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SINUMERIK SINUMERIK 840D sl/SINUMERIK 828D Extended Functions SINUMERIK SINUMERIK 840D sl/SINUMERIK 828D Extended Functions Preface Preface A4:Digital and analog NCK I/Os A4:Digital and analog NCK I/Os 1 1B3:Several operator panels connected to several NCUs,distributed systems-only 840D sl B3:Several operator panels connected to several NCUs,distributed systems-only 840D sl 2 2B4:Operation via PG/PC-only 840D sl B4:Operation via PG/PC-only 840D sl 3 3H1:Manual travel and handwheel travel H1:Manual travel and handwheel travel 4 4K3:Compensation K3:Compensation 5 5K5:Mode groups,channels,axis interchange K5:Mode groups,channels,axis interchange 6 6M1:Kinematic transformation M1:Kinematic transformation 7 7M5:Measuring M5:Measuring 8 8N3:Software cams,position switching cycles-only 40D sl N3:Software cams,position switching cycles-only 40D sl 9 9N4:Punching and nibbling-only 840D sl N4:Punching and nibbling-only 840D sl 1010P2:Positioning axes P2:Positioning axes 1111P5:Oscillation-only 840D slP5:Oscillation-only 840D sl 1212R2:Rotary axes R2:Rotary axes 1313S3:Synchronous spindle S3:Synchronous spindle 1414S7:Memory configuration S7:Memory configuration 1515T1:Indexing axes T1:Indexing axes 1616W3:Tool change W3:Tool change 1717W4:Grinding-specific tool offset and monitoring functions-only 840D sl W4:Grinding-specific tool offset and monitoring functions-only 840D sl 1818Z2:NC/PLC interface signalsZ2:NC/PLC interface signals 1919Appendix Appendix A A SINUMERIK SINUMERIK 840D sl/SINUMERIK 828D Extended Functions SINUMERIK SINUMERIK 840D sl/SINUMERIK 828D Extended Functions Function ManualFunction Manual 09/200909/2009 6FC5397-1BP20-0BA0 Valid for Control System SINUMERIK 840D sl/840DE sl SINUMERIK 828D Software Version NCU system software for 840D sl/840DE sl 2.6 NCU system software for 828D 2.6 Legal information Legal information Legal information Warning notice system Legal information Warning notice system This manual contains notices you have to observe in order to ensure your personal safety,as well as to prevent damage to property.The notices referring to your personal safety are highlighted in the manual by a safety alert symbol,notices referring only to property damage have no safety alert symbol.These notices shown below are graded according to the degree of danger.DANGER DANGER indicates that death or severe personal injury willwill result if proper precautions are not taken.WARNING WARNING indicates that death or severe personal injury maymay result if proper precautions are not taken.CAUTION CAUTION with a safety alert symbol,indicates that minor personal injury can result if proper precautions are not taken.CAUTION CAUTION without a safety alert symbol,indicates that property damage can result if proper precautions are not taken.NOTICE NOTICE indicates that an unintended result or situation can occur if the corresponding information is not taken into account.If more than one degree of danger is present,the warning notice representing the highest degree of danger will be used.A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.Qualified Personnel Qualified Personnel The product/system described in this documentation may be operated only by personnel qualifiedpersonnel qualified for the specific task in accordance with the relevant documentation for the specific task,in particular its warning notices and safety instructions.Qualified personnel are those who,based on their training and experience,are capable of identifying risks and avoiding potential hazards when working with these products/systems.Proper use of Siemens products Proper use of Siemens products Note the following:WARNING WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation.If products and components from other manufacturers are used,these must be recommended or approved by Siemens.Proper transport,storage,installation,assembly,commissioning,operation and maintenance are required to ensure that the products operate safely and without any problems.The permissible ambient conditions must be adhered to.The information in the relevant documentation must be observed.Trademarks Trademarks All names identified by are registered trademarks of the Siemens AG.The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.Disclaimer of Liability Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described.Since variance cannot be precluded entirely,we cannot guarantee full consistency.However,the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.Siemens AG Industry Sector Postfach 48 48 90026 NRNBERG GERMANY Order number:6FC5397-1BP20-0BA0 10/2009 Copyright Siemens AG 2009.Technical data subject to change Extended Functions Function Manual,09/2009,6FC5397-1BP20-0BA0 3 PrefacePreface SINUMERIK Documentation SINUMERIK Documentation The SINUMERIK documentation is organized in three parts:General documentation User documentation Manufacturer/service documentation Information on the following topics is available at http:/ documentation Here you can find an up-to-date overview of publications.Downloading documentation Links to more information for downloading files from Service&Support.Researching documentation online Information on DOConCD and direct access to the publications in DOConWEB.Compiling individual documentation on the basis of Siemens contents with the My Documentation Manager(MDM),refer to http:/ Documentation Manager provides you with a range of features for generating your own machine documentation.Training and FAQs Information on our range of training courses and FAQs(frequently asked questions)is available via the page navigation.Target group Target group This publication is intended for:Project engineers Technologists(from machine manufacturers)System startup engineers(Systems/Machines)Programmers Benefits Benefits The function manual describes the functions so that the target group knows them and can select them.It provides the target group with the information required to implement the functions.Preface Extended Functions 4 Function Manual,09/2009,6FC5397-1BP20-0BA0 Standard version Standard version This documentation only describes the functionality of the standard version.Extensions or changes made by the machine tool manufacturer are documented by the machine tool manufacturer.Other functions not described in this documentation might be executable in the control.This does not,however,represent an obligation to supply such functions with a new control or when servicing.Further,for the sake of simplicity,this documentation does not contain all detailed information about all types of the product and cannot cover every conceivable case of installation,operation or maintenance.Installation Installation Structure of this Function Manual:Inner title(page 3)with the title of the Function Manual,the SINUMERIK controls as well as the software and the version for which this version of the Function Manual is applicable and the overview of the individual functional descriptions.Description of the functions in alphabetical order(e.g.A2,A3,B1 etc.)Appendix with:List of abbreviations Fax template for feedback for documentation Overview Index of terms Note Note For detailed descriptions of data and alarm see:Machine and setting data:Detailed description of machine data(only electronically on DOConCD or DOConWEB)NC/PLC interface signals:Function Manual Basic Functions;NC/PLC Interface Signals(Z1)Function Manual Basic Functions;NC/PLC Interface Signals(Z2)Function Manual Special Functions;NC/PLC Interface Signals(Z3)Alarms:Diagnostics Manual Preface Extended Functions Function Manual,09/2009,6FC5397-1BP20-0BA0 5 Notation of system data Notation of system data The following notation is applicable for system data in this documentation:Signal/Data Notation Example Signal/Data Notation Example NC/PLC interface signals.NC/PLC interface signal:()When the new gear step is engaged,the following NC/PLC interface signals are set by the PLC program:DB31,.DBX16.0-2(actual gear stage A to C)DB31,.DBX16.3(gear is changed)Machine data.machine data:()Master spindle is the spindle stored in the machine data:MD20090$MC_SPIND_DEF_MASTER_SPIND(Position of deletion of the master spindle in the channel).Setting Data.Setting data:()The logical master spindle is contained in the setting data:SD42800$SC_SPIND_ASSIGN_TAB0(Spindle number converter)Note Signal address Note Signal address The description of functions include as of an NC/PLC interface signal,only the address valid for SINUMERIK 840D sl.The signal address for SINUMERIK 828D should be taken from the data lists Signals to/from.at the end of the particular description of functions.Quantity structure Quantity structure Explanations concerning the NC/PLC interface are based on the absolute maximum number of sequential components:Mode groups(DB11)Channels(DB21,etc.)Axes/spindles(DB31,etc.)Preface Extended Functions 6 Function Manual,09/2009,6FC5397-1BP20-0BA0 Data types Data types The following elementary data types are used in the control system:Type Meaning Value range Type Meaning Value range INT Signed integers-2147483648.+2147483647 REAL Figures with decimal point acc.to IEEE(2.2*10-308 1.8*10+308)BOOL Truth values TRUE(1)and FALSE(0)1,0 CHAR ASCII characters Corresponding to code 0 to 255 STRING Character string,number of characters in.Maximum of 200 characters(no special characters)AXIS Axis names only All axis identifiers in the channel FRAME Geometrical parameters for moving,rotating,scaling,and mirroring Arrays can only be formed from similar elementary data types.Up to 3-dimensional arrays are possible.Technical Support Technical Support If you have any questions,please contact our hotline:Europe/Africa Europe/Africa Phone+49 180 5050-222 Fax+49 180 5050-223 0.14/min.from German landlines,cell phone prices may differ Internet http:/www.siemens.de/automation/support-request Americas Americas Phone+1 423 262 2522 Fax+1 423 262 2200 E-mail mailto: Asia/Pacific Asia/Pacific Phone+86 1064 757575 Fax+86 1064 747474 E-mail mailto: Preface Extended Functions Function Manual,09/2009,6FC5397-1BP20-0BA0 7 Note Note You will find telephone numbers for other countries for technical support on the Internet:http:/ Questions about the manual Questions about the manual If you have any queries(suggestions,corrections)in relation to this documentation,please send a fax or e-mail to the following address:Fax:+49 9131-98 2176 Email:mailto: A fax form is available in the appendix of this document.SINUMERIK Internet address SINUMERIK Internet address http:/ SINUMERIK 828D system performance(region)SINUMERIK 828D system performance(region)PPU 260/261 PPU 280/281 PPU 260/261 PPU 280/281 T M T M T M T M System performance System performance Basic quantity of axes/spindles 3 4 3 4 Max.number of axes/spindles 6 6 8 6 Max.number of interpolating axes 4 4 4 4 Max.number of channels/mode groups 1/1 1/1 1/1 1/1 Min.block change time 6 ms 2 ms 6 ms 1 ms Speed/current control cycle 125 s 125 s 125 s 125 s CNC user memory(buffered)3 MB 3 MB 5 MB 5 MB CNC functions CNC functions Tool Management Number of tools/cutting edges 128/256 128/256 256/512 256/512 Safety Integrated:Safe Torque Off,Safe Brake Control Safety Integrated:Safe velocity Max.number of ASUBs(permanently set)2 2 2 2 TRANSMIT/TRACYL Inclined Y axis-Synchronous spindle for counterspindle-Synchronous spindle for polygon machining -Gantry Temperature compensation Preface Extended Functions 8 Function Manual,09/2009,6FC5397-1BP20-0BA0 PPU 260/261 PPU 280/281 PPU 260/261 PPU 280/281 T M T M T M T M HMI,CNC programming HMI,CNC programming ShopMill/ShopTurn HMI functions DIN/ISO programming with programGUIDE Online ISO dialect interpreter ShopMill/ShopTurn machining step programming Measuring cycles Simulation in surface display Simulation in 3D display PLC PLC SIMATIC S7-200(integrated)Basic I/O modules:PP 72/48D PN PP 72/48D 2/2A PN(being prepared)PLC cycle time 6 ms 6 ms 6 ms 6 ms Max.number of PLC operations 24000 24000 24000 24000 Servo-synchronous high-speed PLC task Reaction time to process interrupts(terminal to terminal)7.5 ms 7.5 ms 4.5 ms 4.5 ms Max.number of digital inputs/outputs 288/192 288/192 360/240 360/240 Max.number of analog inputs/outputs 8/8 8/8 10/10 10/10 Commissioning functions Commissioning functions Service Planner(maintenance scheduler)Easy Extend(for managing machine units)Easy Archive(data archiving)T T Turning MM Milling Standard(basic scope)CNC option-Not available Extended Functions Function Manual,09/2009,6FC5397-1BP20-0BA0 9 Contents Contents Preface.3 1 A4:Digital and analog NCK I/Os.27 Preface.3 1 A4:Digital and analog NCK I/Os.27 1.1 Brief description.27 1.2 NCK I/O via PLC.28 1.2.1 General functionality.28 1.2.2 NCK digital inputs/outputs.35 1.2.2.1 NCK digital inputs.35 1.2.2.2 NCK digital outputs.37 1.2.3 Connection and logic operations of fast NCK inputs/outputs.41 1.2.4 NCK analog inputs/outputs.43 1.2.4.1 NCK analog inputs.43 1.2.4.2 NCK analog outputs.45 1.2.5 Direct PLC I/Os,addressable from the NC.49 1.2.6 Analog-value representation of the NCK analog input/output values.52 1.2.7 Comparator inputs.54 1.3 NCK I/O via PROFIBUS-only 840D sl.58 1.3.1 Functionality.58 1.3.2 Parameter assignment.59 1.3.3 Programming.61 1.3.3.1 Communication via part programs/synchronous actions.61 1.3.3.2 Communication via compile cycles.64 1.4 Constraints.66 1.4.1 NCK I/O via PLC.66 1.4.2 NCK I/O via PROFIBUS-only 840D sl.67 1.5 Examples.68 1.5.1 NCK I/O via PLC.68 1.5.1.1 Writing to PLC-I/Os.68 1.5.1.2 Reading from PLC-I/Os.69 1.5.2 NCK I/O via PROFIBUS-only 840D sl.70 1.5.2.1 PROFIBUS-I/O in write direction.70 1.5.2.2 PROFIBUS-I/O in read direction.71 1.5.2.3 Query of the RangeIndex in case of PROFIBUS-I/O in write direction.73 1.6 Data lists.75 1.6.1 Machine data.75 1.6.1.1 General machine data.75 1.6.1.2 Channel-specific machine data.76 1.6.2 Setting data.76 1.6.2.1 General setting data.76 1.6.3 Signals.76 1.6.3.1 Signals to NC.76 1.6.3.2 Signals from NC.77 2 B3:Several operator panels connected to several NCUs,distributed systems-only 840D sl.79 2 B3:Several operator panels connected to several NCUs,distributed systems-only 840D sl.79 2.1 Brief description.79 2.1.1 Topology of distributed system configurations.79 Contents Extended Functions 10 Function Manual,09/2009,6FC5397-1BP20-0BA0 2.1.2 Several operator panels and NCUs with control unit management(option).84 2.1.2.1 General information.84 2.1.2.2 System features.85 2.1.2.3 Hardware.86 2.1.2.4 Functions.88 2.1.2.5 Configurability.89 2.1.3 Several operator panel fronts and NCUs,standard functionality.90 2.1.3.1 System features.90 2