number Actual value: Encoder type
Meaning: The encoder type used is entered in the MD:
0: Simulation
1: Raw signal generator (1VPP, sin, cos)
4: Absolute encoder with EnDat interface
2, 3, 5: reserved
Application example(s) Simulation:
Machine functions can be simulated even if there is no measuring system.
30350 SIMU_AX_VDI_OUTPUT
MD number Output of axis signals for simulation axes
Meaning: The machine data specifies whether axis-specific interface signals are output to the PLC during
the simulation of an axis.
1: The axis-specific interface signals of a simulated axis are output to the PLC.
The PLC user program can thus be tested even if the drives are not available.
0: The axis-specific interface signals of a simulated axis are not output to the PLC.
All axis-specific interface signals are set to “0”.
MD irrelevant for ... ... MD 30130: CTRLOUT_TYPE (output type of setpoint value) = 1
Application example(s) MD: SIMU_AX_VDI_OUTPUT = 0
For instance, this prevents the brake from being opened during the simulation of an axis.
31000 ENC_IS_LINEAR
MD number Direct measuring system (linear scale)
Default setting: 0 Minimum input limit: *** Maximum input limit: ***
Changes effective after POWER ON Protection level: 2/2 Unit:
Data type: BOOLEAN Applies from SW: 1.1
Meaning: Value 1: Encoder is a linear scale
References
31010 ENC_GRID_POINT_DIST
MD number Distance between reference marks on linear scales
Changes effective after POWER ON Protection level: 2/2 Unit: mm
Data type: DOUBLE Applies from SW: 1.1
Meaning: Distance of marks with linear encoders
References

3-70 6FC5397-1CP10-1BA0
31020 ENC_RESOL[n]
MD number Encoder pulses per revolution
Meaning: The encoder lines per encoder revolution should entered in the MD.
31030 LEADSCREW_PITCH
MD number Leadscrew pitch
Changes effective after POWER ON Protection level: 2/2 Unit: mm/rev.
Meaning: The pitch of the leadscrew is entered in this MD.
31040 ENC_IS_DIRECT[n]
MD number Encoder is connected directly to the machine
Meaning: 1: Encoder for actual-value assignment is mounted directly at the machine.
0: Encoder for actual-value assignment is mounted on the motor.
Special cases, errors, ... ... Entering the wrong information can cause an incorrect encoder resolution, because, for example,
the wrong gear ratios are used for calculation.
31050 DRIVE_AX_RATIO_DENOM[n]
MD number Load gearbox, denominator
Default setting: 1 Minimum input limit: 1 Maximum input limit: 2 147 000 000
Meaning: The denominator of the load gearbox should entered in the MD.
The index[n] of the machine data has the following code: [closed-loop control set of parameters
set no.]: 0–5
References
31060 DRIVE_AX_RATIO_NUMERA [n]

MD number Load gearbox, numerator
Default setting: 1 Minimum input limit: –2 147 000 000 Maximum input limit: 2 147 000 000
Meaning: The numerator of the load gearbox should entered in the MD.
The index[n] of the machine data has the code: Closed-loop control set of parameters set no.: 0–5
31070 DRIVE_ENC_RATIO_DENOM[n]
MD number Measuring gearbox denominator
Meaning: The denominator of the measuring gearbox should entered in the MD.
31080 DRIVE_ENC_RATIO_NUMERA[n]
MD number Measuring gearbox numerator
Meaning: The numerator of the measuring gearbox should entered in the MD.

6FC5397-1CP10-1BA0 3-71
32000 MAX_AX_VELO
MD number Maximum axis velocity
27.77 rpm
Changes effective after NEW_CONF Protection level: 2/7 Unit: mm/min,
rpm
Meaning: The limit velocity to which the axis can accelerate (rapid traverse limit) is entered in this MD. This
velocity is used for traversing when rapid traverse G0 is programmed.
The maximum linear or rotary axis velocity should be entered in the MD in accordance with
MD 30300: IS_ROT_AX.
The maximum permissible axis velocity depends on the machine and drive dynamics and the limit
frequency of the actual-value acquisition.
32100 AX_MOTION_DIR
MD number Traversing direction
Meaning: The traversing direction of the machine axis can be reversed with this MD. The control direction is
not reversed, i.e. closed-loop control remains stable.
0 or 1: Direction not reversed
–1: Direction reversed
32110 ENC_FEEDBACK_POL[n]
MD number Sign of actual value (control direction)
Default setting: 1 Minimum input limit: - 1 Maximum input limit: 1
Meaning: The direction of evaluation of the rotary encoder signals is entered in this MD.
0 or 1: Direction not reversed
–1: Direction reversed
If the direction is reversed, the control direction is also reversed if the encoder is used for position
control.
Special cases, errors, ... ... If the wrong control direction is entered, the axis may go out of control.
One of the following alarms is output, depending on the settings of the associated limit values:
Alarm 25040 “Zero-speed monitoring”
Alarm 25050 “Contour monitoring”
Alarm 25060 “Speed setpoint limit”
The associated limit values are described in:
The control direction selected might be incorrect if an uncontrolled setpoint jump occurs when a
drive is connected.

3-72 6FC5397-1CP10-1BA0
32200 POSCTRL_GAIN [n]

MD number Servo gain factor
Changes effective after NEW_CONF Protection level: 2/7 Unit: (m/min)/mm
Meaning: Position controller gain, so-called servo gain factor
The input/output unit for the user is [(m/min)/mm].
That is, MD: POSCTRL_GAIN[n] = 1 corresponds to 1 mm following error at V = 1m/min.
If the value “0” is entered the position controller is opened.

When entering the servo gain factor it is important to check that the gain factor of the whole posi-
tion control loop is still dependent on other parameters of the controlled system. A distinction
should be made between a “desired servo gain factor” (MD: POSCTRL_GAIN) and the “actual
servo gain” (produced by the machine). Only when all the parameters of the control loop are
matched will these servo gain factors be the same.
Note:
Axes which interpolate with one another for a machining operation must either have the same gain
setting (i.e. an identical following error at the same velocity).
The real servo gain factor can be checked with the following error in the service displays.
The index[n] of the machine data has the following code: [closed-loop control set of parameters
set no.]: 0–5
36210 CTRLOUT_LIMIT[n]
MD number Maximum speed setpoint
Meaning: The maximum speed setpoint is defined as a percentage in this MD.
The value refers to the speed (100%) at which the axis velocity of MD 32000: MAX_AX_VELO is
reached. A value larger than 100% contains the required control reserve for digital drives.
If settings beyond the limit are made, the MD value is used as the limiter, an alarm is emitted and
the axes brought to a halt.
With an analog spindle the maximum speed that con be output is limited by the maximum setpoint
output voltage of 10V. The value in this MD should not be greater than the speed value that is
reached at this voltage (100%).
Index[n] of the machine data is coded as follows: [setpoint branch]: 0

References See Chapter “Axis monitoring functions”.

6FC5397-1CP10-1BA0 3-73
3.6 Signal descriptions
V2700 0001.7 INCH dimension system

Signal state 1 The NC works with the inch dimension system.
Signal state 0 The NC works with the metric dimension system.
3.7 Data fields, data lists

rence
General
V2700 0001 .7 INCH dimension system
Axis-specific
V380x 2000 .0 to .2 Actual gear stage of spindle S1
3.7.2 Machine data

rence
Specific to control panel
203 DISPLAY_RESOLUTION Display resolution Chap. 19
204 DISPLAY_RESOLUTION_INCH Display resolution for INCH dimension system Chap. 19
205 DISPLAY_RESOLUTION_SPINDLE Display resolution for spindle Chap. 19
General
10000 AXCONF_MACHAX_NAME_TAB[n] Machine axis name Chap. 19
10200 INT_INCR_PER_MM Calculation resolution for linear positions
10210 INT_INCR_PER_DEG Calculation resolution for angular positions
10240 SCALING_SYSTEM_IS_METRIC Basic system metric
11240 PROFIBUS_SDB_NUMBER SDB1000 number (PROFIBUS DP)
13060 DRIVE_TELEGRAM_TYPE[n] Default message frame type for drives connected to PROFI-
BUS DP
Channel-specific
20150 GCODE_RESET_VALUES[n] Reset G groups
Axis-specific
30110 CTRLOUT_MODULE_NR[0] Setpoint assignment: Drive number/module number (analog
spindle)
30120 CTRLOUT_NR[0] Setpoint: Output to module:
30130 CTRLOUT_TYPE[0] Output type of setpoint
30134 IS_UNIPOLAR_OUTPUT Setpoint output is unipolar (analog spindle) S1

3-74 6FC5397-1CP10-1BA0

rence
30200 NUM_ENCS Number of encoder =1 (spindle without encoder value =0)
30220 ENC_MODULE_NR[0] Actual value: Drive module number/control loop number
30230 ENC_INPUT_NR[0] Actual value: Input number on module/ measuring circuit
board
30240 ENC_TYPE[0] Type of actual-value acquisition (position actual value)
30300 IS_ROT_AX Rotary axis R2
30350 SIMU_AX_VDI_OUTPUT Output of axis signals for simulation axes
31000 ENC_IS_LINEAR Direct measuring system (linear scale)
31010 ENC_GRID_POINT_DIST Distance between reference marks on linear scales
31020 ENC_RESOL[0] Encoder pulses per revolution
31030 LEADSCREW_PITCH Leadscrew pitch
31040 ENC_IS_DIRECT[0] Encoder is connected directly to the machine
31050 * DRIVE_AX_RATIO_DENOM[0]...[5] Load gearbox, denominator
31060 * DRIVE_AX_RATIO_NUMERA[0]...[5] Load gearbox, numerator
31070 DRIVE_ENC_RATIO_DENOM[0] Measuring gearbox denominator
31080 DRIVE_ENC_RATIO_NUMERA[0] Measuring gearbox numerator
32000 MAX_AX_VELO Maximum axis velocity
32100 AX_MOTION_DIR Traversing direction
32110 ENC_FEEDBACK_POL[0] Sign of actual value (control direction)
32200 * POSCTRL_GAIN[0]...[5] Servo gain factor
32450 BACKLASH[0] Backlash K3
32700 ENC_COMP_ENABLE[0] Interpolatory compensation K3
32810 * EQUIV_SPEEDCTRL_TIME[0]...[5] Equivalent time constant speed control loop for feedforward K3
control
33630 FFW_ACTIVATION_MODE Activate feedforward control from program K3
35100 SPIND_VELO_LIMIT Maximum spindle speed S1
36200 * AX_VELO_LIMIT[0]...[5] Threshold value for velocity monitoring A3
36210 CTRLOUT_LIMIT[0] Maximum speed setpoint
37600** PROFIBUS_ACTVAL_LEAD_TIME Actual-value acquisition time (PROFIBUS Ti)
The machine data marked with * are contained in a parameter set of the position controller.
The machine data marked with ** are only available for 802D with drives on the PROFIBUS.

6FC5397-1CP10-1BA0 3-75
Notes

3-76 6FC5397-1CP10-1BA0
Acceleration (B2) 4
4.1 Acceleration profiles
Abrupt acceleration changes

With the v/t-linear control of the axis velocity that is normally applied, the motion is controlled
such that the acceleration rate changes abruptly over time. With the discontinuous, stepped
acceleration, jerkfree starting and braking of the axes is not possible, but a timeoptimized ve-
locity/time profile can be implemented.
Acceleration with jerk limitation

The jerk is the change of acceleration over time. For jerk-limited acceleration the maximum
acceleration is not abrupt, but is specified by a ramp.
Due to the smoother acceleration curve, the traversing time is longer than abrupt acceleration
for the same distance and speed and acceleration. This time loss could be compensated for
by setting a higher acceleration for the axes.
However, it has the following advantages:
S Reduced wear to mechanical parts of the machine
S Reduction of the excitation of highfrequency, difficult to control vibrations of the machine.

6FC5397-1CP10-1BA0 4-77
Acceleration (B2)
4.2 Jerk limitation on interpolator level
4.2 Jerk limitation on interpolator level
Selection and deselection of jerk-limited acceleration

Via the MD 32431: MAX_AX_JERK (maximum axis-specific jerk during path motion) can limit
the change in acceleration per machine axis individually. It only acts on the axes interpolated
by the path when SOFT is active. Jerk limitation is implemented entirely on the interpolator
level.
Acceleration with jerk limitation is activated by:

the program code SOFT in the part program. SOFT is modal and causes deselection of
the abrupt acceleration profile (BRISK). If SOFT is programmed in a block with path axes,
the previous block is ended with exact stop.
Acceleration with jerk limitation (SOFT) is deactivated by:

the program code BRISK in the part program. BRISK is modal. If path axes are program-
med in a block with BRISK, the previous block is ended with exact stop. BRISK activates
the profile with abrupt acceleration changes associated with v/tlinear velocity control.
Applicability
Path-related jerk limitation is available for interpolating path axes in operation modes AUTO
and MDA. The SOFT and BRISK acceleration profiles can be used in traverse modes exact
stop G9, G60, continuouspath modes G64, and with LookAhead. The profiles are also active
with the dry run feedrate function. With alarms that trigger a rapid stop, both acceleration
profiles are inactive.
Further information about velocity, acceleration and jerk whilst traversing in continuous path
mode and at block transitions can be found in:
References: Chapter “Continuous Path Mode, Exact Stop and Look Ahead”
Note: We recommend setting MD 32431: MAX_AX_JERK and MD 32432:
PATH_TRANS_JERK_LIM (maximum axis-specific jerk during path motion at the block transition) must be
set for the relevant axis with equal values.

4-78 6FC5397-1CP10-1BA0
Acceleration (B2)
4.3 Jerk limitation in JOG mode
4.3 Jerk limitation in JOG mode

The jerk limitation is active for axes in JOG mode during
S jogging
S handwheel jogging
S repositioning
The jerk limitation is not active during
S reference point approach with
S alarms that initiate a rapid stop.
Jerk limitation can be determined for specific axes. The acceleration response corresponds
with the SOFT acceleration profile of path-related jerk limitation. This limitation cannot be de-
selected for the axes in the relevant modes.
The axes for which jerk limitation is to be programmed can be selected with MD32420:
JOG_AND_POS_JERK_ENABLE. The maximum permissible axis-specific maximum jerk is
stored in MD 32430: JOG_AND_POS_MAX_JERK.

6FC5397-1CP10-1BA0 4-79
Acceleration (B2)
4.4 Percentage acceleration correction, ACC
4.4 Percentage acceleration correction, ACC
Functions
In program sections it may be necessary to reprogram the axis and spindle acceleration
set via the machine data. This programmable acceleration is a percentage acceleration
correction.
The ACC[channel axis name] = percentage
command in the program allows you set a percentage for each axis (e.g. X) or spindle (S1) of
> 0% and v 200%. The axis interpolation is then carried out with this proportional accelera-
tion. The axis-specific acceleration defined in MD 32300: MAX_AX_ACCEL represents the
reference for one axis (100%). For the spindle the reference (100%) corresponds to the active
spindle mode and gear stage (n = 1 ...5)
MD 35200: GEAR_STEP_SPEEDCTRL_ACCEL[n] in control mode or
MD 35210: GEAR_STEP_POSCTRL_ACCEL[n] in positioning mode.
Example: N10 ACC[X]=80 ; 80% acceleration for the X axis
Activation
The limitation is effective in all interpolation types of the AUTOMATIC and MDA modes. The
limitation is not active in JOG mode and during reference point approach.
The value assignment ACC [...] = 100 deactivates the correction (100% of the MD values) as
well as RESET and program end.
The programmed value is also active with dry run feedrate.
Error states
The acceleration limitation is not active in error states that cause a rapid stop with an open
position-controlled loop (because the axis is stopped according to a braking ramp of the set
speed).
Note: A programmable value greater than 100% can only be carried out if the drives have
appropriate reserves - otherwise an alarm will sound.

4-80 6FC5397-1CP10-1BA0
Acceleration (B2)
4.5 Data descriptions (MD, SD)
32300 MAX_AX_ACCEL
MD number Axis acceleration
Default setting: 1.0 m/s2, Minimum input limit: 0.0 Maximum input limit: ***
2.77 rev/s2
Changes effective after NEW_CONF Protection level: 2/7 Unit: m/s2, rev/s2
Meaning: The acceleration defines a change in velocity of the axis against time. Different axes do not have
to have the same acceleration. The lowest acceleration value of all the axes involved in interpola-
tion is taken into account.
In the case of rotary axes, the entered value corresponds to the angular acceleration.
The machine manufacturer should determine for which continuous deceleration and acceleration
the machine is suitable. This value is entered in the machine data.
The acceleration value is active for every type of acceleration and delay operation.
MD irrelevant for ... ... Error states that lead to rapid stop.
32420 JOG_AND_POS_JERK_ENABLE
MD number Enabling axis-specific jerk limitation
Meaning: Enables the axisspecific jerk limitation function for JOG and REF modes and positioning axis
operation.
Related to .... MD 32430: JOG_AND_POS_MAX_JERK (axis-specific jerk)
32430 JOG_AND_POS_MAX_JERK
MD number Axis-specific jerk
Default setting: 1,000.00 m/s3, Minimum input limit: 10–9 Maximum input limit: ***
2,777.77 rev/s3
Changes effective after RESET Protection level: 2/2 Unit: m/s3, rev/s3
Meaning: The jerk limitation restricts changes to axis acceleration in JOG mode.
MD irrelevant for ... ... Path interpolation and error states that lead to rapid stop.
Related to .... MD 32420: JOG_AND_POS_JERK_ENABLE (enabling of axis-specific jerk limitation)
32431 ** MAX_AX_JERK
MD number Maximum axis-specific jerk during path motion (in AUTO, MDA mode)
Default setting: 1,000.00 m/s3, Minimum input limit: 10–9 Maximum input limit: ***
2,777.77 rev/s3
Meaning: This maximum axis-specific jerk is active for path motion.
Path motion is possible in AUTO, MDA modes.
Related to .... MD 32432: PATH_TRANS_JERK_LIM acts at block transition
We recommend setting equal values for both MD.

6FC5397-1CP10-1BA0 4-81
Acceleration (B2)
4.6 Data fields, lists

rence
32300 MAX_AX_ACCEL Axis acceleration
32420 JOG_AND_POS_JERK_ENABLE Enabling axis-specific jerk limitation
32430 JOG_AND_POS_MAX_JERK Axis-specific jerk
32431 MAX_AX_JERK Maximum axis-specific jerk during path movement
32432 PATH_TRANS_JERK_LIM Maximum axis-specific jerk during path movement at the B1
block transition

4-82 6FC5397-1CP10-1BA0
Spindle (S1) 5
5.1 Brief description
Spindle functions
Depending on the machine type the following functions are possible for a spindle controlled by
the NC:
S Input of a direction of rotation for the spindle (M3, M4)
S Input of a spindle speed (S)
S Spindle stop, without orientation (M5)
S Spindle positioning (SPOS=)
(position-controlled spindle required)
S Gear change (M40 to M45)
S Thread cutting/tapping (G33, G34, G35, G331, G332, G63)
S Revolutional feedrate (G95)
S Constant cutting rate (G96)
S Programmable spindle speed limits (G25, G26, LIMS=)
S Position encoder assembly on the spindle or on the spindle motor
S Spindle monitoring for min. and max. speed.
S Dwell time in spindle revolutions (G4 S)
An “enabled” spindle can be used instead of a controlled spindle. However, a spindle speed
(S) is then not entered via the program but, for example, manually (gearbox) at the machine.
This does not permit programming of speed limits. The following is possible via the program:
S Input of a direction of rotation for the spindle (M3, M4)
S Spindle stop, without orientation (M5)
S Tapping (G63)
If the spindle has a position measuring device, the following functions are also available:
S Thread cutting/tapping (G33, G34, G35)
S Revolutional feedrate (G95)
If the spindle is enabled, the setpoint output for the spindle via
MD 30130: CTRLOUT_TYPE =0 must be suppressed.

6FC5397-1CP10-1BA0 5-83
Spindle (S1)
5.2 Spindle modes
Definition of the spindle

A machine axis is declared a spindle by setting the following machine data:
MD 30300: IS_ROT_AX, MD 30310: ROT_IS_MODULO, MD 30320: DISPLAY_IS_MODULO
and MD 35000: SPIND_ASSIGN_TO_MACHAX The IS “Spindle/no axis” reports the spindle
mode (V390x 0000.0).
5.2 Spindle modes
Spindle modes
The spindle can have the following modes:
S Control mode see Section 5.2.1
S Oscillation mode See Section 5.2.2
S Positioning mode See Section 5.2.3
S Axis mode See Section 5.2.4
S Rigid tapping see also “Feedrate” (thread interpolation) and
Switching between spindle modes
Oscillation mode
Change Gearbox
gearbox changed
SPOS
Control mode SPCOF Positioning mode
M3, M4, M5
M4145 SPOS
SPCOF
M3, M4, M5 M70
M4145
Axis name
Axis mode
G332 G331
Rigid tapping
Fig. 5-1 Switching between spindle modes
S Open-loop control mode –––> Oscillation mode

The spindle changes to oscillation mode if a new gear stage has been specified using the
automatic gear stage selection (M40) in conjunction with a new S value or by M41 to M45.
The spindle only changes to oscillation mode if the new gear stage is not equal to the cur-
rent actual gear stage.

5-84 6FC5397-1CP10-1BA0
Spindle (S1)
5.2 Spindle modes
S Oscillation mode –––> control mode

When the new gear is engaged, the IS “Oscillation mode” (V390x 2002.6) is reset and the
spindle is switched to control mode with the IS “Gear changed” (V380x 2000.3). The last
programmed spindle speed (S value) is reactivated.
S Control mode –––> positioning mode
To stop the spindle from rotating (M3 or M4) with orientation or to reorient it from standstill
(M5), SPOS is used to switch to positioning mode.
S Positioning mode –––> control mode
M3, M4 or M5 are used to change to the control mode if the orientation of the spindle is to
be terminated. The last programmed spindle speed (S value) is reactivated.
S Positioning mode –––> oscillation mode
If the orientation of the spindle is to be terminated, M41 to M45 can be used to change to
oscillation mode. When the gear change is complete, the last programmed spindle speed
(S value) and M5 (control mode) are reactivated.
S Positioning mode –––> rigid trapping
Rigid tapping (thread interpolation) is activated via G331/G332. SPOS must first be used
to set the spindle to position-controlled operation.
5.2.1 Spindle control mode
When open-loop control mode?

The spindle is in control mode with the following functions:
S Constant spindle speed S, M3/M4/M5 and G94, G95, G97, G33, G63
S Constant cutting rate G96 S, M3/M4/M5
Requirements
A spindle position actual value sensor is absolutely essential for M2/M4/M5 in conjunction
with revolution feedrate (G95, F in mm/rev or inch/rev), constant cutting rate (G96, G97),
thread cutting (G33).
Independent spindle reset

MD 35040: SPIND_ACTIVE_AFTER_RESET defines the response of the spindle after reset
or program end (M2, M30):
S If MD value=0, the spindle is immediately braked to rest at the valid acceleration. The last
programmed spindle speed and direction of rotation are deleted.
S If MD value =1 (independent spindle reset), the last programmed spindle speed (S func-
tion) and the last programmed spindle rotation (M3, M4, M5) is retained.
If the constant cutting rate (G96) is active before reset or program end, the current spindle
speed (referring to 100% spindle override) is transferred internally as the last programmed
spindle speed.

6FC5397-1CP10-1BA0 5-85
Spindle (S1)
5.2 Spindle modes
Note
The spindle can always be stopped with the IS “Delete distance-to-go/Spindle Reset”.
CAUTION: The program continues at G94! With G95 the axes stop due to the missing feedra-
tes as does the program run if G1, G2, ... is active.
5.2.2 Spindle oscillation mode
Starting oscillation mode

This oscillation movement makes it easy to engage a new gear stage. In principle, the new
gear stage can also be engaged without oscillation
The spindle is in oscillation mode if a new gear stage was defined using the automatic gear
stage selection (M40) or M41 to M45 (IS “Change gear” (V390x 2000.3) is enabled). The
IS “Change gear” is only enabled when a new gear stage is selected that is not the same as
the current actual gear stage. The spindle oscillation is started with the IS “Oscillation speed”
(V380x 202.5).
If the IS “Oscillation speed” is enabled without defining a new gear stage, the spindle does not
change to oscillation mode.
Oscillation is started with the IS “Oscillation speed”. The setting of the IS “Oscillation via PLC”
(V380x 2002.4) distinguishes between:
S Oscillation via NCK
S Oscillation via PLC
Oscillation time
The oscillation time for oscillation mode can be defined in a machine date for each direction of
rotation:
S Oscillation time in M3 direction (referred to as t1 in the following) in
MD 35440: SPIND_OSCILL_TIME_CW
S Oscillation time in M4 direction (referred to as t2 in the following) in
MD 35450: SPIND_OSCILL_TIME_CCW.
Oscillation via NCK

Phase 1: With the IS “Oscillation speed” (V380x 2002.5) , the spindle motor accelerates to the
speed specified in MD 35400: SPIND_OSCILL_DES_VELO (oscillation speed). The start di-
rection is defined by MD 35430: SPIND_OSCILL_START_DIR.
Phase 2: When time t1 (t2) expires, the spindle motor accelerates in the opposite direction to
the speed defined in MD 35400: SPIND_OSCILL_DES_VELO (oscillation speed). Time t2 (t1)
starts.
Phase 3: When time t2 (t1) expires, the spindle motor accelerates in the opposite direction
(same direction as phase 1), etc.

5-86 6FC5397-1CP10-1BA0
Spindle (S1)
5.2 Spindle modes
Oscillation via PLC

With the IS “Oscillation speed” (V380x 2002.5), the spindle motor accelerates to the speed
specified in MD 35400: SPIND_OSCILL_DES_VELO (oscillation speed). The direction of ro-
tation is determined by IS “Set counterclockwise” or IS “Set clockwise” (V380x 2002.7 or .6).
The oscillation movement and the two times t1 and t2 (for clockwise and counterclockwise
rotation) must be simulated on the PLC.
End of oscillation mode

The IS “Gear changed” (V380x 2000.3) tells the NC that the new gear stage (IS “Actual gear
stage” (V380x 2000.0 to .2)) applies and oscillation mode is quitted. The actual gear stage
should correspond to the set gear stage. Oscillation mode is also ended if the IS “oscillation
speed” (V380x 2002.5) is still set. The last programmed spindle speed (S function) and
spindle rotation (M3, M4 or M5) are active again.
After termination of oscillation mode the spindle returns to control mode.
All gear-specific limit values (min./max. speed etc.) correspond to the set values of the actual
gear stage and are de-activated when the spindle stops.
Block change
If the spindle has been changed over to oscillation mode (IS “Change gear” (V390x 2000.3))
is set), part program processing is stopped. A new block is not executed. If oscillation mode is
quitted using the IS “Gear switched” (V380x 2000.3), the execution of the part program is con-
tinued. A new block is executed.
Speed
(rev/min)
IS: Gear changed
Block change occurs here
Time (s)
Fig. 5-2 Block change following oscillation mode

6FC5397-1CP10-1BA0 5-87
Spindle (S1)
5.2 Spindle modes

S The acceleration is defined in MD 35410: SPIND_OSCILL_ACCEL (acceleration in oscilla-
tion mode).
S If the IS “oscillation speed” (V380x 2002.5) is reset, the oscillation stops. However, the
spindle remains in oscillation mode.
S The IS “Gear changed” should always be used for terminating gear stage change.
S The IS “Reset” (V3000 0000.7) does not terminate oscillation mode.
S If an indirect measuring system is used, the spindle becomes de-synchronized. The
spindle is re-synchronized the next time the zero mark is crossed.
Reset during gear stage change

The spindle cannot be stopped via IS “Reset” (V3000 0000.7) or IS “NC Stop”
(V3200 0007.3) if the spindle is in oscillation mode for gear stage change and the IS “Gear
changed” (V380x 2000.3) is not yet available.
In these cases the alarm 10640 “Stop not possible during gear change” is displayed if reset is
selected.
After changing the gear stages, the reset request is performed and the alarm is cancelled,
provided that it is still applied at the interface.
Note
Option for aborting: Set IS “Delete distance-to-go/Spindle Reset” (V380x 0002.2).
5.2.3 Spindle positioning mode
When is positioning mode used?

The spindle positioning mode stops the spindle at the defined position and activates the posi-
tion control, which remains active until it is de-activated. With SPOS =..... program function
the spindle is in positioning mode (see also Section 5.5 “Programming”).
Block change
Programming with SPOS:
block change is carried out when all functions programmed in the block have reached their
end criterion (e.g. axis traverse completed, all auxiliary functions acknowledged by PLC) and
the spindle has reached its position (IS “Exact stop fine” for spindle (V390x 0000.7)).
Prerequisite
A spindle position actual value encoder is absolutely essential.

5-88 6FC5397-1CP10-1BA0
Spindle (S1)
5.2 Spindle modes
Positioning from rotation
Phase 1 to 5:
Speed
(rev/min) 1 MD 36300: ENC_FREQ_LIMIT
( Encoder limit frequency)
MD 36302: ENC_FREQ_LIMIT_LOW
(encoder limit frequency re-synchronization,
2 % value of MD 36300)
3
MD 35300: SPIND_POSCTRL_VELO
(position control activation speed)
1a 4
4a
5 Time (s)
SPOS=...
Fig. 5-3 Positioning from rotation at different speeds
Sequence
Phase 1: Spindle rotates at a lower speed than the encoder limit frequency. The spindle is
synchronized. It is set to control mode. Process continues with Phase 2.
Phase 1a: Spindle rotates at a lower speed than the position control activation speed. The
spindle is synchronized. It is set to control mode. The process can be continued via 4a.
Phase 1b (not marked): Spindle rotates at a speed higher than the encoder limit frequency.
The spindle is not synchronized initially, but is then synchronized when the rotation speed falls
below the speed defined by the encoder frequency in MD 36302: ENC_FREQ_LIMIT_LOW
(% value of MD 36300). Process continues with Phase 2.
Phase 2: When the command SPOS comes into effect, the spindle starts decelerating at the
acceleration rate defined in MD 35200: GEAR_STEP_SPEEDCTRL_ACCEL until it reaches
the position control activation speed.
Phase 3: When the position control activation speed defined in MD 35300:
SPIND_POSCTRL_VELO is reached:
S the position control is activated,
S the distance-to-go (to target position) is calculated, (easier from Phase 1a)
S the acceleration is switched to MD 35210: GEAR_STEP_POSCTRL_ACCEL (acceleration
in position control mode) (always active below the position control activation speed)
Phase 4: The spindle brakes from the calculated “braking point” with
MD 35210: GEAR_STEP_POSCTRL_ACCEL down to the destination point.
Phase 5: The position control remains active and stops the spindle in the programmed posi-
tion. The IS “Position reached with exact stop fine/coarse” (V390x 0000.7) and “... coarse”
(V390x 0000.6) are set if the distance between the spindle actual position and the program-
med position (spindle setpoint position) is less than the settings for the exact stop fine and
coarse limits (defined in MD 36010: STOP_LIMIT_FINE and MD 36000: STOP_LIMIT_
COARSE).

6FC5397-1CP10-1BA0 5-89
Spindle (S1)
5.2 Spindle modes
Positioning from standstill, spindle not synchronized

The spindle is not synchronized after the control has been activated. The first movement of
the spindle must be positioning (SPOS=...).
Speed
(rev/min) Phase 1 to 4:
MD 35300:
SPIND_POSCTRL_VELO 2
3
1
Position reached Time (s)

Start with: SPOS=...
Brake application point
synchronized at Zero mark
Fig. 5-4 Positioning with stopped, not synchronized spindle
Sequence
Phase 1: Programming SPOS accelerates the spindle by the acceleration in MD 35210:
GEAR_STEP_ POSCTRL_ACCEL (acceleration in position control mode) until the maximum
speed entered in MD 35300: SPIND_POSCTRL_VELO (acceleration position control mode) is
reached.
The direction of rotation is defined by MD 35350: SPIND_POSITIONING_ DIR (direction of
rotation during positioning from standstill), if no input results from SPOS programming ( ACN,
ACP, IC). The spindle is synchronized with the next zero mark of the position actual-value en-
coder.
Phase 2: When the spindle is synchronized, the position control is activated. The spindle rota-
tes at the speed defined in MD 35300: SPIND_POSCTRL_VELO until it detects the braking
start point, at which point it can approach the programmed spindle position accurately with the
defined acceleration.
Phase 3: At the brake application point the spindle is braked down to standstill with the acce-
leration set in MD 35210: GEAR_STEP_ POSCTRL_ACCEL (acceleration in position control
mode).
Phase 4: The spindle has reached the target point and is stationary. The position control is
active and stops the spindle in the programmed position. The IS “Position reached with exact
stop fine” (V390x 0000.7) and “... coarse” (V390x 0000.6) are set if the distance between the
spindle actual position and the programmed position (spindle setpoint position) is less than
the settings for the exact stop fine and coarse limits (MD 36010: STOP_LIMIT_FINE and
MD 36000: STOP_LIMIT_COARSE).

5-90 6FC5397-1CP10-1BA0
Spindle (S1)
5.2 Spindle modes
Positioning from standstill, spindle is synchronized

The spindle has already been turned by one spindle revolution with M3 and M4 and was then
brought to a standstill with M5.
Speed
(rev/min) Phase 1 to 4:
MD 35300:
SPIND_POSCTRL_VELO 2
3a 3
1
4a 4
Position reached Time (s)

Start with: SPOS=...
Brake application point
Fig. 5-5 Positioning with stopped, synchronized spindle
Sequence
The spindle travels to the programmed destination point optimally in terms of time. Depending
on the appropriate secondary conditions, the operational sequences in phases 1 – 2 – 3 – 4 or
1 – 3a – 4a are executed.
Phase 1: SPOS will switch the spindle to position control mode. The acceleration from
MD 35210: GEAR_STEP_POSCTRL_ACCEL (acceleration in position control mode) is acti-
vated. The direction of rotation is determined by the relevant distance-to-go (type of path set-
ting with SPOS). The axis velocity defined in MD 35300: SPIND_POSCTRL_VELO (position
control activation speed) is not exceeded.
The travel path to the destination point is calculated. If the end point can be accessed imme-
diately from this phase, Phase 3a, 4a continues instead of Phase 2.
Phase 2: The spindle has been accelerated to the rotation speed defined in MD 35300:
SPIND_POSCTRL_VELO (position control activation speed). The braking start point calcula-
tion detects at what instant the spindle can accurately approach the programmed spindle posi-
tion (SPOS=...) at the acceleration in MD 35210: GEAR_STEP_POSCTRL_ACCEL.
Phase 3 and Phase 4: The sequence for “Deceleration” and “Position reached” is the same
as for non-synchronized spindles.
Spindle reset
The positioning process can be aborted with the IS “Delete distancetogo/spindle reset”
(V380x 0002.2). However, the spindle remains in positioning mode.
Notes
S In positioning mode the spindle speed override switch continues to be valid.
S Positioning (SPOS) is canceled with “Reset” or “NC stop”.

6FC5397-1CP10-1BA0 5-91
Spindle (S1)
5.2 Spindle modes
5.2.4 Spindle mode axis mode
When axis mode?

For certain machining tasks on lathes: For face machining with TRANSMIT or peripheral sur-
face machining with TRACYL the spindle must be operated as rotary axis.
Outside of TRANSMIT, TRACYL you can perform normal rotary axis functions. In this case it
is programmed under the address of the rotary axis, e.g. C.
Requirements
The spindle can be switched from spindle mode to axis mode (rotary axis) if the same motor is
used for spindle and axis operation.
A position actual value encoder is a mandatory requirement for axis mode.
Activation/de-activation
The spindle must be set to position-controlled operation (positioning mode):
N10 SPOS=0
If the spindle is synchronized this can also be performed via M70 or SPCON.
Traversal as rotary axis is now possible in the program:
N20 G94 G1 C124.4 F4000 ; feedrate F: 4000 degrees/min
The closed-loop speed controlled spindle mode is re-selected by programming
N100 M3 ; or M4, M5, M41 ... M45 or SPCOF

Feedrate override is valid.
RESET does not terminate axis mode by default.
The IS “Spindle/no axis” (V390x 0000.0) is set to zero.
Axis mode can be activated on any gear stage.
The gear stage cannot be changed when the axis mode is active.
In axis mode, the MD of the set of parameters with index zero are effective in order to carry
out adaptation in this mode.

5-92 6FC5397-1CP10-1BA0
Spindle (S1)
5.3 Synchronizing
5.3 Synchronizing
Why synchronize?
The control must be synchronized with the position measurement system on the spindle so
that the control knows the exact 0 degree position when switched on. Only a synchronized
spindle can cut threads or position.
For axes, this process is referred to as referencing (see Chapter “Reference Point Approach”).
Installation locations of the position measurement systems

S directly on the motor in combination with a BERO proximity switch on the spindle (zero
mark encoder)
S directly on the spindle
S above the measuring gearbox plus BERO switch on the spindle.
Synchronization possibilities
When the spindle is switched on, the spindle can be synchronized as follows:
S The spindle is started with a spindle speed (S function) and a spindle rotation (M3 or M4),
and synchronized with the next zero mark of the position measurement system or with the
BERO signal. The 0 degree position is shifted by MD 34080: REFP_MOVE_DIST +
MD 34090: REFP_MOVE_DIST_CORR – MD 34100: REFP_SET_POS.
Note: Only use MD 34080: REFP_MOVE_DIST for shifting the 0 degree position. Monito-
ring with MD 34060: REFP_MAX_MARKER_DIST should be set to two spindle revolutions
(720 degrees).
S Programming SPOS=... from various states (refer to Section 5.2.3 “Spindle positioning
mode”)
S In JOG mode the spindle is started in speed control mode with the direction keys and
synchronizes with the next zero mark of the position measurement system or the BERO
signal.
Value acceptance
When synchronizing the spindle the associated reference point from MD 34100:
REFP_SET_POS[0] (default value =0) is transferred as well as a possible shift of the refe-
rence point. These shifts (machine data) act irrespective of the connected measurement
system and are described in the Chapter: “Reference point approach”:
Maximum encoder frequency exceeded

If the spindle speed reaches a speed (large S value programmed), which exceeds the maxi-
mum encoder limit frequency MD 36300:ENC_FREQ_LIMIT (the maximum mechanical speed
limit of the encoder must not be exceeded), the synchronization is lost. The spindle continues
to rotate, but with reduced functionality.

6FC5397-1CP10-1BA0 5-93
Spindle (S1)
5.4 Gear stage change
If a speed is then reached that is below the encoder limit frequency MD 36302:
ENC_FREQ_LIMIT_LOW (% value of MD 36300), the spindle automatically synchronizes with
the next zero mark signal. You can change this by programming a lower S value, changing the
spindle speed override switch, etc.
Re-synchronizing
In the following case, however, the position measuring system must be re-synchronized:
the position measurement encoder is on the motor, a BERO (distance sensor for synchroniza-
tion signals) is mounted to the spindle and the gear stage is changed. The synchronization is
triggered internally when the spindle is rotating in the new gear stage.
No. of gear stages

5 gear stages can be configured for the spindle. If the spindle motor installed on the spindle
has a direct transmission ratio (1:1) or a fixed transmission ratio,
MD 35010: GEAR_STEP_CHANGE_ENABLE (gear stage change is possible ) must be set
to zero.
Motor
speed With automatic gear stage selection, this speed
(rev/min) range is not utilized
in gear stage 1.
Max. motor
speed
Gear
step 1
Gear
step 2
0
Spindle speed (rev/min)
n n2max
1max
g1min g1max
g2min g2max
Definable by MD:
D n1max ...max. spindle speed of the 1st gearbox stage
D g1min ... min. spindle speed of the 1st gearbox stage
for autom. gearbox stage selection
D g1max ...max. spindle speed of the 1st gearbox stage
D n2max ...max. spindle speed of the 2nd gearbox stage
D g2min ... min. spindle speed of the 2nd gearbox stage
D g2max ...max. spindle speed of the 2nd gearbox stage
Fig. 5-6 Gear stage change with gear stage selection

5-94 6FC5397-1CP10-1BA0
Spindle (S1)
Defining a gear stage

A gear stage can be defined as follows:
S Permanent definition in the part program (M41 to M45)
S Automatic definition by the programmed spindle speed (M40)
In the case of M40, the spindle must be in control mode for automatic gear stage selection
with an S value. The gear stage change is otherwise rejected and alarm 22000 “Gear change
not possible” is output.
M41 to M45
The gear stage can be permanently defined in the part program with M41 to M45. If a gear
stage is defined by M41 to M45, which is different than the current (actual) gear stage, the
IS “Change gear” (V390x 2000.3) and the IS “Set gear stage A” to “...C” (V390x 2000.0 to .2)
are set. The programmed spindle speed (S) then refers to this permanently defined gear
stage. If a spindle speed exceeding the maximum speed of the permanently defined gear
stage is programmed, the speed is limited to the maximum speed of this gear stage and the
IS “Programmed speed too high” (V390x 2001.1) is enabled. If a speed is programmed lower
than the minimum speed of this gear stage, the speed is raised to this speed. The IS “Setpoint
speed increased” (V390x 2001.2) is then enabled.
M40
M40 in the part program causes the gear stage to be selected automatically by the control.
The control checks which gear stage is possible for the programmed spindle speed
(S function). If the suggested gear stage is not equal to the current (actual) gear stage, the
IS “Change gear” (V390x 2000.3) and the IS “Set gear stage A to C” (V390x 2000.0 to .2) are
enabled.
The automatic gear stage selection function initially compares the programmed spindle speed
with the minimum and maximum speed of the current gear stage. If the comparison is positive,
a new gear stage is not defined. If the comparison is negative, the comparison is performed
on each of the gear stages (starting with gear stage 1) until the result is positive. If the compa-
rison in the 5th gear stage is also not positive, no gear stage change is triggered. If necessary
the speed is limited to the maximum speed of the current gear stage or increased to the mini-
mum speed of the current gear stage, and the IS “Setpoint speed limited” (V390x 2001.1) or
IS “Setpoint speed increased” (V390x 2001.2) is enabled.

6FC5397-1CP10-1BA0 5-95
Spindle (S1)
Speed
(rev/min)
step 1
step 2
Gear
Gear
MD35100:SPIND_VELO_LIMIT: Maximum spindle speed
ÉÉÉ
MD35130:GEAR_STEP_MAX_VELO_LIMIT[2]: Maximum speed of gear stage 2
MD35110:GEAR_STEP_MAX_VELO[2]: Maximum speed for gear change 2
ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉ
ÉÉÉ
MD35130:GEAR_STEP_MAX_VELO_LIMIT[1]: Maximum speed of gear stage 1
Maximum speed for gear change 1
ÉÉÉ
ÉÉ
MD35110:GEAR_STEP_MAX_VELO[1]:
ÉÉÉ
ÉÉ
MD35120:GEAR_STEP_MIN_VELO[2]: Minimum speed for gear change 2
ÉÉ
MD35120:GEAR_STEP_MIN_VELO_LIMIT[2]:
MD35120:GEAR_STEP_MIN_VELO[1]:
Minimum speed for gear stage 2
Minimum speed for gear change 1
ÉÉ
ÉÉ
MD35120:GEAR_STEP_MIN_VELO_LIMIT[1]: Minimum speed for gear stage 1
Fig. 5-7 Example for speed ranges for automatic gear stage selection (M40)
Gear stage change

A new gear stage can only be selected when the spindle is stationary.
The spindle is stopped internally in the control if a gear stage change is requested.
If the new gear stage is preselected by M40 and spindle speed or M41 to M45, the IS “Set
gear stage A” to “...C” (V390x 2000.0 to .2) and the IS “Change gear” (V390x 2000.4) are set.
At the point when the IS “Oscillation speed” (V380x 2002.5) is enabled, the spindle decelera-
tes to a stop with the acceleration of oscillation or with the acceleration for speed control/posi-
tion control.
The next block in the part program after the gear stage change via M40 and S value or M41
to M45 is not performed (same effect as if the IS “Read-in disable” (V3200 0006.1) were
enabled).
When stationary the spindle (IS “Axis/spindle stationary” (V390x 0001.4) can be activated with
the IS “Oscillation speed” (V380x.2002.5) (see Section 5.2.2). When the new gear stage is
engaged, the PLC user sets the IS “Actual gear stage” (V380x 2000.0 to .2) and IS “Gear
changed” (V380x 2000.3). The gear stage change is considered completed (spindle mode
“Oscillation mode” is de-selected) and the spindle is switched to the parameter block of the
new actual gear stage. The spindle accelerates at the new gear stage to the spindle speed
last programmed (if M3 or M4 are active). The IS “Change gear” (V390x 2000.3) is reset by
the NCK, which causes the PLC user to reset the IS “Gear changed” (V380x 2000.3). The
next block in the part program can be executed.

5-96 6FC5397-1CP10-1BA0
Spindle (S1)
Typical time sequence for the gear stage change:
IS: Control mode
IS: Oscillation mode
Programmed S value 1000 1300
IS: Gear changed
IS: Change gear stage
IS: Set gear stage 1 2
IS: Spindle in setpoint range
IS: Spindle is stationary
IS: Actual gear stage 1 2

1
IS: Oscillation speed
1st gear stage engaged
2nd gear stage engaged
Internal feed disable

T1 T2
Spindle speed
IS: Spindle stop 0

t1 t2 t3 t4
t1 When S1300 is programmed, the NCK detects a new gear stage
(2nd gear stage), enables IS: change gear and inhibits execution of the next
part program block.
t2 The spindle is stationary and oscillation starts (oscillation via NCK).
The IS interface signal must be enabled by the time t2.
t3 The new gear stage is engaged. The PLC user transmits the new (actual)
Gear stage to the NCK and sets the IS: gear changed.
t4 At this point, the NCK cancels the change gear interface signal, terminates
oscillation, enables execution of the next part program block and accelerates
the spindle to the new S value (S1300).
Fig. 5-8 Gear stage change with stationary spindle

6FC5397-1CP10-1BA0 5-97
Spindle (S1)
Parameter set
One parameter set each is provided for each of the 5 gear stages. The appropriate parameter
set is activated using the IS “Actual gear stage A” to “...C” (V380x 2000.0 to .2).
It is assigned as follows:
Parameter set, PLC interface, coding for IS Data of the data set Content,
index “Actual gear stage A, machine data
n to “...C” for
CBA
0 – Data for axis mode
Kv factor,
factor
1 000 Data for 1st gear stage monitoring,
001 min/max speed
p of
2 010 Data for 2nd gear stage rotation,
t ti
acceleration
3 011 Data for 3rd gear stage
4 100 Data for 4th gear stage
The machine data included in a parameter set are marked specifically in Section 3.7.2 “Ma-
chine Data”. The following machine data are added per gear stage for each parameter set
index n (n=1 –> 1st gear stage of the spindle, etc.):
MD 35110: GEAR_STEP_MAX_VELO[n]
MD 35120: GEAR_STEP_MIN_VELO[n]
MD 35130: GEAR_STEP_MAX_VELO_LIMIT[n]
MD 35140: GEAR_STEP_MIN_VELO_LIMIT[n]
MD 35200: GEAR_STEP_SPEEDCTRL_ACCEL[n]
MD 35210: GEAR_STEP_POSCTRL_ACCEL[n]
MD 35310: SPIND_POSIT_DELAY_TIME[n]

5-98 6FC5397-1CP10-1BA0
Spindle (S1)
5.5 Programming
5.5 Programming
Functions
The spindle can be set for the following functions:
S G95 Revolutional feedrate
S G96 S... LIMS=... Constant cutting rate in m/min, upper speed limit
S Cancel G97 G96 and freeze last spindle speed
S G33,G331,G332 Thread cutting, tapping
S G4 S ... Dwell time in spindle revolutions
M3 Direction of spindle rotation clockwise

M4 Direction of spindle rotation anticlockwise
M5 Spindle stop, without orientation
S... Spindle speed in rev/min, e.g.: S300
SPOS=... Spindle positioning, e.g.: SPOS=270 –> at position 270 degrees.
The block change does not occur until the spindle is in position.
SPOS=DC(Pos) The direction of movement is retained from the movement during
positioning and the position is approached. When positioning from
standstill the position is approached via the shortest route.
SPOS=ACN(Pos) The position is always approached in negative direction of movement.
If necessary the direction of movement is inverted prior to positioning.
SPOS=ACP(Pos) The position is always approached in positive direction of movement.
If necessary the direction of movement is inverted prior to positioning.
SPOS=IC(Pos) The travel path is specified. The direction of travel is obtained from
the sign in front of the travel path. If the spindle is in motion,
the direction of travel is inverted as necessary to allow traversing in the
programmed direction.
M40 Automatic gear stage selection for the spindle
M41 to M45 Select gear stage 1 to 5 for the spindle
SPCON Position control on
SPCOF Position control off
M70 Position control on
G25 S... Programmable lower spindle speed limiting, e.g. G25 S8
G26 S... Programmable upper spindle speed limiting, e.g. G26 S1200
LIMS=... Programmable maximum spindle speed for G96

6FC5397-1CP10-1BA0 5-99
Spindle (S1)
5.6 Spindle monitoring
Speed ranges
The spindle monitoring functions and the currently active functions (G94, G95, G96, G33,
G331, G332, etc.) define the admissible speed ranges of the spindle.
Speed
Maximum encoder limit frequency
Maximum spindle speed
Maximum spindle speed for current gear stage
Programmable spindle speed limit G26
Programmable spindle speed limit LIMS
Programmable spindle speed limit G25
Minimum spindle speed for current gear stage
Spindle is stationary
0
Speed range of current gear stage
IS: Referenced/synchronized
at a constant cutting rate
limited by G25 and G26
Speed range of spindle
IS: Axis/spindle stops
or spindle chuck
Fig. 5-9 Ranges of spindle monitoring functions/speeds
5.6.1 Axis/spindle stops
Only when the axis/spindle is stationary, i.e. the actual spindle speed is below a value defined
in MD 36060: STANDSTILL_VELO_TOL is the IS “Axis/spindle stationary” (V390x 0001.4)
enabled. Functions such as tool change, open machine door, path feed can be activated using
the PLC user program.
Monitoring is effective in the 3 spindle modes.

5-100 6FC5397-1CP10-1BA0
Spindle (S1)
5.6.2 Spindle in setpoint range
The “Spindle in setpoint range” monitor checks whether the programmed spindle speed has
been reached, whether the spindle is stationary (IS “Axis/spindle stationary”) or whether it is
still in the acceleration phase.
In the spindle “control mode”, the speed setpoint (programmed speed with spindle override
including the active limits) is compared with the actual speed. If the deviation of the actual
speed from the speed setpoint is greater than the spindle speed tolerance
(MD 35150: SPIND_DES_VELO_TOL (spindle speed tolerance),
S the IS “Spindle in setpoint range” (V390x 2001.5) is set to zero.
S the next machining block is not enabled if the
MD 35500: SPIND_ON_SPEED_AT_IPO_START is enabled.
5.6.3 Maximum spindle speed
Maximum spindle speed

A maximum speed is defined for “maximum spindle speed” spindle monitoring, which the
spindle may not exceed. The maximum spindle speed is preset in
MD 35100: SPIND_VELO_LIMIT. The control limits an excessive spindle speed setpoint to
this value. If the actual spindle speed continues to exceed the maximum limit despite allo-
wance for the spindle speed tolerance (MD 35150: SPIND_DES_VELO_TOL, (spindle speed
tolerance) there is still a fault in the drive and the IS “Speed limit exceeded” (V390x 2002.0) is
set. Furthermore the alarm 22100 is output and all axes and the spindle are decelerated.
Speed limiting the PLC

The spindle speed can be limited to a specific value via the PLC. This value is stored in
MD 35160: SPIND_EXTERN_VELO_UNIT and is activated via the IS “Velocity/spindle speed
limits” (V380x 0003.6).
5.6.4 Minimum/maximum speed for gear stage
Maximum speed
Machine data 35130: GEAR_STEP_MAX_VELO_LIMIT defines the maximum speed for the
gear stage. In the gear stage engaged, this set speed can never be exceeded. When the pro-
grammed spindle speed is limited, the IS “Set speed limited” (V390x 2001.1) is enabled.

6FC5397-1CP10-1BA0 5-101
Spindle (S1)
Minimum speed
Machine data 35140: GEAR_STEP_MIN_VELO_LIMIT contains the minimum gear stage
speed. It is not possible that the speed falls below this (set) speed if an S value is program-
med, which is too small. Then, the IS “Setpoint speed increased” (V390x 2001.2) is enabled.
The minimum gear stage speed is operative only in spindle open loop control mode; the
speed of the gear stage can only fall below the minimum limit through:
S Spindle override 0%
S M5
S S0
S IS “Spindle stop”
S Remove IS “Servo enable”
S IS “Reset”
S IS “Spindle reset”
S IS “Oscillation speed”
S IS “NCSTOP axes and spindle”
S IS “Axis/spindle disable”
5.6.5 Max. encoder limit frequency
Warning
! The maximum encoder frequency limit of the actual spindle position encoder is monitored by
the control (the limit can be exceeded). It is the responsibility of the machine tool
manufacturer to ensure that the configuration of the spindle motor, gearbox, measuring
gearbox, encoder and machine data prevents the maximum speed of the actual spindle
position encoder from being exceeded.
Maximum encoder limit frequency exceeded

If the spindle reaches a speed in the open loop control mode (a high S value has been pro-
grammed) which is higher than the max. encoder limit frequency (the max. speed of the
encoder may not be exceeded), the synchronization is lost. However, the spindle continues to
rotate.
If one of the thread cutting (G33), revolutional feedrate (G95), constant cutting rate (G96, G97)
functions is programmed, the spindle speed is reduced automatically so far until the active
measuring system is working reliably again.
In the “positioning mode” spindle mode and with position-controlled threads (G331, G332) the
max. encoder limit frequency is not exceeded.
If the encoder limit frequency is exceeded, the IS “Referenced/synchronized” V390x 0000.4)
is reset for the measurement system and IS “Encoder limit frequency 1 exceeded” (V390x
0000.2) is enabled.

5-102 6FC5397-1CP10-1BA0
Spindle (S1)
If the max. encoder limit frequency is exceeded and a speed is again reached which is below
the encoder frequency in MD 36302: ENC_FREQ_LIMIT_LOW (% value of MD36300:
ENC_FREQ_LIMIT) the spindle synchronizes automatically with the next zero mark or the
next BERO signal.
5.6.6 Target point monitoring
Functions
During positioning (the spindle is in “positioning mode”), the system monitors the distance
from the spindle (with reference to the actual position) to the programmed spindle set position
(target point).
Two limit values can be defined in MD 36000: STOP_LIMIT_COARSE (exact stop coarse
limit) and MD 36010: STOP_LIMIT_FINE (exact stop fine limit) as the incremental path
(starting at the spindle set position). Regardless of the two limit values, the positioning of the
spindle is always as accurate as the connected spindle measurement encoder, the backlash,
the transmission ratio, etc.
Reference
Speed
position
Position
Exact stop limit fine
Exact stop limit coarse
Fig. 5-10 Exact stop zones of a spindle for positioning
IS: Position reached with exact stop ...

When the limits in MD 36000: STOP_LIMIT_COARSE and
MD 36010: STOP_LIMIT_FINE (exact stop limit coarse and fine) are reached, the IS “Position
reached with exact stop coarse” (V390x 0000.6) and the IS “Position reached with exact stop
fine” (V390x 0000.7) are output to the PLC.
Block change with SPOS

If the spindle is being positioned with SPOS, the block change will be dependent on the end
point monitoring with the IS “Position reached with exact stop fine”. All other functions pro-
grammed in the block must have achieved their end criterion (e.g. axes ready, all auxiliary
functions acknowledged by the PLC).

6FC5397-1CP10-1BA0 5-103
Spindle (S1)
5.7 2nd spindle/master spindle
5.7 2nd spindle/master spindle
Note
This function is not available for the 802D sl.
Functions
The TRANSMIT and TRACYL kinematic transformation functions are available for milling on
lathes. These functions require a second spindle for the driven milling tool. The main spindle
is operated as a rotary axis with these functions.
Master spindle
A series of functions is connected to the master spindle, which are only possible for this
spindle:
S G95 ; Revolutional feedrate
S G96, G97 ; Constant cutting speed
S LIMS ; Upper speed limit for G96, G97
S G33, G34, G35, G331, G332 ; Thread cutting, thread interpolation
S M3, M4, M5, S... ; Simple instructions for direction of rotation,
stop and speed
The master spindle is defined via configuration (machine data). Generally it is the main
spindle (spindle 1). A different spindle can be defined as master spindle in the program:
S SETMS(n) ; Spindle n (= 1 or 2) is master spindle as of now.
Resetting is also possible via:
S SETMS ; Configured master spindle is now
master spindle again or
S SETMS(1) ; Spindle 1 is now master spindle again.
The definition of the master spindle changed in the program is only valid until program end/
program abort. After this the configured master spindle is active again.

5-104 6FC5397-1CP10-1BA0
Spindle (S1)
5.8 Analog spindle
Programming via spindle number

Some spindle functions can also be selected via the spindle number:
S S1=..., S2=... ; Spindle speed for spindle 1 or 2
S M1=3, M1=4, M1=5 ; Instructions for direction of rotation, stop for spindle 1
S M2=3, M2=4, M2=5 ; Instructions for direction of rotation, stop for spindle 2
S M1=40, ..., M1=45 ; Gear stages for spindle 1 (if available)
S M2=40, ..., M2=45 ; Gear stages for spindle 2 (if available)
S SPOS[ n ] ; Positioning spindle n
S SPI (n) ; Converts spindle number n to axis identifier,
e.g. “SP1” or “CC”
; n must be a valid spindle number (1 or 2)
; The functions of spindle identifiers SPI(n) and Sn are
identical.
S P_S[ n ] ; Last programmed speed of spindle n
S $AA_S[ n ] ; Actual speed of spindle n
S $P_SDIR[ n ] ; Last-programmed direction of rotation of spindle n
S $AC_SDIR[ n ] ; Current direction of rotation of spindle n
Two spindles available

The following can be interrogated in the program via system variable:
S $P_NUM_SPINDLES ; Number of configured spindles (in the channel)
S $P_MSNUM ; Number of programmed master spindle
S $AC_MSNUM ; Number of active master spindle
5.8 Analog spindle
Functions
With the “Analog spindle” function, the MCPA option module is used as the setpoint output,
and a free DRIVE-QLiQ encoder interface is used as the actual-value input.
To be able to transfer the spindle encoder actual value, an SDB must be reloaded, which re-
flects this hardware configuration (see Toolbox 802D_SL\V0100xx00\Special\DMSforSpindle).
For the analog spindle without encoder, the machine data 30240 must be set to zero. If an
analog spindle without encoder is used, no reloadable SDB is required.

6FC5397-1CP10-1BA0 5-105
Spindle (S1)
20090 SPIND_DEF_MASTER_SPIND
MD number
Data type: BYTE Applies from SW: 2.0
Meaning: Definition of the master spindle default setting (in channel).
The spindle number is entered.
A series of functions are linked to the master spindle which are not possible for a different spindle.
Note:
The SETMS(n) language command can be used to declare the spindle number n as master
spindle.
The spindle defined as master spindle in this MD is declared as master spindle again with SETMS.
At the program end or program termination, the spindle defined in this MD is also declared as ma-
ster spindle.
References
30134 IS_UNIPOLAR_OUTPUT[0]
MD number Setpoint output is unipolar
Meaning:
Application example(s) Unipolar output driver (for unipolar, analog drive actuator) –> analog spindle:
For unipolar setting, only positive speed setpoints are supplied to the drive; the sign of the speed
setpoint value is output separately in its own digital control signal.
0: Bipolar output ("10V) with pos./neg. speed setpoint value, controller enable (regular case)
1: Unipolar output 0...+10V with enabling and direction signal
(controller enable, neg. direction of travel)
2: unipolar output 0...+10V with linkage of enabling and direction of travel signals
(controller enabling pos. direction of travel, controller enabling neg. direction of travel)
References The assignment of the signal connectors at the SIMODRIVE 611UE drive are described in:
“Operation Instructions 802D”
35000 SPIND_ASSIGN_TO_MACHAX
MD number Assignment of spindle to machine axis
Meaning: The machine axis that is to be used as a spindle is entered into this MD.
Application example(s) An example of a milling machine with 3 machine axes (X1, Y1, Z1) and a spindle:
SPIND_ASSIGN_TO_MACHAX[AX1] = 0 –––> X1
SPIND_ASSIGN_TO_MACHAX[AX2] = 0 –––> Y1
SPIND_ASSIGN_TO_MACHAX[AX3] = 0 –––> Z1
SPIND_ASSIGN_TO_MACHAX[AX4] = 1 –––> Spindle no. 1 is the 4th machine axis
Related to .... MD 30300: IS_ROT_AX (rotary axis/spindle)
MD 30310: ROT_IS_MODULO (modulo conversion for rotary axis/spindle)
This machine data must be set; otherwise, the alarms 4210 “Rotary axis declaration missing” and
4215 “Modulo axis declaration missing” are output.
MD 30320: DISPLAY_IS_MODULO (display modulo 360 degrees)
IS “Spindle/no axis” (V390x 0000.0)

5-106 6FC5397-1CP10-1BA0
Spindle (S1)
35010 GEAR_STEP_CHANGE_ENABLE
MD number Gear stage change possible
Meaning: If the spindle motor is mounted to the spindle directly (1:1) or with a non-adjustable gear ratio,
GEAR_STEP_CHANGE_ENABLE (gear stage change is possible) must be set to zero. It is not
possible to change the gear stage with M40 to M45.
If the spindle motor is mounted to the spindle via a gearbox with changeable gear stages,
GEAR_STEP_CHANGE_ENABLE must be set to one. The gear can have up to 5 gear stages,
which can be selected using M40, M41 to M45.
Related to .... MD 35110: GEAR_STEP_MAX_VELO (maximum speed for gear stage change)
MD 35120: GEAR_STEP_MIN_VELO (min. speed for gear stage change)
GEAR_STEP_MAX_VELO and GEAR_STEP_MIN_VELO must cover the whole speed range.
35040 SPIND_ACTIVE_AFTER_RESET
MD number Spindle active after reset
Meaning: This MD defines the response of the spindle after reset (V3200 0000.7) and program end (M2,
M30). It is only active in the spindle control mode.
0:
Open-loop control mode: – Spindle stops; applies to M2/M30 and Reset
– Program is aborted; applies to M2/M30
Oscillation mode: – Alarm 10640 “Stop not possible during gear change”
– Oscillation is not aborted
– Axes are stopped
– Program is aborted after gear change or spindle reset,
the alarm is cleared.
Positioning mode: – Is stopped
Axis mode: – Is stopped
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
1:
Open-loop control mode: – Spindle does not stop
– Program is aborted
Oscillation mode: – Alarm 10640 “Stop not possible during gear change”
– Oscillation is not aborted
– Axes are stopped
– Program is aborted after gear change, the
alarm is cleared and the spindle continues rotating at the
programmed M and S value.
Positioning mode: – Is stopped
Axis mode: – Is stopped
The IS “Spindle reset” (V380x 0002.2) is always active irrespective of

SPIND_ACTIVE_AFTER_RESET.
MD irrelevant for ... ... All spindle modes except control mode
Related to .... IS “Reset” (V3200 0000.7)
IS “Spindle reset” (V380x 0002.2)

6FC5397-1CP10-1BA0 5-107
Spindle (S1)
35100 SPIND_VELO_LIMIT
MD number Maximum spindle speed
Default setting: 10 000.0 Minimum input limit: 0.0 Maximum input limit: ***
Changes effective after POWER ON Protection level: 2/7 Unit: rpm
Meaning: The maximum spindle speed is defined in this MD, which the spindle (the spindle chuck with the
workpiece or the tool) must not exceed. The NCK limits an excessive spindle speed setpoint to
this value. If the maximum spindle actual speed is exceeded, even allowing for the spindle speed
tolerance (MD 35150: SPIND_DES_VELO_TOL, there is a fault in the drive and the IS “Speed limit
exceeded” (V390x 2001.0) is enabled. Alarm 22050 “Maximum speed reached” is also output and
all of the axes and spindles on the channel brought to a standstill (provided the encoder is still
functioning correctly).
Related to .... MD 35150: SPIND_DES_VELO_TOL (spindle speed tolerance)
IS “Speed limit exceeded” (V390x 2001.0)
Alarm 22050 “Maximum speed reached”
35110 GEAR_STEP_MAX_VELO[n]
MD number Maximum speed for gear stage change [gear stage number]: 0...5
(index 0 is irrelevant for spindles)
Default setting: Minimum input limit: 0.0 Maximum input limit: ***
(500, 500, 1000, 2000, 4000, 8000)
Changes effective after NEW_CONF Protection level: 2/2 Unit: rpm
Meaning: The maximum speed of the gear stage for automatic gear stage change (M40 ) is defined. The
gear stages must be defined by this MD and MD 35120: GEAR_STEP_MIN_VELO_LIMIT in a
way that avoids gaps in the programmable spindle speed range between the gear stages.
Incorrect
GEAR_STEP_MAX_VELO [gear stage1] =1000
GEAR_STEP_MIN_VELO [gear stage2] =1200
Correct
GEAR_STEP_MAX_VELO [gear stage1] =1000
GEAR_STEP_MIN_VELO [gear stage2] =950
Related to .... MD 35010: GEAR_STEP_CHANGE_ENABLE (gear stage change is possible)
MD 35120: GEAR_STEP_MIN_VELO (minimum speed for gear stage change)
MD 35140: GEAR_STEP_MIN_VELO_LIMIT (minimum speed for gear stage)
MD 35130: GEAR_STEP_MAX_VELO_LIMIT (maximum speed for gear stage)
35120 GEAR_STEP_MIN_VELO[n]
MD number Minimum speed for gear stage change [gear stage number]: 0...5
(50, 50, 400, 800, 1500, 3000)
Meaning: The minimum speed of the gear stage for automatic gear stage change (M40 ) is defined.
Refer to MD 35120: GEAR_STEP_MAX_VELO for more information.
Related to .... MD 35110: GEAR_STEP_MAX_VELO (maximum speed for gear stage change)
MD 35010: GEAR_STEP_CHANGE_ENABLE (gear stage change is possible)
MD 35140: GEAR_STEP_MIN_VELO_LIMIT (minimum speed for gear stage)
MD 35130: GEAR_STEP_MAX_VELO_LIMIT (maximum speed for gear stage)

5-108 6FC5397-1CP10-1BA0
Spindle (S1)
35130 GEAR_STEP_MAX_VELO_LIMIT[n]
MD number Maximum speed for gear stage [gear stage number]; 0 ...5
(500, 500, 1000, 2000, 4000, 8000)
Meaning: The maximum speed for the gear stage is defined. This speed can never be exceeded in the cur-
rently engaged gear stage.
Special cases, errors, ... ... S When the closed-loop position control is enabled, then a limit is set to 90% of the value
(control margin)
S If an S value is programmed, that lies above the max. speed of the gearbox stage selected,
the reference (setpoint) speed is limited to the maximum speed of the gear stage (for gear
stage selection – M41 to M45); further, the IS: “Programmed speed too high” is set.
S If an S value is programmed that lies above the max. speed for gear stage change, a new gear
stage is specified (for automatic gear stage selection M40).
S If an S value is programmed, that lies above the max. speed of the highest gear stage, the
speed is limited to the max. speed of the gear stage (for automatic gear stage selection –
M40).
S If an S value is programmed for which there is no matching gear stage, then a gear stage
change is not made.
MD 35110: GEAR_STEP_MAX_VELO (maximum speed for gear stage change)
MD 35140: GEAR_STEP_MIN_VELO_LIMIT (min. speed of gear stage)
IS “Setpoint speed limited” (V390x 2001.1)
35140 GEAR_STEP_MIN_VELO_LIMIT[n]
MD number Minimum speed for gear stage [gear stage number]: 0...5
(5, 5, 10, 20, 40, 80)
Meaning: The minimum gear stage speed is entered. The speed cannot drop to below this value, even if a
very low S value is programmed.
The speed can only drop to below this minimum value as a result of the signals/commands/states
listed in “Minimum/maximum speed for the gear stage”.
MD irrelevant for ... ... Spindle mode, oscillation mode, positioning mode
Application example(s) Smooth operation of the motor is not assured below the minimum speed.
MD 35110: GEAR_STEP_MAX_VELO (maximum speed for gear stage change)
MD 35130: GEAR_STEP_MAX_VELO_LIMIT (max. speed of gear stage)
IS “Setpoint speed increased” (V390x 2001.2)

6FC5397-1CP10-1BA0 5-109
Spindle (S1)
35150 SPIND_DES_VELO_TOL
MD number Spindle speed tolerance
0.1 = 10%
Meaning: Factor for spindle speed for determining the tolerance in the spindle mode control mode.
The set speed (programmed speed x spindle override, allowing for limits) is compared with the
actual speed.
S If the actual speed deviates from the setpoint speed by more than the
SPIND_DES_VELO_TOL, IS “spindle in setpoint range” (V390x 2001.5) is set to zero.
S If the actual speed exceeds the maximum spindle speed (MD 35100: SPIND_VELO_LIMIT) by
more than SPIND_DES_VELO_TOL, the IS “Speed limit exceeded” is set (V390x 2001.0) and
alarm 22050 “Maximum speed reached” is output. All axes and spindles of the channel are
brought to a standstill.
MD irrelevant for ... ... Spindle mode oscillation mode
Spindle mode positioning mode
Fig. 5-11
Speed
(rev/min) SPIND_DES_VELO_TOL
Upper
Spindle speed tolerance
Set speed
Lower
Spindle speed tolerance
Actual speed
Time (t)
Related to .... MD 35500: SPIND_ON_SPEED_AT_IPO_START
MD 35100: SPIND_VELO_LIMIT (maximum spindle speed)
IS “Spindle in setpoint range” (V390x 2001.5)
IS “Speed limit exceeded” (V390x 2001.0)
35160 SPIND_EXTERN_VELO_LIMIT
MD number Spindle speed limiting via PLC
Changes effective after NEW_CONF Protection level: 2/2 Unit: rev/min
Meaning: A limit for the spindle speed is entered, which is taken into account when the IS “Velocity/speed
limiting” (V380x 0003.6) is enabled. The control limits an excessive spindle speed setpoint to this
value.

5-110 6FC5397-1CP10-1BA0
Spindle (S1)
35200 GEAR_STEP_SPEEDCTRL_ACCEL[n]
MD number Acceleration in control mode [gear stage number]: 0...5
(30, 30, 25, 20, 15, 10)
Changes effective after NEW_CONF Protection level: 2/2 Unit: rev./s2
Meaning: If the spindle is in control mode, the acceleration in GEAR_STEP_SPEEDCTRL_ACCEL is
entered.
Special cases, errors, ... ... Thus the acceleration in speed control mode can be set so that the current limit is reached.
Related to .... MD 35210: GEAR_STEP_POSCTRL_ACCEL (acceleration in position control mode)
35210 GEAR_STEP_POSCTRL_ACCEL[n]
MD number Acceleration in position control mode [gear stage number]: 0...5
(30, 30, 25, 20, 15, 10)
Meaning: The acceleration in position control mode must be set so that the current limit is not reached.
Related to .... MD 35200: GEAR_STEP_SPEEDCTRL_ACCEL
35300 SPIND_POSCTRL_VELO
MD number Position control activation speed
Meaning: When positioning a spindle that is not in position control mode, the position control is not activated
until the spindle has reached the speed defined in MD: SPIND_POSCTRL_VELO.
Please refer to Chapter “Spindle mode, positioning mode” for a description of spindle operating
characteristics under various supplementary conditions (positioning from movement, positioning
from standstill).
Related to .... MD 35350: SPIND_POSITIONING_DIR (direction of rotation during positioning from standstill), if
no synchronization is available.
35310 SPIND_POSIT_DELAY_TIME[n]
MD number Positioning delay time [gear stage number]: 0...5
(0.0, 0.05, 0.1, 0.2, 0.4, 0.8)
Meaning: After reaching the positioning end (exact stop fine) the time delay for block search is activated at
output of a collected positioning block (SPOS).
Related to ....
35350 SPIND_POSITIONING_DIR
MD number Positioning direction of rotation for a nonsynchronized spindle
Meaning: When SPOS is programmed, the spindle is switched to position control mode and accelerates with
the acceleration defined in MD 35210: GEAR_STEP_POSCTRL_ACCEL (acceleration in position
control mode) if the spindle is not synchronized. The direction of rotation is defined by MD 35350:
SPIND_POSITIONING_DIR (direction of rotation for positioning from standstill).
SPIND_POSITIONING_DIR = 3 –––> Clockwise rotation
SPIND_POSITIONING_DIR = 4 –––> Counterclockwise rotation
Related to .... MD 35300: SPIND_POSCTRL_VELO (position control activation speed)

6FC5397-1CP10-1BA0 5-111
Spindle (S1)
35400 SPIND_OSCILL_DES_VELO
MD number Oscillation speed
Meaning: During oscillation, the IS “Oscillation speed” (V380x 2002.5) is used to select a motor speed for
the spindle motor. The motor speed is defined here. This motor speed is independent of the current
gear stage. In the AUTOMATIC and MDA displays, the oscillation speed is displayed in the
“spindle setpoint” window until the gear is changed.
MD irrelevant for ... ... All spindle modes except oscillation mode
Application example(s) The to and fro oscillation of the spindle motor makes it easier to engage a new gear
stage because the teeth on the gear wheels can mesh with each other better.
Special cases, errors, ... ... The oscillation acceleration defined in
MD 35410: SPIND_OSCILL_ACCEL is valid for the oscillation speed defined in this MD.
Related to .... MD 35410: SPIND_OSCILL_ACCEL (acceleration in oscillation mode)
MD 35130: GEAR_STEP_MAX_VELO_LIMIT[n] (maximum speed of the gear stage)
IS “Oscillation via PLC” (V380x 2002.4)
IS “Oscillation speed” (V380x 2002.5)
35410 SPIND_OSCILL_ACCEL
MD number Oscillation acceleration
Meaning: The acceleration specified is only effective for the output of the oscillation speed
(MD 35400: SPIND_OSCILL_DES_VELO) to the spindle motor. The oscillation speed is selected
using the IS “Oscillation speed”.
Related to .... MD 35400: SPIND_OSCILL_DES_VELO (Oscillation speed)
35430 SPIND_OSCILL_START_DIR
MD number Oscillation start direction
Meaning: With the IS “Oscillation speed”, the spindle motor accelerates to the speed specified in MD 35400:
SPIND_OSCILL_DES_VELO. The start direction is defined by this MD:
SPIND_OSCILL_START_DIR if IS “Oscillation via PLC” is not enabled.
0: start direction corresponding with the last direction of rotation
1: start direction in opposite direction of last rotation
2: start direction in opposite direction of last rotation
3: start direction is M3
4: start direction is M4
Related to .... MD 35400: SPIND_OSCILL_DES_VELO (Oscillation speed)

5-112 6FC5397-1CP10-1BA0
Spindle (S1)
35440 SPIND_OSCILL_TIME_CW
MD number Oscillation time for M3 direction
(0 means the time of one interpolation
cycle)
Meaning: The oscillation time defined here acts in direction of M3.
MD irrelevant for ... ... S All spindle modes except oscillation mode
S Oscillation set by the PLC (IS “Oscillation via PLC” (V380x 2002.4))
Related to .... MD 35450: SPIND_OSCILL_TIME_CCW (Oscillation time for M4 direction)
IS ”Oscillation via PLC” (V380x 2002.4)
35450 SPIND_OSCILL_TIME_CCW
MD number Oscillation time for M4 direction
(0 means the time of one interpolation
cycle)
Meaning: The oscillation time defined here acts in direction of M4.
MD irrelevant for ... ... S All spindle modes except oscillation mode
S Oscillation set by the PLC (IS “Oscillation via PLC” (V380x 2002.4))
Fig. 5-12
Speed
(rev/min)
Oscillation time
Time (t)
Related to .... MD 35440: SPIND_OSCILL_TIME_CW (Oscillation time for M3 direction)

35500 SPIND_ON_SPEED_AT_IPO_START
MD number Feed enable with spindle in setpoint range
Meaning: 0: path interpolation is not influenced
1: path interpolation is only enabled when the spindle has reached the specified speed (tole-
rance band is set via MD35150).
2: function as for value =1=1, in addition:
Traveling path axes are also stopped before machining. e.g. continuous path mode (G64) and
change of rapid traverse (G60) in one machining block (G1, G2,...). The path is stopped at the last
G0 block and does not start moving until the spindle has reached the speed setpoint range.
Application example(s) see MD 35510
IS “Spindle in setpoint range” (V390x 2001.5)

6FC5397-1CP10-1BA0 5-113
Spindle (S1)
35510 SPIND_STOPPED_AT_IPO_START
MD number Feed enable with stationary spindle
Meaning: When a spindle is stopped (M5), the path feed is disabled if this MD is enabled and the spindle is
in control mode.
When the spindle has come to a standstill (IS, “axis/spindle stationary” (V390x 0001.4) is enabled),
the path feed is enabled.
Application example(s) The MD 35500 and this MD 35510 can be used to control the path feed according to the actual
spindle speed (control mode):
S If the spindle is in the acceleration phase (programmed setpoint not yet reached), the path
feed is disabled.
S If the actual speed deviates from the speed setpoint by less than the spindle speed tolerance
(MD 35150: SPIND_DES_VELO_TOL), the path feed is enabled.
S If the spindle is in the braking phase, the path feed is disabled.
S If the spindle is signaled to be stationary (IS: “Axis/spindle stationary “ V390x 0001.4)
path feed is enabled.
S In blocks with G0, the modification is not active.
Related to .... MD 35500: SPIND_ON_SPEED_AT_IPO_START (feed enable for spindle in setpoint range)
36720 DRIFT_VALUE
MD number Basic drift value for analog spindles only
Default setting: 0.0 Minimum input limit: –5.0 Maximum input limit: 5.0
Meaning: The basic drift value entered here is always applied as an additional speed setpoint value for the
analog spindle.
MD irrelevant for ... ...
5.9.3 Spindle-specific setting data
43210 SPIND_MIN_VELO_G25
SD number Programmable lower spindle speed limiting for G25
Changes effective immediately Protection level: 7/7 Unit: rpm
Meaning: The spindle speed is not permitted to drop below the minimum spindle speed limit entered in this
SD. The NCK limits an excessively small spindle speed setpoint to this value.
The spindle speed can only fall below the minimum limit through:
S Spindle override 0%
S M5
S S0
S IS “Spindle stop” (V380x 0004.3)
S IS “Controller enable” (V380x 0002.1)
S IS “Reset” (V3000 0000.7)
S IS “Spindle reset” (V380x 0002.2)
S IS “Oscillation speed” (V380x 2002.5)
SD irrelevant for ... ... All spindle modes except control mode
Special cases, errors, ... ... The value in SD: SPIND_MIN_VELO_G25 can be altered by means of:
S G25 S .... in the part program
S Operator commands from the HMI
The value in SD: SPIND_MIN_VELO_G25 is retained after reset or power off.
Related to .... SD 43220: SPIND_MAX_VELO_G26
SD 43230: SPIND_MAX_VELO_LIMS (progr. Spindle speed limiting with G96)

5-114 6FC5397-1CP10-1BA0
Spindle (S1)
43220 SPIND_MAX_VELO_G26
SD number Programmable upper spindle speed limiting for G26
Meaning: The spindle speed is not permitted to exceed the maximum spindle speed limit entered in this SD.
The NCK limits an excessive spindle speed setpoint to this value.
SD irrelevant for ... ... All spindle modes except control mode.
Special cases, errors, ... ... The value in this SD: SPIND_MIN_VELO_G26 can be altered by means of:
S G26 S .... in the part program
The value in SD: SPIND_MIN_VELO_G26 is retained after reset or power off.
Related to .... SD 43210: SPIND_MIN_VELO_G25 (progr. spindle speed limiting G25)
SD 43230: SPIND_MAX_VELO_LIMS (progr. Spindle speed limiting with G96)
43230 SPIND_MAX_VELO_LIMS
SD number progr. Spindle speed limiting G96
Meaning: At constant cutting rate (G96 and G97) an extra limits entered in SPIND_MAX_VELO_LIMS is
operative in addition to the continually applied limits. Furthermore this can be described with
SPIND_MAX_VELO_LIMS in the part program with LIMS=... .
SD irrelevant for ... ... All spindle functions except for G96 and G97 (constant cutting speed)
Application example(s) When cutting-off and for very small diameters of the workpiece to be machined, the spindle with
the workpiece (lathe) accelerates higher and higher at a constant cutting rate (G96), theoretically
reaching an infinitely high set speed in the position of the traverse axis X=0. In cases such as this,
the spindle rotates up to its maximum spindle speed in the current gear stage (limited, where appli-
cable, by G26). If, especially for G96, the spindle is to be limited to a lower speed, then this can be
defined using LIMS=.... SPIND_MAX_VELO_LIMS.
Special cases, errors, ... ... The value SD 43210: SPIND_MIN_VELO_LIMS can be changed using:
S LIMS S .... in the part program
The value SD SPIND_MIN_VELO_LIMS is retained after reset or power down.
Related to .... SD 43220: SPIND_MAX_VELO_G26 (maximum spindle speed)
SD 43210: SPIND_MIN_VELO_G25 (minimum spindle speed)

6FC5397-1CP10-1BA0 5-115
Spindle (S1)
Transferred M/S functions, axis-specific
VD370x 0000 M function for spindle

Interface signal Signals from axis/spindle (NCK –> PLC), axisspecific
Edge evaluation: Signal(s) updated: cyclic Signal(s) valid from SW:
Generally the M functions are output in V2500... channel-specific. In the V25001... range these
only remain valid for one PLC cycle; in V25003... until a new function is output.
In this IS “M function for spindle” selected spindle M functions are available to the PLC as a
current integer value.
S M3 - > value: 3
S M4 - > value: 4
S M5 - > value: 5
Related to .... IS “S function for spindle” (VD370x 0004), axis-specific
IS auxiliary function transfer from NC channel (V2500...)
VD370x 0004 S function for spindle

Interface signal Signals from axis/spindle (NCK –> PLC), axisspecific
Generally the S function is transferred to the PLC channel-specific in VD2500 4000 as a floating
point value.
In this IS “S function for spindle” the floating point value is output to the PLC on an axis-specific
basis:
S S.... as the spindle speed in rpm (programmed value)
S S.... as the constant cutting speed in m/min or ft/min for G96
The following S functions are not output here:

S S.... as the programmed Spindle speed limiting G25
S S.... as the programmed Spindle speed limiting G26
S S.... as the dwell time in spindle revolutions
Related to .... IS “M function for the spindle” (VD370x 0000), axis-specific
IS “Transferred S function” (VD2500 4000), channel-specific

5-116 6FC5397-1CP10-1BA0
Spindle (S1)
V380x 0002.2 Spindle reset/Delete distance-to-go

Interface signal Signal(s) to axis/spindle (PLC –> NCK)
Edge evaluation: yes Signal(s) updated: cyclic Signal(s) valid from SW:
Edge change 0 –––> 1 Independent of MD 35040: SPIND_ACTIVE_AFTER_RESET, spindle reset has the following effects
for the different spindle modes:
Open-loop control mode: – Spindle stops
– Program continues running
– Spindle continues to run with subsequent M and S program
commands
Oscillation mode: – Oscillation is aborted

– Axes continue to run
– Program is continued with current gear stage
– With a subsequent M value and a higher S value,
IS “Setpoint speed limited” (V390x 2001.1) is set if necessary.
Positioning mode: – is stopped
Signal state 0 or signal No effect
Related to .... MD 35040: SPIND_ACTIVE_AFTER_RESET (own spindle reset)
IS “Reset” (V300 00000.7)
IS “Delete distance-to-go” (V380x 0002.2) is another name for the same signal; however, it applies
to each axis.
V380x 2000.3 Gear changed

Signal state 1 or signal When the new gear is engaged, the IS “Actual gear stage A to C” and “Gear changed” are enabled
transition 0 –––> 1 by the PLC user. This informs the NCK that the correct gear stage has been successfully enga-
ged. The gear stage change is complete (spindle oscillation mode is deselected), the spindle acce-
lerates in the new gear stage to the last programmed spindle speed and the next block in the part
program can be executed. The IS “Change gear” is reset by the NCK, which causes the PLC user
to reset the IS “Gear changed”.
Signal irrelevant for ... ... All spindle modes except oscillation mode
Special cases, errors, ... ... If the PLC user reports back to the NCK with a different actual gear stage than issued by the NCK
as the set gear stage, the gear change is still treated as having been successfully completed and
the actual gear stage A to C is activated.
Related to .... IS “Actual gear stage A” to C” (V380x 2000.0 to .2)
IS “Set gear stage A” to “...C” (V390x 2000.0 to .2)
IS “Change gear” (V390x 2000.3)

6FC5397-1CP10-1BA0 5-117
Spindle (S1)
V380x 2000.0 to .2 Actual gear stage A to C

Signal state 1 When the new gear is engaged, the IS “Actual gear stage A to C” and “Gear changed” are enabled
(leveloperated) by the PLC user. This informs the NCK that the correct gear stage has been successfully enga-
ged. The gear change is complete (spindle oscillation mode is deselected), the spindle accelerates
in the new gear stage to the last programmed spindle speed and the next block in the part program
can be executed.
The actual gear stage is specified in coded format (ABC values).
A parameter set is used for each of the 5 gear stages and is assigned as follows:
Parameter VDI Data in data set contents

set no. code
CBA
0 – Data for axis mode Servo gain factor
Monitoring functions
1 000 Data for 1st gear stage M40 speed
001 Min/max speed
Acceleration
2 010 Data for 2nd gear stage etc.
3 011 Data for 3rd gear stage
110
111
Special cases, errors, ... ... If the PLC user reports back to the NCK with a different actual gear stage than issued by the NCK
as the set gear stage, the gear change is still treated as having been successfully completed and
the actual gear stage A to C is activated.
Related to .... IS “Set gear stage A” to “...C” (V390x 2000.0 to .2)
IS “Gear changed” (V380x 2000.3)
Parameter sets (MD) for gear stages.
V380x 2001.4 Re-synchronize spindle during positioning 1

Signal state 1 The spindle must be re-synchronized during positioning.
Signal irrelevant for ... ... All spindle modes except for positioning mode
Application example(s) The spindle has an indirect measuring system and slipping may occur between the motor and the
clamp. If the signal=1 when the positioning process is started, the old reference is deleted and the
zero mark searched for again before the end position is approached.
Related to .... “Referenced/synchronizing 1” interface signal (V390x 0000.4)
V380x 2001.6 Invert M3/M4

Signal state 1 or signal The direction of rotation of the spindle motor changes with the following functions:
transition 0 –––> 1 S M3
S M4
S M5
S SPOS from movement; not active for SPOS from standstill.
Application example(s) The machine has a selector switch for a vertical and horizontal spindle. The mechanical design
incorporates one gear wheel more on the horizontal spindle than on the vertical spindle. The
direction of rotation must therefore be changed on the vertical spindle if the spindle is always to
rotate clockwise with M3.

5-118 6FC5397-1CP10-1BA0
Spindle (S1)
V380x 2002.7 / .6 Setpoint direction of rotation, counter-clockwise/setpoint direction of rotation, clockwise

Edge evaluation: yes Signal(s) updated: cyclic Signal(s) valid from SW: 1.1
Signal state 1 or signal When the IS “Oscillation via PLC” is enabled, the two IS “Direction of rotation setpoint counter-
transition 0 –––> 1 clockwise” and “Direction of rotation setpoint clockwise” can be used to set the direction of rotation
for the oscillation speed. The times for the oscillation movement of the spindle motor are defined
by enabling the IS “Direction of rotation setpoint counterclockwise and clockwise” for a correspon-
ding length of time.
Application example(s) See IS “Oscillation via PLC”
Special cases, errors, ... ... S If both of the IS are enabled simultaneously, no oscillation speed is output.
S If no IS are set, then an oscillation speed is not output.
Related to .... IS “Oscillation via the PLC” (V380x 2002.4)
V380x 2002.5 Oscillation speed

Edge evaluation: no Signal(s) updated: cyclic Signal(s) valid from SW: 1.1
Signal state 1 or signal If the gear stage must be changed (IS “Change gear” (V390x 2000.3) is enabled), the spindle
transition 0 –––> 1 changes to oscillation mode.
The spindle decelerates to a standstill with different acceleration levels, according to the point
when the IS “Oscillation speed” (V380x 2002.5) was enabled:
1. The IS “Oscillation speed” is enabled before the IS “Change gear” is enabled by the NCK. The
spindle is brought to a standstill with the
acceleration during oscillation (MD: SPIND_OSCILL_ACCEL). Once the spindle is stationary,
oscillation is immediately initiated.
2. The IS “Oscillation speed” is enabled after the IS “Change gear” is enabled by the NCK and
when the spindle is stationary. The position controller is disabled. The spindle decelerates with
the deceleration rate in speed controlled mode. After the IS “Oscillation speed”is set, the
spindle starts to oscillate with the oscillation acceleration (MD:SPIND_OSCILL_ACCEL).
If the IS “Oscillation via PLC” (V380x 2002.4) is not enabled, the IS “Oscillation speed” triggers
automatic oscillation on the NCK. The two times for the directions of rotation are entered in MD: in
SPIND_OSCILL_TIME_CW (oscillation time for M3 direction) and SPIND_OSCILL_TIME_CCW
(oscillation time for M4 direction).
If the IS “Oscillation via PLC” is enabled, the IS “Oscillation speed” effects output of a speed only
in conjunction with the IS “Direction of rotation setpoint counter-clockwise and clockwise”. The
oscillation, i.e. the continuous change of the direction of rotation, is performed by the PLC user
with the IS “Direction of rotation setpoint counter-clockwise and clockwise” (oscillation via PLC).
Signal state 0 or signal The spindle does not oscillate.
Application example(s) The oscillation speed is used to facilitate the engagement of a new gear stage.
Related to .... IS “Oscillation via the PLC” (V380x 2002.4)
IS “Set direction of rotation counterclockwise” (V380x 2002.7)
IS “Set direction of rotation clockwise” (V380x 2002.6)

6FC5397-1CP10-1BA0 5-119
Spindle (S1)
V380x 2002.4 Oscillation via PLC

Signal state 1 or signal If the IS “Oscillation via PLC” is enabled, the IS “Oscillation speed” effects output of a speed only
transition 0 –––> 1 in conjunction with the IS “Direction of rotation setpoint counter-clockwise and clockwise”. The
oscillation, i.e. the continuous change of the direction of rotation, is performed by the PLC user
with the IS “Direction of rotation setpoint counter-clockwise and clockwise” (oscillation via PLC).
Signal state 0 or signal If the IS “Oscillation via PLC” is not enabled, the IS “Oscillation speed” triggers automatic oscilla-
transition 1 –––> 0 tion on the NCK. The two times for the directions of rotation are entered in MD 35440:
SPIND_OSCILL_TIME_CW (oscillation time for M3 direction) SPIND_OSCILL_TIME_CW (oscilla-
tion time for M3 direction) and MD 35450: SPIND_OSCILL_TIME_CCW (oscillation time for M4
direction).
Application example(s) If the new gear stage cannot be engaged in spite of several attempts by the NCK, the system can
be switched to oscillation via PLC. Both of the times can then be altered by the PLC user. This
assures a reliable change of the gear stage, even with unfavorable gear wheel positions.
Related to .... MD 35440: SPIND_OSCILL_TIME_CW (oscillation time for direction M3)
MD 35450: SPIND_OSCILL_TIME_CCW (oscillation time for M4 direction)
IS “Set direction of rotation counterclockwise” (V380x 2002.7)
IS “Set direction of rotation clockwise” (V380x 2002.6)
V390x 0000.0 Spindle/no axis

Interface signal Signal(s) from axis/spindle (NCK –> PLC)
Signal state 1 or signal The machine axis is operated as a spindle in the following spindle modes:
transition 0 –––> 1 S Control mode
S Oscillation mode
S Positioning mode
S Thread drilling (tapping) without comensating chuck (rigid tapping)
The IS to axis (V380x 1000 to V380x 1003) and from axis (V390x 1000 to V390x 1003) are invalid.
The IS to spindle (V380x 2000 to V380x 2003) and from spindle (V380x 2000 to V380x 2003) are
valid.
Signal state 0 or signal The machine axis is operated as an axis
transition 1 –––> 0 The IS to axis (V380x 1000 to V380x 1003) and from axis (V390x 1000 to V390x 1003) are valid.
The IS to spindle (V380x 2000 to V380x 2003) and from spindle (V380x 2000 to V380x 2003) are
invalid.
Application examples If a spindle is sometimes also used as a rotary axis on a machine tool (turning machine with
spindle/Caxis or milling machine with spindle/rotary axis for rigid tapping), the “Spindle/no axis”
signal can be used to determine whether the machine axis is in axis mode or spindle mode.

5-120 6FC5397-1CP10-1BA0
Spindle (S1)
V390x 2000.3 Change gear stage

Signal state 1 or signal A gear stage can be defined as follows:
transition 0 –––> 1 S Permanent definition in the part program (M41 to M45)
M41 to M45:
S The gear stage can be permanently defined in the part program with M41 to M45. If the M41 to
M45 commands select a gear stage which is not the same as the current (actual) gear stage,
the IS “Change gear” and the IS “Set gear stage A to C” are enabled.
M40:
S M40 in the part program causes the gear stage to be selected automatically by the control.
The control checks which gear stage is possible for the programmed spindle speed (S func-
tion). If a gear stage is identified that is not equal to the current (actual) gear stage, the
“Change gear” and “Set gear stage A” to “...C” interface signals are set.
S While the signal = 1, the text “Wait for gear stage change” is displayed
in the channel operating message”.
Special cases, errors, ... ... The IS “Change gear” is only enabled when a new gear stage is selected that is not equal to the
current actual gear stage.
Related to .... IS “Set gear stage A” to C”(V390x 2000.0 to .2)
IS “Actual gear stage A” to “...C” (V380x 2000.0 to .2)
V390x 2000.0 to .2 Set gear stage A to C

Signal state 1 or signal A gear stage can be defined as follows:
transition 0 –––> 1 S Permanent definition in the part program (M41 to M45)
M41 to M45:
S The gear stage can be permanently defined in the part program with M41 to M45. If the M41 to
M45 commands select a gear stage which is not the same as the current (actual) gear stage,
the IS “Change gear” and the IS “Set gear stage A to C” are enabled.
M40:
S M40 in the part program causes the gear stage to be selected automatically by the control.
The control checks which gear stage is possible for the programmed spindle speed (S func-
tion). If a gear stage is identified that is not equal to the current (actual) gear stage, the
“Change gear” and “Set gear stage A” to “...C” interface signals are set.
The set gear stage is output in coded format:
1st gear stage 0 0 0 (C B A)
1st gear stage 001
2nd gear stage 010
3rd gear stage 011
4th gear stage 100
5th gear stage 101
Invalid value 110
Invalid value 111
Signal irrelevant for ... ... Other spindle modes except oscillation mode
Related to .... IS “Change gear” (V390x 2000.3)
IS “Actual gear stage A” to “...C” (V380x 2000.0 to .2)

6FC5397-1CP10-1BA0 5-121
Spindle (S1)
V390x 2001.7 Actual direction of rotation clockwise

Signal state 1 or signal When the spindle is rotating, “Actual direction of rotation clockwise” = 1 signals that the direction of
transition 0 –––> 1 rotation is CLOCKWISE. The actual direction of rotation is derived from the spindle position mea-
surement encoder.
Signal state 0 or signal When the spindle is rotating, “Actual direction of rotation clockwise” = 0 signals that the direction of
transition 1 –––> 0 rotation is COUNTER-CLOCKWISE.
Signal irrelevant for ... ... S Spindle stationary, IS “Axis/spindle stationary” = 1 (at standstill it is not possible to evaluate a
direction of rotation)
S Spindles without a position measuring encoder
Related to .... IS “Spindle stationary” (V390x 0001.4)
V390x 2001.5 Spindle in setpoint range

Signal state 1 or signal The IS “Spindle in setpoint range” reports whether the programmed, and possibly limited spindle
transition 0 –––> 1 speed has been reached.
In the spindle “control mode”, the speed setpoint (programmed speed + spindle override including
limits) is compared with the actual speed. If the actual speed deviates from the set speed by less
than the spindle speed tolerance in MD 35150: SPIND_DES_VELO_TOL, the IS “Spindle in setpo-
int range” is enabled.
Signal state 0 or signal The IS “Spindle in setpoint range” reports whether the spindle is still in the acceleration or braking
transition 1 –––> 0 phase.
In the spindle control mode, the speed setpoint (programmed speed * spindle override) is compa-
red with the actual value. If the actual speed deviates from the set speed by more than the spindle
speed tolerance in SPIND_DES_VELO_TOL, the IS “Spindle in setpoint range” is reset.
Signal irrelevant for ... ... all spindle modes except for speed mode (control mode).
Application example(s) The path feed must generally be disabled when the spindle is in the acceleration phase (program-
med speed setpoint not yet reached).
This can be performed as follows:
S The IS “Spindle in setpoint range” is evaluated and the IS “Feed disable”
(V3200 0006.0) is enabled.
S MD 35500: SPIND_ON_SPEED_AT_IPO_START (feed enable with spindle in setpoint range)
is enabled and the NCK then internally evaluates whether the spindle is in the setpoint range.
The path feed is only enabled if the spindle is within the setpoint range. The positioning axes
are never stopped by this function.
V390x 2001.2 Setpoint speed increased (programmed speed too low)

Signal state 1 or signal If a spindle speed (rev/min) or a constant cutting speed (m/min or ft/min) is programmed, the value
transition 0 –––> 1 is below one of the following limits:
S Minimum speed of the specified gear stage
S Min. spindle speed
S Speed limitated by the PLC
S Progr. Spindle speed limiting G25
S Progr. spindle speed limit for G96
The spindle speed is limited to the minimum limit.
Signal state 0 or signal If a spindle speed (1/min) or a constant cutting speed (m/min or ft/min) is programmed, the value
transition 1 –––> 0 has not fallen below any of the limits.
Application example(s) The IS “Setpoint speed increased” can be used to detect that the programmed speed cannot be
achieved. The PLC user can recognize this condition as not permissible and block path feed, or he
can block the path feed or the entire channel. IS “Spindle in set range” is processed.

5-122 6FC5397-1CP10-1BA0
Spindle (S1)
V390x 2001.1 Setpoint speed limited (programmed speed too high)

Signal state 1 or signal If a spindle speed (rev/min) or a constant cutting speed (m/min or ft/min) is programmed, the value
transition 0 –––> 1 is exceeded one of the following limits:
S Max. speed of specified gear stage
S Maximum spindle speed
S Speed limited by the PLC interface signal
S Progr. Spindle speed limiting G26
S Progr. Spindle speed limiting for G96
The spindle speed is limited to the maximum limit.
Signal state 0 or signal If a spindle speed (1/min) or a constant cutting speed (m/min) or ft/min) is programmed, none of
transition 1 –––> 0 the limit values have been exceeded.
Application example(s) The IS “Setpoint speed limited” can be used to detect that the programmed speed cannot be
achieved. The PLC user can recognize this condition as not permissible and block path feed, or he
can block the path feed or the entire channel. IS “Spindle in set range” is processed.
V390x 2001.0 Speed limit exceeded

Signal state 1 or signal If the actual speed exceeds the maximum spindle speed MD 35100: SPIND_VELO_ LIMIT by
transition 0 –––> 1 more than the spindle speed tolerance MD 35150: SPIND_DES_VELO_TOL the IS “Speed limit
exceeded” is enabled and alarm 22050 “Maximum speed reached” is output. All axes and spindles
of the channel are brought to a standstill.
MD 35100: SPIND_VELO_LIMIT (maximum spindle speed)
V390x 2002.7 Active spindle control mode

Signal state 1 or signal The spindle is in control mode with the following functions:
transition 0 –––> 1 Spindle direction of rotation input M3/M4 or spindle stop M5
Related to .... IS “Active spindle mode oscillation mode” (V390x 2002.6)
IS “Active spindle mode positioning mode” (V390x 2002.5)
V390x 2002.6 Active spindle mode oscillation mode

Signal state 1 or signal The spindle is in oscillation mode if a new gear stage was defined using the automatic gear stage
transition 0 –––> 1 selection (M40) or M41 to M45 (IS “Change gear” is enabled). The IS “Change gear” is only ena-
bled when a new gear stage is selected that is not equal to the current actual gear stage.
Related to .... IS “Active spindle mode control mode” (V390x 2002.7)
IS “Active spindle mode positioning mode” (V390x 2002.5)
V390x 2002.5 Active spindle positioning mode

Signal state 1 or signal When programming SPOS=..... the spindle is in positioning mode.
Related to .... IS “Active spindle mode control mode” (V390x 2002.7)
IS “Active spindle mode oscillation mode” (V390x 2002.6)

6FC5397-1CP10-1BA0 5-123
Spindle (S1)
V390x 2002.3 Rigid tapping active (no compensation)

Signal state 1 or signal The spindle is running in the rigid tapping function [no compensating chuck] (thread interpolation
transition 0 –––> 1 G331/G332).
The spindle speed is also programmed with S.... in rev/min for rigid tapping, however the direction
of rotation is stored in the sign for the pitch.
There is no reaction or updating of all spindle-specific interface signals such as:
IS “Spindle reset”
IS “Synchronize spindle”
IS “Invert M3/M4”
IS “Spindle in setpoint range”
IS “Programmable speed too high”
Application example(s) Certain functions should not be used during rigid tapping (no compensating chuck), such as:
S Reset IS “Controller enable” (V380x 0002.1)
S IS “Set feed stop” (V380x 0004.3)
S Reset
S When activating the EMERGENCY STOP during rigid tapping, it should be remembered that
the tool and workpiece are locked together.
Related to ....
V390x 2002.0 Constant cutting rate active

Signal state 1 or signal For programming G96 S... the constant cutting rate function is carried out. The S word is now the
transition 0 –––> 1 cutting value.
Related to ....

5-124 6FC5397-1CP10-1BA0
Spindle (S1)

rence
Axis-specific
VD30x 0000 – M function for the spindle (DINT), axis-specific
VD30x 0004 – S function for the spindle (REAL), axis-specific
VB380x 0000 – Feed override
V380x 0001 .7 Override active
V380x 0001 .5 Position measuring system 1
V380x 0001 .3 Axis/spindle disable
V380x 0002 .2 Spindle reset/Delete distance-to-go
V380x 0002 .1 Controller enable
V380x 0003 .6 Velocity/spindle speed limiting
V380x 2000 .3 Gear changed
V380x 2000 .0 to .2 Actual gear stage A to ...C
V380x 2001 .4 Resynchronize spindle during positioning 1 (spindle)
V380x 2001 .6 Invert M3/M4
V380x 2002 .7 Direction of rotation setpoint left
V380x 2002 .6 Direction of rotation setpoint right
V380x 2002 .5 Oscillation speed
V380x 2002 .4 Oscillation via PLC
VB380x 2003 – Spindle override
V390x 0000 .7 Position reached with exact stop fine
V390x 0000 .6 Position reached with exact stop coarse
V390x 0000 .4 Referenced/synchronized 1
V390x 0000 .2 Encoder limit frequency exceeded 1
V390x 0000 .0 Spindle/no axis
V390x 0001 .7 Current controller active
V390x 0001 .6 Speed control loop active
V390x 0001 .5 Position controller active
V390x 0001 .4 Axis/spindle stationary (n < nmin)
V390x 2000 .3 Change gear stage
V390x 2000 .0 to .2 Actual gear stage A to ...C
V390x 2001 .7 Actual direction of rotation clockwise
V390x 2001 .5 Spindle in setpoint range
V390x 2001 .2 Setpoint speed increased
V390x 2001 .1 Setpoint speed limited
V390x 2001 .0 Speed limit exceeded
V390x 2002 .7 Active spindle control mode
V390x 2002 .6 Active spindle mode oscillation mode
V390x 2002 .5 Active spindle positioning mode
V390x 2002 .3 Rigid tapping active (no compensation)
V390x 2002 .0 Constant cutting rate active (G96)

6FC5397-1CP10-1BA0 5-125
Spindle (S1)
5.11.2 Machine data

rence
Channel-specific
20090 SPIND_DEF_MASTER_SPIND Master spindle
Axis-specific
30134 IS_UNIPOLAR_OUTPUT[0] Setpoint output is unipolar
30300 IS_ROT_AX Rotary axis R2
30310 ROT_IS_MODULO Modulo conversion R2
30320 DISPLAY_IS_MODULO Position display R2
31050 * DRIVE_AX_RATIO_DENOM [n] Load gearbox, denominator G2
31060 * DRIVE_AX_RATIO_NUMERA [n] Load gearbox, numerator G2

32200 * POSCTRL_GAIN [n] Servo gain factor G2
32810 * EQUIV_SPEEDCTRL_TIME [n] Equivalent time constant speed control circuit for K3
feedforward control
34040 REFP_VELO_SEARCH_MARKER Reference point creep velocity R1
34060 REFP_MAX_MARKER_DIST Monitoring of zero mark distance R1
34080 REFP_MOVE_DIST Reference point distance/destination point for R1
distance-coded system
34090 REFP_MOVE_DIST_CORR Reference point offset/absolute offset, R1
distance-coded
34100 REFP_SET_POS Reference point value R1
34200 ENC_REFP_MODE Homing mode (referencing mode) R1
35000 SPIND_ASSIGN_TO_MACHAX Assignment of spindle to machine axis
35010 GEAR_STEP_CHANGE_ENABLE Gear stage change possible
35040 SPIND_ACTIVE_AFTER_RESET Spindle active after reset
35100 SPIND_VELO_LIMIT Maximum spindle speed
35110 * GEAR_STEP_MAX_VELO[n] Maximum speed for gear change
35120 * GEAR_STEP_MIN_VELO[n] Minimum speed for gear change
35130 * GEAR_STEP_MAX_VELO_LIMIT[n] Maximum speed of gear stage
35140 * GEAR_STEP_MIN_VELO_LIMIT[n] Minimum speed of gear stage
35150 SPIND_DES_VELO_TOL Spindle speed tolerance
35160 SPIND_EXTERN_VELO_LIMIT Spindle speed limiting via PLC
35200 * GEAR_STEP_SPEEDCTRL_ACCEL[n] Acceleration in speed control mode
35210 * GEAR_STEP_POSCTRL_ACCEL[n] Acceleration in position control mode
35300 SPIND_POSCTRL_VELO Position control activation speed
35310 SPIND_POSIT_DELAY_TIME[n] Positioning delay time
35350 SPIND_POSITIONING_DIR Positioning direction of rotation for a
non-synchronized spindle
35400 SPIND_OSCILL_DES_VELO Oscillation speed
35410 SPIND_OSCILL_ACCEL Oscillation acceleration
35430 SPIND_OSCILL_START_DIR Oscillation start direction
35440 SPIND_OSCILL_TIME_CW Oscillation time for M3 direction
35450 SPIND_OSCILL_TIME_CCW. Oscillation time for M4 direction
35500 SPIND_ON_SPEED_AT_IPO_START Feed enable with spindle in setpoint range

5-126 6FC5397-1CP10-1BA0
Spindle (S1)

rence
Axis-specific
35510 SPIND_STOPPED_AT_IPO_START Feed enable with stationary spindle
36060 STANDSTILL_VELO_TOL Threshold velocity “Axis/spindle stationary” A3
36200 * AX_VELO_LIMIT [n] Threshold value for velocity monitoring A3
36300 ENC_FREQ_LIMIT Encoder limit frequency A3
36302 ENC_FREQ_LIMIT_LOW Encoder limit frequency re-synchronization R1
36720 DRIFT_VALUE Drift basic value
The machine data marked with * are contained in the param-

eter set for a gear stage.
5.11.3 Setting data

rence
General
41200 JOG_SPIND_SET_VELO JOG velocity for the spindle H1
Spindle-specific
43210 SPIND_MIN_VELO_G25 Progr. spindle speed limiting G25
43220 SPIND_MAX_VELO_G26 Progr. spindle speed limiting G26
43230 SPIND_MAX_VELO_LIMS Progr. spindle speed limiting with G96

6FC5397-1CP10-1BA0 5-127
Spindle (S1)
Notes

5-128 6FC5397-1CP10-1BA0
Rotary Axes (R2) 6
6.1 General
Properties of a rotary axis

Rotary axes are always programmed in degrees. They are generally characterized by the fact
that they assume the same position again after exactly one rotation (modulo 360 degrees).
Depending on the application in question, the traversing range of the rotary axis can be limited
to less than 360 degrees (e.g. on swiveling axes for tool holders) or may be endless (e.g.
when tool or workpiece is rotated).
Definition of the rotary axis

An axis is defined as a rotary axis with the help of MD 30300: IS_ROT_AX = 1.
Note
The geometry axes (X, Y, Z) cannot be used as rotary axes or spindle. MD 20050:
AXCONF_GEOAX_ASSIGN_TAB (assignment of geometry axis – channel axis) defines
these geometry axes.
Axis addresses, axis identifier, direction
Cartesian coordinate system +Y
+B
–X –Z
+C +O
+Z +X
–Y
Fig. 6-1 Identification of axes and positive direction of movement for rotary axes
For axes/rotary axes, the extended addressing (e.g.: C2=) or an axis name can also be defi-
ned via configuration in MD 1000: AXCONF_MACHAX_NAME_TAB, or
MD 20080: AXCONF_CHANAX_NAME_TAB.

6FC5397-1CP10-1BA0 6-129
Rotary Axes (R2)
6.1 General
Units of measurement
The following units of measurement apply as standard to data inputs and outputs for rotary
axes:
Table 6-1 Units of measurement for rotary axes
Physical quantity Unit

Angular position Degrees
Programmed angular speed Degrees/minute
MD for angular speed rev/min 1)
MD for angular acceleration rev/sec2 1)

MD for angular jerk limiting rev/sec3 1)
1) These units are interpreted by the control for axis-specific machine data
as soon as the axis is declared as a rotary axis.
References: Chapter “Velocities/Setpoint/Actual Value Systems/Closed-Loop Control”
Feed
The programmed feedrate F corresponds to an angular speed [degrees/min] for rotary axes
programmed alone in a block.
If rotary axes and linear axes traverse along a common path with G94 or G95, the feed should
be interpreted in the unit of measurement of the linear axes [e.g. mm/min, inch/min].
The tangential speed of the rotary axis in this case refers to the diameter DE (unit diameter
DE = 360/p mm, with p = circle constant).
If the diameter is the same as the unit diameter (D=DE), the programmed angular speed in
degrees/mm and the tangential speed in mm/min are numerically identical.
For the inch measuring setting, “inch” applies instead of “mm”.
The following applies for the tangential speed in general:
F = FW * D / DE F = tangential speed [mm/min]
FW = angular speed [degrees/min]
D = diameter to which F is applied [mm]
with DE = 360 / p DE = unit diameter [mm]
p = circle constant Pi = 3,14...
JOG speed for rotary axes

With MD 41130: JOG_ROT_AX_SET_VELO (JOG velocity for rotary axes), a jog velocity that
is valid for all rotary axes can be set.
If a value of 0 is entered in the setting data, then axis-specific MD 32020: JOG_VELO (JOG
axis velocity).
References: Chapter “JOG with and without handwheel”

6-130 6FC5397-1CP10-1BA0
Rotary Axes (R2)
6.2 Modulo 360 degrees

The software limit switches and working area limits are operative and are required for swivel
axes with a restricted operating range. For endlessly turning rotary axes with (MD 30310:
ROT_IS_MODULO=1), however, the software limit switches and working area limits are set
inactive for specific axes.
References: Chapter “Axis Monitoring Functions”
6.2 Modulo 360 degrees
Term “Modulo 360 degrees”

With respect to a rotary axis, the term “Modulo” refers to mapping of the axis position inter-
nally in the control within the range from 0 to 359.999 degrees. With path settings > 360 (e.g.
for incremental dimension programming using G91) the axis position is imaged in the value
range between 0 to < 360 degrees through a conversion process in the control. The mapping
process is applied in JOG and AUTOMATIC mode. Exception: Service display.
Machine data settings

Using machine data it is possible to define the programming and positioning settings
(MD 30310: ROT_IS_MODULO) and the position display (MD 30320: DISPLAY_IS_MO-
DULO) in modulo 360 degrees for each individual rotary axis to suit the requirements of indivi-
dual machine tools.
Axis is modulo
MD 30310: ROT_IS_MODULO = 1:
Activation of this machine data allows the special rotary axis action implemented in the
system to be utilized. The positioning action of the rotary axis for programming (G90, AC,
ACP, ACN or DC). A modulo 360° mapping process is executed internally in the control after
the current zero offsets have been taken into account. Next the detected target position within
a revolution is approached.
The software limit switches and working area limiting are inactive and the working area is
then indefinite.
The Modulo 360° should also always be selected for a modulo axis
(MD 30320: DISPLAY_IS_MODULO = 1).
Modulo position display

MD 30320: DISPLAY_IS_MODULO = 1:
A “modulo 360°”(1 rotation) position display is frequently required for rotary axes; i.e. when the
axis is rotating in the positive direction, the display is periodically reset from 359.999° to
0.000° in the control system. With a negative direction of rotation, the axis positions are also
displayed in the 0°...359.999° range.

6FC5397-1CP10-1BA0 6-131
Rotary Axes (R2)
6.3 Programming of rotary axes
MD 30320: DISPLAY_IS_MODULO = 0:
In contrast to the modulo 360° display method, absolute positions are indicated, e.g. in the
positive direction after 1 rotation +360°, after 2 rotations +720° etc. In this case, the display
range is limited by the control in accordance with the linear axes.
Note
For general information on programming, please refer to
6.3.1 Rotary axis with active modulo conversion
Absolute dimension programming (AC, ACP, ACN, G90)

Examples with ACP: C=ACP(5.33) , general: Axis name =ACP(value)
S The value identifies the target position of the rotary axis in a range from 0 to ... 359.999
degrees. Alarm 16830 “Incorrect modulo position programmed” is output for values with a
negative sign or y 360 degrees.
S ACP (positive) and ACN (negative) define the traversing direction of the rotary axis unam-
biguously (irrespective of actual position).
S When programming with AC or with G90, the traversing direction depends on the actual
position of the rotary axis. If the target position is larger than the actual position, the axis
traverses in the positive direction, otherwise it traverses in the negative direction.
S Use of ACP and ACN: With asymmetrical workpieces, it must be possible to define the
traversing direction to prevent collisions during rotation.
Absolute dimension programming along the shortest path (DC)

Examples with DC: C=DC(25.3), general: Axis name =DC(value)
S The value identifies the target position of the rotary axis in a range from 0 to ... 359.999 deĆ
grees. Alarm 16830 “Incorrect modulo position programmed” is output for values with a
negative sign or ≥ 360 degrees.
S With DC (Direct Control), the rotary axis approaches the programmed absolute position via
the shortest route within one revolution (traversing movement max. ±180 degrees).
S The control calculates the direction of rotation and the traversing distance according to the
actual position. If the distance to be traversed is the same in both directions (180 deĆ
grees), the positive direction receives preference.
S Example application of DC: the rotary table is required to approach the changeover posi-
tion in the shortest time (and therefore via the shortest path).
Note: If DC is programmed with a linear axis, alarm 16800 “DC traversing instruction cannot
be used” is output.

6-132 6FC5397-1CP10-1BA0
Rotary Axes (R2)
Incremental dimension programming (IC, G91)

S The value identifies the traversing distance of the rotary axis. The value can be negative
as well as w 360 degrees.
S The leading sign of the value defines thetraversing direction of the rotary axis.
Example:
C=IC(720) ;C axis traverses incrementally in positive direction through 720° (2 revolutions)
C=IC(–180) ;C axis traverses incrementally in negative direction through 180°
Endless traversing range

As soon as the modulo function is active, no limit is placed on the traversing range (soft-
ware limit switches are not active). The rotary axis can now be programmed to traverse
continuously.
Example:
N10 LOOP: C=IC(7200)
N20 GOTOB LOOP
6.3.2 Rotary axis without modulo conversion
Absolute dimension programming (AC, G90)

Example of AC: C=AC(–410), general: Axis name =AC (+/–value)
S The value and its leading sign provide a unique identification of the destination position of
the rotary axis. The value can be above +/–360 degrees. The position value is limited by
the software limit switch.
S The traversing direction is ascertained by the control according to the leading sign of the
actual position of the rotary axis.
S If ACP or ACN is programmed, alarm 16810 “ACP traversing instruction cannot be used”
or alarm 16820 “ACN traversing instruction cannot be used” is output.
Absolute dimension programming along the shortest path (DC)

Example of DC: C=DC(60.3), general: Axis name =DC(value)
Even if the rotary axis is not defined as a modulo axis, the axis can still be positioned with DC
(direct control). The response is the same as on a modulo axis.
Incremental dimension programming (IC, G91)

Example of IC: C=IC(–532.4), general: Axis name =IC (+/–value)
When programming with incremental dimensions, the rotary axis traverses along the same
path as with the modulo axis. In this case, however, the traversing range is limited by the soft-
ware limit switches.

6FC5397-1CP10-1BA0 6-133
Rotary Axes (R2)
Limited traversing range

The traversing range is limited as with linear axes. The range limits are defined by the plus
and minus software limit switches.
30300 IS_ROT_AX
MD number Rotary axis
Meaning: 1: Axis: The axis is defined as a “rotary axis” .
The units of the axis-specific machine data/setting data are interpreted
by the control in default setting as follows:
D position in degrees
D velocity in rev/min
D acceleration in rev/s2
D jerk limiting in rev/s3
spindle:
For a spindle the machine data should always be set to “1”,
or alarm 4210 “Rotary axis declaration missing” is sent.
0: The axis is defined as a linear axis.
Special cases, errors, ... ... For axis: alarm 4200 if the axis is already defined as a geometry axis.
For spindle: Alarm 4210
Related to .... The subsequent machine data only become effective after activating the
MD 30300:IS_ROT_AX = 1:
S MD 30310:ROT_IS_MODULO (modulo conversion for rotary axis))
S MD 30320:DISPLAY_IS_MODULO (position display is modulo)
S MD 10210:INT_INCR_PER_DEG (calculation resolution for angular positions)
References Tab. 2.2 Combination options for machine data
30310 ROT_IS_MODULO
MD number Modulo conversion for rotary axis
Meaning: 1: A modulo conversion is performed on the setpoints for the rotary axis..
The software limit switches and the working area limits are inoperative; the
traversing range is therefore unlimited in both directions.
ROT_IS_AX must be set to “1”
0: no modulo conversion
MD irrelevant for ... ... MD 30300: IS_ROT_AX = 0 (linear axis)
Tab. 2.2 Combination options for machine data
Application example(s) Continuously rotating axes (e.g. for eccentric rotation, grinding, winding)
Related to .... MD 30320: DISPLAY_IS_MODULO (position display is modulo 360°)
MD 30300: IS_ROT_AX = 1 (rotary axis)
MD 36100: POS_LIMIT_MINUS (software limit switch minus)
MD 36110: POS_LIMIT_PLUS (software limit switch plus)
SD 43430: WORKAREA_LIMIT_MINUS (working area, limiting minus)
SD 43420: WORKAREA_LIMIT_PLUS (working area, limiting plus)

6-134 6FC5397-1CP10-1BA0
Rotary Axes (R2)
30320 DISPLAY_IS_MODULO
MD number Position display “Modulo 360°
Meaning: 1: Position display “Modulo 360 degree” is active:
The position display of the rotary axis or spindle (for basic or machine coordinate system) is
defined as “Modulo 360 degree”. In the positive direction of rotation, the control periodically
resets the position display internally to 0.000 degrees after 359.999 degrees. The display range
is always positive and is always between 0 and 359,999 degrees
0: Absolute position display is active:
Contrary to the modulo 360 degree position display, for the absolute position display – e.g. for a
positive direction of rotation – after 1 revolution +360 degrees is displayed; after 2 revolutions,
+720 degrees etc.
Here, the display range is limited corresponding to the linear axes.
MD irrelevant for ... ... Linear axes MD 30300: IS_ROT_AX = 0
Application example(s) S For endlessly rotating rotary axes (MD 30310:ROT_IS_MODULO = 1) we recommend that the
position display is activated with modulo 360 degrees.
S For spindles, the position display should always be activated with 360 degrees.
Related to .... MD 30300: IS_ROT_AX (axis is rotary axis)
34220 ENC_ABS_TURNS_MODULO[0]
MD number Range, rotary absolute value encoders
Changes effective after POWER ON Protection level: 2 / 2 Unit: –
Meaning: Number of encoder revolutions that a rotary value encoder can resolve
0 degrees <= position <= n * 360 degrees, (with n = ENC_ABS_TURNS_MODULO)
Note: With control disabled the encoder may be turned by half this value max.
Special cases, errors, ... ... Only powers of two are allowed as values ( 1, 2, 4, 8, 16, ..., 4096).
If other values are entered, they are “rounded off”. Rounding off is shown in the machine data; the
change is displayed in alarm 26025.
The MD is only relevant for rotary encoders (with linear and rotary axes).
Important information:
When using an encoder with smaller multi-turn information, or when using single-turn encoders,
the value must be decreased accordingly. In any case, for multi-turn absolute encoders the value
should be changed to the maximum quantity supported by the encoder so that the unambiguous
traversing range that is increased as a result can be utilized (Note: This value also influences the
permissible position offset when the encoder or power supply is switched off).
Related to ....

6FC5397-1CP10-1BA0 6-135
Rotary Axes (R2)
6.5.1 Machine data

rence
General
10000 AXCONF_MACHAX_NAME_TAB Machine axis name Chap. 19
10210 INT_INCR_PER_DEG Calculation resolution for angular positions G2

Channel-specific
20050 AXCONF_GEOAX_ASSIGN_TAB Assignment between geometry axis and channel Chap. 19
axis
20080 AXCONF_CHANAX_NAME_TAB Channel axis name Chap. 19
30300 IS_ROT_AX Axis is rotary axis
30310 ROT_IS_MODULO Modulo conversion for rotary axis
30320 DISPLAY_IS_MODULO Actual-value display modulo
34220 ENC_ABS_TURNS_MODULO Range, rotary absolute value encoders
36100 POS_LIMIT_MINUS Software limit, switch minus A3
36110 POS_LIMIT_PLUS Software limit, switch plus A3
6.5.2 Setting data

rence
General
41130 JOG_ROT_AX_SET_VELO JOG speed for rotary axes H1
Axis-specific
43430 WORKAREA_LIMIT_MINUS Working area, limiting minus A3
43420 WORKAREA_LIMIT_PLUS Working area, limiting plus A3

6-136 6FC5397-1CP10-1BA0
Transverse Axes (P1) 7
7.1 Transverse axis definition
Geometry axis as transverse axis

The geometry axis X is defined as a transverse axis. The transverse axis is important for
lathe functions.
7.2 Diameter programming
Activation and de-activation

Transverse axes can be programmed in diameter or radius mode.
Program commands “DIAMON” and “DIAMOF” can be used to activate and de-activate dia-
meter programming of the transverse axis.
DIAMON and DIAMOF belong to G group 29 and are modal.
JOG mode
If DIAMON is active, then the increments entered for machine functions INC (incremental di-
mension) and handwheel traverse in JOG are interpreted and traversed as diameter values
for the associated transverse axis (traversal in WCS with this axis).
Setpoint display/actual value display

If the “DIAMON” function is activated for a transverse axis, then the position, distancetogo and
REPOS offset are displayed as diameterrelated data when the workpiece coordinate system
(WCS) is selected.
It is always displayed as radius in the machine coordinate system (MCS).
Offsets
All offsets (e.g. tool offsets, programmable and settable zero offsets) are always entered, pro-
grammed and displayed as radius values (even if they are active in the transverse axis and
command DIAMON is active).
Work area limiting, software limit switch, feed values

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

6FC5397-1CP10-1BA0 7-137
Transverse Axes (P1)
7.3 Constant cutting rate: G96
Conversion of diameter values to internal radius values

With diameter programming active, the internal radius values are converted for the transverse
axis (i.e. the programmed values are halved):
S Programmed end positions
S Absolute interpolation parameters (e.g. I, J, K) for G2/G3 programming.
Absolute interpolation parameters reference the coordinate origin of the WCS. Interpola-
tion parameters programmed relatively are not converted.
Conversion of internal radius values to diameter values

For active diameter programming the measurement results when measuring in the WCS are
converted for the transverse axis with the “MEAS”, “MEASW” functions (i.e. the internal radius
values are doubled) and stored.
For measurement or reading in the MCS the calculated values are stored as radius values.
7.3 Constant cutting rate: G96
Functionality
Prerequisite: A controlled spindle must be configured.
When function G96 is active, the spindle speed is adapted to the currently machined work-
piece diameter (transverse axis position = geometry axis X) in such a way that a programmed
cutting rate S at the cutting edge remains constant (spindle speed multiplied by diameter=
constant).
The S value is interpreted as the cutting rate from the block with G96. G96 is modal until can-
cellation by different G function of the group (G94, G95, G97).
Programming
G96 S... LIMS=... F... ;constant cutting range ON
G97 ;constant cutting rate OFF
S cutting rate, dimension units m/min
LIMS= upper limit speed of the spindle, for G96, G97 effective
F feed in the dimension units mm/revolution – as for G95
X (Transverse axis)
M D2 W SDS= Spindle speed

D1
D1, D2 =diameter
D1 x SD1=D2 x SD2=Dn x SDn=constant
Fig. 7-1 Constant cutting rate G96

7-138 6FC5397-1CP10-1BA0
Reference Point Approach (R1) 8
8.1 Fundamentals
Why reference?
The control must be synchronized with the position measurement system of each machine
axis so that the control can detect the exact machine zero when it is switched on. This pro-
cess is known as referencing.
The spindle process (synchronizing) is largely described in the Chapter “Spindles”.
Position measurement systems

The following position measuring systems can be mounted on the motor:
S Incremental rotary measuring system
S Absolute rotary measurement system
Referencing for the connected position measurement systems can be set
with MD 34200: ENC_REFP_MODE (referencing mode).
Cam
An output cam for referencing may be required for linear axes, and its signal has the following
tasks:
S Selection of the direction of travel when approaching the zero mark (synchronized pulse)
S Selection of the zero mark, where required.
BERO
A BERO (inductive proximity switch) can be used as the encoder for the synchronous pulse
(instead of the position encoder zero mark) (preferred for rotary axes, spindle).
The connection is provided via the terminal X20 on the 802D sl.
Special inputs to BERO inputs are switched via macro parameterization.
References: “SINUMERIK 802D sl Instruction Manual”,
Section “Configuring SINAMICS S120 with 802D sl”

6FC5397-1CP10-1BA0 8-139
Reference Point Approach (R1)
8.1 Fundamentals
IS “Active machine function REF” (V3100 0001.2)

The reference point approach is performed with the REF machine function activated
(IS “active machine function REF”). The REF machine function can be selected in JOG
modes (IS “REF machine function” (V3000 0001.2)).
Axis-specific referencing
Axis-specific referencing is started separately for each machine axis with the “plus/minus tra-
vel keys” interface signal (V380x 0004.7 /.6). All axes can be referenced at the same time. If
the machine axes are to be referenced in a particular sequence, the following options are
available:
S The operator must observe the correct sequence on start-up
S The PLC user program checks the sequence on start-up or defines the sequence itself.
S The order is defined in MD 34110: REFP_CYCLE_NR (see channel-specific referencing)
Channel-specific referencing
Channel-specific referencing is started with the “activate referencing” interface signal (V3200
0001.0). The control acknowledges a successful start with the “referencing active” interface
signal (V3300 0001.0). Each machine axis assigned to the channel can be referenced with
channel-specific referencing (this is achieved internally on the control by simulating the plus/
minus travel keys). The axis-specific MD 34110: REFP_CYCLE_NR (axis sequence for chan-
nel-specific referencing) can be used to define the sequence in which the machine data are
referenced. When all axes entered in MD 34110: REFP_CYCLE_NR have reached their end
points, the “all axes referenced” interface signal (V3300 0004.2) is enabled.

S Referencing is aborted with “Reset” interface signal (V3000 0000.7). Any axes which have
not yet reached their reference point at this time are considered to be not referenced.
The “Referencing active” interface signal is reset and alarm 20005 is signaled.
S Working area limiting and software limit switches are not active for non-referenced
machine axes.
S The defined axis-specific accelerations are observed at all times during referencing
(except when alarms occur).
S The reference point approach can be started only with the direction key for the direction
stored in MD 34010: REFP_CAM_DIR_IS_MINUS.

8-140 6FC5397-1CP10-1BA0
8.1 Fundamentals
Referencing in the part program

One or more axes that have lost their reference can be referenced at the same time. The se-
quence of the individual phases is identical to axis-specific referencing, except that the pro-
cess is started with the G74 command instead of the plus/minus travel keys and is done via
the machine axis identifiers.
Note: MD 20700: REFP_NC_START_LOCK = 1 prevents a part program from being started

(alarm output) if not all required axes are referenced.

6FC5397-1CP10-1BA0 8-141
8.2 Referencing with incremental measuring systems
Chronological sequence
The referencing sequence for incremental measurement systems can be subdivided into
three phases:
1st phase: travel to reference cam
2nd phase: synchronization with the zero mark
3rd phase: travel to reference point
IS “Approach ref. point delay”

(V380x 1000.7)
IS “Travel command plus”

(V390x 0004.7)
IS “Travel command minus”

(V390x 0004.6)
IS “Travel command plus/minus”

(V380x 0004.7 and .6)
IS “Referenced/synchronized”
(V390x 0000.4)
Zero-mark positioning
measurement system |Velocity|
MD 34020: REFP_VELO_SEARCH_CAM
Reference-point approach velocity
MD 34070: REFP_VELO_POS
Reference-point positioning velocity
MD 34040: REFP_VELO_SEARCH_MARKER
Reference-point creep velocity
t
Phase 1 Phase 2 Phase 3
Fig. 8-1 Referencing sequence with incremental measuring system (example)
Characteristics of travel to the reference point cam (phase 1)

S The feedrate override and feedrate stop is in effect.
S The machine axis can be stopped/started.
S The cam must be reached within the traverse distance in MD 34030:
REFP_MAX_CAM_DIST, otherwise a corresponding alarm is triggered.
S The machine axis must come to a halt at the cam, otherwise a corresponding alarm is
triggered.

8-142 6FC5397-1CP10-1BA0
Characteristics when synchronizing with the zero pulse (phase 2)

S Feedrate override is not active. Feedrate override 100% is active. Termination occurs at
feedrate override 0%.
S Feedrate stop is active, the axis comes to a halt and a corresponding alarm is displayed.
S The machine axis cannot be stopped and restarted with NC stop/NC start.
S Monitoring of the zero mark is active via MD 34060: REFP_MAX_MARKER_DIST.
Characteristics of travel to the reference point (phase 3)

S The feedrate override and feedrate stop is in effect.
S The machine axis can be stopped and re-started with NC stop/NC start.
S If reference point offset is smaller than the braking distance of the machine axis from the
reference point positioning velocity to stop, the reference point is approached from the
opposite direction.
Different motion sequences during referencing:
Synchronizing pulse
Referencing type Motion sequence
(zero mark, BERO)
Synchronizing pulse
RV
before cam,
VC
reference coordinates
with reference point cam VP
before synchronized
pulse VM
(MD 34000:
REFP_CAM_IS_ACTIVE = 1)
= without reserval: Start RK
(MD 34050:
REFP_SEARCH_MAR- Cam
KER_REVERSE = 0) Synchronizing pulse
Synchronizing pulse RV
on cam, VC
reference coordinate af- VP

ter synchronized pulse on VM
cam
= reversed: Start RK
(MD 34050:
REFP_SEARCH_MAR- Cam
KER_REVERSE = 1)
Synchronizing pulse

6FC5397-1CP10-1BA0 8-143
Synchronizing pulse
Referencing type Motion sequence
(zero mark, BERO)
RV
VP
without reference cam VM
Reference coordinate af-
(MD 34000: ter synchronizing pulse
REFP_CAM_IS_ACTIVE = 0) Start
RK
Synchronizing pulse
VC – reference point approach velocity (MD 34020: REFP_VELO_SEARCH_CAM)

VM – reference point creep velocity (MD 34040: REFP_VELO_SEARCH_MARKER)
VP – reference point positioning velocity (MD 34070: REFP_VELO_POS)
RV – reference point offset (MD 34080: REFP_MOVE_DIST + MD 34090:
REFP_MOVE_DIST_CORR)
RK – reference point coordinate (MD 34100: REFP_SET_POS)
What is the minimum length of a reference cam?

Example of case: Synchronizing impulse before cam, reference coordinate before
synchronizing pulse = synchronizing pulse search with falling cam edge).
The reference cam must be long enough for the braking process to end at the cam (comes to
halt at the cam) when the cam is approached at reference point approach speed and the cam
is exited when axis is retracted in the opposite direction at reference point creep speed (exit
at constant velocity).
To calculate the minimum length of the cam, the larger of the two speeds must be inserted
into the formula:
(reference point approach speed or creep speed)2
Minimum length =
2 x axis acceleration (MD 32300: MAX_AX_ACCEL)
If the machine axis does not come to a halt at the reference cam (interface signal “Reference
point approach delay” (V380x 1000.7) is reset), alarm 20001 is output. Alarm 20001 can oc-
cur if the reference cam is too short and the machine axis travels over it when decelerating in
phase 1.
If the reference cam extends to the end of travel of the axis, an inadmissible starting point for
referencing (after the cam) can be excluded.

8-144 6FC5397-1CP10-1BA0
Reference cam calibration

The reference cam must be calibrated exactly. The following factors influence the response
time of the control when detecting the reference cam (”Reference point approach delay” inter-
face signal):
S Switching accuracy of the reference cam switch
S Delay of the reference cam switch (NC contact)
S Delay at the PLC input
S PLC cycle time
S Internal processing time
Practice has shown that the signal edge of the reference cam, which is required for synchro-
nizing, is aligned between two synchronized pulses (zero marks). This can be achieved by:
S MD 34080: REFP_MOVE_DIST = MD 34090: REFP_MOVE_DIST_CORR = MD 34100:
REFP_SET_POS = 0
S Reference axis
S In JOG mode, traverse the axis to half the path length between the two zero marks. This
path is independent of the pitch of the leadscrew S and the gear ratio n (e.g.: S=10 mm/
rev, n=1:1 produces a path of 5mm).
S Calibrate the cam switch such that switching is done at exactly this position (IS “Refe-
rence point approach delay” (V380x 1000.7))
S Alternatively, the value of
MD 34092: REFP_CAM_SHIFT can be changed instead of moving the cam switch.
Warning
! If the reference cam is not calibrated precisely, an incorrect synchronizing pulse (zero mark) may be evaluated.
In this case, the control assumes an incorrect machine zero and moves the axes to incorrect positions. Software
limit switches act on incorrect positions and are therefore not able to protect the machine.

6FC5397-1CP10-1BA0 8-145
8.3 Referencing with absolute value encoders
8.3.1 General
Prerequisites
An axis with absolute value encoder is referenced automatically when the control is switched
on if the system detects that the relevant axis is already calibrated. This transfer of the abso-
lute value takes place without any axis motion, e.g. on POWER ON. Two conditions must be
fulfilled before an axis can be automatically referenced:
S The axis has an absolute value encoder with which the position control operates
S The absolute value encoder is calibrated (MD 34210: ENC_REFP_STATE = 2)
Calibration
In the case of axes with absolute value encoders, the measurement system is not synchroni-
zing by approaching a reference cam. It is calibrated instead. For this purpose, the actual
value of the absolute value encoder is set once during start-up and transferred to the control.
8.3.2 Operator-assisted calibration
General procedure
Move the axis to be calibrated to a defined position to set the resulting actual value.
Chronological sequence
1. MD 34200: ENC_REFP_MODE and MD 34210: ENC_REFP_STATE to 0 and activate by

means of a POWER ON.
MD: ENC_REFP_MODE = 0 means that the actual value of the axis is set once.
2. Traverse axis manually in JOG mode to a known position. The direction in which the posi-
tion is approached must match the direction stored in MD 34010:
REFP_CAM_DIR_IS_MINUS (0 = positive direction, 1 = negative direction).
Note
This known position must always be approached at a low velocity and from a defined
direction so that it is not falsified by any backlash present in the drive train.
3. Enter the actual value corresponding to the approached position in MD 34100:

REFP_SET_POS. This value may be a specified design value (e.g. fixed stop) or can now
be determined with a measuring instrument.

8-146 6FC5397-1CP10-1BA0
4. MD 34210: set ENC_REFP_STATE to 1 to enable the “calibration” function.

5. The modified machine data become effective after a RESET.
6. Switch to JOG-REF mode.
7. When you press the traversing key used in step 2, the current offset is entered in MD
34090: REFP_MOVE_DIST_CORR and MD 34210: ENC_REFP_STATE switches to “2”,
i.e. the axis is considered calibrated.
(The display is updated by pressing the traverse key.)
Note
The axis does not move when the correct traversing key is actuated! The value entered in
MD 34100: REFP_SET_POS appears in the actual value display of the axis position.
8. Exit JOG-REF operating mode. The calibration operation for this axis is now complete.

6FC5397-1CP10-1BA0 8-147
8.4 Secondary conditions for absolute encoders
8.4 Secondary conditions for absolute encoders
8.4.1 Calibrating absolute encoders
When to calibrate the system

The calibration process determines the offset between the machine zero and the encoder
zero and stores it in a non-volatile memory. Normally, calibration need only be performed
once, i.e. during initial start-up. The control then knows the value and can calculate the abso-
lute machine position from the encoder absolute value at any time. This status is identified by
MD 34210: ENC_REFP_STATE=2.
The offset is stored in MD 34090: REFP_MOVE_DIST_CORR.
The calibration process must be repeated in the following situations:
S After mounting/removal or replacement of encoder or of motor with built-in encoder.
S After change of an existing gear unit between motor (with absolute encoder) and load.
S Generally speaking, every time the mechanical connection between the encoder and load
is separated and not reconnected in exactly the same way.
Caution: The control may not always recognize the need for recalibration. If it detects such a
need, it records this by setting machine data MD 34210: ENC_REFP_STATE to 0 or 1.
The following is recognized: changeover to another gear speed with a different gear ratio bet-
ween the encoder and load.
In all other cases, the user must overwrite MD 34210: ENC_REFP_STATE.
Data backup
When machine data is backed up, the status of MD 34210: ENC_REFP_STATE is also
stored.
By loading this data set, the axis is automatically deemed calibrated!
Warning
! If the data set has been taken from another machine (e.g. series installation), calibration
must still be carried out after loading and activating the data.

8-148 6FC5397-1CP10-1BA0
20700 REFP_NC_START_LOCK
MD number NC start disable without reference point
Meaning: 0: The “NC start” interface signal (V3200 0007.1) for starting part programs or part program
blocks (MDA) is also possible if none or not all channel axes are referenced. To ensure that
the axes move to the correct position after NC Start, the workpiece coordinate system
(WCS) must be set to a correct value by other methods (scratching method).
1: The NC only starts if all of the axes have been referenced.
31122 BERO_DELAY_TIME_PLUS[0]
MD number BERO delay time plus
Meaning: In conjunction with the setting MD 34200: ENC_REFP_MODE = 7, the MD causes a
signal propagation delay compensation in the positive direction of motion when a Bero (zero
mark) is used for defining position.
Related to .... MD 34200: ENC_REFP_MODE
31123 BERO_DELAY_TIME_MINUS[0]
MD number BERO delay time minus
Meaning: In conjunction with the setting MD 34200: ENC_REFP_MODE = 7, the MD causes a
signal propagation delay compensation in the negative direction of motion when a Bero (zero
mark) is used for defining position.
Related to .... MD 34200: ENC_REFP_MODE
34000 REFP_CAM_IS_ACTIVE
MD number Axis with reference point cam
Meaning: Machine axes with only one zero mark across their entire traversing range or rotary axes with
only one zero mark per revolution are not identified as a machine axis with reference cam by the
MD: REF_CAM_IS_ACTIVE. A machine axis identified as a machine axis with reference cam
accelerates, when the plus/minus travel key is pressed, to the velocity defined in MD 34040:
REFP_VELO_SEARCH_MARKER (reference point creep velocity).

6FC5397-1CP10-1BA0 8-149
34010 REFP_CAM_DIR_IS_MINUS
MD number Reference point approach in minus direction
Meaning: 0: Reference point approach in the positive direction
1: Reference point approach in negative direction
Approach with incremental measuring systems:
Starting via the traverse key is only possible in the specified direction. If the wrong travel key is
pressed, reference point approach does not start.
If the machine axis is positioned before the reference cam, it accelerates to the velocity specified
in MD 34020: REFP_VELO_SEARCH_CAM (reference point creep velocity).
If the machine axis is on the reference cam, it accelerates to the velocity specified in MD 34020:
REFP_VELO_SEARCH_CAM and travels initially away from the preset direction, away from the
cam.
Note for absolute encoders:

The direction of the traversing key is also significant for calibrating the absolute encoders: Appro-
ach the direction for fixed position and update values in MD 34090 and MD 34210.
34020 REFP_VELO_SEARCH_CAM
MD number Reference point approach velocity
Default setting: 5000.0 mm/min, Minimum input limit: 0.0 Maximum input limit: ***
13.88 rpm
Changes effective after RESET Protection level: 2/2 Unit: mm/min,
rpm
Meaning: The reference point approach velocity is the velocity at which the machine axis travels in the
direction of the reference cam when the travel key is pressed (phase 1). This value should be set
at a magnitude large enough for the axis
to be stopped before it reaches a hardware limit switch.
34030 REFP_MAX_CAM_DIST
MD number Maximum distance to reference cam
Changes effective after RESET Protection level: 2/2 Unit: mm, degrees
Meaning: If the machine axis travels a path defined in this MD from the starting position in the direction of
the reference cam without reaching the reference cam (“Reference point approach delay” inter-
face signal is not set), the axis stops and alarm 20000 “Reference cam not reached” is signaled.

8-150 6FC5397-1CP10-1BA0
34040 REFP_VELO_SEARCH_MARKER[n]
MD number Reference point creep speed [encoder number]: 0
0.833 rpm
rpm
Meaning: 1) For incremental measuring systems:
This is the velocity at which the axis travels between initial detection of the reference cam
and synchronization with the first zero mark (phase 2).
Traversing direction: opposite to the direction specified for cam detection
(MD 34010: REFP_CAM_DIR_IS_MINUS)
If MD 34050: REFP_SEARCH_MARKER_REVERSE (direction reversal at the reference
cam) is set, then for synchronization with a rising reference cam edge, at the cams, the axis
travels at the velocity defined in MD 34020: REFP_VELO_SEARCH_CAM.
2) Indirect measurement system with BERO on the load-side (preferred for spindles)
At this velocity, the zero mark associated with the BERO is searched for.
The zero mark is accepted if the actual velocity is within the tolerance range defined by
MD 35150: SPIND_DES_VELO_TOL, from the velocity specified in
MD 34040: MD 34040: REFP_VELO_SEARCH_MARKER[n].
34050 REFP_SEARCH_MARKER_REVERSE[n]
MD number Change of direction on reference cam [encoder number]: 0
Meaning: This can be used to set the search direction for the zero mark:
0: Synchronization with falling reference cam edge
The machine axis accelerates to the velocity defined in MD 34040:
REFP_VELO_SEARCH_MARKER (reference point creep velocity) in the opposite direction to
that defined in MD 34010: REFP_CAM_DIR_IS_MINUS (approach reference point in minus
direction).
If the reference cam is exited (“Reference point approach delay” interface signal is reset), the
control synchronizes itself with the first zero mark.
1: Synchronization with rising reference cam edge
The machine axis accelerates to the velocity defined in MD 34020:
REFP_VELO_SEARCH_MARKER (reference point creep velocity) in the opposite direction to
that specified in the MD: REFP_CAM_DIR_IS_MINUS. When the axis leaves the reference cam
(“Reference point approach delay” interface signal
is reset), the machine axis decelerates to a stop and accelerates in the opposite direction to-
wards the reference cam at the velocity defined in MD: REFP_VELO_SEARCH_MARKER.
When the reference cam is reached (“Reference point approach delay” interface signal is ena-
bled), the control is synchronizing with the first zero mark.
34060 REFP_MAX_MARKER_DIST[n]
MD number Maximum distance to reference mark [encoder no.]: 0
Meaning: For incremental measuring systems:
If, after leaving the reference cam (”Reference point approach delay” interface signal is reset),
the machine axis travels a distance defined in MD: REFP_MAX_MARKER_DIST without detec-
ting the reference mark, the axis stops and alarm 20002 “Zero mark missing” is signaled.
Application example(s) If, on incremental measurement systems, the control is required to detect reliably that the same
zero mark is always used for synchronization (to avoid detection of an incorrect machine zero),
the maximum value in this MD must not exceed the distance between two reference marks.

6FC5397-1CP10-1BA0 8-151
34070 REFP_VELO_POS
MD number Reference point positioning velocity
Standard default value: 1000.0 mm/min, Minimum input limit: 0.0 Maximum input limit: ***
2.77 rpm
rpm
Meaning: With incremental measuring systems:
The axis travels at this velocity between the time of synchronization with the first zero mark and
arrival at the reference point.
34080 REFP_MOVE_DIST[n]
MD number Reference point distance/target point with distance-coded system [encoder number]: 0
Default setting: –2.0 Minimum input limit: *** Maximum input limit: ***
Meaning: With incremental measuring systems
Following synchronization with the first zero mark, the machine accelerates to the velocity
defined in MD 34070: REFP_VELO_POS (reference point positioning velocity) and travels
a distance calculated from the addition of MD: REFP_MOVE_DIST and MD 34090:
REFP_MOVE_DIST_CORR (reference point offset). This distance precisely matches the
distance between the zero mark detected in phase 2 and the reference point.
MD 34100: REFP_SET_POS[0]
Velocity MD: REFP_MOV_DIST + MD: REFP_SET_POS_CORR
MD 34020:
REFP_VELO_SEARCH_CAM
(Reference point approach velocity)
MD 34040: REFP_VELO_SEARCH_
MARKER
(reference point creep velocity)
Reference point
Zero mark approach delay Reference point
cam
34090 REFP_MOVE_DIST_CORR[n]
MD number Reference point offset/absolute offset, distance-coded, n: [encoder number]: 0
Default setting: 0.0 Minimum input limit: *** Maximum input limit: ***
Meaning: S Incremental encoder with zero mark(s):
After detecting the zero mark, the axis is positioned away from the zero mark through the
distance specified by MD 34080: REFP_MOVE_DIST + REFP_MOVE_DIST_CORR. Once
the axis has traveled this distance, it has reached the reference point. MD 34100:
REFP_SET_POS is included in the actual value.
Override switches are effective during the traversing motion through
REFP_MOVE_DIST+REFP_MOVE_DIST_CORR
S Absolute value encoder:
REFP_MOVE_DIST_CORR is effective as absolute offset. It defines the offset between ma-
chine zero and the zero mark of the absolute measuring system.
Note: this MD is changed by the control during calibration and modulo correction in conjunc-
tion with the absolute encoders!

8-152 6FC5397-1CP10-1BA0
34092 REFP_CAM_SHIFT
MD number Electronic reference cam offset for incremental measurement systems with equidistant zero
marks
Changes effective after RESET Protection level: 2/2 Unit: mm
Meaning: When the reference cam signal occurs, the zero mark search is not started immediately,
but with a delay after the distance of REFP_CAM_SHIFT. The reproducibility of the zero
mark search can thus be ensured even in the case of temperature-dependent expansion
of the reference cam through defined selection of a zero mark. As the control calculates
the reference cam offset in the interpolation cycle, the actual cam offset is
at least
REFP_CAM_SHIFT and
maximum
REFP_CAM_SHIFT+(MD 34040: REFP_VELO_SEARCH_MARKER * interpolation
cycle)
The reference cam offset acts in the direction of zero mark search.
The reference cam offset is active only if the cam MD 34000: REFP_CAM_IS_ACTIVE=1
is present.
ÉÉÉÉ
Thermal expansion
ÉÉÉÉ
Cam signal
ÉÉÉÉÉÉÉ Zero mark search
ÉÉÉÇÇÇÇ
Zero mark
ÉÉÉÇÇÇÇ
1 2
Cam signal
REMEDY with
offset
REFP_CAM_SHIFT 1+2
34093 REFP_CAM_MARKER_DIST
MD number Reference cam/reference mark distance
Meaning: The indicated value is equivalent to the distance between departure from the reference cam and
detection of the reference mark. If the values are too small, there is a risk that the determination
of the reference point will be non-deterministic, due to temperature effects or fluctuations in the
operating time of the cam signal. The path covered can be used as a guide for setting the elec-
tronic reference cam offset.
The machine data is read only.
Related to .... REFP_CAM_IS_ACTIVE, REFP_SHIFT_CAM

6FC5397-1CP10-1BA0 8-153
34100 REFP_SET_POS[0]
MD number Reference point for an incremental system
Meaning: S Incremental encoder with zero mark(s):
The position value which is set as the current position after detecting the zero mark and tra-
veling through the distance REFP_MOVE_DIST + REFP_MOVE_DIST_CORR (relative to
the zero mark).
REFP_SET_POS corresponds to the correct actual value at the calibration position. The
reaction on the machine depends on the status of MD34210: ENC_REFP_STATE:
When MD 34210: ENC_REFP_STATE = 1, the value of REFP_SET_POS is transferred as
the absolute value.
When MD 34210: ENC_REFP_STATE = 2 and MD 34330: REFP_STOP_AT_ABS_MAR-
KER=0, the axis approaches the target position defined in REFP_SET_POS. The value from
REFP_SET_POS is used.
Note: MD: REFP_SET_POS[1]...[3] reserved – do not use.

Related to ....
34110 REFP_CYCLE_NR
MD number Axis sequence for channel-specific referencing
Default setting: 0 Minimum input limit: –1 Maximum input limit:
4
Meaning: 0 : Axis-specific referencing
Axis-specific referencing is started separately for each machine axis with the “plus/minus
travel keys” interface signal. All axes can be referenced at the same time. If the machine
axes are to be referenced in a particular order, the following options are available:
D The operator must follow the order himself after starting.
D The PLC must check the order after starting or define the order itself.
The machine axis is not started via channel-specific referencing . The NC cannot be started
without first referencing this axis.
–1: The machine axis is started using channel-specific referencing.
NC start is possible without referencing this axis.
Note:
The effect of inputting –1 for all axes of a channel can be achieved by setting the channel-
specific MD 20700: REFP_NC_START_LOCK (NC start disable without reference point) to
zero.
> 0 : Channel-specific referencing
Channel specific referencing is started with the “activate referencing” interface signal
(V3200 0001.0). The control acknowledges a successful start with the “referencing active”
interface signal. Each machine axis assigned to the channel can be referenced with chan-
nel-specific referencing (this is achieved internally on the control by simulating the plus/mi-
nus travel keys).
MD: REFP_CYCLE_NR can be used to define the sequence in which machine data is
referenced:
1: The machine axis is started using channel-specific referencing.
2: The machine axis is started using channel-specific referencing if all of the machine axes
designated in MD: REFP_CYCLE_NR with a 1 are referenced.
MD irrelevant for ... ... Axis-specific referencing
Related to .... “Activate referencing” interface signal
“Referencing active” interface signal

8-154 6FC5397-1CP10-1BA0
34200 ENC_REFP_MODE[n]
MD number Referencing mode [encoder no.]: 0
Meaning: All mounted position measuring systems can be subdivided as follows for referencing:
0: if absolute encoder exists: transfer of MD 34100: REFP_SET_POS
Other encoders: no reference point travel possible
1: referencing with incremental measuring systems:
Incremental rotary measuring system
Incremental linear measuring system (position measuring system)
Zero pulse on encoder track
(not with absolute encoders)
2, 3, 4, 5, 6: not available
7: synchronize spindle with BERO, configured approach velocity (MD 34040)
Related to ....
34210 ENC_REFP_STATE[n]
MD number Status of absolute value encoder [encoder number]: 0
Changes effective after SOFORT Protection level: 2/2 Unit: –
Meaning: S Absolute value encoder:
0: Default when installing for the first time: encoder is not calibrated.
1: encoder calibration enabled, encoder not yet calibrated
2: encoder is calibrated
S Incremental encoder:
0: default: no auto referencing
1: auto referencing enabled, but encoder not yet referenced or
not in exact stop
2: encoder is referenced and in exact stop
auto referencing effective next time the encoder is activated.
Application example(s) The MD ENC_REFP_STATE can be altered by the person installing and by the operating
system:
– Alteration by the installer:
The data must be set to “1” by the commissioning engineer encoder is required.
– Alteration by the operating system:
on successful adjustment from 1 ==> 2
if adjustment from 2 ==> 0 or 1 has become invalid
gear speed changes with change of ratio are identified by the operating system.
Changes to the mechanical components of the machine (e.g. encoder change,
motor and encoder change, etc.) are not detected.
S Incremental encoder:
– Alteration by the installer:
The data must be set to “1” by the commissioning engineer if automatic referencing is to
be carried out.
– Alteration by the operating system:
for referenced axis and “axis at exact stop” from 1 ==> 2
if the reference position has become invalid or if the axis is not at exact stop from 2==> 1
Unlike the absolute value encoder, changes in position here are notdetected during
power OFF or when the encoder is inactive.

6FC5397-1CP10-1BA0 8-155
36302 ENC_FREQ_LIMIT_LOW
MD number Encoder limit frequency re-synchronization
Meaning: The encoder frequency monitoring function operates with a hysteresis.
MD 36300: ENC_FREQ_LIMIT defines the encoder limit frequency at which the encoder is
switched off, MD: ENC_FREQ_LIMIT_LOW the frequency at which the encoder is switched back
on again.
MD: ENC_FREQ_LIMIT_LOW is a fraction of MD: ENC_FREQ_LIMIT in percent.
Normally the default of MD: ENC_FREQ_LIMIT_LOW is enough. However, the limit frequency of
the absolute track on absolute value encoders with En-Dat interface is significantly lower than
the limit frequency of the incremental track. By setting a low value in
MD: ENC_FREQ_LIMIT, it is possible to ensure that the encoder is not switched on again until
the frequency is lower than the limit frequency of the absolute track and is thus not referenced
until permitted by the absolute track. This referencing takes place automatically for spindles.
Example EQN 1325:
Limit frequency of incremental track electronics: 430 kHz
===>MD 36300: ENC_FREQ_LIMIT = 430000 Hz
Limit frequency of absolute track: approx. 2000 encoder rev/min with 2048 marks, i.e. limit fre-
quency (2000/60) * 2048 Hz = 68 kHz
===>MD 36302: ENC_FREQ_LIMIT_LOW = 68/430 = 15 %
Related to ....

8-156 6FC5397-1CP10-1BA0
8.6.1 Channel-specific signals
Signals to channel
V3200 0001.0 Activate referencing

Interface signal Signal(s) to channel (PLC –> NCK)
Signal state 1 or signal Channel-specific referencing is started with the “Activate referencing” interface signal. The con-
transition 0 –––> 1 trol acknowledges a successful start with the “Referencing active” interface signal. Each machine
axis assigned to the channel can be referenced with channel-specific referencing (this is achie-
ved internally on the control by simulating the plus/minus travel keys). The axis-specific
MD 34110: REFP_CYCLE_NR (axis sequence for channel-specific referencing) can be used to
define the sequence in which the machine data are referenced. If all axes entered in
MD: REFP_CYCLE_NR have reached their reference point, the “all axes referenced” interface
signal (V3300 0004.2) is enabled.
Application example(s) If the machine axes are to be referenced in a particular sequence, the following options are
available:
S The operator must observe the correct sequence on start-up
S The PLC umust check the sequence when starting or define it itself.
S The channel-specific referencing function is used.
Related to .... “Referencing active” interface signal (V3300 0001.0)
“All axes referenced” interface signal (V3300 0004.2)
Signals from channel
V3300 0001.0 Referencing active

Interface signal Signal(s) from channel (NCK –> PLC)
Signal state 1 or signal Channel-specific referencing has been started with the “Activate referencing” interface signal and
transition 0 –––> 1 successful start acknowledged with the “Referencing active” interface signal. Channel-specific
referencing is operational.
Signal state 0 or signal S Channel-specific referencing has been completed
transition 1 –––> 0 S Axis-specific referencing running
S No referencing active
Signal irrelevant for ... ... Spindles
Related to .... “Activate referencing” interface signal (V3200 0001.0)
V3300 0004.2 All axes referenced

Interface signal Signal(s) from channel (PLC –> NCK)
Signal state 1 or signal All axes referenced.
transition 0 –––> 1 (Note for axes requiring referencing:
MD 34110: REFP_CYCLE_NR, MD 20700: REFP_NC_START_LOCK )
Signal state 0 or signal One or more axes on the channel have not been referenced.
Special cases, errors, ... ... The spindles of the channel have no effect on this interface signal.
Related to .... “Referenced/synchronizing 1” interface signal (V390x 0000.4)

6FC5397-1CP10-1BA0 8-157
8.7 Data Fields, lists
V380x1000.7 Reference point approach delay

Signal state 1 or signal The machine axis is positioned at the reference cam.
Signal state 0 or signal The machine axis is positioned in front of the reference cam. A reference cam of appropriate
transition 1 –––> 0 length (to the end of the traversing range) has been used to prevent the machine axis from being
positioned behind the referencing cam.
Related to ....
V390x 0000.4 Referenced/synchronizing 1

Edge evaluation: Signal(s) updated: Signal(s) valid from SW:
Signal state 1 or signal Axes:
transition 0 –––> 1 When, during a reference point approach, the machine axis has reached the
reference point (incremental measurement systems) or target point (linear
measuring system with distance-coded reference marks), the machine axis is
deemed to have been referenced and the “referenced/synchronizing 1” interface
signal (depending on which position measurement system is active during referencing) is
enabled.
Spindles:
A spindle is synchronized (zero mark crossed or BERO responded) after Power On after one
spindle revolution at the latest.
Signal state 0 or signal The machine axis/spindle with position measurement system 1 is not referenced/synchronizing.
Related to .... “Position measuring system 1” interface signal (V380x 0000.5)
References Chapter “Spindles”


rence
Specific to operating mode
V3000 0001 .2 Machine function REF
V3100 0001 .2 Active machine function REF
Channel-specific
V3200 0001 .0 Activate referencing
V3300 0001 .0 Referencing active
V3300 0004 .2 All axes referenced
Axis-specific
V380x 0000 .5 Position measuring system 1

8-158 6FC5397-1CP10-1BA0
Axis-specific
V380x 1000 .7 Reference point approach delay
V390x 0000 .4 Referenced, synchronizing 1
8.7.2 Machine data

rence
Channel-specific
20700 REFP_NC_START_LOCK NC start disable without reference point
Axis-specific
30200 NUM_ENCS Number of encoders G1
30240 ENC_TYP Actual value encoder type G1
31122 BERO_DELAY_TIME_PLUS BERO delay time in plus direction
31123 BERO_DELAY_TIME_MINUS BERO delay time in minus direction
34000 REFP_CAM_IS_ACTIVE Axis with reference cam
34010 REFP_CAM_DIR_IS_MINUS Reference point approach in minus direction
34020 REFP_VELO_SEARCH_CAM Reference point approach velocity
34030 REFP_MAX_CAM_DIST Maximum distance to reference cam
34040 REFP_VELO_SEARCH_MARKER[0] Reference point creep velocity
34050 REFP_SEARCH_MARKER_REVERSE[0] Direction reversal to reference cam
34060 REFP_MAX_MARKER_DIST[0] Maximum distance to reference mark; maximum
distance to 2 reference marks with distance-coded
scales
34070 REFP_VELO_POS Reference point positioning velocity
34080 REFP_MOVE_DIST[0] Reference point distance/destination point for
distance-coded system
34090 REFP_MOVE_DIST_CORR[0] Reference point/absolute offset, distance-coded
34092 REFP_CAM_SHIFT Electronic reference cam shift for incremental
measurement systems with equidistant zero marks.
34093 REFP_CAM_MARKER_DIST Reference cam/reference mark distance
34100 REFP_SET_POS[0] Reference point value
34110 REFP_CYCLE_NR Axis sequence for channel-specific referencing
34200 ENC_REFP_MODE[0] Referencing mode
34210 ENC_REFP_STATE[0] Status of absolute value encoder
34220 ENC_ABS_TURNS_MODULO Absolute value encoder range for rotary encoders R2
36300 ENC_FREQ_LIMIT Encoder limit frequency A3
36302 ENC_FREQ_LIMIT_LOW Encoder limit frequency re-synchronization
36310 ENC_ZERO_MONITORING Zero-mark monitoring A3

6FC5397-1CP10-1BA0 8-159
Notes

8-160 6FC5397-1CP10-1BA0
Manual and Handwheel Travel (H1) 9
9.1 General characteristics of traversing in JOG
JOG mode
Axes/Spindles can be traversed manually in JOG mode. The active mode is transmitted to
the PLC via the IS “Active mode: JOG” (V3100 0000.2) and is visible in the display.
References: Chapter “Operating Modes, Program Mode”
Traversing possibilities
Traversing the axes can be done via the traverse keys of a connected machine control panel
(manual travel) or via connected handwheels (handwheel jogging).
Traversing can be done simultaneously for all machine axes via keys (with an appropriately
configured customized machine control panel) or via handwheel depending on the number of
handwheels connected.
This simultaneous movement of multiple machine axes does not give rise to an interpolatory
grouping.
Coordinate systems
The user has the option of traversing axes in the coordinate systems:
S Machine coordinate system (MCS); machine axes manually traversable
S Workpiece coordinate system (WCS); geometry axes manually traversable
Machine functions
Variants exist for manual traverse (the so-called machine functions):
S Continuous traversal
S Incremental traversal (INC, preset number of traversal increments)
An increment is evaluated as 0.001mm if the basic system setting is metric.
The PLC user program transfers a user-specific machine function queued at the machine
control interface to the relevant PLC/NCK interface. Here the axis-specific NCK/PLC interface
should be used for a machine axis/spindle, and the channel-specific NCK/PLC interface
should be used for a geometry axis or valid for all axes/spindles and geometry axes: Signals
in the operating mode range (see also following section).

6FC5397-1CP10-1BA0 9-161
Manual and Handwheel Travel (H1)
Handwheel jogging
The axes can also be traversed via the handwheel in MCS or WCS. Incremental traversing
(INC...) must be set to evaluate the handwheel pulses (see Section 9.4).
Traversing the geometry axes

If workpieces whose workpiece coordinate system is not parallel to the machine coordinate
system are being machined (inclined clamping, programmed rotation active in the contour),
traversing can be done along the axes of the workpiece coordinate system via the traverse
keys or handwheel. In the stopped state, switch from the operating mode AUTO to JOG and
traverse a geometry axis instead of a machine axis. Depending on the active rotation of the
workpiece coordinate system, between one and three machine axes move.
If a machine axis is traversed, this cannot also be moved via the traverse keys of a geometry
axis. The traversing motion of the machine axis must first have been completed – otherwise
alarm 20062 “Axis already active” is output.
Three geometry axes can be traversed simultaneously with the handwheels 1 to 2.
Note: A separate, channel-specific PLC interface supplies geometry axes.
Transverse axis in “turning” technology

A geometry axis is defined as a transverse axis. If radius programming (DIAMOF) is selected
instead of diameter programming (DIAMON), the following must be noted when traversing in
JOG:
S Continuous jogging:
there are no differences when a transverse axis is traversed in continuous mode.
S Incremental jogging:
Only half the distance of the selected increment size is traversed.
S Jogging with the handwheel:
as for incremental jogging, only half the path is traversed per handwheel pulse.
References: Chapter “Transverse axis”
Moving the spindle in the JOG mode

The spindle can also be traversed manually in the JOG mode. Essentially the same condi-
tions apply as for manual traverse of machine axes. With JOG, the spindle can be traversed
via the traverse keys/ IS “continuous” or “INC...”. The mode is selected and activated via the
axis/spindle-specific PLC interface as for the axes.
The spindle can be traversed both in positioning mode (spindle in position control) and in
control mode.
The parameter set (machine data) of the current gear stage applies.

9-162 6FC5397-1CP10-1BA0
Velocity
The velocity of the axes/spindle during manual traverse in JOG is defined by the following
default values:
S With linear axes with the general SD 41110: JOG_SET_VELO (JOG velocity with G94) or
for rotary axes with SD 41130: JOG_ROT_AX_SET_VELO (JOG velocity for rotary axes)
or SD 41200: JOG_SPIND_SET_VELO (JOG velocity for spindles).
S If the corresponding SD is zero, the appropriate axis-specific
MD 32020 applies: JOG_VELO (JOG axis velocity).
In the case of geometry axes, the value of the assigned machine axis is used: X–>X1,
Y–>Y1, Z–>Z1 (in default setting).
Rapid traverse override

If in the case of machine axes the rapid traverse override key is pressed at the same time as
the traversing keys, then the movement is executed at the rapid traverse velocity set in axis-
specific MD 32010: JOG_VELO_RAPID (axis velocity in JOG mode with rapid traverse
override).
The value of the assigned machine axis is used for geometry axes: X–>X1, Y–>Y1, Z–>Z1
(in default setting). The separate PLC interface area of the geometry axes must be used for
control.
Velocity override
The velocity at which axes traverse in JOG can also be influenced by the axis-specific feed-
rate override switch for machine axes, provided that axis-specific IS “Override active” (V380x
0001.7) is set.
If the switch is set at 0%, the axis is not traversed – even if IS “Override active” is not set.
The channel-specific feedrate override switch applies to geometry axes, or, in the case of
rapid traverse override, the rapid traverse override switch.
The activated spindle override switch applies to the spindle.
References: Chapter “Feedrate”
Acceleration
The maximum axis acceleration is defined by the axis-specific MD 32300: MAX_AX_ACCEL.
The acceleration can also be set via a preset characteristic curve in JOG mode. The possible
settings are described in:
References: Chapter “Acceleration”
PLC interface
A separate PLC interface (VB 3200 1000, ff or VB 3300 1000, ff ) exists for geometry axes
(axes in WCS) that contains the same signals as the axis-specific PLC interface.

6FC5397-1CP10-1BA0 9-163
When the spindle is traversed manually, the PLC interface signals between the NCK and
PLC have the same effect as for machine axes. The IS “Position reached with exact stop fine/
coarse” are set only if the spindle is in position control mode.
For purely spindle-specific interface signals, the following should be noted when traversing
the spindle in JOG:
S The following PLC interface signals to the spindle have no effect:
– IS “Invert M3/M4” (V380x 2001.6)
– IS “Set direction of rotation ccw” or “Set direction of rotation cw” (V380x 2002.7 or .6)
– IS “Oscillation speed” (V380x 2001.5)
S The following PLC interface signals from the spindle are not set:
– IS “Actual speed cw” (V390x 2001.7)
– IS “Spindle in setpoint range” (V390x 2001.5)
Note
A reset causes the manual traverse motion (axis/spindle) to be terminated with brake ramp.
Limiting
The following limits are active in JOG mode:
S Working area limits (axis must be referenced)
S Software limit switches 1 or 2 (axis must be referenced)
S Hardware limit switches
The control ensures that the traversing movement is aborted as soon as the first valid limiting
has been reached. Velocity control ensures that deceleration is initiated early enough for the
axis to stop exactly at the limit position (e.g. software limit switch). Only when the hardware
limit switch is triggered does the axis stop abruptly with “Rapid stop”.
An alarm is output when the corresponding limit is reached. The control automatically pre-
vents further movement in this direction. The traverse keys and the handwheel have no effect
in this direction.
Important
The software limit switches and working area limits are only active if the axis has previously
been referenced.
Machine manufacturer
The function for retracting an axis that has reached the limit position depends on the machine-tool
manufacturer. Please refer to the machine-tool manufacturer’s documentation!

9-164 6FC5397-1CP10-1BA0
9.2 Continuous jogging
For further information on working area limits and hardware and software limit switches see:
9.2 Continuous jogging
Selection
When JOG mode is selected, the active machine function “continuous” interface signal is set
automatically:
For geometry axes: V3300 1001.6, V3300 1005.6, V3300 1009.6
For machine axes/spindle: V390x 0005.6
Continuous mode in JOG mode can also be selected via the PLC interface (IS “Machine
function: continuous”).
The PLC defines via the “INC inputs in mode group range active” interface signal (V2600
0001.0) the signal range with which the INC/continuous signals are supplied to the NCK:
V2600 0001.0 = 1 –> in operating mode range: VB3000 0002,
valid for all axes
V2600 0001.0 = 0 –> in geometric axis/axis range:
VB3200 1001, VB3200 1005,
VB3200 1009, VB380x 0005
Traversing keys +/–

The plus and minus traversing keys are selected to move the relevant axis in the appropriate
direction.
Traverse key signals PLC to NCK IS:
For geometry axes (traverse in WCS): V3200 1000.7 /.6, V3200 1004.7 /.6,
V3200 1008.7 /.6
For machine axes/spindle (traverse in MCS): V380x 004.7 /.6
If both traverse keys of an axis are activated at the same time, no traverse motion occurs, or
any axis in motion is stopped.
Travel command +/–

As soon as a traverse request for an axis/spindle is active (e.g. after selection of a traverse
key), the IS “Travel command+” or “Travel command–” is sent to the PLC (depending on se-
lected traverse direction):
For geometry axes: V3300 1000.7 /.6, V3300 1004.7 /.6, V3300 1008.7 /.6
For machine axes/spindle: V390x 004.7 /.6
Continuous traversal in jog mode

The axis traverses for as long as the traverse key is held down if no axis limit is reached first.
When the traverse key is released, the axis is decelerated to zero speed and the movement
comes to an end.

6FC5397-1CP10-1BA0 9-165
9.3 Incremental jogging (INC)
9.3 Incremental jogging (INC)
Programming increments
The traversing path to be traversed by the axis is defined by so-called increments (also ter-
med “incremental dimensions”). The required increment must be set by the machine operator
before the axis is jogged.
The setting is made on the machine control panel, for example. The IS “Machine function:
INC1 to INCvar” associated with the required increment must be set by the PLC user pro-
gram after it has been correctly linked.
The PLC defines via the “INC inputs in mode group range active” interface signal (V2600
0001.0) the signal range within which INC signals are delivered to the NCK:
V2600 0001.0 = 1 –> in operating mode range: VB3000 0002,
valid for all axes
V2600 0001.0 = 0 –> in geometric axis/axis range:
VB3200 1001, VB3200 1005,
VB3200 1009, VB380x 0005
The active machine function: IS “INC... “ is signaled by the NCK to the PLC:
For geometry axes: V3300 1001.0 , V3300 1005.0, V3300 1009.0 to .5
For machine axes/spindle: V390x 0005.0 to .5
Settable increments
The operator can set different increment sizes:
S Fixed increments whose increment sizes are common to all axes: INC1, INC10, INC100,
INC1000 (only via IS: INC10000).
S And a variable increment (INCvar). The increment setting for the variable increment also
applies jointly to all axes and is entered in SD 41010: JOG_VAR_INCR_SIZE (size of the
variable increment for INC/handwheel).
Incremental jogging in JOG mode

If the traverse key for the required direction (e.g. +) is pressed, the axis begins to traverse the
increment set. If the traverse key is released before the increment has been traversed, the
movement is interrupted and the axis stops. If the same key is pressed again, the axis moves
the remaining distance. As long as the remaining distance is greater than zero, the move-
ment can again be interrupted by releasing the traverse key.
Pressing the key for the opposite direction has no effect until the increment has been comple-
tely traversed or the movement has been interrupted.
Traverse keys and travel command

As for continuous traversing (see Section 9.2)
Abort traversing movement

If you do not want to traverse the whole increment, the traverse movement can be aborted
with RESET or “Delete distance-to-go” interface signal (V380x 0002.2).

9-166 6FC5397-1CP10-1BA0
9.4 Handwheel traversal in JOG
Selection
JOG mode must be active. The operator must also set the increment INC1, INC10, ... which
applies when jogging with the handwheel.
Up to two handwheels can be connected. In this way, up to two axes can be traversed by
handwheel simultaneously and independently.
A handwheel is assigned to the geometry or machine axes (WCS or MCS) via interface
signals.
The axis to be moved as a result of rotating handwheel 1 to 2 can be set:
S Via PLC user interface with “Activate handwheel 1 to 2” interface signal
For machine axes (traverse in MCS): V380x 0004.0 to .2
For geometry axes (traverse in WCS): V3200 0000.0 to .2, V3200 0004.0 to .2,
V3200 0008.0 to .2
The link to the PLC interface is made via the PLC user program. Only here can several
machine axes be assigned to one handwheel simultaneously.
S By menu-guided operation (HMI)
Operating the soft key Handwheel in the JOG mode basic menu displays the window
“Handwheel”. This enables an axis (WCS or MCS) to be assigned to each handwheel.
A separate user interface between the HMI and PLC is provided to allow activation of the
handwheel from the operator panel (HMI). This interface that the basic PLC program supplies
for handwheels 1 to 3 contains the following information:
S The axis numbers assigned to the handwheel
IS “Axis number handwheel n” (VB1900 1003, ff)
S Additional information on machine or geometry axis
IS “Machine axis” (VB1900 1003.7, ff)
The “Activate handwheel” interface signal is either set to “0” (disable) or to “1” (enable) by the
PLC user program for the defined axis.
Settings as path or velocity

When the electronic handwheel is turned, the assigned axis is traversed either in the positive
or negative direction depending on the direction of rotation.
The general MD 11346: HANDWH_TRUE_DISTANCE (handwheel path or velocity setting)
enables the setting type of the handwheel motion to be set and thus adapted to the purpose
of use.
MD value =0 (default):
The settings from the handwheel are velocity default settings. Deceleration in the case of
handwheel standstill is done along the shortest path.
MD value=1:
The settings from the handwheel are path settings. No pulses are lost. Limiting the velocity to
the maximum permissible value can cause the axes to overtravel. Particular care should be
taken in the case of a high weighting of the handwheel pulses.
Further variants of the path or speed setting are possible via value=2 or 3.

6FC5397-1CP10-1BA0 9-167
Evaluation
The traversing path/velocity produced by rotation of the handwheel is dependent on the follo-
wing factors:
S Number of handwheel pulses received at the interface
S Active increment (machine function INC1, INC10, INC100, ... )
An increment is evaluated as 0.001mm for the metric basic system setting.
S Handwheel pulse weighting with general MD11320: HANDWH_IMP_PER_LATCH
(handwheel pulses per detent position)
Travel command +/–

While the axis is moving, the “Travel command+” or “Travel command–” interface signal is
transmitted to the PLC depending on the direction of motion.
For geometry axes: V3300 1000.7 /.6, V3300 1004.7 /.6, V3300 1008.7 /.6
For machine axes/spindle: V390x 004.7 /.6
If the axis is already being moved using the direction keys, the handwheel cannot be used.
Alarm 20051 “Jogging with the handwheel not possible” is output.
Velocity
The velocity results from the pulses generated by the handwheel and the pulse evaluation:
Traverse path per time unit.
This velocity is limited by the value in the axis-specific
MD 32000: MAX_AX_VELO.
Abortion/interruption of traversing movement

The traversing movement is aborted as the result of a RESET or the axis-specific IS “Deletion
of distance-to-go” (V380x 0002.2). The setpoint/actual-value difference is deleted.
NC STOP only interrupts the traversing movement. NC-START releases the handwheel mo-
tion again.
Movement in the opposite direction

Depending on the setting in MD 11310: HANDWH_REVERSE is the behavior when the tra-
versing direction is reversed:
S MD value =0:
If the handwheel is moved in the opposite direction, the resulting distance is computed
and the calculated end point is approached as fast as possible: If this end point is located
before the point where the moving axis can decelerate in the current movement direction,
the unit is decelerated and the end point is approached by movement in the opposite di-
rection. If this is not the case, the newly calculated end point is approached immediately.
S MD value >0:
If the handwheel is moved in the opposite direction by at least the number of pulses indi-
cated in the machine data, the axis is decelerated as fast as possible and all pulses recei-
ved until the end of interpolation are ignored. That means that another movement takes
place only after zero speed (setpoint side) of the axis.

9-168 6FC5397-1CP10-1BA0
Response at software limit switches, working area limits

When axes are traversed in JOG mode, they can traverse only up to the first active limit be-
fore the corresponding alarm is output. Depending on machine data
MD 11310: HANDWH_REVERSE, the behavior is as follows (as long as the axis on the set-
point side has not yet reached the end point):
S MD value =0:
The distance resulting from the handwheel pulses forms a fictitious end point which is
used for the subsequent calculations: If this fictitious end point is positioned for example
10mm behind the limit, these 10 mm must be traversed in the opposite direction before
the axis traverses again. If a movement in the opposite direction is to be performed imme-
diately after a limit, the fictitious distance-to-go can be deleted via IS “Delete distance-to-
go” (V380x 0002.2) or by de-selecting of the handwheel assignment.
S MD value >0:
All handwheel pulses leading to an end point behind the limit are ignored. Any movement
of the handwheel in the opposite direction results immediately in a movement in the oppo-
site direction, i.e. away from the limit.
11310 MN_HANDWH_REVERSE
MD number Threshold for change in handwheel direction
Meaning: 0: No immediate movement in the opposite direction
>0: Immediate movement in the opposite direction if the handwheel is turned in the opposite
direction by at least the number of pulses indicated
11320 HANDWH_IMP_PER_LATCH[0]...[2]
MD number Handwheel pulses per detent position [handwheel index]:
Default setting: (1, 1, 1) Minimum input limit: *** Maximum input limit: ***
Meaning: This adapts the connected handwheels to the control system.
The number of pulses generated by the handwheel for each handwheel detent position is ent-
ered. The handwheel pulse weighting may be defined for each connected handwheel (1 to 2)
separately.
When adapted to the control, each handwheel detent position has the same effect as one press
of the traverse key in incremental jogging mode.
If a negative value is entered, the handwheel is active in the reverse direction.
Related to .... MD: JOG_INCR_WEIGHT (weighting of an increment of a machine axis for INC/manual).

6FC5397-1CP10-1BA0 9-169
11346 HANDWH_TRUE_DISTANCE
MD number Handwheel path or velocity values
Meaning: 0: The settings from the handwheel are velocity settings. When the handwheel is stationary,
braking is realized along the shortest path.
1: The settings from the handwheel are distance settings. No pulses are lost. Limiting the
velocity to the maximum permissible value can cause the axes to overtravel.
2: Effect as for value=0, however, with a longer braking travel when the handwheel is
stationary.
3: Effect as for value=1, however, with a longer braking travel when the handwheel is
stationary.
Related to ....
32010 JOG_VELO_RAPID
MD number Rapid traverse in JOG mode
Default setting: 10000 mm/min, Minimum input limit: 0.0 Maximum input limit: ***
27.77 rpm
Changes effective after RESET Protection level: 2/7 Unit:
Linear axis: mm/min
Rotary axis: rpm
Meaning: The axis velocity entered here applies when the rapid traverse override key is operated in JOG
mode and when the feedrate override switch is set to 100%.
The value entered may not exceed the maximum permissible axis velocity
(MD 32000: MAX_AX_VELO).
MD 32010 will not be used for the programmed rapid traverse G0.
MD irrelevant for ... ... Operating modes AUTOMATIC and MDA
Related to .... MD 32000: MAX_AX_VELO (maximum axis velocity)
IS “Rapid transverse override” (V3200 1000.5, V3200 1004.5, V3200 1008.5, V380x 0004.5,)
IS “Feedrate override” (VB380x 0000) – axis-specific
IS “Rapid transverse override” (VB3200 0005) – for geom. axes

9-170 6FC5397-1CP10-1BA0
32020 JOG_VELO
MD number Axis velocity in JOG mode
Default setting: 2000 mm/min, Minimum input limit: 0.0 Maximum input limit: ***
5.55 rpm
Changes effective after RESET Protection level: 2/7 Unit:
Linear axis: mm/min
Rotary axis: rpm
Meaning: The velocity entered applies to traversing axes in JOG mode when the feedrate override switch
is at position 100%.
The velocity of MD 32020: JOG_VELO is only used when general setting data is SD 41110:
JOG_SET_VELO = 0 for linear axes or
SD 41130: JOG_ROT_AX_SET_VELO = 0 for rotary axes.
If this is the case, the axis velocity is active for
– Continuous jogging
– Incremental traversing (INC1, ..., INCvar)
Spindle in JOG mode:

This can also be used to define the traverse velocity in JOG mode for specific spindles if
SD 41200: JOG_SPIND_SET_VELO = 0.
The velocity is influenced by the spindle speed override switch.
MD irrelevant for ... ... Operating modes AUTOMATIC and MDA
Application example(s) If different velocities have to be set for the individual axes traversing in JOG mode, this can be
done for specific axes in this MD.
SD 41110: JOG_SET_VELO (or equivalent) may be set to 0!
Related to .... MD 32000: MAX_AX_VELO (maximum axis velocity)
SD 41110: JOG_SET_VELO (JOG velocity for G94, linear axis)
SD 41130: JOG_ROT_AX_SET_VELO (JOG velocity for rotary axes)
SD 41200: JOG_SPIND_SET_VELO (JOG speed for spindle), which applies to all spindles,
Axis-specific IS “Feedrate override” (VB380x 0000)
Axis-specific IS “Spindle override” (VB380x 2003)
Channel-specific IS “Feedrate override” (VB3200 0004) for geom. axes
9.5.3 General setting data
41010 JOG_VAR_INCR_SIZE
SD number Size of variable increment for INC/handwheel
Changes effective immediately: immediately Protection level: 7/7 Unit: mm or degrees
Meaning: This setting data defines the number of increments when variable increment (INCvar) is selec-
ted. This increment size is traversed by the axis in JOG mode whenever the traverse key is pres-
sed or the handwheel is turned one detent position and variable increment is selected (“Active
machine function: INC variable” interface signal for machine or geometry axes is set to 1).
Note: Please note that the increment size is active for incremental jogging and handwheel
jogging.
SD irrelevant for ... ... If INCvar not active
Related to .... IS “Active machine function: INCvariable” (V3200 1001.5, V3200 1005.5, V3200 1009.5,
V380x 0005.5)

6FC5397-1CP10-1BA0 9-171
41110 JOG_SET_VELO
SD number JOG velocity for linear axes (for G94)
Changes effective immediately: immediately Protection level: 7/7 Unit: mm/min or
rpm
Meaning: Value > 0:
The velocity entered applies to all linear axes in JOG mode if they are traversed manually using
the “traversing keys plus and minus”.
The axis velocity setting is active for:
– Continuous traversing
– Incremental traversing (INC1, ..., INCvar)
Value = 0:
The feedrate in JOG mode is the corresponding axis-specific MD 32020: JOG_VELO “JOG axis
velocity”. In this way, it is possible to define a separate JOG velocity for every axis.
SD irrelevant for ... ... – For rotary axes (SD 41130: JOG_ROT_AX_SET_VELO) applies
Related to .... Axis-specific MD 32020: JOG_VELO (JOG axis velocity)
Axis-specific MD 32000: MAX_AX_VELO (maximum axis velocity)
SD 41130: JOG_ROT_AX_SET_VELO (JOG velocity for rotary axes)
41130 JOG_ROT_AX_SET_VELO
SD number JOG velocity for rotary axes
Changes effective immediately: immediately Protection level: 7/7 Unit: rpm
Meaning: As for SD 41110: JOG_AX_SET_VELO – but for all rotary axes instead of linear axes
Application example(s) The operator can define a JOG velocity for a particular application.
Related to .... MD 32020: JOG_VELO (JOG axis velocity)
MD 32000: MAX_AX_VELO (maximum axis velocity)
41200 JOG_SPIND_SET_VELO
SD number JOG velocity for spindles
Changes effective immediately: immediately Protection level: 7/7 Unit: rpm
Meaning: Value > 0:
The velocity entered applies to spindles in JOG mode if they are traversed manually using the
“traversing keys plus and minus”.
The velocity setting is active for:
– Incremental jogging (INC1, ..., INCvar)
The value entered must not exceed the maximum permissible velocity (MD 32000:
MAX_AX_VELO).
Value = 0:
If 0 has been entered in the setting data, the active JOG velocity is
MD 32020: JOG_VELO (JOG axis velocity). Each axis can be given its own JOG velocity with
this MD (axis-specific MD).
When the spindle is traversed in JOG mode, the maximum velocity of the active gear stage
(MD 35130: GEAR_STEP_MAX_VELO_LIMIT) is taken into account.
SD irrelevant for ... ... Axes
Related to .... MD 32020: JOG_VELO (JOG axis velocity)
MD 35130: GEAR_STEP_MAX_VELO_LIMIT (maximum velocity of gear stages)
References Chapter “Spindle”

9-172 6FC5397-1CP10-1BA0
9.6.1 HMI signals to the PLC
V1900 0003.7 Machine axis for handwheel 1

V1900 0004.7 for handwheel 2
V1900 0005.7 for handwheel 3
Interface signal Signal(s) from NC (HMI –> PLC)
Signal state 1 or signal The operator has assigned an axis to the handwheel (1, 2, 3) directly on the operator panel. This
transition 0 –––> 1 axis is a machine axis – not a geometry axis (axis in the WCS).
For further information see IS “Axis number”.
Signal state 0 or signal The operator has assigned an axis to the handwheel (1, 2, 3) directly on the operator panel. This
transition 1 –––> 0 axis is a geometry axis (axis in the WCS).
For further information see IS “Axis number”.
Related to .... IS “Axis number” (V1900 0003.0 to .4, ff)
V1900 1003.0 to .2 Axis number for handwheel 1

V1900 1004.0 to .2 for handwheel 2
V1900 1005.0 to .2 for handwheel 3
Interface signal Signal(s) from NC (HMI –> PLC)
Significance of signal The operator can assign an axis to every handwheel directly via the operator panel. To do so, he
defines the required axis (e.g. X).
The PLC user interface provides the number of the axis plus the information ’machine axis or
geometry axis’ (”machine axis” interface signal) as HMI interface signals.
The “Activate handwheel” interface signal for the defined axis must be set from the PLC user
program. Depending on the setting in the HMI interface signal “machine axis”, either the interface
for the geometry axis or for the machine axis is used.
The following must be noted when assigning the axis designation to the axis number:
S IS “Machine axis” = 1; i.e. machine axis – not geometry axis:
The assignment is made via MD 10000: AXCONF_MACHAX_NAME_TAB[n]
(machine axis name).
S IS “Machine axis” = 0; i.e. geometry axis (axis in WCS):
The assignment is made via MD 20060: AXCONF_GEOAX_NAME_TAB[n]
(geometry axis name in channel). IS “Channel number geometry axis handwheel n” defines
the channel assigned to the handwheel.
The following coding applies to the axis number:
Bit 2 Bit 1 Bit 0 axis number
0 0 0 –
0 0 1 1
0 1 0 2
0 1 1 3
1 0 0 4
1 0 1 5
Note: Bit 3 and bit 4 must always be left with value =0.
Related to ....
IS “Machine axis” (V1900 1003.7 ff)
IS “Activate handwheel” 1 to 3 /geometry axes 1, 2, 3
(V3200 1000.0 to .2, V3200 1004.0 to .2, V3200 1008.0 to .2)
IS “Activate handwheel” 1 to 3 /machine axes (V380x 0004.0 to .2)
MD 10000: AXCONF_MACHAX_NAME_TAB [n] (machine axis name)
MD 20060: AXCONF_GEOAX_NAME_TAB[n] (name of the geometry axis in the channel)

6FC5397-1CP10-1BA0 9-173
9.6.2 NCK signals and signals in the operating mode range
Description of signals to NCK
V2600 0001.0 INC inputs in mode group range active

Interface signal Signal(s) to NCK (PLC –> NCK)
Signal state 1 or signal
transition 0 –––> 1 The IS “INC1”, “INC10”, ..., “continuous” in the operating mode range are used as input signals
(V3000 0002.0 to .6).
transition 1 –––> 0 The IS “INC1”, “INC10”, ..., “continuous” in the axis and geometry axis range are used as input
signals.
Related to .... IS “Machine function INC1 to continuous” in operating mode range (V3000 0002.0 to .6)
IS “Machine function INC1,...,continuous”
for geometry axis 1 (V3200 1001.0 to .6)
IS “Machine function INC1,...,continuous” in axis range (V380x 0005.0 to .6)
Description of signals to modes
V3000 0000.0 to .6 Machine function INC1, INC10, INC100, INC1000, INC10000, INCvar, continuous
Interface signal Signal(s) to modes (PLC –> NCK)
Signal state 1 or signal This input range is only used if the “INC inputs in mode group range active” interface signal
transition 0 –––> 1 (V2600 0001.0) is set. The signals then apply to all axes and geometry axes.
IS “INC...” defines how many increments the axis traverses when the traversing key is pressed
or the handwheel turned one detent position. JOG mode must be active. With “INCvar” the value
in the general SD 41010: JOG_VAR_INCR_SIZE applies.
In “continuous mode” the associated axis can be traversed with the plus or minus traversing key
according to how the traverse key is pressed.
As soon as the selected machine function becomes active, this is signaled to the PLC interface
(IS “Active machine function INC1; ...”). If several machine function signals (INC1, INC... or “Con-
tinuous jogging”) are selected at the interface simultaneously, no machine function is activated
by the control.
Note:
The input IS “INC...” or “continuous” for changing an active machine function must be active for
at least one PLC cycle. A static application is not required.
Signal state 0 or signal The machine function in question is not selected. No change to the active machine function is
transition 1 –––> 0 required.
If an axis is currently traversing an increment, this movement is also aborted if this machine func-
tion is de-selected or changed over.
Related to .... IS “INC inputs in mode group range active” (V2600 0001.0)
IS “Machine function INC1, ..., continuous”
IS “Machine function INC1, ..., continuous” in axis range (V380x 0005.0 to .6)
IS “Active machine function INC1, ..., continuous”
for geometry axis1 (V3300 1001.0 to .6)
IS “Active machine function INC1, ..., continuous” in axis range (V390x 0005.0 to .6)

9-174 6FC5397-1CP10-1BA0
Description of signals to channel
V3200 1000.0 to .2 Activate handwheel (1 to 3) for geometry axis 1

V3200 1004.0 to .2 for geometry axis 2
Signal state 1 or signal These machine data determine whether this geometry axis is assigned to handwheel 1, 2, 3 or
transition 0 –––> 1 no handwheel.
Only one handwheel can be assigned to an axis at any one time.
If several “Activate handwheel” interface signals are set, priority
“Handwheel 1” before “Handwheel 2” before “Handwheel 3” applies.
Note:Three geometry axes can be traversed simultaneously with handwheels 1 to 3!

Signal state 0 or signal Neither handwheel 1, 2 nor 3 is assigned to this geometry axis.
Application example(s) The PLC user program can use this interface signal to disable the influence of turning the
handwheel on the geometry axis.
Related to .... IS “Handwheel active” 1 to 3 for geometry axis 1: V3300 1000.0 to .2
for geometry axis 2: V3300 1004.0 to .2
for geometry axis 3: V3300 1008.0 to .2
V3200 1000.4 Traverse key disable for geometry axis 1

V3200 1004.4 for geometry axis 2
Signal state 1 or signal The traverse keys plus and minus have no effect on the geometry axes in question. It is thus not
transition 0 –––> 1 possible to traverse the geometry axis in JOG with the traverse keys on the machine control
panel.
If the traverse key disable is activated during a traverse movement, the geometry axis is
stopped.
Signal state 0 Traverse keys plus and minus are enabled.
Application example(s) It is thus possible, depending on the operating mode, to disable manual traverse of the geometry
axis in JOG mode with the traverse keys from the PLC user program.
Related to .... IS “Traverse key plus” and “ ... minus” for geometry axis 1 (V3200 1000.7 and .6)
for geometry axis 2 (V3200 1004.7 and .6)
V3200 1000.5 Rapid traverse override for geometry axis 1

Signal state 1 or signal If the PLC interface signal “Rapid traverse override” is set together with “Traverse key plus” and
transition 0 –––> 1 “Traverse key minus”, the geometry axis in question traverses at rapid traverse set for JOG on
the assigned machine axis (e.g.: X –> X1).
The rapid traverse velocity is defined in MD 32010: JOG_VELO_RAPID.
Rapid traverse override is active in the following JOG modes:
– Continuous traversing
– Incremental traversing
If rapid traverse override is active, the velocity can be modified with the rapid traverse override
switch.
Signal state 0 or signal The geometry axis traverses at the defined JOG velocity (SD: JOG_SET_VELO or MD:
transition 1 –––> 0 JOG_VELO).

6FC5397-1CP10-1BA0 9-175
V3200 1000.5 Rapid traverse override for geometry axis 1

Signal irrelevant for ... ... – Operating modes AUTOMATIC and MDA
– Reference point approach (JOG mode)
References Chapter “Feedrates”
V3200 1000.7 and .6 Traverse keys plus and minus for geometry axis 1
V3200 1004.7 and .6 for geometry axis 2
Signal state 1 or signal The selected axis can be traversed in both directions in JOG mode with the traverse keys plus
transition 0 –––> 1 and minus.
Incremental traversing
With signal 1 the axis starts to traverse at the set increment. If the signal changes to
the 0 state before the increment is traversed, the traversing movement is interrupted.
When the signal state changes to 1 again the movement is continued.
The axis can be stopped and started several times as described above until the incre-
ment has been completely traversed.
Continuous traversal
If no INC measure is selected, and “continuous” is, the axis travels for as long as the
traverse key is pressed.
If both traverse signals (plus and minus) are set at the same time, no movement occurs, or
any current movement is aborted!
The effect of the traverse keys can be disabled for every axis individually with the PLC inter-
face signal “Traverse key disable”.
Notice! In contrast to machine axes, for geometry axes, only one geometry axis can be tra-
versed at any one time using the traversing keys. Alarm 20062 is triggered if an at-
tempt is made to traverse more than one axis with the traverse keys.
Signal state 0 or signal No traverse
Signal irrelevant for ... ... Operating modes AUTOMATIC and MDA
Special cases, errors, ... ... The geometry axis cannot be traversed in JOG mode:
– If it is already being traversed via the axis-specific PLC interface (as a machine axis).
– If another geometry axis is already being traversed with the traverse keys.
Alarm 20062 “Axis already active” is output.
Related to .... IS “Traverse key plus” and “Traverse key minus” for the machine axes (V380x 0004.7 and .6)
IS “Traverse key disable” for geometry axis 1 (V3200 1000.4)
for geometry axis 2 (V3200 1004.4)
for geometry axis 3 (V3200 1008.4)

9-176 6FC5397-1CP10-1BA0
Machine function INC1, INC10, INC100, INC1000, INC10000, INCvar, continuous

V3200 1005.0 to .6 V3200 for geometry axis 2
1009.0 to .6 for geometry axis 3
Signal state 1 or signal This input range is only used if IS “INC inputs in mode group range active” (V2600 0001.0) is not
transition 0 –––> 1 set.
The interface signals INC... define how many increments the geometry axis traverses when the
traverse key is pressed or the handwheel is turned one detent position. JOG mode must be
active.
With “INCvar” the value in the general SD 41010: JOG_VAR_INCR_SIZE applies.

In mode “continuous” the associated geometry axis can be traversed with the plus or minus tra-
versing key according to how the traverse key is pressed.
(interface signal “Active machine function INC1;...”).
If several machine function signals (INC1, INC... or “Continuous jogging”) are selected at the
interface simultaneously, no machine function is activated by the control.
Note:
transition 1 –––> 0 requested.
Related to .... IS “Active machine function INC1, ...” for geometry axis 1 (V3300 1001.0 ... .6)
for geometry axis 2 (V3300 1005.0 ... .6)
IS “INC inputs in the mode group area active” (V2600 0001.0)
Description of signals from channel
V3300 1000.0 to .2 Handwheel active (1 to 3) for geometry axis 1

Signal state 1 or signal These PLC interface signals report whether this geometry axis is assigned to handwheel 1, 2 or
transition 0 –––> 1 3 or to no handwheel.
If the assignment is active, the geometry axis can be traversed with the handwheel in JOG
mode.
Related to .... IS “Activate handwheel” (V3200 1000.0 to .2, V3200 1004.0 to .2, V3200 1008.0 to .2)

6FC5397-1CP10-1BA0 9-177
V3300 1000.7 and .6 Travel command plus and minus

for geometry axis 3
Signal state 1 or signal A traverse movement of the axis is to be executed in one or the other direction. Depending on
transition 0 –––> 1 the mode selected, the command is triggered in different ways:
– JOG mode: with the plus or minus traverse key
– REF sub-mode: with the traverse key that takes the axis to the reference point
– AUTO/MDA mode: the program block containing a coordinate value for the axis
in question is executed.
Signal state 0 or signal A travel command in the relevant axis direction has not been given or a traverse movement has
transition 1 –––> 0 been completed.
S JOG mode:
– Cancelation of traverse key
– While ending traversing with the handwheel.
S REF submode:
When the reference point is reached
S AUTO/MDA mode:
– The program block has been executed (and the next block does not contain any coordi-
nate values for the axis in question)
– Abort with “RESET”, etc.
– IS “Axis disable” is active
Application example(s) To release clamping of axes with clamping
Note: If the clamping is not released until the travel command is given, these
axes cannot be operated under continuous path control!
Active machine function INC1, ..., continuous

V3300 1001.0, ..., .6 for geometry axis 1
Signal state 1 or signal The PLC interface receives a signal stating which JOG mode machine function is active for the
transition 0 –––> 1 geometry axes.
Signal state 0 or signal The machine function in question is not active.
Related to .... IS “Machine function INC1, ..., continuous” for geometry axis 1 (V3200 1001.0 ... .6)

9-178 6FC5397-1CP10-1BA0
Description of signals to axis/spindle
V380x 0004.0 to .2 Activate handwheel (1 to 3)

Signal state 1 or signal This PLC interface signal defines whether this machine axis is assigned to handwheel 1, 2, 3 or
transition 0 –––> 1 no handwheel.
If the assignment is active, the machine axis can be traversed with the handwheel in JOG mode.
Application example(s) The PLC user program can use this interface signal to disable the influence of turning the
handwheel on the axis.
Related to .... IS “Handwheel active” 1 to 3 (V390x 0004.0 to .2)
V380x 0004.4 Traverse key disable

Signal state 1 or signal The traverse keys plus and minus have no effect on the machine axes in question. It is thus not
transition 0 –––> 1 possible to traverse the machine axis in JOG with the traverse keys on the machine control
panel.
If the traverse key disable is activated during a traverse movement, the machine axis is stopped.
Signal state 0 or signal Traverse keys plus and minus are enabled.
Application example(s) It is thus possible, depending on the operating mode, to disable manual traverse of the machine
axis in JOG mode with the traverse keys from the PLC user program.
Related to .... IS “Traverse key plus” and “Traverse key minus” (V380x 0004.7 and .6)
V380x 0004.5 Rapid traverse override

Signal state 1 or signal If interface signal “Rapid traverse override” is set together with “Traverse key plus” and “Traverse
transition 0 –––> 1 key minus”, the machine axis in question traverses at rapid traverse.
The rapid traverse velocity is defined in MD 32010: JOG_VELO_RAPID.
Rapid traverse override is active in the following JOG modes:
– Incremental jogging
If rapid traverse override is active, the velocity can be modified with the axis-specific feedrate
override switch.
Signal state 0 or signal The machine axis traverses at the defined JOG velocity
transition 1 –––> 0 (SD 41110: JOG_SET_VELO or SD 41130, or MD 32020: JOG_VELO).
Signal irrelevant for ... ... – Operating modes AUTOMATIC and MDA
– Reference point approach (JOG mode)
IS axis-specific “Feedrate override” (VB380x 0000)

6FC5397-1CP10-1BA0 9-179
V380x 0004.7 and .6 Plus and minus traverse keys

Signal state 1 or signal The selected axis can be traversed in both directions in JOG mode with the traverse keys plus
transition 0 –––> 1 and minus.
Incremental traversing
With signal 1 the axis starts to traverse at the set
increment. If the signal changes to the 0 state before the increment is traversed,
the traversing movement is interrupted. When
signal state 1 occurs again, the traverse motion is restarted.
The traversing motion
of the axis can be stopped and restarted multiple times as described above
until the increment has been fully traversed.
Continuous traversing
If no INC measure is selected but “continuous” is, the axis travels for as long as the
traverse key is actuated.
If both traverse signals (plus and minus) are set at the same time there is no movement or a
current movement is aborted.
The effect of the traverse keys can be disabled for every axis individually with the PLC inter-
face signal “Traverse key disable”.
Signal state 0 or signal No traverse
Signal irrelevant for ... ... Operating modes AUTOMATIC and MDA
Application example(s) The machine axis cannot be traversed in JOG mode if it is already being traversed via the chan-
nel-specific PLC interface (as a geometry axis). Alarm 20062 is signaled.
Special cases, ...... Indexing axes
IS “Traverse key disable” (V380x 0004.4 )
V380x 0005.0 to .6 Machine functions INC1, INC10, INC100, INC1000, INC10000, INCvar, continuous
Signal state 1 or signal This input range is only used if IS “INC inputs in mode group range active” (V2600 0001.0) is not
transition 0 –––> 1 set.
The interface signals “INC...” define how many increments the machine axis traverses when the
traverse key is pressed or the handwheel is turned one detent position. JOG must be active.
With “INCvar” the value in the general SD 41010: JOG_VAR_INCR_SIZE applies.
In “continuous” mode the associated axis can be traversed with the plus or minus traversing key
according to how the traverse key is pressed.
(IS “Active machine function INC1...”).
If several machine function signals (INC1, INC... or “Continuous jogging”) are selected at the
interface simultaneously, no machine function is activated by the control.
Note:
transition 1 –––> 0 requested.
Related to .... IS “Active machine funciton INC1, ...” (V390x 0005.0 ... .6)
IS “INC inputs in te mode group area active” (V2600 0001.0)

9-180 6FC5397-1CP10-1BA0
Description of signals from axis/spindle
V390x 0004.0 to .2 Handwheel active (1 to 3)

Signal state 1 or signal These PLC interface signals provide feedback whether the machine axis is assigned to hand-
transition 0 –––> 1 wheel 1, 2, 3 or no handwheel.
”Handwheel 1” before “Handwheel 2” before “Handwheel 3” applies.
If the assignment is active, the machine axis can be traversed with the handwheel in JOG mode.
Related to .... IS “Activate handwheel” (V380x 0004.0 to .2)
IS “Handwheel selected” from HMI (V1900 0003, ff)
V390x 0004.7 and .6 Plus and minus traverse keys

Signal state 1 or signal A traverse movement of the axis is to be executed in one or the other direction. Depending on
transition 0 –––> 1 the mode selected, the command is triggered in different ways:
– JOG mode: with the plus or minus traverse key
– REF sub-mode: with the traverse key that takes the axis to the reference point
– AUT/MDA mode: the program block containing a coordinate value for the axis in
question is executed.
Signal state 0 or signal A travel command in the relevant axis direction has not been given or a traverse movement has
transition 1 –––> 0 been completed.
S JOG mode:
– Cancelation of traverse key.
– While ending traversing with the handwheel.
– REF submode: When the reference point is reached
S AUT/MDA mode:
– The program block has been executed (and the next block does not contain
any coordinate values for the axis in question)
– Abort with “RESET”, etc.
– IS “Axis disable” is active
Application example(s) To release clamping of axes with clamping (e.g. on a rotary table).
Note: If the clamping is not released until the travel command is given, these
axes cannot be operated under continuous path control!
V390x 0005.0, ..., .6 Active machine function INC1, ..., continuous

Signal state 1 or signal The PLC interface receives a signal stating which JOG mode machine function is active for the
transition 0 –––> 1 machine axes.
Signal state 0 or signal The machine function in question is not active.
Related to .... IS “Machine function INC1,...,continuous” (V380x 0005.0, ..., .6)

6FC5397-1CP10-1BA0 9-181

rence
Signals from HMI to PLC
VB1900 1003 – Axis number, machine/geometry axis for handwheel 1
VB1900 1004 for handwheel 2
VB1900 1005 for handwheel 3
NCK-specific
V2600 0001 .0 INC inputs in operating mode range active
Specific to operating mode
V3000 0000 .2 JOG mode
V3000 0002 .0 to .6 Machine function INC1 up to continuous in operating mode range
V3100 0000 .2 Active mode JOG
Channel-specific
V3200 1000 .2, .1, .0 Activate handwheel (3, 2, 1) for geometry axis 1
V3200 1004 .2, .1, .0 for geometry axis 2
V3200 1000 .4 Traverse key disable for geometry axis 1
V3200 1004 .4 for geometry axis 2
V3200 1008 .4 for geometry axis 3
V3200 1000 .5 Rapid traverse override for geometry axis 1
V3200 1004 for geometry axis 2
V3200 1008 for geometry axis 3
V3200 1000 .7 or .6 Traverse key plus or minus for geometry axis 1
V3200 1004 .7 or .6 for geometry axis 2
V3200 1000 .0 to .6 Machine function INC1 up to continuous for geometry axis 1
V3200 1004 .0 to .6 for geometry axis 2
V3300 1000 .2, .1, .0 Handwheel active (3, 2, 1) for geometry axis 1
V3300 1000 .7 or .6 Travel command plus or minus for geometry axis 1
Active machine function INC1 to continuous
V380x 0000 .7 Override active
V380x 0002 .2 Delete distance-to-go
V380x 0004 .2, .1, .0 Activate handwheel 1, 2, 3
V380x 0004 .4 Traversing key lock
V380x 0004 .5 Rapid traverse override

9-182 6FC5397-1CP10-1BA0
V380x 0004 .7 or .6 Plus or minus traverse keys
V380x 0005 .0 to .6 Machine function INC1 up to continuous in axis range
V390x 0000 .7 / .6 Position reached with exact stop coarse/fine
V390x 0004 2, .1, .0 Handwheel active (3, 2, 1)
V390x 0004 .7 or .6 Plus or minus travel command
V390x 0005 .0 to .6 Active machine function INC1 to continuous
9.7.2 Machine data

rence
General
10000 AXCONF_MACHAX_NAME_TAB[n] Machine axis name [n = axis index] Chap.19
11310 HANDWH_REVERSE Defines movement in the opposite direction
11320 HANDWH_IMP_PER_LATCH[0]...[2] Handwheel pulses per detent position [handwheel
index]
11346 HANDWH_TRUE_DISTANCE Handwheel path or velocity values
Channel-specific
20060 AXCONF_GEOAX_NAME_TAB[n] Geometry axis in channel [n = geometry axis index] Chap.19
20100 DIAMETER_AX_DEF Geometry axes with transverse axis (facing axis) P1
functions
32010 JOG_VELO_RAPID Conventional rapid traverse
32020 JOG_VELO Conventional axis velocity
32300 MAX_AX_ACCEL Axis acceleration B2
32420 JOG_AND_POS_JERK_ENABLE Enabling of axis-specific jerk limiting B2
32430 JOG_AND_POS_MAX_JERK Axis-specific jerk B2
35130 GEAR_STEP_MAX_VELO_LIMIT[0]...[5] Maximum velocity for gear stage/spindle S1
9.7.3 Setting data

rence
General
41010 JOG_VAR_INCR_SIZE Size of variable increment for INC/handwheel
41110 JOG_SET_VELO JOG velocity for linear axes
41130 JOG_ROT_AX_SET_VELO JOG speed for rotary axes
41200 JOG_SPIND_SET_VELO JOG velocity for the spindle

6FC5397-1CP10-1BA0 9-183
Notes

9-184 6FC5397-1CP10-1BA0
Operating Modes, Program Mode (K1) 10
Program mode
The term “Program mode” refers to the state in which part programs or part program blocks
are processed in the AUTOMATIC or MDA mode. Program processing can be modified with
PLC interface signals and commands.
Channel
A channel constitutes a unit in which a part program can be executed.
A channel is assigned an interpolator with program processing by the system. A certain mode
is valid for it.
The SINUMERIK 802D control unit has one channel.

6FC5397-1CP10-1BA0 10-185
Operating Modes, Program Mode (K1)
10.2 Operating modes
Activation
The required operating mode is activated by the interface signals in the VB 3000 0000. If se-
veral modes are selected at the same time the priority of the operating modes is as follows:
S JOG (high priority): The axes can be traversed manually with the handwheel or the traver-
sing keys. Channel-specific signals and interlocks are not observed.
S MDA: Program blocks can be processed
S AUTOMATIC (lower priority): Automatic processing of part programs
Checkback
The active operating mode is displayed by the interface signals in the VB3100 0000.
Possible machine functions

The following machine function can be selected inside the JOG operating mode:
REF (reference point approach)
The required machine function is activated with IS “REF” (V3000 0001.2). The display is visi-
ble in the IS “active machine function REF” (V3100 0001.2).
Stop
A stop signal can be given with the aid of the IS “NC Stop” (V3200 0007.3), IS “NC stop axes
plus spindles” (V3200 0007.4) or “NC stop at block limit” (V3200 0007.2). Depending on the
interface signal used, either only the axes or in addition the spindles of the channels are stop-
ped or the axes at block end.
RESET
The active part program is aborted by the IS “Reset” (V3000 0000.7).
The following actions are executed when the IS “Reset” is triggered:
S Part program conditioning is stopped immediately.
S Axes and spindles are stopped.
S Any auxiliary functions of the current block not yet output by this point are no longer
output.
S The block indicator is reset to the beginning of the relevant part program.
S All Reset alarms are deleted from the display.
S The reset is complete as soon as IS “Channel state Reset” (V3300 0003.7) is set.
Ready to run
Ready to run is displayed by IS “802 Ready” (V3100 0000.3).

10-186 6FC5397-1CP10-1BA0
10.2.1 Mode change
General
A changeover to another operating mode is requested and activated via the interface.
Note
The mode is not changed internally until the IS “Channel status active” (V3300 0003.5) is no
longer present.
In the “Channel status Reset” (IS: V3300 0003.7 , e.g. after pressing the “Reset key”) one
can switch from any operating mode into another.
In the “Channel status interrupted” (IS: V3300 0003.6) only a conditional changeover is possi-
ble (see Table 10-1).
If one leaves AUTO to change to JOG, one must return to AUTO again or press “Reset”.
Thus a change AUTO-JOG-MDA is made impossible. The same applies for MDA from which
one may change neither directly nor indirectly to AUTO, provided the Reset state is present.
The following table shows the possible operating mode changes depending on the current
operating mode and the channel state (”Channel in reset” or “Channel interrupted”).
Table 10-1 Operating mode change depending on channel state
AUTOMATIC JOG MDA
from AUTO MDI

previously previously
To reset interrupted reset interrupted interrupted reset interrupted
AUTOMATIC X X X
JOG X X X X
MDA X X X
Possible mode changes are shown by an “X”.
Error on operating mode changeover

A corresponding error message is output if a mode change request is rejected by the system.
This error message can be cleared without changing the channel status.
Mode change disable

Changeover between operating modes can be inhibited by means of IS “Mode group
changeover disable” (V3000 000.4). This suppresses the operating mode change request.

6FC5397-1CP10-1BA0 10-187
10.2.2 Functional possibilities in the individual modes
Overview of functions
You see from the following table which function can be selected in which operating mode and
in which operating state.
Table 10-2 Functional possibilities in the individual modes
Channel active JOG in MDA during MDA interrupt

Channel interrupted JOG during AUTO interrupt
Channel interrupted JOG during MDA interrupt

Channel in reset status AUTOMATIC
Channel in reset status MDA

Channel in reset status JOG
Channel active JOG in MDA

Channel interrupted
Channel interrupted
Channel active
Channel active
Channel active
Channel active
Channel active
Functionalities
Loading a part program from sb sb sb sb sb sb sb sb
outside through “Services”

Processing a part program/ s s b s s b
block
Block search s s b
Reference point approach via sb sb
part program command

(G74)
s: Function can be started in this status
b: Function can be processed in this status

10-188 6FC5397-1CP10-1BA0
10.2.3 Monitoring functions in the individual modes
Overview of monitoring functions

Different monitoring functions are active in individual operating modes.
Table 10-3 Monitoring functions and interlocks




Channel interrupted
Channel interrupted
Channel active
Channel active
Channel active
Channel active
Channel active
Axis-specific monitoring functions or when positioning the spindle
Software limit switch + x x x x x x x
Software limit switch – x x x x x x x
Hardware limit switch + x x x x x x x x x x x x x x
Hardware limit switch – x x x x x x x x x x x x x x
Exact stop coarse/fine x x x x x x x x x x x x x x
Clamping tolerance x x x x x x x x x x x x x x
DAU limit x x x x x x x x x x x x x x
(analog spindle)
Contour monitoring x x x x x x x
Spindle-specific monitoring functions
Speed limit exceeded x x x x x x
Spindle is stationary x x x x x x x x x x x x x x
Spindle synchronized x x x x x x
Speed in setpoint range x
Maximum permissible speed x x x x x x
Encoder limit frequency x x x x x x
x: Monitoring is active in this status

6FC5397-1CP10-1BA0 10-189
10.2.4 Interlocks in the individual modes
Overview of interlocks
A variety of interlocks can be active in the different operating modes.
The following table shows which interlocks can be activated in which operating mode and in
which operating state.




Channel interrupted
Channel interrupted
Channel active
Channel active
Channel active
Channel active
Channel active
General interlocks
802 Ready x x x x x x x x x x x x x x
Mode change disable x x x x x x x x x x x x x x
Channel-specific interlocks
Feed stop x x x x x x x
NC Start disable x x x x x x x x x x x x x x
Read-in disable x x x x x x x x x x x x x x
Axis-specific interlocks
Spindle disable x x x x x x x x x x x x x x
Controller disable x x x x x x x x x x x x x x
Axis disable x x x x x x x x x x x x x x
Spindle-specific interlocks
Controller disable x x x x x x x x x x x x x x
Spindle disable x x x x x x x x x x x x x x
x: Interlock can be activated in this status

10-190 6FC5397-1CP10-1BA0
10.3 Processing a part program
10.3.1 Program mode and part program selection
Definition
Program mode applies if a part program is processed in the AUTOMATIC mode or program
blocks are processed in the MDA mode.
Channel control
The Program mode can be controlled even while being executed via interface signals from
the PLC. These can be either mode groupspecific or channelspecific interface signals.
The channel reports its current program operation status to the PLC with interface signals.
Selection
A part program can be selected only if the relevant channel is in the Reset state.
The part program can be selected via:
S operator input (Machine operating area)/Program manager
S the PLC
– Selection of a program via the program number in “Program list” (see Manual “Opera-
tion and Programming...” Chapter 7)
– Reselection of an active program via the PLC-HMI interface (see Chapter 20.5)
10.3.2 Start of part program or part program block
START command, channel status

The channel-specific IS “NC start” (V3200 0007.1), which is usually controlled from the ma-
chine control panel key NC Start, starts program processing.
The START command can only be executed in AUTOMATIC and MDA modes. For this pur-
pose, the channel must be in the “Channel status reset” (V3300 0003.7) or “Channel status
interrupted” (V3300 0003.6).

6FC5397-1CP10-1BA0 10-191
Required signal states

The selected part program can now be enabled for processing with the START command.
Relevant enable signal settings:
S IS “802 Ready” may be set (V3100 0000.3)
S IS “Activate program test” may not be set (V3200 0001.7)
S IS “NC Start disable” may not be set (V3200 0007.0)
S IS “NC Stop at block limit” may not be set (V3200 0007.2)
S IS “NC Stop” may not be set (V3200 0007.3)
S IS “NC Stop axes plus spindle” may not be set (V3200 0007.4)
S IS “EMERGENCY STOP” may not be set (V2700 0000.1)
S Neither axis nor NCK alarm may be active
Execution of command
The part program or part program block is automatically processed and IS “Channel status
active” (V3300 0003.5) and IS “Program status running” (V3300 0003.0) are set.
The program is processed until the end of the program has been reached or the channel is
interrupted or aborted by a STOP or RESET command.
Interrupts
The START command is not effective if the prerequisite is not fulfilled. Then one of the
following interrupts occurs: 10200, 10202 , 10203
10.3.3 Part program interruption
Channel status
The STOP command is executed only if the channel concerned is in the “Channel active”
status (V3300 0003.5).
STOP commands
There are various commands which stop processing of the program and set the channel
status to “interrupted”. These are:
S IS “NC Stop at block limit” (V3200 0007.2)
S IS “NC stop” (V3200 0007.3)
S IS “NC Stop axes plus spindle” (V3200 0007.4)
S IS “Single block” (V3200 0000.4)
S Programming command “M0” or “M1” and corresponding activation

10-192 6FC5397-1CP10-1BA0
Execution of command
After execution of the STOP command, IS “Program status interrupted” (V3300 0003.2) and
the IS “Channel status interrupted” (V3300 0003.6) are set. Processing of the interrupted part
program can continue from the point of interruption with another START command.
The following actions are executed when the STOP command is triggered:
S Part program processing is stopped at the next block limit (with NC stop at block limit,
M0/M1 or single block), processing is stopped immediately with the other STOP
commands.
S Any auxiliary functions of the current block not yet output by this point are no longer
output.
S The axes are stopped with subsequent stop of the part program processing.
S The block indicator stops at the point of interruption.
10.3.4 RESET command
Functions
The RESET command (IS “Reset” (V3000 000.7)) can be executed in every channel state.
This command is aborted by another command.
A RESET command can be used to interrupt an active part program or part program blocks.
After execution of the Reset command, IS “Channel status reset” (V3300 0003.7) and the
IS “Program status aborted” (V3300 0003.4) are set.
The part program cannot be continued at the point of interruption. All axes in the channel are
at exact stop.
The following actions are executed when the RESET command is triggered:
S Part program conditioning is stopped immediately.
S All axes and if appropriate spindles are braked.
S Any auxiliary functions that have not yet been output at this point are not longer output.
S The block indicator is reset to the beginning of the part program.
S All alarms are cleared from the display if they are not POWER ON alarms.

6FC5397-1CP10-1BA0 10-193
10.3.5 Program control
Selection/Activation
The user can control part program processing via the operator interface. Under the “Program
control” menu (operating mode AUTOMATIC, operating area “Position”) certain functions can
be selected, whereby some functions act on interface signals of the PLC. These signals are
merely selection signals from the operator interface. They do not activate the selected
function.
These signal states must be transferred from the PLC user program to another area of the
data block to activate the selected functions. With program control by the PLC the signals are
to be set directly.
Table 10-4 Program control
Functions Selection signal Activation signal Feedback signal

SKP Skip block V1700 0001.0 V3200 0002.0
DRY Dry run feedrate V1700 0000.6 V3200 0000.6
ROV Rapid traverse override V1700 0001.3 V3200 0006.6
Preselection:
SBL –single block coarse – –
SBL –single block fine – –
Single block User-specific V3200 0000.4
M1 Programmed stop V1700 0000.5 V3200 0000.5 V3300 0000.5
PRT Program test V1700 0000.7 V3200 0001.7 V3300 0001.7
10.3.6 Program status
Program statuses
The status of the selected program is displayed in the interface in the AUTOMATIC and MDA
operating modes. If the JOG operating mode is selected when the program is stopped, then
the “interrupted” program status is displayed there or on reset also “aborted”.
The following program statuses are available in SINUMERIK 802D:
S IS “Program status aborted” (V3300 0003.4)
S IS “Program status interrupted” (V3300 0003.3)
S IS “Program status stopped” (V3300 0003.2)
S IS “Program status running” (V3300 0003.0)
The effect of commands/signals

The program status can be modified by activating different commands or interface signals.
The following table shows the resulting program status when these signals are set (status
before the signal is set –> Program status running).

10-194 6FC5397-1CP10-1BA0
Table 10-5 Effect on program status
Program processing statuses

Commands
Aborted Interrupted Stopped Running
IS “Reset” X
IS “NC Stop” X
IS “NC stop at block limit” X
IS “NC stop axes and spindles” X
IS “Read-in disable” X
IS “Feed stop, channelsp.” X
IS “Feed stop, axissp.” X
Feed override = 0% X
IS “Spindle stop” X
M2 in the block X
M0/M1 in the block X
IS “Single block” X
Auxiliary functions output to PLC X
but not yet acknowledged
10.3.7 Channel status
Channel statuses
The current channel status is signaled at the interface for the channel. The PLC can then trig-
ger certain responses and interlocks configured by the manufacturer depending on the status
at the interface. The channel status is displayed in all operating modes.
The following channel statuses are available:
S IS “Channel status reset” (V3300 0003.7)
S IS “Channel status interrupted” (V3300 0003.6)
S IS “Channel status active” (V3300 0003.5)
The effect of commands/signals

The channel status can be modified through the activation of various commands or interface
signals. The following table shows the resulting channel status when these signals are set
(status before the signal is set –> Channel status active).
The “Channel status active” signal is obtained when a part program or part program block is
being executed or when the axes are traversed in JOG mode.

6FC5397-1CP10-1BA0 10-195
Table 10-6 Effect on channel status
Resulting channel status

Commands
Reset Interrupted active
IS “Reset” X
IS “NC Stop” X
IS “NC stop at block limit” X
IS “NC stop axes and spindles” X
IS “Read-in disable” X
IS “Feed stop, channelsp.” X
IS “Feed stop, axissp.” X
Feed override = 0%
IS “Spindle stop” X
M2 in the block X
M0/M1 in the block X
IS “Single block” X
Auxiliary functions output to PLC X
but not yet acknowledged
10.3.8 Responses to operator or program actions
Responses
The following table shows the channel and program states that result after certain operator
and program actions.
The left-hand side of the table shows the channel and program statuses and the mode
groups from which the initial situation can be selected. Various operator/program actions are
listed on the righthand side of the table, the number of the situation after the action has been
carried out is shown in brackets after each action.
Table 10-7 Responses to operator or program actions
Situation Channel status Program status Active mode Operator or program action
(Situation after the action)
R U O N U S O O M J
(G
ND)
1 x x x RESET (4)
2 x x x RESET (5)
3 x x x RESET (6)
4 x x x NC Start (13); Mode change (5 or 6)
6 x x x Direction key (15); Mode change (4 or 5)
7 x x x NC Start (14)
8 x x x NC Start (15)

10-196 6FC5397-1CP10-1BA0
Table 10-7 Responses to operator or program actions
R U O N U S O O M J
(G
ND)
11 x x x Direction key (17); Mode change (9 or 10)
13 x x x NC Stop (12)
14 x x x NC Stop (7); at block end (5)
15 x x x NC Stop (8); at JOG end (6)
16 x x x NC Stop (10); at block end (10)
17 x x x NC Stop (11); at JOG end (11)
Explanation:
Channel status: Program status: Modes:
R: aborted N: aborted A: AUTOMATIC
U: interrupted U: interrupted M: MDA
A: running S: stopped J: JOG
A: running
10.3.9 Example of timing diagram for a program run
NC–START (from PLC)............................................... .......

NC STOP (from PLC,)............................................... .......
IS “NC Start disable” (V3200 0007.0).............................
IS “Read-in disable” (V3200 0006.1)......................................
IS “Controller enable”, axis (V380x 0002.1).......................

IS “Feed STOP”, axis (V380x 0004.3)..............................
IS “Controller enable”, spindle (V380x 0002.1)..................

IS “Spindle STOP” (V380x 0004.3).................................
IS “Program status running” (V3300 0003.0)......................

IS “Program status aborted” (V3300 0003.4).....................
IS “Program status stopped” (V3300 0003.2)........

M0
IS “Travel command plus” (V390x 0004.7)..............................

IS “Exact stop fine” (V390x 0000.7)...............................
IS “Spindle stationary” (V390x 0001.4)...................................

IS “Spindle in setpoint range” (V390x 2001.5)....................
Explanation: t4 t5
Controlling input signals generated by PLC user program,
Spindle rampup Axis running
t4: Block advance to N20 stopped with “Read-in disable”, Program:
t5: Program aborted with RESET N10 G01 G90 X100 M3 S1000 F1000 M88
N20 M0
Fig. 10-1 Examples of signals during a program run

6FC5397-1CP10-1BA0 10-197
10.4 Program testing
10.4.1 General notes on the program test
Purpose
Several control functions are available for testing a new part program. These functions are
provided to reduce danger at the machine and time required for the test phase. It is possible
to activate several program test functions simultaneously.
The following test options are described here:
S Program processing without axis movements
S Program processing in singleblock mode
S Program processing with dry run feedrate
S Processing of certain program sections
S Skipping certain program parts
S Graphic simulation
10.4.2 Program processing without axis movements (PRT)
Functionality
The part program can be started and processed with active “Program test” function via the IS
“NC Start” (V3200 0007.1), i.e. with auxiliary function outputs, dwell times. Only the axes/
spindles are simulated. The software limit switch safety function continues to be valid.
The position control is not interrupted, so the axes do not have to be referenced when the
function is switched off.
The user can check the programmed axis positions and auxiliary function outputs of a part
program.
Note: Program processing without axis motion can also be activated with the function “dry run
feedrate”.
This function is selected via the operator interface in the menu “Program control”. IS “Pro-
gram test selected” (V1700 0001.7) is set on selection of the function.
The PLC user program must activate the function via the IS “Activate program test”
(V3200 0001.7).

10-198 6FC5397-1CP10-1BA0
Displays
As a checkback for the active program test, “PRT” is displayed in the status line on the opera-
tor interface and the IS “Program test active” (V3300 0001.7) is set in the PLC.
10.4.3 Program processing in single block mode (SBL)
Functionality
The user can process a part program block by block to check the individual machining steps.
Once he has decided that a processed part program block is correct, he can call the next
block. The program is advanced to the next part program block via IS “NC Start” (V3200
0007.1).
When the function “single block” is activated, the part program stops after every program
block during processing. In this case the activated single block type must be observed.
Single block type

The following different types of single block are provided:
S Single block coarse
With this type, the blocks which initiate actions (traversing motions, auxiliary function out-
puts, etc.) are processed individually. If tool radius compensation is active (G41,G42), pro-
cessing stops after every intermediate block inserted by the control. Processing is howe-
ver not stopped at calculation blocks as these do not trigger actions.
S Single block fine
With this type of single block, all blocks in the part program (even the pure calculation
blocks without traversing motions) are processed sequentially by “NC Start”.
“Single block coarse” is the default setting after switching on.
Caution
! In a series of G33 blocks single block is effective only if “dry run feedrate” is selected.
The selection signal normally comes from a user machine control panel.
This function must be activated by the PLC user program via the IS “Activate single block”
(V3200 0000.4).
The preselection whether “Single block coarse” or “Single block fine” type is made in the
operator interface in the “Program control” menu.

6FC5397-1CP10-1BA0 10-199
Displays
The checkback signal that single block mode is active is displayed in the relevant “SBL” field
on the operator interface.
As soon as the part program has processed a part program block because of the single block
mode, the IS “Channel status interrupted” (V3300 0003.6) and the IS “Program status stop-
ped” (V3300 0003.2) are set and the IS “Channel status active” (V3300 0003.5) and the IS
“Program status running” (V3300 0003.0) are reset.
10.4.4 Program processing with dry run feedrate (DRY)
Functionality
The part program can be started via IS “NC Start” (V3200 0007.1). When the function is ac-
tive, the traversing velocities programmed in conjunction with G1, G2, G3, CIP, and CT are
replaced by the feed value stored in SD 42100: DRY_RUN_FEED. The dry run feedrate also
replaces the programmed revolutional feedrate in program blocks with G95. However, if the
programmed feedrate is larger that the dry run feedrate, then the larger value is used.
Caution
! Workpieces may not be machined when “dry run feedrate” is active because the altered
feedrates might cause the permissible tool cutting rates to be exceeded and the workpiece or
machine tool could be damaged.
Operation with dry run feedrate is selected in the “Position” operating area –> softkey
“Program control” (AUTOMATIC mode). IS “Dry run feedrate” (V1700 0000.7) is set on selec-
tion of the function. In addition, the required dry run feedrate must be entered in the menu
“Setting data”. This does not activate the function.
This function is activated via the IS “Activate dry run feedrate” (V3200 0000.4) and is evalua-
ted at NC start.
The dry run feedrate must be entered before program start in SD 42100: DRY_RUN_FEED.
Displays
The checkback signal that dry run feedrate is active is displayed in the relevant “DRY” status
line on the operator interface.

10-200 6FC5397-1CP10-1BA0
10.4.5 Block search: Processing of selected program sections
Functionality
To set the program run to a certain block (target block) of a part program, the block search
function can be used. It can be selected whether or not the same calculations are to be per-
formed during the block search up to the target block as would be performed during normal
program operation.
After the target block is reached, the part program can be started via IS “NC Start” (give 2x)
(V3200 0007.1). If necessary there is an automatic compensating movement of the axes to
start or end positions of the target block. Execution of the remaining program then continues.
Note: Pay attention to a collision-free start position and appropriate active tools and other
technological values! If necessary, a collisionfree start position must be approached manually
with JOG. Select the target block considering the selected block search type.
The block search is selected in AUTOMATIC mode on the operator interface.
The search run can be activated with corresponding softkey for the following functions:
S Block search with calculation to contour
Is used in any circumstances in order to approach the contour. On NC Start, the start
position of the target block or the end position of the block before the target block is
approached. This is traversed up to the end position. Processing is true to contour.
S Block search with calculation to block end point
Is used in any circumstances in order to approach a target position (e.g. tool change posi-
tion). The end position of the target block or the next programmed position is approa-
ched using the type of interpolation valid in the target block. This is not true to contour.
Only the axes programmed in the target block are moved.
S Block search without calculation.
Used for fast search in the main program.
No calculations are performed. The internal controller values indicate the status valid be-
fore the search. Whether the program can be executed subsequently depends on the pro-
gram and must be decided by the operator.
This search run is suitable for a fast syntax check of a new program.
Interface signal
In the PLC the IS
S “Block search active” (V3300 0001.4)
S “Action block active” (V3300 0001.3)
S “Approach block active” (V3300 0000.4)
S “Last action block active” (V3300 0000.6)

6FC5397-1CP10-1BA0 10-201
are set in the chronological order in Fig. 10-2.
Note
The “Approach block active” is only enabled with “Block search with calculation on contour”
because a separate approach block is not generated with “Block search with calculation at
block end point” (the approach block is the same as the target block).
Start Search NC Start Last NC Start Target

search target output action action output block in
found blocks block approach main run
block
Block search active

(V3300 0001.4)
Action block active

(V3300 0000.3)
Approach block active

(V3300 0000.4)
Last action block active

(V3300 0000.6)
Fig. 10-2 Chronological order of interface signals
After “Block search with calculation at block end point”, automatic repositioning is not perfor-
med between “Last action block active” and continuation of part program processing by
NC Start. The start point of the approach movement is the current axis position on NC Start;
the end point results from the processing of the part program.
Action blocks
Action blocks contain the actions accumulated during “block search with calculation”, e.g.
auxiliary function outputs, and tool (T, D), spindle (S) and feed programming commands.
During “block search with calculation” (contour or block end point), actions such as M func-
tion outputs are accumulated in so-called “action blocks”. These blocks are output on an
NC start after “search target found”.
Note
The action blocks also activate the accumulated spindle programming (S value, M3/M4/M5,
SPOS). The PLC user program must ensure that the tool can be operated and, if necessary,
the spindle programming is reset via the IS “Spindle reset” (V380x 0002.2).

10-202 6FC5397-1CP10-1BA0
PLC actions after block search

There is the IS “Last action block active” to enable activation of PLC actions after block
search. The signal indicates that all action blocks have been executed and it is now possible
to perform PLC actions or operator actions (e.g. mode change). This allows the PLC to per-
form another tool change, for example, before the start of the movement.
The alarm 10208 is also output per default at this time. It should indicate to the operator that
a NC start is still necessary to continue program processing.
Supplementary condition
The approach movement “Search with calculation to block end point” is performed using the
type of interpolation valid in the target block. This should be G0 or G1, as appropriate. With
other types of interpolation, the approach movement can be aborted with an alarm (e.g. circle
end point error on G2/G3).
Note
For further information about the block search function, please see
10.4.6 Skip part program blocks (SKP)
Functionality
When testing new programs it is useful to be able to disable or skip certain part program
blocks during program processing.
PROGRAM1 Main program or subroutine
N10 ...
N20 ...
Block N30 ...
currently Blocks N40 and N50
being /N40 ... skipped during
executed processing
/N50 ...
N60 ...
N70 ...
N80 ...
N90 M2
Fig. 10-3 Skipping part program blocks

6FC5397-1CP10-1BA0 10-203
The skip function is selected via the operator interface in the menu “Program control”.
IS “Skip block selected” (V1700 0002.0) is set when the function is selected. In addition, a
slash “/” must be written before the blocks to be skipped (see fig. 10-3). This does not acti-
vate the function.
This function is activated via IS “Activate skip block”
(V3200 0002.0).
Displays
The checkback signal that the “Skip block” function is active is displayed in the relevant
“SKP” status line on the operator interface.
10.4.7 Graphic simulation
Functions
In the AUTOMATIC operating mode a selected and opened program can be simulated
graphically on the screen of the control unit. The movements of the programmed axes are
recorded as line diagram after an “NC Start”.
Selection/De-selection
The graphic simulation can be reached for the selected program through the “Program”
operating area, open program and “Simulation” softkey. Here the IS “Simulation active”
(V1900 0000.6) is set and reset again on leaving the “Program” operating area or changing to
“Edit”.
Displays
Due to numerous operating possibilities a complete workpiece or else only enlarged details of
it can be displayed on the screen.
PLC user program

The PLC user program must itself influence the required behavior of the control system in
simulation, for example:
S Stop axes/spindle by transition into the program test: Set IS “Activate program test”
(V3200 0001.7)
S Abort the running program if “Simulation” is exited by setting IS “Reset” (V3000 000.7),
etc.

10-204 6FC5397-1CP10-1BA0
Display machine data

A number of display machine data (MD 283 to MD 292) are available for the user-specific
configuration of the graphic simulation.
References: Subsection 10.7.1 “Display machine data”

6FC5397-1CP10-1BA0 10-205
10.5 Timers for program execution time
10.5 Timers for program execution time
Functions
Timers are provided under the “Program execution time” function and these can be used for
monitoring technological processes in the program or only in the display.
These timers can only be read. There are timers that are always active. Others can be
de-activated through machine data.
Timers – always active

S Time since the last “Controller run-up with default values” ( in minutes ):
$AN_SETUP_TIME
It is zeroed automatically on “Controller run-up with default values”.
S Time since the last run-up of the controller ( in minutes ):
$AN_POWERON_TIME
It is zeroed automatically on every run-up of the controller.
Timers – de-activatable
The following timers are activated through machine data (default setting)
The start is timer-specific. Each active execution time measurement is interrupted automati-
cally in the stopped program status or at feedrate override =zero.
The behavior of the activated time measurements in active dry run feedrate and program test
can be defined by machine data.
S Total execution time of NC programs in the Automatic mode ( in seconds ):
$AC_OPERATING_TIME
In the Automatic mode the execution times of all programs are summed between NC start
and program end/reset. The timer is zeroed with every controller run-up.
S The runtime of the selected NC program ( in seconds):
$AC_CYCLE-TIME
The runtime between NC start and program end/reset is measured in the selected NC
program. The timer is reset with the start of a new NC program.
S Tool operating time (in seconds):
$AC-CUTTING-TIME
The runtime of the path axes without active rapid traverse in all NC programs between NC
start and program end/reset with active tool is measured.
The measurement is also interrupted with active dwell time.
The timer is zeroed automatically at a “Controller run-up with default values”.
Displays
The timer readings are visible on the screen in the “OFFSET/PARAM” operating area –> Soft-
key “Settingdate”–>SK “Times, counters” visible:
Run time = $AC_OPERATING_TIME
Cycle time = $AC_CYCLE_TIME
Cutting time = $AC_CUTTING_TIME
Setup time = $AN_SETUP_TIME
Power on time = $AN_POWERON_TIME

10-206 6FC5397-1CP10-1BA0
10.6 Workpiece counter
“Cycle time” is also visible in the AUTOMATIC mode in the “Position” operating area in the
information line.
Functions
The “Workpiece counter” function provides counters for counting workpieces.
These counters can be read and written by the program or by operation (note protection level
for writing).
The value range: 0 to 999 999 999.
Channel-specific machine data MD 27880: PART_COUNTER and
MD 27882: PART_COUNTER_MCODE can be used to control counter activation, counter
reset timing and the counting algorithm.
Counters
S Number of the required workpieces ( workpiece target ):
$AC_REQUIRED_PARTS
In this counter you can define the number of workpieces at which the actual workpiece
counter $AC_ACTUAL_PARTS is reset to zero.
The MD 27880: PART_COUNTER (Bit 0) can be used to generate the display alarm
21800 “Required number of workpieces reached” and to output the IS “Required number
of workpieces reached” (V3300 40001.1).
S Total number of workpieces actually produced (total actual):
$AC_TOTAL_PARTS
The counter indicates the total number of workpieces produced since the starting time.
S Number of actual workpieces (current actual):
$AC_ACTUAL_PARTS
This counter records the number of all workpieces produced since the starting time. The
counter is automatically reset to zero (on condition that $AC_REQUIRED_PARTS is not
equal to 0) when the required number of workpieces ($AC_REQUIRED_PARTS) has
been reached.
S Number of workpieces specified by the user:
$AC_SPECIAL_PARTS
This counter allows user-defined workpiece counting. Alarm output can be defined for the
case of identity with $AC_REQUIRED_PARTS (workpiece target). The user must reset
the counter himself.
The first output of the M command for counting after resetting the counter applies as start
point. This M command is set in MD 27880: PART_COUNTER or
MD 27882: PART_COUNTER_MCODE for the relevant counter.

6FC5397-1CP10-1BA0 10-207
Displays
The contents of the counters are visible on the screen in the operating area
“OFFSET/PARAM” –> Softkey “Settingdate”–>page down (2nd page) visible:
Part total = $AC_TOTAL_PARTS
Part required = $AC_REQUIRED_PARTS
Part count = $AC_ACTUAL_PARTS
$AC_SPECIAL_PARTS not available in display
“Part count” is visible in addition in the AUTOMATIC mode in the “Position” operating area in
the information line.

10-208 6FC5397-1CP10-1BA0
10.7.1 Machine data display
283 CTM_SIMULATION_DEF_X
MD number Simulation default value for X
Changes effective after: IMMEDIATELY Protection level: Unit: mm or inch
Data type: INTEGER Valid as of software version:
Meaning: This MD defines the size of the X coordinate of the display area. When you press softkey
TO ORIGIN in simulation mode, you will go to the value set in this MD.
Related to .... MD 284: CTM_SIMULATION_DEF_Y
MD 285: CTM_SIMULATION_DEF_VIS_AREA
284 CTM_SIMULATION_DEF_Y
MD number Simulation default value for Z
Meaning: This MD defines the size of the 2nd coordinate (Y or Z) of the display area. When you
press softkey TO ORIGIN in simulation mode, you will go to the value set in this MD.
Related to .... MD 283: CTM_SIMULATION_DEF_X
MD 285: CTM_SIMULATION_DEF_VIS_AREA
285 CTM_SIMULATION_DEF_VIS_AREA
MD number Simulation default value for display area
Meaning: These machine data define the size of the display area above the X coordinate. The Z
coordinate is automatically calculated from this setting.
Related to .... MD 283: CTM_SIMULATION_DEF_X
MD 284: CTM_SIMULATION_DEF_Z
286 CTM_SIMULATION_MAX_X
MD number Simulation of maximum display X
Meaning: This MD defines the size of the X coordinate of a second display area (e.g. for larger
workpieces).
When you press softkey MAX in simulation mode, the value preset in this MD will apply.
Related to .... MD 287: CTM_SIMULATION_MAX_Z

MD 288: CTM_SIMULATION_MAX_VIS_AREA

6FC5397-1CP10-1BA0 10-209
287 CTM_SIMULATION_MAX_Y
MD number Simulation maximum display Z

Meaning: This MD defines the size of the 2nd coordinate (Y or Z) of a second display area.
When you press softkey MAX in simulation mode, the value preset in this MD will apply.
Related to .... MD 286: CTM_SIMULATION_MAX_X

MD 288: CTM_SIMULATION_MAX_VIS_AREA
288 CTM_SIMULATION_MAX_VIS_AREA
MD number Simulation of maximum display area
Meaning: This machine data defines the second display area above the X coordinate. The Z coordi-
nate is automatically calculated from this setting.
Related to .... MD 286: CTM_SIMULATION_MAX_X
MD 287: CTM_SIMULATION_MAX_Y
289 CTM_SIMULATION_TIME_NEW_POS
MD number Simulation updating rate of actual value
Changes effective after: IMMEDIATELY Protection level: Unit: ms
Data type: WORD Valid as of software version:
Meaning: This MD is set to specify the time intervals at which the simulation graphic must be upda-
ted in accordance with the current machining process on the machine tool.
Value = 0 means no update.
290 CTM_POS_COORDINATE_SYSTEM
MD number Position of coordinate system
Changes effective after: IMMEDIATELY Protection level: Unit: –
Data type: BYTE Valid as of software version:
Meaning: The position of the coordinate system can be altered as follows:
+X +X
0 1
+Z +Z
+Z +Z
2 3
+X +X
+Z +Z
4 5
+X +X
+X +
X
6 7
+Z +Z

10-210 6FC5397-1CP10-1BA0
291 CTM_CROSS_AX_DIAMETER_ON
MD number Diameter display for active transverse axes
Meaning: 0: Inputs for absolute values as radius value.
Zero offsets always as radius,
tool lengths always as radius,
tool wear always as radius
1: Position display as diameter,

distance to go as diameter
absolute distances as diameter
292 CTM_G91_DIAMETER_ON
MD number Incremental infeed
Meaning: 0: Input in radius
1: Input in diameter

6FC5397-1CP10-1BA0 10-211
21000 CIRCLE_ERROR_CONST
MD number Circle end point monitoring constant
Meaning: This machine data identifies the permissible absolute circle difference.
In circle programming, the radii from the programmed center point to the starting point and to
the end point are usually not equal (the circle is “overdefined”). The maximum permissible
difference between these two radii which is accepted without an alarm being triggered is defi-
ned by the larger value in the following data:
– MD: CIRCLE_ERROR_CONST
– Start radius multiplied by 0.001
I.e. for small circles the tolerance is a fixed value (MD: CIRCLE_ERROR_CONST) and for
large circles it is proportional to the start radius.
Application example MD 21000: CIRCLE_ERROR_CONST = 0.01 mm
With these MD and a radius 10mm, the constant has an effect, with > 10mm, the proportio-
nal factor has an effect.
27860 PROCESSTIMER_MODE
MD number Activating the program runtime measurement
Default setting: 0x7 Minimum input limit: 0 Maximum input limit: 0x3F (HEX)
Meaning: The channel-specific timers can be activated/de-activated through this machine data.
Meaning:
Bit 0 = 0 No measurement of the total runtime for all part programs
Bit 0 = 1 The measurement of the total runtime for all part programs
is active ( $AC_OPERATING_TIME )
Bit 1 = 0 No measurement of the current program runtime
Bit 1 = 1 The measurement of the current program runtime is active
( $AC_CYCLE_TIME )
Bit 2 = 0 No measurement of the tool cutting time
Bit 2 = 1 The measurement of the tool cutting time is active
( $AC_CUTTING_TIME )
Bit 3 Reserved
Further bits only for Bit 0, 1, 2 = 1:

Bit 4 = 0 No measurement with active dry run feedrate
Bit 4 = 1 Measurement also with active dry run feed
Bit 5 = 0 No measurement in program test
Bit 5 = 1 Measurement also in program test
Bit 6, 7 Reserved
Application example
Special cases, errors, ... It is recommended that timers that are never used are de-activated. This helps the free-up
... comutational time other user applications.

10-212 6FC5397-1CP10-1BA0
27880 PART_COUNTER
MD number Activation of the workpiece counters
Default setting: 0x0 Minimum input limit: 0x0 Maximum input limit: 0x0FFFF
Meaning: The workpiece counters can be set with this machine data.
Meaning of the individual Bits:
Bit 0 – 3: Activation $AC_REQUIRED_PARTS
––––––––––––––––––––––––––––––––––––––––––––––
Bit 0 = 1: Counter $AC_REQUIRED_PARTS is active
Further meaning Bit 1–3 only when bit 0 =1:
Bit 1 = 0: Alarm IS output when $AC_ACTUAL_PARTS
matches $AC_REQUIRED_PARTS
Bit 1 = 1: Alarm IS output when $AC_SPECIAL_PARTS
matches $AC_REQUIRED_PARTS
Bit 2, 3 Reserved
Bit 4 – 7: Activation $AC_TOTAL_PARTS

–––––––––––––––––––––––––––––––––––––––––––
Bit 4 = 1: Counter $AC_TOTAL_PARTS is active
Further meaning Bit 5–7 only when Bit 4 =1:
Bit 5 = 0: Counter $AC_TOTAL_PARTS is incremented by 1 on output of M2/M30.
Bit 5 = 1: Counter $AC_TOTAL_PARTS is incremented by 1 on the M command from

MD 27882: PART_COUNTER_MCODE[0]
Bit 6 = 0: Counter $AC_TOTAL_PARTS also active in program test/block search
Bit 6 = 1: no processing $AC_TOTAL_PARTS in program test/block search
Bit 7 Reserved
Bit 8 – 11: Activation $AC_ACTUAL_PARTS

––––––––––––––––––––––––––––––––––––––––––––
Bit 8 = 1: Counter $AC_ACTUAL_PARTS is active
Bit 9 = 0: Counter $AC_ACTUAL_PARTS is incremented by 1 on output of M2/M30.
Bit 9 = 1: Counter $AC_ACTUAL_PARTS is incremented by 1 on the M command from

Bit 10 = 0: Counter $AC_ACTUAL_PARTS also active in program test/block search
Bit 10 = 1: no processing $AC_ACTUAL_PARTS in program test/block search
Bit 11 Reserved
Bit 12 – 15: Activation $AC_SPECIAL_PARTS

–––––––––––––––––––––––––––––––––––––––––––––
Bit 12 = 1: Counter $AC_SPECIAL_PARTS is active
Bit 13 = 0: Counter $AC_SPECIAL_PARTS is incremented by 1 on output of M2/M30
Bit 13 = 1: Counter $AC_SPECIAL_PARTS is incremented by 1 on output of the M command

from
Bit 14, 15 Reserved
Application example
Related to .... MD 27882: PART_COUNTER_MCODE
IS “Required number of workpieces reached” (V3300 40001.1)

6FC5397-1CP10-1BA0 10-213
27882 PART_COUNTER_MCODE[n] n = 0 ... 2, index to assign a counter

MD number Workpiece counting via M command
Default setting: (2, 2, 2) Minimum input limit: 0 Maximum input limit: 99
Changes effective after POWER ON Protection level: 2/2 Unit:
Meaning: On activation of workpiece counting through MD 27880: PART_COUNTER the counting pulse
can be triggered by a special M command.
Only in this case are the values defined here observed.
Meaning:
The workpiece counters are incremented by 1 at the IS signal output of the described
M command. The following applies:
$PART_COUNTER_MCODE[0] for $AC_TOTAL_PARTS
$PART_COUNTER_MCODE[1] for $AC_ACTUAL_PARTS
$PART_COUNTER_MCODE[2] for $AC_SPECIAL_PARTS
Application example
Related to .... MD 27880: PART_COUNTER
10.7.3 Channel-specific setting data
42000 THREAD_START_ANGLE
SD number Start angle for thread G33
Changes effective immediately Protection level: 3/3 Unit: Degr.
Meaning: This setting data can be used to program the offset of the individual threads when cutting mul-
tiple threads.
This SD can be changed from the part program by the SF=... command. If no SF=... is written
in the G33 block of the part program, then the setting data applies.
References “Operation and Programming”
42010 THREAD_RAMP_DISP[n] (Index n = 0: run-up distance, n=1: Deceleration path)

SD number Starting and deceleration behavior of feed axis in thread cutting G33
Default setting: (–1, –1) Minimum input limit: –1 Maximum input limit: 999 999.
Changes effective immediately Protection level: 3/3 Unit: mm/inch
Meaning: Run-up distance or braking distance of the feed axis for thread cutting:
–1: The feed axis starts/brakes at the configured acceleration rate.
The jerk acts corresponding to the current programming of BRISK/SOFT.
0: Start/braking of the feed axis for thread cutting is abrupt.
>0: The maximum starting/deceleration distance is defined. The defined distance
may lead to an acceleration overload of the axis.
The default value is activated with reset/part program end.
Example:
THREAD_RAMP_DISP[0] = 2 run-up distance 2 mm
References Description of Functions, Chapter “Feedrate”

10-214 6FC5397-1CP10-1BA0
42100 DRY_RUN_FEED
SD number Dry run feedrate
Changes effective immediately Protection level: 7/7 Unit: mm/min
Meaning: To check a part program with regard to the traversing path (without workpiece to be machined)
the operator can activate the dry run feed function on the operator interface (Program control
softkey). The value of this setting data is then taken instead of the programmed feed value.
Rapid traverse feed values are not changed.
The dry run feedrate value can be entered in the Setting data menu.
The function is effective only in the AUTOMATIC and MDA modes.
SD irrelevant for ... ... Dry run feedrate function not activated
Application example(s) Checking traversing distances with new part programs
Special cases, errors, ... The function may not be activated if a workpiece should be machined. The maximum cutting
... speed of the tool might be exceeded by the activated dry run feedrate. The destruction of the
workpiece and of the tool could be the consequence.

6FC5397-1CP10-1BA0 10-215
10.8.1 Operating mode signals
V3000 0000.0 AUTOMATIC mode

Interface signal Signal(s) to NCK (PLC –––> NCK)
Signal state 1 or signal AUTOMATIC mode is selected by the PLC program.
Signal state 0 or signal AUTOMATIC mode is not selected by the PLC program.
Signal irrelevant for ... ... if “Mode group changeover disable” signal
Related to .... IS “Active mode AUTOMATIC”
V3000 0000.1 MDA mode

Signal state 1 or signal MDA mode is selected by the PLC program.
Signal state 0 or signal MDA mode is not selected by the PLC program.
Related to .... IS “Active mode MDA”
V3000 0000.2 JOG mode

Signal state 1 or signal JOG mode is selected by the PLC program.
Signal state 0 or signal JOG mode is not selected by the PLC program.
Related to .... IS “Active mode JOG”
V3000 0000.4 Mode group changeover disable

Signal state 1 or signal The currently active mode (JOG, MDA or AUTOMATIC) cannot be changed.
Signal state 0 The mode can be changed.

10-216 6FC5397-1CP10-1BA0
V3000 0000.7 Reset

Signal state 1 or signal The channel must change to the “RESET” status. The current program is then in program
transition 0 –––> 1 status “aborted”. All moving axes and spindles are decelerated to zero speed according to
their acceleration ramp without contour violation. The initial settings are set (e.g. for G func-
tions). The alarms are cleared if they are not POWER ON alarms.
Signal state 0 or signal Channel status and program run are not affected by this signal.
Related to .... IS “Channel reset”
IS “All channels in reset state”
Special cases, errors, ... An alarm which cancels IS “802 ready” ensures that the channel is no longer in the Reset
... state. In order to switch to another operating mode, a “reset” must then be initiated.
V3000 0001.2 Machine function REF

Signal state 1 or signal Machine function REF is activated in JOG mode.
Signal state 0 or signal Machine function REF is not activated.
Signal irrelevant for ... ... if JOG mode is not active.
V3100 0000.0 Active mode AUTOMATIC

Interface signal Signal(s) from NCK (NCK –––> PLC)
Signal state 1 or signal AUTOMATIC mode is active.
Signal state 0 or signal AUTOMATIC mode is not active.
V3100 0000.1 Active mode MDA

Signal state 1 or signal MDA mode is active.
Signal state 0 or signal MDA mode is not active.
V3100 0000.2 Active mode JOG

Signal state 1 or signal JOG mode is active.
Signal state 0 or signal JOG mode is not active.

6FC5397-1CP10-1BA0 10-217
V3100 0000.3 802 READY

Signal state 1 or signal This signal is set after POWER ON when all voltages are present. The mode group is now re-
transition 0 –––> 1 ady and part programs can be processed and axes traversed in the channel.
Signal state 0 or signal The mode group/channel is not ready. Possible causes of this are:
transition 1 –––> 0 – A serious axis or spindle alarm is active
– Hardware fault
– Mode group incorrectly configured (machine data)
If the mode group ready signal changes to the “0” state

– the axis and spindle drives are decelerated with max. braking current to zero speed,
– the signals from the PLC to the NCK are switched to the inactive state (initial setting).
Special cases, errors, ... ... An alarm which cancels IS “802 READY” ensures that the channel is no longer in the Reset
state. In order to switch to another operating mode, a “reset” must then be initiated. (V3000
0000.7)
V3100 0001.2 Active machine function REF

Signal state 1 or signal Machine function REF is active in JOG.
Signal state 0 or signal Machine function REF is not active.
V3200 0000.4 Activate single block

Interface signal Signal(s) to channel (PLC –––> NCK)
Signal state 1 or signal In the AUTOMATIC mode the program is processed in the single-block mode; in MDA only 1
transition 0 –––> 1 block can be entered in any case.
Application example(s) A new program can first be tested in singleblock mode in order to monitor the individual pro-
gram steps more exactly.
Special cases, errors, ... S Intermediate blocks can be inserted if tool radius compensation (G41,G42) is selected.
... S In a series of G33 blocks single block is effective only if “dry run feedrate” is selected.
S Pure calculation blocks are not processed in the single step in “Single block coarse” but
only in “Single block fine”. The preselection is made via softkey “Program control”.
Related to .... IS “Single-block selected”
IS “Program status stopped”
References Subsection 10.4

10-218 6FC5397-1CP10-1BA0
V3200 000.5 Activate M1

Signal state 1 or signal M1 programmed in the part program leads to a programmed stop when processed in AUTO-
transition 0 –––> 1 MATIC or MDA mode.
Signal state 0 or signal M1 programmed in the part program does not lead to a programmed stop.
Related to .... IS “M01 selected” (V1700 0000.5)
IS “M0/M1 active” (V3300 0000.5)
V3200 0001.7 Activate program test

Signal state 1 or signal Axis disable is set internally for all axes (not spindle). Therefore the machine axes do not
transition 0 –––> 1 move when a part program block or a part program is being processed. The axis movements
are simulated on the operator interface with changing axis position values. The axis position
values for the display are generated from the calculated setpoints.
The part program is processed in the normal way.
Signal state 0 or signal Part program processing is not affected by the function program test
Related to .... IS “Program test selected”
IS “Program test active”
V3200 0002.0 Skip block

Signal state 1 or signal Blocks marked in the part program with an oblique (/) are skipped. If there is a series of skip
transition 0 –––> 1 blocks, this signal is only active if it is pending before decoding of the first block of the series,
ideally before NC start.
Signal state 0 or signal The marked part program blocks are not skipped.
Related to .... IS “Skip block selected”

6FC5397-1CP10-1BA0 10-219
V3200 0006.1 Read-in disable

Signal state 1 or signal Data transfer of the next block into the interpolator is disabled. This signal is only active in
transition 0 –––> 1 modes AUTOMATIC and MDA.
Signal state 0 or signal Data transfer of the next block into the interpolator is enabled. This signal is only active in
transition 1 –––> 0 modes AUTOMATIC and MDA.
Application example(s) In a case where an auxiliary function has to have been executed before the next
block can be processed (e.g. for a tool change), automatic block change must be
inhibited with readin disable.
N20 T... N21 G...

X ...M...
N20 T... N21

T M (GND)

"

Reading into buffer

Block processed
Read-in disable signal
Data transfer
Contents of the interpolator
Output of the auxiliary function

Data transfer into the interpolator
Read-in disable for tool change
Query point of the read-in enable
Remove read-in disable
Related to .... IS “Program status running”
V3200 0006.4 Program level abort

Signal state 1 or signal On each signal transition 0 –> 1 the current program level being processed (subroutine
transition 0 –––> 1 level) is immediately aborted. Processing of the part program continues one level higher
after the exit point.
Special cases, errors, ... ... The main program level cannot be aborted with this IS, only with IS “Reset”.

10-220 6FC5397-1CP10-1BA0
V3200 0007.0 NC start disable

Signal state 1 or signal IS “NC Start” is ineffective
Signal state 0 or signal IS “NC Start” is effective.
Application example(s) This signal is used to suppress renewed program processing because, for example, there is
no lubricant.
Related to .... IS “NC Start”
V3200 0007.1 NC Start

Edge evaluation: yes Signal(s) updated: cyclic Signal(s) valid from SW status
Signal state 1 or signal AUTOMATIK mode: The selected NC program is started or resumed.
transition 0 –––> 1 If data are transferred from the PLC to the NC in the “Program interrupted” state, the data are
calculated immediately on NC Start.
MDA mode: The entered part program blocks are released for execution or continued.
Related to .... IS “NC Start disable”
V3200 0007.2 NC Stop at block limit

Signal state 1 or signal The current NC program is stopped after the current part program block has been processed.
transition 0 –––> 1 Otherwise as for IS “NC Stop”.
Related to .... IS “NC Stop”
IS “NC Stop axes plus spindles”
IS “Channel status interrupted”

6FC5397-1CP10-1BA0 10-221
V3200 0007.3 NC stop

Signal state 1 or signal The current NC program is stopped immediately, the current block is not completed. Only the
transition 0 –––> 1 axes without contour violation are stopped.
Distances to go are traversed only after a renewed start.
The program status changes to “stopped”, the channel status changes to “interrupted”.
Application example(s)
On NC start the program is continued at the point of interruption.
IS “NC Stop”
IS “NC Start”
Program
running
Axis
running
Block processed
Special cases, errors, ... The signal NC stop must be active for at least one PLC cycle.
...
Related to .... IS “NC Stop at block limit”

10-222 6FC5397-1CP10-1BA0
V3200 0007.4 NC Stop axes plus spindles

Signal state 1 or signal The current NC program is stopped immediately, the current block is not completed. Distan-
transition 0 –––> 1 ces-to-go are not completed until a start signal is given. The axes and the spindle are stop-
ped. They are brought to a controlled standstill, however.
The program status changes to stopped, the channel status changes to interrupted.
Signal irrelevant for ... ... Channel status Reset
Program status aborted
Special cases, errors, ... All axes and spindles that were not caused to move by a program or program block (e.g. axes
... are moved by pressing the travel keys on the machine control panel) are not decelerated to
zero speed with “NC stop axes plus spindles”.
The program is continued at the interrupted place with NC Start.
The signal “NC stop axes plus spindles” must be pending for at least one PLC cycle.
Signal NC Stop axes
Signal NC Start
Program running
Axis running
Spindle running
Block processed
Related to .... IS “NC Stop at block limit”
IS “NC Stop”
V3300 0000.3 Action block active

Interface signal Signal(s) from channel (NCK –––> PLC)
Signal state 1 or signal Block search: Output with accumulated auxiliary function outputs in progress (see Subsection
transition 0 –––> 1 10.4.5)
V3300 0000.4 Approach block active

Signal state 1 or signal Block search with calculation/on contour: Start block in progress (see Subsection 10.4.5)

6FC5397-1CP10-1BA0 10-223
V3300 0000.5 M0/M1 active

Signal state 1 or signal The part program block has been processed, the auxiliary functions have been output and
transition 0 –––> 1 – M0 is stored in the working memory
– M1 is stored in the working memory and IS “Activate M01” is active
The program status changes to stopped.
Signal state 0 or signal – With IS “NC Start”
transition 1 –––> 0 – On program abort as a result of Reset
Data transfer to
working memory
Block processed
NC block with M0 M0
M change signal
(1 PLC cycle time)
IS “M0/M1 active”
IS “NC Start”
Related to .... IS “Activate M01”
IS “M01 selected”
V3300 0000.6 Last action block active

Signal state 1 or signal Block search: Last block of the output with collected auxiliary function outputs in progress
transition 0 –––> 1 (see Subsection 10.4.5)
V3300 0001.4 Block search active

Signal state 1 or signal The Block search function is active. It was selected and started on the operator interface.
Signal state 0 or signal The block search function is not active.
Application example(s) The block search function makes it possible to jump to a certain block within a part program
and to start processing the part program at this block.

10-224 6FC5397-1CP10-1BA0
V3300 0001.5 M2/M30 active

Signal state 1 or signal NC block with M2 is completely processed. If traversing motions are also programmed in this
transition 0 –––> 1 block, the signal is not output until the target position is reached.
Signal state 0 or signal – No program end or abort

transition 1 –––> 0 – Status after power-up of control system
– Start of an NC program
Data transfer to
working memory
Block processed
NC block with M2 M2
M change signal
(1 PLC cycle time)
Application example(s) The PLC can detect the end of program processing with this signal and react appropriately.
Special cases, errors, ... – The functions M2 and M30 have equal priority. Only M2 should be used.
... – IS “M2/M30 active” is applied statically at the end of a program.
– Not suitable for automatic follow-on functions such as workpiece counting, bar feed, etc. M2
must be programmed in a separate block and the word M2 or the decoded M signal used for
these functions.
– No auxiliary functions leading to read-in stop may be written in the last block of a program.
V3300 0001.7 Program test active

Signal state 1 or signal Program control “Program test” is active. Axis disable is set internally for all axes (not spind-
transition 0 –––> 1 les). Therefore the machine axes do not move when a part program block or a part program
is being processed. The axis movements are simulated on the operator interface with chan-
ging axis position values. The axis position values for the display are generated from the
calculated setpoints.
The part program is processed in the normal way.
Signal state 0 or signal Program control Program test is not active.
Related to .... IS “Activate program test”
IS “Program test selected”

6FC5397-1CP10-1BA0 10-225
V3300 0003.0 Program status running

Signal state 1 or signal The part program has been started with IS “NC start” and is running.
Signal state 0 or signal – Program stopped by M00/M01 or NC Stop or mode change.
transition 1 –––> 0 – The block is executed in single-block mode.
– End of program reached (M2)
– Program abort by Reset
– Current block cannot be processed
Special cases, errors, ... The IS “Program status running” does not change to 0 if workpiece machining is stopped by
... the following events:
– Output of feed disable or spindle disable
– IS “Read-in disable”
– Feed override to 0%
– Response of the spindle and axis monitoring
V3300 0003.2 Program status stopped

Signal state 1 or signal The NC part program has been stopped by “NC stop”, “NC stop axes plus spindles”, “NC stop
transition 0 –––> 1 at block limit”, programmed M0 or M1 or single block mode.
Signal state 0 or signal Program status “stopped” is not active.
Related to .... IS “NC Stop”
IS “NC Stop at block limit”
V3300 0003.3 Program status interrupted

Signal state 1 or signal When changing from AUTOMATIC or MDA mode (when program has stopped) after JOG the
transition 0 –––> 1 program status switches to “interrupted”. The program can be continued at the point of inter-
ruption in AUTOMATIC or MDA mode when “NC start” is operated.
Signal state 0 or signal Program status interrupted is not active.
Special cases, errors, ... IS “Program status interrupted” signifies that the part program can be continued after an NC
... start.
V3300 0003.4 Program status aborted

Signal state 1 or signal The program has been selected but not started or the current program was aborted with
transition 0 –––> 1 Reset.
Signal state 0 or signal Program status interrupted is not active.
Related to .... IS “Reset”

10-226 6FC5397-1CP10-1BA0
V3300 0003.5 Channel status active

Signal state 1 or signal In this channel
transition 0 –––> 1 – a part program or block is currently being processed in AUTOMATIC or MDA mode or
– at least one axis is
being traversed in JOG mode.
Signal state 0 or signal ”Channel status interrupted” or “Channel status Reset” is active.
V3300 0003.6 Channel status interrupted

Signal state 1 or signal The NC part program in AUTOMATIC or MDA mode can be stopped by “NC stop”, “NC stop
transition 0 –––> 1 axes plus spindles”, “NC stop at block limit”, programmed M0 or M1 or single block mode.
With NC start the part program or the interrupted traversing movement can be continued.
Signal state 0 or signal ”Channel status active” or “Channel status Reset” is active.
V3300 0003.7 Channel status reset

Signal state 1 or signal The signal changes to 1 as soon as the channel goes into Reset status, i.e. no processing
transition 0 –––> 1 taking place.
Signal state 0 or signal The signal changes to 0 if processing is taking place in the channel, e.g.
transition 1 –––> 0 execution of a part program or block search
V3300 4001.1 Workpiece setpoint reached

Signal state 1 or signal The required number of workpieces is reached.
According to setting in MD 27880: PART_COUNTER:
Bit 1 = 0: when $AC_REQUIRED_PARTS equal to $AC_ACTUAL_PARTS
Bit 1 = 1: when $AC_REQUIRED_PARTS equal to $AC_SPECIAL_PARTS
Signal state 0 or signal The required number of workpieces is not reached.
V1700 0000.5 M01 selected

Interface signal Signal(s) from HMI –––> PLC
Signal state 1 or signal Program control Activate M1 has been selected on the operator interface. This does not
transition 0 –––> 1 activate the function.
Signal state 0 or signal Program control Activate M1 has not been selected via the operator interface.
Related to .... IS “Activate M01”

6FC5397-1CP10-1BA0 10-227
V1700 0000.6 Dry run feedrate selected

Signal state 1 or signal Program control –dry run feedrate– has been selected via the operator interface. This does
transition 0 –––> 1 not activate the function.
Signal state 0 or signal Program control –dry run feedrate– has not been selected via the operator interface.
Related to .... IS “Activate dry run feed”
V1700 0001.7 Program test selected

Signal state 1 or signal Program control Program test has been selected via the operator interface. This does not
Signal state 0 or signal Program control Program test has not been selected via the operator interface.
Related to .... IS “Activate program test”
IS “Program test active”
V1700 0001.3 Feed override for rapid traverse selected

Signal state 1 or signal Program control –Feed override for rapid traverse– has been selected via the operator inter-
transition 0 –––> 1 face. This does not activate the function.
Signal state 0 or signal Program control –Feed override for rapid traverse– has not been selected via the operator
transition 1 –––> 0 interface.
Related to .... IS “Rapid traverse override active”
V1700 0002.0 Skip block selected

Signal state 1 or signal Program control –skip block– has been selected via the operator interface. This does not
Signal state 0 or signal Program control –skip block– has not been selected via the operator interface.
Related to .... IS “Activate skip block”
V1900 0000.6 Simulation active

Signal state 1 or signal The –simulation– function has been selected via the operator interface.
Signal state 0 or signal The –simulation– function has not been selected via the operator interface.
Related to ....

10-228 6FC5397-1CP10-1BA0
Basic machine data of channel

rence
Channel-specific
20050 AXCONF_GEOAX_ASSIGN_TAB[n] Assignment between geometry axis and channel axis Chapter
[GEOaxis no.]: 0...2 19
20060 AXCONF_GEOAX_NAME_TAB[n] Geometry axis name in channel Chapter
[GEOaxis no.]: 0...2 19
20070 AXCONF_MACHAX_USED[n] Machine axis number valid in channel Chapter
[channel axis no.]: 0...4 19
20080 AXCONF_CHANAX_NAME_TAB[n] Channel axis name in channel Chapter
[channel axis no.]: 0...4 19
20100 DIAMETER_AX_DEF Geometry axis with transverse axis function P1
20700 REFP_NC_START_LOCK NC start disable without reference point R1
21000 CIRCLE_ERROR_CONST Circle end point monitoring constant
Auxiliary function settings of the channel

rence
Channel-specific
22000 AUXFU_ASSIGN_GROUP[n] Auxiliary function group H2
[aux. func. no. in channel]: 0...63
22010 AUXFU_ASSIGN_TYPE[n] Auxiliary function type [aux. func. no. in channel]: 0...63 H2
22020 AUXFU_ASSIGN_EXTENSION[n] Auxiliary function extension H2
[aux. func. no. in channel ]: 0...63
22030 AUXFU_ASSIGN_VALUE[n] Auxiliary function value H2
[aux. func. no. in channel ]: 0...63
22550 TOOL_CHANGE_MODE New tool offset for M function W1
Timers and counters of the channel

rence
Channel-specific
27860 PROCESSTIMER_MODE Activating the program runtime measurement
27880 PART_COUNTER Activation of the workpiece counters
27882 PART_COUNTER_MCODE[n] Workpiece counting via M command, n = 0 ... 2

6FC5397-1CP10-1BA0 10-229
Display machine data

rence
Display MD
283 ... Setting of the display for the graphic simulation
292
10.9.2 Channel-specific setting data

rence
Channel-specific
42000 THREAD_START_ANGLE Start angle for thread
42010 THREAD_RAMP_DISP Starting and deceleration distance of feed axis in
thread cutting G33
42100 DRY_RUN_FEED Dry run feedrate
Operating mode signals

rence
PLC to NCK
V3000 0000 .0 AUTOMATIC mode
V3000 0000 .1 MDA mode
V3000 0000 .2 JOG mode
V3000 0000 .4 Mode group changeover disable
V3000 0000 .7 RESET
V3000 0001 .2 Machine function REF

rence
NCK to PLC
V3100 0000 .0 Active mode AUTOMATIC
V3100 0000 .1 Active mode MDA
V3100 0000 .2 Active mode JOG
V3100 0000 .3 802 READY
V3100 0001 .2 Active machine function REF

10-230 6FC5397-1CP10-1BA0
Channel signals

rence
PLC to NCK
V3200 0000 .3 Activate DRF
V3200 0000 .4 Activate single block
V3200 0000 .5 Activate M01
V3200 0000 .6 Activate dry run feed V1
V3200 0001 .0 Activate referencing
V3200 0001 .7 Activate program test
V3200 0002 .0 Skip block
V3200 0006 .0 Feed disable
V3200 0006 .1 Read-in disable
V3200 0006 .2 Delete distance-to-go
V3200 0006 .3 Deleting UP number of passes
V3200 0006 .4 Program level abort
V3200 0006 .6 Rapid traverse override active
V3200 0006 .7 Feedrate override active
V3200 0007 .0 NC Start disable
V3200 0007 .1 NC Start
V3200 0007 .2 NC Stop at block limit
V3200 0007 .3 NC stop
V3200 0007 .4 NC Stop axes plus spindles
V3200 0007 .7 Reset

rence
NCK to PLC
V3300 0000 .3 Action block active
V3300 0000 .4 Approach block active
V3300 0000 .5 M00/M01 active
V3300 0000 .6 Last action block active
V3300 0001 .0 Referencing active R1
V3300 0001 .4 Block search active
V3300 0001 .5 M2/M30 active
V3300 0001 .7 Program test active
V3300 0003 .0 Program status: Running
V3300 0003 .2 Program status: Stopped
V3300 0003 .3 Program status: Interrupted
V3300 0003 .4 Program status: Aborted
V3300 0003 .5 Channel status: Active
V3300 0003 .6 Channel status: Interrupted
V3300 0003 .7 Channel status: Reset
V3300 4001 .1 Workpiece setpoint reached

6FC5397-1CP10-1BA0 10-231

rence
HMI to PLC
V1700 0000 .5 M01 selected
V1700 0000 .6 Dry run feedrate selected
V1700 0001 .3 Feedrate override selected for rapid traverse
V1700 0001 .7 Program test selected
V1700 0002 .0 Skip block selected
V1900 0000 .6 Simulation active

10-232 6FC5397-1CP10-1BA0
Feed (V1) 11
11.1 Path feedrate F
Functionality
The feedrate F is the path velocity of the tool along the programmed workpiece contour. The
individual axis velocities result from the proportion of the axis path in the path.
The feedrate F is active for interpolation types G1, G2, G3, CIP, CT and is maintained in a
program until a new F word is written.
References: ”Operator control and programming”
Dimension units for F: G94, G95

The dimension unit for the F word is determined by G functions:
S G94 F as the feedrate in mm/min or inch/min
S G95 F as the feedrate in mm/rotation of the spindle
or inch/rotation (only makes sense if the spindle is running!)
The inch dimension system applies to G700 or the “inch” system setting with
MD 10240: SCALING_SYSTEM_IS_METRIC =0.
Dimension units for F with G96, G97

For lathes the group with G94, G95 has been extended by the G96, G97 functions for the
constant cutting rate (ON/OFF). These functions also affect the S word.
When function G96 is active, the spindle speed is adapted to the currently machined work-
piece diameter (transverse axis) in such a manner that a programmed cutting rate S remains
constant at the tool cutting edge (spindle speed x diameter = constant).
The S word is interpreted as the cutting rate from the block with G96. G96 is modal until can-
cellation by different G function of the group (G94, G95, G97).
The feedrate F is always evaluated in the unit of dimension of mm/rotation or inch/rotation (as
for G95).

6FC5397-1CP10-1BA0 11-233
Feed (V1)
Maximum path velocity

The maximum path velocity is obtained from the maximum velocities of the axes involved
(MD 32000: MAX_AX_VELO) and their proportion in the path. The maximum velocity of an
axis stored in the MD cannot be exceeded.
CFC feedrate override for circles

When machining circular contours using milling tools and the active tool radius compensation
(G41/G42), the feedrate at the milling cutter center must be adjusted if the programmed F
value is intended to be active at the circular contour. If the CFC feedrate override is active,
inside and outside circle machining is detected automatically.
The feedrate override can be switched-off using CFTCP.
References: ”Operator control and programming”
Interface signals
If the revolutional feedrate is active, the IS “Revolutional feedrate active” (V3300 0001.2) is
set.
If the G96 function is active, the IS “Constant cutting rate active” (V390x 2002.0) is set for the
spindle.
Alarms
S If no F word is programmed at G1, G2, G3, ..., the alarm 10860 is issued. An axis move-
ment is not possible. However, please note: SD 42110: DEFAULT_FEED !
S If F0 is programmed, alarm 14800 is issued.
S If G95 is active and the spindle is stationary, an axis movement is not possible. No alarm
is issued.
Notes
S If the “Dry run feedrate” function is activated and the program is started, the feedrates
programmed in combination with G1, G2, G3, CIP, CT are replaced by the feedrate value
stored in SD 42100: DRY_RUN_FEED.
References: Subsection10.4.4 “Program machining with dry run feedrate”
S The velocity of the traversing movement of an axis in the JOG mode is determined by the
machine data/setting data. Please refer to
References: Chapter 9, “JOG with and without handwheel” for a detailed description of
the velocities, including the possible “Rapid traverse override”.

11-234 6FC5397-1CP10-1BA0
Feed (V1)
11.1.1 Feedrate with G33, G34, G35 (thread cutting)
Types of thread cutting

G33 – thread with constant pitch
G34 – thread with (linearly) increasing pitch
G35 – thread with (linearly) decreasing pitch
Axis velocity
With respect to G33, G34, or G35 threads, the axis velocity for the thread length results from
the set spindle speed and the programmed thread pitch. The axis velocity defined in MD
32000: MAX_AX_VELO cannot be exceeded.
The feedrate F is not relevant. It is, however, kept in the memory.
The axis velocity, e.g. for a cylinder thread, results from the set spindle speed (S) and the
programmed thread pitch (e.g. K):
Fz [mm/min] = speed S [rev/min] * thread pitch K[mm/U]
Note:
For G34 and G35 the pitch modification in mm/U2 is programmed under the F address.
References: “Operator control and programming”
Minimum spindle speed

In order to ensure smooth rotation at low speeds, the spindle speed is not permitted to fall
below a minimum level. This speed can be defined using
SD 43210: SPIND_MIN_VELO_G25 (minimum spindle speed) and depending on the gear
stage can be adjusted unsing with
MD 35140: GEAR _STEP_MIN_VELO_LIMIT (minimum speed for gear stage change). The
minimum spindle speed can be changed in the part program with G25.
NC stop, single block

NC stop and single block are only active after completion of thread chaining.
information
S The spindle speed override switch should remain unchanged during thread machining
(tapping).
S The feedrate override switch is irrelevant in a block with G33, G34, G35.
Programmable runin and runout path: DITS, DITE

The run-in and run-out path is to be traversed in addition to the required thread. The starting
and braking of the axis (both axes in case of tapered threads) are performed in these areas.
This path depends on the thread pitch, spindle speed, and the axis dynamics (configuration).
If the available path for run-in or run-out is limited, it may be necessary to reduce the spindle
speed so that this path is sufficient.

6FC5397-1CP10-1BA0 11-235
Feed (V1)
In this case, the run-in and run-out paths can be specified separately in the program to
achieve favorable cutting values and short machining times or to simplify the handling of this
issue. If no values are specified, the values from the setting data (SD) apply. The specifica-
tions in the program are written in SD 42010: THREAD_RAMP_DISP[0] ... [1].
If this path is not sufficient for the traversing with the configured axis acceleration, the axis is
overloaded in terms of acceleration. Alarm 22280 (”Programmed run-in path too short”) is
then issued for the thread run-in. The alarm is purely for information and has no effect on part
program execution.
The run-out path acts as an approximate distance at the end of the thread. This achieves a
smooth change in the axis movement during the lifting process.
Programming
DITS= ... ; run-in path of the thread
DITE= ... ; run-out path of the thread
SD 42010
Only paths, and not positions, are programmed with DITS and DITE. The part program
instructions are related to the setting data SD 42010: THREAD_RAMP_DISP[0], ...[1] that
defines the following acceleration response of the axis during thread cutting ([0]–run-in,
[1]–run-out):
S SD 42010 = < 0 to –1: Starting/braking of the feedrate axis is carried out with the configu-
red acceleration. Jerk according to current BRISK/SOFT programming.
S SD 42010 = 0:
Abrupt starting/braking of the feedrate axis during thread cutting.
S SD 42010 = > 0:
The thread run-up/deceleration distance is set. To avoid technology alarm 22280, the
acceleration limits of the axis must be observed in case of very small run-in and run-out
paths.
Note
DITE acts at the end of the thread as an approximate distance. This achieves a smooth
change in the axis movement.
Thread pitch change F with G34, G35

If you already know the initial and final pitch of a thread, you can calculate the thread pitch
change F to be programmed according to the following equation:
|K2e–K2a|
F = –––––––––––– [mm/U 2 ]
2*LG
Whereby:
Ke thread pitch of the axis target coordinate [mm/U]
Ka initial thread pitch (progr. under I, K) [mm/U]
LG thread length in [mm]

11-236 6FC5397-1CP10-1BA0
Feed (V1)
11.1.2 Feedrate for G63 (tapping with compensation chuck)
Feedrate F
In the case of G63 it is necessary to program a feedrate F. It must be suitable for the selected
spindle speed S (programmed or set) and for the thread pitch of the drill:
Feedrate F [mm/min] = speed S [rev/min] x thread pitch [mm/rev]
The compensation chuck absorbs possible path differences of the drill axis to a limited extent.
11.1.3 Feedrate for G331, G332 (rigid tapping)
Axis velocity
With respect to G331/G332 rigid tapping, the axis velocity for the thread length results from
the effective spindle speed S and the programmed thread pitch. The axis velocity defined in
MD 32000: MAX_AX_VELO cannot be exceeded.
The feedrate F is not relevant. It is, however, kept in the memory.
Interface signal
If the G331/G332 function is active, the IS “Rigid tapping active” (V390x 2002.3) is set for the
spindle.
Note
The tapping may only be carried out without a compensation chuck if an exact dynamic
adjustment of the spindle and the relevant axis has been performed. With G331/G332 the
parameter set n (0...5) of the axis becomes effective automatically. This parameter set also
applies to the current gear stage of the spindle (M40, M41 to M45 – see also Chapter 5,
“Spindle”). In general, the axis is adjusted to the slower spindle

6FC5397-1CP10-1BA0 11-237
Feed (V1)
11.1.4 Feedrate for chamfer/rounding: FRC, FRCM
Chamfer/rounding
You can insert the chamfer (CHF or CHR) or rounding (RND) elements into a contour corner.
If you wish to round several contour corners sequentially in the same manner, use the “Modal
rounding” (RNDM) command.
You can program the feedrate for the chamfer/rounding with FRC=... (blockwise) or
FRCM= ... (modal). If FRC/FRCM is not programmed, the normal feedrate F is applied.
Programming
FRC=... ; non-modal feedrate for chamfer/rounding,
value >0, feedrate in mm/min with G94 or mm/rev. with G95
FRCM=... ; modal feedrate for chamfer/rounding:

value > 0: feedrate in mm/min (G94) or mm/rev. (G95),
modal feedrate for chamfer/rounding ON
value =0: modal feedrate for chamfer/rounding OFF
The feedrate F applies for the chamfer/rounding.
Notes
F, FRC, FRCM is not active if a chamfer is traversed with G0. If the feedrate F is applied to
the chamfer/rounding this is, by default, the value from the block that leads away from the
corner. Other settings can be configured via machine data MD 20201:
CHFRND_MODE_MASK.
A maximum of 3 blocks without corresponding information may be put between two blocks
containing traversing information for chamfer/rounding (axes of the plane). In the case of
more blocks without axis information in the plane and existing instructions for inserting cham-
fer or rounding, an alarm is triggered.

11-238 6FC5397-1CP10-1BA0
Feed (V1)
11.2 Rapid traverse G0
11.2 Rapid traverse G0
Application
The rapid traverse motion G0 is used for the rapid positioning of the tool, but not for direct
workpiece machining.
All axes can be traversed simultaneously. This results in a straight path.
The maximum velocity (rapid traverse) for each axle is set in the machine date
(MD 32000: MAX_AX_VELO). If only one axis traverses, it uses its rapid traverse. If, for
example, two path axes are traversed simultaneously, the path velocity (resulting velocity) is
selected such that the maximum possible path velocity under consideration of both axes is
obtained.
If, for example, two axes have the same maximum velocity and must travel the same path,
the
path velocity = 1.41 * max. axis velocity
(geometrical sum of the two axis components).
The feedrate F is not relevant for G0. It is, however, kept in the memory.
Rapid traverse override

In the AUTOMATIC operating mode, it can be set through the “Position” operation area –>
“Program control” softkey that the feedrate override switch also applies to the rapid traverse.
The active function is displayed with ROV in the status line. HMI to PLC sets the IS “Feedrate
override for rapid traverse selected” (V1700 0001.3). The PLC user program must place this
signal on the IS “Rapid traverse override active” (V3200 0006.6).

6FC5397-1CP10-1BA0 11-239
Feed (V1)
11.3 Feedrate control
11.3.1 Overview
progr. F value progr. S value

X axis (radius)
IS: Activate dry run feedrate stored

SD: DRY_RUN_FEED G96 S value
G95
(dry run
feedrate)
F value G97
(G94) SG96
G95/G96/G97 2*Π*X
G94
Maximum
*
Spindle override
* from machine PLC
control panel
IS: Activate dry run feed
Spindle speed setpoint
G94 G95
*
100 %
Feedrate override
from machine control
* PLC
panel 0 – xxx %
IS: Rapid traverse override active
IS: Feedrate override active
IS: Override active
Path velocity
Fig. 11-1 Possibilities for programming and controlling the feedrate
11.3.2 Feed disable and feed/spindle stop
General
The “Feed disable” or “Feed/spindle stop” brings the axes to a standstill. The path contour is
maintained (exception: G33 block).
Feed disable
The channel-specific interface signal “Feed disable” (V3200 0006.0) will stop all axes
(geometry and special axes) in all operating modes.
This feed disable is not effective if G33 is active; it is, however, active with G63, G331,
G332.

11-240 6FC5397-1CP10-1BA0
Feed (V1)
Feed stop for axes in the WCS

The “Feed stop” interface signals (V3200 1000.3, V32001 004.3, and V3200 1008.3) are
used to stop the geometry axes (axes in the WCS) during traversing in the workpiece coordi-
nate system (WCS) in the JOG mode.
Axis-specific feed stop

The axis-specific “Feed stop” interface signal (V380x 0004.3) is used to stop the relevant
machine axis. The following applies to the automatic mode:
If the “Feed stop” is performed for a path axis, all the axes traversed in the current block and
all axes participating in the axis group are stopped.
Only the current axis is stopped in JOG mode.
The axisspecific “Feed stop” is active when G33 is active (but: contour deviations = thread
error!).
Spindle stop
The “Spindle stop” interface signal (V380x 0004.3) is used to stop the spindle.
“Spindle stop” is inactive when G33 or G63 are active (but: contour deviations = thread
error!).
11.3.3 Feedrate override on a machine control panel
General
The operator can use the feedrate override switch to immediately increase or decrease the
path feedrate relative to the programmed feedrate by a percentage. The feedrates are multi-
plied by the override values.
An override between 0 and 120% can be programmed for the path feedrate F.
The rapid traverse override switch is used to reduce the traversing velocity when testing a
part program.
An override between 0 and 100% can be programmed for the rapid traverse.
The spindle override can be used to modify the spindle speed and the cutting rate (with G96).
The override can be between 50 and 120%.
The override is not permitted to exceed the machinespecific acceleration and speed limits or
generate a contour error.
The override acts on the programmed values before limits (e.g. G26) intervene.
Channel-specific feedrate and rapid traverse override

One enable signal and one byte are provided on the PLC interface for the override factor in
percent for feedrate and rapid traverse.

6FC5397-1CP10-1BA0 11-241
Feed (V1)
IS “Feedrate override” (VB3200 0004)

IS “Feedrate override active” (V3200 0006.7)
IS “Rapid traverse override” (VB3200 0005)
IS “Rapid traverse override active” (V3200 0006.6)
The interface for the override (value) is supplied by a machine control panel via the PLC to
the NC and it is gray-coded.
An active feedrate override acts on all path axes. An active rapid traverse override acts on all
axes traversing with rapid traverse.
If there is no dedicated rapid traverse override switch, the feedrate override switch can be
used. In this case, feedrate overrides above 100% are limited to 100% for rapid traverse
override.
The override to be active can be selected via the PLC or operator panel.
If the selection is made using the operator panel (display: ROV), the IS “Feedrate override for
rapid traverse selected” (V1700 0001.3) is set and must be transferred by the PLC user pro-
gram to the IS “Rapid traverse override active” (V3200 0006.6). The value itself is to be trans-
ferred by the PLC user program from a machine control panel to the IS “Rapid traverse over-
ride” (VB3200 0005).
The channel-specific feedrate and rapid traverse overrides are inactive if G33, G63, G331,
and G332 are active.
Axis-specific feedrate override

One enable signal and one byte for the feedrate override factor in percent are available on
the PLC interface for each axis.
IS “Feedrate override” (VB380x 0000)
IS “Override active” (V380x 0001.7)
If G33, G331, G331, G63 are active, the axis-specific feedrate override has no effect (is inter-
nally set to a fixed value of 100%).
Spindle override
One enable signal and one byte for the spindle override factor in percent are available on the
PLC interface for each spindle.
IS “Spindle override” (VB380x 2003)
IS “Override active” (V380 x 0001.7)
The additional signal IS “Feedrate override for spindle valid” (V380x 2001.0) allows the PLC
user program to determine that the value of the IS “Feedrate override” (VB380x 0000) should
apply.
The spindle override is active with G33, but it should not be actuated for reasons of accuracy;
also active with G331, G332. In the case of G63, the spindle override is set to a fixed value of
100%.
Override active
The set override values are effective in all operating modes and machine functions. This ap-
plies if the IS “Rapid traverse override active”, “Feedrate override active” or “Override active”
are set.
An override value of 0% acts like a feed disable.

11-242 6FC5397-1CP10-1BA0
Feed (V1)
Override inactive
When the override is inactive (i.e. the above interface signals are set to “0”), the override fac-
tor “1” is used internally for all switch positions (except from the 1st position), i.e. the override
is 100%.
Note:
The 1st switch position of the gray-coded interfaces for the value represents a special case.
In this case, the override factor of the 1st switch position is also used if the IS “Rapid traverse
override active”, “Feedrate override active”, “Override active” are not set. Thus, 0% is issued
as the override value for axes (acts the same as “Feed disable”). The following applies to the
spindle if the IS “Override active” is not set: Override value 50%.

6FC5397-1CP10-1BA0 11-243
Feed (V1)
Machine data, channel-specific

20201 CHFRND_MODE_MASK
MD number Properties for chamfer/rounding
Changes effective immediately: Power on Protection level: 2/2 Unit:
Data type: Byte Applies from SW:
Meaning: Specifies properties for chamfer/rounding.
The MD is coded as follows:
Bit 0: = 0: Take the feedrate from the following block (default value)
= 1: Take the feedrate from the preceding block
Setting data, channel-specific

4210 THREAD_RAMP_DISP[0], [1]
SD number Acceleration behavior of the feedrate axis when thread cutting
Default setting: –1 Minimum input limit: –1 Maximum input limit: 999999
Changes effective immediately: immediately Protection level: 7/7 Unit: mm, inch
Meaning: The SD is effective for thread cutting with G33, G34, G35. It provides two elements that deter-
mine the behavior during the starting of the thread axis (1st element = index 0) and during the
braking with rounding (2nd element = index 1).
The values possess the same properties for the thread run-in and run-out:
–1: Starting/braking of the thread axis is carried out with the configured acceleration.
Jerk according to current BRISK/SOFT programming.
0: Abrupt starting/braking of the feedrate axis during thread cutting.

>0: The maximum thread starting/braking distance is defined. The defined distance may
cause an acceleration overload of the axis. The SD is defined during
the programming of DITR (Displacement Thread Ramp) from the block.
The default values (–1) for both elements of the SD are set with NC reset and at the end of the
part program.
Example: $SC_THREAD_RAMP_DISP[0]=2 ; run-in path 2 mm
The SD is defined during the programming of DITS (index 0) and DITE (index 1) from the block.
SD irrelevant for ... ... no G33, G34, G35
Related to .... With the DITS and DITE (Displacement Thread Start/End) part program instructions.
42110 DEFAULT_FEED
SD number Default value for path feedrate
Default setting: 0.0 Minimum input limit: 0.= Maximum input limit: ***
Changes effective immediately: immediately Protection level: 7/7 Unit:
mm/min, mm/rev.
Meaning: The setting date is evaluated during the start of the part program with consideration of the
switch-on position of the feedrate type.
Switch-on positions:
Turning: G95 – feedrate in mm/rev. of the spindle
Milling: G94 – feedrate in mm/min
If no F word is written at G1, G2, G2, ... for the applicable feedrate type and if the SD value is not
zero, the feedrate from this SD is used. Otherwise, an alarm indicating the missing feedrate is
issued.
SD irrelevant for ... ... Turning: G94 programmed
Milling: G95 programmed

11-244 6FC5397-1CP10-1BA0
Feed (V1)
V3200 0000.6 Activate dry run feedrate

Interface signal Signal(s) to channel (PLC → NCK)
Signal state 1 or signal Instead of the programmed feedrate (for G1, G2, G3, CIP, CT), the dry run feedrate defined in
transition 0 –––> 1 SD 42100: DRY_RUN_FEED is used if the dry run feedrate is larger than the programmed
feedrate.
This interface signal is evaluated on an NC start when the channel is in the “Reset” state.
When selected on the PLC, the “Activate dry run feedrate” interface signal is required to be set
by the PLC user program.
Signal state 0 or signal The programmed feedrate is used for traversing.
transition 1 –––> 0 Active after Reset.
Application example(s) Testing a workpiece program with an increased feedrate.
Related to .... IS “Dry run feedrate selected” (V1700 0000.6)
SD 42100: DRY_RUN_FEED (Dry run feedrate)
VB3200 0004 Feedrate override

Signal state 1 or signal Table 11-1 Gray coding for feedrate override
Switch Feedrate override
position Code factor
1 00001 0.0
2 00011 0.01
3 00010 0.02
4 00110 0.04
5 00111 0.06
6 00101 0.08
7 00100 0.10
8 01100 0.20
9 01101 0.30
10 01111 0.40
11 01110 0.50
12 01010 0.60
13 01011 0.70
14 01001 0.75
15 01000 0.80
16 11000 0.85
17 11001 0.90
18 11011 0.95
19 11010 1.00
20 11110 1.05
21 11111 1.10
22 11101 1.15
23 11100 1.20
24 10100 1.20
25 10101 1.20
26 10111 1.20
27 10110 1.20
28 10010 1.20
29 10011 1.20
30 10001 1.20
31 10000 1.20
Related to .... IS “Feedrate override active” (V3200 0006.7)

6FC5397-1CP10-1BA0 11-245
Feed (V1)
VB3200 0005 Rapid traverse override

transition 0 –––> 1 Table 11-2 Gray coding for rapid traverse override
Switch Code Rapid traverse override

position factor
1 00001 0.0
2 00011 0.01
3 00010 0.02
4 00110 0.04
5 00111 0.06
6 00101 0.08
7 00100 0.10
8 01100 0.20
9 01101 0.30
10 01111 0.40
11 01110 0.50
12 01010 0.60
13 01011 0.70
14 01001 0.75
15 01000 0.80
16 11000 0.85
17 11001 0.90
18 11011 0.95
19 11010 1.00
20 11110 1.00
21 11111 1.00
22 11101 1.00
23 11100 1.00
24 10100 1.00
25 10101 1.00
26 10111 1.00
27 10110 1.00
28 10010 1.00
29 10011 1.00
30 10001 1.00
31 10000 1.00
Related to .... IS “Rapid traverse override active” (V3200 0006.6)
V3200 0006.0 Feed disable

Signal state 1 or signal The signal is active on a channel in all operating modes.
transition 0 –––> 1 S The signal disables all axes interpolating relative to each other as long as G33 (thread) is
not active.
All axes are brought to a standstill with adherence to the path contour. When the feed dis-
able is canceled (0 signal), the interrupted part program is continued.
S The position control is retained, i.e. the following error is eliminated.
S If a travel request is issued for an axis with an active “Feed disable”, The pending travel
request is executed immediately when the “Feed disable” is canceled.
If the axis is interpolating in relation to others, this also applies to these axes.
Signal state 0 or signal S The feedrate is enabled for all axes on the channel.
transition 1 –––> 0 S If a travel request (”Travel command”) exists for an axis or group of axes when the “Feed
disable” is canceled, this is executed immediately.
Special cases, errors, ... The feed disable is inactive when G33 is active.
...

11-246 6FC5397-1CP10-1BA0
Feed (V1)
V3200 0006.6 Rapid traverse override active

Signal state 1 or signal The rapid traverse override between 0 and a maximum of 100% entered in the PLC interface
transition 0 –––> 1 is channel-specific.
Signal state 0 or signal The rapid traverse override entered in the PLC interface is ignored.
transition 1 –––> 0 If the rapid traverse override is not active, an override factor of 100% is used
internally on the NC.
Note:
The 1st switch position of the gray-coded interface for the value represents an exception. In
this case, this override factor is also used with “Rapid traverse override inactive” and 0% is
issued as the override value for axes.
Special cases, errors, ... The rapid traverse override is inactive if G33 is active.
...
Related to .... IS “Rapid traverse override” (V3200 0005)
V3200 0006.7 Feedrate override active

Signal state 1 or signal The feedrate override between 0 and a maximum of 120% entered in the PLC interface is
transition 0 –––> 1 active for the path feedrate and therefore automatically for the related axes.
In JOG mode, the feedrate override acts directly on the axes.
Signal state 0 or signal The feedrate override entered in the PLC interface is ignored.
transition 1 –––> 0 If the feedrate override is not active, an override factor of 100% is used internally on the NC.
Note:
The 1st switch position of the gray-coded interface for the value represents an exception. In
this case, this override factor is also used with “Feedrate override inactive” and 0% is issued
as the override value for axes (acts the same as “Feed disable”).
Special cases, errors, ... The feedrate override is inactive if G33 is active.
...
Related to .... IS “Feedrate override” (V3200 0004)
V3200 1000.3
and Feed stop Geo-axes (axes in the WCS)
V3200 1008.3
Signal state 1 or signal The signal is only active in JOG mode (axes traversed in the WCS).
transition 0 –––> 1 S The signal triggers a feed stop for the axis. Traversing axes are brought to a standstill
under controlled braking (ramp stop). No alarm is output.
S If a travel request is issued for an axis with an active “Feed stop”, the request is retained.
This pending travel request is executed immediately after the “Feed stop” is canceled.
Signal state 0 or signal S The feedrate is enabled for the axis.
transition 1 –––> 0 S If a travel request (“Travel command”) is active when the “Feed stop” is canceled, this is
executed immediately.
V1700 0000.6 Dry run feedrate selected

Interface signal Signal(s) to channel (HMI → PLC)
Signal state 1 or signal Dry run feedrate is selected.
transition 0 –––> 1 Instead of the programmed feedrate, the dry run feedrate entered in SD 42100:
DRY_RUN_FEED is used.
When activated from the operator panel, the dry run feedrate signal is automatically entered in
the PLC interface and transmitted by the PLC basic program to the “Activate dry run feedrate”
PLC interface signal.
Signal state 0 or signal Dry run feedrate is not selected.
transition 1 –––> 0 The programmed feedrate is active.
Related to .... IS “Activate dry run feedrate” (V3200 0000.6)
SD: DRY_RUN_FEED (Dry run feedrate)

6FC5397-1CP10-1BA0 11-247
Feed (V1)
V1700 0001.3 Feedrate override selected for rapid traverse

Interface signal Signal(s) to channel (HMI → PLC)
Signal state 1 or signal The feedrate override switch should also be active as rapid traverse override switch.
transition 0 –––> 1 Override values above 100% are limited to the maximum value for 100% rapid traverse override.
The IS “Feedrate override selected for rapid traverse” is automatically entered in the PLC inter-
face from the operator panel and transferred to the “Rapid traverse override active” PLC inter-
face signal by the PLC basic program.
In addition, the IS “Feedrate override” (VB3200 0004) is copied by the PLC basic
program into the IS “Rapid traverse override” (VB3200 0005).
Signal state 0 or signal The feedrate override switch should not be activated as rapid traverse override switch.
Application example(s) The signal is used when no separate rapid traverse override switch is available.
V3300 0001.2 Revolutional feedrate active

Interface signal Signal(s) from channel (NCK → PLC)
Signal state 1 or signal When programming G95 (revolutional feedrate) in the AUTOMATIC mode.
Related to ....

11-248 6FC5397-1CP10-1BA0
Feed (V1)
VB380x 0000 Feedrate override (axisspecific)

Interface signal Signal(s) to axis (PLC → NCK)
Signal state 1 or signal The axisspecific feedrate override is defined via the PLC in gray coding.
Switch Code Axial feedrate over

position ride factor
1 00001 0.0
2 00011 0.01
3 00010 0.02
4 00110 0.04
5 00111 0.06
6 00101 0.08
7 00100 0.10
8 01100 0.20
9 01101 0.30
10 01111 0.40
11 01110 0.50
12 01010 0.60
13 01011 0.70
14 01001 0.75
15 01000 0.80
16 11000 0.85
17 11001 0.90
18 11011 0.95
19 11010 1.00
20 11110 1.05
21 11111 1.10
22 11101 1.15
23 11100 1.20
24 10100 1.20
25 10101 1.20
26 10111 1.20
27 10110 1.20
28 10010 1.20
29 10011 1.20
30 10001 1.20
31 10000 1.20
Table 11-3 Gray coding for axisspecific feedrate override
Related to .... IS “Override active” (V380x 0001.7)

6FC5397-1CP10-1BA0 11-249
Feed (V1)
VB380x 2003 Spindle override

Interface signal Signal(s) to spindle (PLC → NCK)
Signal state 1 or signal The spindle override is defined via the PLC in gray coding.
transition 0 –––> 1 The override value determines the percentage of the programmed speed setpoint that is
issued to the spindle.
Switch Code Spindle override factor

position
1 00001 0.5
2 00011 0.55
3 00010 0.60
4 00110 0.65
5 00111 0.70
6 00101 0.75
7 00100 0.80
8 01100 0.85
9 01101 0.90
10 01111 0.95
11 01110 1.00
12 01010 1.05
13 01011 1.10
14 01001 1.15
15 01000 1.20
16 11000 1.20
17 11001 1.20
18 11011 1.20
19 11010 1.20
20 11110 1.20
21 11111 1.20
22 11101 1.20
23 11100 1.20
24 10100 1.20
25 10101 1.20
26 10111 1.20
27 10110 1.20
28 10010 1.20
29 10011 1.20
30 10001 1.20
31 10000 1.20
Table 11-4 Gray coding for spindle override

Related to .... IS “Override active” (V380x 0001.7)
IS “Feedrate override for spindle valid” (V380x 2001.0)
V380x 2001.0 Feedrate override for spindle valid (instead of spindle override)
Interface signal Signal(s) from axis/spindle (PLC –> NCK)
Signal state 1 or signal The “Feedrate override” value
transition 0 –––> 1 (VB380x 0000) is used for the spindle instead of the “Spindle override” value.
Signal state 0 or signal The “Spindle override” value is used.
Related to .... IS “Spindle override” (VB380x 2003)
IS “Feedrate override” (V380x 0000)
IS “Override active” (V380x 0001.7)

11-250 6FC5397-1CP10-1BA0
Feed (V1)
V380x 0001.7 Override active

Interface signal Signal(s) to axis/spindle (PLC → NCK)
Signal state 1 or signal Feedrate override active (for axes):
transition 0 –––> 1 S The axis-specific feedrate override between
0 and a maximum of 120% entered in the PLC interface is used.
Spindle override active (for spindle):
S The spindle override of 50 to a maximum of 120% is used.
Signal state 0 or signal The existing axisspecific feedrate override or spindle override is not active.
transition 1 –––> 0 If the feedrate override is inactive, 100% is used as the internal override factor.
Note:
The 1st switch position of the gray-coded interface for the value represents a special case. In
this case, the override factor of the 1st switch position is also used with “Override inactive”
and 0% is issued as the override value for axes (acts the same as “Feed disable”); accordin-
gly 50%, is issued for the spindle.
Special cases, errors, ... S The spindle override is always accepted with 100% in the spindle “Oscillation mode”.
... S The spindle override acts on the programmed values before the limits (e.g. G26)
intervene.
S The feedrate override is inactive if G33 is active.
Related to .... IS “Feedrate override” and IS “Spindle override”
V380x 0004.3 Feed stop/Spindle stop (axisspecific)

Interface signal Signal(s) to axis/spindle (PLC → NCK)
Signal state 1 or signal The signal is active in all modes.
transition 0 –––> 1 Feed stop:
S The signal triggers a feed stop for the axis. Traversing axes are brought to a standstill
under controlled braking (ramp stop). No alarm is output.
S The signal triggers a feed stop for all path axes interpolating relative to each other when
the “Feed stop” is activated for any one of these axes. In this case, all the axes are
brought to a stop with adherence to the path contour. When the feed stop signal is can-
celed, execution of the interrupted part program is resumed.
S If a travel request is issued for an axis with an active “Feed stop”, the request is retained.
This pending travel request is executed immediately when “Feed stop” is canceled.
If the axis is interpolating in relation to others, this also applies to these axes.
Spindle stop:
S The spindle is brought to a standstill along the acceleration characteristic.
S In positioning mode, activation of the “Spindle stop” signal interrupts the positioning pro-
cess. The above response applies with respect to individual axes.
Signal state 0 or signal Feed stop:
transition 1 –––> 0 S The feedrate is enabled for the axis.
S If a travel request (”Travel command”) is active when the “Feed stop” is canceled, this is
executed immediately.
Spindle stop:
S The speed is enabled for the spindle.
S The spindle is accelerated to the previous speed setpoint with the acceleration character-
istic or, in positioning mode, positioning is resumed.
Application example(s) Feed stop:
S The traversing motion in the machine axes is not started when “Feed stop” is active, if, for
example, certain operating states that do not permit axis motion (e.g. door not closed)
prevail.
Spindle stop:
S Change a tool
Special cases, errors, ...
...

6FC5397-1CP10-1BA0 11-251
Feed (V1)

rence
Channel-specific
V3200 0000 .6 Activate dry run feed
V3200 0004 – Feed override
V3200 0005 Rapid traverse override
V3200 0006 .0 Feed disable
V3200 0006 .6 Rapid traverse override active
V3200 0006 .7 Feedrate override active
V32001000 .3 Feed stop, geometry axis 1
V1700 0000 .6 Dry run feedrate selected
V1700 0001 .3 Feedrate override selected for rapid traverse
V3300 0001 .2 Revolutional feedrate active
VB380x 2003 – Spindle override
V380x 0001 .7 Override active (axis or spindle)
V380x 2001 .0 Feedrate override for spindle valid
V380x 0004 .3 Feed stop/Spindle stop
V390x 2002 .0 Constant cutting rate active (spindle) S1
V390x 2002 .3 Rigid tapping active (spindle) S1
11.6.2 Machine data/setting data

rence
General machine data
10240 SCALING_SYSTEM_IS_METRIC Basic system metric G1
Channel-specific machine data
20201 CHFRND_MODE_MASK Specifications regarding the chamfer/rounding behavior
35100 SPIND_VELO_LIMIT Maximum spindle speed S1
Channel-specific setting data
42100 DRY_RUN_FEED Dry run feedrate K1
42010 THREAD_RAMP_DISP Acceleration behavior of the feedrate axis when thread
cutting
42110 DEFAULT_FEED Default value for path feedrate

11-252 6FC5397-1CP10-1BA0
Continuous Path Mode, Exact Stop
and LookAhead (B1) 12
For continuous path control, the CNC processes a part program block by block. Only when
the functions of the current block have been completed is the next block processed. Various
requirements with respect to machining or positioning require different block change criteria.
There are two ways that the path axes can behave at block boundaries.
The first way is called “exact stop” and means that all path axes must have reached the set
target position depending on an exact stop criterion before the next block change is initiated.
To be able to fulfill the criterion, the path axes must reduce the path velocity at every block
change which, however, delays the block change.
The second way is called “continuous-path mode” and it attempts to avoid deceleration of the
path velocity at the block boundary in order to change to the next block with as little change of
path velocity as possible.
“LookAhead” is a procedure in continuous-path mode that achieves velocity control with Look-
Ahead over several NC part program blocks extending beyond the current block.

6FC5397-1CP10-1BA0 12-253
Continuous Path Mode, Exact Stop and LookAhead (B1)
12.2 General
12.2 General
Machine axes that interpolate with one another must have the same dynamic response, i.e.
the same following error at any given velocity.
The term path axes refers to all machining axes which are controlled by the interpolator calcu-
lating the path points in such a manner that:
S All axes involved start at the same time
S All the axes involved travel with the correct velocity ratios
S All the axes reach the programmed target position at the same time
The acceleration rates of individual axes can be different depending on the path, e.g. circle.
Path axes can be geometry axes as well as special axes (e.g.: workpiece turning axes that
are involved in the workpiece machining process).
Velocity for zero cycle blocks

The term zero cycle is applied to blocks whose path length is shorter than the distance that
can be traveled on the basis of the programmed set feedrate and the interpolator cycle (time).
For reasons of precision the velocity is reduced until at least one interpolator cycle is required
for the distance. The velocity is then equal to or less than the quotient of the path length of the
block and the IPO cycle.
Stop for synchronization

Regardless of whether exact stop or continuous path mode is selected, the block change can
be delayed by synchronization processes which can stop the path axes. In exact stop mode,
the path axes are stopped at the end of the current block. In continuous path mode, the path
axes are stopped at the next block end point at which they can be decelerated without viola-
ting their deceleration limits. The following synchronization processes cause axes to stop.
S PLC acknowledgement.
If the acknowledgment by the PLC is required for an auxiliary function that is output before
or after the end of motion, the axes stop at the end of the block.
S Missing following blocks.
If following blocks are conditioned too slowly (e.g.: “External processing) the axes stop at
that last possible block boundary.
S Emptying the buffer.
If the NC part program requests that the pre-processing run be synchronized with the main
run (emptying the buffer, e.g. STOPRE), this involves an implicit blockrelated velocity re-
duction or exact stop.
Stopping because of synchronization does not cause contour violations. However, stopping is
undesirable, especially in continuous path mode because it can cause backing off.

12-254 6FC5397-1CP10-1BA0
12.3 Exact stop
12.3 Exact stop

With the exact stop function (G60, G9), all the path axes must reach the programmed block
end point. Only when all path axes have reached the exact stop criterion is the block change
performed. The velocity at the block transition is practically zero.
This means:
S The path axes at the block end point are decelerated almost to rest without overshoot.
S The delay for fulfilling the exact stop criterion prolongs the machining time.
S The delay for fulfilling the exact stop criterion can cause backing off.
The use of the exact stop function is suitable for precise traversing of contours.
Exact stop is not suitable if
S Exact traversing of the contour on the basis of the criterion (e.g. exact stop fine) can
deviate from the programmed contour in order to achieve faster machining.
S An absolutely constant velocity is required.
Activate exact stop

The “Exact stop” function can be selected in the NC part program by command G60 or G9.
G60 is modal, G9 is non-modal. G9 is used if continuous path mode is to be interrupted. Both
exact stop functions only function with the selected exact stop criterion (G601, G602). The
“Exact stop” function is de-selected with the continuous path mode function (G64).
Exact stop criteria

S Exact stop fine: G601
This criterion is applied to monitor whether the actual/setpoint position deviation of the axis
has remained within a specific distance. The permissible deviation distance is defined in
MD 36010: STOP_ LIMIT_FINE (exact stop fine).
S Exact stop coarse: G602
Functionality as for exact stop fine, but the monitoring window for this function is defined in
MD 36000: STOP_LIMIT_COARSE (exact stop coarse). To permit a faster block change

than with the exact stop fine criterion, the exact stop coarse criterion is set to be larger
than the exact stop fine criterion.
Block change times

v t1 = Interpolator end
Actual value with G602
with G601
Setpoint Exact stop coarse > Exact stop fine
t1 t
Fig. 12-1 Block change depending on exact stop criteria

6FC5397-1CP10-1BA0 12-255
12.4 Continuous path mode
Interpolator end
Interpolator end is achieved when the interpolator has calculated the setpoint velocity of the
axes from zero for an interpolation cycle. The actual positions of the path axes have not yet
achieved the target (following error).
With interpolator end, the auxiliary functions in the block are transferred to the PLC, if they are
to be output at the end of motion, independently of continuous path mode or of the active
exact stop criterion of the exact stop function.
12.4.1 General
In continuous path mode, the path velocity is not decelerated for the block change in order to
permit the fulfillment of an exact stop criterion. The objective of this mode is to avoid rapid
deceleration of the path axes at the block change point so that the axis velocity remains as
constant as possible when the program moves on to the next block. To achieve this objective,
the function “LookAhead” is also activated when continuous path mode (G64) is selected (see
Section 12.5).
Continuous path operation causes:
S Rounding of the contour
S Shorter machining times through elimination of braking and acceleration processes that
are required to comply with the exact stop criterion
S Improved cutting conditions as the velocity is more uniform
The continuous-path mode is suitable if a contour is to be traversed as quickly as possible.
Continuous-path mode operation is not suitable if:
S A contour is to be traversed precisely.
S An absolutely constant velocity is required.
Implicit exact stop

In some cases, an exact stop needs to be generated in continuous-path mode to allow the
execution of subsequent actions. In such situations, the path velocity is reduced to zero.
S If auxiliary functions are output before the traverse motion, the previous block is only termi-
nated when the selected exact stop criterion is fulfilled.
S If auxiliary functions are to be output after the traverse motion, they are output after the
interpolator end of the block.
S If an executable block contains no travel information for the path axes, the previous block
is terminated on reaching the selected exact stop criterion.
S A block is terminated on interpolator end if the following block contains the changeover of
the acceleration profile BRISK/SOFT.
S If the function “Empty buffer” (STOPRE) is programmed, the previous block is terminated
when the selected exact stop criterion is reached.

12-256 6FC5397-1CP10-1BA0
Velocity = 0 in continuous path mode

Regardless of the implicit exact stop response, the path motion is braked down to zero velo-
city at the end of the block in cases where:
S The time taken to position a spindle programmed with SPOS is longer than the travel time
of the path axes. The block change is carried out when exact stop fine of the positioning
spindle is reached.
S A synchronization process needs to be carried out (see Section 12.2).
Auxiliary function output during traversal

If the traversal time is not sufficient due to the programmed path length and velocity of the
block with auxiliary function output, the path velocity for the block is reduced such that the
acknowledgment of the auxiliary function can arrive with a PLC cycle time. If the acknowledg-
ment is not received within one PLC cycle time, the following conditions block cannot be pro-
cessed and the axes are braked to rest with setpoint = 0 (without considering the acceleration
limits). If the acknowledgment is not received by the block end in long blocks in which the ve-
locity has not needed to be reduced on account of the PLC acknowledgment time, the velocity
is maintained until the block end and then reduced as described above. If the acknowledg-
ment arrives while the axis is decelerating, the axis is not accelerated back up to the reque-
sted velocity.
12.4.2 Velocity reduction according to overload factor
Functions
This function lowers the path velocity in continuous path mode until the nontangential block
transition can be traversed in one interpolation cycle whilst respecting the deceleration limit
and taking and overload factor into account. With the reduced velocity, axis-specific jumps in
velocity are produced with a nontangential contour at the block transition. The jump in velocity
prevents the path velocity dropping to zero. This jump is performed if the axial velocity was
reduced with the axial acceleration to a velocity from which the new setpoint can be reached
with the jump. The magnitude of the setpoint jump can be limited using an overload factor.
Because the magnitude of the jump is axial, the minimum jump of the path axes which are
active during the block change is considered during block transition. With a practically tangen-
tial block transition, the path velocity is not reduced if the permissible axial accelerations are
not exceeded. In this way, very small sudden changes in the contour can be directly passed
through.

6FC5397-1CP10-1BA0 12-257
Overload factor
The overload factor restricts step changes in the machine axis velocity at block ends. To en-
sure that the velocity jump does not exceed the maximum load on the axis, the jump is deri-
ved from the acceleration of the axis. The overload factor defines the amount by which the
acceleration rate of the machine axis set in MD 32300: MAX_AX_ACCEL (axis acceleration)
may be exceeded for one IPO cycle. The velocity jump is the product of the axial acceleration
* (overload factor –1) * interpolator cycle. The overload factor is 1.2.
Factor 1.0 means that only tangential transitions with a finite velocity can be traversed. For all
other transitions, the velocity is reduced to zero by changing the setpoint.
Selection and de-selection of velocity reduction

Continuous-path mode with velocity reduction according to overload factor can be selected
modally in every NC part program block by means of program code G64 (BRISK active, not
SOFT).
Continuous path mode G64 can be
S interrupted non-modally when exact stop G9 is selected,
S de-selected when exact stop G60 is selected,
12.4.3 Jerk limiting along the path through velocity reduction
Introduction
With the jerk limiting along the path, another method of influencing the continuous-path mode
is introduced. While the “Velocity reduction according to overload factor” function (see Sub-
section 12.4.2) limits the rate of velocity change, the function described here restricts step
changes in the acceleration rate (jerks).
When sections of the contour consisting of blocks (e.g. circle straight line transitions) are ma-
chined, step changes in the acceleration rate occur at the block transition in continuous path
mode.
Reference: Chapter “Acceleration”.
Reduction of jerking
The severity of such jerks can be reduced by decreasing the path velocity at transitions bet-
ween blocks containing different degrees of curvature. A smoother transition is thus achieved
between the contour sections.
Jerk limit
The user sets the maximum jerk that may occur on a path axis during a block transition in
MD 32432: PATH_TRANS_JERK_LIM (maximum axis-specific jerk of a path axis at block
transition).

12-258 6FC5397-1CP10-1BA0
Activation
Jerk limiting at block transitions becomes active if continuous path mode is programmed with
G64 and SOFT acceleration characteristics. MD 32432: PATH_TRANS_JERK_LIM must be
set to a positive value.
12.4.4 Machine axis-specific jerk limiting
Functions
The acceleration change per machine axis can be separately set in the axis-specific machine
data MD 32431: MAX_AX_JERK, as is already the case for acceleration limiting in machine
data MD 32300: MAX_AX_ACCEL.
MD 32431: MAX_AX_JERK acts on the axes interpolated by the path if SOFT (smooth acce-
leration curve) is active within a block.
A basic distinction is made between the axis acceleration curve within a block and at the tran-
sition between two blocks.
Advantages
The deployment of axis-specific machine data for the path offers the following advantages:
S Immediate allowance is made in the interpolation for the dynamic response of the axes,
which can then be fully utilized for each axis.
S Jerk limiting for separate axes is performed not just in linear blocks, but also in curved
contours.
References: Chapter 4 “Acceleration”.

6FC5397-1CP10-1BA0 12-259
12.5 LookAhead
12.5 LookAhead
Functions
LookAhead is a procedure in continuous path mode (G64) that achieves velocity control with
LookAhead over several NC part program blocks beyond the current block.
Without LookAhead: If the program blocks only contain very small paths, a velocity per block
is achieved that permits deceleration of the axes at the block end point without violating acce-
leration limits. This means that the programmed velocity was not actually reached although a
sufficient number of prepared blocks with virtually tangential path transitions was available.
With the LookAhead function: It is possible to plan the acceleration and deceleration phase
with approximately tangential path transitions over several blocks in order to achieve a higher
feedrate with shorter distances. Deceleration to velocity limits is possible with LookAhead
such that violation of the acceleration and velocity limit is prevented.
Feed
G64 – Continuous-path mode with LookAhead
Programmed feedrate F
F1
G60 – Exact stop
N1 N2 N3 N4 N5 N6 N7 N8 N9 N10 N11 N12 Block path
Fig. 12-2 Comparison of the G60 and G64 velocity behavior with short paths in the blocks
LookAhead takes plannable velocity limits into consideration such as:

S Velocity limit in the block
S Acceleration limit in the block
S Velocity limit on block transition
S Synchronization with block change at block transition.
S Exact stop at block end during termination
Operating principle
LookAhead functionality is available only for path axes, but not for the spindle.

12-260 6FC5397-1CP10-1BA0
12.5 LookAhead
For safety reasons, the velocity at the end of the last prepared block must initially be assumed
to be zero because the next block might be very small or be an exact stop block and the axes
must have been stopped by the end of the block. With a series of blocks with high set velocity
and very short paths, the speed can be increased in each block depending on the velocity
value currently calculated by the LookAhead function in order to achieve the required set velo-
city. After this it can be reduced so that the velocity at the end of the last block considered by
the LookAhead function can be zero. This results in a serrated velocity profile which can be
avoided by reducing the set velocity for the number of blocks considered by the LookAhead
function (fixed value).
Velocity profiles
In addition to the fixed, plannable velocity limits, LookAhead can also take account of the pro-
grammed velocity. This makes it possible to achieve a lower velocity by applying LookAhead
beyond the current block.
Following block velocity

One possible velocity profile contains the determination of the following block velocity. Using
information from the current and the following NC block, a velocity profile is calculated from
which, in turn, the required velocity reduction for the current override is derived. The calcula-
ted maximum value of the velocity profile is limited by the maximum path velocity. With this
function it is possible to initiate a speed reduction in the current block taking the override into
account such that the lower velocity of the following block can be achieved. If the reduction in
velocity takes longer than the traverse time of the current block, the velocity is further reduced
in the following block. Velocity control is only ever considered for the following block.
Selection and de-selection of LookAhead

If the continuous-path mode (G64) is selected LookAhead is called and de-selected/interrup-
ted with G60/G9.

6FC5397-1CP10-1BA0 12-261
29000 LOOKAH_NUM_CHECKED_BLOCKS
MD number Number of blocks considered by the LookAhead function
Meaning: Maximum number of blocks that are used by LookAhead for the velocity control.
Related to ....
12.6.2 Axis-specific machine data
32432 ** PATH_TRANS_JERK_LIM
MD number Maximum axis-specific jerk during path movement at the block transition
Default setting: 1,000.00 m/s3, Minimum input limit: 0.0 Maximum input limit: ***
2,777.77 rev/s3
Meaning: The control limits the jerk (acceleration jump) at a block transition between contour sections of
different curvature to the value set.
MD irrelevant for ... ... Exact stop
Related to .... Continuous path mode, SOFT type of acceleration
MD 32431: MAX_AX_JERK (maximum axis-specific jerk with path movement)
It is recommended to set both MD to the same values.

12-262 6FC5397-1CP10-1BA0
V3300 00004.3 All axes stationary

Data block Signal(s) from channel (NCK –> PLC)
Signal state 1 or signal All axes assigned to the channel are stationary with interpolator end. No other traversing move-
transition 0 –––> 1 ments are active.
12.7.2 Axis-specific signals
V390x 0000.6 Position reached with exact stop coarse

Data block Signal(s) from axis/spindle (NCK –> PLC)
Signal state 1 or signal The axis is in the appropriate exact stop and no interpolator is active for the axis and
transition 0 –––> 1 – The control system is in the Reset mode (Reset key or end of program).
– The axis was last programmed as a positioning spindle.
– The path movement was stopped with NC Stop.
– The spindle is in position-controlled mode and is stationary.
– The axis is switched from speed-controlled to position-controlled mode with IS “Position mea-
suring system”.
Signal state 0 or signal The axis is not in the appropriate exact stop or the interpolator is active for the axis or
transition 1 –––> 0 – The path movement was stopped with NC Stop.
– The spindle is in the speedcontrolled mode.
– “Parking mode” is active for the axis.
– The axis is switched from the position-controlled to the speedcontrolled mode with using the
IS “Position measuring system”.
Signal irrelevant for ... ...
Related to .... MD 36000: STOP_LIMIT_COARSE (exact stop coarse)
V390x 0000.7 Position reached with exact stop fine

Data block Signal(s) from axis/spindle (NCK –> PLC)
Signal state 1 or signal See IS “Position reached with exact stop coarse”
Signal state 0 or signal See IS “Position reached with exact stop coarse”
Signal irrelevant for ... ...
Related to .... MD 36010: STOP_LIMIT_FINE (exact stop fine)

6FC5397-1CP10-1BA0 12-263

rence
Channel-specific
V3300 0004 .3 All axes stationary
V390x 0000 .6 Position reached with exact stop coarse
V390x 0000 .7 Position reached with exact stop fine
12.8.2 Machine data

rence
Channel-specific
29000 LOOKAH_NUM_CHECKED_BLOCKS Number of blocks considered by the LookAhead
function
32431 MAX_AX_JERK Maximum axis-specific jerk for path movement B2
32432 PATH_TRANS_JERK_LIM Maximum axis-specific jerk for path movement at
block transition
36000 STOP_LIMIT_COARSE Exact stop coarse A3
36010 STOP_LIMIT_FINE Exact stop fine A3
36020 POSITIONING_TIME Delay time exact stop fine A3

12-264 6FC5397-1CP10-1BA0
Auxiliary Function Output to PLC (H2) 13
Auxiliary functions
For the purpose of workpiece machining operations, it is possible to program process-related
functions (feedrate, spindle speed, gear stages) and functions for controlling additional devi-
ces on the machine tool (sleeve forward, gripper open, clamp chuck) in the part program in
addition to axis positions and interpolation methods. This is performed with the “auxiliary func-
tions” as collective term for various types.
The following different types of auxiliary function are available:
S Miscellaneous function (M)
S Spindle function (S)
S Auxiliary function (H)
S Tool number (T)
S Tool offset D
S Feed F (For SINUMERIK 802D there is no output from F to PLC.)
Output of auxiliary functions to PLC

The auxiliary function output sends information to the PLC indicating, for example, when the
NC program needs the PLC to perform specific switching operations on the machine tool. The
auxiliary functions are output, together with their parameters, to the PLC. The values and si-
gnals must be processed by the PLC user program. The following section describes the va-
rious methods of configuring and programming auxiliary functions as well as their operating
principles.
Auxiliary function groups

Auxiliary functions can be combined to form groups.

6FC5397-1CP10-1BA0 13-265
Auxiliary Function Output to PLC (H2)
13.2 Programming of auxiliary functions
13.2 Programming of auxiliary functions
General structure of an auxiliary function

Letter[address extension]=Value
The letters which can be used for auxiliary functions are: M, S, H, T, D, F.
An address extension only exists for the H function. The address extension must be an inte-
ger. The square brackets can be omitted when an address extension is specified directly as a
numeric value.
The value is defined differently for the individual auxiliary functions (INT = integer or REAL =
fractional decimal number (floating)).
Table 13-1 Overview of auxiliary functions, programming
Func- Address extension Value Explanation Number

tions (integer) per
block
Meaning Area Area Type Meaning max.
M for selected 1–2 0–99 INT Functions Specific numbers are as- 5
M: signed a fixed function.
The address extension
Spindle no. only exists for spindle-re-
lated M functions.
S Spindle no. 1–2 0–3.4028 ex 38 REAL Spindle speed 1
H Any 0 – 99 3.4028 ex 38 REAL Any Functions have no effect 3

in the NCK; only to be im-
plemented on the PLC
T – – 0–32000 INT Tool selection 1
D – – 0–9 INT Tool offset D0 selection, 1

selection default D1
F – – 0,001– REAL path feed 1
999 999,999
A maximum total of 10 auxiliary functions may be programmed in one block. Alarm 14770
“Auxiliary function incorrectly programmed” is output when the specified length for address
extension of value is exceeded or when the wrong data type is used. The following table
shows some programming examples for H functions.
If the admissible number of auxiliary functions per block is exceeded, alarm 12010 is issued.
Table 13-2 Programming examples for H functions
Programming Output of H function to the PLC

H5 H0=5.0
H=5.379 H0=5.379
H17=3.5 H17=3.5
H5.3=21 Error, alarm 14770

13-266 6FC5397-1CP10-1BA0
13.3 Transfer of values and signals to the PLC interface
Block change
A new auxiliary function output from the NCK to the PLC is only possible after the PLC has
acknowledged all transferred auxiliary functions. Auxiliary functions are queued in the user
interface for at least one PLC cycle.
A block is considered completed when the programmed movement has been completed and
the acknowledgment of the auxiliary function was performed. To do so, the NCK stops the part
program processing if necessary to ensure that no auxiliary functions are lost from the PLC
user program’s point of view.
13.3 Transfer of values and signals to the PLC interface
Time of transfer
With respect to auxiliary functions that are issued at the end of the block (e.g.: M2) the output
is only made after all axis movements and the SPOS movement of the spindle have been
completed.
If several auxiliary functions with different output types (prior, during, at end of motion) are pro-
grammed in one motion block, then they are output individually according to their output type.
In a block without axis movements or SPOS movement of the spindle, the auxiliary functions
are all output immediately in a block.
Continuous-path mode
A path movement can only remain continuous if auxiliary function output takes place during
the movement and is acknowledged by the PLC before the path end is reached.
References: Chapter “Continuous-Path Mode, Exact Stop, Look Ahead”
Interface signals
Transfer of the signals from NCK to the PLC: see Section 13.8 Signal Descriptions

6FC5397-1CP10-1BA0 13-267
13.4 Grouping of auxiliary functions
13.4 Grouping of auxiliary functions
Functionality
The auxiliary functions of the types M, H, D, T, and S that are to be issued can be grouped to
auxiliary function groups by means of machine data.
An auxiliary function can only be assigned to one group.
Only one auxiliary function of a group can be programmed per block. Otherwise, alarm 14760
is issued.
Configuring
A maximum of 64 auxiliary function groups can be defined.
A maximum of 64 auxiliary functions can be assigned to these 64 auxiliary function groups.
The standard auxiliary functions (group 1 to 3) are not considered.
The actual number of the auxiliary functions that are to be assigned to the groups must be
entered in the NCK-specific MD 11100: AUXFU_MAXNUM_GROUP_ASSIGN (number of the
auxiliary functions distributed to the AUXFU groups). To do so, the password for protection
level 2 must be set. Then, the control must be turned off and on again. Now, the subsequent
machine data with an index n greater than zero are available and additional values can be
entered.
An allocated auxiliary function is defined in the following machine data:
MD 22000: AUXFU_ASSIGN_GROUP[n] Auxiliary function group
MD 22010: AUXFU_ASSIGN_TYPE[n] Auxiliary function type
MD 22020: AUXFU_ASSIGN_EXTENSION[n] Auxiliary function extension
MD 22030: AUXFU_ASSIGN_VALUE[n] Auxiliary function value
Predefined auxiliary function groups

Group 1:
The auxiliary functions M0, M1, and M2 (M17, M30) are, by default, allocated to group 1. The
output is always made at the end of the block.
Group 2:
The M functions M3, M4, and M5 (M70) are, by default, allocated to group 2. The output is
always made before the movement.
Group 3:
The S function is, by default, contained in group 3. The output is made with the movement.
User-defined groups
The other (user-defined) groups are issued with the movement.
A different setting of the outputs can only be set with the “Expert mode” access (protection
level 1).
Ungrouped auxiliary functions

The output of auxiliary functions that are not assigned to groups is made with the movement.

13-268 6FC5397-1CP10-1BA0
13.5 Block search response
Configuring example:
Distribute 8 auxiliary functions to 7 groups:
Group 1: M0, M1, M2 (M17, M30) – by default, should be kept
Group 2: M3, M4, M5 (M70) – by default, should be kept
Group 3: S functions – by default, should be kept
Group 4: M78, M79
Group 5: M80, M81
Group 6: H1=10, H1=11, H1=12
Group 7: all T functions
Password for protection level 2 is set. Make an entry in MD 11100: AUXFU_MAX-
NUM_GROUP_ASSIGN = 8. Then, turn off the control and turn it on again or perform the
control start-up through the softkey and define the remaining machine data with a subsequent
restart of the control.
Table 13-3 Entries into the machine data for the example
Index n MD 22000 MD 22010 MD22020 MD22030

(GROUP) (TYPE) (EXTENSION) (VALUE)
0 4 M (GND) 0 78
1 4 M (GND) 0 79
2 5 M (GND) 0 80
3 5 M (GND) 0 81
4 6 H 1 10
5 6 H 1 11
6 6 H 1 12
7 7 T 0 –1
Block search with calculation

For the block search with calculation all auxiliary functions that are assigned to a group are
collected and are issued at the end of the block search before the actual re-entry block (ex-
cept from group 1: M0, M1,...). The last auxiliary function of a group is issued.
All collected auxiliary functions are issued in a separate block as regular auxiliary functions
and before the movement.
Important: If the auxiliary functions are to be collected during the block search, they must be
assigned to an auxiliary function group!

6FC5397-1CP10-1BA0 13-269
13.6 Description of the auxiliary functions
13.6.1 M function
Application
You can use the M functions to enable the various switching operations on the machine per
part program.
Scope of functions
S 5 M functions per part program block are possible.
S Value range of M functions: 0 to 99; integer
S Permanent functions have already been assigned to some of the M functions by the con-
trol manufacturer (see “Operation and Programming” in the user manual). The machine
manufacturer can freely dispose of the other functions.
13.6.2 T function
Application
The T function can be used to make the tool required for a machining operation available
through the PLC. Whether a tool change is to be performed directly with the T command or
with a subsequent M6 command can be set in MD 22550: TOOL_CHANGE_MODE.
The programmed T function can be interpreted as tool number or as location number.
References: Chapter “Tool offset”
Scope of functions
1 T function per part program block is possible.
Special feature
T0 is reserved for the following function: remove the current tool from the tool holder without
loading a new tool.
13.6.3 D function
The D function is used to select the tool offset for the active tool. Tool offsets are described in
detail under:

13-270 6FC5397-1CP10-1BA0
13.6.4 H function
Application
The H functions can be used to transfer different values from the part program to the PLC.
The meaning can be chosen by the user.
Scope of functions
S 3 H functions per part program block are possible.
S Value range of the H functions: Floating data (as calculating parameter R)
S Address extension 0 to 99 (H0=... to H99=...) possible
13.6.5 S function
The S function is used to determine the speed for the spindle with M3 or M4. For turning
machines with G96 (constant cutting speed) the cutting value is specified.

6FC5397-1CP10-1BA0 13-271
11100 AUXFU_MAXNUM_GROUP_ASSIGN
MD number Number of auxiliary functions distributed among the AUXFU groups
Meaning: The number of the auxiliary functions that have been distributed to the groups must be entered in
the MD. This number only includes the customer-specific auxiliary functions, not the predefined
auxiliary functions.
Related to .... MD 22010: AUXFU_ASSIGN_TYPE [n] (auxiliary function type)
22000 AUXFU_ASSIGN_GROUP[n]
MD number Auxiliary function group [aux. func. no. in channel]: 0...63
Meaning: see MD 22010: AUXFU_ASSIGN_TYPE [n] (auxiliary function type)

13-272 6FC5397-1CP10-1BA0
22010 AUXFU_ASSIGN_TYPE[n]
MD number Auxiliary function type [aux. func. no. in channel]: 0...63
Default setting: – Minimum input limit: – Maximum input limit: 1 character
Data type: STRING Applies from SW:
Meaning: This MD (auxiliary function type) and MD 22020: AUXFU_ASSIGN_EXTENSION[n]
(auxiliary function extension) and MD 22030: AUXFU_ASSIGN_VALUE[n] (auxiliary
function value) and MD 22000: AUXFU_ASSIGN_GROUP[n] (auxiliary function group) are
used to allocate an auxiliary function type (M, H, T, D, S), the related extension and the
auxiliary function value to an auxiliary function group.
Example: M 0 = 99 => Group 5 (corresponds to M99)
Auxiliary function type

Auxiliary function extension
Auxiliary function value
Auxiliary function group
⇒ MD: AUXFU_ASSIGN_TYPE[0] = M
MD: AUXFU_ASSIGN_EXTENSION[0] = 0 ; other values only for type H
MD: AUXFU_ASSIGN_VALUE[0] = 99
MD: AUXFU_ASSIGN_GROUP[0] = 5 ; (Group 5)
M00, M01, M02, (M17 and M30) are assigned to Group 1 by default. M3, M4, M5 are
assigned to Group 2 by default.
The machine data index [n] indicates the auxiliary function number in the channel: 0–63
All auxiliary functions that are assigned to auxiliary function groups must be numbered in
ascending order.
[0]81st auxiliary function
[1]82. ,,
...
The machine data for the allocation of an auxiliary function to an auxiliary function group
must be provided with the same index [n].
Application example(s) See Section 13.4
Special cases, errors, ... ... If the auxiliary function value of an auxiliary function is less than 0, then all auxiliary functions of
this type and extension are assigned to a group.
Related to .... MD 11100: AUXFU_MAXNUM_GROUP_ASSIGN
22020 AUXFU_ASSIGN_EXTENSION[n]
MD number Auxiliary function extension [aux. func. no. in channel]: 0...63
Meaning: see MD 22010: AUXFU_ASSIGN_TYPE [n] (auxiliary function type)
22030 AUXFU_ASSIGN_VALUE[n]
MD number Auxiliary function value [aux. func. no. in channel]: 0...63
Meaning: If the value in this MD is smaller than 0 all auxiliary functions of this type and this
address extension are assigned to this group.
See MD 22010: AUXFU_ASSIGN_TYPE [n] (auxiliary function type)
Application example(s) See Section 13.4

6FC5397-1CP10-1BA0 13-273
V2500 0004. 0 to .4 M function Change 1 to 5

V2500 0006.0 S function Change 1
V2500 0008.0 T function Change 1
V2500 0010.0 D function Change 1
V2500 0012.0 to .2 H function Change 1 to 3
Signal state 1 An M, S, T, D or H function has been output to the interface with a new value together with the
associated change signal. In this case, the change signal indicates that the appropriate value is
valid.
The change signals are only valid for one PLC cycle! That means that there is a pending
change for this cycle if the signal is 1.
Signal state 0 The value of the data concerned is not valid.
VD2500 2000 T function 1

Edge evaluation: no Signal(s) updated: Job controlled by Signal(s) valid from SW:
NCK
Signal state 1 The T function programmed in an NC block is made available here as soon as the T change
signal is applied.
Value range of T function: 0–32000; integer
The T function remains valid until it is overwritten by a new T function.
Signal state 0 After PLC power-up.
All auxiliary functions are deleted before a new function is entered.
Application example(s) Control of automatic tool selection.
Special cases, errors, ... When T0 is selected, the current tool is removed from the tool holder but not replaced by a new
... tool (default configuration by machine manufacturer).
VB2500 1000 to
VB2500 1012 Decoded M signals: M0 – M99
Signal state 1 The dynamic M signal bits are set by decoded M functions.
Signal state 0 With a general auxiliary function output, dynamic M signal bits are acknowledged by the PLC
system program after the complete AWP routine has been executed once.
Application example(s) Spindle clockwise/counter-clockwise rotation, switch coolant ON/OFF
Related to .... IS “M function for the spindle (DINT), axis-specific” (VD370x 0000)
VD2500 3000 M function 1

VB2500 3004 Extended address M function 1
NCK
Signal state 1 Up to 5 M functions programmed in an NC block are made available here simultaneously as soon
as the M change signals are applied.
Value range of the M functions: 0 to 99; integer
Value range of extended address: 1–2; integer (spindle number)
The M functions remain valid until they are overwritten by new M functions.
Related to .... IS “M function for the spindle (DINT), axis-specific” (VD370x 0000)

13-274 6FC5397-1CP10-1BA0
VD2500 4000 S function 1

VD2500 4008 S function 2
VB2500 4004 Extended address S function 1
VB2500 4012 Extended address S function 2
NCK
Signal state 1 The S function programmed in an NC block (speed or cutting value with G96) is made available
here as soon as the S change signal is applied.
Value range of the S function: : Floating point (REAL format/4-byte)
Value range of extended address: 1–2; integer (spindle number)
The S function remains valid until it is overwritten by a new S function.
Related to .... IS “S function for the spindle (REAL), axis-specific” (VD370x 0004)
VD2500 5000 D function 1

NCK
Signal state 1 The D function programmed in an NC block is made available here as soon as the D change
signal is applied.
Value range of D function: 0–9; integer
The D function remains valid until it is overwritten by a new D function.
Special cases, errors, ... ... D0 is reserved for de-selecting the current tool offset.
VD2500 6000 H function 1

VW2500 6004 Extended address H function 1
NCK
Signal state 1 Up to 3 H functions programmed in an NC block are made available here simultaneously as soon
as the H change signals are applied.
Value range of the H functions: Floating point (REAL format/4-byte)
Value range of extended address: 0 to 99; integer
The H functions remain valid until they are overwritten by new H functions.
Application example(s) Switching functions on the machine.

6FC5397-1CP10-1BA0 13-275

rence
Channel-specific
V2500 0000 .0 to .4 M function 1 change to M function 5 change
V2500 0006 .0 S function 1 change
V2500 0008 .0 T function 1 change
V2500 0010 .0 D function 1 change
V2500 0012 .0 to .2 H function 1 change to H function 3 change
VD2500 2000 T function 1 (DINT)
VD2500 3000 M function 1 (DINT)
VB2500 3004 Extended address of M function 1 (BYTE)
VD2500 4000 S function 1 (REAL format)
VB2500 4004 Extended address of S function 1 (BYTE)
VD2500 4008 S function 2 (REAL format)
VB2500 4012 Extended address of S function 2 (BYTE)
VD2500 5000 D function 1 (DINT)
VW2500 6004 Extended address of H function 1 (Word)
VD2500 6000 H function 1 (REAL format)
V2500 1000 .0 – .7 Decoded M signals: M00–M07
up to
VD370x 0000 – M function for the spindle (DINT), axis-specific S1
VD370x 0004 – S function for the spindle (REAL), axis-specific S1

13-276 6FC5397-1CP10-1BA0
13.9.2 Machine data

rence
11100 AUXFU_MAXNUM_GROUP_ASSIGN Number of auxiliary functions distributed among the
AUXFU groups
22000 AUXFU_ASSIGN_GROUP[n] Auxiliary function group
22010 AUXFU_ASSIGN_TYPE[n] Auxiliary function type
22020 AUXFU_ASSIGN_EXTENSION[n] Auxiliary function extension
22030 AUXFU_ASSIGN_VALUE[n] Auxiliary function value

6FC5397-1CP10-1BA0 13-277
Notes

13-278 6FC5397-1CP10-1BA0
Tool: Compensation and Monitoring (W1) 14
14.1 Tool and tool compensation overview
Characteristic
The SINUMERIK 802Dsl control system is capable of calculating the tool offset data for diffe-
rent tool types (drill, milling cutter, turning tool, ...).
S Length compensation
S Radius compensation
S Storage of the tool compensation data in the tool offset memory
– Tool identification with T numbers from 0 to 32000
– Definition of a tool with a maximum of 9 cutting edges (offset blocks) through D number
– Cutting edge described by tool parameters:
– Tool type
– Geometry: Length Wear: Length
– Geometry: Radius Wear: Radius
– Cutting edge position (for turning tools)
S Tool change selectable: Immediately with T command or through M6
S Tool radius compensation
– Compensation active for all interpolation types: Linear and circle
– Compensation at outer corners selectable: transition circle (G450) or equidistant inter-
section (G451)
– automatic detection of outer/inner corners
Detailed description:

6FC5397-1CP10-1BA0 14-279
Tool: Compensation and Monitoring (W1)
14.2 Tools
14.2 Tools
Selecting a tool
A tool is selected in the program with the T function. Whether the new tool is immediately loa-
ded with the T function or with M6 depends on the setting in MD 22550:
TOOL_CHANGE_MODE (new tool offset with M function).
Value range of T
The T function can assume integer values from T0 (no tool) to T32000 (tool with the num-
ber 32000).
The following is the maximum that can be simultaneously stored in the control:
S SINUMERIK 802D sl value: 32 tools
S SINUMERIK 802D sl plus: 64 tools
S SINUMERIK 802D sl pro: 128 tools.

14-280 6FC5397-1CP10-1BA0
14.3 Tool compensation
14.3 Tool compensation
Tool compensation through D function

A tool can have up to 9 cutting edges. The 9 tool cutting edges are assigned to the D func-
tions D1 to D9.
The following are the maximum tool compensation blocks which can be simultaneously stored
in the control:
S SINUMERIK 802D sl value: 32 data fields (D numbers)
S SINUMERIK 802D sl plus: 64 data fields (D numbers)
S SINUMERIK 802D sl pro: 128 data fields (D numbers).
The tool cutting edge is programmed with D1 (edge 1) to D9 (edge 9). The tool cutting edge
always refers to the currently active tool. An active tool cutting edge (D1 to D9) without an
active tool (T0) is inactive. Tool cutting edge D0 de-selects all tool offsets of the active tool.
Selection of the cutting edge when changing tool

When a new tool (new T number) has been programmed and the old one replaced, the follo-
wing options are available for selecting the cutting edge:
1. The cutting edge number is programmed
2. The cutting edge number is not programmed D1 is active automatically.
Activating the tool compensation (offset)

D1 to D9 activates the tool compensation (offset) for a cutting edge on the active tool. Tool
length compensation and tool radius compensation can be activated at different times:
S Tool length compensation (TLC) is performed on the first traversing motion of the axis on
which the TLC is to act. This traversing motion must be a linear interpolation (G0, G1).
S Tool radius compensation (TRC) becomes active when G41/G42 is programmed in the
active plane (G17, G18 or G19). The selection of tool radius compensation with G41/G42
is only permitted in a program block with G0 (rapid traverse) or G1 (linear interpolation).
Detailed description of the tool compensation (offset) including tool radius compensation:
References: “Operation and Programming”, Section “Tool and tool offset”

6FC5397-1CP10-1BA0 14-281
14.4 Tool monitoring
Note
This function is available for the 802D sl plus and pro.
14.4.1 Tool monitoring overview
General
The tool monitoring is activated using the following machine data:
MD 18080: MM_TOOL_MANAGEMENT_MASK – Bit 1 =1
MD 20310: TOOL_MANAGEMENT_MASK – Bit 1 =1
The “Tool monitoring” function works without active tool management and allows the following
monitoring types of the active cutting edge of the active tool for SINUMERIK 802Dsl:
S Monitoring of the service life
S Monitoring of the workpiece count
The above mentioned monitoring types can be activated simultaneously for a tool.
Monitoring counter
Monitoring counters exist for each monitoring type. The monitoring counters count from a set
value > 0 down to zero. When a counter has decremented to a value of <= 0, the limit value is
reached. A corresponding alarm message is triggered and an interface signal is issued.
Another interface signal is issued beforehand if the cutting edge of a tool has reached the pre-
set pre-warning limit.
System variable for type and condition of the monitoring

S $TC_TP8[t] – condition of the tool with the number t:
Bit 0 =1: Tool is active
=0: Spare tool
Bit 1 =1: Tool is released
=0: not released
Bit 2 =1: Tool is disabled
=0: not disabled
Bit 3 : reserved
Bit 4 =1: Warning limit reached
=0: not reached
S $TC_TP9[t] – Type of the monitoring function for the tool with the number t :
= 0: No monitoring
= 1: Tool monitored by (service life) time
= 2: Tool monitored by workpiece count

14-282 6FC5397-1CP10-1BA0
These system variables can be read/written in the NC program and can be accessed
through the control (HMI). As the “Tool management” function package is not available for
SINUMERIK 802D these system parameters must be managed by the operator/programmer.
For operation (HMI), please refer to References: “Operation and Programming”
System variables for tool monitoring data
Table 14-1 Tool monitoring data
Identifiers Description Data type Default

$TC_MOP1[t,d] Downtime preĆwarning limit in minutes REAL 0.0
$TC_MOP2[t,d] Residual service life in minutes REAL 0.0
$TC_MOP3[t,d] PreĆwarning limit for count INT 0
$TC_MOP4[t,d] Residual unit quantity INT 0
... ...
$TC_MOP11[t,d] Tool life setpoint REAL 0.0
$TC_MOP13[t,d] Unit quantity setpoint REAL 0.0
t for tool number T, d for D number
System variables for active tool

The following can be read in the NC program via system variables:
S $P_TOOLNO – number of the active tool T
S $P_TOOL – active D number of the active tool
Interface signals
Some monitoring conditions are made available to the PLC/operator:
S “Tool pre-warning limit reached” (V5300 0000.0)
S “Tool limit reached” (V5300 0000.1)
S “T number for tool pre-warning limit” (VD5300 1000)
S “T number for tool limit” (VD5300 1004)
The workpiece counter can be turned off from the PLC:
S “Turn off workpiece counter” (V3200 0013.5)

6FC5397-1CP10-1BA0 14-283
14.4.2 Service life monitoring
The monitoring of the service life is performed for the tool cutting edge that is being used
(active cutting edge D of the active tool T).
As soon as the path axes traverse (G1, G2, G3, ..., but not for G0), the remaining service life
($TC_MOP2[t,d] of this tool cutting edge is updated. If the remaining service life of the cutting
edge of a tool falls below the value of “Service life ewarning limit" ($TC_MOP1[t,d] ) during
machining, the IS “Tool warning limit reached” (V5300 0000.0) and the IS “T number for tool
warning limit” (VD5300 1000) are set.
If the remaining service life <= 0, an alarm is issued and the IS “Tool limit reached” (V5300
000.1) as well as the IS “T number for tool limit” (VD5300 1004) are set. The tool changes to
the “disabled” condition and cannot be programmed again until this condition changes. The
operator must intervene and ensure that he provides an operational tool for machining.
$A_MONIFACT system variable

The $A_MONIFACT system variable (REAL data type) allows the monitoring clock to be
run slower or faster. This factor can be set before the use of the tool in order to consider, for
example, the different wear according to the used workpiece material.
After the control start-up, reset/program end the $A_MONIFACT factor has the value 1.0.
Realtime operation applies.
Calculation examples:
$A_MONIFACT=1 1 minute realtime = 1 minute service life that is decremented
$A_MONIFACT=0.1 1 minute realtime = 0.1 minute service life that is decremented
$A_MONIFACT=5 1 minute real time = 5 minutes service life that are decremented
Setpoint update with RESETMON( )

The RESETMON(state, t, d, mon) function sets the actual value to the setpoint:
S for all cutting edges or only for a specific cutting edge of a specific tool
S for all monitoring types or only for a specific monitoring type.
Transfer parameters:
INT state Condition of the command execution:
=0 Successful execution
= –1 The cutting edge with the specified D number d does not exist.
= –2 The tool with the specified T number t does not exist.
= –3 The specified tool t has no defined monitoring function.
= –4 The monitoring function is not activated, i.e. the command is
not executed.
INT t Internal T number:
=0 for all tools
<> 0 for this tool ( t < 0 : Absolute value generation |t|)
INT d optional: D number of the tool with the number t:
>0 for this D number
without d / = 0 all cutting edges of the tool t

14-284 6FC5397-1CP10-1BA0
INT mon optional: Bit-coded parameter for the monitoring type

(values analogous to $TC_TP9):
= 1: Service life
= 2: Workpiece count
without mon or = 0: All actual values of the monitoring types that are active for the
tool t are set to the setpoints.
Notes:
– RESETMON( ) is not active if the interface signal “Program test active” is set.
– The variable for the state status feedback must be defined at the beginning of the pro-
gram using a DEF statement: DEF INT state
You can also define a different name for the variable (instead of state, with a maximum
of 15 characters, beginning with 2 letters). The variable is only available in the program
if it was defined in this program.
This also applies to mon. If a data is required at all, this can also be directly transferred
as a number (1 or 2).
14.4.3 Workpiece count monitoring
The workpiece count of the active cutting edge of the active tool is monitored.
The workpiece count monitoring records all the tool cutting edges that are used to produce a
workpiece. If the workpiece count is changed by an operator input, the monitoring data of all
the cutting edges that have become active since the last workpiece count are adjusted.
Updating the workpiece count by operator input or SETPIECE( )

The workpiece count can be updated by an operator input (HMI) or in the NC program through
the SETPIECE( ) language command.
With the SETPIECE function, the user can refresh the workpiece count monitoring data of the
tools that were involved in the machining process. All tools with the D numbers that have be-
come active since the last time SETPIECE was activated are included in the update. If a tool
is active at the time SETPIECE is called, this is counted as well.
As soon as a block with path axis movements is executed after SETPIECE( ) this tool is also
considered for the subsequent SETPIECE call.
SETPIECE(x )
x : = 1... 32000 Number of workpieces that have been produced since the last execution of
the SETPIECE function. The count for the remaining workpiece count
($TC_MOP4[t,d] ) is reduced by this value.
x: = 0 Deleting all counts for the remaining workpiece count ($TC_MOP4[t,d] ) for
the tools/D number that have been involved in machining since that point of
time. Alternatively, the deletion via operator input (HMI) is recommended.
Example:
N10 G0 X100
N20 ...
N30 T1
N40 M6 D2

6FC5397-1CP10-1BA0 14-285
N50 SETPIECE(2) ;$TC_MOP4[1,2 ] (T1,D2) is decremented by 2

N60 X... Y...
N100 T2
N110 M6 D1
N120 SETPIECE(4) ;$TC_MOP4[2,1 ] (T2,D1) and $TC_MOP4[1,2 ] is
decremented by 4
N130 X... Y...
N200 T3
N210 M6 D2
N220 SETPIECE(6) ;$TC_MOP4[3,2 ] (T3,D2) and $TC_MOP4[2,1 ] (T2,D1) and
$TC_MOP4[1,2 ] and is decremented by 6
N230 X... Y...
N300 SETPIECE(0) ;Deletes all above $TC_MOP4[t,d ]
N400 M2
Notes:
S The SETPIECE( ) command is not active in the block search.
S Direct writing of $TC_MOP4[t,d] is recommended only in simple cases. A subsequent
block with the STOPRE command is required.
Setpoint update
The setpoint update, i.e. setting the remaining workpiece counters ($TC_MOP4[t,d]) to the
workpiece count setpoint ($TC_MOP13[t,d]) is typically performed via operator input (HMI). It
can, however, also be performed through the RESETMON (state, t, d, ,mon) function as al-
ready described for the service life monitoring.
Example:
DEF INT state ; Define the variable for the status feedback at the beginning of the program
...
N100 RESETMON(state,12,1,2) ; Setpoint update of the workpiece counter for T12, D1
...
14.4.4 Examples for the service life monitoring
1. Activating the tool monitoring if the “Tool monitoring” option is present:

Md 18080: MM_TOOL_MANAGEMENT_MASK = 0x02
MD 20310: TOOL_MANAGEMENT_MASK= 0x02
2. Service life monitoring for tool 2, cutting edge 1 in the NC program:
$TC_TP9[2,1]=1 ; activation of the service life monitoring
$TC_MOP1[2,1]=100 ; pre-warning limit in minutes
$TC_MOP2[2,1]=245 ; remaining service life in minutes
$TC_MOP11[2,1]=800 ; service life setpoint in minutes
Another example for the service life monitoring for the active tool with active D number in the
NC program:
$TC_TP9[$P_TOOLNO,$P_TOOL]=1 ; activation of the service life monitoring
$TC_MOP1[$P_TOOLNO,$P_TOOL]=200 ; pre-warning limit in minutes
$TC_MOP2[$P_TOOLNO,$P_TOOL]=602 ; remaining service life in minutes
$TC_MOP11[$P_TOOLNO,$P_TOOL]=700 ; setpoint service life in minutes

14-286 6FC5397-1CP10-1BA0
14.5 Special handling of tool compensation

For SINUMERIK 802D sl plus und pro, the following special tool compensation handling is
possible.
Influence of setting data

Using specific setting data the operator/programmer can influence the calculation of the length
compensation of the used tool:
S SD 42940: TOOL_LENGTH_CONST
(allocation of the tool length components to the geometry axes)
S SD 42950: TOOL_LENGTH_TYPE
(allocation of the tool length components independent of tool type)
Note: The modified setting data will become effective with the next cutting edge selection.
Tool length and plane change (SD 42940: TOOL_LENGTH_CONST)

The value of the setting data is 0:
The behavior corresponds to the standard definition: The lengths 1 to 3 in geometry and wear
are allocated to the 1st to 3rd axes of the plane according to the active G17 to G19 and accor-
ding to the tool type. If the active G17 to G19 changes, the axis allocation for the lengths 1 to
3 also changes because abscissa, ordinate and applicate are allocated to different geometry
axes.
Detailed description: References: “Operation and Programming”
The value of the setting data is not equal to 0:

The assignment of the tool lengths 1 to 3 in geometry and wear to the geometry axes is per-
formed according to the SD value and is not changed if the machining plane (G17 to G19)
changes.
The assignment of the tool lengths 1 to 3 to the geometry axes for turning tools (tool types
500 to 599) results from the value of the setting data SD 42940 in accordance with the follo-
wing table:
Plane/value Length 1 Length 2 Length 3
17 Y X Z
18*) X Z Y
19 Z Y X
–17 X Y Z
–18 Z X Y
–19 Y Z X
*) Each value not equal to 0 which is not equal to one of the six listed values is evaluated as
the value for 18.
With respect to the values with a negative sign the allocation of length 3 is identical, length 1
and 2 are exchanged – compared to the allocation with the corresponding positive values.

6FC5397-1CP10-1BA0 14-287
The following table shows the assignment of the tool lengths 1 to 3 to the geometry axes for
drills/milling cutters (tool types 100 to 299):
17*) Z Y X
18 Y X Z
19 X Z Y
–17 Z X Y
–18 Y Z X
–19 X Y Z
*) Each value not equal to 0 which is not equal to one of the six listed values is evaluated as
the value for 17.
With respect to the values with a negative sign the allocation of length 1 is identical, length 2
and 3 are exchanged – compared to the allocation with the corresponding positive values.
Note:
For the representation in the tables, it is assumed that the geometry axes 1 to 3 are named X,
Y, Z. The axis order (1st, 2nd and 3rd geometry axis) and not the axis identifier determines the
assignment between an offset and an axis.
Length compensation for tool type (SD 42950: TOOL_LENGTH_TYPE)

The value of the setting data is equal to 0:
The behavior corresponds to the standard definition: The lengths 1 to 3 in geometry and wear
are assigned to the actual tool type (milling cutter/drill or turning tool).
Detailed description: References: ”Operation and Programming”
Value of the setting data is not 0:

The assignment of the tool lengths is always independent of the actual tool type.
Value 1: Length allocation always as for milling tools.
Value 2: Length allocation always as for turning tools.
Notes
S The influence of these two setting data only refers to tool lengths. The tool radius is not
affected.
S If SD 42940: TOOL_LENGTH_CONST is set to a value other than 0 and the value in SD
42950: TOOL_LENGTH_TYPE is 1 or 2, the related table for the allocated tool type (mil-
ling or turning tool) applies in SD 42940.
Example
SD 42940: TOOL_LENGTH_CONST =18
SD 42950: TOOL_LENGTH_TYPE =2

14-288 6FC5397-1CP10-1BA0
Explanation:
The active tool with the active D number always behaves as a turning tool in the length com-
pensation (–> SD 42950 =2).
The length allocation is performed in all planes G17 to G19 as well as for G18
(–> SD 42940=18):
Length 1 –> X axis
Length 2 –> Z axis
if Y axis exists: Length 3 –> Y axis
The tool radius acts according to the actual tool type and the active plane.

6FC5397-1CP10-1BA0 14-289
18080 ** MM_TOOL_MANAGEMENT_MASK
MD number Memory reservation for the tool monitoring
Default setting: 0x0 Minimum input limit: 0x0 Maximum input limit: 0x2
Meaning: Value = 0: no memory is reserved, tool monitoring not possible
Value = 0x2: Monitoring data/memory is made available
(only possible if “Tool monitoring” option is present)
Related to .... MD 20310: TOOL_MANAGEMENT_MASK
** This machine data is not available with 802D sl value.
20310 ** TOOL_MANAGEMENT_MASK
MD number Activation of the tool monitoring
Default setting: 0x0 Minimum input limit: 0x0 Maximum input limit: 0xFFFF
Meaning: Value = 0: no tool monitoring
Value = 0x2: Tool monitoring activated
(only possible if “Tool monitoring” option is present)
Related to .... MD 18080: MM_TOOL_MANAGEMENT_MASK
20360 TOOL_PARAMETER_DEF_MASK
MD number Definition of tool parameters
Default setting: 0 Minimum input limit: 0 Maximum input limit: 0x01
Meaning: Bit 0=0: For turning tools the wear parameter of the transverse axis X is applied as a
radius value.
Bit 0=1: For turning tools the wear parameter of the transverse axis X is applied as a
diameter value.
Special cases, errors, ... ...
22550 TOOL_CHANGE_MODE
MD number New tool offset for M function
Meaning: The T function is used to select a tool in a program. The setting in this machine data determines
whether the new tool is loaded immediately on execution of the T function:
1: The new tool is prepared for changing with the T function. This setting is used mainly on mil-
ling machines with a tool magazine, in order to bring the new tool into the tool change position
without interrupting the machining process. The old tool is removed from the spindle with an
M function and the new tool is loaded into the spindle. According to DIN 66025, this tool
change is programmed using the M function M6.
Related to ....

14-290 6FC5397-1CP10-1BA0
Setting data
42940 TOOL_LENGTH_CONST
SD number Retain the assignment of tool lengths 1 to 3 to the geo-axes when changing the machining plane
(G17 to G19)
Changes effective: Immediately Protection level: 3/3 Unit: –
Meaning: If this setting data is not zero, the allocation of the tool lengths 1 to 3
(length, wear) to the geometry axes is not changed if the machining plane (G17 to G19) changes.
The allocation of tool length components to the geometry axes results from the value of the setting
data according to the following tables. With respect to the allocation, a distinction is made between
turning tools (tool types 500 to 599) and other tools (drilling/milling tools). For the representation in
the tables it is assumed that geometry axes 1 to 3 are named X, Y, Z. However, the geometry axis
sequence, and not the axis identifier, is the determining factor in the assignment of an offset to an
axis.
The assignment of the tool lengths to the geometry axes for turning tools (tool types
500 to 599) results from the value of setting data SD 42940 in accordance with the
following table:
17 Y X Z
18*) X Z Y
19 Z Y X
–17 X Y Z
–18 Z X Y
–19 Y Z X
The following table shows the allocation of the tool lengths 1 to 3 to the geometry axes
for drills/milling cutters (tool types 100 to 299):
17*) Z Y X
18 Y X Z
19 X Z Y
–17 Z X Y
–18 Y Z X
–19 X Y Z
Related to .... SD 42950: TOOL_LENGTH_TYPE
42950 TOOL_LENGTH_TYPE
SD number Allocation of the tool length compensation independent of tool type
Changes effective: Immediately Protection level: 3.3 Unit: –
Meaning: 0: The assignment is performed by default. A distinction is made between turning tools (tool type
500 to 599) and drilling/milling tools (tool type 100 to 299).
1: The assignment of the tool length components is, independent of the actual tool type, always
the same as for milling tools.
2: The assignment of the tool length components is, independent of the actual tool type, always
the same as for turning tools.
Related to .... SD 42940: TOOL_LENGTH_CONST

6FC5397-1CP10-1BA0 14-291
V1900 5001.0 Update the tool list

Interface signal Signal(s) from channel (PLC –––> NCK)
Signal state 1 or signal Tool display is updated
V3200 0013.5 De-activate workpiece counter

Signal state 1 or signal The workpiece count monitoring is turned off with activated tool monitoring.
Related to ....
V5300 0000.0 Tool pre-warning limit reached

Edge evaluation: yes Signal(s) updated: Job controlled by Signal(s) valid from SW:
NCK
Signal state 1/ value The pre-warning limit for a tool to be monitored was reached.
The T number is provided in VD5300 1000.
Signal state 0 No pre-warning limit reached
V5300 0000.1 Tool limit value reached

NCK
Signal state 1/ value The limit for a tool to be monitored was reached.
The T number is provided in VD5300 1004.
Signal state 0 Limit value reached
VD5300 1000 T number for tool pre-warning limit

NCK
Signal state 1/ value The T number for which the tool pre-warning limit is set is provided.
Signal state 0 No tool number reported
VD5300 1004 T number for tool limit value

NCK
Signal state 1/ value The T number for which the tool limit value is set is provided.
Signal state 0 No tool number reported

14-292 6FC5397-1CP10-1BA0

rence
Channel-specific
V2500 0008 .0 T function 1 change H2
V2500 0010 .0 D function 1 change H2
VD2500 2000 – T function 1 H2
VD2500 5000 – D function 1 H2
V2500 1000 .6 M6 H2
V3200 0013 .5 De-activate workpiece counter
V5300 0000 .0 Tool pre-warning limit reached
V5300 0000 .1 Tool limit value reached
VD5300 1000 – T number for tool pre-warning limit
VD5300 1004 – T number for tool limit value
14.8.2 Machine data

rence
General
18080 ** MM_TOOL_MANAGEMENT_MASK Memory reservation for the tool monitoring
Channel-specific
20310 ** TOOL_MANAGEMENT_MASK Activation of the tool monitoring
22360 TOOL_PARAMETER_DEF_MASK Definition of tool parameters
22550 TOOL_CHANGE_MODE New tool offsets with M function

6FC5397-1CP10-1BA0 14-293
Notes

14-294 6FC5397-1CP10-1BA0
Measurement (M5) 15
Channel-specific measuring
A measurement mode is programmed in a part program block (with or without DDTG). A trig-
ger event (edge of the probe) is defined additionally, which will trigger the measuring process.
The instructions apply to all axes programmed in this particular block. The program with the
measurement process in AUTOMATIC mode is executed and can be employed for workpiece
or tool measuring.
Tool measuring in JOG

SINUMERIK 802D includes operator support for the measuring process in JOG mode spe-
cially for measuring tools on turning and milling machines. Channel-specific measuring is inte-
grated into this sequence. The PLC user program must include the required functionality. The
measured offset values of the tool are available in the tool offset memory at the end of the
measuring sequence.
The detailed operations are included in

6FC5397-1CP10-1BA0 15-295
Measurement (M5)
15.2 Hardware requirements
15.2.1 Suitable probes
General information
In order to sense the dimensions of tool and workpiece, a touch trigger probe that outputs a
constant signal (not a pulse) on deflection is required.
The measuring probe must operate virtually bounce-free. Most measuring probes can be
adjusted mechanically to ensure that they operate in this manner.
Different types of probe supplied by a variety of manufacturers are available on the market.
Probes are therefore divided into three groups according to the number of directions in which
they can be deflected (see Fig. 15-1).
Multi-directional Bi-directional Mono-directional

Probe Probe Probe
Fig. 15-1 Probe types
Table 15-1 Assignment between probe type and application
Probe type Turning machines Milling and machining

centers
Tool measurements Workpiece measurements Workpiece measurements
Multi-directional X X X
Bi-directional _ X X
Mono-directional _ _ X
Bi-directional probes must be used on turning machines for workpiece measurements,

whereas a mono-probe can also be used for this purpose on milling and machining centers.
Multidirectional probe (3D)

This probe type can be used unconditionally for measuring tool and workpiece dimensions.

15-296 6FC5397-1CP10-1BA0
Measurement (M5)
Bi-directional probe
This probe type is applied in the same way as a mono probe in milling and machining centers.
Bi-directional probes can be used to take workpiece measurements on turning machines.
Mono-directional probe
This probe type can be used subject to some restrictions to take workpiece measurements on
milling and machining centers.
The spindle must be capable of being positioned with the SPOS NC function if the measure-
ment is to be carried out in different axis directions/axes. The probe must therefore be aligned
according to the measuring task.
Switching performance
The signal level of the connected probe (deflected/non-deflected condition) must be communi-
cated to the control via the MD 13200:MEAS_PROBE_LOW_ACTIVE[0].
15.2.2 Probe connection
The probe for SINUMERIK 802D sl is connected to the terminals of X20. The particular as-
signment is determined by the macro you are using. Thus, all measuring inputs of the axis
drive modules are operated whose axes are involved in measuring. For the probe, use an ex-
ternal voltage (24 V) whose reference potential must be connected to X20, pin 12.
To ensure optimum interference immunity when connecting probes, shielded lines must be
used.
References: “Instruction Manual”, Section “Configuring SINAMICS S120 with 802D sl”

6FC5397-1CP10-1BA0 15-297
Measurement (M5)
15.3 Channel-specific measuring
15.3 Channel-specific measuring
15.3.1 Measuring mode
Measuring commands MEAS and MEAW

The measuring operation is activated from the part program. A trigger event and a measuring
mode are programmed. Two different measuring modes are available:
S MEAS: Measurement with deletion of distance-to-go
Example: N10 G1 F300 X300 Z200 MEAS=–1
Trigger event is the falling edge (–) of the probe (1): from deflected to non-deflected status.
S MEAW: Measurement without deletion of distance-to-go
Example: N20 G01 F300 X300 Y100 MEAW=1
Trigger event is the rising edge of the probe (1): from non-deflected to deflected status.
The measurement block is terminated when the probe signal has arrived or the programmed
position has been reached.
The measurement job can be canceled with RESET.
Note
If a GEO axis (axis in the WCS) is programmed in a measuring block, the measured values
are stored for all current GEO axes.
15.3.2 Measurement results
Reading measurement results from the program

The results of the measuring command can be read in the part program via system variables.
S System variable $AC_MEA[1]
Scans the status signal of the measurement job.
The variable is deleted at the beginning of a measurement. The variable is set as soon as
the probe fulfills the activation criterion (rising or falling edge). Execution of the measure-
ment job can thus be checked in the part program.
S System variable $AA_MM[<axis>]
Access to measurement result in machine coordinate system. Read in part program and in
synchronized actions. <[Axis]> stands for the name of the measurement axis (X, Y, ...).
S System variable $AA_MW[axis]
Access to measurement result in workpiece coordinate system. Read in part program and
in synchronized actions. <[Axis]> stands for the name of the measurement axis (X, Y, ...).

15-298 6FC5397-1CP10-1BA0
Measurement (M5)
15.4 Measuring accuracy and functional testing
PLC service display

The measuring signal can be checked via the “PLC status” diagnostics menu:
IS “Probe 1 activated” (V2700 0001.0).
The current measuring status of the axis is shown by the IS “Measurement active” (measuring
block with this axis running).
15.4.1 Measuring accuracy
Accuracy
The propagation time of the measuring signal is determined by the hardware used. The delay
times are in the µs range plus the sensing probe response time.
The measurement uncertainty is calculated as follows:
Measurement uncertainty = measuring signal propagation time x traversing velocity
Correct results can be only be guaranteed for traversing velocity where not more than 1 trig-
gering signal arrives per position controller cycle.
15.4.2 Probe functional test
Example of functional test

The functional test for the probe is conducted favorably via an NC program.
%_N_PRUEF_MESSTASTER_MPF
;Testing program probe connection
N10 ;R10 Flag for trigger status
N20 ;R11 MESSWERT_IN_X
N30 T1 D1 ;pre-select tool offset for probe.
N40 ANF: G0 G90 X0 F150 ;start position and measuring velocity
N50 MEAS=1 G1 X100 ;measurement at measuring input 1 in the x-axis
N60 STOPRE
N70 R10=$AC_MEA[1] ;read switching signal at 1st measuring input.
N80 IF R10==0 GOTOF FEHL1 ;evaluate signal
N90 R11=$AA_MW[X] ;read measured value in workpiece coordinates
N95 M0
N100 M2
N110 FEHL1: MSG (“Probe not switching!”)
N120 M0
N130 M2

6FC5397-1CP10-1BA0 15-299
Measurement (M5)
Example of repeat accuracy

This program allows the measuring scatter (repeat accuracy) of the entire measuring system
(machine-probe-signal transmission) to be calculated.
In the example, ten measurements are taken in the X axis and the measured value recorded
in the workpiece coordinates.
It is possible to determine the so-called “random dimensional deviations” which are not sub-
ject to any trend.
%_N_PRUEF_GENAU_MPF
N05 ;R11 switching signal
N06 R12=1 ;counter
N10 ; R1 to R10 MESSWERT_IN_X
N15 T1 D1 ;initial conditions, pre-select
tool offset for probe
N20 ANF: G0 X0 F150 ;pre-position in measuring axis
N25 MEAS=+1 G1 X100 ;measurement at 1st measuring input with rising
switching edge, in the x-axis
;N30 STOPRE ;stop decoding for subsequent evaluation of
result
(automatically executed when reading MEA)
N35 R11= $AC_MEA[1] ;read switching signal at 1st measuring input
N37 IF R11==0 GOTOF FEHL1 ;check switching signal
N40 R[R12]=$AA_MW[X] ;read measurement value in WCS
N50 R12=R12+1
N60 IF R12<11 GOTOB ANF ;repeat 10 times
N65 M0
N70 M02
N80 FEHL1: MSG (“Probe is not switching”)
N90 M0
N95 M02
The measurement results R1 to R10 can be read after selecting the parameter display.

15-300 6FC5397-1CP10-1BA0
Measurement (M5)
15.5 Tool measuring in JOG
Measuring principle
The employed tool is traversed to the probe by the user in JOG mode using the travel keys or
handwheel. When the probe switches, the movement is stopped automatically and switched
internally to AUTOMATIC mode, and a measuring program is launched. The measuring pro-
gram controls the real measurement sequence with a second approach of the probe and
further positioning. In the end the tool offsets are entered and JOG mode is activated again.
Advantage: The entered offset values before measuring the tool can deviate entirely from the
actual values. The tools must not be “pre-measured”.
Note: The tool is “re-measured”, not its wear.
Softkeys and templates are provided for use by the user in JOG mode. This supports the user
during tool measuring.
Important
The PLC user program must be created with the necessary sequences. The functionality is
not available beforehand.
Extreme caution must be taken when approaching the probe. The probes only have a limited
deflection path. They will be damaged or destroyed if this is exceeded! Observe the
manufacturers instructions!
In particular, the approach speed should be reduced to such an extent that the probe can
always be stopped promptly. “Rapid traverse override” may not be active.
The screen forms provided and the sequence depend on the technology. Accordingly, the fol-
lowing used tool types can be measured:
Turning technology
S Turning tool (geometry length 1 and length 2)
S Drill (geometry length 1)
Milling technology
S Milling tool (geometry length 1 and geometry radius)
S Drill (geometry length 1)

6FC5397-1CP10-1BA0 15-301
Measurement (M5)
Tool offsets
The screens initially include the active tool T and the active offset number D for the target of
the measurement result entry. A different tool can be specified by the PLC via the interface, or
the user can enter a different tool T and/or offset number D.
Important
If a tool or offset number different to the active values has been entered, this must first be
made known to the NC for working after measurements have been made with this tool/tool
offset, e.g. by programming and start in MDA mode. Only then can the control unit calculate
the correct tool offsets.
A tool length compensation is automatically entered into the GEO component of the active/
specified tool offset D of the active/specified tool, and the associated “wear” and “adapter”
components are deleted.
When measuring the cutter radius it is assumed that no further offset is applied to the axes of
the cutter radius level (values in the axes of the “adapter” component and GEO lengths 2 and
3 are equal to zero).
The result for the radius is entered in the “geometry” component. The associated “adapter”
and “wear” components of both axes of the level are deleted.
Probe
The tool measuring probe is a touch probe at a fixed location or is swiveled into the working
area by means of a mechanical device. If the probe plate is of rectangular design, the edges
should be aligned parallel to the axis. The tool/calibration tool is traversed against the measu-
ring probe. The probe must be calibrated before a measurement is taken. This means that the
precise probe triggering points in relation to the machine zero are known.
Preparation, probe calibration

S Select JOG mode.
S The following values should be entered in the opened window via the “Settings” softkey:
return plane, safety clearance, JOG feed, variable INC and direction of rotation of the
spindle for general use in JOG and for tool measuring.
S The following value must be entered in the window which opens when pressing the “Probe
data” softkey:
– feed for automatic probe approach in the measuring program.
– Probe triggering points (the values are set during calibration).
If the precise values are known, they can be entered manually. The probe does not
then need to be calibrated).
S The adjustment sequence of the probe (calibration) is controlled via the “tool measuring”
–> and “tool calibration” softkeys and the opening window. The tool used in this case is the
calibration tool with precisely known and entered dimensions.

15-302 6FC5397-1CP10-1BA0
Measurement (M5)
The calibration tool for the milling technology is of “cutter” type, and for turning it is of “tur-
ning tool” type with a cutter radius of zero. The entered cutting edge position is not taken
into account in this case.
The internal sequence is the same as in measuring. The measuring results, however, are
stored in the data for the probe triggering points – not in the tool offsets.
S Note: The internal NC programs for measuring or calibrating are designed that measuring
is carried out with the rising edge of the probe.
Measuring sequence
S JOG mode is selected. The measuring feed is entered. The probe is calibrated or the pre-
cise measuring trigger points are registered.
S Depending on the tool type, the measuring sequence is controlled via the “tool measuring”
softkey and further softkeys.
S The IS “Measuring in JOG is active” (V1700 0003.7) is transmitted to the PLC from the
HMI by pressing the “tool measuring” softkey. PLC can specify a different T number to the
active one via the IS “T number for tool measuring in JOG” (VD1900 5004). If the probe
switches when the selected axis is traversed, NCK outputs the IS “Probe 1 active”
(V27000001.0). The PLC then sets IS “Feed disable” (V3200 0006.0) and NCK stops the
axis movement. Feed disable is maintained as long as a traverse key is depressed in JOG
and the IS “Measuring in JOG is active” (V1700 0003.7) is set. After this the PLC outputs
the IS “Reset” (V3000 000.7). The traverse movement in JOG is thereby cancelled.
HMI recognizes switching of the probe and outputs the change mode to AUTOMATIC, IS
command “AUTOMATIC mode” (V1800 0000.0) after the traverse key has been released
(immediately after handwheel jog). PLC transfers this to the NCK (V3000 0000.0).
AUTOMATIC mode is set to active by the NCK (IS “Active mode AUTOMATIC” (V3100
0000.0)) and is displayed in the HMI screen. PLC cancels the IS “Feed disable (V3200
0006.0). The HMI then outputs the IS “Mode change disable” (V1800 0000.4) to the PLC. If
the PLC recognizes this signal (is only applied for one PLC cycle), the PLC outputs the IS
“Mode change disable “ (V3000 0000.4) to the NCK.
An NC measuring program has been loaded to the NCK by the HMI. This is activated now.
The automatic direction of approach to the probe and the traverse path including the safety
clearance is calculated in this measuring program.
The HMI outputs the command to start the measuring program to the PLC via the IS “Start
measuring in JOG” (V1800 0000.6). The signals in the V1800 area are only applied for a
single PLC cycle. The IS “Start measuring in JOG” is therefore stored intermediately in the
PLC. The NC measuring program is launched by the PLC by outputting the IS “NC
START” (V3200 0007.1) to the NCK.
The axis is repositioned by the NC program, the probe is approached again, and finally
retracted. The HMI then transmits the command to switch back to JOG mode (V1800
0000.2) to the PLC. The “Change mode disable” interface signal (V3000 0000.4) is then
reset by the PLC. The PLC outputs JOG mode (V3000 0000.2) to the NCK and the NCK
returns the IS “JOG mode active” (V3100 0000.2) to the NCK.

6FC5397-1CP10-1BA0 15-303
Measurement (M5)
The next direction of approach/axis for traversing to the probe is selected with the “Next
step” softkey. The further procedure is analogous – until all directions/axes have been
traversed.
After measuring or probe calibration is complete the function can be unselected via the
“Back” softkey. This also resets the IS “Measuring in JOG active” (V1700 0003.0). A reset
is also triggered by leaving the operating area.
The automatic program can be canceled via IS “Reset” (V3000 0000.7) or measuring in
JOG can be closed via the the “Back” softkey. This also cancels any set IS “Feed disable”
(V3200 0006.0) and IS “Change mode disable” (V3000 0000.4) or intermediately saved
signals.
PLC user program
The required functionality corresponding with the above-described procedure in the PLC user
program must be provided by the user.
The toolbox for SINUMERIK 802D supplied by SIEMENS includes a user example in the PLC
802D library of versions V01.05 and higher. You can use this. In this case it should be noted
that PLC_INI (SBR32) and MCP_NCK (SBR38) must always be opened in OB1 as these
transfer the signals of the MEAS_JOG (SBR43) subroutine to the NCK/HMI.

15-304 6FC5397-1CP10-1BA0
Measurement (M5)
361 MEAS_TOOL_CHANGE
MD number Input enable for T/D no. for tool measuring
Changes effective immediately Protection level: 3/3 Unit: –
Meaning: 0: T/D number input blocked
1: T/D number input enabled
373 MEAS_SAVE_POS_LENGTH2
MD number Enable tool measuring SK “Save Pos” for all values.
Changes effective immediately Protection level: 2/2 Unit: –
Meaning: Controls “Save/Pos” softkey for “Manual tool measuring” function:
0: The SK “Save Pos” is only active when measuring length 1
1: SK “Save Pos” is generally active
13200 MEAS_PROBE_LOW_ACTIVE [0]

MD number Switching characteristics of probe
Meaning: 0: non-deflected status 0 V deflected status 24 V
1: non-deflected status 24 V deflected status 0V

6FC5397-1CP10-1BA0 15-305
Measurement (M5)
V1700 0003.7 *** Measuring in JOG active

Interface signal Signal(s) to PLC (HMI –––> PLC)
Signal state 1 or signal The “Tool measuring in JOG” function is activated by HMI.
transition 0 –––> 1 Note: This signal remains set when changing to AUTOMATIC mode in this function. The HMI
maintains the JOG image in the display. Only the active mode display changes.
Signal state 0 or signal The “Tool measuring” function is not active.
V1800 0000.0 AUTOMATIC mode

Signal state 1 or signal AUTOMATIC mode has been selected by the HMI.
transition 0 –––> 1 The signal status 1 is active for only one PLC cycle.
Signal state 0 AUTOMATIC mode is not selected by the HMI.
Signal irrelevant for ... ... if “Change mode disable” signal
V1800 0000.1 MDA mode

Signal state 1 or signal MDA mode has been selected by the HMI.
Signal state 0 MDA mode is not selected by the HMI.
V1800 0000.2 JOG mode

Signal state 1 or signal JOG mode has been selected by the HMI.
Signal state 0 JOG mode is not selected by the HMI.
V1800 0000.4 Mode group changeover disable

Signal state 1 or signal Request by MMC: The current active mode (JOG, MDA or AUTOMATIC) should not be
transition 0 –––> 1 changed.
The signal status is active for only one PLC cycle.
Signal state 0 The mode can be changed.
V1800 0000.6 *** Start measuring in JOG

Signal state 1 or signal Request to PLC by HMI to start the measuring program with NC start.
transition 0 –––> 1 The signal status 1 is active for only one PLC cycle only.
Signal state 0
V1800 0001.2 Machine function REF

Signal state 1 or signal The REF machine function is selected from within JOG mode.
transition 0 –––> 1 The signal status 1 is active for only one PLC cycle only.
Signal state 0 Machine function REF is not selected.
Signal irrelevant for ... ... if JOG mode is not active.

15-306 6FC5397-1CP10-1BA0
Measurement (M5)
V1900 5002.0 Enabling machine tool measuring in JOG

Interface signal Signal(s) from NCK (PLC → HMI)
Edge evaluation: no Signal(s) updated: cyclic Signal(s) valid from SW: 2
Signal state 1 or signal Measuring in JOG function can be activated.
Signal state 0 or signal Measuring in JOG is not possible.
VD1900 5004 Tool number for tool measuring in JOG

Interface signal Signal(s) to HMI (PLC –––> HMI)
Value > 0 (DWORD) Input of T number from PLC for entering measurement results to HMI. The number entered in
the HMI screen is used as offset number D.
Value = 0 No specification of the T no. by PLC
Signal irrelevant for ... ... if IS “Measuring in JOG active” (V1700 0003.7) is not set.
V2700 0001.0 Probe 1 is actuated

Interface signal Signal(s) from NCK (NCK → PLC)
Signal state 1 or signal Probe 1 is actuated
Signal state 0 or signal Probe 1 is not actuated
V390x 0002.3 Measurement active

Interface signal Signal(s) from axis/spindle (NCK → PLC)
Signal state 1 or signal The “Measuring” function is active.
This displays the current measurement status of the axis (measuring block with this axis is
running).
Signal state 0 or signal The “Measuring” function is not active.

6FC5397-1CP10-1BA0 15-307
Measurement (M5)

rence
HMI signals (from HMI to PLC)
V1700 0003 .7 *** Measuring in JOG active
V1800 0000 .0 AUTOMATIC mode (request by HMI)
V1800 0000 .1 MDA mode (request by HMI)
V1800 0000 .2 JOG mode (request by HMI)
V1800 0000 .4 Change mode disable (request by HMI)
V1800 0000 .6**** Start measuring in JOG (request by HMI)
V1800 0001 .2 REF machine function (request by HMI)
HMI signals (from PLC to HMI)
VD1900 5004 Tool number for tool measuring in JOG (input by PLC)
General (from HMI to PLC)
V2700 0001 .0 Probe 1 activated
Axis-specific/spindle-specific (from axis to PLC)
V390x 0002 .3 Measurement active
15.8.2 Machine data

rence
13200 MEAS_PROBE_LOW_ACTIVE Switching characteristics of probe

15-308 6FC5397-1CP10-1BA0
Compensation (K3) 16
Compensation
For SINUMERIK 802D the following axis-specific compensation functions can be activated:
S Backlash compensation
S LEC interpolatory compensation
(leadscrew error and measuring system error compensation)
S Following error compensation (speed feedforward control)
These compensation functions can be set for each machine individually with axis-specific
machine data.
Position display
The normal actual-value and setpoint position displays ignore the compensation values and
show the position values of an ideal machine. The compensation values are displayed in the
“System” –> “Service Display” –> “Service Axis” operating area at “Abs. compens. value
meas. system 1”.

6FC5397-1CP10-1BA0 16-309
Compensation (K3)
16.2 Backlash compensation
16.2 Backlash compensation

Effect
In the case of axes/spindles with indirect measuring systems, mechanical backlash results in
corruption of the traverse path, causing an axis, for example, to travel too much or too little by
the amount of the backlash when the direction of movement is reversed (see Fig. 16-1).
Compensation
To compensate for backlash, the axis-specific actual value is corrected by the amount of back-
lash every time the axis/spindle changes direction.
This quantity can be entered for each axis/spindle at the start-up phase in machine data
MD 32450: BACKLASH.
Activation
Backlash compensation is always active in all operating modes after reference point
approach.
Positive backlash
The encoder leads the machine part (e.g. table). Since the actual position acquired by the
encoder also leads the real actual position of the table, the table travels too short a distance
(see Fig. 16-1). The backlash compensation value must be entered as a positive value here
(= normal case).
Table
Backlash
ÉÉÉ ÉÉÉÉÉ
ÉÉÉ ÉÉÉÉÉ
En-
M (GND)
coder
Encoder actual value leads the real actual value (table):

The table does not travel far enough
Fig. 16-1 Positive backlash (normal case)
Negative backlash
The encoder lags behind the machine part (e.g. table); the table then travels too far. The
correction value entered is negative.
High backlash compensation values

The user has the option of applying the backlash compensation value gradually in several in-
crements when the relevant axis reverses direction. This prevents an excessive setpoint step
change from causing specific axis errors.
The content of the axis-specific MD 36500: ENC_CHANGE_TOL determines the increment
with which the backlash compensation value (MD 32450: BACKLASH) is applied.
Please note that the backlash compensation is fully calculated only after n – servo cycles ( n=
MD32450/MD 36500). A time interval which is too long may result in the triggering of zero
speed monitoring alarms.
If the MD 36500: ENC_CHANGE_TOL is set higher than MD 32450: BACKLASH, the com-
pensation is performed in one servo cycle.

16-310 6FC5397-1CP10-1BA0
Compensation (K3)
16.3 Interpolatory compensation
16.3.1 General
Terms
Compensation value: The difference between the axis position measured by the position
actual-value encoder and the required programmed axis position (= axis position of the ideal
machine). The compensation value is often also referred to as the correction value.
Interpolation point: A position of the axis and the corresponding offset value.
Offset table: Table containing interpolation points
Compensation table
Because dimensional deviations between the leadscrew pitch and the measuring system di-
rectly affect the accuracy of workpiece machining, they must be compensated for by the rele-
vant position-dependent compensation values. The compensation values are derived from
measured error curves and entered in the control in the form of compensation tables during
installation. A separate table must be created for each compensation relation.
The compensation values and additional table parameters are entered in the compensation
tables using special system variables.
Input of compensation table

Compensation tables can be downloaded into the buffered NC user memory by two different
methods.
S The compensation values are loaded when an NC program with the compensation tables
is started.
S The compensation values can also be loaded by transferring the tables from a PC via the
serial interface on the HMI.
Note
The compensation tables can be output via the serial interface on the HMI from operating
area “System” –> “Data I/O” –> “Data selection”/Data .../Compensation: Leadscrew error” and
loaded back following editing.

6FC5397-1CP10-1BA0 16-311
Compensation (K3)
Linear interpolation between the interpolation points

The traversing path to be compensated – defined using the start and end positions – is divi-
ded up into several (number depends on error curve shape) path segments of equal size (see
Fig. 16-2). The actual positions that limit these segments are designated “interpolation points”.
A compensation value must be entered for each interpolation point (actual position) during
installation. The compensation value applied between 2 interpolation points is generated on
the basis of linear interpolation using the compensation values for the adjacent interpolation
points (i.e. adjacent interpolation points are linked along a line).
Offset value Error curve

Compensation curve
Linear interpolation
n n+1 n+2 n+3 Position of

Interpolation point axis
Fig. 16-2 Linear interpolation between the interpolation points
Compensation value at reference point

The compensation table should be structured such that the compensation value at the refe-
rence point is “zero”. This prevents position jumps occurring when the LEC is activated (after
reference point approach).
16.3.2 LEC
Function
The leadscrew error compensation/measuring system error compensation (LEC) is an axis-
specific compensation.
The principle of the LEC is to modify the axis-specific position actual value by the assigned
compensation value in the interpolation cycle and to apply this value to the machine axis for
immediate traversal. A positive compensation value causes the corresponding machine axis
to move in the negative direction.
The magnitude of the compensation value is not limited and is not monitored. In order to avoid
impermissibly high velocities and accelerations caused by compensation, small compensation
values must be selected. Large compensation values can cause other axis monitoring func-
tions to output alarms (e.g. contour monitoring, velocity setpoint limits).

16-312 6FC5397-1CP10-1BA0
Compensation (K3)
Activation
S The compensation values are stored in the NC user memory and active (after power ON).
S The function has been activated for the machine axis concerned
(MD 32700: ENC_COMP_ENABLE [0] = 1).
S The axis has been referenced (IS “Referenced/synchronized 1” V390x 0000.4 set).
As soon as these conditions have been fulfilled, the axis-specific actual value is altered by the
compensation value in all modes and traversed by the machine axis immediately.
If the reference is then lost, e.g. because the encoder frequency has been exceeded (IS “Re-
ferenced/synchronized 1 “ =‘0’), compensation processing is de-activated.
Compensation table
The position-related compensation values are stored in the form of system variables for the
relevant axis in the compensation table. 125 interpolation points (N = 0...124) are possible.
The following measuring-system-specific parameters must be set for the table (see Fig. 16-3):
S Compensation value for interpolation point N in compensation table:
$AA_ENC_COMP [0,N,AXi]=...
where: AXi = machine axis name e.g. X1, Y1, Z1 ; N = interpolation point index
For every individual interpolation point (axis position) the compensation value must be ent-
ered in the table. The magnitude of the compensation value is not limited.
Note
The first and last compensation values remain active over the entire traversing range, i.e.
these values should be set to “0” if the compensation table does not cover the entire
traversing range.
S Point spacing: $AA_ENC_COMP_STEP[0,AXi]= ...

The distance between interpolation points corresponds to the distance between the com-
pensation values in the relevant compensation table (for AXi, see above).
S Starting position: $AA_ENC_COMP_MIN[0,AXi]= ...
The initial position is the axis position at which the compensation table for the relevant axis
begins (interpolation point 0).
The compensation value for the initial position is $AA_ENC_COMP[0,0,AXi].
For all positions smaller than the initial position the compensation value of interpolation
point zero is used (does not apply for table with modulo).
S End position: $AA_ENC_COMP_MAX[0,AXi]= ...
The end position is the axis position at which the compensation table for the relevant axis
ends (interpolation point k < 125).
The compensation value for the end position is $AA_ENC_COMP[0,k,AXi)]

6FC5397-1CP10-1BA0 16-313
Compensation (K3)
The compensation value of interpolation point k is used for all positions larger than the end
position (exception: table with modulo functions). Compensation values which are greater
than k are inactive.
S Compensation with modulo function: $AA_ENC_COMP_IS_MODULO[0,AXi] = 1
When activating the compensation with modulo function, the compensation table is cycli-
cally repeated, i.e. the compensation value at the point $AA_ENC_COMP_MAX (8inter-
polation point $AA_ENC_COMP[0,k,AXi]) is directly followed by the compensation value
at the point $AA_ENC_COMP_MIN (8interpolation point $AA_ENC_COMP[0,0,AXi]).
For rotary axes with modulo 360 degrees it is therefore suitable to program 0 degrees as
the initial position ($AA_ENC_COMP_MIN) and 360 degrees as the end position
($AA_ENC_COMP_MAX). In this case both compensation values must be entered di-
rectly.
Caution
! When the compensation values are entered it is important that all interpolation points are
assigned a position value within the defined range (i.e. there may be no gaps). Otherwise, the
previous valid position value is used for these interpolation points!
Note
S Table parameters which contain positional data are interpreted with MD 10240:
SCALING_SYSTEM_IS_METRIC=0 in inches.
The positional data can be automatically re-calculated by changing over manually (see
Subsection 3.2.2 “Manual changeover of the basic system”).
S The compensation table can only be loaded if MD 32700: ENC_COMP_ENABLE=0 has
been set. The value =1 causes the compensation to be activated and write protection to
be applied (output alarm 17070).
Example
The following example shows compensation value inputs for machine axis X1 as a program.
%_N_AX_EEC_INI
CHANDATA (1)
$AA_ENC_COMP[0,0,X1]= 0.0 ;compensation value 1 (interpolation point 0)
+0mm
+10mm
+12mm
...
$AA_ENC_COMP[0,120,X1]= 0.0 ;last compensation value (interpolation point 120)
$AA_ENC_COMP_STEP[0,X1]= 2.0 ;distance between interpolation points 2.0 mm

$AA_ENC_COMP_MIN[0,X1]= –200.0 ;compensation begins at –200.0 mm
$AA_ENC_COMP_MAX[0,X1]= 40.0 ;compensation ends at +40.0 mm
$AA_ENC_COMP_IS_MODULO[0,X1] = 0 ;compensation without modulo function
M17
Values for more than 125 interpolation points result in Alarm 12400: “Element does not exist”.

16-314 6FC5397-1CP10-1BA0
Compensation (K3)
Error curve
Offset value Compensation curve
(linear interpolation between interpolation points)
Compensation values of compensation table
Starting position End position
($AA_ENC_COMP_MIN) ($AA_ENC_COMP_MAX)
Compensation value for

Point spacing interpolation point 5
($AA_ENC_COMP)
Reference point
–200 –198 –196 –194 38 40 Axis position
0 1 2 3 4 5 Interpolation
119 120 points
Linear interpolation
Fig. 16-3 Compensation table parameters (system variables for LEC)
16.3.3 Special features of interpolatory compensation
Measurement
The “Measurement” function supplies the compensated actual positions (ideal machine) requi-
red by the machine operator or programmer.

For software limit switches the ideal position values are also monitored (i.e. the position actual
values corrected by the LEC and backlash compensation functions).

6FC5397-1CP10-1BA0 16-315
Compensation (K3)
16.4 Following error compensation (feedforward control)
16.4.1 General
Axis-specific following error

The following error can be reduced to almost zero with the help of the feedforward control.
This feedforward control is therefore also called “following error compensation”.
The following error causes undesired velocity-dependent contour errors especially during ac-
celeration at contour curves, e.g. arcs and corners.
The SINUMERIK 802D control is equipped with the “speed feedforward control” feedforward
control type.
Activation/de-activation in part program

The feedforward control can be activated and de-activated by means of the following high-le-
vel language elements in the part program:
FFWON Feedforward control ON
FFWOF Feedforward control OFF (activation setting)
With MD 32630: FFW_ACTIVATION_MODE, the activation (via FFWON) or de-activation (via
FFWOF) of a specific axis can be determined.
FFWON and FFWOF are used to activate and de-activate respectively the feedforward control
of all axes/spindles for which MD 32630: FFW_ACTIVATION_MODE = 1.
MD 32630: FFW_ACTIVATION_MODE should therefore have identical
settings for axes that interpolate with each other.
The feedforward control should only be switched on or off while the axis/spindle is stationary
to prevent jerk. This is the responsibility of the programmer.
Conditions
The following points should be noted before the feedforward control is applied:
S Rigid machine behavior
S Precise knowledge about the machine dynamic response
S No sudden changes in the position and speed setpoints
Optimization of control loop

The feedforward control is set on an axis/spindle-specific basis. First of all, the current control
loop, speed control loop and position control loop must be set to an optimum for the axis/
spindle.
References: “Operating Instructions”

16-316 6FC5397-1CP10-1BA0
Compensation (K3)
Parameter assignments
The feedforward control parameters must then be assigned to the relevant axis/spindle and
then entered in the machine data (see next section).
16.4.2 Speed feedforward control
In the case of speed feedforward control, a velocity setpoint is also applied directly to the input
of the speed controller (see Fig. 16-4).
In order to achieve a correctly set speed feedforward control, the equivalent time constant of
the speed control loop must be determined exactly and entered as a machine data.
NCK drive
+
Setpoint Feed-
forward Position Speed
(reference control controller controller
value) –
Actual position value
MD 32810: EQUIV_SPEEDCTRL_TIME
Fig. 16-4 Speed feedforward control
Parameters
The following axis-specific MD must be defined for the speed feedforward control during in-
stallation: MD 32810: EQUIV_SPEEDCTRL_TIME (equivalent time constant of the closed
speed control loop).

6FC5397-1CP10-1BA0 16-317
Compensation (K3)

32450 BACKLASH[n]
MD number Backlash
Changes effective after NEW_CONF Protection level: 2/2 Unit: mm or degrees
Meaning: Backlash between the positive and the negative direction of travel.
The compensation value input is
S positive if the encoder leads the machine part (normal case)
S negative if the encoder lags behind the machine part.
If zero is entered backlash compensation is de-activated.
Backlash compensation is always activated after reference point approach in all modes.
The index [n] has the following coding: [encoder no.]: 0
Related to .... MD 36500: ENC_CHANGE_TOL (backlash compensation partial section)
32630 FFW_ACTIVATION_MODE
MD number Feedforward control can be activated from program
Data type: Byte Applies from SW:
Meaning: This MD can be used to define whether the feedforward control for this axis/spindle can be swit-
ched on and off in the part program.
0: Feedforward control cannot be switched on/off with FFWON or FFWOF.
1: Feedforward control can be switched on/off with FFWON or FFWOF in the part program.
The last condition to be active remains active even after Reset (and therefore with JOG).
Because the feedforward control for all axes of a channel is switched on/off with FFWON or
FFWOF, this MD should therefore have identical settings for axes that interpolate with each other.
Related to ....
References ”Operation and Programming”
32700 ENC_COMP_ENABLE[n]
MD number Encoder/spindle error compensation (LEC )
Meaning: 1: ’LEC’ is activated for the axis/measuring system.
With LEC, leadscrew errors and measuring system errors can be compensated.
The function is only enabled internally if the measuring system has been referenced (IS: “Re-
ferenced/synchronized 1” = 1).
Write protection function (compensation values) active.
0: ’LEC’ is not active for the axis/measuring system.
Index [n] has the following coding: [encoder no.]: 0

Related to .... IS “Referenced/synchronized 1”
32810 EQUIV_SPEEDCTRL_TIME[n] n= control parameter set no.: 0 to 5

MD number Equivalent time constant of speed control loop
(0.0005, 0.0005, ... ,0.0005)
Meaning: This equivalent time constant is required for the “speed feedforward control” function.
The value must correspond with the equivalent time constant of the closed speed control loop.
Setting aid: Guide value is the time constant of the setpoint value smoothing in the drive.
Related to ....

16-318 6FC5397-1CP10-1BA0
Compensation (K3)
36500 ENC_CHANGE_TOL
MD number Backlash compensation partial section/tolerance for position actual value changeover
Changes effective after NEW_CONF Protection level: 2/2 Unit: mm or degrees
Meaning: Partial section when applying backlash compensation.
This MD is used to manage large backlash compensation values. It ensures that the backlash is
not switched through to the actual value all at once, but in n steps with an increment size as set in
MD: ENC_CHANGE_TOL. Calculation of the backlash thus takes n servo cycles. If it takes too
long to complete computation of the backlash, zero speed monitoring alarms may be generated.
This MD only becomes effective if the MD: ENC_CHANGE_TOL is set higher than MD:
BACK_LASH.
Related to .... MD 32450: BACKLASH[0] (backlash compensation)
38000 MM_ENC_COMP_MAX_POINTS[n] (MD can only be displayed!)

MD number Interpolation points for encoder/spindle compensation (LEC )
Default setting: 125 Minimum input limit: – Maximum input limit: –
Meaning: For leadscrew error compensation, the maximum number of interpolation points per axis/measu-
ring system is 125.
The required number k can be calculated as follows using the defined parameters:
$AA_ENC_COMP_MAX–$AA_ENC_COMP_MIN
k = ––––––––––––––––––––––––––––––––––––––––––– + 1
$AA_ENC_COMP_STEP
$AA_ENC_COMP_MIN Initial position (system variable)

$AA_ENC_COMP_MAX End position (system variable)
$AA_ENC_COMP_STEP Distance betw. interpolation points
(system variable)
Index[n] has the following coding: [encoder no.]: 0

Related to .... MD 32700: ENC_ COMP_ ENABLE[n] Interpolatory compensation active

6FC5397-1CP10-1BA0 16-319
Compensation (K3)

rence
V390x 0000 .4 Referenced/synchronized 1 R1
16.6.2 Machine Data

rence
General
10240 SCALING_SYSTEM_IS_METRIC Basic system metric G2
Axis-specific
32450 BACKLASH[0] Backlash
32630 FFW_ACTIVATION_MODE Feedforward control can be activated from program
32700 ENC_COMP_ENABLE[0] Interpolatory compensation active
32810 EQUIV_SPEEDCTRL_TIME[0]...[5] Equivalent time constant of the speed control loop
36500 ENC_CHANGE_TOL Backlash compensation partial section
38000 MM_ENC_COMP_MAX_POINTS[0] Interpolation points for encoder/spindle compensation
(LEC ) (for display only)

16-320 6FC5397-1CP10-1BA0
Travel to Fixed Stop (F1) 17
Note
Range of application
The travel to fixed stop (FXS = Fixed Stop) function can be used to establish defined forces
for clamping workpieces, such as those required for sleeves and grippers. The function can
also be used for the approach of mechanical reference points. With sufficiently reduced tor-
que, it is also possible to perform simple measurement operations without connecting a probe.
Travel to fixed stop can be performed simultaneously for several axes and parallel to the mo-
vement of other axes.
The fixed stop can be approached on a path (straight line, circle).
Availability
The “Travel to fixed stop” function is available where the option exists if MD 37000: FI-
XED_STOP_MODE (Travel to fixed stop mode)= 1 is set. The function can then be started
from the NC program with command “FXS[x]=1”.

6FC5397-1CP10-1BA0 17-321
17.2 Functionality
17.2 Functionality
Programming
Travel to fixed stop is selected with command
FXS[machine axis identifier] = 1 selected.
FXS[machine axis identifier] = 0 de-selected.
The clamping torque is set with command
FXST[machine axis identifier] = <torque>.
It is given as a percentage of the zero speed torque of the drive or a percentage
of the nominal motor torque for MSD.
The following command is used for setting the width of the fixed stop monitoring
window
FXSW[machine axis identifier] = <monitoring window width>
Unit: mm, inches or degrees – depending on the
basic measurement system,
Linear or rotary axis.
The commands are modal. The travel path and the command which activates the
function must be programmed in the same block
Note
The programming of the machine axis identifier according to MD 10000:
AXCONF_NAME_TAB is permitted with FXS... and is to be used preferentially.
The channel axis identifiers according to MD 20070: AXCONF_CHANAX_NAME_TAB are
permitted for FXS... provided this is assigned to precisely one axis – e.g. no rotation is
activated in the coordinate system.
Axis-specific setting data/machine data

If no monitoring window is programmed, the value from SD 43520:
FIXED_STOP_WINDOW applies. If a value is programmed, this is applied and adopted by
the SD. Initially, the SD is loaded using the value from MD 37020: FIXED_STOP_WIN-
DOW_DEF.
If no clamping torque is programmed, the value from SD 43510:
FIXED_STOP_TORQUE is applied. If a value is programmed, this is applied and adopted by
the SD. Initially, the SD is loaded using the value from MD 37010: FIXED_STOP_WIN-
DOW_DEF.
The selection/de-selection of the function is made in the program via FXS[X1]=1 / =0 only.
This value is also written in SD 43500: FIXED_STOP_SWITCH (selection of travel to fixed
stop).

17-322 6FC5397-1CP10-1BA0
17.2 Functionality
Programming examples
X250 Y100 F100 FXS[X1]=1 ; selected for machine axis X1 FXS
Clamping torque and window width from SD
X250 Y100 F100 FXS[X1]=1 FXST[X1]=12.3 ; selected for machine axis X1 FXS,
Clamping torque 12.3%, window width
from SD
X250 Y100 F100 FXS[X1]=1 FXST[X1]=12.3 FXSW[X1]=2
; selected for machine axis X1 FXS,
Clamping torque 12.3%,
Window width 2 mm
X250 Y100 F100 FXS[X1]=1 FXSW[X1]=2 ; selected for machine axis X1 FXS,
Clamping torque from SD, window width 2 mm
Note
Once the function “Travel to fixed stop” has been activated for an axis/spindle (not analog
spindle), a new position cannot be programmed for this axis.
Before the function is selected, the spindle must be switched to the position-controlled mode.
System variable $AA_FXS[X1] for status

This system variable provides the “Travel to fixed stop” status for the axis specified:
Value = 0: Axis is not at stop
1. Stop successfully approached
(axis is in fixed stop monitoring window)
2: Approach to stop failed (axis is not at stop)
3: Travel to fixed stop activated
4: Stop has been detected
5: Travel to fixed stop will be de-selected. The de-selection is not yet completed
Interrogation of the system variable in the part program initiates a block search stop.
As a result of the status interrogation in the part program, it is possible, for example, to react
to an erroneous operational sequence of the “Travel to fixed stop” function.
Note: With SINUMERIK 802D only the static statuses may be recorded.

6FC5397-1CP10-1BA0 17-323
17.2 Functionality
Example of function
Actual position after

“Travel to fixed stop”
Start position
Programmed Fixed stop
end position monitoring window
Fig. 17-1 Example of travel to fixed stop Sleeve is pushed on to the workpiece
Selection
The NC detects when preparing the block that the function “Travel to fixed stop” is selected
via the command FXS[x]=1 and signals the PLC via the IS “Activate travel to fixed stop” that
the function has been selected.
If MD 37060: FIXED_STOP_ACKN_MASK (register PLC acknowledgments for travel to fixed
stop) is set accordingly, the NC waits for acknowledgment by the PLC through IS “Activate
travel to fixed stop”.
The programmed target position is then approached from the start position at the programmed
velocity. The fixed stop must be located between the start and target positions of the axis/
spindle. Any programmed torque limit is effective from the block start, i.e. the fixed stop is also
approached at a reduced torque. Allowance for this limit is made in the NC through an auto-
matic reduction in the acceleration rate.
If no torque has been programmed in the block or since the start of the program, then the va-
lue set in axis-specific MD 37010: FIXED_STOP_TORQUE_DEF (default setting for clamping
torque) is applicable.
Fixed stop reached

As soon as the axis comes into contact with the mechanical fixed stop (workpiece), the clo-
sed-loop control in the drive increases the torque so that the axis can move on. The torque
increases up to the programmed limit value and then remains constant.
The “Fixed stop reached” status can be determined in the following ways depending on the
setting in MD 37040:
FIXED_STOP_BY_SENSOR (detection of fixed stop via sensor):
S FIXED_STOP_BY_SENSOR = 0
The “Fixed stop reached” status is achieved when the axis-specific contour deviation
(= difference between actual and expected following error) has exceeded the value set in
MD 37030: FIXED_STOP_THRESHOLD (threshold for fixed stop detection).

17-324 6FC5397-1CP10-1BA0
17.2 Functionality
External sensor transmits “Fixed stop reached” status to NC via the PLC by means of
IS “Sensor fixed stop”.
The status “Fixed stop reached” is provided if either this status has been determined by
the contour monitoring function or if the external sensor signals this status in response to
signal edge change 0 → 1.
Internal processes
Once the NC has detected the “Fixed stop reached” status, it deletes the distance-to-go and
the position setpoint is made to follow. The controller enabling command remains active.
The PLC is then informed of the state by means of IS “Fixed stop reached”.
If MD 37060: FIXED_STOP_ACKN_MASK is set accordingly, then the NC waits for acknow-
ledgment by the PLC in the form of IS “Acknowledge fixed stop reached”.
The NC then executes a block change or considers the positioning motion to be completed,
but still leaves a setpoint applied to the drive actuator to allow the clamping torque to take
effect.
The fixed stop monitoring function is activated as soon as the stop position is reached.
Monitoring window
If no fixed stop monitoring window is programmed in the block or since the beginning of the
program, then the value set in MD 37020: FIXED_STOP_WINDOW_DEF (default setting for
fixed stop monitoring window) is applicable.
If the axis leaves the position it was in when the fixed stop was detected, then alarm 20093
“Fixed stop monitoring has responded” is output and the “Travel to fixed stop” function de-se-
lected.
The window must be selected by the user such that the alarm is activated only when the axis
leaves the fixed stop position.
Enabling the fixed stop alarms

MD 37050: FIXED_STOP_ALARM_MASK can suppress the output of the following alarms:
S 20091 “Fixed stop not reached”
S 20094 “Fixed stop aborted”
Fixed stop is not reached

If the programmed end position is reached without the “Fixed stop reached” status being
recognized, then the torque limit in the drive is canceled and IS “Activate travel to fixed stop”
is reset.
Depending on the setting in MD 37060: FIXED_STOP_ACKN_MASK, the NC waits for the
PLC to acknowledge by resetting IS “Activate travel to fixed stop”; the program then advances
to the next block.

6FC5397-1CP10-1BA0 17-325
17.2 Functionality
Function abort
If the “Travel to fixed stop” function is aborted owing to a pulse cancellation command, cance-
lation of PLC acknowledgments or a Reset in the approach block, the display or suppression
of alarm 20094 can be controlled via MD 37050: FIXED_STOP_ALARM_MASK.
Abort without alarm

The PLC can initiate travel to fixed stop without an alarm in the approach block (for example,
when the operator actuates a key) if alarm 20094 is suppressed in MD 37050: FIXED_STOP_
ALARM_MASK.
The Travel to fixed stop function is de-selected in response to both “Fixed stop not reached”
and “Fixed stop aborted”.
Interrupts
S If the fixed stop position is not reached when the function is active, alarm 20091 “Fixed
stop not reached” is output and a block change executed.
S If a traversing request (e.g. from the part program or from the operator panel) is provided
for an axis after the fixed stop has been reached, the alarm 20092 “Travel to fixed stop still
active” is output and the axis is not moved.
S If an axis has reached the fixed stop and is then moved out of this position by more than
the value specified in SD 43520: FIXED_STOP_WINDOW (fixed stop monitoring window),
alarm 20093 “Fixed stop monitoring has responded” is output; the “Travel to fixed stop”
function is then de-selected for this axis and system variable $AA_FXS[x] is set to “2”.
Sequence in case of a fault or abnormal termination

The IS “Activate travel to fixed stop” is reset.
Depending on MD 37060: FIXED_STOP_ACKN_MASK, the NC waits for the PLC to acknow-
ledge by resetting IS “Activate travel to fixed stop”;
the torque limit is then canceled and the program advances to the next block.
De-selection
The NC detects de-selection of the function on the basis of command FXS[x]=0. Then, a pre-
processing stop (STOPRE) is initiated internally, since it can not be foreseen where the axis
will be after deselection.
Torque limiting and monitoring of the fixed stop monitoring window are canceled. IS “Activate
travel to fixed stop” and “Fixed stop reached” are reset.
Depending on the setting in MD 37060: FIXED_STOP_ACKN_MASK, the NC waits for the
PLC to acknowledge by resetting IS “Activate travel to fixed stop” and/or “Acknowledge fixed
stop reached”.
The axis will then change to position control. The followup mode of the position setpoints is
ended and a synchronization to the new actual position is carried out.

17-326 6FC5397-1CP10-1BA0
17.2 Functionality
A programmed traverse motion must then be executed. This motion must lead away from the
fixed stop or else the stop or even the machine may sustain damage.
A block change is executed after the target position has been reached.
Multiple selection
A selection may only be carried out once. If the function is called once more due to faulty pro-
gramming (FXS[axis] = 1), the alarm 20092 “Travel to fixed stop still active” is initiated.
Changing clamping torque and monitoring window

The commands FXST[x] and FXSW[x] can be used to change the clamping torque and the
fixed stop monitoring window in the part program. The changes take effect before traversing
movements in the same block.
Programming of a new fixed stop monitoring window causes a change not only in the window
width but also in the reference point for the center of the window if the axis has moved prior to
reprogramming. The actual position of the machine axis when the window is changed is the
new window center point.
Ramp for the torque limit

Machine data 37012: FIXED_STOP_TORQUE_RAMP_TIME a ramp for changing the torque
is specified. This determines the length of the ramp until the new torque limit is reached.
Without ramp
The torque limit is changed without taking into account the ramp if:
S FXS with (FXS[]=1) is activated to make sure that the reduction takes effect immediately
S the drive needs to be de-energized as quickly as possible in the event of a fault.
Response to pulse inhibit for the drive

With MD 37002: FIXED_STOP_CONTROL can be used to control the response in the case of
pulse inhibit at a fixed stop. When the pulses are cancelled, e.g. by using the IS “Pulse ena-
ble”, will not abort the function. As a result, the drive will press against the fixed stop again
without any further operating action when the machine is restarted.
The rise time of the torque corresponds to the time needed by the current controller of the
drive to reach the limit again.
If the pulses are deleted when a de-selection is active (waiting for PLC acknowledgments),
the torque limit will be reduced to zero. If the pulses are re-activated during this phase, torque
is no longer built up. Once the response has been completed, you can continue traversing as
normally.

6FC5397-1CP10-1BA0 17-327
17.3 Response to RESET and function abort
17.3 Response to RESET and function abort
Response to Reset
During selection (fixed stop not yet reached) the function FXS can be aborted with RESET.
The function is aborted such that an “almost achieved” fixed stop (setpoint already beyond the
fixed stop, but still within the threshold for the fixed stop detection) will not result in a damage.
This is achieved by synchronizing the position setpoint to the new actual position. As soon as
the fixed stop is reached, the function remains operative even after RESET.
Function abort
In the case of an EMERGENCY STOP, the NC and drive cannot respond, i.e. the PLC must
respond.
Caution
! Make sure that after the function “Travel to fixed stop” due to EMERGENCY STOP has been
canceled, no dangerous machine situation can arise (MD 37002: FIXED_STOP_CONTROL
e.g. Cancel pulse inhibit).
The fixed stop monitoring function responds in the case of:

S Exit from fixed stop position by axis
S Tool breakage
S Pulse inhibit
Block search with calculation

No fixed stop may be approached before the target block.
Remedy: Switch off blocks with fixed stops using the script function
Block search without calculation

The commands FXS, FXST and FXSW are ignored.

17-328 6FC5397-1CP10-1BA0
17.5 Miscellaneous
17.5 Miscellaneous
Inapplicable interface signals

The following interface signals (PLC NCK) are inoperative for axes at the fixed stop until
the function is de-selected (incl. traversing motion):
S IS “Axis/spindle disable”
S IS “Servo enable”
Actual position at fixed stop

System variable $AA_IM[x] can determine the actual position of the machine axis, e.g. for test
purposes after successful travel to fixed stop.
Combination with measuring function

“Measure with deletion of distancetogo” (“MEAS” command) and “Travel to fixed stop” cannot
be programmed at the same time in one block.
Contour monitoring
Axis-specific contour monitoring is not performed while “Travel to fixed stop” is active.
Selection for G64

Machine data 37060: FIXED_STOP_ACKN_MASK, bit 0 must be 0 (do not wait for PLC input
signal “Travel to fixed stop not activated”), since the selection of FXS may not initiate a motion
stop. If this bit is programmed, however, the alarm 20090 “Travel to fixed stop not possible –
check programming and axis data” is output.

6FC5397-1CP10-1BA0 17-329
17.5 Miscellaneous
Diagram
The following diagram shows the sequence of the motor current, following error and interface
signals for “Activate travel to fixed stop” with a digital drive.
FXST[x] or MD: FIXED_STOP_TORQUE_DEF
Motor current
0
MD 37030:
Following error
FIXED_STOP_THRESHOLD
0
Block with FXS[x]=1

IS “Activate FXS”
IS “FXS reached”
Block change
Fig. 17-2 Diagram for FXS with a digital drive

17-330 6FC5397-1CP10-1BA0
37000 FIXED_STOP_MODE
MD number Travel to fixed stop mode
Meaning: The machine data specifies how the “Travel to fixed stop” function can be started.
Value
=0: Travel to fixed stop not available.
=1: Travel to fixed stop may be started from the NC program using the command
FXS[x]=1.
37002 FIXED_STOP_CONTROL
MD number Special function when traveling to fixed stop
Meaning: Bit 0: Response for pulse inhibit at limit
=0: Travel to fixed stop is canceled.
=1: Travel to fixed stop is interrupted, i.e. the drive is rendered powerless.
As soon as the pulse block is canceled once more, the drive applies pressure
again with
the limited torque.
The torque is applied abruptly.
37010 FIXED_STOP_TORQUE_DEF
MD number Default for clamping torque
Default setting: 5.0 Minimum input limit: 0 Maximum input limit: 100.0
Changes effective after POWER ON Protection level: 2/2 Unit: %
Meaning: The clamping torque is entered in this machine data as a percentage of the maximum motor torque
(for FSD, corresponds with percentage of max. current setpoint)
The clamping torque becomes operative as soon as the fixed stop is reached or IS “Acknowledge
fixed stop” has been set.
The entered value is a default and is effective only on the condition that
S no clamping torque has been programmed with command FXST[x].
S the clamping torque set in SD 43510: FIXED_STOP_TORQUE has not been changed
(after fixed stop was reached).
Related to .... SD 43510: FIXED_STOP_TORQUE (clamping torque for travel to fixed stop)
37012 FIXED_STOP_TORQUE_RAMP_TIME
MD number Virtual time until reaching the new clamping torque when traveling to fixed stop
Changes effective after POWER ON Protection level: 2/2 Unit: s
Meaning: Virtual time until reaching the modified torque limit.
The subdivision is measured in the position controller cycle and applied abruptly.
The value 0.0 deactivates the ramp function.

6FC5397-1CP10-1BA0 17-331
37020 FIXED_STOP_WINDOW_DEF
MD number Default for fixed stop monitoring window
Default setting: 1.0 Minimum input limit: 0 Maximum input limit: ***
Changes effective after POWER ON Protection level: 2/2 Unit: mm, degrees
Meaning: The default setting for the fixed stop monitoring window is set in this machine data.
The fixed stop monitoring window becomes operative as soon as the fixed stop is reached, i.e.
IS “Fixed stop reached” is set.
If the axis/spindle leaves the position at which the fixed stop has been detected by more than the
tolerance specified in MD: FIXED_STOP_WINDOW_DEF, then alarm 20093 “Fixed stop monitor-
ing has responded” is output and the “FXS” function de-selected.
The entered value is a default and is effective only on the condition that
S no fixed stop monitoring window has been programmed with command FXSW[x].
S the fixed stop monitoring window set via SD 43520: FIXED_STOP_WINDOW has not been
changed (after fixed stop was reached).
Related to .... SD 43520: FIXED_STOP_WINDOW (fixed stop monitoring window)
37030 FIXED_STOP_THRESHOLD
MD number Threshold for fixed stop detection
Default setting: 2.0 Minimum input limit: 0 Maximum input limit: ***
Meaning: The contour monitoring threshold for fixed stop detection is entered in this machine data.
This machine data is effective only if MD: FIXED_STOP_BY_SENSOR is set to 0.
IS “Fixed stop reached” is set if the axis-specific contour deviation exceeds the threshold set in
MD: FIXED_STOP_THRESHOLD.
MD irrelevant for ... ... MD 37040: FIXED_STOP_BY_SENSOR = 1
Related to .... IS “Fixed stop reached”
37040 FIXED_STOP_BY_SENSOR
MD number Fixed stop detection via sensor
Meaning: The machine data specifies how the “Fixed stop reached” criterion
is determined.
Value =0: The “Fixed stop reached” criterion is determined internally based on the axis-specific
contour deviation (threshold specified by MD: FIXED_STOP_THRESHOLD).
=1: The “Fixed stop reached” criterion is determined via an external sensor and
the NC is notified via IS “Fixed stop sensor”.
=2: The “Fixed stop reached” criterion is accepted provided either the
contour monitoring function (setting = 0) or
the signal from the external sensor (setting = 1) has responded.
Related to .... MD 37030: FIXED_STOP_THRESHOLD (threshold for fixed stop detection)
IS “Sensor for fixed stop”

17-332 6FC5397-1CP10-1BA0
37050 FIXED_STOP_ALARM_MASK
MD number Enabling the fixed stop alarms
Meaning: The machine data specifies whether the alarm
20091 “Fixed stop not reached” and
20094 “Fixed stop aborted” will be generated.
Value = 0: suppress alarm 20091 “Fixed stop not reached”
= 2: suppress alarms 20091 “Fixed stop not reached” and
20094 “Fixed stop aborted”
= 3: suppress alarm 20094 “Fixed stop aborted”
All other permissible values of 7 do not suppress any alarms.
37060 FIXED_STOP_ACKN_MASK
MD number Monitoring of PLC acknowledgments for travel to fixed stop
Meaning: This machine data determines whether or not the NC waits for acknowledgment
messages from the PLC when the “Travel to fixed stop” function is active.
Bit 0 = 0: Once the NC has transmitted IS “Activate travel to fixed stop” to the PLC, it starts the
programmed travel motion.
Bit 0 = 1: After the NC has transferred IS “Activate travel to fixed stop” to the PLC, it waits for
the PLC to acknowledge with IS “Enable travel to fixed stop” and then starts the pro-
grammed travel motion.
Bit 1 = 0: Once the NC has transferred IS “Fixed stop reached” to the PLC, the program ad-
vances to the next block.
Bit 1 = 1: After the NC has transferred IS “Fixed stop reached” to the PLC, it waits for the PLC
to acknowledge with IS “Acknowledge fixed stop reached”, outputs the programmed
torque and then executes a block change.
Related to .... IS “Activate travel to fixed stop”
IS “Enable travel to fixed stop”
IS “Fixed stop reached”
IS “Acknowledge fixed stop reached”
Axisspecific setting data
43500 FIXED_STOP_SWITCH
SD number Selection of travel to fixed stop
Changes effective immediately Protection level: 2.2 Unit: –
Meaning: This setting data allows the “Travel to fixed stop” function to be checked.
Value =0: Deselect “Travel to fixed stop” function
=1: Select “Travel to fixed stop” function
The setting data can be overwritten by the part program using the command FXS[x]=1/0.

6FC5397-1CP10-1BA0 17-333
43510 FIXED_STOP_TORQUE
SD number Clamping torque for travel to fixed stop
Changes effective immediately Protection level: 2/2 Unit: %
Meaning: The clamping torque is entered in this setting data as a percentage of the maximum
motor torque (for FSD, corresponds with percentage of max. current setpoint)
Please note that a clamping torque greater than 100% may only be present for a short
time; otherwise, the motor will be damaged.
When selecting the function “Travel to fixed stop” through programming FXS[.]
the default setting of the MD 37010: FIXED_STOP_TORQUE_DEF applies until it is programmed
with FXST[.].
The FXST[x] command acts like a block-synchronous change of this setting data.
The setting data can be modified by the operator.
The SD is already operative as the stop is approached.
The fixed stop is considered reached if: FIXED_STOP_ACKN_MASK,
Bit 1 = 0, with MD37060: (no acknowledgment required) IS “Fixed stop reached” is set
by the NC.
Bit 1 = 1: (acknowledgment required) IS “Fixed stop reached” is set by the NC
and acknowledged by IS “Acknowledge fixed stop reached”.
Related to .... MD 37010: FIXED_STOP_TORQUE_DEF (default setting for clamping torque)
43520 FIXED_STOP_WINDOW
SD number Fixed stop monitoring window
Changes effective immediately Protection level: 7/7 Unit: mm, degrees
Meaning: The fixed stop monitoring window is entered in this setting data.
The setting data is effective only if the fixed stop has been reached.
The fixed stop is considered reached if: FIXED_STOP_ACKN_MASK,
Bit 1 = 0, with MD 37060: (no acknowledgment required) IS “Fixed stop reached” is set
by the NC.
Bit 1 = 1: (acknowledgment required) IS “Fixed stop reached” is set by the NC
and acknowledged by IS “Acknowledge fixed stop reached”.
If the position at which the fixed stop was detected leaves the tolerance band by more than the
amount specified in SD 43520: FIXED_STOP_WINDOW_DEF, then alarm 20093
“Fixed stop monitoring has responded” is output and the “FXS” function de-selected.
The FXSW[x] command acts like a block-synchronous change of the setting data.
The setting data can be modified by the operator.
The value is otherwise transferred from MD: FIXED_STOP_WINDOW_DEF to the setting data
when “Travel to fixed stop” is active.
Related to .... MD 37020: FIXED_STOP_WINDOW_DEF (default setting for fixed stop monitoring window)

17-334 6FC5397-1CP10-1BA0
V380x 0001.1 Acknowledge fixed stop reached

Interface signal Signal(s) to axis/spindle (PLC NCK)
Signal state 1 or signal Meaning after the fixed stop has been reached
transition 0 –––> 1 IS “Fixed stop reached” = 1
→ The axis pushes against the fixed stop with the clamping torque
→ The fixed stop monitoring window is activated
→ A block change is performed.
Signal state 0 Meaning after the fixed stop has been reached
IS “Fixed stop reached” = 1
The axis pushes against the fixed stop with the clamping torque
→ The fixed stop monitoring window is activated
→ No block change is performed and channel alarm
”Wait: Auxiliary function acknowledgment missing” is displayed.
Edge change 1–––>0
Meaning once the fixed stop has been reached:
The function is aborted, the alarm “20094 axis %1 Function aborted” is displayed.
Meaning when function is de-selected “FXS = 0” via part program:
Torque limiting and monitoring of the fixed stop window are canceled.
IS irrelevant for .... MD 37060: FIXED_STOP_ACKN_MASK (monitoring of PLC acknowledgments for travel to fixed
stop) = 0 or 1 (for values >1, however)
Related to .... MD 37060: FIXED_STOP_ACKN_MASK (monitoring of PLC acknowledgments for travel to fixed
stop)
IS “Fixed stop reached”
V380x 0001.2 Sensor for fixed stop

Signal state 1 or signal Fixed stop is reached.
Signal state 0 or signal Fixed stop is not reached.
Related to .... The signal is effective only if MD 37040: FIXED_STOP_BY_SENSOR is set to 1.

6FC5397-1CP10-1BA0 17-335
V380x 0003.1 Enable travel to fixed stop

Signal state 1 or signal Meaning when “FXS” function is selected via part program,
transition 0 –––> 1 (IS “Activate travel to fixed stop” = 1):
Travel to fixed stop is enabled and the axis traverses from the start position at the programmed
velocity to the programmed target position.
Signal state 0 Meaning when “FXS” function is selected via part program,
(IS “Activate travel to fixed stop” = 1):
Travel to fixed stop is disabled.
→ The axis is at the start position with reduced torque.
→ Channel alarm “Wait: Auxiliary function acknowledgment missing” is displayed.
Edge change 1–––>0 Meaning before the fixed stop has been reached
Travel to fixed stop is aborted
Alarm “20094: axis%1 Function aborted” is displayed
Meaning once fixed stop has been reached
IS “Fixed stop reached” = 1.
Torque limiting and the monitoring of the fixed stop monitoring window are canceled.
IS irrelevant for .... MD 37060: FIXED_STOP_ACKN_MASK (monitoring of PLC acknowledgments for travel to fixed
stop) = 0 or 2
Related to .... MD 37060: FIXED_STOP_ACKN_MASK (monitoring of PLC acknowledgments for travel to fixed
stop)
IS “Activate travel to fixed stop”

V390x 0002.4 Activate travel to fixed end stop
Interface signal Signal(s) from axis/spindle (NCK PLC)
Signal state 1 or signal The “Travel to fixed stop function” is active.
Signal state 0 or signal The “Travel to fixed stop function” is not active.
V390x 0002.5 Fixed stop reached

Interface signal Signal(s) from axis/spindle (NCK PLC)
Signal state 1 or signal The fixed stop was reached after selection of the “FXS” function.
Signal state 0 or signal The fixed stop has still not been reached after selection of the “FXS” function.

17-336 6FC5397-1CP10-1BA0

rence
V380x 0001 .1 Acknowledge fixed stop reached
V380x 0001 .2 Sensor for fixed stop
V380x 0001 .3 Axis/spindle disable Chapter
18
V380x 0002 .1 Controller enable Chapter
18
V380x 0003 .1 Enable travel to fixed stop
V390x 0002 .4 Activate travel to fixed end stop
V390x 0002 .5 Fixed stop reached
Machine data
rence
Axis-specific
37000 FIXED_STOP_MODE Travel to fixed stop mode
37002 FIXED_STOP_CONTROL Special function when Traveling to fixed stop
37010 FIXED_STOP_TORQUE_DEF Default for clamping torque
37012 FIXED_STOP_TORQUE_RAMP_TIME Virtual time until reaching the new clamping torque
when Traveling to fixed stop
37020 FIXED_STOP_WINDOW_DEF Default for fixed stop monitoring window
37030 FIXED_STOP_THRESHOLD Threshold for fixed stop detection
37040 FIXED_STOP_BY_SENSOR Fixed stop detection via sensor
37050 FIXED_STOP_ALARM_MASK Enabling the fixed stop alarms
37060 FIXED_STOP_ACKN_MASK Monitoring of PLC acknowledgments for travel to
fixed stop
Setting data

rence
Axis-specific
43500 FIXED_STOP_SWITCH Selection of travel to fixed stop
43510 FIXED_STOP_WINDOW Fixed stop monitoring window
43520 FIXED_STOP_TORQUE Clamping torque when traveling to fixed stop

6FC5397-1CP10-1BA0 17-337
Notes

17-338 6FC5397-1CP10-1BA0
Kinematic Transformations (M1) 18
Note
Range of application
The control transforms programmed traversing instructions from a Cartesian coordinate
system into a real machine axis system.
The TRANSMIT transformation is used for the face-end milling of turned parts on turning ma-
chines (without Y machine axis).
The TRACYL transformation is used to machine the peripheral surfaces of cylindrical bodies.
The main application is the milling of grooves. A TRACYL variant is provided for turning ma-
chines. A second variant is provided for turning machines with an additional Y machine axis or
for milling machines with a suitable rotary table.
Machine prerequisite
The turning machine must be equipped with a C axis enabled main spindle. A second spindle
must be able to drive the milling tool.
When used with TRACYL, the milling machine must be equipped with a rotary table which is
capable of interpolating with the other axes.
Availability
The TRANSMIT and TRACYL functions are available where the respective option exists.
They are configured using separate machine data sets and switched on or off by means of
special instructions in the program.
With SINUMERIK 802D, a maximum of two kinematic transformations (TRANSMIT, TRACYL)
may be configured and one of them may be activated using the program.

6FC5397-1CP10-1BA0 18-339
Kinematic Transformations (M1)
18.2 TRANSMIT
18.2 TRANSMIT
18.2.1 Overview
CM Y X XM
ÏÏÏ
ASM
Z ZM
Fig. 18-1 Face-end milling of turned parts with TRANSMIT
Legend for figure:

X, Y, Z Cartesian coordinate system for programming face-end milling operation
ASM Spindle 2 (working spindle for milling cutter, drill)
ZM Z machine axis (linear)
XM X machine axis (linear)
CM C axis (main spindle used as rotary axis)
Required machine kinematics

The two linear axes (XM, ZM) must be mutually perpendicular. The movement of the rotary
axis (CM) must be parallel to the linear axis ZM (rotating around ZM). The linear axis XM inter-
sects the rotary axis CM (center of rotation).
Activation/de-activation of TRANSMIT
The TRANSMIT function is activated in the program with
TRANSMIT in a separate block and de-activated with
TRAFOOF in a separate block.
TRAFOOF de-activates each active transformation function.

18-340 6FC5397-1CP10-1BA0
18.2 TRANSMIT
Programming – principle
N10 G0 X... Z... SPOS=... ; output positions, spindle in closed-loop pos. control
N20 G17 G94 T... ; level, feed type, select milling tool
N30 SETMS(2) ; changeover: The master spindle is now the milling
spindle
N40 TRANSMIT ; switch-in TRANSMIT
N50 G1 G41 F200 X... Y... Z... M3 S... ; milling of the face with milling radius correction
...
N90 G40 ...
N100 TRAFOOF ; switch-out TRANSMIT
N110 G18 G95 T... ; return to turning
N120 SETMS ; master spindle as main spindle
Explanation:
The movement of the machine axes XM and CM produces the contour on the face-end of the
turned part with the milling cutter in accordance with the X-Y path programmed (straight or
circular path). The programmed Z axis (infeed) continues to be traversed as the Z axis.
18.2.2 TRANSMIT configuration
General
The TRANSMIT transformation function is configured using machine data settings.
Note:
A file containing default machine data is available in the SINUMERIK 802D “Toolbox”. A fast
installation of TRANSMIT is possible by defining specific values and loading this file in the
control.

The names of the machine data, channel axes and geometry axes from the general machine
data ($MN_AXCONF... and $MC_AXCONF... and $MC_AXCONF... ) are also used for a
transformation.
The geometry axis assignments specified in $MC_AXCONF_GEOAX_ASSIGN_TAB only
apply when the transformation is de-activated. Additional assignments are specified for a
transformation.
Note
The assigned machine axis names, channel axis names and geometry axis names must
differ:
MD 10000: AXCONF_MACHAX_NAME_TAB,
MD 20080: AXCONF_CHANAX_NAME_TAB,
MD 20060: AXCONF_GEOAX_NAME_TAB.
Exception with TRANSMIT:
The axis names of MD 20060 and MD 20080 (geometry and channel axes) can be the same
for the TRANSMIT transformation, e.g.: X, Y, Z. No Y axis exists here outside the
transformation.

6FC5397-1CP10-1BA0 18-341
18.2 TRANSMIT
Machine data for transformation

$MC_TRAFO_TYPE_n ; = 256 for TRANSMIT transformation
$MC_TRAFO_GEOAX_ASSIGN_TAB_n : Geometry axes, specifically for transformation n
$MC_TRAFO_AXES_IN_n ; assignment of channel axes for transformation n
n = 1 of 2 (number of transformation)
Required assignment of channel axes for TRANSMIT transformation:
$MC_TRAFO_AXES_IN_1[0]= channel axis number of axis perpendicular to rotary axis.
$MC_TRAFO_AXES_IN_1[1]= channel axis number of rotary axis
$MC_TRAFO_AXES_IN_1[2]= channel axis number of axis parallel to rotary axis
Machine data specifically for TRANSMIT

$MC_TRANSMIT_ROT_AX_OFFSET_1 ; rotational position of Cartesian
coordinate system x-y plane with respect to the defined zero position of
rotary axis in degrees (0...<360)
$MC_TRANSMIT_ROT_SIGN_IS_PLUS_1; if the rotary axis rotates in an anti-clockwise
direction on the X-Y
plane when viewed along the Z axis, then the
machine axis must be set to “1”, but otherwise to “0”.
y
Fig. 18-2 Direction of rotation for MD value =1
$MC_TRANSMIT_BASE_TOOL_1 ; informs the control of the position

of the tool zero point in relation to the origin of the coordinate system
declared for TRANSMIT. The machine data has three
components for the three axes of the Cartesian coordinate system.
Assignment of axis components:
$MC_TRANSMIT_BASE_TOOL_1[0]=Tx
$MC_TRANSMIT_BASE_TOOL_1[1]=Ty
$MC_TRANSMIT_BASE_TOOL_1[2]=Tz (see next figure )
Y
Tx X
Tz
Tool zero point
Ty z
Tx, Ty, Tz – axis components of position
Fig. 18-3 Position of tool zero in relation to origin of the Cartesian coordinate system (center of rotation)
$MC_TRANSMIT_POLE_SIDE_FIX_1 = 0 ; continuous movement through the pole

18-342 6FC5397-1CP10-1BA0
18.2 TRANSMIT
Traversal of pole
The pole is defined as the center of rotation at point X=0, Y=0 of TRANSMIT plane (X ma-
chine axis intersects the center of rotation).
In the vicinity of the pole, small positional changes in the geometry axes X, Y generally result
in large changes in the machine rotary axis position (exception: path only results in a move-
ment of the XM axis).
Workpiece machining operations close to the pole are therefore not recommended since
these may require sharp feedrate reductions to prevent overloading of the rotary axis. Avoid
selecting TRANSMIT when the tool is positioned exactly on the pole. Ensure that the path of
the tool center point does not travel through the X0/Y0 pole.
Example: Machine data settings for TRANSMIT

; General settings (in this example, axis names: XM–>X1, ZM–>Z1, CM–>SP1):
N10000 $MN_AXCONF_MACHAX_NAME_TAB[0]=”X1”
N10000 $MN_AXCONF_MACHAX_NAME_TAB[1]=”Z1”
N10000 $MN_AXCONF_MACHAX_NAME_TAB[2]=”SP1”
N10000 $MN_AXCONF_MACHAX_NAME_TAB[4]=””
N20050 $MC_AXCONF_GEOAX_ASSIGN_TAB[0]=1
N20060 $MC_AXCONF_GEOAX_NAME_TAB[0]=”X”
N20060 $MC_AXCONF_GEOAX_NAME_TAB[1]=”Y”
N20060 $MC_AXCONF_GEOAX_NAME_TAB[2]=”Z”
N20070 $MC_AXCONF_MACHAX_USED[0]=1
N20080 $MC_AXCONF_CHANAX_NAME_TAB[0]=”X”
N20080 $MC_AXCONF_CHANAX_NAME_TAB[1]=”Z”
N20080 $MC_AXCONF_CHANAX_NAME_TAB[2]=”C”
N20080 $MC_AXCONF_CHANAX_NAME_TAB[3]=”SP2”
N20080 $MC_AXCONF_CHANAX_NAME_TAB[4]=””
N20090 $MC_SPIND_DEF_MASTER_SPIND=1
; TRANSMIT transformation type:
N24100 $MC_TRAFO_TYPE_1=256
N24110 $MC_TRAFO_AXES_IN_1[0]=1
N24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_1[0]=1

6FC5397-1CP10-1BA0 18-343
18.2 TRANSMIT
; special TRANSMIT settings:

N24900 $MC_TRANSMIT_ROT_AX_OFFSET_1=0
N24910 $MC_TRANSMIT_ROT_SIGN_IS_PLUS_1=1
N24920 $MC_TRANSMIT_BASE_TOOL_1[0]=0
; setting data for special handling of tool compensation:
; (only if required)
N42940 $SC_TOOL_LENGTH_CONST=18
N42950 $SC_TOOL_LENGTH_TYPE=2
; settings for 2nd spindle (milling spindle on turning machine):
N30300 $MA_IS_ROT_AX[AX4]=1
N30310 $MA_ROT_IS_MODULO[AX4]=1
N30320 $MA_DISPLAY_IS_MODULO[AX4]=1
N35000 $MA_SPIND_ASSIGN_TO_MACHAX[AX4]=2
N43300 $SA_ASSIGN_FEED_PER_REV_SOURCE[AX4]=0
Note: A special handling of milling tools on lathes with respect to length compensation is pos-
sible. References: Section “Tool: Compensation and monitoring”

18-344 6FC5397-1CP10-1BA0
18.3 TRACYL
18.3 TRACYL
18.3.1 Overview
Standard lathe (without Y machine axis)
CM
ÈÈ
ÈÈ
ASM XM
ZM
Legend:
XM Feed axis, perpendicular to rotary axis

ZM Axis parallel to rotary axis
CM Rotary axis
ASM Working spindle
Fig. 18-4 Machining grooves on a cylinder surface with X-C-Z kinematics
Required machine kinematics

The two linear axes (XM, ZM) must be mutually perpendicular. The rotary axis (CM) must tra-
vel parallel to the linear axis ZM (rotating around ZM). The linear axis XM intersects the rotary
axis CM (center of rotation).

6FC5397-1CP10-1BA0 18-345
18.3 TRACYL
Machine with Y axis
CM
È
YM
È
XM
ASM
ZM
Legend:
XM Feed axis, perpendicular to rotary axis

YM Supplementary axis
ZM Axis parallel to rotary axis
CM Rotary axis
ASM Working spindle
Fig. 18-5 Machining grooves on a cylinder surface with X-Y-Z-C kinematics
Extended machine kinematics

The YM linear axis is also available to enable the machine kinematics requirements to be met
(see above). This is arranged perpendicular to XM and ZM respectively and, with these, forms
a right-handed Cartesian coordinate system.
This type of kinematics is typical for milling machines and makes it possible to machine groo-
ves where the groove wall and groove base are mutually perpendicular – provided the milling
tool diameter is less than the groove width (groove wall offset). These grooves can otherwise
only be machined using milling tool diameters which fit precisely.

18-346 6FC5397-1CP10-1BA0
18.3 TRACYL
Grooves in transverse section
ÏÏÏ
ÏÏÏÏÏ
ÏÏ ËËË ËË ÏÏ
ÏÏ
ÏÏ
ÏÏ
ÏÏÏÏÏ ËËË ËË ÏÏ
ÏÏ
Longitudinal slot Transverse groove
Longitudinal groove with parallel
without groove wall offset limitation and groove wall offset
(without YM axis) (using YM axis)
Fig. 18-6 Grooves with and without groove wall offset
Activation/de-activation of TRACYL
The TRACYL function is activated in the program with
TRACYL(d) in a separate block and de-activated with
TRAFOOF in a separate block.
d – machining diameter of cylinder in mm
TRAFOOF de-activates each active transformation function.
Programming – principle
; without YM axis
; the geometry axes X, Y, Z are programmed
N10 G0 X... Z... SPOS=... ; output positions, spindle in closed-loop control
N20 G19 G94 T... ; level, feed type, select milling tool
N30 SETMS(2) ; changeover: Master spindle is now milling spindle
N40 TRACYL(24.876) ; activate TRACYL, diameter: 24.876 mm
N50 G1 F200 X... M3 S... ; feed, switch-in milling spindle
N600 G41 F200 Y... Z... ; mill the cylinder surface with
miller-radius compensation
...
N90 G40 ...
N100 TRAFOOF ; switch-out TRACYL
N110 G18 G95 T... ; re-select turning
N120 SETMS ; master spindle is the main spindle
Explanation:
The movement of the machine axes ZM and CM produces this contour on the peripheral sur-
face of the cylindrical workpiece with the milling cutter in accordance with the Y-Z path pro-
grammed (straight or circular). The programmed X axis (infeed) continues to be traversed as
the X axis.

6FC5397-1CP10-1BA0 18-347
18.3 TRACYL
The cylinder on unrollled external diameter d, produces the

peripheral surface with the programming plane Y-Z (G19).
This is also used to determine the rotational direction of the
circle for G2, G3.
0
Z
d*π
Groove
Fig. 18-7 Peripheral surface of cylinder, G19 (Y-Z plane)
OFFN address
Distance of groove side wall from the reference contour (also see “TRACYL programming
example”)
Programming: OFFN=... ; Distance in mm
The groove center line is normally programmed. OFFN determines the groove width when the
milling radius compensation is active (G41, G42). Set OFFN=0 once the groove has been
completed.
18.3.2 TRACYL configuration
General
The TRACYL transformation function is configured using machine data settings.
Note:
A file containing default machine data is available in the SINUMERIK 802D “Toolbox”. A
fast installation of TRACYL is possible by defining specific values and loading this file in the
control.

The names of the machine data, channel axes and geometry axes from the general machine
data ($MN_AXCONF... and $MC_AXCONF... and $MC_AXCONF... ) are also used for a
transformation.

18-348 6FC5397-1CP10-1BA0
18.3 TRACYL
The geometry axis assignments specified in $MC_AXCONF_GEOAX_ASSIGN_TAB only

apply when the transformation is de-activated. Additional assignments are specified for a
transformation.
Note
The assigned machine axis names, channel axis names and geometry axis names must
differ:
MD 10000: AXCONF_MACHAX_NAME_TAB,
MD 20080: AXCONF_CHANAX_NAME_TAB,
MD 20060: AXCONF_GEOAX_NAME_TAB.
Exception with TRACYL:
The axis names of MD 20060 and MD 20080 (geometry and channel axes) can be the same
for the TRACYL transformation (e.g.: X, Y, Z.) if no Y axis exists outside the transformation.
This is usually the case for lathes.
Machine data for transformation

$MC_TRAFO_TYPE_n ; = 512 for TRACYL transformation
(without YM axis)
; = 513 for TRACYL transformation with YM axis
$MC_TRAFO_GEOAX_ASSIGN_TAB_n : Geometry axes, specifically for transformation n
$MC_TRAFO_AXES_IN_n ; assignment of channel axes for transformation n
n = 1 of 2 (number of transformation)
Required assignment of channel axes for TRACYL transformation:
$MC_TRAFO_AXES_IN_1[0]= channel axis number of axis radial to rotary axis.
if configuration is performed using existing YM axis:

$MC_TRAFO_AXES_IN_1[3]= channel axis number of axis parallel to peripheral cylinder
surface and perpendicular to rotary axis (–> YM axis)
Machine data specifically for TRACYL

$MC_TRACYL_ROT_AX_OFFSET_1 ; rotational position: rotary axis setting, when Y=0 is
in degrees (0...<360)
Y
b
a
Angle a–b in degrees
a Rotational position of rotary axis

with C=0
b Position of Y= 0
Fig. 18-8 Center of rotation of axis in the peripheral cylinder surface

6FC5397-1CP10-1BA0 18-349
18.3 TRACYL
$MC_TRACYL_ROT_SIGN_IS_PLUS_1 ; if the rotary axis rotates in an anti-clockwise

direction in the X-Y plane when viewed along the Z axis, then the
machine data must be set to “1”, but otherwise to “0”.
Fig. 18-9 Direction of rotation for MD value =1
$MC_TRACYL_BASE_TOOL_1 ; informs the control of the position

of the tool zero point in relation to the origin of the coordinate system
declared for TRACYL. The machine data has three
components for the three axes of the Cartesian coordinate system.
Assignment of axis components:
$MC_TRACYL_BASE_TOOL_1[0]=Tx
$MC_TRACYL_BASE_TOOL_1[1]=Ty
$MC_TRACYL_BASE_TOOL_1[2]=Tz (see next figure )
Ty
Tx
0 Z
Y
X Tz
YC
Tool zero point
Fig. 18-10 Position of tool zero in relation to machine zero
Example: Machine data settings for TRACYL with a standard turning machine
; General settings (in this example, axis names: XM–>X1, ZM–>Z1, CM–>SP1):
N10000 $MN_AXCONF_MACHAX_NAME_TAB[0]=”X1”
N10000 $MN_AXCONF_MACHAX_NAME_TAB[1]=”Z1”
N10000 $MN_AXCONF_MACHAX_NAME_TAB[4]=””
N20060 $MC_AXCONF_GEOAX_NAME_TAB[0]=”X”

18-350 6FC5397-1CP10-1BA0
18.3 TRACYL
N20060 $MC_AXCONF_GEOAX_NAME_TAB[1]=”Y”
N20060 $MC_AXCONF_GEOAX_NAME_TAB[2]=”Z”
N20080 $MC_AXCONF_CHANAX_NAME_TAB[0]=”X”
N20080 $MC_AXCONF_CHANAX_NAME_TAB[1]=”Z”
N20080 $MC_AXCONF_CHANAX_NAME_TAB[2]=”C”
N20080 $MC_AXCONF_CHANAX_NAME_TAB[3]=”SP2”
N20080 $MC_AXCONF_CHANAX_NAME_TAB[4]=””
N20090 $MC_SPIND_DEF_MASTER_SPIND=1
; TRACYL transformation type for 2nd transformation:
N24200 $MC_TRAFO_TYPE_2=512 ; = without groove wall offset (no YM axis)
; special TRACYL settings:
N24900 $MC_TRACYL_ROT_AX_OFFSET_1=0
N24910 $MC_TRACYL_ROT_SIGN_IS_PLUS_1=1
N24920 $MC_TRACYL_BASE_TOOL_1[0]=0
; setting data for special handling of tool compensation:
; (only if required)
N42940 $SC_TOOL_LENGTH_CONST=18
N42950 $SC_TOOL_LENGTH_TYPE=2
; settings for 2nd spindle (milling spindle on turning machine):
N30300 $MA_IS_ROT_AX[AX4]=1
N30310 $MA_ROT_IS_MODULO[AX4]=1
N30320 $MA_DISPLAY_IS_MODULO[AX4]=1
N35000 $MA_SPIND_ASSIGN_TO_MACHAX[AX4]=2
N43300 $SA_ASSIGN_FEED_PER_REV_SOURCE[AX4]=0
Note: A special handling of milling tools on lathes with respect to length compensation is pos-
sible. References: Section “Tool: Compensation and monitoring”

6FC5397-1CP10-1BA0 18-351
18.3 TRACYL
18.3.3 Programming example, TRACYL
Machining grooves with groove wall compensation

($MC_TRAFO_TYPE_1 = 513)
Contour
It is possible to machine a groove which is wider than the tool by using address OFFN=... to
program the compensation direction (G41, G42) in relation to the programmed reference con-
tour and the distance of the groove side wall from the reference contour.
Tool radius
The tool radius in relation to the groove side wall is automatically taken into account with G41,
G42. The full functionality of the plane tool radius compensation is available (steady transition
at outer and inner corners as well as solution of bottleneck problems).
50 100 115
0 Z
N100
10
N80
Path I Milling tool
OFFN N70
N60
N105
OFFN
70
N110 Path II
N120
D x Pi =
40 x 3.1415 =
125.664
Y Programmed path
Peripheral surface
Fig. 18-11 Groove with groove wall offset – figure as example
Program example for X-Y-Z-C machine kinematics

TRACYL is used for the milling of grooves on a peripheral cylinder surface. During this pro-
cess, the “Path I” and “Path II” sections are processed using different OFFN values.
CC is the channel axis name of the rotary axis, milling radius of T1, D1: 8.345 mm

18-352 6FC5397-1CP10-1BA0
18.3 TRACYL
N1 SPOS=0 ; transfer of spindle to position control (for turning machines only)

N5 T1 D1 ; tool selection
N10 G500 G0 G64 X50 Y0 Z115 CC=200 DIAMOF
; positioning of machine, Y in center of rotation
N20 TRACYL(40) ; transformation selection, reference diameter for sheath: 40mm
N30 G19 G90 G94 G1 F500
; machining plane is the peripheral cylinder surface Y/Z
N40 OFFN=12.35 Y70 Z115
; define groove wall offset, starting position, Y is now transformer
axis
N50 X20 M2=3 S2=300 ; place tool on groove base, activate milling spindle
; Approach groove wall
N60 G1 G42 Y70 Z100 ; TRC selection to approach groove wall
; Machining of groove section path I :
N70 Z50 ; Groove section parallel to cylinder plane
N80 Y10 ; Groove section parallel to periphery
N90 OFFN=11.5 ; Change groove wall offset
; Machining of groove section path II :
N100 G1 G42 Y10 Z50 ; TRC selection to approach the groove wall for path II
N105 Y70 ; Groove section parallel to periphery
N110 Z100 ; return to initial value
; Traversing of groove wall:
N120 G1 G40 Y70 Z115 ; TRC de-selection, move away from groove wall
N130 G0 X25 M2=5 ; Lift off, milling spindle stops
N140 TRAFOOF ; Switch off TRACYL
N150 G0 X50 Y0 Z115 CC=200 OFFN=0 ; Return to starting point
N160 M30

6FC5397-1CP10-1BA0 18-353
18.4 Special features of TRANSMIT and TRACYL
18.4 Special features of TRANSMIT and TRACYL
Power ON/Reset/Program end

The system response after power ON or Reset (program end) is determined by the settings
stored in the machine data
MD 20110: RESET_MODE_MASK (access to this MD only possible at protection level 1/1)
and
MD 20140:TRAFO_RESET_VALUE (active transformation following RESET).
Please note on selection

S Tool radius compensation must be de-selected (G40).
S The frame which was active prior to TRANSMIT/TRACYL is de-selected by the control.
(G500).
S The control de-selects an active working area limit for axes affected by the transformation
(WALIMOF).
S Continuous path control and rounding (smoothing) are interrupted.
S DRF offsets in transformed axes must have been deleted by the operator.
S An instructed intermediate movement block with chamfer or radius is not inserted.
Please note on de-selection

S Tool radius compensation must be de-selected (G40).
S Continuous path control and rounding (smoothing) are interrupted.
S An instructed intermediate movement block with chamfer or radius is not inserted.
S Following TRANSMIT/TRACYL de-selection, zero offsets (Frame) and all settings used for
the turning operation are to be reset.
Operating modes, operating mode changeover

S The program processing with TRANSMIT/TRACYL is performed in AUTOMATIC.
S It is possible to interrupt the AUTOMATIC operation and change over to JOG. When retur-
ning to AUTOMATIC mode, the operator must ensure a problem-free repositioning of the
tool.
S Axes cannot be referenced when a transformation is active.

18-354 6FC5397-1CP10-1BA0
Transformation-specific machine data
20140 TRAFO_RESET_VALUE
MD number Active transformation following RESET
Meaning: Definition of the transformation data set selected during booting and for a
reset or an end of the part program.
(In conjunction with machine data $MC_RESET_MODE_MASK and for a part program start in
conjunction with machine data $MC_START_MODE_MASK)
22534 TRAFO_CHANGE_M_CODE
MD number M code for transformation changeover
Data type: DWORD Applies from SW: 2.0
Meaning: Number of M code that is output at the VDI interface in the case of a transformation changeover on
the geometry axes.
No M code is output if this MD is set to one of the values 0 to 6, 17 or 30.
It is not monitored whether an M code created in this way will conflict with other functions.
24100 TRAFO_TYPE_1
MD number Type of 1st transformation
Meaning: Transformation type of 1st transformation:
0 no transformation
256 TRANSMIT transformation
512 TRACYL transformation
513 TRACYL transformation with X-Y-Z-C kinematics
further transformations are not available with SINUMERIK 802D.

MD irrelevant for ... ... No transformations
Related to .... TRAFO_TYPE_2
24110 TRAFO_AXES_IN_1[i]
MD number Axis assignment for transformation 1 [axis index]: 0 ... 4
Default setting: 1,2,3,4,5 Minimum input limit: 1 Maximum input limit: 5
Data type: Byte Applies from SW: 2.0

6FC5397-1CP10-1BA0 18-355
MD number Axis assignment for transformation 1 [axis index]: 0 ... 4
Meaning: Axis assignment at input of 1st transformation
Example for Transmit:
Index i assumes the values 0,1, 2 with TRANSMIT.
$MC_TRAFO_AXES_IN_1[0]= channel axis number of axis perpendicular to rotary axis
Example for TRACYL: see TRACYL section
MD irrelevant for ... ... No transformation
Related to .... TRAFO_AXES_IN_2
24120 TRAFO_GEOAX_ASSIGN_TAB_1[i]
MD number Assignment of geometry axes to channel axes with transformation 1
[geometry axis number]: 0 ... 2
Default setting: 0,0,0 Minimum input limit: 0 Maximum input limit: 5
Meaning: This MD specifies the channel axes on which the axes of the Cartesian coordinate system
are mapped when transformation 1 is active.
Index i assumes the values 0, 1, 2 with TRANSMIT. It refers to the first, second and third geometry
axis.
MD irrelevant for ... ... No transformation
Application example(s) $MC_TRAFO_GEOAX_ASSIGN_TAB_1 [0] = 2 ; 2nd channel axis
Related to .... $MC_AXCONF_GEOAX_ASSIGN_TAB, if no transformation is active.
24200 TRAFO_TYPE_2
MD number Type of transformation
Meaning: Same as TRAFO_TYPE_1, but for transformation 2
MD number Axis assignment for transformation 2/3/4/5/6/7/8 [axis index]: 0 ... 4
Default setting: 1,2,3,4,5 Minimum input limit: 1 Maximum input limit: 5
Meaning: Axis assignment at input of 2nd transformation.
Same meaning as for TRAFO_AXES_IN_1.
24220 TRAFO_GEOAX_ASSIGN_TAB_2[i]
MD number Assignment of geometry axes to channel axes with transformation 2
[geometry axis number]: 0 ... 2
Default setting: 0,0,0 Minimum input limit: 0 Maximum input limit: 5
Meaning: The channel axes on which the axes of the Cartesian coordinate system are mapped
when transformation 2 is active are set in this MD.
The meaning otherwise corresponds to TRAFO_GEOAX_ASSIGN_TAB_1.

18-356 6FC5397-1CP10-1BA0
Function-specific machine data, TRANSMIT
24900 TRANSMIT_ROT_AX_OFFSET_1
MD number Position offset of rotary axis
Changes effective after NEW_CONF Protection level: 2/2 Unit: Degr.
Meaning: Specifies the offset of the rotary axis in degrees in relation to the zero position – while TRANSMIT
is active – for the TRANSMIT transformation.
MD irrelevant for ... ... No TRANSMIT active
Application example(s) $MC_TRANSMIT_ROT_AX_OFFSET_1=15.0
24910 TRANSMIT_ROT_SIGN_IS_PLUS_1
MD number Sign of rotary axis
Meaning: Specifies the sign which is applied to the rotary axis during the TRANSMIT transformation for the
TRANSMIT transformation.
MD irrelevant for ... ... No TRANSMIT transformation
Application example(s) $MC_TRANSMIT_ROT_SIGN_IS_PLUS_1= 1
24911 TRANSMIT_POLE_SIDE_FIX_1
MD number Restriction of working range in front of/behind pole
Meaning: Restriction of working range in front of/behind pole or no restrictions, i.e. traversal through pole.
The setpoints have the following meanings:
0: No restrictions of working range. Traversal through pole.
1: Working range of linear axis for positions >=0,

(if tool length compensation parallel to linear axis equals 0)
2: Working range of linear axis for positions <=0,
(if tool length compensation parallel to the linear axis equals 0)
24920 TRANSMIT_BASE_TOOL_1[i]
MD number Vector of base tool on activation of transformation, [Geo-Axis-Index]]: 0 ... 2
Default setting: 0 Minimum input limit: 0 Maximum input limit:
Changes effective after NEW_CONF Protection level: 2/2 Unit: mm
Meaning: MD specifies the distance of the tool zero point referred to the appropriate geometry axes valid
with TRANSMIT active and without tool length offset selected for the TRANSMIT transformation.
Programmed length compensations are added to the base tool.
Index i assumes values 0, 1, 2 for the 1st to 3rd geometry axes.
MD irrelevant for ... ... No TRANSMIT transformation
Application example(s) $MC_TRANSMIT_BASE_TOOL_1[0]=20.0

6FC5397-1CP10-1BA0 18-357
Function-specific machine data, TRACYL
24800 TRACYL_ROT_AX_OFFSET_1
MD number Offset of rotary axis for the TRACYL transformation
Changes effective after NEW_CONF Protection level: 2/2 Unit: Degr.
Meaning: Specifies the offset of the rotary axis in degrees in relation to the zero position while TRACYL is
active for the first declared TRACYL transformation for each channel.
MD irrelevant for ... ... No TRACYL active
Application example(s) $MC_TRACYL_ROT_AX_OFFSET_1=15.0
24810 TRACYL_ROT_SIGN_IS_PLUS_1
MD number Sign of rotary axis for the TRACYL transformation
Meaning: Specifies the sign which is applied to the rotary axis during the TRACYL transformation for the
TRACYL transformation.
MD irrelevant for ... ... No TRACYL transformation
Application example(s) $MC_TRACYL_ROT_SIGN_IS_PLUS_1 = 1
24820 TRACYL_BASE_TOOL_1[i]
MD number Vector of base tool for TRACYL transformation, [Geo-Axis-Index]: 0 ... 2
Default setting: 0 Minimum input limit: 0 Maximum input limit:
Changes effective after NEW_CONF Protection level: 2/2 Unit: mm
Meaning: MD specifies the distance of the tool zero point referred to the appropriate geometry axes valid
with TRACYL active and without tool length offset selected for the TRACYL transformation.
Programmed length compensations are added to the base tool.
Index i assumes values 0, 1, 2 for the 1st to 3rd geometry axes.
MD irrelevant for ... ... No TRACYL transformation
Application example(s) $MC_TRACYL_BASE_TOOL_1[0]=tx

18-358 6FC5397-1CP10-1BA0
V3300 0001.6 Transformation active

Interface signal Signal(s) from NCK channel (NCK–>PLC)
Signal state 1 or signal The NC command TRANSMIT or TRACYL is programmed in the part program. The corresponding
transition 0 –––> 1 block has been processed by the NC and a transformation is now active.
Signal state 0 No transformation is active.

Edge change 1–––>0

6FC5397-1CP10-1BA0 18-359

rence
Channel-specific
V3800 0001 .6 Transformation active
Machine data
rence
Channel-specific
20110 RESET_MODE_MASK Definition of control basic setting after run-up and
RESET/part program end (access only possible at
protection level 1/1)
20140 TRAFO_RESET_VALUE Default setting: Transformation active after Reset
22534 TRAFO_CHANGE_M_CODE M code for transformation changeover
24100 TRAFO_TYP_1 Type of 1st transformation, possibly with axis
sequence
24110 TRAFO_AXES_IN_1 Axis assignment at input of 1st transformation
24120 TRAFO_GOEAX_ASSIGN_TAB_1 Geo-axis assignment for 1st transformation
24200 TRAFO_TYP_2 Type of 2nd transformation, possibly with axis
sequence
24210 TRAFO_AXES_IN_2 Axis assignment at input of 2nd transformation
24220 TRAFO_GOEAX_ASSIGN_TAB_2 Geo-axis assignment for 2nd transformation
24800 TRACYL_ROT_AX_OFFSET_1 Deviation of rotary axis from zero position in degrees
(1st TRACYL)
24810 TRACYL_ROT_SIGN_IS_PLUS_1 Sign of rotary axis for TRACYL (1st TRACYL)
24820 TRACYL_BASE_TOOL_1 Distance of tool zero point from origin of geo-axes
(1st TRACYL)
24900 TRANSMIT_ROT_AX_OFFSET_1 Deviation of rotary axis from zero position in degrees
(1st TRANSMIT)
24910 TRANSMIT_ROT_SIGN_IS_PLUS_1 Sign of rotary axis for TRANSMIT (1st TRANSMIT)
24911 TRANSMIT_POL_SIDE_FIX_1 Limiting the working range in front of/behind pole,
1st transformation
24920 TRANSMIT_BASE_TOOL_1 Distance of tool zero point from origin of geo-axes
(1st TRANSMIT)

18-360 6FC5397-1CP10-1BA0
Tangential Control (T3) 19
Note
This function is only available for 802D sl pro.
Functions
The “tangential control” function belongs to the category of NC functions with coupled axes
and has the following characteristics:
S There are two leading axes (guide axes) which are moved using standard traversing in-
structions and therefore traverse a path. A following axis also exists and its movement is
dependent on this path contour (on the direction of the tangent in the current point on the
path).
S The leading axes are defined as geometry axes and the following axis as a rotary axis.
S The coupled axes are axes in the same NC channel.
S The position of the following axis can be the input value for a transformation.
S Tangential control is only active in AUTOMATIC or MDA modes.
Application examples
– Positioning and tangential follow-up of a turnable tool for nibbling
– Follow-up of workpiece alignment when using a band saw
– Positioning and tangential follow-up of a dressing tool on a grinding wheel
– Tangential follow-up of a small cutting wheel during glass or paper processing
– Tangential feed of a wire during 5-axis welding processes
Defining, activating, de-activating the axis coupling

A program instruction defines the tangential axis
coupling. Additional activation and de-activation instructions exist in the program.
Deleting an axis coupling

The definition of a tangential axis coupling may be deleted by means of a program instruction.
An axis coupling with this following axis can then be defined again.

6FC5397-1CP10-1BA0 19-361
Tangential Control (T3)
19.2 Characteristics of “Tangential control” function
19.2 Characteristics of “Tangential control” function
Task assignment
Follow-up control for the rotary axis must be implemented so that the axis is always positioned
at a specified angle to the tangent on a programmed path of two leading axes.
Y
C
+
Fig. 19-1 Example of a tangential control with an angle of zero degrees to the path tangent
In the figure, X and Y are the leading axes inside which the path is programmed. C is the follo-
wing axis, the position of which is determined by the control with reference to the leading axis
path and the desired angle between the tangent and alignment in C.
The prerequisite for the tangential control is that the leading axes are used as path axes.
A leading axis which is programmed as a positioning axis (POS or POSA) does not specify
values required for the follow-up control function.
Response to corners in the path
Y C
+
+
Fig. 19-2 Corner in the path contour

19-362 6FC5397-1CP10-1BA0
19.3 Use of “Tangential control” function
Corner in the path contour

If the path specified by the leading axes has a corner, jumps in the direction of the path tan-
gent occur at this point. In this situation, the following responses can be selected for the follo-
wing axis:
S Without programming TLIFT (TLIFT, see next Chapter):
The path velocity is decreased to such an extent that the follow-up axis achieves its new
alignment at the same time as the leading axes reach their target position.
S If TLIFT has been programmed,
an intermediate block is inserted at any corner whose angle is greater than the “tangential
angle for corner recognition” (MD 37400: EPS_TLIFT_TANG_STEP). In this inserted inter-
mediate block, the rotary axis is moved as fast as possible to the position corresponding to
the tangent after the corner. The limit values set for this axis are not violated. At the begin-
ning of the intermediate block, the path velocity of the leading axes is zero.
Information
In blocks with G641 rounding, no intermediate block is generated for the following axis with
TLIFT. An intermediate block is not required in this case. The compensation of the following
axis is performed in conjunction with the rounding operation.
Hidden corner in space
A corner relevant for the tangential follow-up control can be hidden in space. The projection of
the contour on the plane defined by the two leading axes is relevant. If there is a hidden cor-
ner in space, an intermediate block is inserted before the block causing the tangential jump.
This intermediate block moves the following axis to the new position. The block transition is
not rounded.
19.3.1 Overview
Definition, activation
The “Tangential control” function requires the following program sequence:
– Define assignment of leading axes and following axis with TANG( ).
– Specify response at path corners – if required, program TLIFT( ).
– Activate defined coupling using TANGON( )..
Change response at corners, de-activate, delete definition

– If required:
Change the response at path corners (TANG without following TLIFT)
– De-activate coupling with TANGOF( )
– Delete definition with TANGDEL( ).

6FC5397-1CP10-1BA0 19-363
Influence on transformations
The position of the rotary axis to which follow-up control is applied can act as the input value
for a transformation.
References: /FB/, M1, “Transmit/Peripheral Surface Transformation”
Note
The user is recommended to program TLIFT if tangential control is used together with a
transformation. TLIFT prevents the follow-up axis from over-traveling and protects against
excessive compensating motion.
Explicit programming of following axis in an active coupling

If the following axis is programmed directly, then the positional data is added to the offset an-
gle programmed in the activation instruction TANGON. In this case, positional data with AC,
IC, DC, POS for the following axis are permitted.
Referencing
Axis coupling is de-activated during reference point approach.
Detailed programming instructions

References: “Operator control and programming – milling”
19.3.2 Definition of axis coupling: TANG
Programming
The programming is carried out using the pre-defined sub-program TANG( ). The following
parameters are transmitted:
Following axis (rotary axis) Example: C
Leading axis 1 (geometry axis) Example: X
Leading axis 2 (geometry axis) Example: Y
Coupling factor default 1
Coordinate system code “B”–>Base coordinate system, optional
Optimization “S” = Standard (default) or
“P” = automatic adaptation of
variation with time of following and leading
axes
The appropriate axis identifiers are used to specify the axes. The coupling factor is normally 1.
The coupling factor of 1 can be omitted, the same applies for “B”.
Example of abbreviated call: TANG(C, X, Y)
Examples of possible calls: TANG(C, X, Y,1)
TANG(C, X, Y,1,”B”)
Example of complete call: TANG(C, X, Y, 1, “B”,”S”)

19-364 6FC5397-1CP10-1BA0
19.3.3 Switching-in the axis coupling: TANGON
Programming
The axis coupling is switched-in using the pre-defined sub-program TANGON( ). The follow-
on axis is hereby specified. The specification refers to the definition of leading axes and the
following axis previously specified using TANG.
As an option, an offset angle between the tangent and position of the follow-on axis can be
specified during activation. This angle is maintained by the control for as long as the following
axis is made to follow. The angle is added to the angle stored in machine data MD 37402:
TANG_OFFSET. If the angle is zero both in TANGON and in the MD, the following axis takes
the direction of the tangent.
Example without offset angle: TANGON(C)
Example with offset angle at 90 degrees: TANGON(C, 90).
19.3.4 Response at corners, activation “with intermediate block”: TLIFT
Programming
Following the definition with TANG( ), the TLIFT instruction with the following axis must be
written if corner response “with intermediate block” is required.
TLIFT (C)
The control considers the corresponding data MD 37400: EPS_TLIFT_TANG_STEP. If the
tangential angle jump exceeds the angle (absolute value) of the angle set in the MD, the con-
trol recognizes a “corner” and approaches the new position of the follow-up axis via an inser-
ted intermediate block.
19.3.5 De-activation of axis coupling: TANGOF
Programming
The de-activation is carried-out using the predefined subprogram TANGOF( ). The follow-on
axis is hereby specified. This specification refers to the definition of leading and following axes
made beforehand with TANG. With reference to the above example, the termination is:
TANGOF(C)
The follow-on process started by TANGON is ended. Termination of follow-up control initiates
a pre-processing stop (pre-processor stop).
information
The master (leading) axes and following axis, defined using TANG( ... ) are not cleared by
TANGOF.
After RESET/part program end, no tangential control is active (default setting).

6FC5397-1CP10-1BA0 19-365
19.3.6 De-activate corner response “with intermediate block”
Programming
In order to stop generating the intermediate block at corners with active tangential follow-up
control, the definition block TANG(...) must be repeated without a following TLIFT().
19.3.7 Deleting the definition of axis coupling: TANGDEL
Programming
An axis coupling definition specified by TANG(...) remains active after TANGOF. This inhibits a
plane change or geometry axis changeover. The pre-defined sub-program TANGDEL( ) may
be used to delete the definition of the axis coupling. Other axis couplings can subsequently be
defined with this following axis.
TANGDEL(C) ; The existing definition in example TANG(C,X,Y) is canceled.
19.3.8 Programming examples
Example with insertion of an intermediate block for positioning of rotary axis

N10 TANG (C, X, Y, 1) ; Definition of tangential control
N20 TLIFT (C) ; Activate insertion of intermediate block at corners
N30 G1 G641 X0 Y0 F1000
N40 TANGON (C) ; Activate tangential control
N50 X10
N60 Y10 ; Before this block is processed, the rotary axis C is repositioned
in an intermediate block
N70 M2
Example with plane change for the leading axes

N10 TANG(A, X, Y, 1) ; Definition, follow-on axis is rotary axis A
N20 TANGON(A) ; Activate
N30 X10 Y20
......
N80 TANGOF(A) ; De-activate
N90 TANGDEL(A) ; Delete defined coupling from A to X and Y as leading axes
......
N120 TANG(A, X, Z) ; New definition, A can be coupled to new leading axes
N130 TANGON(A) ; Activate new coupling
......
N200 M2

19-366 6FC5397-1CP10-1BA0
19.4 Limit angle for reversal of path direction
19.4 Limit angle for reversal of path direction
Problem
When the axis moves backwards and forwards along the path, the tangent direction turns ab-
ruptly through 180 degrees at the path reversal point. This response is not generally desirable
for machining operations (e.g. grinding of a contour). It is far better for the reverse motion to
be executed using the same absolute offset angle as the forward motion.
required direction
Y at reversal
C C’
Point of direction reversal
Fig. 19-3 Path movement with direction reversal and alignment of follow-on axis
Solution and programming

A minimum and a maximum value for the position of the following axis (“C” in example) refer-
red to the base coordinate system are transferred to the control with G25 and G26 (working
area limit). These working area limit are activated with WALIMON and de-activated again with
WALIMOF. The working area limit must be active at the instant of path reversal.
Effect
If the current offset angle is outside the active working area limit for the following axis, an at-
tempt is made to return to within the permissible working area by means of the negative offset
angle.
Programming example for direction reversal, principle

N10 TANG (C, X, Y) ; Definition of tangential control
N20 TLIFT (C) ; Activate insertion of intermediate block at corners
N30 G1 X10 Y0 F1000
N40 G25 C50 ; Value for lower working area limitation
N50 G26 C70 ; Value for upper working area limitation
N60 TANGON (C, 60) ; Activate tangential control, offset angle 60 degrees
N70 WALIMON ; Activate working area limitation
N80 X100
N90 X10 ; Before this block is processed, the rotary axis C is repositioned
in an intermediate block, C’ –60 degrees.
N200 M2

6FC5397-1CP10-1BA0 19-367
37400 EPS_TLIFT_TANG_STEP
MD number Tangential angle for corner recognition
Changes effective after RESET Protection level: 3/7 Unit: Degr.
Meaning: If TLIFT has been programmed and the axis is under tangential follow-up control (tracking), a step
change in the position setpoint which is larger than the value of this MD causes an intermediate
block to be inserted. The intermediate block moves the axis to the position corresponding to the
initial tangent in the next block.
MD irrelevant for ... ... TLIFT not activated
Related to .... TLIFT instruction
37402 TANG_OFFSET
MD number Default angle for tangential follow-up control
Changes effective after RESET Protection level: 3/7 Unit: Degr.
Meaning: Default offset (angle) which the following axis forms with the tangent.
The angle acts additively to the angle programmed in the TANGON block.
MD irrelevant for ... ... if no tangential follow-up control
Related to .... TANGON instruction
Machine data
Number Names Name Refe-
rence
Axis-specific
37400 EPS_TLIFT_TANG_STEP Tangential angle for corner recognition
37402 TANG_OFFSET Default angle for tangential follow-up control

19-368 6FC5397-1CP10-1BA0
Various Interface Signals (A2) 20
20.1 General
Brief Description
This Description of Functions describes the functionality of various interface signals which are
of general relevance but are are not included in the other existing Descriptions of Functions.
Interfaces
The exchange of signals and data between the PLC user program and
S NCK (core of numerical control)
S HMI (display unit)
takes places through various data areas. The PLC user program does not have to handle the
exchange of data and signals. From the users point of view, this takes place automatically.
NCK General PLC
Signals to NC
General
Signals from NC
User
program
Operating modes
Signals to NCK
Operating
modes
Signals from NCK
Channel
Signals to NCK
Signals to NCK
Channel Signals from NCK
Signals from NCK
Spindle (n+1)
Axis n
Axis 2
Axis, Axis 1
Spindle
Signals to NCK
Signals from NCK
Fig. 20-1 PLC/NCK interface

6FC5397-1CP10-1BA0 20-369
Various Interface Signals (A2)
20.2 Signals from PLC to NCK
Cyclical signal exchange

The control and status signals of the PLC/NCK interface are updated cyclically.
The signals can be subdivided into the following groups (see Fig. 20-1):
S General signals
S Operating mode signals
S Channel signals
S Axis/spindle signals
Access authorization
Access to programs, data and functions is useroriented and controlled via 8 hierarchical pro-
tection levels. These are subdivided into:
S 4 password levels for Siemens, machine manufacturer (2x) and end user
S 4 protection levels for end users (interface signals V2600 0000.4 to .7)
This provides a multilevel safety concept for controlling access rights.
See also Instruction Manual, Section “Access levels”
Table 20-1 Access protection
Prot. level Type Users Access to (examples)
0 Key SIEMENS, reserved

word
1 Code Expert mode defined functions, programs and data

word
2 Key Machine manufacturer defined functions, programs and data;

word for standard installation
3 Key End user assigned functions, programs and data

word
4 IS end user: less than protection level 0 to 3;

V2600 Programmer determined by machine manufacturer or
0000.7 Installer end user
5 IS end user: less than protection level 0 to 3;

V2600 qualified operator, determined by end user
0000.6 who does not program Decreasing
access rights
6 IS end user: Example:
V2600 trained operator, only program selection, tool wear
0000.5 who does not program input and entry of zero point offsets
7 IS end user: Example:

V2600 apprentice operator no input and program selection
0000.4 possible, machine control panel only can be operated

20-370 6FC5397-1CP10-1BA0
Delete distance-to-go – channel-specific (V3200 0006.2)

IS “Delete distance-to-go (channel-specific)” is only active for path axes.
As the edge of the interface signal rises, the distancetogo of all axes in the geometry grouping
is deleted and the axes thus brought to a standstill with ramp stop. The next program block is
then started.
Axis/spindle disable (V380x 0001.3)

IS “Axis/spindle lock” can be used for testing purposes.
Axis disable (for axis):
If IS “Axis disable” is output, no more position partial setpoints are output for this axis to the
position controller; the axis travel is therefore disabled. The position control loop remains clo-
sed and the remaining following error is corrected. If an axis is traversed with axis disable the
actual value position display shows the setpoint position and the velocity actual value display
shows the setpoint velocity even though the machine axis is not actually traversing. IS “RE-
SET” (V3000 0000.7) sets the position actual value display to the real actual value of the ma-
chine. Travel commands continue to be output to the PLC for this axis. If the interface signal is
canceled the associated axis can again traverse normally. If the interface signal “Axis disable”
is set for a traversing axis, the axis is stopped with a ramp stop.
Spindle disable (for spindle):
If IS “Spindle disable” is set, no more speed setpoints are output to the speed controller in the
open-loop control mode and no more position partial setpoints are output to the position con-
troller in positioning mode. The movement of the spindle is thus disabled. The speed actual
value display displays the speed setpoint value. The spindle disable is canceled via “Reset” or
program end (M2) and program restart. If interface signal “Spindle disable” is set while a
spindle is turning, the spindle is stopped according to its acceleration characteristic.
Cancellation of the “Axis/spindle disable signal” (edge change 1 → 0) does not take effect until
the axis/spindle is stationary (i.e. no interpolation setpoint is applied). The new movement be-
gins with new specified setpoints. (e.g.: new program block with movement specifications in
AUTOMATIC operating mode).
Note: actual values vary between simulated and real axis!
Follow-up mode (V380x 0001.4)

If an axis/spindle is operating in followup mode, then its setpoint position is made to track the
current actual value position. The position setpoint in follow-up mode is not defined by the in-
terpolator but derived from the actual position value. Since the actual position value of the axis
continues to be measured, it is not necessary to reference the axis when follow-up mode is
canceled.
Zero speed, clamping and positioning monitoring are not active in follow-up mode.
Effect:
The IS “Follow-up mode” is only of relevance if the drive controller enable has been removed
(e.g. by IS “Controller enable” = 0 signal or because of a fault in the control), or because con-
troller enable is being re-issued.

6FC5397-1CP10-1BA0 20-371
IS “Follow-on operation” = 1:
If “Controller enable” is removed the position setpoint of the axis concerned is continuously
corrected to the actual value. This state is signaled to the PLC by means of IS “Follow-up
mode active” (V390x 0001.3). If the “Controller enable” is enabled again and a part program is
active, a controlinternal re-positioning operation is initiated (REPOSA: linear approach with all
axes) to the last programmed position.
Otherwise,
the axis movement starts at the new actual position (which may have changed).
IS “Follow-up operation” = 0:
If “Controller enable” is removed, the old position setpoint is maintained. If the axis is pushed
out of position, a following error between position setpoint and actual value results which is
corrected when IS “Controller enable” is set. The axis movement begins at the position
setpoint which applied before the “Controller enable” was removed.
In the “Hold” state, IS “Follow-up mode active” (V390x 0001.3) is set to the 0 signal.
The clamping or zero speed monitoring system is active.
Position measuring system (V380x 0001.5)

A position measuring system may be connected to the spindle. In this case, the signal for the
spindle is to be set.
Axes always require this signal. In this case, a position measuring system must be installed.
Controller enable (V380x 0002.1)

When the controller enable is activated for the drive, the position control loop of the axis/
spindle is closed. The axis/spindle is then in position control.
When controller enable is removed, the position control loop of the axis/spindle is opened
while the speed control loop is delayed.
A 0 signal (response) is set for IS “Position control active” (V390x 0001.5).
Activation:
The controller enable for the drive can be set and removed from the following places:
1. From the PLC user program with interface signal “Controller enable” (in normal cases)
Application: Removal of controller enable before clamping an axis/spindle.
2. Controller enable is set automatically by the control when certain faults occur in the ma-
chine, the drive, the position measuring system or the control (when faults occur)
Application: The traversing axes must be brought to a standstill by a rapid stop due to a
fault.
3. By the control if the following event occurs: IS “EMERGENCY STOP” (V2600 0000.1) is
active
Cancelling controller enable for a moving axis/spindle:

S The spindle is braked down to zero speed according to the setting in
MD 36610: AX_EMERGENCY_STOP_TIME (duration of the braking ramp in error states)
with rapid stop. Alarm 21612 “Controller enable reset during movement” is then triggered.
S The position control loop of the axis/spindle is opened. Checkback signal to PLC with IS
“Position controller active” (V390x 0001.5) = 0 state. The timer for the controller enable
delay time (MD 36620: SERVO_DISABLE_DELAY_TIME (shutdown delay controller ena-
ble)) is also triggered.

20-372 6FC5397-1CP10-1BA0
S As soon as the actual speed has reached the zero speed range, the drive controller enable
is removed. Checkback signal to PLC with IS “Speed controller active” (V390x 0001.6) = 0
state. The controller enable for the drive is canceled at the latest after the time set in
MD 36620: SERVO_DISABLE_DELAY_TIME has expired.
Caution: If the setting for the controller enable shutdown delay is too small the servo ena-
ble will be removed even though the axis/spindle is still moving. The axis/spindle is then
stopped abruptly with setpoint 0.
S The position actual value of the axis/spindle continues to be acquired by the control.
This axis/spindle state cannot be changed until after “Reset”.
Interpolatory group of axes:
All the axes traversing within the interpolatory axis grouping are stopped as soon as the con-
troller enable signal is canceled for one of the axes.
The axes are brought to a standstill as described above. All axes in the geometry grouping
are brought to a standstill with rapid stop. Alarm 21612 “Controller enable reset during move-
ment” is also triggered. Continued processing of the NC program after this event is no longer
possible.
Signals for digital drives, to axis/spindle
Drive parameter set selection A, B, C (V380x 4001.0 to .2)

Using bit combination A, B, C, the PLC user program can select up to 8 different drive para-
meter sets on the SIMODRIVE 611UE.
Speed controller integrator disabled (V380x 4001.6)

The PLC user program inhibits the integrator of the speed controller for the drive. The speed
controller is thus changed over from PI to P controller.
Pulse enable (V380x 4001.7)

The PLC user program enables the pulses for the axis/spindle. However, the pulse enable is
only activated for the drive module if all the enable signals are present.

6FC5397-1CP10-1BA0 20-373
20.3 Signals from NCK to PLC
Drives in cyclical operation (V2700 0002.5)

The PLC is signaled via the NCK by means of a cyclical exchange of data that the availa-
ble drives have reached run-up status.
Drive ready (V2700 0002.6)

The PLC is signaled via NCK that all installed drives are ready to operate. IS “Drive Ready”
(group signal) is active on all axes and spindles.
NCK alarm is active (V2700 0003.0)

The control sends this signal to the PLC to indicate that at least one NCK alarm is active. An
enquiry can be made via the channel-specific interface (V3300 0004.7) as to whether a pro-
cessing stop has been triggered.
Ambient temperature alarm (V2700 0003.6)

The ambient temperature or fan monitoring function has responded.
NCK alarm channel-specific active (V3300 0004.6)

The control system sends this signal to the PLC to indicate that at least one NCK alarm is ac-
tive for the channel. To what extent this may influence whether the current program run will be
interrupted or aborted can be determined from IS “NCK alarm with processing stop is active”
(V3300 0004.7).
External language mode active (V3300 4001.0)

The control system sends this signal to the PLC to indicate that the active program language
used for the part program is not a SIEMENS language. A language changeover has been
made with G291.
NCK alarm with processing stop present (V3300 0004.7)

The control sends this signal to the PLC to indicate that at least one NCK alarm, which has
interrupted or aborted the current program run (processing stop), is active for the channel.
Follow-up active (V390x 0001.3)

Follow-up operation for this axis is active.
(“Follow-up”, detailed: see IS “Follow-up operation” (V380x 0001.4))
Axis/spindle standstill (V390x 0001.4)

The current velocity of the axis or actual speed of the spindle is within the range which is defi-
ned as standstill. This range is set in MD 36060: STANDSTILL_VELO_TOL (maximum velo-
city/speed for signal “Axis/spindle stationary”).

20-374 6FC5397-1CP10-1BA0
Position control active (V390x 0001.5)

The position control loop for the axis/spindle is closed; the position control function is active.
Speed control active (V390x 0001.6)

The speed control loop for the axis/spindle is closed; the speed control function is active.
Current control active (V390x 0001.7)

The current control loop for the axis/spindle is closed; the current control function is active.
Lubrication pulse (V390x 1002.0)

The IS “Lubrication pulse” is sent by the NCK and changes status once the axis/spindle has
traveled a greater distance than that set in MD 33050: LUBRICATION_DIST (travel path for
lubrication from PLC).
Signals for digital drives, from axis/spindle
Active drive parameter set A, B, C (V390x 4001.0 to .2)

The drive module sends this checkback to the PLC to indicate which drive parameter set is
currently active. With bit combination A, B, C, eight different drive parameter sets can be se-
lected by the PLC for the SIMODRIVE 611UE.
Drive ready (V390x 4001.5)

Checkback signal indicating that the drive is ready. The conditions required for traversing the
axis/spindle are fulfilled.
Integrator for n-controller disabled (V390x 4001.6)

The speed controller integrator is disabled. The speed controller has thus been switched from
PI to P controller.
Pulse enabled (V390x 4001.7)

Drive pulse enable for drive module available. The axis/spindle can now be traversed.
Motor temperature warning (V390x 4002.0).

The drive module signals to the PLC that the motor temperature has exceeded the warning
threshold. If the motor temperature remains at this level the drive will be stopped after a defi-
ned time (drive MD) and the pulse enable removed.

6FC5397-1CP10-1BA0 20-375
Heatsink temperature warning (V390x 4002.1).

The drive modules signals to the PLC that the heatsink temperature has exceeded the
warning threshold. The pulse enable will be removed for the drive module in question after
20 seconds.
Acceleration procedure completed (V390x 4002.2)

This signal confirms that the speed actual value has reached the new setpoint allowing for the
tolerance band set in drive. The acceleration procedure is thus completed. Any subsequent
speed fluctuations due to load changes will not affect the interface signal.
|Md| < Mdx (V390x 4002.3)

This signal indicates that the current torque |Md| is lower than the threshold torque Mdx set in
the drive.
|nact| < nmin (V390x 4002.4)

This signal indicates that the actual speed |nact| is lower than the set threshold speed nmin.
|nact| < nmin (V390x 4002.5)

This signal indicates that the actual speed |nact| is lower than the set threshold speed nx.
nact = nset (V390x 4002.6)

The PLC receives this signal confirming that the actual speed nact has reached the new setpo-
int allowing for the tolerance band set in drive and continues to remain within the tolerance
band.

20-376 6FC5397-1CP10-1BA0
20.4 Signals from PLC to HMI
20.4 Signals from PLC to HMI
OP key disable (V1900 5000.2)

IS “OP key disable” can be applied to disable (1 signal) or enable (0 signal) the connected
keyboard.
Program number (VB1700 1000)

A declared program number is transferred from the PLC to HMI if a NC program is selected by
the PLC. The current NC program selected can be stored via the command interface (see VB
1700 1001) and also selected again.
With SINUMERIK 802D, a program with the program name (STRING) is administered. To as-
sign a program name to a program number, the file PLCPROG.LST is available in the control.
In this assignment list, the names for a maximum of 255 programs can be declared and assi-
gned.
The use of the numbers is divided into protection areas of the programs:
1 to 100: User range (end user protection level)
101 to 200: Machine manufacturer (machine manufacturer protection level)
201 to 255: SIEMENS (SIEMENS protection level).
The PLCPROG.LST file can be edited with the minimum end user protection level set using
the following operation: System –> PLC –> Program list or by using the standard editor (Pro-
gram manager –> User cycles). The protection level for the editor should be at least the ma-
chine manufacturer protection level.
This file may also be compiled externally and loaded into the control system via the PCIN
tool/V.24 interface. The following structure specification must be observed, header entry first:
%_N_PLCPROG_LST
;$PATH=/_N_CUS_DIR
Each line contains two columns. These are separated via tabs or blanks or characters “ | ”.
The first column contains the program number, the second contains the program
name.
Example:
%_N_PLCPROG_LST
;$PATH=/_N_CUS_DIR
1|BOHR2.MPF
2|PUMPT14.MPF
54|BOHR3.MPF
“Program number” (VB 1700 1000) corresponds with the IS “Program was selected”
(V1700 2000.0) and IS “Program selection error” (V1700 2000.1).
When a program number >0 is written, program selection is started by the PLC.As soon as
the HMI detects a program number >0, it begins the internal processing of this job and sets
the program number (VB 1700 1000) to 0.
PLC waits until the acknowledgement signal from HMI is received: V1700 2000.0 or
V1700 2000.1 and evaluates this immediately. The acknowledgement signals are available for
one PLC cycle once they have been received and are then automatically deleted by the PLC
operating system.

6FC5397-1CP10-1BA0 20-377
20.5 Signals from HMI to PLC
Command (VB 1700 1001)

A command job is transferred from the PLC to the HMI.
Table 20-2
Command Action
0 none
1 Save name of the selected program
2 Select program with saved program name
“Command” (VB 1700 1001) corresponds with the IS “Execute command” (V1700 2001.0) and
IS “Program execution error” (V1700 2001.1). When the command >0 is written, the job is
started by the PLC. As soon as the HMI detects a >0 command, it begins with the internal pro-
cessing of this job and sets the command (VB 1700 101) to 0.
PLC waits until the acknowledgement signal has been reached by HMI: V1700 2001.0 or
V1700 2001.1 and evaluates this immediately. The acknowledgement signals are available for
one PLC cycle once they have been received and are then automatically deleted by the PLC
operating system.
20.5 Signals from HMI to PLC
Program has been selected (V1700 2000.0)

Successful selection of the required NC program is signaled back from the HMI to the PLC.
This signal is available for one PLC cycle. It corresponds with VB1700 1000.
Program selection error (V1700 2000.1)

Failed selection of the required NC program is signaled back from the HMI to the PLC. This
signal is available for one PLC cycle. It corresponds with VB1700 1000.
Execute command (V1700 2001.0)

Successful execution of the required command is signaled back from the HMI to the PLC.
This signal is available for one PLC cycle. It corresponds with VB1700 1001.
Command execution error (V1700 2001.1)

Failed execution of the required command is signaled back from the HMI to the PLC. This si-
gnal is available for one PLC cycle. It corresponds with VB1700 1001.

20-378 6FC5397-1CP10-1BA0
20.6 Reading/writing NC variables

It is possible to read/write NC data controlled by PLC.
20.6.1 User interface
Access to variables from the PLC side is performed via a PLC-NCK interface “Read/write NC
data”. The interface contains one global part each for job V12000000 and result V12002000
and the variable-specific parts for V120x1000 and result V120x3000.
1 to 8 values can be read or written with a read or write job (variable x: 0...7).
Job, global part:

Reading or writing
The selection of reading or writing is performed via the signal (V12000000.1).
Reading: V12000000.1 = 0 Writing: V12000000.1 = 1
Start
A job is always strated with setting the signal V12000000.0 = 1. A new job can only be strated
if the previous job has been completed, i.e. the acknowledgement signals (“Job completed”
V12002000.0 and “Error in job” V12002000.1) must be zero.
The execution of a job may take several PLC cycles and vary depending on the utilization;
thus, this function is not real-time-capable.
Note
A job already started cannot be canceled. If the Start signal is inadvertently reset before
receiving the acknowledgement, the result signals for this job are not refreshed; the job,
however, is executed.
Job, variable-specific part:

NC variables
The NC variable is selected in the variable index (VB120x1000), see Section 20.6.2
Area number, column/line index (VB120x1001 ... VB120x1005)
Various variables are declared as fields. For flexible addressing, the relevant field index must
be specified as a column and/or line index (e.g. R parameter no.).
Values:
The values to be written must be entered in the range 120x1008...11 in the S7-200 data type
specific for the appropriate variable.

6FC5397-1CP10-1BA0 20-379
If necessary, the values are converted (e.g. NCL floating point values (64-bit) into the PLC
format (32-bit) and vice versa). A loss of accuracy results from the conversion from the
64-to-32-bit REAL conversion. The maximum precision of 32bit REAL numbers is
approximately 107..
Job, global part:

The results are written by the PLC operating system; therefore, these signals can only be writ-
ten by the user.
If the job was completed without errors, the “Job completed” signal 12002000.0 is set to 1.
If an error occurs when executing a write/read job, the “Error in job” signal V12002000.1 is set.
The result signals in VB12002000 are global bits for the whole job. Possible error causes can
be here, e.g.:
S Number of variables (12000001) out of the valid range
S Variable index (12001000) out of the valid range
After evaluating the result, the “Start” signal (V12000000.0) is reset by the user. Subsequently,
the PLC operating system will reset “Job completed” or “Error in job”.
Result, variable-specific part:

A result is reported for each variable in the job.
If the write/read process was successful, “Variable valid” V120x3000.0 is set to 1; the access
result VB120x3001 is 0.
When reading, the data from VB120x3004 are entered type-specifically.
In case of error, V120x3000.0 remains “0”, and an entry is made in the access result
VB120x3001:
0 No error
3 Illegal acces to object
5 Invalid address
10 Object does not exist
Values:
When reading, the read data are to be found in the range 120x3004...7 in the S7-200 data
type specific for the appropriate variable. (If necessary, the values are converted from the
64-bit to the 32-bit REAL format.)

20-380 6FC5397-1CP10-1BA0
1 3 1 5 1 3
Start
Job 2 4 6 4
Complete
Error in
job
Fig. 20-2 Pulse diagram
Explanations regarding the pulse diagram:

1. Starting of the job by setting “Start”
(“Job completed” and “Errors in job” must be reset)
2. Job completed without errors (the results of the individual variables must still be evaluated)
3. Resetting “Start” after receiving the result
4. Signal change by PLC operating system
5. If the “Start” signal is reset inadvertently before receiving the result, the output signals are
not refreshed without influence on the internal execution of the function triggered
6. Error in job
20.6.2 NC variables
Variable cuttEdgeParam
Compensation value parameters and cutting edge list with D numbers for a tool
1st part: Compensation value parameters for a tool edge:
The meanings of the individual parameters depend on the type of the tool in question. Cur-
rently, 25 parameters are reserved for each tool edge (but only a part of them is loaded with
values). To be able for future extensions, it is not recommneded to use a fixed value of 25 pa-
rameters for calculation, but the variable value ’numCuttEdgeParams’ (variable index 2).
For a detailed description of the tool parameters, please refer to the documentation “Tool com-
pensation (W1)”, Section 14.

6FC5397-1CP10-1BA0 20-381
Variable cuttEdgeParam [r/w]

VB120x1000 1
VB120x1001 –
VW120x1002 (EdgeNo – 1) * numCuttEdgeParams + ParameterNo (WORD)
VW120x1004 T number (1...32000) (WORD)
VD120x1008 Writing: Data to NCK variable x (data type of the variables: REAL)
VD120x3004 Reading: Data to NCK variable x (data type of the variables: REAL)
Variable numCuttEdgeParams
Number of P elements of an edge
Variable numCuttEdgeParams [r]

VB120x1000 2
VB120x1001 –
VW120x1002 –
VW120x1004 –
VD120x1008 –
VW120x3004 Reading: Data to NCK variable x (data type of the variables: WORD)
Variable linShift
Translation of a settable work offset (channel-specific settable frames)
They only exist if MD 18601: MM_NUM_GLOBAL_USER_FRAMES > is 0.
There are the frame indices:
0: ACTFRAME = current resulting work offset
1: IFRAME = current settable work offset
2: PFRAME = current programmable work offset
3: EXTFRAME = current external work offset
4: TOTFRAME = current total work offset = total of ACTFRAME and EXTFRAME
5: ACTBFRAME = current total base frame
6: SETFRAME = current 1st system frame (PRESET, scratching)
7: SETFRAME = current 2nd system frame (PRESET, scratching)
8: PARTFRAME = current 3rd system frame (TCARR and PAROT with orientable tool
carrier)
9: TOOLFRAME = current 4th system frame (TOROT and TOFRAME)
10: MEASFRAME = result frame for workpiece and tool gauging
11: WPFRAME = current 5th system frame (workpiece reference points)
12: WPFRAME = current 6th system frame (cycles)
The max. frame index is 12.
The value of numMachAxes is contained in the variable with variable index 4.

20-382 6FC5397-1CP10-1BA0
Variable linShift [r]

VB120x1000 3
VB120x1001 –
VW120x1002 Frame index * numMachAxes + axis number
VW120x1004 –
VD120x1008 –
Variable numMachAxes
No. of the highest existing channel axis
If there are no gaps between channels, this corresponds to the number of existing axes in the
channel.
Variable numMachAxes [r]

VB120x1000 4
VB120x1001 –
VW120x1002 –
VW120x1004 –
VD120x1008 –
VW120x3004 Reading: Data to NCK variable x (data type of the variables: WORD)
Variable rpa
R parameters
Variable rpa [r/w]

VB120x1000 5
VB120x1001 –
VW120x1002 R number + 1
VW120x1004 –
VD120x1008 Writing: Data to NCK variable x (data type of the variables: REAL)

6FC5397-1CP10-1BA0 20-383
20.7 Signals from PLC
20.7 Signals from PLC
Start-up mode
The start-up modes are signaled via bit 0 and bit 1 (VB18001000) in the user interface.
Table 20-3
Start-up mode V1800 1000.1 V1800 1000.0

Normal powerup 0 0
Power-up with default values 0 1
Power-up with saved data 1 0

20-384 6FC5397-1CP10-1BA0
PLC User Interface 21
21.1 Address ranges
Operand identifiers Description Area

V Data V0.0 to V79999999.7 (see below)
T Timers T0 to T39
C Counters C0 to C31
I Figure: digital inputs I0.0 to I17.7
Q Figure: digital outputs Q0.0 to Q11.7
M Flag M0.0 to M383.7
SM Special flag SM0.0 to SM 0.6 (see below)
O ACCU (logic) AC0, AC1 (UDword)
O ACCU (arithmetic) AC2, AC3 (Dword)
Structure of V-range addresses:

Type identifier Range No.
Sub-area Offset addressing
(DB no.) (channel and axis No.)
10 00 0 000
symbolic (8-digit)
(10–79) (00–99) (0–9) (000–999)
Special flag – SM bit definition (read-only):

SM bits Description
SM0.0 Flag with defined ONE signal
SM0.1 Initial setting: first PLC cycle ’1’, following cycles ’0’
SM0.2 Buffered data lost – only valid in first PLC cycle (’0’ data ok, ’1’ data lost)
SM0.3 Power On: first PLC cycle ’1’, following cycles ’0’
SM 0.4 60 s cycle (alternating ’0’ for 30 s, then ’1’ for 30 s)
SM 0.5 1 s cycle (alternating ’0’ for 0.5 s, then ’1’ for 0.5 s)
SM 0.6 PLC cycle (alternating one cycle ’0’, then one cycle ’1’)

6FC5397-1CP10-1BA0 21-385
PLC User Interface
21.1 Address ranges
Note
All empty fields in the user interface are “Reserved for Siemens” and must not be written in
or evaluated!
Fields marked with “0” always receive the value “logical 0”.
References to the description of the interface signals refer to the corresponding chapters of
the description of functions and are specified by [F “Chapter number”].
Variable access rights:

[r] labels the range “read only” allowed
[r/w] labels the range “read/ write” allowed
additionally data format specification:
1: BIT
8: BYTE
16: INT/WORD
32: DINT/DWORD/REAL
without data format specification: all named data formats are readable and writable

21-386 6FC5397-1CP10-1BA0
PLC User Interface
21.2 User data
21.2 User data

21.2.1 User data 1
1000 Data 1 [r/w]

Data Block
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
User data
1000 0000
up to
User data
1000 0011
21.2.2 User data 2
1100 Data 2 [r/w]

Data Block
User data
1100 0000
up to
User data
1100 0007
21.2.3 Reading/writing NC data
Job [F20.6]
1200 NC data l/s [r/w]

Data Block PLC interface –––––> NCK
1200 0000 Write vari- Start
able
1200 0001 Number of variables
1200...1207 NC data l/s [r/w]

120x1000 Variable index
120x1001 Area number
120x1002 Line index for the NCK variable x (WORD)
120x1004 Column index for the NCK variable x (WORD)
120x1006
120x1008 Writing: Data to NCK variable x (data type of the variables: 1...4 bytes)

6FC5397-1CP10-1BA0 21-387
PLC User Interface
21.2 User data
Result [F20.6]
1200 NC data l/s [r/w]

Data Block NCK interface –––––> PLC
1200 2000 Error in job Request
completed
1200 2001
1200 2002
1200...1207 NC data l/s [r/w]

120x3000 Invalid vari-
able
120x3001 Access result
120x3002
120x3004 Reading: Data from NCK variable x (data type of the variables: 1...4 bytes)
Access result: 0 No error
3 Illegal access to object
5 Invalid address
10 Object does not exist
21.2.4 Retentive data area
1400 Retentive data [r/w]

Data Block
User data
1400 0000
up to
User data
1400 0127

21-388 6FC5397-1CP10-1BA0
PLC User Interface
21.3 User alarm
21.3 User alarm

Note: Information on PLC alarms, including configuring user alarms, can be found in:
References: “Operating Instructions”, Chapter “PLC alarms”
21.3.1 User alarm: Activation
1600 Activating alarm [r/w]

Data Block PLC interface –––––> HMI
Activation of alarm no.
1600 0000 700007 700006 700005 700004 700003 700002 700001 700000
1600 0001 700015 700014 700013 700012 700011 700010 700009 700008
1600 0002 700023 700022 700021 700020 700019 700018 700017 700016
1600 0003 700031 700030 700029 700028 700027 700026 700025 700024
1600 0004 700039 700038 700037 700036 700035 700034 700033 700032
1600 0005 700047 700046 700045 700044 700043 700042 700041 700040
1600 0006 700055 700054 700053 700052 700051 700050 700049 700048
1600 0007 700063 700062 700061 700060 700059 700058 700057 700056
21.3.2 Variable for alarm
1600 Variable for alarm [r32/w32]

Start byte
1600 1000 Variable for alarm 700000 (4 bytes)
... ...

6FC5397-1CP10-1BA0 21-389
PLC User Interface
21.4 Signals from/to HMI
21.3.3 Active alarm reaction
1600 Active alarm reaction [r]

1600 2000 PLC STOP EMER- Feed Read-in NC
GENCY disable on disable start
STOP all axes disable
1600 2001
1600 2002
1600 2003

21.4.1 Program control signals from HMI (retentive area)
1700 HMI signals [r]
Data Block HMI interface –––––> PLC
1700 0000 Test run M01 se-
feedrate lected
selected [F10.8.2]
[F10.8.2]
1700 0001 Program Feedrate
test se- override for
lected rapid tra-
[F10.8.2] verse se-
lected
[F10.8.2]
[F11.5.1]
1700 0002 Skip block
selected
[F10.8.2]
1700 0003 Measuring
in JOG ac-
tive
[F15.8]
1700 HMI signals [r/w]

1700 1000 Program selection from PLC: Program number [F20.4]
1700 1001 Command job from PLC: Command [F20.4]
1700 1002
to
1700 1003

21-390 6FC5397-1CP10-1BA0
PLC User Interface

1700 2000 Error Program
Program selected
selection [F20.5]
[F20.5]
1700 2001 Error Execute
Command command
execution [F20.5]
[F20.5]
1700 2002
to
1700 2003

1800 0000 Start Mode JOG mode MDA mode AUTO
measuring group [F15.8] [F15.8] mode
in JOG changeover [F15.8]
[F15.8] disable
[F15.8]
1800 0001 Machine
function
REF
[F15.8]
1800 Signals from PLC [r]

Data Block PLC interface
1800 1000 Power-up Power-up
with saved with default
data values
[F20.7] [F20.7]
1800 1001
1800 1002
1800 1003
1900 HMI signals [r/w]

1900 0000 Simulation
active
[F10.8.2]
1900 0001
1900 0002
1900 0003

6FC5397-1CP10-1BA0 21-391
PLC User Interface
21.4.2 General selection/status signals from HMI (retentive area)

1900 1000
1900 1001
1900 1002
Axis number for handwheel 1
1900 1003 Machine C B O
axis [F9.6.1] [F9.6.1] [F9.6.1]
[F9.6.1]
axis [F9.6.1] [F9.6.1] [F9.6.1]
[F9.6.1]
axis [F9.6.1] [F9.6.1] [F9.6.1]
[F9.6.1]
1900 1006
1900 1007
21.4.3 General selection/status signals to HMI (retentive area)
1900 Signals to operator panel [r/w]

1900 5000 OP key dis-
able
[F20.4]
1900 5001 Update tool
list
[F14.7]
1900 5002 Enable tool
measuring
in JOG
[F15.8]
1900 5003
1900 5004
... T number for tool measuring in JOG (DINT)
1900 5007 [F15.8]

21-392 6FC5397-1CP10-1BA0
PLC User Interface
21.5 Auxiliary function transfer from NC channel
2500 Auxiliary functions from NCK channel[r]

2500 0000
up to
2500 0003
2500 0004 M fcts. 5 M fcts. 4 M fcts. 3 M fcts. 2 M fcts. 1
Change Change Change Change Change
[F13.8] [F13.8] [F13.8] [F13.8] [F13.8]
2500 0005
2500 0006 S fcts. 1
change
[F13.8]
2500 0007
2500 0008 T function 1
change
[F13.8]
2500 0009
2500 0010 D function
1 change
[F13.8]
2500 0011
2500 0012 H fcts. 3 H fcts. 2 H fcts. 1
change change change
[F13.8] [F13.8] [F13.8]
2500 0013
up to
2500 0019
21.5.1 Decoded M signals: (M0–M99)
2500 M functions from NCK channel[r]

Dynamic M functions [F13.8]
2500 1000 M7 M6 M5 M4 M3 M2 M1 M0
2500 1001 M15 M14 M13 M12 M11 M10 M9 M8
2500 1002 M23 M22 M21 M20 M19 M18 M17 M16
...

6FC5397-1CP10-1BA0 21-393
PLC User Interface

2500 1012 M99 M98 M97 M96
2500 1013
up to
2500 1015
Remarks: The signals are output for the duration of a PLC cycle.
21.5.2 Transferred T functions
2500 T functions from NCK channel[r]

Start byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
2500 2000 T function 1 (DINT) [F13.8]
2500 2004
to
2500 2007
21.5.3 Transferred M functions
2500 M functions from NCK channel[r]

2500 3000 M function 1 (DINT) [F13.8]
2500 3004 Extended address of M function 1 (byte)
2500 3008 M function 2 (DINT) [F13.8]
2500 3016 M function 3 (DINT) [F13.8]
2500 3024 M function 4 (DINT) [F13.8]
2500 3032 M function 5 (DINT) [F13.8]

21-394 6FC5397-1CP10-1BA0
PLC User Interface
21.5.4 Transferred S functions
2500 S functions from NCK channel[r]

2500 4000 S function 1 (REAL) [F13.8]
2500 4004 Extended address of S function 1 (byte)
2500 4008 S function 2 (REAL) [F13.8]
2500 4012 Extended address of S function 2 (byte)
21.5.5 Transferred D functions
2500 D functions from NCK channel[r]

2500 5000 D function 1 (DINT) [F13.8]
2500 5004
21.5.6 Transferred H functions
2500 H functions from NCK channel[r]

2500 6000 H function 1 (REAL) [F13.8]
2500 6004 Extended address for H function 1 (INT) [F13.8]
2500 6008 H function 2 (REAL)
2500 6016 H function 3 (REAL) [F13.8]

6FC5397-1CP10-1BA0 21-395
PLC User Interface
21.6 NCK signals
21.6 NCK signals
2600 General signals to NCK [r/w]

2600 0000 Protection level [F20.2] Acknowl- EMER-
edge GENCY
EMER
EMER- STOP
4 5 6 7 GENCY [F1.5]
STOP
[F1.5]
2600 0001 Request Request INC inputs

axis axis in mode
distances- actual group
to-go values range
[F21.12] [F21.12] active 1)
[F9.6.2]
2600 0002
2600 0003
Remarks: 1) see operating mode signals
2700 General signals from NCK [r]

2700 0000 EMER-
GENCY
STOP
active
[F1.5]
2700 0001 INCH Probe 1
dimension activated
system [F15.7]
[F3.6]
2700 0002 Drive Drives in

ready cyclical
[F20.3] operation
[F20.3]
2700 0003 Air temper- NCK alarm
ature alarm is active
[F20.3]
[F20.3]

21-396 6FC5397-1CP10-1BA0
PLC User Interface
21.6 NCK signals
3000 Operating mode signals to NCK [r/w]

Reset Mode Operating mode
[F10.8.1] group
3000 0000 changeover JOG MDI AUTOM.
disable
[F10.8.1] [F10.8.1] [F10.8.1]
[F10.8.1]
Machine function
3000 0001 REF Teach In
[F10.8.1]
Machine function 1) [F9.6.2]
3000 0002 Continuous INCvar INC10 000 INC1000 INC100 INC10 INC1
traversal
3000 0003
Remarks:
1) Machine function in order to use machine function signals in VB3000 0002, signal “INC inputs in mode
group range active” (V2600 0001.0) must be set to “1”
Machine function INC10 000 is not supported by all machine control panels.
3100 Operating mode signals from NCK [r]

Active mode
3100 0000 802- JOG MDI AUTOM.
READY [F10.8.1] [F10.8.1] [F10.8.1]
[F10.8.1]
Active machine function
3100 0001 REF Teach In
[F10.8.1]
3100 0002
3100 0003

6FC5397-1CP10-1BA0 21-397
PLC User Interface
21.7 Channel signals

21.7.1 Signals to NC channel
Control signals to NC channel
3200 Signals to NCK channel [r/w]

3200 0000 Activate dry M01 Single block
run feed 4)
Activate
[F11.5.1] [F10.8.2] Activate
[F10.8.2]
3200 0001 Activate Activate
program referencing
test [F8.6]
[F10.8.2]
3200 0002 Activate
skip block
[F10.8.2]
3200 0003
32000004 Feedrate override2) [F11.5.1]
H G F E D C B O
3200 0005 Rapid traverse override3) [F11.5.1]
H G F E D C B O
3200 0006 Feedrate Rapid tra- Program Delete Read-in Feedrate
override1) verse over- level abort distance-to- disable disable
active ride active [F10.8.2] go [F10.8.2] [F11.5.1]
[F11.5.1] [F11.5.1] [F20.2]
3200 0007 NC stop NC stop NC Stop at NC Start NC Start

axes plus [F10.8.2] block limit disable
spindle [F10.8.2] [F10.8.2]
[F10.8.2]
[F10.8.2]
3200 0013 Do not dis- De-activate

able workpiece
tool counter
[F14.4] [F14.7]
Remarks:
1)+ Feedrate override active Even if the feedrate override is not active, (=100%) the 0% position still functions.
2)+ Feedrate override 31 positions (Gray code)
3)+ Rapid override 31 positions (Gray code)
4)+ Single block Select single block type selection (SBL coarse/SBL fine) via softkey (see “User’s Guide”)

21-398 6FC5397-1CP10-1BA0
PLC User Interface
Control signals to geometry axes (axes in WCS)
3200 Signals to NCK channel [r/w]

Geometry axis 1 (axis 1 in WCS)
3200 1000 Traversing keys Rapid tra- Traversing Feedrate Activate handwheel
verse over- key lock stop
+ – ride 2 1
[F9.6.3] [F11.5.1]
[F9.6.3] [F9.6.3] [F9.6.3] [F9.6.3] [F9.6.3]

3200 1001 Machine function 1) [F9.6.3]
Continuous INCvar INC10 000 INC1000 INC100 INC10 INC1
traversal [
3200 1002
3200 1003
verse over- key lock stop[
+ – ride [F11.5.1] 2 1
[F9.6.3]
[F9.6.3] [F9.6.3] [F9.6.3] [F9.6.3] [F9.6.3]

traversal
3200 1006
3200 1007
verse over- key lock stop
+ – ride 2 1
[F9.6.3] [F11.5.1]
[F9.6.3] [F9.6.3] [F9.6.3] [F9.6.3] [F9.6.3]

traversal
3200 1010
3200 1011
Remarks:
1) Machine function specification of machine function in VB3200 1001, VB3200 1005, VB3200 1009, only if
signal “INC inputs in mode group range active” (V2600 0001.0) is not set.

6FC5397-1CP10-1BA0 21-399
PLC User Interface
21.7.2 Signals from NC channel
Status signals from NC channel
3300 Signals from NCK channel [r]

3300 0000 Last action M0/M1 Approach Action
block active block ac- block active
active [F10.8.2] tive [F10.8.2]
[F10.8.2] [F10.8.2]
3300 0001 Program Trans- M2 / M30 Block Revolu- Referenc-
test active formation active search tional feed- ing active
[F10.8.2] active [F10.8.2] active rate active [F8.6]
[F18.6] [F10.8.2] [F11.5.1]
3300 0002
Channel status Program status
3300 0003 Reset interr- active Aborted interr- Stopped Running
[F10.8.2] upted [F10.8.2] [F10.8.2] upted [F10.8.2] [F10.8.2]
[F10.8.2] [F10.8.2]
3300 0004 NCK alarm Channel-sp all axes all axes
with proc- ecific NCK stationary referenced
essing stop alarm is ac- [F12.7] [F8.6]
present tive
[F20.3] [F20.3]
3300 0005
3300 0006
3300 0007
Status signals to geometry axes (axes in WCS)

3300 1000 Motion command Handwheel active
plus minus 2 1
[F9.6.3] [F9.6.3] [F9.6.3] [F9.6.3]
3300 1001 Active machine function [F9.6.3]
traversal
3300 1002
3300 1003
plus minus 2 1
[F9.6.3] [F9.6.3] [F9.6.3] [F9.6.3]
traversal

21-400 6FC5397-1CP10-1BA0
PLC User Interface
3300 1006
3300 1007
plus minus 2 1
[F9.6.3] [F9.6.3] [F9.6.3] [F9.6.3]
traversal
3300 1010
3300 1011

3300 4000 G00 active
3300 4001 Workpiece External
setpoint language
reached mode
[F10.8.2] active
[F20.3]
3300 4002
3300 4003 v
G functions from NC channel

3500 0000 Active G function of group 1
3500 00.. Active G function of group ...
Note:
With SINUMERIK 802D, G group 2 is transferred in VB3500 0001 with values
0: – no group 2 G command is active,
1: G4, 2: G63, 3: G74, 4: G75, 11: G147, 12: G247, 13: G347,
14: G148, 15: G248, 16: G348 (other values: not available in SINUMERIK 802D)
Other settings are possible with MD 22510: see Section 21.3

When the NC program terminates or is aborted, the last status of the groups is retained. The
meaning of the G commands is explained in
References: “Operation and Programming”, Section “Overview of instructions”
Note: It cannot be guaranteed that a PLC user program will have a block-synchronous connection
between the active NC block and the applied G codes at any given time. The connection does not
exist, for instance, if temporally short blocks are used with continuous path mode (G64).

6FC5397-1CP10-1BA0 21-401
PLC User Interface
21.8 Axis/spindle signals

21.8.1 Transferred M/S functions, axis-specific
3700 ... 3704 M/S functions [r]
Data block PLC interface –––––> NCK
370x 0000 M function for spindle (DINT) [F5.10]
370x 0004 S function for spindle (REAL) [F5.10]
21.8.2 Signals to axis/spindle
Common signals to axis/spindle
3800 ... 3804 Signals to axis/spindle [r/w]

Feedrate override [F11.5.2]
380x 0000 H G F E D C B O
380x 0001 Override Position Follow-up Axis/ Sensor for Acknowl-
active measuring mode spindle fixed stop edge fixed
[F11.5.2] system 1 [F20.2] disable [F17.7] stop
[F20.2] [F20.2] reached
[F17.7]
380x 0002 Clamping in Distance-to Controller
progress -go/spindle enable
[F2.7] reset [F20.2]
[F5.10]
380x 0003 Velocity/ Enable
spindle approach to
speed fixed stop
limiting [F17.7]
[F2.7]
Traversing keys Rapid Traversing Feedrate Activate handwheel
traverse key lock stop
380x 0004 plus minus override 2 1
[F9.6.4] Spindle stop
[F9.6.4] [F9.6.4] [F9.6.4] [F9.6.4] [F9.6.4]
[F11.5.2]
380x 0005 Machine function1) [F9.6.3]
traversal
380x 0006
up to
380x 0011
Remarks: 1) Machine function specification of machine function in VB380x 0005, only if signal “INC inputs
in mode group range active” (V2600 0001.0) is not set.

21-402 6FC5397-1CP10-1BA0
PLC User Interface
Signals to axis
3800 ... 3804 Signals to axis [r/w]

Delay. Ref. 2nd software limit switch Hardware limit switch
pt.
pt
380x 1000 approach plus minus plus minus
(axis) [F2.7] [F2.7] [F2.7] [F2.7]
[F8.6]
380x 1001
up to
380x 1003
Signals to spindle
3800 ... 3804 Signals to spindle [r/w]

Gear Actual gear stage
380x 2000 changed
h d C B O
(Spindle) [F5.10] [F5.10] [F5.10] [F5.10]
Invert Resynchro- Feedrate
M3/M4 nize spindle override
380x 2001 [F5.10] during po- valid for
(spindle) sitioning 1 spindle
[F5.10] [F11.5.2]
Setpoint direction of Oscillation Oscillation
rotation p
speed via PLC
380x 2002 Left Right [F5.10] [F5.10]
(Spindle) [F5.10] [F5.10]
380x 2003 Spindle override [F11.5.2]
(Spindle) H G F E D C B O
Signals to drive
3800 ... 3804 Signals to axis/spindle [r/w]

380x 4000
380x 4001 Pulse en- Speed Parameter set selection [F20.2]

able controller
[F20 2]
[F20.2] integrator
disable C B O
[F20.2]
380x 4002
380x 4003

6FC5397-1CP10-1BA0 21-403
PLC User Interface
21.8.3 Signals from axis/spindle
General signals from axis/spindle
3900 ... 3904 Signals from axis/spindle [r]

Data block NCK interface –––––> PLC
Position reached Refe- Encoder p
Spindle/
390x 0000 with exact with exact renced/syn-
d/ limit
li it no axis
i
stop, fine stop, chronized 1 frequency [F5.10]
coarse [F8.6] exceeded 1
[F12.7]
[F12.7] [F2.7]
390x 0001 Current Speed Position Axis/ Follow up
controller control loop controller spindle mode
active active active stationary active
[F20.3] [F20.3] [F20.3] (n < nmin) [F20.3]
[F20.3]
390x 0002 Fixed Activate Measure-
stop travel to ment active
reached fixed stop [F15.7]
[F17.7] [F17.7]
390x 0003
Motion command Handwheel active
390x 0004 p
plus minus 2 1
[F9.6.4] [F9.6.4] [F9.6.4] [F9.6.4]
Active machine function [F9.6.4]
390x 0005 Continuous INCvar INC10 000 INC1000 INC100 INC10 INC1
390x 0006
up to
390x 0011
Signals from axis
3900 ... 3904 Signals from axis [r]

390x 1000
390x 1001
390x 1002 Lubrication
pulse
[F20.3]
390x 1003

21-404 6FC5397-1CP10-1BA0
PLC User Interface
Signals from spindle
3900 ... 3904 Signals from spindle [r]

Gearbox Set gear stage
390x 2000 changeover C B O
(Spindle) [F5.10] [F5.10] [F5.10] [F5.10]
390x 2001 Actual Spindle Setpoint Setpoint Speed limit
(Spindle) direction of In the set- speed speed exceeded
rotation point range increased limited [F5.10]
clockwise [F5.10] [F5.10]
[F5.10]
[F5.10]
Active spindle mode g
Rigid Const. cut-
390x 2002 Control Oscillation Positioning ttapping
i titing velocity
l it
mode mode mode [F5.10] active
(Spindle)
[F5.10] [F5.10] [F5.10] [F5.10]
390x 2003
Signals from drive
3900 ... 3904 Signals from axis/spindle [r]

390x 4000
390x 4001 Pulses Speed con- Drive Active parameter set [F20.3]
enabled troller inte- ready
[F20.3]
[F20 3] grator dis- [F20.3]
[F20 3]
abled C B O
[F20.3]
390x 4002 nact = nset nact<nx nact<nmin Md<Mdx p p
Ramp-up Temperature pre-warning
[F20.3] [F20.3] [F20.3] [F20.3] completed
l t d Heatsink Motor
[F20.3] [F20.3] [F20.3]
390x 4003

6FC5397-1CP10-1BA0 21-405
PLC User Interface
21.9 PLC machine data
21.9 PLC machine data

21.9.1 INT values (MD 14510 USER_DATA_INT)
4500 Signals from NCK [r16]

Start byte
4500 0000 Int values (WORD/ 2 Byte)
up to
21.9.2 HEX values (MD 14512 USER_DATA_HEX)

Byte
4500 1000 Hex value (BYTE)
up to
21.9.3 FLOAT values (MD 14514 USER_DATA_FLOAT)

Start byte
4500 2000 Float value (REAL/ 4 Byte)
up to

21-406 6FC5397-1CP10-1BA0
PLC User Interface
21.10 Reading and writing PLC variables
21.9.4 User alarm: Configuration (MD 14516 USER_DATA_PLC_ALARM)

Byte
4500 3000 Alarm reaction/ deletion criterion Alarm 700000
up to
Note: Information on PLC alarms, including configuring user alarms, can be found in:
References: “Installation and Start-Up Guide”, Section “PLC alarms”
21.10 Reading and writing PLC variables
4900 PLC variables [r/w]

Data block PLC interface
Byte
4900 0000 Offset[0]
4900 0001 Offset[1]
up to
4900 0511 Offset[511]
Note: The application programmers of NCK and PLC themselves are responsible for the or-
ganization of this data area. Data type, position offset and meaning of the variables must be
agreed. The memory range limits per data type must be observed (1, 2 or 4 byte types).
Further information can be found in:
References: “Operation and Programming”, Section “Reading and writing PLC variables”

6FC5397-1CP10-1BA0 21-407
PLC User Interface
21.11 Tool management functions from NC channel
21.11 Tool management functions from NC channel
Change signals for tool management functions
5300 Tool management functions [r]

Data block NCK interface NCK PLC –––––> PLC
Tool limit Tool warn-
5300 0000 value ing limit
reached reached
[F14.7] [F14.7]
Transferred tool management functions
5300 Tool management functions [r32]

Byte
5300 1000 T number for tool warning limit (DINT) [F14.7]
5300 1004 T number for tool limit value (DINT) [F14.7]

21-408 6FC5397-1CP10-1BA0
PLC User Interface
21.12 Axis actual values and distances-to-go
5700 ... 5704 Signals from axis/spindle [r32]

Byte
570x 0000 Axis actual value (REAL)
570x 0004 Axis distance-to-go (REAL)
Note: Axis actual values and distances-to-go can each be requested separately:
– V2600 0001.1 Request for axis actual values
– V2600 0001.2 Request for axis distances-to-go
Once the respective request has been set, these values are provided by NCK for all axes.

6FC5397-1CP10-1BA0 21-409
PLC User Interface
Notes

21-410 6FC5397-1CP10-1BA0
Various Machine Data 22
This Chapter describes machine data which are of general importance but for which there are
no specific chapters in this description of functions.
22.1 Display machine data
202 FIRST_LANGUAGE
MD number Foreground language
Meaning: The language (1 or 2) which is to be automatically active after each system startup is set in the
machine data.
Two languages are available simultaneously in SINUMERIK 802D. Languages other than those
included in the control ex works can be loaded.
It is possible to temporarily switch to a second language using a softkey in the Diagnosis area.
After power ON the predefined language set in MD is again active.
References “Operation and Programming”
203 DISPLAY_RESOLUTION
MD number Display resolution
Meaning: This machine data defines the number of places after the decimal point in the position display for
linear axes in metric systems as well as in general for rotary axes.
Spindle positions are treated as rotary axis positions.
The position is displayed with 10 symbols max. including the plus/minus sign and the decimal
point. A plus sign is not displayed.
All 3 positions after the decimal point are displayed per default.å
MD value=3: Display resolution = 10–3 [mm] or [degrees].
Related to .... MD 10200: INT_INCR_PER_MM or MD 10210: INT_INCR_PER_DEG
204 DISPLAY_RESOLUTION_INCH
MD number Display resolution for the INCH dimension system
Meaning: This machine data specifies the number of places after the decimal point for linear axes for Inch
dimension systems.
The position is displayed with max. 10 characters including the plus/minus sign and the decimal
All 4 positions after the decimal point are displayed per default.å
MD value=4: Display resolution = 10 –4 [inch]
The display is retained according to MD 203 for rotary axes and spindle positions.
Related to .... MD 10200: INT_INCR_PER_MM, MD 203: DISPLAY_RESOLUTION

6FC5397-1CP10-1BA0 22-411
22.2 General machine data
205 DISPLAY_RESOLUTION_SPINDLE
MD number Display resolution for spindle values
Meaning: This machine data specifies the number of places after the decimal point of the spindle speed
display.
The values are displayed with 10 symbols max. including the plus/minus sign and the decimal
1 position after the decimal point is displayed per default.å
MD value=1: Display resolution = 10–1
10000 AXCONF_MACHAX_NAME_TAB[0]...[4]
MD number Machine axis name
Default setting: Minimum input limit: one letter Maximum input limit: 15 characters,
Turning: (“X1”, “Z1”, “SP”, “A1”, “B1”) starting with a letter,
MIlling: (“X1”, “Y1”, “Z1”, “SP”, “A1”) 16th character reserved (end of string)
Meaning: The name of the machine axis is entered in this MD
The preferred axis label (name) should be used comprising a valid address letter
(A, B, C, Q, U, V, W, X, Y, Z), followed by an optional, numerical expansion (1–99).
The selected machine axis label (name) must differ from the label (name) of geometry axes (X,
Y, Z) and additional channel axes (MD 20080: AXCONF_CHANAX_NAME_TAB if a transfor-
mation is planned (e.g.: TRANSMITT).
Comment: Transformation for SINUMERIK 802D, SW release P1, transformations are not
available.
A “free” entered machine axis label (axis name) may not be a name, address, keyword or
pre-defined label or name that is already being used in the control or is reserved for other func-
tions (e.g.: SPOS, DIAMON, ...).
Note: Not all the SINUMERIK control system functions are documented for 802D. Use of a
free axis identifier is therefore conditional.
Special cases, errors, ... ... We recommend the following for machine axis identifiers:
X1, Y1, Z1, U1, V1, W1, Q1 for linear axes,
A1, B1, C1 for rotary axes
Related to .... MD 20060: AXCONF_GEOAX_NAME_TAB (geometry axis identifier)
MD 20080 :AXCONF_CHANAX_NAME_TAB (channel axis identifier)
10074 PLC_IPO_TIME_RATIO
MD number PLC task factor for main run (IPO)
Meaning: Division ratio between IPO and PLC tasks.
A value of 2 means, for example, that the PLC task is processed in every second IPO cycle
only. The PLC cycle time therefore equals 2 IPO times. More runtime is therefore available for
the other tasks.
The PLC runtime must not exceed this PLC cycle time, or a PLC STOPP alarm will be triggered.

22-412 6FC5397-1CP10-1BA0
10136 DISPLAY_MODE_POSITION
MD number Display mode for the actual position in the WCS
Meaning: States how the position and the distance to go are displayed in the WCS.
0: Display as in P5 and earlier

1: In principle the actual value display at the end of the block is equal to the programmed end
point, irrespective of the actual position of the machine (e.g. as a consequence of the tool
radius compensation). The distance to go is equal to the actual residual distance to be traver-
sed. The result is that the displayed actual position must be equal to the end position to be
displayed minus the residual distance, irrespective of the actual position of the machine.
If the block end points are changed by chamfers, radii, contour definitions, spline blocks or
SAR as compared to the NC program, these changes are mirrored in the display as if they
had been programmed.
This does not apply to changes resulting from tool radius compensation or smoothing.
11210 UPLOAD_MD_CHANGES_ONLY
MD number MD backup of changed MD only
Default setting: 0x0F Minimum input limit: 0x00 Maximum input limit: 0x0FF
Meaning: Selection of differential MD upload:
Bit0(LSB) Effectiveness of the differential upload for TEA files (machine data files)
0: All data are output
1: only the values changed as compared to the compiled MD are output
Bit1 Effectiveness of the differential upload for INI files
0: All data are output
1: only the values changed as compared to the compiled MD are output
Bit2 change of a field element
0: complete arrays are output
1: only changed field elements of an array are output
Bit3 R parameter (for INI files only)
0: All R parameters are output
1: only R parameters unequal to ’0’ are output
Bit4 frames (for INI files only)
0: All frames are output
1: only frames are output which are not zero frames.
Bit5 tool data (cutting edge parameter) (for INI files only)
0: All tool data are output
1: only tool data unequal to ’0’ are output.
14510 USER_DATA_INT[0]...[31]
MD number User data (INT)
Meaning: User machine data, evaluation in PLC (displayed as whole number, decimal)
14512 USER_DATA_HEX[0]...[31]
MD number User data (HEX)
Default setting: 0 Minimum input limit: 0 Maximum input limit: 0x0FF
Meaning: User machine data, evaluation in PLC (display in HEX format) 1)

6FC5397-1CP10-1BA0 22-413
22.3 Channel-specific machine data
14514 USER_DATA_FLOAT[0]...[7]
MD number User data (FLOAT)
Default setting: 0.0 Minimum input limit: –3.40e38 Maximum input limit: 3.40e38
Meaning: User machine data, evaluation in PLC (floating point format, restricted to 32Bit IEEE format in
PLC)
14516 USER_DATA_PLC_ALARM[0]...[31]
MD number User data (HEX)
Meaning: User data, evaluation in PLC (display in HEX format) 1)
20050 AXCONF_GEOAX_ASSIGN_TAB[0]...[2]
MD number Assignment between geometry axis and channel axis
Default setting: Minimum input limit: 0 Maximum input limit: 5
Turning: (1, 0, 2) (0 means that the geometry axis is not
Milling: (1, 2, 3) assigned to any channel axis)
Meaning: This MD assigns a geometry axis to a channel axis.
The assignment must be made for all 3 geometry axes (X,Y,Z). If a geometry axis is not assigned,
the value 0 should be entered. The geometry axis is therefore not available and cannot be pro-
grammed, e.g. if the second geometry axis is not required for the “turning” technology Y –> entry:
value 0 (see default setting for turning).
Special cases, errors, ... ... It is advisable to assign the first channel axes to the geometry axes.
20070 AXCONF_MACHAX_USED[0]...[4]
MD number Machine axis number valid in channel
Turning: (1, 2, 3, 0, 0) (0 means that the geometry axis is not
Milling: (1, 2, 3, 4, 5) assigned to any channel axis)
Meaning: This MD assigns a machine axis to a channel axis.
SINUMERIK 802D has 5 channel axes.
Channel axis identifiers for the axes activated in the channel must be specified in MD 20080: AX-
CONF_CHANAX_NAME_TAB. The axes can be programmed.
A machine axis that has not been assigned to a channel axis is not active i.e. no axis control, no
display on the screen.
Special cases, errors, ... ... A channel axis and therefore indirectly a machine axis must be assigned to each geometry axis to
be programmed. The remaining axes (besides the geometry axes) in the channel are additional
axes – also programmable.

22-414 6FC5397-1CP10-1BA0
20070 AXCONF_MACHAX_USED[0]...[4]
MD number Machine axis number valid in channel
Application example(s) Example of assigning the machine axis (MA) to the channel axes:
AXCONF_MACHAX_USED [0] = 3 ;3rd MA is 1st axis in the channel
AXCONF_MACHAX_USED [1] = 1 ;1st MA is 2nd axis in the channel
AXCONF_MACHAX_USED [2] = 5 ;5th MA is 3rd axis in the channel
AXCONF_MACHAX_USED [3] = 0 ; no assignment
Note: Leave no spaces!, Example of programming error:
AXCONF_MACHAX_USED [0] = 1 ;1st MA is 1st axis in the channel
AXCONF_MACHAX_USED [1] = 2 ;2nd MA is 2nd axis in the channel
AXCONF_MACHAX_USED [2] = 0 ;space in list ...
AXCONF_MACHAX_USED [3] = 3 ;... of the channel axes
Related to .... MD 20080: AXCONF_CHANAX_NAME_TAB[0]...[4] (channel axis identifier)
20080 AXCONF_CHANAX_NAME_TAB[0]...[4]
MD number Channel axis name
Default setting: Minimum input limit: Maximum input limit: 15 characters,
Turning: (“X”, “Z”, “SP”, “ ”, “ ”) one letter or blank starting with a letter,
Milling: (“X”, “Y”, “Z”, “SP”, “A”) 16th character reserved (end of string)
Meaning: In this MD you can set the name of the channel axis.
The channel axis is displayed with this identifier in the WCS. This identifier is also written in the
program.
Generally, the first two or three channel axes are used as geometry axes (see also MD 20050:
AXCONF_GEOAX_ASSIGN_TAB). The remaining channel axes are defined as special axes.
SINUMERIK 802D has 5 channel axes.
Special cases, errors, ... ... We recommend the following for the channel axis identifiers:
X, Y, Z, U, V, W, Q for linear axes,
A, B, C for rotary axes
If you decide to use names other than those recommended, follow the rules for creating axis identi-
fiers (see MD 10000: AXCONF_MACHAX_NAME_TAB).
22510 GCODE_GROUPS_TO_PLC
MD number G functions to PLC
2, 0, 0, 0, 0, 0, 0, 0
Meaning: Specification of the G code group that are output to the NCK–>PLC interface.
The interface is updated with every block change after RESET. After the program is started the
initial settings of the G groups are displayed.
In SINUMERIK 802D, only G group 2 with G4, G63, G74, G75, ...
is output per default. A maximum of 8 groups can be output. The special protection level 1/1 for
changing the MD setting, however, should be observed.
Note: It is not guaranteed that a PLC user program

has a block-synchronous relation between the active NC block and
the adjacent code G code at any time. This, for example, is the case when using
continuous-path mode (G64) with short blocks.
References: “Operation and Programming”, Section “Overview of instructions”

6FC5397-1CP10-1BA0 22-415
22.4 Axis-specific machine data
27800 TECHNOLOGY_MODE
MD number Technology in channel
Turning: 1
Milling: 0
Meaning: Selection of the technology for display and operating purposes (HMI)
0: Milling
1: Turning
This makes technology-dependent displays and softkeys available in the HMI.
22.4 Axis-specific machine data
30600 FIX_POINT_POS
MD number Fixed value positions of axes with G75
Meaning: This machine data is used to specify the fixed point position for an axis that is approached when
G75 is programmed.
Application example(s) Travel to fixed point: G75 X1=0
The machine axis identifier is programmed here! A dummy value, here 0, must be defined for
the axis.
References “Operation and Programming”l
33050 LUBRICATION_DIST
MD number Path for lubrication pulse PLC signal
Default setting: 100 000 000 Minimum input limit: 0.0 Maximum input limit: ***
Meaning: Path for triggering the lubrication pulse.
The status of the axis-specific IS: “Lubrication pulse” (V390x 1002.0) is changed according to
the specified path of the respective axis. This enables travel-dependent control of a lubrication
device for one axis by the PLC user program.
The path is added up after POWER ON.
Related to .... IS: “Lubrication pulse” (V390x 1002.0)

22-416 6FC5397-1CP10-1BA0
Index
Index
A D
Acceleration, 9-163 D functions, 14-281
Acceleration profiles, 4-77 Display resolution, 3-49
Abrupt acceleration changes, 4-77 Dry run feedrate, 10-200
Acceleration with jerk limitation, 4-77
Actual values, 2-28
Actual-value processing, 3-61
Actual-value resolution, 3-61
E
Actual-value system, 3-55 EMERGENCY STOP
Assignment between probe type and application, Acknowledgment, 1-17
15-296 Interface, 1-16
Auxiliary function groups Sequence, 1-16
predefined, 13-268 Encoder monitoring functions, 2-29
ungrouped, 13-268 Encoder frequency, 2-29
Auxiliary function output Zero marks, 2-30
Block change, 13-267 Exact stop, 12-255
Block search, 13-269 Exact stop criteria, 12-255
Auxiliary functions, 13-265 Exact stop coarse, 2-23
Description, 13-270 Exact stop fine, 2-24
Axis monitoring functions Exact stop criterion, 12-256
Actual velocity, 2-28 Exact stop limit fine, 2-23
Clamping, 2-25 Example of probe functional test, 15-299
Contour, 2-22
Positioning monitoring, 2-23
Speed setpoint, 2-26
Zero-speed, 2-25
F
Axisrelated jerk limitation, 4-79 Feed disable, 11-240
Feed/spindle stop, 11-240
Feedrate override, 9-163
Feedrate override switch, 11-241
B Feedrates
Backlash compensation Feed disable, 11-240
Negative backlash, 16-310 Feed override, 11-241
Positive backlash, 16-310 Feed/spindle stop, 11-240
Basic system, 3-51 Feedrate control, 11-239, 11-240
Conversion, 3-51 Path feedrate F, 11-233
Manual changeover, 3-53 Rigid tapping without compensation
Bi-directional probe, 15-297 chuck G331/G332, 11-237
Block change point, 12-256 Spindle override, 11-242
Block search, 10-201, 13-269 Tapping with compensation chuck G63, 11-237
Thread cutting G33, 11-235
Following error compensation, 16-316
Parameters, 16-317
C
Calculation resolution, 3-49
Channel, 10-185
Channel status, 10-195
G
Closed-loop control, 3-64 General, 15-296
Commands MEAS, MEAW, 15-298
Compensation, 16-309
Compensation table, 16-313
Continuous jogging, 9-165
H
Continuous-path mode, 12-256 Handwheel, Traversal in JOG, 9-167
Contour violation, 2-33 Hardware limit switches, 2-31, 9-164
Cyclical signal exchange, 20-370

6FC5397-1CP10-1BA0 Index-417
Index
I M
Implicit exact stop, 12-256 Machine data, 22-411
Inch measuring system, 3-51 Manual and Handwheel Travel (H1), 9-161
Incremental jogging, 9-166 Measuring accuracy, 15-299
Input resolution, 3-49 Metric measuring system, 3-51
Interface signals Mode change, 10-187
Activate referencing, 8-157 Monitoring static limits, 2-31
Active spindle control mode, 5-123 Mono-directional probe, 15-297
Active spindle mode oscillation mode, 5-123 Motion monitoring functions, 2-22
Active spindle positioning mode, 5-123 Multidirectional probe (3D), 15-296
Actual direction of rotation clockwise, 5-122
Actual gear stage A to C, 5-118
All axes referenced, 8-157
Change gear stage, 5-121
N
Clamping in progress, 2-43 Normalization of machine and setting data, 3-49
Dry run feedrate selected, 11-247 Notes for the reader, iv
Encoder limit frequency exceeded, 2-44
Feedrate override selected for rapid traverse, 11-248
Gear switchover, 5-117
O
Hardware limit switches plus and minus, 2-44
Invert M3/M4, 5-118 Operating modes, 10-188
Oscillation speed, 5-119 Interlocks, 10-190
Oscillation via PLC, 5-120 Monitoring, 10-189
Probe activated, 15-307 Overload factor, 12-258
Re-synchronize spindle during positioning, 5-118
Reference point approach delay, 8-158
Referencing active, 8-157 P
Revolutional feedrate active, 11-248
Rigid tapping active (no compensation), 5-124 Parameter sets of the position controller, 3-64
Second software limit switch plus or minus, 2-44 Part program interruption, 10-192
Set gear stage A to C, 5-121 Path feed, 3-48
Setpoint direction of rotation, counter-clockwise/ Path-related jerk limitation, 4-78
setpoint direction of rotation, clockwise, 5-119 Physical quantities, 3-49
Setpoint speed increased, 5-122 PLC service display, 15-299
Setpoint speed limited, 5-123 PLC user interface, 21-385
Speed limit exceeded, 5-123 Axis/spindle signals, 21-402
Spindle in setpoint range, 5-122 Channel signals, 21-398
Spindle reset/Delete distance-to-go, 5-117 PLC machine data, 21-406
Spindle/no axis, 5-120 User alarm, 21-389
Velocity/spindle speed limiting, 2-43 User data, 21-387
Interpolatory compensation PLC/NCK interface, 20-369
Linear interpolation, 16-312 Position control, 3-65
Methods, 16-311 Position control direction, 2-28
Position control loop, 3-64
Position controller gain, 2-24
Positioning window large, 2-24
J Probe connection, 15-297
Jerk limit, 12-258 Probe functional test, 15-299
Jerk limiting, 12-258 Probe types, 15-296
Program control, 10-194
Program mode, 10-185, 10-191
Program status, 10-194
L Program test, 10-198
Limit switch monitoring, 2-31
Linear axis, with rotary encoder on motor, 3-63
LookAhead, 12-256, 12-260

Index-418 6FC5397-1CP10-1BA0
Index
R Software limit switch, 2-32, 6-131, 9-164

Speed, Closed-loop control, 2-29
Rapid stop, 2-22, 2-26, 2-27, 2-28, 2-29, 2-30 Speed control loop, 3-64
Rapid traverse override, 9-163 Speed setpoint output, 3-60
Rapid traverse override switch, 11-241 Spindle override factor, 11-242
Read measurement results in PP, 15-298 Spindle speed, 3-48
Reducing jerk, 12-258 Spindles (S1) Gear stage change, 5-94
Referencing Spindles (S1) Spindle monitoring, 5-100
Axis-specific, 8-140 SPOS, 12-257
Channel-specific, 8-140 Suitable probes, 15-296
with incremental measuring system, 8-142 Synchronizing the spindles (S1), 5-93
Referencing with absolute value encoders, 8-146 System variable, 15-298
Reset, 1-18
Rotary axes
Absolute dimension programming, 6-132, 6-133
Axis addresses, 6-129 T
Feed, 6-130 T function, 13-270
Incremental dimension programming, 6-133 Tachogenerator compensation, 2-27
Modulo 360, 6-131 Tools, 14-280, 14-281
Software limit switch, 6-131 select, 14-280
Units of measurement, 6-130 T function, 14-280
Rotary axis, 6-129 Tool compensation, 14-281
with rotary encoder on motor, 3-63 Transverse axes
Diameter programming, 7-137
Geometry axes, 7-137
S Travel to fixed stop, Monitoring window, 17-325
Traversing ranges, 3-48
Selection of the cutting edge when changing tool,
14-281
Setpoint output, 3-55
Setpoint system, 3-55 V
Signal, Transformation active, 15-306 Velocities, 3-47
Signals from NCK to PLC, 20-374 Velocity reduction according to overload factor, 12-257
Signals from PLC to HMI, 20-377
Signals from PLC to NCK, 20-370
Simulation axes, 3-55
Single block mode, 10-199 W
Skip part program blocks, 10-203 Working area limiting, 2-33, 6-131

6FC5397-1CP10-1BA0 Index-419
Index
Notes

Index-420 6FC5397-1CP10-1BA0
To Recommendations
SIEMENS AG
Corrections
A&D MC BMS
for document:
Postfach 3180
D–91050 Erlangen SINUMERIK 802D sl

(Tel. +49 (0) 180 5050 – 222 [Hotline]
Fax +49 (0) 9131 98 – 63315 [Documentation]
email: motioncontrol.docu@siemens.com
Manufacturer Documentation
Description of Functions
From
Order no.: 6FC5397-1CP10-0BA0
Name Edition: 05/2005
Your company address/dept.
Should you come across any printing
Address errors when reading this publication,
please notify us on this sheet.
Postal code: City: Suggestions for improvement are
Phone: / also welcome.
Fax: /
Recommendations and/or corrections

Siemens AG
Automation & Drives
Motion Control Systems
 Siemens AG 2005
Postfach 3180, D–91050 Erlangen Subject to change without prior notice
Federal Republic of Germany Order No. 6FC5397-1CP10-0BA0
Printed in the Federal Republic of Germany

www.ad.siemens.com

802Dsl FB 0505 en

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

802Dsl FB 0505 en

Încărcat de

Drepturi de autor:

Formate disponibile

Description of Functions 05/05 Edition

Axis Monitoring (A3)

Rotary Axes (R2) 6

Tangential Control (T3) 19

Various Interface Signals (A2) 20

PLC User Interface 21

Various Machine Data

Siemens AG Copyright (E) Siemens AG 2005.

Target readership of this documentation

SINUMERIK 802D sl Description of Functions (FB), 05/05 Edition

Notes for the reader

Explanation of the brief description

SINUMERIK 802D sl Description of Functions (FB), 05/05 Edition

SINUMERIK 802D sl Description of Functions (FB), 05/05 Edition

Machine date example

SINUMERIK 802D sl Description of Functions (FB), 05/05 Edition

SINUMERIK 802D sl Description of Functions (FB), 05/05 Edition

3.3.2 Drives with DRIVE-QLiQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

SINUMERIK 802D sl Description of Functions (FB), 05/05 Edition

5.11.3 Setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-127

SINUMERIK 802D sl Description of Functions (FB), 05/05 Edition

9.6.4 Axis/spindle-specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-179

SINUMERIK 802D sl Description of Functions (FB), 05/05 Edition

11.3.2 Feed disable and feed/spindle stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-240

SINUMERIK 802D sl Description of Functions (FB), 05/05 Edition

14 Tool: Compensation and Monitoring (W1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-279

SINUMERIK 802D sl Description of Functions (FB), 05/05 Edition

17 Travel to Fixed Stop (F1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-321

SINUMERIK 802D sl Description of Functions (FB), 05/05 Edition

20.4 Signals from PLC to HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-377

SINUMERIK 802D sl Description of Functions (FB), 05/05 Edition

EMERGENCY STOP in the control system

SINUMERIK 802D sl Description of Functions (FB), 05/05 Edition

EMERGENCY STOP pushbutton

1.2 EMERGENCY STOP sequence

Sequence on the machine

SINUMERIK 802D sl Description of Functions (FB), 05/05 Edition

1.3 EMERGENCY STOP acknowledgment

Acknowledge EMERGENCY STOP

IS “EMERGENCY STOP active”

Fig. 1-1 Reset EMERGENCY STOP

Resetting the EMERGENCY STOP state has the following effects:

SINUMERIK 802D sl Description of Functions (FB), 05/05 Edition

1.4 Data Descriptions (MD, SD)

Axis-specific machine data

SINUMERIK 802D sl Description of Functions (FB), 05/05 Edition

1.5 Signal Descriptions

V2600 0000.1 EMERGENCY STOP

V2600 0000.2 Acknowledge EMERGENCY STOP

V2700 0000.1 EMERGENCY STOP active

SINUMERIK 802D sl Description of Functions (FB), 05/05 Edition

1.6 Data Fields, Lists

1.6.1 Interface signals

Number .Bit Name Refe-

1.6.2 Machine data

Number Identifiers Name Refe-

SINUMERIK 802D sl Description of Functions (FB), 05/05 Edition

SINUMERIK 802D sl Description of Functions (FB), 05/05 Edition

2.2 Motion monitoring functions

2.2.1 Contour monitoring

SINUMERIK 802D sl Description of Functions (FB), 05/05 Edition

2.2.2 Positioning monitoring

V or s 8 Effective tolerance for zero speed