SINUMERIK 802D

preliminary 11/2000

Start–up 11.00 Edition

Start–up Guide

Manufacturer/Service Documentation
 Document structure SINUMERIK 802D

General Documentation: Catalog

SINUMERIK 802D

Turning,
Milling
preliminary 11/2000

User’s Guide: Operation and Programming

SINUMERIK 802D SINUMERIK 802D

Turning Milling

User’s Guide: Diagnostics Guide

SINUMERIK 802D

Turning,
Milling

Technical Manual: Start–up

SINUMERIK 802D
Documentation

Turning, SIMODRIVE
Milling 611U

Technical Manual: Descriptions of Functions

SINUMERIK 802D

Turning,
Milling
 Control System 1

Installing the Control System2

Commissioning 3

SINUMERIK 802D Starting up the PLC 4

preliminary 11/2000

Start–up Guide Series Machine Start–up

and Data Backup 5
Technical Manual
Software Update 6

Machine and Setting Data 7

Start–up in ISO Mode 8

Valid for

Control Software Version

SINUMERIK 802D 1

Edition 11.00
 SINUMERIK documentation

Printing history

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

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

Status code in the ”Remarks” column:

A . . . . New documentation.
B . . . . Unrevized reprint with new Order No.
C . . . . Revised edition with new status.
If actual changes have been made on the page since the last edition,
preliminary 11/2000

this is indicated by a new edition coding in the header on that page.

Edition Order No. Remarks

11.00 6FC5 697-2AA00-0BP0 A

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

Edition Order No. Remarks

Trademarks
SIMATICr, SIMATIC HMIr, SIMATIC NETr, SIROTECr, SINUMERIKr and SIMODRIVEr are registered
trademarks of Siemens. Third parties using for their own purposes any other names in this document which
refer to trademarks might infringe upon the rights of trademark owners.

Other functions not described in this documentation might be

executable in the control. This does not, however, represent an
This documentation was produced using Interleaf 7.0. obligation to supply such functions with a new control or when
servicing.
Subject to change without prior notice.
We have checked that the contents of this document correspond to
The reproduction, transmission or use of this document or its the hardware and software described. Nonetheless, differences might
contents is not permitted without express written authority. Offenders exist and therefore we cannot guarantee that they are completely
will be liable for demages. All rights, including rights created by patent identical. The information contained in this document is, however,
grant or registration of utility model or design, are reserved. reviewed regularly and any necessary changes will be included in the
next edition. We welcome suggestions for improvement.
 Siemens AG 2000. All rights reserved.

Order No. 6FC5 697–2AA00–0BP0 Siemens–Aktiengesellschaft

Printed in the Federal Republic of Germany
 Table of Contents

Table of Contents
1 SINUMERIK 802D Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.1 Components of SINUMERIK 802D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
2 Installing the Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.1 Installing and Removing the SINUMERIK 802D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.2 Interfaces and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2.3 Connecting the Individual Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
preliminary 11/2000

2.3.1 Connecting the Keyboard (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

2.3.2 Connecting Handwheels to the PCU (X14, X15, X16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2.3.3 Connection Configuration of the RS232 Interface (COM1) on the PCU . . . . . . . . . . . . . . . . 2-28
2.3.4 Connecting the I/O to PP 72/48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
2.4 Connecting the SIMODRIVE 611U Drive Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2.5 Connecting Profibus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2.6 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
2.7 Power Supply for PCU (X8) and PP 72/48 (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
2.8 Displays on the PCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
2.9 Displays on PP 72/48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
3 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3.1.1 Access Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3.1.2 Structure of Machine (MD) and Setting Data (SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3.2 Turning on and Booting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3.3 Language Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.4 Setting the Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.5 Input of Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.6 Setting the Profibus Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.7 Starting up the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3.8 Starting up the Axes/Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3.8.1 Set/Actual Value Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3.8.2 Default Setting of Axis Machine Data for Feed Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
3.8.3 Default Settings of Axis Machine Data for the Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
3.8.4 Connecting a direct measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
3.9 Completing Start–up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
3.10 Service Display of Axis Drive Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
4 Starting up the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
4.1 Commissioning of PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
4.2 PLC Start–up Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
4.3 PLC Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
4.3.1 General PLC Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
4.3.2 User Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
4.4 PLC Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
4.4.1 Command Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
4.4.2 Explanation of Stack Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

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4.4.3 Program Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73

4.4.4 Data Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
4.4.5 Interface to the Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
4.4.6 Testing and Monitoring Your Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
4.5 Downloading/Uploading/Copying/Comparing PLC Applications . . . . . . . . . . . . . . . . . . . . . . 4-74
4.6 User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76
5 Series Machine Start–up and Data Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
5.1 Series Machine Start–up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
5.2 Data Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
5.2.1 Internal Data Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
preliminary 11/2000

5.2.2 External Data Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79

5.3 Formatting a PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80
6 Software Update Using the NC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
7 Machine and Setting Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
7.1 List of Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84
7.1.1 Display Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84
7.1.2 General Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
7.1.3 Channel–Specific Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-90
7.1.4 Axis–Specific Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-91
7.2 Setting Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99
8 Start–up inISO Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-101
8.1 Commissioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-101
8.2 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-102
8.2.1 Decimal point programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-102
8.2.2 Straight line control with rapid traverse G00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-102
8.2.3 Spindle positioning M19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-102
8.2.4 Blueprint programming (turning technology only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-102
8.2.5 Tool offset (turning technology only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-103
8.3 Functions (ISO dialect for SINUMERIK 802D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-103

SINUMERIK 802DStart–up Guide

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 SINUMERIK 802D Control System 1
1.1 Components of SINUMERIK 802D
preliminary 11/2000

Hardware components
S PCU (Panel Control Unit): Control component for a maximum of 4 axes and a spindle with
graphical display, softkey bars and NC card plug–in module
S KB (keyboard): horizontal or vertical design
S MCP (Machine Control Panel)
S PP 72/48 (Profibus I/O): 72 digital inputs, 48 digital outputs
S Drive module
– SIMODRIVE 611UE closed–loop control module
– Profibus DP option module

Software components
S System software on the permanent Flash memory of the PCU
– Boot software,
starts the system.
– HMI software (Human Machine Interface),
incorporates all operating functions.
– NCK software (NC kernel)
incorporates all NC functions. It controls an NC channel with a maximum of 4 axes and a
spindle.
– PLC software (Programmable Logic Control),
executes the integrated PLC user program cyclically.
S Toolbox
– Setup file for turning and milling
– Cycle package for turning and milling
– Transfer program WINPCIN for transferring user data and programs from/to an external PC
– Reloadable languages
– Text manager
– PLC user library
– SimoCom U Parameterization and Start–up Tool for drives
– SIMODRIVE 611 UE Firmware
S Programming Tool PLC 802

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 SINUMERIK 802D Control System

PCU MCP

[VAR] Jog Ref Point

Auto Single Block

MDA

Spindle Left
Spindle Stop
Spindle Right
preliminary 11/2000

Rapid

Reset Cycle stopCycle Start

KB

P R O C E S S F IE L D B U S

PP 72/48

Closed–loop control
module SIMODRIVE 611UE

Profibus DP option module

Fig. 1-1 SINUMERIK 802D hardware components

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 SINUMERIK 802D Control System

User data
The user data are:
S Machine data
S Setting data
S Tool data
S R parameters
S Zero offsets
S Compensation data
S
preliminary 11/2000

Part programs
S Standard cycles
S PLC user program
S User alarm texts

Note
After POWER OFF or in case of power failure, modified user data are stored at least 50 h. Then
they can be lost if they have not been stored using appropriate operating actions (see Section
5.2.1)

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 SINUMERIK 802D Control System

1.2 Technical Data

Connection values

Table 1-1 Connection values

Parameter min. typ. max. Unit

Supply voltage 20.4 28.8 V
Ripple 3.6 Vss
Current consumption from 24 V 1 A *
preliminary 11/2000

Power loss of PCU including keyboard (KB) 50 W

Power loss of MCP <5 W
Power loss of PP 72/48 11 W **
Starting current, total 2.6 A

* Basic configuration consisting of PCU, KB, MCP and PP 72/48,

all outputs open
** at nominal load

Weight

Table 1-2 Weight

Component Weight
PCU 4.9 kg
KB 1.7 kg
MCP 1.5 kg
PP 72/48 1.2 kg

Dimensions

Table 1-3 Dimensions of components

Component Dimensions WxHxD [mm]

PCU 310 x 330 x 85
KB, horizontal design 310 x 175 x 32
KB, vertical design 172 x 330 x 32
MCP 170 x 330 x 128
PP 72/48 194 x 325 x 35

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 SINUMERIK 802D Control System

Environmental conditions during operation

Table 1-4 Ambient conditions during operation

Parameters
Temperature range 0...50 °C
Admissible relative humidity 5...95 % without condensing
Air pressure 700...1,060 hPa

The field conditions comply with IEC 1131-2.

For use in the field, the control system should be installed in a housing (e.g., cabinet).
preliminary 11/2000

Transport and storage conditions

Table 1-5 Transport and storage conditions

Parameter
Temperature range -40...70 °C for transport
-20...55 °C for storage
Admissible relative humidity 5...95 % non–condensing
Air pressure 700...1,060 hPa
Shipping height -1,000...3,000 m
Free fall in shipping package v 1,200 mm (PP 72/48 v 1,000 mm)

Protective quality and degree of protection

Class of protection I acc. to IEC 536.

A PE conductor connection is required.

Protection against ingress of solid foreign bodies and water: acc. to IEC 529.
S for PCU : IP 65 front side
IP 00 rear side
S for KB: IP 65 front side
IP 00 rear side
S for MCP: IP 54 front side
IP 00 rear side
S PP 72/48 IP 00

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 SINUMERIK 802D Control System

PP 72/48

Table 1-6 Digital inputs

Parameter min. typ. max. Unit

UH 15 24 30 V
Iin at UH 2 15 mA
UL –30 0 +5 V
Iin at UL not 15 mA
defined
preliminary 11/2000

Signal delay of hardware 0.5 3 ms

24V voltage to control the digital inputs are provided at pin 2 of interfaces X111, X222, X333.
max. current at pin 2 Iout =0.5A

Table 1-7 Digital outputs (high–side drivers)

Parameter min. typ. max. Unit

UH Vcc – 3V Vcc V
Iout at UH and 100% simultaneity factor 250 mA
UL Open output
Iout at UL (leakage current) 50 400 µA
Signal delay of hardware 0.5 ms
Switching frequency of ohmic load 0.1 kHz
Switching frequency of inductive load 0.002 kHz
(free–wheeling diode required)
Switching frequency of lamp load 0.011 kHz

24V voltage to supply the digital outputs must be connected to all 4 pins – pins 47, 48, 49, 50.

A max. of 1 A is permitted per supply pin.

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 Installing the Control System 2
2.1 Installing and Removing the SINUMERIK 802D
preliminary 11/2000

Warning
! Before installing the control system make absolutely sure that it is disconnected from mains!
The modules contain electrostatically sensitive components.
When handling the operator and machine control panel, make sure that neither p.c.boards, nor
components are touched by persons not grounded with ESD protection.

Procedure
1. Install PCU, KB and MCP.
2. Install the PP 72/48.
3. Install the drive combination (see SIMODRIVE 611 UE Documentation).
4. Make a connection between PCU and KB, as well as between MCP and PP 72/48 .
5. Establish the Profibus connection between PCU, PP 72/48 and SIMODRIVE 611 UE.

Removing the control system

The control system components are removed in the reverse order.

Warning
! When removing the control system, make absolutely sure that the control system is dead and
disconnected from mains.

Mounting dimensions

Note
For installing the control system components, observe the dimensions specified in the diagrams on
the next pages. The drill patterns are to be used as a basis for preparing the fastening holes. These
dimensions are binding.

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 Installing the Control System

7
8.2

90_
70
preliminary 11/2000

A–A
ø 4.5 (X8)

50
35 5
Required clearance

15
15

13
309.4

302.2

20
295.6
A
A

Required clearance

50

154.7

13.8

7.2
20

0
13
161.2
330

321

Fig. 2-1 Mounting dimensions of PCU

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Fig. 2-2
295
+3
2
281.8

312

6FC5 697–2AA00–0BP0 11.00

SINUMERIK 802DStart–up Guide
286.6

Drill pattern for PCU

2)
2)

0.5

302

152.2
+0.3

Z
5

281.8 1)
M4

Z
1.6

5
0

140.9

+0.3
285

Montageausschnitt
1) Einniet–, Einpressmutter M4 oder Gewindedurchzug M4 (8x) Panel cutout
Installing the Control System

Rivet nut M4 or threaded plugging M4 (8x)

2) Bohrungen für Lagefixierung ø 5.2 (2x)
location holes ø 5.2 (2x)

2-15
 Installing the Control System

A
90_
128

ø 4.5 (X6)

A
33 34
68.7

263
preliminary 11/2000

17.2
330

170
154

19
8

159.8 152.2 9

Fig. 2-3 Mounting dimensions for MCP

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>= 2

147
140

1) Einniet–, Einpressmutter M4 oder Gewindedurchzug M4

preliminary 11/2000

Rivet nut M4 or threaded plugging M4

6xM4 1)
0
7
301
290

0
11
141.2

Fig. 2-4 Drill pattern for MCP

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 Installing the Control System

330

320

10

0
0

2)
86.1

1) Add this dimension (24+15)=39 mm to the height of the plug.

preliminary 11/2000

172.2

Ground Screw M5 Connection socket

2) Location pins (2xø4.7)

7.7

NOTE:
24
1)

20 290 20

2)

172.2

165
15

158.8
142.2

13.4

7.2
15

0
9

0
330

321

161.2

Fig. 2-5 Mounting dimensions for keyboard (vertical layout for installation alongside the PCU)

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0.5

Fig. 2-6
2+3

2)
ø5(2x)

6FC5 697–2AA00–0BP0 11.00

303.5

SINUMERIK 802DStart–up Guide

302.5

3)
295

Up

143.7
1)
M4(6x)

Drill pattern for keyboard (vertical layout for installation alongside the PCU)
0
7.5
1) Einniet–,Einpressmutter M4 oder Gewindedurchzug M4
Rivet nut M4 or threaded plugging M4
2) Bohrungen fuer lagefixierung ø5 mm (2x) 8.5
location holes ø5 mm (2x)
3) Pay attention to the cut direction .
Installing the Control System

73

146
0.3

151.9
145.7

2-19
 Installing the Control System

87.5
175

0
0

7.2
preliminary 11/2000

Connection socket

1) Add this dimension (24+15)=39 mm to the height of the plug.

Grounding Screw M5

302.2

309.4

2) Location pins (2xø4.7)

2)
7.7
24
1)

15 145 15
2)

309.4
15

295.6

154.7
279.4

13.8
15

0
6

0
175

169

Fig. 2-7 Mounting dimensions for keyboard (horizontal layout for installation alongside the PCU)

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0.5
+3
2

2)
ø5(2x)
290
preliminary 11/2000

285

283.4
1)
M4(6x)

142.5

1) Einniet–,Einpressmutter M4 oder Gewindedurchzug M4 (6x)

Rivet nut M4 or threaded plugging M4 (6x)

2) Bohrungen für Lagefixierung (2x)

Location holes ø5 mm

1.6

5
0

5
158

153

76.5

Fig. 2-8 Drill pattern for keyboard (horizontal layout for installation under the PCU)

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 Installing the Control System

194

10.5
6.5
preliminary 11/2000

325

306

10 10 170

35
35

Fig. 2-9 Mounting dimensions of PP 72/48

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2.2 Interfaces and Cables

Position of interfaces, controls and displays on the PCU

B A

B (side view)
preliminary 11/2000

DC24V

Jumper
Erdanschluss M5
Grounding connection M5

Fig. 2-10 User interface on the PCU

S DC24V power supply connection (X8)

3–pin screw–terminal block for connecting the 24 V load power supply
S Profibus (X4)
9–pin D-Sub female connector for connecting Profibus
S COM1 RS232 interface (X6)
9–pin D-Sub male connector
Interface COM2 has no function.
S Handweels 1 to 3 (X14/X15/X16)
15–pin D-Sub male connector for connecting the handwheels
S Keyboard keyboard connection (X10)
6–pin Mini–DIN
S Reset button
S Jumper X311
S 4 LEDs for error and status displays (behind the front panel)

Interface on the KB
S Keyboard connection
6–pin Mini–DIN

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Position of interfaces, displays and controls on PP 72/48

RESET
OVERTEMP EXCHANGE

POWER READY
X2 X2
S1

X1 X1
preliminary 11/2000

X333 X222 X111

Fig. 2-11 User interfaces on PP 72/48

S X1 power supply connection (DC24V)

3–pin screw–terminal block for connecting the 24 V load power supply
S X2 Profibus
9–pin D-Sub female connector for connecting Profibus
S X111, X222 and X333
50–pin ribbon cable connector for connecting digital inputs and outputs
S 4 LEDs on PP 72/48 for status displays
S S1 DIL switch for setting the Profibus address (see Section 3.6)

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Interfaces on the MCP

X1202

X1201
preliminary 11/2000

Fig. 2-12 User interfaces on the MCP

S X1201 und X1202

50–pin ribbon cable connector for connection to PP 72/48

Interconnecting cables
The interconnection of the individual components is carried out as shown on the Connection
Diagram (Fig. 2-13). For the cable designations and connector types, please refer to the
SINUMERIK 802D Catalog.

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Power Supply P R O C E S S F IE L D B U S

24V DC
PCU

Profibus (X4)
X8

COM 1 (X6) RS232

preliminary 11/2000

Handwheel1 (X14)

Handwheel 2 (X15) Handwheels

Handwheel 3 (X16)

KB
Keyboard (X10)
CNC Keyboard

PP 72/48
X1202 X1201

X111 MCP
X1 X222
X333
X2

X111
X1 X222 Machine I/O
X333
X2

X423

SIMODRIVE 611U

Fig. 2-13 SINUMERIK 802D Connection Diagram

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2.3 Connecting the Individual Components

Note
Use only shielded cables and make sure that the shield is connected to the metallic or metalized
connector casing on the control end.
1. Connect the cables to the components as shown in Fig. 2-13.
2. Lock the D–Sub male connectors in place using the fastening screws and install the cable strain
relief devices.
The preassembled cables offered as accessories provide optimum noise immunity.
preliminary 11/2000

2.3.1 Connecting the Keyboard (KB)

The keyboard is connected to the PCU using the supplied cable. The angular connector must be
plugged into the keyboard.

2.3.2 Connecting Handwheels to the PCU (X14, X15, X16)

Connector designation: HANDWHEEL1 (X14)

HANDWHEEL2 (X15)
HANDWHEEL3 (X16)
Connector type: 15–pin D–Sub female connector
Max. cable length 3m

Table 2-1 Pin connector assignment of female connector X14, X15, X16

X14, X15, X16

Pin Signal Type Pin Signal Type
1 1P5 V 9 1P5 V
2 1M V 10 N.C.
3 A 11 1M V 8 1
4 A 12 N.C.
5 N.C. 13 N.C. 15 9

6 B 14 N.C.
7 B 15 N.C.
8 N.C.

Signal names
A A pulse
A negated A pulse
B B pulse
B negated B pulse
1P5 5V power supply
1M ground

Signal type
V voltage output

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Handwheels
Three electronic handwheels can be connected; these must comply with the following requirements:
Transfer method: 5 V square–wave signals (TTL or RS422)

Signals: track A as a true and negated signal (Ua1, Ua1)

track B as a true and negated signal (Ua2, Ua2)
Max. output frequency: 500 kHz

Phase offset
of track A to B: 90° "30°

Power supply: 5 V, max. 250 mA

preliminary 11/2000

2.3.3 Connection Configuration of the RS232 Interface (COM1) on the PCU

Interface RS232 COM1

Connector designation: COM1 (X6)

Connector type: 9–pin D-Sub plug connector
Max. cable length 15 m

Table 2-2 Pin assignment of COM1 connector (X6)

COM1 (X6)
Pin Name Type Pin Name Type
1 DCD I 6 DSR I
1 5
2 RxD I 7 RTS O
3 TxD O 8 CTS I
6 9
4 DTR O 9 RI I
5 1M V

Signal description:
DCD Carrier Detect
RxD Receive Data V24
TxD Transmit Data V24
RTS Request To Send
CTS Clear To Send
DTR Data Terminal Ready
DSR Data Send Ready
RI Ring Indicator
1M Signal Ground
Signal type

I Input
O Output
V Voltage output

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2.3.4 Connecting the I/O to PP 72/48

The machine control panel is connected to PP 72/48 (X111, X222) using a ribbon cable
(see Fig. 2-13).
Max. cable length: 15 m

Pin assignment of the connectors on PP 72/48 – laterally

Connector designation: X111, X222, X333
Connector type: 50–pin plug connector

Table 2-3 Pin assignment of connectors X111, X222, X333

preliminary 11/2000

Pin Signal Type Pin Signal Type

1 M GND 2 +24V Output
(output for I m+0.0 ... I m+2.7)
3 I m+0.0 Input 4 I m+0.1 Input
5 I m+0.2 Input 6 I m+0.3 Input
7 I m+0.4 Input 8 I m+0.5 Input
9 I m+0.6 Input 10 I m+0.7 Input
11 I m+1.0 Input 12 I m+1.1 Input
13 I m+1.2 Input 14 I m+1.3 Input
15 I m+1.4 Input 16 I m+1.5 Input
17 I m+1.6 Input 18 I m+1.7 Input
19 I m+2.0 Input 20 I m+2.1 Input
21 I m+2.2 Input 22 I m+2.3 Input
23 I m+2.4 Input 24 I m+2.5 Input
25 I m+2.6 Input 26 I m+2.7 Input
27 not connected 28 not connected
29 not connected 30 not connected
31 O n+0.0 Output 32 O n+0.1 Output
33 O n+0.2 Output 34 O n+0.3 Output
35 O n+0.4 Output 36 O n+0.5 Output
37 O n+0.6 Output 38 O n+0.7 Output
39 O n+1.0 Output 40 O n+1.1 Output
41 O n+1.2 Output 42 O n+1.3 Output
43 O n+1.4 Output 44 O n+1.5 Output
45 O n+1.6 Output 46 O n+1.7 Output
47 DOCOM1 VCC 48 DOCOM1 VCC
(input for O n+0.0 ... O n+1.7 (input for O n+0.0 ... O n+1.7
supply) supply)
49 DOCOM1 VCC 50 DOCOM1 VCC
(input for O n+0.0 ... O n+1.7 (input for O n+0.0 ... O n+1.7
supply) supply)

Note
The 24V voltage to supply the digital outputs must be connected to all 4 pins – 47, 48, 49 and 50.

The connectors X111, X222 and X333 have the same pin assignment, but the I/O areas are offset
by 3 bytes (inputs) or 2 bytes (outputs) (cf. Table 2-4).

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Table 2-4

PP 72/48 1 PP 72/48 2
Profibus Address 9 Profibus Address 8
X111 X222 X333 X111 X222 X333
IB 0 3 6 9 12 15
Input
In ut Byte 1 4 7 10 13 16
2 5 8 11 14 17
OB 0 2 4 6 8 10
Output Byte 1 3 5 7 9 11
m 0 3 6 9 12 15
preliminary 11/2000

n 0 2 4 6 8 10

2.4 Connecting the SIMODRIVE 611U Drive Module

All data required to configure the interfaces and for connecting the components of the drive module
are to be found in the SIMODRIVE 611UE Documentation.

2.5 Connecting Profibus

All nodes are connected another to one via Profibus. The PCU is master, SIMODRIVE 611 UE and
PP 72/48 operate as slaves.

The baud rate of the clock–synchronized Profibus is set to 12 Mbaud by default and cannot be
modified. No OLMs, OLPs or repeaters are admissible.

Profibus interface
Female connector type: 9–pin D-Sub female connector
Max. cable length: 100 m at 12 Mbaud

Table 2-5 Pin assignment of female connector

Pin Signal Meaning Pin Signal Meaning

1 Shield 6 VP Supply voltage of

terminators, (P5V)

2 Reserved 7 Reserved
1 5
3 RxD/TxD–P Receive/send data, B 8 RxD/TxD–N Receive/send data, A
line (red) line (green)

4 CNTR–P Control signal for 9 CNTR–N Repeater control 6 9

repeater (direction signal (direction
control) control)

5 DGND Data transfer program

(ground to 5V)

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Note
Use only the recommended Profibus connectors. These are designed such that the PB branch
leading to the outside is disconnected when the terminator is connected.
PB master = PCU should be connected at the beginning of the PB branch.
Make sure that the terminators are only connected at the first and at the last nodes.
Line A green Line B red
preliminary 11/2000

ON OFF OFF ON

A1/B1 A1/B1 A1/B1 A1/B1

A2/B2 A2/B2

PCU PP 72/48 611 UE 611 UE

Fig. 2-14 Structure of a Profibus branch represented as a diagram

2.6 Grounding

Grounding terminals
The following grounding terminals must be provided:

S PCU
S Machine control panel (MCP)
S Keyboard (KB)
When making the ground connection for PCU, MCP and KB, connect the grounding points to the
grounding bar (Fig. 2-15).

Grounding the PP 72/48

The installation of the PP 72/48 must comply with EN 60204. If a large–area, permanent metallic
connection with the central grounding point is not possible via the backpanel, the mounting plate
must be connected to the grounding bar using a line >10 mm2.

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MCP PCU
preliminary 11/2000

to the chassis
Grounding bar

Fig. 2-15 Grounding diagram for installing PCU and MCP

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2.7 Power Supply for PCU (X8) and PP 72/48 (X1)

Screw–terminal block
Connect the required 24 V DC load power supply to the screw–terminal block X8 or X1.

Characteristics of load current distribution

The 24 V DC voltage must be generated as a functional extra–low voltage with safe electrical isola-
tion (acc. to IEC 204-1, Sec. 6.4, PELV) and be grounded by the user (make a connection between
PELV signal M and central grounding point of the system).
preliminary 11/2000

Table 2-6 Electrical parameters of load power supply

Parameter min. max. Unit Conditions

Mean value of voltage range 20.4 28.8 V
Ripple 3.6 Vss
500 ms
continuous
Non–periodic overvoltage 35 V
50 s recovery
time
Nominal current consumption 1 A
Starting current 2.6 A

Table 2-7 Pin assignment of screw–terminal block X8/X1

Terminal Signal Description

1 P24 DC 24 V
2 M Ground
3 PE

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2.8 Displays on the PCU

Four LEDs are located on the front panel of the PCU.

preliminary 11/2000

Fig. 2-16 Display on the PCU alongside the PC card plug–in module

ON (green) Power On

NC (yellow) Sign–of–life of NC (flashing)

WD (red) Process monitoring

PB (yellow) Profibus

2.9 Displays on PP 72/48

4 LEDs are provided for status display.

POWER (green) Power On

READY (red) PP 72/48 is ready; no cyclic data exchange is carried out

EXCHANGE (green) PP 72/48 is ready; cyclic data exchange is carried out

OVTEMP (red) Overtemperature display

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3.1 General
preliminary 11/2000

Commissioning requirements
S The following is required:
– SINUMERIK 802D ”Operation and Programming“
– SINUMERIK 802D “Description of Functions”
– PC for start–up and data backup
– Toolbox
– PLC 802 Programming Tool
S The mechanical and electrical installation of the plant must be completed.
S Start–up of drive SIMODRIVE 611 UE (with the Profibus option module plugged)

Commissioning sequence
The SINUMERIK 802D can be commissioned using the following sequence:

1. Check the PCU boot sequence.

2. Set language.
3. Technology settings
4. Set general machine data.
5. PLC start–up
6. Set axis/spindle–specific machine data.
– Encoder adaptation of axis/spindle
– Setpoint adaptation of axis/spindle
7. Dry run of axes and spindle
8. Drive optimization
9. Complete commissioning, save data.

3.1.1 Access Levels

Protection levels
The SINUMERIK 802D has an integrated protection level concept for enabling data areas.
Protection levels 0 to 7 are provided whereby 0 is the highest and 7 the lowest protection level.

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The protection levels for certain function areas (e.g. Program Editor) are set in display machine data
(USER_CLASS...).

The control system is supplied with default passwords for protection levels 1 to 3. These passwords
can be changed by the authorized user as necessary.

Table 3-1 Protection level concept

Protection Encryption method Area

level
0 Siemens, reserved
preliminary 11/2000

1 Password: SUNRISE (default) Expert mode

2 Password: EVENING (default) Machine manufacturer
3 Password: CUSTOMER (default) Authorized user, machine setter
4 to 7 No password and no Authorized operator, machine setter
user interface PLC
NCK

Protection levels 1 ... 3

Protection levels 1 to 3 require password input. The passwords can be changed after activation. For
example, if the passwords are no longer known, a re–initialization (booting with default machine
data) must be carried out. This will reset all passwords to their factory settings of this software
release.

The password remains set until it is reset using the softkey Delete password. POWER ON will not
reset the password.

Protection levels 4 ... 7

Protection level 7 sets automatically if no password and no interface signal are set. Without
password, protection levels 4 to 7 can be set from the PLC user program by setting bits in the user
interface.

References
The “User Manual” Operation and Programming” describes how to set the access levels.

3.1.2 Structure of Machine (MD) and Setting Data (SD)

Number and identifier

MD and SD are addressed by their numbers or also by their names (identifiers). Number and name,
as well as activation and unit are displayed.

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Activation
The activation levels are listed by their priorities. When a data item has been changed, it comes into
effect after:

S POWER ON (po) – turning off/turning on the SINUMERIK 802D

S NEW_CONF (cf)
with RESET on the PLC interface (V3000 0000.7)
S RESET (re) with RESET on the PLC interface (V3000 0000.7) or at end of program M2/M30
S IMMEDIATELY (im) after the value has been input

Protection level
preliminary 11/2000

Start–up and machine data input usually require protection level 2.

Unit/scaling system
Depending on MD SCALING_SYSTEM_IS_METRIC, the following physical units are distinguished
for MD:

MD10240 = 1 MD10240 = 0
mm inch
mm/min inch/min
m/s2 inch/s2
m/s3 inch/s3
mm/rev inch/rev

If the MD has no physical unit, the field is left empty.

Note
The default setting of the machine data is SCALING_SYSTEM IS METRIC = 1 (metric).

3.2 Turning on and Booting

Procedure
S Visual inspection of the plant for:
– correct mechanical design with fixed connections
– connection voltages
– connection of shield and grounding
S Connect the control system (booting in normal mode)

Booting the control in normal mode

After the control system has been turned on, the booting sequence is displayed with all its individual
phases. The boot sequence is completed when the main screen of the user interface appears.

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Booting the control system in start–up mode

After Power On has been carried out and an appropriate operator prompt has appeared on the
screen, press the SELECT key.

After the DRAM test, the START–UP MENU appears on the display. Use the cursor to choose a
boot/start–up mode and press INPUT to confirm your selection.

The modes listed in the START–UP MENU have the following meaning:
S Normal mode
The control system boots with the machine data set to date and with the programs loaded.
S Default data (display only with set protection level 1 or 2)
preliminary 11/2000

The control system boots with standard machine data.

S Software update
The control system does not boot. A software update is carried out.
S Reload saved user data
The user data saved on the flash (machine data, programs, etc.) are loaded as the current data
and used for booting.
S PLC stop
PLC stop is initiated if this can no longer be carried out via the user interface.

3.3 Language Setting

English is set as both foreground and background language. The foreground language can be
changed. It can be loaded from the toolbox.

Sequence
S Set up a V24 connection between PC and PCU (COM1).
S Turn on the control system and wait until the control system has booted without errors.
S In the operating area “System”, set the password for protection level 2.
S In the operating area “System” \ Data I/O \, position the cursor on the line “Start–up data PC”.
S Press the softkey Read in.
S Start the PC on which WINPCIN is installed.
S In WINPCIN, menu V24_INI, set binary file=on and ETX=off.
S Select the desired language file and transfer it from the PC to the control system using
WINPCIN.
S During the transfer, booting is carried out several times.
S The foreground language is now set to the desired language.

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3.4 Setting the Technology

Note
The SINUMERIK 802D is supplied with standard machine data. Depending on the technology
turning or milling, the relevant setup file must be loaded from the toolbox into the control system.
The setup file must be loaded during the first commissioning after the control system has booted,
but prior to setting the general configuration.
preliminary 11/2000

Sequence
S Set up a V24 connection between PC and PCU (COM1).
S Turn on the control system and wait until the control system has booted without errors.
S In the operating area “System”, set the password for protection level 2.
S In the operating area “System” \ Data I/O \, position the cursor on the line “Start–up data PC”.
S Press the softkey Read in.
S Start the PC on which WINPCIN is installed.
S In WINPCIN, menu V24_INI, set binary file=on and ETX=off.
S Choose the setup file (on the toolbox) for turning and milling (setup_t.ini or setup_m.ini) and
transfer it from the PC to the control system using WINPCIN.
S While the transfer is running, the control system reboots several times.
S The SINUMERIK 802D is now set to the desired technology.

3.5 Input of Machine Data

Overview
For better understanding, the most important machine data of the individual partial areas are listed.
A detailed description of the machine data and interface signals is to be found in the Descriptions of
Functions to which reference is made in the Lists (Chapter 7).

Note
The machine data are defaulted such (standard values) that in most cases the values need not be
modified.

Input of machine data (MD)

Before the machine data can be entered, the password for protection level 2 must be set.

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Select the following machine data areas via softkey and modify them if necessary:

S General machine data MD 10000 ... 19999

S Axis machine data MD 20000 ... 29999
S Channel machine data MD 30000 ... 39999
S Display machine data MD 1 ... 999
S Drive machine data Parameters 599 ... 1999
The data entered are immediately written into the data memory. An exception are the drive machine
data. To save the drive machine data permanently, use SimoComU. If you forget to save the data,
the old data will be effective again after the next drive reset.
preliminary 11/2000

The enabling of the machine data is carried out depending on the machine data property
“Activation“, Section 3.1.2.

3.6 Setting the Profibus Address

Two ready–to–use bus configurations exist for SINUMERIK 802D. The selection of a certain
configuration is set via MD 11240 PROFIBUS_SDB_NUMBER. In all cases, the configuration
constitutes the maximum configuration. It is not necessary to connect all nodes.

Table 3-2

MD 11240 PB node DP (slave) PB address Drive number

3 PP module 1 9 –
PP module 2 8 –
One–axis power section 10 5
One–axis power section 11 6
Two–axis power section Drive A 12 1
Drive B 2
4 PP module 1 9 –
PP module 2 8 –
One–axis power section 10 5
Two–axis power section Drive A 12 1
Drive B 2
Two–axis power section Drive A 13 3
Drive B 4

Note
The assignment between PB address and drive number is fixed and cannot be modified.

Set now MD 11240 according to your bus configuration.

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Parameterize the PB addresses of the PB nodes (SIMODRIVE 611 UE and PP module) according
to the Table above.

The drive is parameterized using the Parameterization and Start–up Tool ”SimoCom U”.

To this aim, you will need the following Documentation: SIMODRIVE 611 UE, “Description of
Functions”

Example:
Turning machine with PP module, a double–axis power section (X and Z axes) and the spindle as a
one–axis power section.
preliminary 11/2000

Table 3-3

MD 11240 PB node (slave) PB address Drive number

3 PP module 1 9 –

One–axis power section 10 5

Two–axis power section Drive A 12 1

Drive B 2

PCU
is master on PROFIBUS; address cannot be modified

PP 72/48
is slave on PROFIBUS. A maximum of two PP modules can be connected. The addresses are set
on the PP module on DIL switch S1.

PB address DIL switch S1 (PP module)

9 (factory settings) 1 + 4 = ON
(PP module 1) 2 + 3 + 5 + 6 + 7 + 8 = OFF
8 4 = ON
(PP module 2) 1 + 2 + 3 + 5 + 6 + 7 + 8 = OFF

Note
The newly set PB node address is only effective after POWER ON.

611 UE
is slave on PROFIBUS; the bus address is only set on commissioning using the start–up tool
SimoComU.

3.7 Starting up the PLC

After start–up of Profibus, the prepared PLC user program can be run and can be used for the
further start–up operations. It must be loaded using the Programming Tool.

The description is to be found in Chapter 4.

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3.8 Starting up the Axes/Spindle

3.8.1 Set/Actual Value Assignment

Axis MD 30130 CTRLOUT_TYPE can be used to switch over the setpoint output, and MD
30240_ENC_TYPE can be used to switch over the actual–value input between simulation and
PROFIBUS drive.

Table 3-4
preliminary 11/2000

Machine data Simulation Normal mode

MD 30130 Value = 0 Value = 1
Simulation The setpoint signals are output via
Profibus.
MD 30240 Wert = 0 Value = 1 (INCR) or 4 (EnDat)
Simulation Actual values are read in via
Profibus.

Note
For Simulation, MD 31130 and MD 30240 must be parameterized with 0.

To make sure that the corresponding NC axis assigns its setpoint to the related PROFIBUS drive
and the actual values are also returned from this PROFIBUS drive, the machine data MD 30110
CTRLOUT_MODULE_NR and MD 30220 ENC_MODULE_NR are parameterized.

Note
In the case of 2–axis power sections, both drives (A and B) must be assigned to one axis each.
Otherwise, a fault message is provided on booting (drive alarm 832: Profibus not clocked with
master), and the entire power section is not ready for operation.

The standard machine data record for turning and milling already contains a reasonable default
setting of these axis machine data.

The following applies to the standard data record ’turning’:

Axis Drive number PROFIBUS address Power section

MD 30110
MD 30220
X1 1 12 Double–axis: Drive A

Z1 2 12 Double–axis: Drive B

SP 5 10 One–axis

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The following applies to the standard data record ’milling’:

Axis Drive number PROFIBUS address Power section

MD 30110
MD 30240
X1 1 12 Double–axis: Drive A

Y1 2 12 Double–axis: Drive B

Z1 3 13 Double–axis: Drive A

SP 5 10 One–axis

A1 4 13 Double–axis: Drive B
preliminary 11/2000

If this default setting does not match with your machine configuration, the data must be adapted
accordingly.

Note
Make sure that the same drive number per axis is set for both machine data MD 31110
CTRLOUT_MODULE_NR and MD 30220 ENC_MODULE_NR, since there is a fixed assignment
between measuring system and motor.

Example:
The machine you want to start–up is a milling machine. The milling machine posseses three axes
and a spindle. The X1 and Y1 axes are controlled by a double–axis power section, the Z1 axis and
the spindle by one single–axis module each.

S The standard data record for a milling machine (setup_m.ini) has been loaded.
S The bus configuration has been selected with MD 11240 = 3.
S Adapt the axis machine data MD 30110 CTRLOUT_MODULE_NR and MD 30240
ENC_MODULE_NR as shown in the Table below (MD 30110 and MD 30240 need merely be
modified in the Z1 axis)

Axis Drive number PROFIBUS address Power section

MD 30110
MD 30240
X1 1 12 Double–axis: Drive A

Y1 2 12 Double–axis: Drive B

Z1 6 11 Single–axis

Sp 5 10 Signel–axis

S Set the PB addresses of the drives as indicated in the Table above (SimoComU). Since the 5th
axis (A1) is not used, MD 20070 AXCONF_MACHAX_USED[4]=0 must be parameterized. This
will remove the axis from the NC configuration.

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3.8.2 Default Setting of Axis Machine Data for Feed Axes

The following machine data list provides a summary of the standard data and their recommended
settings with SIMODRIVE 611 UE PROFIBUS drives connected.

After they have been set, the axes are ready to traverse, and it is merely required to make some fine
settings (reference point approach, SW limit switches, position controller optimization, speed
feedforward control, LEC, ...); see also: /FB/ SINUMERIK 802D, Description of Functions.

Note
preliminary 11/2000

For feed axes, only parameter record 1 = index [0] is processed. Indices [1] ... [5] need only be
parameterized for the function “Switch over parameter record“ (see FB, Chapter 3), with G331
“Rigid tapping“ or G33 (see FB, Chapter 11). In this section, the values need only be entered in
index [0].

MD Name Standard Unit Remark

value
31030 LEADSCREW_PITC 10 mm Leadscrew pitch
H

Load gear ratio

31050 DRIVE_AX_RATIO_ 1 Revolutions of leadscrew
DENOM 1 Motor revolutions
31060 DRIVE_AX_RATIO_
NUMERA

32000 MAX_AX_VELO 10,000 mm/min Maximum axis velocity

32300 MAX_AX_ACCEL 1 m/s2 Maximum axis acceleration

34200 ENC_REFP_MODE 1 1: Incremental encoder

Motor Order Code: 1Fx6xxx–xxxxx–xAxx
0: EnDat encoder
Motor Order Code: 1Fx6xxx–xxxxx–xExx

36200 AX_VELO_LIMIT 11,500 mm/min Threshold value for velocity monitoring

Setting rule:
MD 36200 = 1.15 x MD 32000

Example:

Motor with incremental encoder

Gear ratio: 1:2
Leadscrew pitch 5 mm
Max. axis velocity 12 m/min
Max. axis acceleration 1.5 m/s2

Machine data settings:

MD 30130 = 5
MD 31050 = 1
MD 31060 = 2
MD 32000 = 12000
MD 32300 = 1,5
MD 36200 = 13200

The axis can now be traversed. The direction of movement can be reversed with MD 32100
AX_MOTION_DIR = 1 or –1 (without affecting the control direction of the position control).

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3.8.3 Default Settings of Axis Machine Data for the Spindle

With the SINUMERIK 802D, the spindle is a subfunction of the whole axis functionality. The machine
data of the spindle are therefore to be found under the axis machine data (MD 35xxx).

For this reason, it is also necessary to enter data for the spindle, which are already described with
the start–up of feed axes.
The following variants are available as the spindle drive:

S digital spindle drive (PROFIBUS) with spindle actual–value sensor integrated in the motor
S digital spindle drive (PROFIBUS) with directly attached spindle actual–value sensor
preliminary 11/2000

S digital spindle drive (PROFIBUS) with spindle actual–value sensor integrated in the motor, with
gearbox and external zero mark (BERO)
S digital spindle drive (PROFIBUS) without spindle actual–value sensor
S analog spindle drive without spindle actual–value sensor
S analog spindle drive with directly attached spindle actual–value sensor

Note
For spindles without gear stage switchover, only gear stage 1 = index [1] is processed.
Indices [2] ... [5] need only be parameterized when using the function “Switch over gear stage” (see
FB, Chapter 5).

Table 3-5

MD Name Default Unit Remark

value
30200 NUM_ENCS 1 0: Dig. spindle without speed
actual–value sensor (AM mode =
encoderless operation)

1: Dig. spindle with speed actual–value

sensor integrated in the motor (1PH7
motor)

Load gear transmission ratio

31050 DRIVE_AX_RATIO_DENO 1 Load revolutions
M[1]
31060 DRIVE_AX_RATIO_NUME 1 Motor revolutions
RA[1]

35100 SPIND_VELO_LIMIT 10,000 rev./min Maximum spindle speed

35130 GEAR_STEP_MAX_VELO_ 500 rev./min Max. speed in gear stage 1

LIMIT[1]

35200 GEAR_STEP_SPEEDCTRL 30 rev/s2 Acceleration in open–loop speed control

_ACCEL[1] mode

36200 AX_VELO_LIMIT[1] 11,500 rev/min Threshold value for velocity monitoring

Setting rule:
MD 36200 = 1.1 x MD 35100

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Digital spindle drive (PROFIBUS) with spindle actual–value sensor integrated in the
motor
Parameterize the machine data listed in Table 3-5.

Example:

Motor with incremental encoder

Gear ratio: 1:2
Max. spindle speed 9,000 rpm
Max. spindle acceleration 60 rev/s2

Machine data settings:

preliminary 11/2000

MD 31050 = 1
MD 31060 = 2
MD 35100 = 9000
MD 35130 = 9000
MD 35200 = 60
MD 36200 = 9900

For the spindle, it can be necessary to adapt the following machine data.

Table 3-6 Additional machine data

MD Name Default Unit Recommendation/remark

value
34000 REFP_CAM_IS_ACTIVE 1 0: without reference point approach

34060 REFP_MAX_MARKER_DIST 20 degrees 720_ = two spindle revolutions

34110 REFP_CYCLE_NR 1 ... 5 0: Spindle is not involved in

channel–specific referencing

35300 SPIND_POSCTRL_VELO 500 rev/min

36000 STOP_LIMIT_COARSE 0.04 degrees 0.4

36010 STOP_LIMIT_FINE 0.01 degrees 0.1

36030 STANDSTILL_POS_TOL 0.2 degrees 1

36060 STANDSTILL_VELO_TOL 0.0139 rev/min 1 (IS “Axis/spindle stopped“

V390x 0001.4)

36400 CONTOUR_TOL 1 degrees 3

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Digital spindle drive (PROFIBUS) with directly attached spindle actual–value sensor
(TTL)
S Parameterize the spindle as specified in Table 3-5.
S Connect the TTL encoder to –X472 of the SIMODRIVE 611 UE closed–loop control module for
the spindle.
S Set the message frame type of the spindle to type 104:
MD 13060 DRIVE_TELEGRAM_TYPE[4] = 104.
S Set the encoder input of the spindle to the second encoder MD 30230 ENC_INPUT_NR = 2.
S Adapt the increments of the spindle encoder accordingly: MD 31020 ENC_RESOL = xxxx.
S
preliminary 11/2000

Parameterize the resolver gearbox:

MD 31070 DRIVE_RATIO_DENOM (encoder revolutions)
MD 31080 DRIVE_ENC_RATIO_NUMERA (load revolutions)
MD 31040 ENC_IS_DIRECT 0: Spindle encoder installed on motor end
1: Spindle encoder installed on load side
S The actual value of the position encoder must possibly be inverted (depending on the direction
of installation) MD 32110 ENC_FEEDBACK_POL = –1.
S Set the drive parameters (SimoComU).
P890 shaft–angle encoder terminals = 4
P922 PROFIBUS message frame selection = 104
Save + PowerOn
Example:

Spindle with incremental encoder installed on the chuck

TTL encoder with 2,500 pulses/rev.
Resolver gearbox transmission ratio: 1:3
Encoder
Machine data settings:
MD 13060[4] = 104
MD 30230 = 2
MD 31020 = 2500
MD 31040 = 1
MD 31070 = 3 Motor
MD 31080 = 1
MD 32110 = 0
P890 = 4
P922 = 104

Note
If a resolver gearbox with a gear ratio other than 1:1 is installed, spindle positioning can only be
performed using a BERO.

! Important
A transport axis can only be either axis A of the one–axis power section with PB address 10 or drive
A of the two–axis module with PB addres 12.

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Digital spindle drive (PROFIBUS) with encoder integrated in the motor, with gearbox
and external zero mark
Precondition:

The inductive proximity switch is of type Siemens 3RG4050–0AG05.

The proximity switch is used to switch a positive +24V edge.
preliminary 11/2000

Fig. 3-1

Parameterization:

611 UE (firmware version ≥ 03.01.06): Parameter P660 = 79

611 UE (firmware version ≥ 03.01.06): Parameter P879.13 = 1
In this case, instead of the internal encoder zero mark, the BERO signal connected to terminal I0.A
is evaluated.

802D: MD34200 ENC_REFP_MODE = 7

In this case, a synchronization with the BERO signal is only carried out at a defined speed
(MD34040). This is essential since a BERO always has certain signal runtimes. Only in this way, it
can be guaranteed that the synchronization is always performed at the same position.
802D: MD34040 REFP_VELO_SEARCH_MARKER = 200 rpm
At this speed, the synchronization is performed to the BERO signal.

802D: MD34060 REFP_MAX_MARKER_DIST must possibly be adapted

If SPOS is triggered from a standstill, first the speed is accelerated to the value entered in
MD34040, synchronized to the Bero edge and then positioning is carried out.
The direction of rotation depends on MD35350 SPIND_POSITIONING_DIR (3=CW / 4=CCW). In
CW direction of rotation, the synchronization is carried out to the falling edge, and in CCW direction
of rotation to the rising edge.

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PLC:

To ensure that a resynchronization is carried out when changing from open–loop speed control
mode to positioning mode, interface signal V380x2001.4 “Resynchronize spindle when positioning”
must be linked with V390x0001.5 “Position controller active“.
preliminary 11/2000

Fig. 3-2

! Important
The switchover from open–loop speed control mode to positioning mode with the spindle stopped
may only be carried out from a defined direction. Otherwise, the spindle will be mispositioned! This
can be ensured by programming ACP or ACN.
SPOS = ACP(0)
If first M4 Sxxx was programmed, this will brake to a standstill, then accelerate to the
synchronization speed in CW rotation, synchronize and position.

Analog spindle with directly attached spindle actual–value sensor

The function “Analog spindle” uses the analog output of the SIMODRIVE 611 UE closed–loop
control module as the setpoint output and the encoder interface (–X472) as the actual–value input
for a TTL encoder. When doing so, a digital feed axis is used as the transfer axis for the set and
actual values of the analog spindle.
Servo enable for the analog spindle is output via the digital outputs, and the analog setpoint is
output via the terminal 75.A / 15 of the transfer axis.

There are three modes:

1. MD 30134 IS_UNIPOLAR_OUTPUT =0 bipolar spindle + 10V

Digital output O0.A –> servo enable
2. MD 30134 IS_UNIPOLAR_OUTPUT =1 unipolar spindle 0...+10V (enable and direction
signal)
Digital output O0.A –> servo enable
Digital output O1.A –> direction of rotation
3. MD 30134 IS_UNIPOLAR_OUTPUT =2 unipolar spindle 0...+10V (CW enable, CCW enable)
Digital output O0.A –> CW enable
Digital output O1.A –> CCW enable

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! Important
In the case of RESET, a setpoint is output at the analog output of the 611 UE closed–loop control
module. It is therefore imperative to connect the servo enable of the analog spindle to terminal O0.A
of the transfer axis.

! Important
Handling axis can only be drive A of the one–axis power section with PB address 10 or drive A of
preliminary 11/2000

the double–axis module with PB address 12.

Example:
The following example uses the first machine axis (X1) as the transfer axis. X1 is drive A on a 611
UE closed–loop control board with PROFIBUS address 12.

The spindle is parameterized in the 802D as the third machine axis (SP) (standard machine data
record ’turning’).

The spindle is an analog spindle with +/–10V interface. The maximum speed is 9,000 rpm at 10 V in
this example.

Only the additional machine data required for start–up of an analog spindle will be explained here.

Table 3-7 Settings for the example

Handling axis X1 Analog spindle SP

(machine axis 1) (machine axis 3)
Required wiring between transfer axis X1 and analog spindle SP
Wire terminal 75.A with e.g. terminal 56 (analog setpoint input)
Wire terminal 15 with e.g. terminal 14 (analog setpoint input)
Wire terminal O0.A with e.g. terminal 65 (servo enable)
Connect –X472 with TTL encoder 5V
NC machine data
MD13060 DRIVE_TELEGRAM_TYPE[0] = 0 MD30110 CTRLOUT_MODULE_NR[0,AX3]=1
(drive number of transfer axis)
MD30120 CTRLOUT_NR[0,AX3]=2
MD30130 CTRLOUT_TYPE[0,AX3]=1
MD30220 ENC_MODULE_NR[0,AX3]=1
(ldrive number of transfer axis)
MD30230 ENC_INPUT_NR[0,AX3]=2
MD30240 ENC_TYPE[0,AX3]=1
MD31020 ENC_RESOL[0,AX3]=2500
(increments of TTL encoder)
MD32110 ENC_FEEDBACK_POL[0,AX3]=–1
(the actual value must possibly be inverted)
MD32250 RATED_OUTVAL[0,AX3]=100
MD32260 RATED_VELO[0,AX3]=9000
(adjust analog interface)
MD34060 REFP_MAX_MARKER_DIST[0,AX4]=360
MD35300 SPIND_POSCTRL_VELO=50
(speed at which the position controller becomes active at
SPOS)

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Table 3-7 Settings for the example, Fortsetzung

Handling axis X1 Analog spindle SP

(machine axis 1) (machine axis 3)
Drive data Monitoring data possibly need adaptation
P890 shaft–angle encoder terminals = 4 MD36000 STOP_LIMIT_COARSE[AX3]=10
P922 PROFIBUS message frame selection = 104 MD36010 STOP_LIMIT_FINE[AX3]=10
MD36030 STANDSTILL_POS_TOL[AX3]=10
Save + Reset MD36400 CONTOUR_TOL[AX3]=40

Symmetrize analog output:

preliminary 11/2000

MD 36720 DRIFT_VALUE=0.3891%

P922 PROFIBUS message frame selection = 0

P915[8] PZD setpoint assignment PB = 50103
P915[9] PZU setpoint assignment PB = 50107

Save + Reset

Parameterize analog output 75.A/15 to “Signal DAC1 of

PROFIBUS PPO”

Parameterize digital outputs O0.A and O1.A to “Selection via

PROFIBUS”

Save + Reset

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3.8.4 Connecting a direct measuring system

Prerequisite:
Both rotary and linear measuring systems can be connected to SINUMERIK 802D. These measur-
ing systems must be raw signal generators with 1Vss sin/cos track (A, A*, B, B*). Measuring sys-
tems either with a zero mark (R, R*) or with EnDat interface can be connected. Measuring systems
with position–coded zero marks are not permitted!

If a direct measuring system is connected, the 611UE closed–loop control module can only be oper-
ated with one axis. Connect the direct measuring system to the second encoder interface (X412). It
is not possible to switch over between direct measuring system and motor measuring system using
preliminary 11/2000

the PLC.

Implementation:
Connect the direct measuring system to the encoder interface X412 of the 611UE closed–loop con-
trol module using the Siemens standard cable

– 6FX8002–2CG00–xxxx (incremental encoder)

– 6FX8002–2CH00–xxxx (EnDat encoder)
and parameterize the drive using SimoCom U for the direct measuring system.

Parameterization using the drive configuration wizard

Fig. 3-3 Display

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Parameterization using the expert list

preliminary 11/2000

Fig. 3-4 Values to be entered in the expert list

Change the process data configuration from encoder 1 to encoder 2.

Fig. 3-5 Process data of encoder 1

Approach:
S First set P922 to zero, then save and press Reset.
S Now change P915:6, P916:6 ... P916:10.

Fig. 3-6 Process data of encoder 2

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Adapt the machine data in the control system

Table 3-8

Machine data Designation Remark

30240 ENC_TYPE[0] 1 := incr. encoder
4 := EnDat
31020 ENC_RESOL[0] Number of increments with
rotary encoder
34200 ENC_REFP_MODE[0] 1 := incr. encoder
0 := EnDat
preliminary 11/2000

31000 ENC_IS_LINEAR[0] 0 := rotary encoder

1 := linear scale
31010 ENC_GRID_POINT_DIST[0] Graduation of linear scale

31040 ENC_IS_DIRECT[0] 0 := Motor–mounted encoder

1 := Encoder at the load

32110 ENC_FEEDBACK_POL[0] 0 := Default

–1 := Reverse direction of
rotation

Special feature:
When working with a direct measuring system and if a sensor is connected, this must be connected
on SIMODRIVE 611UE to the interface –X452, terminal I0.B and be parameterized with signal num-
ber 80 via drive parameter P672.

Fig. 3-7 Setting for P672

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3.9 Completing Start–up

After the start–up of the control system has been carried out by the machine manufacturer, an
internal data backup should be carried out before the control system is supplied to the end
customer:

1. Carry out internal data backup (requires at least protection level 3)

– Press softkey Save data.
2. Reset access level.
– Press softkey Delete passw.
preliminary 11/2000

3.10 Service Display of Axis Drive Behavior

Servo Trace
The function Servo Trace is integrated in the Diagnostics menu for axis service to be able to display
axis signals graphically.

The Trace function is selected in the operating area System\Service display\Servo Trace.

References
/BH/ SINUMERIK 802D “Operation and Programming, Chapter 7

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General
The job of the PLC is to control machine–specific sequences of functions. It is implemented as a
software PLC.
preliminary 11/2000

The user program – a PLC cycle – always runs in the same order.
S Process image update (inputs, user interface, timers)
S Processing of communication requirements (Operator Panel, Programming Tool PLC 802,
version 3.0 and higher)
S Execution of user program
S Evaluation of alarms
S Output of process image (outputs, user interface)
In the cycle, the PLC executes the user program from the first to the last operation. The user
program accesses the hardware inputs/outputs only via the process image and not directly. The
PLC updates the hardware I/O at the beginning or the end of program execution. These signals are
thus stable over a whole PLC cycle.
The user program can only be created in Ladder Diagram using Programming Tool PLC 802,
version 3.1 and higher. Ladder Diagram is a graphical programming language to represent electrical
wiring diagrams.

Note
If the Stop and Reset pushbuttons of the machine control panel are not realized as normally closed
contacts, line breakage cannot be detected.
The monitoring can be carried out using software solutions, as illustrated in the example
MCP_802D (SBR 34) of the subroutine library.

4.1 Commissioning of PLC

When the SINUMERIK 802D comes to the user, the user program only consists of a NOP
statement (no operation); it is stored in the permanent memory. It is the user’s job to create a user
program according to the specific requirements of the machine.

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4.2 PLC Start–up Modes

Table 4-1 Start–up modes

Selection Response
PCU PCU PT PLC 802 PLC Program Retentive MD for the
switch–on start–up menu (PC) program status data PLC in the
menu (802D) (802D) pre– (battery– user
selection backed) interface
NCK Start Up *
preliminary 11/2000

Normal booting Normal booting User Run unchanged Acceptance

program *** of active
PLC–MD
Booting with Booting with User Run deleted Standard
default values default values program *** PLC–MD
Booting with Booting with saved User Run saved data Saved
saved data data program *** PLC–MD
PLC stop PLC stop unchanged Stop unchanged Acceptance
after POWER ON possible in of active
Run or Stop PLC–MD

PLC–Start Up **
Cold restart Run (nach User Run unchanged Acceptance
Stop) program *** of active
PLC–MD
Cold restart User Stop unchanged Acceptance
and dbug mode program *** of active
PLC–MD

General reset User Run deleted Acceptance

program *** of active
PLC–MD
General reset User Stop deleted Acceptance
and debug mode program *** of active
PLC–MD
* System hardkey / softkey / Start–up switch / NCK
** System hardkey / softkey / Start up switch / PLC
*** is loaded from the permanent memory into the RAM

The debug mode (see “Operation and Programming “, Section 7) causes the PLC to remain in PLC
Stop after the control system has booted. All boot modes set via softkey come only into effect with
the next booting.

The Run mode activates cyclic operation.

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In Stop mode, the following actions are initiated:

S Alle hardware outputs disabled.

S Profibus DP is disabled.
S No cyclic operation (active user program is not executed)
S Process image is no longer updated (frozen)
S Emergency Stop active
The user can load a corrected or new project into the control system only in Stop mode. The user
program comes only into effect with the next booting of the control system or when Run mode is
active.
preliminary 11/2000

4.3 PLC Alarms

The control system displays a maximum of 8 PLC alarms (system alarms or user alarms).

The PLC manages the alarm information per PLC cycle. It stores the alarms in the alarm list or
deletes them from the alarm list according to their times of occurence. The first alarm in the list is
always the alarm occurred last.

In the case of more than 8 alarms, the first seven alarms and the last alarm with the highest reset
priority are displayed.

Alarm reaction and reset criteria

Furthermore, the PLC manages the alarm reactions. The alarm reactions come always into effect,
independently of the number of active alarms. Depending on the kind of the alarm reaction, the PLC
triggers the required action.
A reset criterion must be defined for each alarm. By default, the PLC uses the reset criterion
SELF–CLEARING (see “Configuring User Alarms”).

Reset criteria are:

S POWERONCLEAR: The alarm is reset by POWER ON (turning off/turning on the control
system).
S CANCELCLEAR: The alarm is reset by pressing “Cancel“ or “Reset” (analogous to NCK
alarms).
S SELF–CLEARING: The alarm is reset since the alarm cause is no longer present.

The reset criteria have the following priority:

S POWERON CLEAR – system alarms ( highest priority )
S CANCEL CLEAR – system alarms
S SELF–CLEARING – system alarms
S POWERON CLEAR – user alarms
S CANCEL CLEAR – user alarms
S SELF–CLEARING – user alarms ( lowest priority )
For each alarm, reactions are defined which are to be triggered by the alarm. The PLC uses the
alarm reaction SHOWALARM by default.

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Alarm reactions are:

S PLC Stop : No user program is executed any more, Profibus–DP is inactive and the hardware
outputs are disabled ( OUTDS ).
S EMERGENCY STOP: After the user program has been executed, the PLC signals Emergency
Stop to the NCK.
S Feed Disable: After the user program has been executed, the PLC signals Feed Disable to the
NCK.
S Read–in Disable: After the user program has been executed in the user interface, the PLC
signals Read–in Disable to the NCK.
S NC Start Disable: After the user program has been executed in the user interface, the PLC
preliminary 11/2000

signals NC Start Disable to the NCK.

S SHOWALARM : This alarm has no alarm reaction.

4.3.1 General PLC Alarms

References
SINUMERIK 802D, Diagnostics Guide

4.3.2 User Alarms

The user interface ‘’ 1600xxxx ‘’ provides the user with sub–areas (0, 1) to define his own user
alarms.

S Sub–area 0: 4 x 8 bits for setting user alarms (0 –>1 edge)

Byte 0 : Bit 0 => 1st user alarm “ 700000 “
Byte 1 : Bit 0 => 9th user alarm “ 700008 “
Byte 3 : Bit 7 => 32nd user alarm “ 700031 “
New user alarms are enabeled with the appropriate bit (sub–area 0) using a 0/1 edge.
S Suba–area 1: Variables of user alarms
Sub–area 1 is intended for additinal information of the user. It can only be read or written as a
double–word.
S Sub–area 2: Alarm reaction
Byte 0 : Bit 0 => NC start disable
Bit 1 => Read–in disable
Bit 2 => Feed disable of all axes
Bit 3 => EMERGENCY STOP
Bit 4 => PLC STOP
The user can use sub–area 2 to evaluate the active alarm reactions. It is a read–only sub–area.
Self–clearing user alarms must be cleared by the user by resetting the appropriate bit in sub–area 0
(1 –> 0 edge).

All the other user alarms are cleared by the PLC after the related reset condition has been detected.
If the bit of the user alarm is still present, the alarm will recur.

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Activation of a user alarm

A user alarm’s priority is generally higher than that of the related signal in the user interface (e.g.,
NC Start Disable, Feed Disable and EMERGENCY STOP).

Configuring user alarms

A configuring byte is provided for each alarm. The user can configure his own alarms in machine
data 14516_MN_USER_DATA_PLC_ALARM.

Default setting of MD 14516[0...31]: 0 => SHOWALARM/SELF–CLEARING user alarm

Structure of a configuring byte:

preliminary 11/2000

S Bit0 – Bit5 : Alarm reactions

S Bit6 – Bit7 : Reset criterion
Alarm reactions: Bit0 – Bit 5 = 0: Showalarm (default)
Bit0 = 1: NC Start Disable
Bit1 = 1: Read–in Disable
Bit2 = 1: Feed Disable of all axes
Bit3 = 1: EMERGENCY STOP
Bit4 = 1: PLC Stop
Bit5 = Reserved

Reset criteria: Bit6 + Bit7 = 0: SELF–CLEARING alarm (default)

Bit6 = 1 : CANCELCLEAR alarm
Bit7 = 1 : POWERONCLEAR alarm
The user alarm reaction PLC Stop has always the reset condition POWER ON.

Alarm texts
There are two possible ways for the user to configure his own alarm texts.

S using the System hardkey \ PLC Softkey \ Edit PLC txt (cf. “Operation, Programming“,
Chapter 7)
S using the Toolbox
If the user does not assign a user alarm text, only the alarm number is displayed.

The % character in the alarm text marks an additional variable. The variable type identifies the type
of representation of the variable.
The following variable types are possible:

S %D integer decimal number

S % I integer decimal number
S %U decimal number without sign
S %O integer octal number
S %X integer hexadecimal number
S %B binary representation of a 32–bit value
S %F 4–byte floating point number

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Examples – user alarm texts (Note: The text after “//” is a comment and is not displayed.)

S 700000 ‘’ ‘’ // only user alarm number

S 700001 ‘’ hardware limit switchfor axis X +’’
S 700002 ‘’ %D ‘’ // only variable as an integer decimal number
S 700003 ‘’ alarm number with fixed alarm text and variable %X ‘’
S 700004 ‘’ %U alarm number with variable and fixed alarm text ‘’
S 700005 ‘’Monitoring of axis active : %U’’
Display: 700005 Monitoring of axis active : 1
or 700005 Monitoring of axis active : 3
preliminary 11/2000

4.4 PLC Programming

A PLC user program is created using the Programming Tool PLC 802.
The handling for an S7–200 is described in the Documentation “SIMATIC S7–200 Automation
System – System Manual“. The Programming Tool PLC 802 constitutes a subset of this
Documentation.

The following should be observed, compared with the basic system S7– 200 MicroWin:
S Programming Tool PLC 802 is available in the English language version.
S The user program can only be programmed in Ladder Diagram.
S Only a subset of the programming language S7–200 is supported.
S The compilation of the user program is either offline on a PG/PC (PG = programming unit) or
automatically when the program is downloaded into the control system.
S The project can be downloaded into the control system (Download).
S It is also possible to upload the project from the control system (Upload).
S Indirect addressing of the data is not possible. Therefore, no programming errors in this regard
are possible during the execution of the program.
S The user must manage his data and process information type–specifically.
Example:
Information 1 T–value Memory size of DWord (32–bit)
Information 2 Override Byte memory size (8–bit)
User data
Byte 0 DWord (Information 1)
Byte 4 Byte (Information 2)
Mixed data access is not allowed for the data above; otherwise, the user should observe the
relevant data access rules.
S Furthermore, the data direction (alignment) of all data in the memory model and their type must
be observed.
Example:
Flagb bit MB0.1,MB3.5
Flag byte MB0,MB1,MB2
Flag word MW0,MW2,MW4
MW3, MW5 ... are not permitted
Flag double–word MD0,MD4,MD8
MD1,MD2,MD3, MD5 ... are not permitted

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Table 4-2 PLC data types admitted in the control system

Data type Size Address Range for logical operations Range for arithmetical
alignment operations
BOOL 1 bit 1 0, 1 –
BYTE 1 byte 1 00 ... FF 0 ... +255
WORD 2 bytes 2 0000 ... FFFF –32 768 ... + 32 767
DWORD 4 bytes 4 0000 0000 ... FFFF FFFF –2 147 483 648 ...
(Double +2 147 483 647
Word)
$10–37... $1038
preliminary 11/2000

REAL 4 bytes 4 –

PLC project
The PLC 802 Programming Tool always manages one project (logic operation, symbols and
comments). Using a Download operation, all relevant information of a project can be stored in the
control system. An Upload operation can be used to transfer information from the control system
into the PC.

The control system can store a maximum of 6,000 statement commands and 1,500 symbols. The
following factors have influence on the required PLC memory:
S Number of statements
S Number and length of symbol names
S Number and length of comments

S7–200 Ladder Diagram

The addresses and operations can be defined in the type of representation “International”. The user
programs his program in networks using Ladder Diagram. Each network corresponds to a certain
logics reflecting a certain sequence. In a Ladder Diagram, contacts, coils and boxes are possible as
basic elements. The contacts are divided into normally open and normally closed contacts. Each
coil corresponds to a relay. A box reflects a certain function. A box can be enabled using an Enable
bit.

4.4.1 Command Overview

Table 4-3 Operand identifiers

Operand identifier Description Range

V Data V1000 0000.0 to V7999 9999.7
T Timers T0 to T15 (100 ms)
T16 to T31 (10 ms)
C Counters C0 to C31
I Image of digital inputs I0.0 to I17.7
Q Image of digital outputs Q0.0 to Q11.7
M Flags M0.0 to M255.7

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Table 4-3 Operand identifiers

Operand identifier Description Range

SM Spezial – Merker SM0.0 bis SM 0.6
(see Table 4-6)
AC ACCU AC0 ... AC3

Table 4-4 Formation of V range address (see user interface)

Type Range No. Sub–area Offset Addressing

preliminary 11/2000

identifier (channel/
(module No.) axis No.)
00 00 0 000 symbolic
(10–79) (00–99) (0–9) (000–999) (8–digit)

Table 4-5 802D Operand Ranges

Access Method Valid operand ranges for

programming the 802D
Bit access (byte, bit) V(1000 0000.0–7900 9999.7)
I(0.0–17.7)
Q(0.0–11.7)
M(0.0–255.7)
SM(0.0–0.7)
–
T(0–31)
C(0–31)
Byte access VB(1000 0000–7999 9999)
IB(0–17)
QB(0–11)
MB(0–255)
AC(0–3)
SMB(0)
–
KB (Constant)

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Table 4-5 802D Operand Ranges

Access Method Valid operand ranges for

programming the 802D
Word access VW(1000 0000–7999 9998)
T(0–31)
C(0–31)
IW(0–16)
QW(0–10)
MW(0–254)
AC(0–3)
–
preliminary 11/2000

–
KW (Constant)
Double–word access VD(1000 0000–7999 9994)
ID(0–14)
QD(0–8)
MD(0–252)
AC(0–3)
–
–
AC(0–3)
KD (Constant)

Table 4-6 Bit definition for special flags (SM)

SM bits Description
SM 0.0 Flag with defined ONE signal
SM 0.1 Default setting: First PLC cycle ‘1’, following cycles ‘0’
SM 0.2 Buffered data lost – only valid in the first PLC cycle
(‘0’ – data o.k., ‘1’ – data lost)
SM 0.3 POWER ON: First PLC cycle ‘1’, folllowing cycles ‘0’
SM 0.4 60 s clock (alternating ‘0’ for 30 s, then ‘1’ for 30 s)
SM 0.5 1 s clock (alternating ‘0’ for 0.5 s, then ‘1’ for 0.5 s)
SM 0.6 PLC cycle clock (alternating: one cycle ‘0’, then a cycle ‘1’)

The user can only view the Statement List (STL) in PT802 using “View STL”. This type of
representation (see Table : Mnemonic) shows the sequential processing.

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4.4.2 Explanation of Stack Operations

Table 4-7 INSTRUCTION SET

BASIC BOOLEAN INSTRUCTIONS

Instruction Ladder symbol Valid operands
Load normally open n: V, I, Q, M, SM, T, C, L
n
And n=1 closed
Or n=0 open
preliminary 11/2000

Load Not normally closed n: V, I, Q, M, SM, T, C, L

n
And Not n=0 closed
Or Not n=1 open
Output first 0, n=0 n n: V, I, Q, M,T, C, L
first 1, n=1

Set first 0, not set Bit S_Bit: V, I, Q, M, T, C, L

(1 bit) first 1 or ½ S n =1

Reset first 0, no reset Bit

S_Bit: V, I, Q, M, T, C, L
(1 bit) first 1 or ½ n=1
R

OTHER BOOLEAN INSTRUCTIONS

Instruction Ladder symbol Valid operands
Edge Up first ½, close
P
(1 PLC cycle)
Edge Down first ¿, close
N
(1 PLC cycle)
Logical Not first 0, then 1
NOT
first 1, then 0
No operation n n = 0 ... 255
NOP

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BYTE COMPARISONS (unsigned)

Instruction Ladder symbol Valid operands
Load Byte = a = b closed a a: VB, IB, QB, MB, SMB, AC, constant,
And Byte = a  b open ==B LB
b b: VB, IB, QB, MB, SMB, AC, constant,
Or Byte =
LB
Load Byte . a ≥ b closed a
And Byte . a t b open > =B
b
Or Byte .
Load Byte 3 a ≤ b closed a
And Byte 3 a u b open
preliminary 11/2000

< =B
b
Or Byte 3

WORD COMPARISONS (signed)

Instruction Ladder symbol Valid operands
Load Word = a = b closed a a: VW, T, C, IW, QW, MW, AC, constant,
And Word = a  b open ==I LW
Or Word = b b: VW, T, C, IW, QW, MW, AC, constant,
LW
Load Word . a ≥ b closed a
And Word . a t b open > =I
b
Or Word .
Load Word 3 a ≤ b closed a
And Word 3 a u b open < =I
b
Or Word 3

DOUBLE WORD COMPARISONS (signed)

Instruction Ladder symbol Valid operands
Load DWord = a = b closed a a: VD, ID, QD, MD, AC, constant, LB
And DWord = a  b open ==D b: VD, ID, QD, MD, AC, constant, LB
b
Or DWord =
Load DWord . a ≥ b closed a
And DWord . a t b open > =D
b
Or DWord .
Load DWord 3 a ≤ b closed a

And DWord 3 a u b open < =D

b
Or DWord 3

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REAL WORD COMPARISONS (signed)

Instruction Ladder symbol Valid operands
Load RWord = a = b closed a a: VD, ID, QD, MD, AC, constant, LD
And RWord = a  b open = =R b: VD, ID, QD, MD, AC, constant, LD
b
Or RWord =
Load RWord . a ≥ b closed a
And RWord . a t b open > =R
b
Or RWord .
Load RWord 3 a ≤ b closed a
And RWord 3 a u b open
preliminary 11/2000

< =R
b
Or RWord 3

TIMERS
Instruction Ladder Symbol Valid operands
Timer Retentive EN=1, Start Enable: (IN)
On Delay EN=0, Stop Txxx S0
If TValue ≥ PT, TONR Txxx: T0 – T31
Tbit=1 IN
Preset: (PT)
VW, T, C, IW, QW, MW, AC,
constant
PT
100 ms T0 – T15
10 ms T16 – T31
Timer On Delay EN=1, Start Enable: (IN)
EN=0, Stop Txxx S0
If TValue ≥ PT, TON Txxx: T0 – T31
Tbit=1 IN
Preset: (PT)
VW, T, C, IW, QW, MW, AC,
constant
PT
100 ms T0 – T15
10 ms T16 – T31
Timer Of Delay If TValue < PT, Enable: (IN)
Tbit=1 Txxx S0
TOF Txxx: T0 – T31
IN
Preset: (PT)
VW, T, C, IW, QW, MW, AC,
constant
PT
100 ms T0 – T15
10 ms T16 – T31

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COUNTER
Instruction Ladder symbol Valid operands
Count Up CU ½, Value+1 Cnt Up: (CU)
Cxxx S1
R=1, Reset
If CValue ≥ PV, Reset: (R)
CU CTU S0
Cbit=1
Cxxx: C0 – 31
R
PV
Preset: (PV)
VW, T, C, IW, QW, MW, AC,
constant, LW
CU ½, Value+1
preliminary 11/2000

Count Up/Down Cnt Up: (CU)

CD ½, Value–1 S2
R=1, Reset Cxxx Cnt Dn: (CD)
If CValue ≥ PV, S1
CU CTUD
Cbit=1 Reset: (R)
CD S0
R
Cxxx: C0 – 31
PV
Preset: (PV)
VW, T, C, IW, QW, MW, AC,
constant, LW
Count Down If CValue = 0, Cnt Down: (CD)
Cbit=1 Cxxx S2
Reset: (R)
CD CTD S0
LD
Cxxx: C0 – 31
PV
Preset: (PV)
VW, T, C, IW, QW, MW, AC,
constant, LW

MATH OPERATIONS
Instruction Ladder symbol Valid operands
Word Add If EN = 1, ADD_I Enable: EN
Word Subtract b=a+b EN ENO In: VW, T, C, IW, QW, MW, AC,
b=b–a IN1 Constant, LW
IN2 OUT Out: VW, T, C, IW, QW, MW, AC, LW

DWord Add If EN = 1, SUB_DI Enable: EN

DWord Subtract b=a+b EN ENO In: VD, ID, QD, MD, AC, constant, LD
b=b–a IN1 Out: VD, ID, QD, MD, AC, LD
IN2 OUT

Multiply If EN = 1, MUL Enable: EN

b=axb EN ENO In: VW, T, C, IW, QW, MW, AC,
IN1 constant, LW
IN2 OUT Out: VD, ID, QD, MD, AC, LD

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Instruction Ladder symbol Valid operands

Divide If EN = 1, Enable: EN
b=b÷a DIV
In: VW, T, C, IW, QW, MW, AC,
Out: EN ENO constant, LW
16 bit remainder IN1
Out: VD, ID, QD, MD, LD
IN2 OUT
Out+2:
16 bit quotient
Add If EN = 1, ADD_R Enable: EN
Subtract b=a+b EN ENO In: VD, ID, QD, MD, AC, constant, LD
Real Numbers b=b–a IN1 Out: VD, ID, QD, MD, AC, LD
IN2 OUT
preliminary 11/2000

Multiply If EN = 1, MUL_R Enable: EN

Divide b=axb EN ENO In: VD, ID, QD, MD, AC, constant, LD
Real Numbers b=b÷a IN1 Out: VD, ID, QD, MD, AC, LD
IN2 OUT

INCREMENT, DECREMENT
Instruction Ladder symbol Valid operands
Increment If EN = 1, Enable: EN
INC_B
Decrement a=a+1 In: VB, IB, QB, MB, AC, constant LB
EN ENO
Byte a=a–1 Out: VB, IB, QB, MB, AC, LB
IN OUT

Increment If EN = 1, Enable: EN
Decrement a=a+1 INC_W In: VW, T, C, IW, QW, MW, AC,
Word a=a–1 EN ENO constant, LW
a = /a Out: VW, T, C, IW, QW, MW, AC, LW
IN OUT

Increment If EN = 1, Enable: EN
INV_DW
Decrement. a=a+1 In: VD, ID, QD, MD, AC, constant, LD
EN ENO
a=a–1 Out: VD, ID, QD, MD, AC, LD
IN OUT

LOGIC OPERATIONS
Instruction Ladder symbol Valid operands
Byte AND If EN = 1, WAND_B Enable: EN
Byte OR b = a AND b EN ENO In: VB, IB, QB, MB, AC, constant, LB
Byte XOR b = a OR b IN1 Out: VB, IB, QB, MB, AC, LB
IN2 OUT
b = a XOR b
Word AND If EN = 1, WAND_W Enable: EN
Word OR b = a AND b EN ENO In: VW, T, C, IW, QW, MW, AC,
Word XOR b = a OR b IN1 constant, LW
IN2 OUT
b = a XOR b Out: VW, T, C, IW, QW, MW, AC, LW

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Instruction Ladder symbol Valid operands

DWord AND If EN = 1, WXOR_DW Enable: EN
DWord OR b = a AND b EN ENO In: VD, ID, QD, MD, AC, constant, LD
DWord XOR b = a OR b IN1 Out: VD, ID, QD, MD, AC, LD
IN2 OUT
b = a XOR b
Invert Byte If EN = 1, INC_B Enable: EN
a = /a EN ENO In: VB, IB, QB, MB, AC, constant, LB
Out: VB, IB, QB, MB, AC, LB
IN OUT

Invert Word If EN = 1, Enable: EN

preliminary 11/2000

INC_W
a = /a EN ENO In: VW, T, C, IW, QW, MW, AC,
constant, LW
IN OUT Out: VW, T, C, IW, QW, MW, AC, LW

Invert DWord If EN = 1, INV_DW Enable: EN

a = /a EN ENO In: VD, ID, QD, MD, AC, constant, LD
Out: VD, ID, QD, MD, AC, LD
IN OUT

SHIFT AND ROTATE OPERATIONS

Instruction Ladder Symbol Valid Operands
Shift Right If EN = 1, SHL_R Enable: EN
Shift Left a = a SR c bits EN ENO In: VB, IB, QB, MB, AC, constant, LB
a = a SL c bits IN Out: VB, IB, QB, MB, AC
N OUT
Count: VB, IB, QB, MB, AC, constant, LB

Shift Right If EN = 1, Enable: EN

SHL_W
Shift Left a = a SR c bits EN
In: VW, T, C, IW, QW, MW, AC,
ENO
a = a SL c bits constant, LW
IN
N OUT Out: VW, T, C, IW, QW, MW, AC, LW
Count: VB, IB, QB, MB,AC, constant, LB
DWord Shift R If EN = 1, SHL_DW Enable: EN
DWord Shift L a = a SR c bits EN ENO In: VD, ID, QD, MD, AC, constant, LD
a = a SL c bits IN Out: VD, ID, QD, MD, AC, LD
N OUT
Count: VB, IB, QB, MB, AC, constant, LB

CONVERSION OPERATIONS
Instruction Ladder Symbol Valid Operands
Convert Double If EN = 1, convert DI_REAL Enable: EN
Word Integer to a the double word EN ENO In: VD, ID, QD, MD, AC, constant, LD
Real integer i to a real
IN OUT Out: VD, ID, QD, MD, AC, LD
number o.

Convert a Real to If EN = 1, convert TRUNC Enable: EN

a Double Word the real number i to EN ENO In: VD, ID, QD, MD, AC, constant, LD
Integer a double word
IN OUT Out: VD, ID, QD, MD, AC, LD
integer o.

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PROGRAM CONTROL FUNCTIONS

Instruction Ladder sSymbol Valid operands
Jump to Label If EN = 1, go to n Enable: EN
label n. Label: WORD: 0–127
JMP

Label Label marker for the n Label: WORD: 0–127

jump. LBL

Conditional Return If EN = 1, exit the Enable: EN

from Subroutine subroutine. RET
preliminary 11/2000

Return from Exit subroutine.

Subroutine RET

Conditional End If EN = 1, END Enable: EN

terminates the main END
scan.

PROGRAM CONTROL FUNCTIONS

Instruction Ladder symbol Valid operands
Subroutine If EN ½, go to n Label: Constant : 0–63
subroutine n. SBR
EN
x1
x2 x3

(x... optional paramete

MOVE, FILL AND FIND OPERATIONS

Instruction Ladder symbol Valid operands
Move Byte If EN = 1, MOV_B Enable: EN
copy i to o. EN ENO In: VB, IB, QB, MB, AC, constant, LB
Out: VB, IB, QB, MB, AC, LB
IN OUT

Move Word If EN = 1, MOV_W Enable: EN

copy i to o. EN ENO In: VW, T, C, IW, QW, MW, AC,
constant, LW
IN OUT Out: VW, T, C, IW, QW, MW, AC, LW

Move DWord If EN = 1, MOV_DW Enable: EN

copy i to o. EN ENO In: VD, ID, QD, MD, AC, constant, LD
Out: VD, ID, QD, MD, AC, LD
IN OUT

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Instruction Ladder symbol Valid operands

Move Real If EN = 1, MOV_R Enable: EN
copy i to o. EN ENO In: VD, ID, QD, MD, AC, Constant, LD
Out: VD, ID, QD, MD, AC, LD
IN OUT

Swap Bytes If EN = 1, SWAP Enable: EN

exchange MSB and EN ENO In: VW, IW, QW, MW, T, C, AC, LW
LSB of w.
IN
preliminary 11/2000

4.4.3 Program Organization

Every programmer should divide his user program into independent program sections (subroutines).
The programming language S7–200 allows the user to create structured user programs. Two
program types exist – main program and subroutine. Eight program levels are possible.

A PLC cycle can be a multiple of the control–internal interpolation cycle (IPO cycle). The machine
manufacturer must set the PLC cycle according to his particular requirements (see machine data
“PLC_IPO_TIME_RATIO”). The ratio IPO/ PLC of 1:1 is the fastest possible cycle processing.
Example: The programmer writes a sequencing control in his main program using his own defined
cycle counter. This sequencing control will organize all cyclic signals in the subroutine (UP0),
UP1/UP2 is called every two cycles, and UP3 controls all signals at an interval of three cycles.

4.4.4 Data Organization

The data can be divided into three ranges:

S non–retentive data
S retentive data
S machine data for the PLC (These machine data come into effect after POWER ON.)
Most data, such as process image, timers and counters, are non–retentive data and are deleted
with every booting of the control system.
Data range 1400 0000 –1400 0127 is provided for the retentive data. The user can store there all
data that are to remain effective beyond POWER ON.

The user can use the PLC–MD (see user interface) to assign his program default data or to
parameterize various program sections.

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4.4.5 Interface to the Control System

This interface can be selected via SYSTEM, softkey Setup PLC \ STEP7–connect.

This V24 interface remains active after cold restart or normal booting. The connection to the control
system (STEP7 connect active) can be checked using the PLC 802 Programming Tool in the menu
“PLC/Information”. If the interface is active, for example, the active PLC mode (Run/Stop) appears in
this window.

4.4.6 Testing and Monitoring Your Program

preliminary 11/2000

Check and error analysis of the user program is possible as follows:

S PLC Status menu (PCU)

S Status List menu (PCU)
S PLC 802 Programming Tool (see Documentation “Automation System S7–200”, Section “Testing
and Monitoring Your Program”)

4.5 Downloading/Uploading/Copying/Comparing PLC Applications

The user can save, copy or overwrite the PLC applications in his control system with another PLC
project.

This is possible using the

S PLC 802 Programming Tool or
S WINPCIN (binary file)

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PT PLC 802

Download/

Upload/
Compare

Permanent
preliminary 11/2000

802D
memory
PLC
project
 

PLC user PLC machine
alarm texts data Series machine
start–up


PLC
Toolbox applications


PLC
application
NC card


WINPCIN
Series machine start–up

Fig. 4-1 PLC applications in the control system

Download
This function writes the transferred data into the permanent memory (load memory) of the control
system.

S Download PLC project using the PLC 802 Programming Tool

(Step 7 connect on)
S Series machine start–up using WINPCIN Tool (PLC MD, PLC project and user alarm texts)
Data In or NC card
S Read–in PLC applications using WINPCIN Tool or NC card (PLC project and user alarm texts)
analogous to series machine start–up Data In
When the control system boots next time, the loaded PLC user program is transferred from
the permanent memory to the user memory and is active in the control system from this
moment up.

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 Starting up the PLC

Upload
The PLC applications can be saved from the permanent memory of the control system using the
PLC 802 Programming Tool or WINPCIN Tool.

S Uploading the PLC project using the PLC 802 Programming Tool (Step 7 connect on)
Read out the project from the control system, thus reassembling the current project using the
PLC 802 Programming Tool.
S Series machine start–up “Start up Data” with WINPCIN Tool (PLC MD, PLC project and user
alarm texts) Data Out or NC card
S Read out PLC applications using WINPCIN Tool or NC card (PLC project info and user alarm
texts) Data Out
preliminary 11/2000

Compare
The project contained in the PLC 802 Programming Tool is compared with the project stored in the
permanent memory (load memory) in the control system.

Version display
is called using the hardkey SYSTEM, softkey Service Display / Version
S Project
The transferred project including the user program that is active in the user memory of the PLC
after booting of the control system.
In the PLC 802 Programming Tool, the programmer can use the beginning of the first comment
line in the comment of OB1 for his own supplementary information in the version display (see
View Properties).

4.6 User Interface

This interface includes all signals exchanged between NCK/PLC and HMI/PLC. In addition, the PLC
decodes the auxiliary function commands for simple further processing in the user program.

References
/FB/ Sinumerik 802D, Description of Functions, Chapter 17

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5.1 Series Machine Start–up
preliminary 11/2000

Functionality
The objective of the series machine start–up is:
S to bring another control system connected to the same machine type to the condition as after
commissioning with lowest possible effort after commissioning
or
S to bring a new control system with lowest possible effort to the initial state in service case (after
replacing the hardware).

Precondition
A series machine start–up requires a PC with V24 interface for data transfer from/to the control
system and an NC card.
On the PC, WINPCIN Tool must be used.

Sequence with PC
1. Create series machine start–up file in the PC (transfer from the control system to the PC):
– Make a V24 cable connection between PC (COM interface) and SINUMERIK 802D (COM1).
– Make the following settings in WINPCIN Tool in the menu RS232 Config (the settings not
typed in bold correspond to the default settings of WINPCIN):
Com Port Number of PC–COM to the SINUMERIK 802D
Baud rate 19200
Parity none
Data bit 8
Stop bit 1
Software (XON/XOFF) OFF
Hardware (RTS/CTS) ON
Timeout 0s
BIN Format ON
– Call the menu Resave Data on your PC,
enter the file name (any archive name) and start the transfer.
The PC will change to reception and will wait for data from the control system.
– In the control system, the password for protection level 2 is required.
– Select the line Start–up data PC in the menu System \Data I/O and read out the series
machine start–up file using Read out.
2. Read in the series machine start–up file from the PC into the SINUMERIK 802D.
– Make the required settings for the V24 interface on the PC as prescribed in 1).

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– Select the line Start–up data PC in the menu System \Data I/O and press Read in. The
control system is ready to receive.
– Use WINPCIN to choose the series machine start–up file from the menu Sent Data and start
the transfer.
– After reading–in has started, confirm the series machine start–up file in the screen form that
will then appear on the display of the control system.
– The control system reboots several times during and at the end of the transfer. If the transfer
has completed without errors, the control system is fully configured and ready for operation.

Sequence with NC card

preliminary 11/2000

! Important
A flash file system with a maximum of 2 MB must be formatted on the NC card.

1. Create a series machine start–up file on the NC card:

– Make sure that the NC card (flash card from Siemens) is plugged before the control system
is booted.
– The password for protection level 2 is required on the control system.
– Select the line Start–up data NC–Card in the menu System \ Data I/O and read out the
series machine start–up file using Read out.
2. Read in the series machine start–up file from the NC card into the SINUMERIK 802D.
– Make sure that the NC card (flash card from Siemens) is plugged before the control system
is booted.
– The password for protection level 2 is required on the control system.
– Select the line Start–up data PC in the menu System \Data I/O and press Read in. The
control system is ready to receive.

Series machine start–up file

The series machine start–up file has the following contents:
S Machine data
S R parameters
S PLC user alarm texts
S Display machine data
S PLC user program
S Part programs
S Cycles
S Setting data
S Zero offsets
S Tool offsets
S Leadscrew error compensation data
S Drive machine data of SIMODRIVE 611UE

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5.2 Data Backup

5.2.1 Internal Data Backup

The data of the battery–backed memory with limited storage time require an internal data backup
into the permanent memory of the control system. An internal data backup must be carried out
whenever the control system is switched off longer than 50 hours (at least 10 min/day control
system ON).

It is recommended to carry out an internal data backup immediately after substantial data
modifications.
preliminary 11/2000

Note
An internal data backup creates a memory copy of the battery–backed memory in the permanent
memory. Selected data backup (e.g. only the machine data and not the workpiece programs) is
not possible.

Making an internal data backup

Press the softkey Save Data in the operating area System (at least protection level 3 required).

Loading data saved with an internal data backup

S Boot the control system in start–up mode “Reload saved user data”
S In case of data loss of the battery–backed memory, the data saved in the permanent memory
are automatically reloaded into the memory at POWER ON.

Note
The message ”4062 Data backup copy was loaded” appears.

5.2.2 External Data Backup

In addition to the internal data backup, the user data of the control system can also be backed up
externally. Such an external data backup requires a PC with V24 and WINPCIN Tool (contained in
the Toolbox).

An external data backup should always be carried out in the case of substantial data modifications
and at the end of the start–up.

To backup all data of a machine, it is sufficient to create a series machine start–up file.

Variants of external data backup:

1. Read out all data: Series machine start–up

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2. The files are read in/read out by ranges. The following user data can be chosen as individual
files:
Data
– Machine data
– Setting data
– Tool data
– R parameters
– Zero offset
– Compensation data (LEC)
preliminary 11/2000

Part programs, Standard cycles, PLC programs (binary file)

Making an external data backup:

S Choose text format from the menu System \ Data I/O \ RS232 setting.
S Set text format also in WINPCIN.
S Use the menu System \ Data I/O \ Data selection to transfer the user data as individual data to
an external PC via the V24 interface.

Loading externally saved data into the control system:

Choose the softkey Read in from the menu System \ Data I/O.

5.3 Formatting a NC Card

An appropriate menu item has been implemented in the start menu of the control system to format
NC cards. Choose “Format NC card” to delete a plugged NC card and to format a 1.5 MB file sy-
stem on it.

Note
The menu item is only unhidden with protection level 0 ... 3.

Sequence
S The NC card is plugged; turn on the control system.
S Choose the menu item “Format NC card” from the start menu.
S After the initialization has been completed, answer the question “Do you really want [N/Y]?”.
“N” will cancel the process without formatting;
“Y” will start formatting when you press the Input key.
S If you have finished formatting, further NC cards can be formatted.
“Format another NC card [N/Y]?”
“Y” will repeat the process after a new card has been inserted,
“N” will quit the process.
S Turn off the control system and turn it on again.

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 Software Update Using the NC Card 6
General
Modifications to the system software can be necessary for the following reasons:
preliminary 11/2000

S A new system software is to be installed (new SW version).

S After changing the hardware if another system software than the supplied is to be loaded.

Sequence
Precondition: Control system is OFF

1. Insert the supplied NC card with system software and flash file system.

! Important
The NC card may be plugged or removed only when the PC is turned off. Plugging/removing the
NC card when the control system is turned on may damage the NC card.

2. Turn on the control system.

3. Set the password for protection level 2.
4. Choose the line “Start–up data PC” from System \ Data I/O und and save it to the NC card
using Read out.
Make sure that MD 11210 UPLOAD_MD_CHANGES_ONLY is parameterized with default value
= F. Thus only the modified machine data are saved.
5. Carry out POWER ON (control system OFF and ON again).
6. Press the SELECT key as required by the message

“DRAM CHECK”
“You can press SELECT–Key to get START UP MENUE after DRAM Check”.
7. After the DRAM test, the selection menu appears.
Use the cursor to choose “software update” and confirm with INPUT.
8. The update is carried out. The progress is displayed on the screen by various messages.
If the update was successful, the following message appears:
“SINUMERIK 802D – UPDATE O. K.”
“VERSION 802D SW xx.xx.xx
9. Turn the control system off and on again (POWER ON).
10. Set the password for protection level 2.
11. Choose the line “Start–up data PC” from System \ Data I/O and read it in from the NC card
using Read in.
12. Tunr off the control system and remove the card; the update is completed.

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Note
If required, load the appropriate language acc. to Section 3.3.
preliminary 11/2000

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 Machine and Setting Data 7
Data type
BOOLEAN Boolean value: 1 (TRUE) or 0 (FALSE)
preliminary 11/2000

BYTE 8–bit value,

as an integer value: -128 to 127,
as a hexadecimal value: 00 to FF
as a character acc. to ASCII standard, e.g. “a”

STRING Sequence of characters (max. 16 characters)

WORD 16–bit value,

as an integer value: -32768 to 32767,
as a hexadecimal value: 0000 to FFFF

UNSIGNED WORD 16–bit value,

as an integer value: 0 to 65535
as a hexadecimal value: 0000 to FFFF

INTEGER 16–bit value (in this case, defined locally),

integer value: -32768 to 32767

DWORD 32–bit value,

as an integer value: –2147483648 to 2147483647
as a hexadecimal value: 0000 0000 to FFFF FFFF

UNSIGNED DWORD 32–bit value,

as an integer value: 0 to 4294967295
as a hexadecimal value: 0000 0000 to FFFF FFFF

DOUBLE 64–bit value,

Floating point value: " 4.19  10-307 to " 1.67  10308

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 Machine and Setting Data

7.1 List of Machine Data

7.1.1 Display Machine Data

Cross reference
to Chapter in
Number MD identifier
Description of
Functions
Protection level
Representation Name, miscellaneous Activation
Write/read
Unit Default value Minimum value Maximum value Data type

202 FIRST_LANGUAGE 19
preliminary 11/2000

decimal Foreground language POWER ON 2/3

1 1 2 BYTE

203 DISPLAY_RESOLUTION 19
decimal Display resolution POWER ON 2/3
3 0 5 BYTE

204 DISPLAY_RESOLUTION_INCH 19
decimal Display resolution POWER ON 2/3
4 0 5 BYTE

205 DISPLAY_RESOLUTION_SPINDLE 19
decimal Display resolution POWER ON 2/3
1 5 BYTE

207 USER_CLASS_READ_TOA
decimal Protection level: Read tool offsets, general Immediately 2/3
3 0 7 BYTE

208 USER_CLASS_WRITE_TOA_GEO
decimal Protection level: Write tool geometry immediately 3/3
3 0 7 BYTE

209 USER_CLASS_WRITE_TOA_WEAR
decimal Protection level: Write tool wear data immediately 3/3
3 0 7 BYTE

210 USER_CLASS_WRITE_ZOA
decimal Protection level: Write settable zero offset immediately 3/3
3 0 7 BYTE

212 USER_CLASS_WRITE_SEA
decimal Protection level: Write setting data immediately 3/3
3 0 7 BYTE

213 USER_CLASS_READ_PROGRAM
decimal Protection level: Read part program immediately 3/3
7 0 7 BYTE

214 USER_CLASS_WRITE_PROGRAM
decimal Protection level: Enter part program immediately 3/3
7 0 7 BYTE

215 USER_CLASS_SELECT_PROGRAM
decimal Protection level: Program selection immediately 3/3
3 0 7 BYTE

218 USER_CLASS_WRITE_RPA
decimal Protection level: Write R parameters immediately 3/3
3 0 7 BYTE

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219 USER_CLASS_SET_V24
decimal Protection level: Set V24 immediately 3/3
3 0 7 BYTE

221 USER_CLASS_DIR_ACCESS
decimal Protection level: Directory access immediately 3/3
3 0 7 BYTE

222 USER_CLASS_PLC_ACCESS
decimal Protection level: PLC project immediately 2/3
3 0 7 BYTE

223 USER_CLASS_WRITE_PWA
preliminary 11/2000

decimal Protection level: Protected working area immediately 2/3

3 0 7 BYTE

247 V24_PG_PC_BAUD
Bit pattern PG: Baud rate (300, 600, 1200, 2400, 4800, 9600, 19200, 38400) immediately 3/3
7 0 7 BYTE

280 V24_PPI_ADDR_PLC
PLC station address POWER ON 3/3
2 0 126 BYTE

281 V24_PPI_ADDR_NCK
NCK station address POWER ON 3/3
3 0 126 BYTE

283 CTM_SIMULATION_DEF_X 10 (K1)

decimal Simulation: X default value immediately 3/7
0 –10000 10000 INTEGER

284 CTM_SIMULATION_DEF_Y 10 (K1)

decimal Simulation: Z default value immediately 3/7
0 –10000 10000 INTEGER

285 CTM_SIMULATION_DEF_VIS_AREA 10 (K1)

decimal Simulation: Display range default value immediately 3/7
100 –10000 10000 INTEGER

286 CTM_SIMULATION_MAX_X 10 (K1)

decimal Simulation: Maximum X display immediately 3/7
0 –10000 10000 INTEGER

287 CTM_SIMULATION_MAX_Y 10 (K1)

decimal Simulation: Maximum Z display immediately 3/7
0 –10000 10000 INTEGER

288 CTM_SIMULATION_MAX_VIS_AREA 10 (K1)

decimal Simulation: Maximum display range immediately 3/7
1000 –10000 10000 INTEGER

289 CTM_SIMULATION_TIME_NEW_POS 10 (K1)

decimal Simulation: Actual value update rate immediately 3/7
100 0 4000 INTEGER

290 CTM_POS_COORDINATE_SYSTEM 10 (K1)

decimal Position of coordinate system immediately 3/7
2 0 7 BYTE

291 CTM_CROSS_AX_DIAMETER_ON 10 (K1)

decimal Diameter display for transverse axis active immediately 3/7
1 0 1 BYTE

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292 CTM_G91_DIAMETER_ON 10 (K1)

decimal Incremental infeed immediately 3/7
1 0 1 BYTE

305 G_GROUP1
decimal User–oriented G group for position display immediately 3/7
1 1 1000 INTEGER

306 G_GROUP2
decimal User–oriented G group for position display immediately 3/7
2 1 1000 INTEGER

307 G_GROUP3
preliminary 11/2000

decimal User–oriented G group for position display immediately 3/7

8 1 1000 INTEGER

308 G_GROUP4
decimal User–oriented G group for position display immediately 3/7
9 1 1000 INTEGER

309 G_GROUP5
decimal User–oriented G group for position display immediately 3/7
10 1 1000 INTEGER

310 FG_GROUP1
decimal User–oriented G group for position display (external language) immediately 3/7
1 1 1000 INTEGER

311 FG_GROUP2
decimal User–oriented G group for position display (external language) immediately 3/7
2 1 1000 INTEGER

312 FG_GROUP3
decimal User–oriented G group for position display (external language) immediately 3/7
8 1 1000 INTEGER

313 FG_GROUP4
decimal User–oriented G group for position display (external language) immediately 3/7
9 1 1000 INTEGER

314 FG_GROUP5
decimal User–oriented G group for position display (external language) immediately 3/7
10 1 1000 INTEGER

330 CMM_POS_COORDINATE_SYSTEM
decimal Coordinate position of machine *) immediately 3/7
0 0 7 BYTE

331 CONTOUR_MASK
decimal Enable 802S contour definition programming immediately 3/7
0 0 1 BYTE

332 TOOL_LIST_PLACE_NO
decimal Enable location number in tool list immediately 3/3
0 0 0 1 INTEGER

343 V24_PPI_ADDR_MMC
decimal POWER ON 3/3
0 4 0 126

344 V24_PPI_MODEM_ACTIVE
decimal immediately 3/3
0 0 0 1 Byte

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345 V24_PPI_MODEM_BAUD
decimal Baud rate for modem connection immediately 3/3
0 7 5 9 Byte

346 V24_PPI_MODEM_PARITY
decimal Parity for modem connection immediately 3/3
0 0 0 2 Byte
*) Explanation:
Location and size of the representation are transferred during the initialization. The position of the coordinate system can be influenced by the
parameter “Axis direction” of the file header. The following positions are possible:
Position X+ Z+
0 upward to the right
1 upward to the left
2 downward to the right
3 downward to the left
preliminary 11/2000

4 to the right upward

5 to the left upward
6 to the right downward
7 to the left downward
All position specifications of the elements must be performed at position 4 (mathematic coordinate system). The simulation will then automatically
convert the representation to the individual systems.

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 Machine and Setting Data

7.1.2 General Machine Data

Cross reference
to Chapter in
Number MD identifier
Description of
Functions
Protection level
Unit Name, miscellaneous Activation
Write/read
Representation Default value Minimum value Maximum value Data type

10000 AXCONF_MACHAX_NAME_TAB[0]...[4] 19
– Machine axis name POWER ON 2/2
always – – STRING
preliminary 11/2000

Turning X1, Z1, SP, A1, B1 – – STRING

Milling X1, Y1, Z1, SP, A1 – – STRING

10074 PLC_IPO_TIME_RATIO 19
– Factor of PLC taskto ipo Task POWER ON 2/2
always 2 1 50 DWORD

10200 INT_INCR_PER_MM 3 (G2)

– Calculation accuracy for linear positions POWER ON 2/2
always 1000 1 1000000000 DOUBLE

10210 INT_INCR_PER_DEG 3 (G2)

– Calculation accuracy for angular positions POWER ON 2/2
always 1000 1 1000000000 DOUBLE

10240 SCALING_SYSTEM_IS_METRIC 3 (G2)

– Basic system metric POWER ON 2/7
always 1 *** *** BOOLEAN

10715 M_NO_FCT_CYCLE[0]
– M–Code to be substituted by subroutine POWER ON 2/7
always –1 *** *** DWORD

10716 M_NO_FCT_CYCLE_NAME
– Name of subroutine for M code substitution POWER ON 2/7
always “” – – STRING

10717 T_NO_FCT_CYCLE_NAME
– Name of subroutine for T code substitution POWER ON 2/7
always “” – – STRING

10760 G53_TOOLCORR
– Specification of G53 POWER ON 2/2
always 0 *** *** BOOLEAN

10880 MM_EXTERN_CNC_SYSTEM
– Definition of the adapted CNC system POWER ON 2/7
always 1 2 DWORD
Turning 2 1 2 DWORD
Milling 1 1 2 DWORD

10882 NC_USER_EXTERN_GCODES_TAB[0]...[59]
– User G code list for an external NC language POWER ON 2/2
always “” *** *** STRING

10884 EXTERN_FLOATINGPOINT_PROG
– Calculation command values without decimal point POWER ON 2/7
always 1 *** *** BOOLEAN

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10886 EXTERN_INCREMENT_SYSTEM
– Incremental system POWER ON 2/7
always 0 *** *** BOOLEAN

10888 EXTERN_DIGITS_TOOL_NO
– Digits for T number POWER ON 2/7
always 2 0 8 BYTE

10890 EXTERN_TOOLPROG_MODE
HEX Tool prog. mode for external language POWER ON 2/7
always 0x00000000 0x00000000 0xFFFFFFFF DWORD

11100 AUXFU_MAXNUM_GROUP_ASSIGN 13 (H2)

preliminary 11/2000

– Number of auxiliary functions in aux. fct. groups POWER ON 2/2

always 1 1 64 BYTE

11210 UPLOAD_MD_CHANGES_ONLY 19
HEX MD save for changed MD only immediately 2/2
– 0x0F 0x00 0x0FF BYTE

11240 PROFIBUS_SDB_NUMBER 3 (G2)

– SDB1000 number POWER ON 2/2
always 0 0 5 BYTE

11310 HANDWH_REVERSE 9 (H1)

– Threshold for direction change handwheel POWER ON 2/2
always 2 0 *** BYTE

11320 HANDWHL_IMP_PER_LATCH[0]...[2] 9 (H1)

– Handwheel pulses per detent position POWER ON 2/2
always 1., 1., 1. *** *** DOUBLE

11346 HANDWH_TRUE_DISTANCE 9 (H1)

– Handwheel: POWER ON 2/2
always 0 0 3 BYTE

13060 DRIVE_TELEGRAM_TYPE[0]...[8] 3 (G2)

– Standard frame type for Profibus–DP POWER ON 2/2
always 102, 102, 102, 102, 102 *** *** DWORD

13200 MEAS_PROBE_LOW_ACTIVE[0] 15 (M5)

– Probe polarity change POWER ON 2/7
always 0 *** *** BOOLEAN

14510 USER_DATA_INT[0]...[31] 19
– User data (INT) POWER ON 2/7
always 0 –32768 32767 DWORD

14512 USER_DATA_HEX[0]...[31] 19
– User data (Hex) POWER ON 2/7
– 0 0 0x0FF BYTE

14514 USER_DATA_FLOAT[0]...[7] 19
– User data (Float) POWER ON 2/7
– 0.0 –3.40S1038 3.40S1038 DOUBLE

14516 USER_DATA_PLC_ALARM[0]...[31] 19
– User data (Hex) POWER ON 2/7
– 0, 0, 0, 0, ... *** *** BYTE

18102 MM_TYPE_OF_CUTTING_EDGE
– Type of D–No. programming POWER ON 2/2
always 0 0 1 DWORD

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 Machine and Setting Data

7.1.3 Channel–Specific Machine Data

Cross reference
to Chapter in
Number MD identifier
Description of
Functions
Degr. of protect.
Unit Name, miscellaneous Activation
Write/read
Representation Default value Minimum value Maximum value Data type

20050 AXCONF_GEOAX_ASSIGN_TAB[0]...[2] 19
– Assignment GEO axis to channel axis POWER ON 2/2
always 0 5 BYTE
preliminary 11/2000

Turning 1, 0, 2 0 5 BYTE
Milling 1, 2, 3 0 5 BYTE

20070 AXCONF_MACHAX_USED[0]...[4] 19
– Machine axis number valid in channel POWER ON 2/2
always 0 5 BYTE
Turning 1, 2, 3, 0, 0 0 5 BYTE
Milling 1, 2, 3, 4, 5 0 5 BYTE

20080 AXCONF_CHANAX_NAME_TAB[0]...[4] 19
– Channel axis name in channel POWER ON 2/2
always – – STRING
Turning “X”, “Z”, “SP”, “ “, “ “ – – STRING
Milling “X”, “Y”, “Z”, “SP “, “A “ – – STRING

20094 SPIND_RIGID_TAPPING_M_NR 5 (S1)

– M function for switching over to controlled axis mode (Siemens mode) POWER ON 2/7
always 70 –1 0x7FFF DWORD

20095 EXTERN_RIGID_TAPPING_M_NR
– M function for switching over to controlled axis mode (external mode) POWER ON 2/7
always 29 6 0x7FFF DWORD

20360 TOOL_PARAMETER_DEF_MASK 14 (W1)

HEX Definition of tool parameters POWER ON 2/2
always 0x0 0 0x01 DWORD

20700 REFP_NC_START_LOCK 8 (R1)

– NC start inhibited without reference point RESET 2/7
always 1 *** *** BOOLEAN

20732 EXTERN_GO_LINEAR_MODE
– Interpolation behavior with G00 POWER ON 2/7
always 1 0 1 BOOLEAN

21000 CIRCLE_ERROR_CONST 10 (K1)

mm Circle end point monitoring constant POWER ON 2/7
always 0.01 *** *** DOUBLE

21020 WORKAREA_WITH_TOOL_RADIUS 2 (A3)

– Tool radius for working area limitation RESET 2/2
always 0 *** *** BOOLEAN

22000 AUXFU_ASSIGN_GROUP[0]...[63] 13 (H2)

– Auxiliary function group POWER ON 2/7
always 1, 1, 1, 1, 1, ... 1 64 BYTE

22010 AUXFU_ASSIGN_TYPE[0]...[63] 13 (H2)

– Auxiliary function type POWER ON 2/7
always “”, “”, “”, ... – – STRING

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22020 AUXFU_ASSIGN_EXTENSION[0]...[63] 13 (H2)

– see MD 22010AUXFU_ASSIGN_TYPE POWER ON 2/7
always 0, 0, 0, ... 0 99 BYTE

22030 AUXFU_ASSIGN_VALUE[0]...[63] 13 (H2)

– Auxiliary function value POWER ON 2/7
always 0, 0, 0, 0, ... *** *** DWORD

22400 S_VALUES_ACTIVE_AFTER_RESET 5 (S1)

– S function active via RESET POWER ON 2/2
always 0 *** *** BOOLEAN

22550 TOOL_CHANGE_MODE 14 (W1)

preliminary 11/2000

– New tool compensation with T or M function POWER ON 2/2

always 0 0 1 BYTE

22910 WEIGHTING_FACTOR_FOR_SCALE
– Input sensitivity for scaling factor POWER ON 2/2
always 0 *** *** BOOLEAN

22914 AXES_SCALE_ENABLE
– Activate axial scaling factor G51 POWER ON 2/2
always 0 *** *** BOOLEAN

27800 TECHNOLOGY_MODE 19
– Mode of technology in channel NEW CONF 2/2
always 0 1 BYTE
Turning 1 0 1 BYTE
Milling 0 0 1 BYTE

27860 PROCESSTIMER_MODE 10 (K1)

HEX Activation of program runtime measure RESET 2/7
always 0x07 0 0x03F BYTE

27880 PART_COUNTER 10 (K1)

HEX Activation of part counter RESET 2/7
always 0x0 0 0x0FFFF DWORD

27882 PART_COUNTER_MCODE[0]...[2] 10 (K1)

– Part counter with M code defined by user POWER ON 2/7
_always 2, 2, 2 0 99 BYTE

29000 LOOKAH_NUM_CHECKED_BLOCKS 12 (B1)

Number of LookAhead blocks POWER ON 1/7
_always 10 *** *** DWORD

7.1.4 Axis–Specific Machine Data

Cross reference
to Chapter in
Number MD identifier
Description of
Functions
Degr. of protect.
Unit Name, miscellaneous Activation
Write/read
Representation Default value Minimum value Maximum value Data type

30110 CTRLOUT_MODULE_NR[0] 3 (G2)

– Setpoint: drive no. / module no. POWER ON 2/2
_always 1 1 9 BYTE

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 Machine and Setting Data

30120 CTRLOUT_NR[0] 3 (G2)

– Setpoint: Output on submodule / module POWER ON 2/2
always 1 1 2 BYTE

30130 CTRLOUT_TYPE[0] 3 (G2)

– Output type of setpoint POWER ON 2/2
always 0 0 1 BYTE

30134 IS_UNIPOLAR_OUTPUT[0] 5 (S1)

– Setpoint output is unipolar POWER ON 2/2
always 0 0 2

30200 NUM_ENCS 3 (G2)

preliminary 11/2000

– Number of encoders POWER ON 2/2

always 1 0 1 BYTE

30220 ENC_MODULE_NR[0] 3 (G2)

– Actual value: drive type POWER ON 2/7
always 1 1 9 BYTE

30230 ENC_INPUT_NR[0] 3 (G2)

– Actual value: input no. module/meas. circ. board POWER ON 2/2
always 1 1 3 BYTE

30240 ENC_TYPE[0] 3 (G2)

– Actual value: Encoder type POWER ON 2/2
always 0 0 4 BYTE

30300 IS_ROT_AX 6 (R2)

– Rotary axis/spindle POWER ON 2/2
always 0 *** *** BOOLEAN

30310 ROT_IS_MODULO 6 (R2)

– Modulo conversion for rotary axis/spindle POWER ON 2/2
always 0 *** *** BOOLEAN

30320 DISPLAY_IS_MODULO 6 (R2)

– Display modulo 360 deg for rotary axis POWER ON 2/2
always 0 *** *** BOOLEAN

30350 SIMU_AX_VDI_OUTPUT 3 (G2)

– Axis signals for simulation axis POWER ON 2/2
always 0 *** *** BOOLEAN

30600 FIX_POINT_POS[0] 10 (K1)

mm, degrees Positions of axis with G75 POWER ON 2/7
always 0.0 *** *** DOUBLE

31000 ENC_IS_LINEAR 3 (G2)

– Direct measuring system (linear scale) POWER ON 2/2
always 0 *** *** BOOLEAN

31010 ENC_GRID_POINT_DIST 3 (G2)

mm Scale division with linear scales POWER ON 2/2
always 0.01 0 *** DOUBLE

31020 ENC_RESOL[0] 3 (G2)

– Encoder markings per revolution POWER ON 2/2
_always 2048 *** *** DWORD

31030 LEADSCREW_PITCH 3 (G2)

mm Pitch of leadscrew POWER ON 2/2
_always 10.0 *** *** DOUBLE

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 Machine and Setting Data

31040 ENC_IS_DIRECT[0] 3 (G2)

– Encoder mounted directly on the machine POWER ON 2/2
always 0 *** *** BOOLEAN

31050 DRIVE_AX_RATIO_DENOM[0]...[5] 3 (G2)

– Denominator of load gearbox POWER ON 2/2
always 1, 1, 1, 1, 1, 1 1 2147000000 DWORD

31060 DRIVE_AX_RATIO_NUMERA[0]...[5] 3 (G2)

– Counter of load gearbox POWER ON 2/2
always 1, 1, 1, 1, 1, 1 –2147000000 2147000000 DWORD

31070 DRIVE_ENC_RATIO_DENOM[0] 3 (G2)

preliminary 11/2000

– Denominator of resolver gearbox POWER ON 2/2

always 1 1 2147000000 DWORD

31080 DRIVE_ENC_RATIO_NUMERA[0] 3 (G2)

– Counter of resolver gearbox POWER ON 2/2
always 1 1 2147000000 DWORD

31122 BERO_DELAY_TIME_PLUS[0] 8 (R1)

s BERO delay time NEW CONF 2/2
always 0.000110 *** *** DOUBLE

31123 BERO_DELAY_TIME_MINUS[0] 8 (R1)

s BERO delay time NEW CONF 2/2
always 0.000078 *** *** DOUBLE

32000 MAX_AX_VELO 3 (G2)

mm/min,
Maximum axis velocity NEW CONF 2/7
rpm
10000. (mm/min)
always *** *** DOUBLE
27,77 (rpm)

32010 JOG_VELO_RAPID 9 (H1)

mm/min,
Rapid traverse in Jog mode RESET 2/7
rpm
10000. (mm/min)
always *** *** DOUBLE
27,77 (rpm)

32020 JOG_VELO 9 (H1)

mm/min,
Axis velocity in Jog mode RESET 2/7
rpm
2000. (mm/min)
always *** *** DOUBLE
5,55 (rpm)

32100 AX_MOTION_DIR 3 (G2)

– Traversing direction (not control direction) POWER ON 2/2
always 1 –1 1 DWORD

32110 ENC_FEEDBACK_POL[0] 3 (G2)

– Sign of actual value (control direction) POWER ON 2/2
always 1 –1 1 DWORD

32200 POSCTRL_GAIN[0]...[5] 3 (G2)

(m/min)/mm Servo gain factor NEW CONF 2/7
always 1, 1, 1, 1, 1, 1 0 2000. DOUBLE

32300 MAX_AX_ACCEL 4 (B2)

mm/s^2,
Axis acceleration NEW CONF 2/7
rev/s^2
1 (mm/s^2)
always 0.001 *** DOUBLE
2.77 (rev/s^2)

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 Machine and Setting Data

32420 JOG_AND_POS_JERK_ENABLE 4 (B2)

– Enable axial jerk limitation RESET 2/2
always 0 *** *** BOOLEAN

32430 JOG_AND_POS_MAX_JERK 4 (B2)

mm/s^3,
Axial jerk RESET 2/2
degrees/s^3
1000 (mm/s^3)
always 10–9 *** DOUBLE
2777,77 (degrees/s^3)

4 (B2)
32431 MAX_AX_JERK
12 (B1)
mm/s^3,
Maximum axial jerk for path movement NEW CONF 2/7
degrees/s^3
preliminary 11/2000

1000 (mm/s^3)
always 10–9 *** DOUBLE
2777,77 (degrees/s^3)

32432 PATH_TRANS_JERK_LIM 12 (B1)

mm/s^3,
Maximum axial jerk for path movement NEW CONF 2/7
degrees/s^3
1000 (mm/s^3)
always *** *** DOUBLE
2777,77 (degrees/s^3)

32450 BACKLASH [0] 16 (K3)

mm Backlash NEW CONF 2/2
always 0.0 *** *** DOUBLE

32630 FFW_ACTIVATION_MODE 16 (K3)

– Feedforward control can be activated from the program RESET 2/2
always 1 *** *** BYTE

32700 ENC_COMP_ENABLE [0] 16 (K3)

– Encoder / leadscrew error compensation NEW CONF 2/2
always 0 *** *** BOOLEAN

32810 EQUIV_SPEEDCTRL_TIME[0]...[5] 16 (K3)

s Equiv. time constant of speed control loop NEW CONF 2/2
0.003, 0.003, 0.003,
always *** *** DOUBLE
0.003, 0.003, 0.003,

33050 LUBRICATION_DIST 19
mm, degrees Traversing distance for lubrication pulse PLC signal NEW CONF 2/7
always 100000000 *** *** DOUBLE

34000 REFP_CAM_IS_ACTIVE 8 (R1)

– Axis with reference point cam RESET 2/2
always 1 *** *** BOOLEAN

34010 REFP_CAM_DIR_IS_MINUS 8 (R1)

– Approach ref. point in the negative direction RESET 2/2
always 0 *** *** BOOLEAN

34020 REFP_VELO_SEARCH_CAM 8 (R1)

mm/min,
Cam approach velocity RESET 2/2
rpm
5000.0 (mm/min)
always *** *** DOUBLE
13.88 (rpm)

34030 REFP_MAX_CAM_DIST 8 (R1)

mm, degrees Maximum distance to reference cam RESET 2/2
always 10000.0 *** *** DOUBLE

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 Machine and Setting Data

34040 REFP_VELO_SEARCH_MARKER[0] 8 (R1)

mm/min,
Speed for reference marker search RESET 2/2
rpm
300.0 (mm/min)
always *** *** DOUBLE
0.833 (rpm)

34050 REFP_SEARCH_MARKER_REVERSE[0] 8 (R1)

– Direction reversal on reference cam RESET 2/2
always 0 *** *** BOOLEAN

34060 REFP_MAX_MARKER_DIST[0] 8 (R1)

mm, degrees Maximum distance to reference mark RESET 2/2
always 20.0 *** *** DOUBLE
preliminary 11/2000

34070 REFP_VELO_POS 8 (R1)

mm/min,
Reference point approach velocity RESET 2/2
rpm
1000.0 (mm/min)
always *** *** DOUBLE
2.77 (rpm)

34080 REFP_MOVE_DIST[0] 8 (R1)

mm, degrees Reference point distance RESET 2/2
always -2.0 *** *** DOUBLE

34090 REFP_MOVE_DIST_CORR[0] 8 (R1)

mm, degrees Reference point offset RESET 2/2
always 0.0 *** *** DOUBLE

34092 REFP_CAM_SHIFT[0] 8 (R1)

mm, degrees Electronic cam offset RESET 2/2
always 0.0 *** *** DOUBLE

34100 REFP_SET_POS[0]...[3] 8 (R1)

mm, degrees Reference point position RESET 2/2
always 0. *** *** DOUBLE

34110 REFP_CYCLE_NR 8 (R1)

– Sequence of axes when referencing RESET 2/2
always 1 –1 5 DWORD

34200 ENC_REFP_MODE[0] 8 (R1)

– Referencing mode POWER ON 2/2
always 1 0 7 BYTE

34210 ENC_REFP_STATE[0] 8 (R1)

– Adjustment status of absolute value encoder immediately 2/2
always 0 0 2 BYTE

34220 ENC_ABS_TURNS_MODULO 6 (R2)

– Modulo area of rotary abs. value encoder POWER ON 2/2
always 4096 1 4096 DWORD

35000 SPIND_ASSIGN_TO_MACHAX 5 (S1)

– Assignment of spindle to machine axis POWER ON 2/2
always 0 0 1 BYTE

35010 GEAR_STEP_CHANGE_ENABLE 5 (S1)

– Gear stage change possible POWER ON 2/2
always 0 0 2 BOOLEAN

35040 SPIND_ACTIVE_AFTER_RESET 5 (S1)

– Own spindle reset POWER ON 2/2
always 0 *** *** BOOLEAN

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 Machine and Setting Data

35100 SPIND_VELO_LIMIT 5 (S1)

rpm Maximum spindle speed POWER ON 2/7
always 10000.0 *** *** DOUBLE

35110 GEAR_STEP_MAX_VELO[0]...[5] 5 (S1)

rpm Maximum speed for gear stage change NEW CONF 2/7
500., 500., 1000., 2000.,
always *** *** DOUBLE
4000., 8000.

35120 GEAR_STEP_MIN_VELO[0]...[5] 5 (S1)

rpm Minimum speed for gear stage change NEW CONF 2/7
50., 50., 400., 800.,
always *** *** DOUBLE
1500., 3000.
preliminary 11/2000

35130 GEAR_STEP_MAX_VELO_LIMIT[0]...[5] 5 (S1)

rpm Maximum speed of gear stage NEW CONF 2/7
500., 500., 1000., 2000.,
always *** *** DOUBLE
4000., 8000.

35140 GEAR_STEP_MIN_VELO_LIMIT[0]...[5] 5 (S1)

rpm Minimum speed of gear stage NEW CONF 2/7
always 5., 5., 10., 20., 40., 80. *** *** DOUBLE

35150 SPIND_DES_VELO_TOOL 5 (S1)

– Spindle speed tolerance RESET 2/2
always 0.1 0.0 1.0 DOUBLE

35160 SPIND_EXTERN_VELO_LIMIT 5 (S1)

rpm Spindle speed limitation from PLC NEW CONF 2/7
always 1000.0 *** *** DOUBLE

35200 GEAR_STEP_SPEEDCTRL_ACCEL[0]...[5] 5 (S1)

Umdr/s^2 Acceleration in open–loop control mode NEW CONF 2/7
30.0, 30.0, 25.0, 20.0,
_always 0.001 *** DOUBLE
15.0, 10.0

35210 GEAR_STEP_POSCTRL_ACCEL[0]...[5] 5 (S1)

Umdr/s^2 Acceleration in position control mode NEW CONF 2/7
30.0, 30.0, 25.0, 20.0,
_always 0.001 *** DOUBLE
15.0, 10.0

35300 SPIND_POSCTRL_VELO 5 (S1)

rpm Position control threshold speed NEW CONF 2/2
always 500.0 *** *** DOUBLE

35310 SPIND_POSIT_DELAY_TIME[0]...[5] 5 (S1)

s Positioning delay time NEW CONF 2/2
0.0, 0.05, 0.1, 0.2, 0.4,
always 0.0 *** DOUBLE
0.8

35350 SPIND_POSITIONING_DIR 5 (S1)

– Direction of rotation when positioning RESET 2/2
always 3 3 4 BYTE

35400 SPIND_OSCILL_DES_VELO 5 (S1)

rpm Oscillation speed NEW CONF 2/2
always 500.0 *** *** DOUBLE

35410 SPIND_OSCILL_ACCEL 5 (S1)

Umdr/s^2 Acceleration when oscillating NEW CONF 2/2
always 16 0.001 *** DOUBLE

35430 SPIND_OSCILL_START_DIR 5 (S1)

– Start direction when oscillating RESET 2/2
always 0 0 4 BYTE

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 Machine and Setting Data

35440 SPIND_OSCILL_TIME_CW 5 (S1)

s Oscillation time for M3 direction NEW CONF 2/2
always 1.0 *** *** DOUBLE

35450 SPIND_OSCILL_TIME_CCW 5 (S1)

s Oscillation time for M4 direction NEW CONF 2/2
always 0.5 *** *** DOUBLE

35500 SPIND_ON_SPEED_AT_IPO_START 5 (S1)

– Feed enable for spindle in setp. range RESET 2/2
always 1 0 2 BYTE

35510 SPIND_STOPPED_AT_IPO_START 5 (S1)

preliminary 11/2000

– Feedrate enable for spindle stopped RESET 2/2

always 0 *** *** BOOLEAN

36000 STOP_LIMIT_COARSE 2 (A3)

mm, degrees Limit for exact stop coarse NEW CONF 2/2
always 0.04 *** *** DOUBLE

36010 STOP_LIMIT_FINE 2 (A3)

mm, degrees Exact stop fine NEW CONF 2/2
always 0.01 *** *** DOUBLE

36020 POSITIONING_TIME 2 (A3)

s Exact stop fine delay time NEW CONF 2/2
always 1.0 *** *** DOUBLE

36030 STANDSTILL_POS_TOL 2 (A3)

mm, degrees Standstill tolerance NEW CONF 2/2
always 0.2 *** *** DOUBLE

36040 STANDSTILL_DELAY_TIME 2 (A3)

s Delay time for zero-speed monitoring NEW CONF 2/2
always 0.4 *** *** DOUBLE

36050 CLAMP_POS_TOL 2 (A3)

mm, degrees Clamping tolerance NEW CONF 2/2
always 0.5 *** *** DOUBLE

36060 STANDSTILL_VELO_TOL 2 (A3)

mm/min,
Threshold value for signal “Axis stopped” NEW CONF 2/2
rpm
5.0 (mm/min)
always *** *** DOUBLE
0.01388 (rpm)

36100 POS_LIMIT_MINUS 2 (A3)

mm, degrees 1st software limit switch minus NEW CONF 2/7
always -100000000 *** *** DOUBLE

36110 POS_LIMIT_PLUS 2 (A3)

mm, degrees 1st software limit switch plus NEW CONF 2/7
always 100000000 *** *** DOUBLE

36120 POS_LIMIT_MINUS2 2 (A3)

mm, degrees 2nd software limit switch minus NEW CONF 2/7
always -100000000 *** *** DOUBLE

36130 POS_LIMIT_PLUS2 2 (A3)

mm, degrees 2nd software limit switch plus NEW CONF 2/7
always 100000000 *** *** DOUBLE

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 Machine and Setting Data

36200 AX_VELO_LIMIT[0]...[5] 2 (A3)

mm/min,
Threshold value for velocity monitoring NEW CONF 2/7
rpm
11500., 11500., 11500.,
... (mm/min)
always *** *** DOUBLE
31.944; 31,944; 31,944;
31.944; ... (rpm)

36210 CTRLOUT_LIMIT[0] 3 (G2)

% Maximum speed setpoint value NEW CONF 2/7
always 110.0 0 200 DOUBLE

36300 ENC_FREQ_LIMIT[0] 2 (A3)

Hz Encoder limit frequency POWER ON 2/2
preliminary 11/2000

always 300000 *** *** DOUBLE

36302 ENC_FREQ_LIMIT_LOW[0] 8 (R1)

% Encoder limit frequency for resynchronization NEW CONF 2/2
always 99.9 0 100 DOUBLE

36310 ENC_ZERO_MONITORING[0] 2 (A3)

– Zero mark monitoring NEW CONF 2/2
always 0 *** ***v DWORD

36400 CONTOUR_TOL 2 (A3)

mm, degrees Tolerance band of contour monitoring NEW CONF 2/2
always 1.0 *** *** DOUBLE

36500 ENC_CHANGE_TOL 16 (K3)

mm, degrees Tolerance for actual position value switchover NEW CONF 2/2
always 0.1 *** *** DOUBLE

36600 BRAKE_MODE_CHOICE 2 (A3)

– Braking behavior at hardware limit switch POWER ON 2/2
always 0 0 1 BYTE

36610 AX_EMERGENCY_STOP_TIME 2 (A3)

s Time of braking ramp for errors NEW CONF 2/2
always 0.05 0.02 1000 DOUBLE

36620 SERVO_DISABLE_DELAY_TIME 1 (N2)

s Delay time for servo disable NEW CONF 2/2
always 0.1 0.02 1000 DOUBLE

36720 DRIFT_VALUE[0] 5 (S1)

% Drift basic value NEW CONF 2/2
always 0.0 –5.0 5.0 DOUBLE

37600 PROFIBUS_ACTVAL_LEAD_TIME 3 (G2)

s Actual value sensing time (Profibus Ti) POWER ON 2/7
always 0.000125 0.0 0.032 DOUBLE

38000 MM_ENC_COMP_MAX_POINTS[0] 16 (K3)

– Intermediate points for encoder/spindle compensation POWER ON 1/7
always 125 0 5000 DWORD

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7-98 6FC5 697–2AA00–0BP0 11.00
 Machine and Setting Data

7.2 Setting Data

Cross reference
to Chapter in
Number MD identifier
Description of
Functions
Protection level
Unit Name, miscellaneous Activation
Write/read
Representation Default value Minimum value Maximum value Data type

41010 JOG_VAR_INCR_SIZE 9 (H1)

mm or degree Size of variable increment in JOG mode immediately 7/7
always 0. *** *** DOUBLE
preliminary 11/2000

41110 JOG_SET_VELO 9 (H1)

mm/min Axis velocity in JOG mode immediately 7/7
always 0.0 *** *** DOUBLE

41130 JOG_ROT_AX_SET_VELO 9 (H1)

rpm Axis velocity of rotary axis in JOG mode immediately 7/7
always 0.0 0.0 *** DOUBLE

41200 JOG_SPIND_SET_VELO 9 (H1)

rpm Speed for spindle in JOG mode immediately 7/7
_always 0.0 *** *** DOUBLE

42000 THREAD_START_ANGLE 10 (K1)

degrees Starting angle for thread immediately 7/7
always 0. *** *** DOUBLE

42010 THREAD_RAMP_DISP [0]...[1] 10 (K1)

mm Accel. behavior of axis on thread cutting immediately 7/7
always –1., –1. –1. 999999. DOUBLE

42100 DRY_RUN_FEED 10 (K1)

mm/min Dry run feedrate immediately 7/7
always 5000.0 *** *** DOUBLE

42110 DEFAULT_FEED 11 (V1)

mm/min Feedrate default value immediately 7/7
always 0. *** *** DOUBLE

42140 DEFAULT_SCALE_FACTOR_P
– Default scaling factor for address P immediately 7/7
always 1 *** *** DWORD

42440 FRAME_OFFSET_INCR_PROG
– Traversing of zero offsets with incremental programming immediately 7/7
_always 1 *** *** BOOLEAN

42442 TOOL_OFFSET_INCR_PROG
– Traversing of tool offsets with incremental programming immediately 7/7
always 1 *** *** BOOLEAN

42444 TARGET_BLOCK_INCR_PROG
– Touch–down mode after block search with calculation immediately 7/7
always 1 *** ****** BOOLEAN

42480 STOP_CUTCOM_STOPRE
– Alarm response with TRC and preprocessing stop immediately 7/7
always 1 *** *** BOOLEAN

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 Machine and Setting Data

42490 CUTCOM_G40_STOPRE
– Retraction behavior of TRC with preprocessing stop immediately 7/7
always 0 *** *** BOOLEAN

42494 CUTCOM_ACT_DEACT_CTRL
– Approach and retraction behavior with tool radius compensation (TRC) immediately 7/7
always 2222 *** *** DWORD

43120 DEFAULT_SCALE_FACTOR_AXIS
– Axial default scaling factor when G51 is active immediately 7/7
always 1 *** *** DWORD

43200 SPIND_S
preliminary 11/2000

rpm Spindle speed when starting the spindle through VDI interface signals immediately 7/7
always 0.0 *** *** DOUBLE

43202 SPIND_CONSTCUT_S
rpm Setting of constant cutting rate for the master spindle immediately 7/7
always 0.0 *** *** DOUBLE

43210 SPIND_MIN_VELO_G25 5 (S1)

rpm Progr. spindle speed limitation G25 immediately 7/7
always 0.0 *** *** DOUBLE

43220 SPIND_MAX_VELO_G26 5 (S1)

rpm Progr. spindle speed limitation G26 immediately 7/7
always 1000.0 *** *** DOUBLE

43230 SPIND_MAX_VELO_LIMS 5 (S1)

rpm Spindle speed limitation with G96 immediately 7/7
always 100.0 *** *** DOUBLE

43240 M19_SPOS
rpm Spindle pos. for spindle positioning with M19 immediately 7/7
always 0.0 –10000000.0 10000000.0 DOUBLE

43250 M19_SPOSMODE
– Spindle position approach mode for spindle positioning with M19 immediately 7/7
always 0 0 5 DOUBLE

43400 WORKAREA_PLUS_ENABLE 2 (A3)

– Working area limitation in the positive direction active immediately 7/7
always 0 *** *** BOOLEAN

43410 WORKAREA_MINUS_ENABLE 2 (A3)

– Working area limitation in the negative direction active immediately 7/7
always 0 *** *** BOOLEAN

43420 WORKAREA_LIMIT_PLUS 2 (A3)

mm, degrees Working area limitation plus immediately 7/7
always 100000000 *** *** DOUBLE

43430 WORKAREA_LIMIT_MINUS 2 (A3)

mm, degrees Working area limitation minus immediately 7/7
always –100000000 *** *** DOUBLE

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7-100 6FC5 697–2AA00–0BP0 11.00
 Start–up inISO Mode 8
To enable you to use the programming function ISO 66025 Programmiung, setup files have been
implemented to start up SINUMERIK 802D; these are part of the Toolbox.

The following variants are offered:

preliminary 11/2000

S setISO_T turning technology

S setISO_M milling technology

8.1 Commissioning Procedure

! Important
It is imperative to observe this ISO mode SINUMERIK 802D commissioning procedure.

1. Carry out “Power–up with default data” in start–up mode.

2. After the control has rebooted, set the password ( EVENING ).
3. Set the V24 interface and PCIN to binary format.
The further steps are different for turning and milling.

Turning variant
4. Transfer the setISO_T file for the turning variant to the control system.
With loading the setISO_T file, the ISO System B Programming System is activated and defined as
the default setting.

Note
Using settings other than the ISO System B default setting, you can adapt the system to other va-
riants of the DIN 66025 programming. To this aim, reload the following files:
S ISO_A_T.INI file for the ISO System A programming language
S ISO_C_T.INI file for the ISO System C programming language

Milling variant
4. Transfer the setISO_M file for the milling variant to the control system.

With loading the setISO_M file, the ISO Milling Programming System is activated, the inch/metric
switchover has been enabled G20/G21 and defined as a function.

Using settings other than this default setting, the inch/metric switchover can be defined as a function
by reloading the file ISOG70_M.INI using G70/G71.

SINUMERIK 802DStart–up Guide

6FC5 697–2AA00–0BP0 11.00 8-101
 Start–up inISO Mode

8.2 Machine data

To adapt SINUMERIK 802D to ISO 66025 programming, the following machine data are provided.

8.2.1 Decimal point programming

MD 10884: EXTERN_FLOATINGPOINT_PROGRAMMING can be used to select whether the axis

positions will be programmed with or without decimal point notation.

S Bit = 1 means notation without decimal point.

preliminary 11/2000

Example: G0 G90 X10 The X axis is traversed absolutely to position 10 mm/inch/degrees.

S Bit = 0 means notation with decimal point.
Example: G0 G90 X10 The X axis is traversed absolutely to the position defined in
MD 10200: INT_INCR_PER_MM or MD 10210: INT_INCR_PER_DEG as an increment
resolution.
Value : 1000 means axis position 0.1 mm/inch/degrees

8.2.2 Straight line control with rapid traverse G00

MD 20732: EXTERN_G0_LINEAR_MODE can be used to select whether the axes approach their
programmed end position with G00 blocks interpolating or on the shortest way.

S Bit = 1 Continuous path mode

S Bit = 0 Straight line control

8.2.3 Spindle positioning M19

The spindle position for M19 is defined in the setting data 43240: M19_SPOS.

8.2.4 Blueprint programming (turning technology only)

With blueprint programming, the names have been assigned to the angle = A, to the radius = R and
to the chamfer = C as fixed values in the appropriate machine data by loading the file
SETISO_T.INI.

! Important
Do not use the names otherwise, e.g. as an axis name “A”.

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8-102 6FC5 697–2AA00–0BP0 11.00
 Start–up inISO Mode

8.2.5 Tool offset (turning technology only)

MD 10880: EXTERN_DIGITS_TOOL_NO can be used to define the number of digits for the tool
number.

Value = 2 ( default ) tool number with 2 decimals

Value = 4 ( maximum value) tool number with 4 decimals
MD 10900: EXTERN_TOOLPROG_MODE can be used to define the kind of the tool and offset
programming.

Example:

MD 10880: EXTERN_DIGITS_TOOL_NO=2
preliminary 11/2000

Bit = 0 T = 1234 tool number = 12

offset number = 34

Bit = 1 T = 12 tool number = 12

offset number = 12
MD 20360: TOOL_PARAMETER_DEF_MASK can be used to define whether the input of the tool
wear data is taken into account in the radius or in the diameter.
Bit = 0 – Taking into account the tool wear in the radius

Bit = 1 – Taking into account the tool wear in the diameter

8.3 Functions (ISO dialect for SINUMERIK 802D)

Table 8-1 Functions that can be programmed to ISO 66025

Turning Milling Function

version (B) version
G00 G00 Rapid traverse
G01 G01 Linear interpolation
G02 G02 Circular interpolation CW
G03 G03 Circular interpolation CCW
G04 G04 Dwell time

G09 G09 Non–modal exact stop

G10 G10 Load zero offset/tool offset

G11 G11 End loading zero offset/tool offset

G15 Polar coordinate programming OFF

G16 Polar coordinate programming ON
G17 G17 Select machining plane X–Y
G18 G18 Select machining plane Z–X
G19 G19 Select machining plane Y–Z

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 Start–up inISO Mode

Table 8-1 Functions that can be programmed to ISO 66025, Fortsetzung

Turning Milling Function

version (B) version

G20 G20 (G70) Inch input system

G21 G21 (G71) Metric input system

G28 G28 Reference point approach

preliminary 11/2000

G31 G31 Measuring with switching sensor

G33 Thread cutting with constant lead

G40 G40 Tool radius compensation OFF

G41 G41 Tool radius compensation left of contour ON
G42 G42 Tool radius compensation right of contour ON
G43 Tool length compensation, positive, ON
G44 Tool length compensation, negative, ON

G49 Tool length compensation OFF

G52 Select additive zero offset

G53 Approach position in the machine coordinate system
G54 Select 1st zero offset
G55 Select 2nd zero offset
G56 Select 3rd zero offset
G57 Select 4th zero offset
G58 Select 5th zero offset
G59 Select 6th zero offset
G61 G61 Exact stop

G63 Tapping
G64 G64 Continuous path mode

G73 Deep drilling cycle with chip breaking

G74 Tapping cycle LH thread
G76 Fine drill cycle
G80 Cycle OFF
G81 Drill cycle Counterboring
G82 Drill cycle Countersinking

SINUMERIK 802DStart–up Guide

8-104 6FC5 697–2AA00–0BP0 11.00
 Start–up inISO Mode

Table 8-1 Functions that can be programmed to ISO 66025, Fortsetzung

Turning Milling Function

version (B) version
G83 Deep hole drilling cycle with swarf removal
G84 Tapping cycle RH thread
G85 Drilling cycle

G90 G90 Absolute programming

G91 G91 Incremental programming
preliminary 11/2000

G92 G92 Preset actual value memory

G94 G94 Feedrate in mm/min, inch/min

G95 G95 Feedrate in mm/rev, inch/rev

G96 G96 Constant cutting rate ON

G97 G97 Constant cutting rate OFF

G98 Return to the starting point with fixed cycles

G99 Return to point R with fixed cycles

G290 G290 Deselect ISO 66025 programming

G291 G291 Select ISO 66025 programming

M98 M98 Subroutine call

M99 M99 End of subroutine

References
For further information, please refer to the Manufacturer/Service Documentation
ISO Dialectics for SINUMERIK (Order No. 6FC5297–5AE10–0AP1)

SINUMERIK 802DStart–up Guide

6FC5 697–2AA00–0BP0 11.00 8-105
 Start–up inISO Mode
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SINUMERIK 802DStart–up Guide

8-106 6FC5 697–2AA00–0BP0 11.00
 Index

Index
C ISO mode, 8-101
Functions, 8-103
Connecting handwheels (X10), 2-27
programming, 8-101
Connecting the individual components, 2-27
Connecting the operator panel, 2-27
Connection configuration of the RS232 interface
(X8), 2-28 M
Connection values, 11102, 1-10 Measuring system, direct
connecting, 3-52
Parameterization, 3-52
preliminary 11/2000

D
Displays and controls of ENC, 2-34
Drive interface|assignment, 11102, 2-28 P
PC card, formatting, 5-80
Power supply of ENC and operator panel (X1),
G 2-33
Access levels, 3-35
Grounding, 2-31
Protection levels, 16102, 3-35

I W
Installing and removing the SINUMERIK 802D,
Weight, 11102, 1-10
2-13
Interfaces and cables, 2-23

SINUMERIK 802DStart–up Guide

6FC5 697–2AA00–0BP0 11.00 Index-107
 Index
preliminary 11/2000

SINUMERIK 802DStart–up Guide

Index-108 6FC5 697–2AA00–0BP0 11.00
 Suggestions
SIEMENS AG Correktions
A&D MC IS for Publication/Manual:
Postfach 3180
SINUMERIK 802D
D–91050 Erlangen
(Tel. 0180 / 538 – 8008 [Hotline]
Fax 09131 / 98 – 1145
Mailto: motioncontrol.docu@erlf.siemens.de) Manufacturer Documentation
Start–up
From:
preliminary 11/2000

Order No.: 6FC5697–2AA00–0BP0

Name Edition: 11.00

Company/dept. Should you come across any printing errors

when reading this publication, please notify us on
Street this sheet.
Suggestions for improvement are also welcome.
Zip code: City:
Telephone: /
Telefax: /

Suggestions and/or corrections

preliminary 11/2000

Siemens AG
Automation and Drives
Motion Control Systems

Postfach 31 80, D–91050 Erlangen

Bundesrepublik Deutschland  Siemens AG 2000
Subject to change without prior notice

Bestell–Nr.: 6FC5697–2AA00–0BP0
Siemens Aktiengesellschaft Printed in the Federal Republic of Germany