SINUMERIK 840CSIMODRIVE 611-DInstallation Guide 09.2001 Edition

Installation Instructions

Service Documentation

SINUMERIK 840CSIMODRIVE 611-DInstallation Instructions

Installation Guide

SINUMERIK 840C/CE ControlStandard/Export Version

SIMODRIVE 611-D Drive

Software Version Software Version

1.x2.x3.x 1.x4.x 2.x5.x 3.x6.x 4.x

09.2001 Edition

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 ”Remarks” column:

A . . . New documentation.B . . . Unrevised reprint with new Order No.C . . . Revised edition with new status.

If factual changes have been made on the page since the last edition, this isindicated by a new edition coding in the header on that page.

Edition Order No. Remarks

11.92 6FC5197-0AA50-1BP0 A

06.93 6FC5197-2AA50-0BP0 C

12.93 6FC5197-3AA50-0BP0 C

10.94 6FC5197-4AA50-0BP0 C

03.95 6FC5197-4AA50-0BP1 C

09.95 6FC5197-5AA50-0BP0 C

04.96 6FC5197-5AA50-0BP1 C

08.96 6FC5197-5AA50-0BP2 C

07.97 6FC5197-6AA50-0BP0 C

01.99 6FC5197-6AA50-0BP1 C

09.01 6FC5197-6AA50-0BP2 C

You will find further information in the Internet under:http://www.ad.siemens.de/sinumerik

This publication was produced on the Siemens 5800 OfficeSystem and with Interleaf 7.

The reproduction, transmission or use of this document or itscontents is not permitted without express written authority.Offenders will be liable for damages. All rights, includingrightscreated by patent grant or registration of a utility model ordesign, are reserved.

© Siemens AG 1993-2001All Rights Reserved

Order No. 6FC5197-6AA50-0BP2Printed in the Federal Republic of Germany

This manual is included in the documentation available on CD-ROM (DOCONCD)Edition Order No. Remarks10.01 6FC5198-6CA00-0BG2 C

TrademarksSIMATIC®, SIMATIC HMI®, SIMATIC NET®, SIROTEC®, SINUMERIK® and SIMODRIVE® are trade-marks of Siemens AG. All other product and system names are registered trademarks of theirrespective companies and must be treated accordingly.

Other functions not described in this documentation might beexecutable in the control. This does not, however, represent anobligation to supply such functions with a new control or whenservicing.

We have checked that the contents of this publication agree withthe hardware and software described herein. The information givenin this publication is reviewed at regular intervals and anycorrections that might be necessary are made in the subsequentprintings. Suggestions for improvement are welcome at all times.

Subject to change without prior notice.

Siemens-Aktiengesellschaft

Preliminary Remarks

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a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a

a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a

a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a

a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a

a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a

a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a

a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a

a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a

Notes for the reader

This manual is intended for manufacturers of machine tools who use SINUMERIK 840C.

The "Installation Instructions" discuss the installation and start-up procedures, from installationof the system through the testing of the most important functions.

The SINUMERIK 840C Installation Guide is divided into two separate manuals:

• 840C Installation Instructions• 840C Installation Lists

The supplementary manual, which is entitled "SINUMERIK 840, Installation Lists", providesadditional aids in the form of lists and detailed information on NC and PLC machine data andsetting data, as well as lists of control and programmer alarms.

The manufacturer documentation for the SINUMERIK 840C control is divided into thefollowing parts:

• InterfacePart 1: SignalsPart 2: Connection Conditions

• Planning Guide PLC 135 WB/WB2/WD• Function Macros• Function Blocks

Package 0: Basic FunctionsPackage 1: Tool ManagementPackage 4/5: Computer LinkPackage 7: Code CarrierPackage 8: PLC-controlled Data Input/Output

Additional SINUMERIK publications which are valid for all SINUMERIK controls may also beconsulted (e.g. Universal Interface, Measuring Cycles, CL800 Cycle Language).

Please contact your local SIEMENS office for further details.

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a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a

a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a

a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a

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Technical notes

A new Installation Guide is required for each new software version. Old Installation Guides canbe used only in part for new software versions.

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a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a

a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a

a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a

a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a

As from software version 4, please refer to the Installation Lists manualfor a description of the alarms (Monitoring section).

This manual is valid for software versions 1, 2, 3, 4, 5 and 6.As from software version 3, the data relevant to SIMODRIVE 611-D

is also provided.

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Safety notes

DANGER

This warning notice means that loss of life, severe personal injury orsubstantial material damage will result if the appropriate precautionsare not taken.

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WARNING

This warning notice means that loss of life, severe personal injury orsubstantial material damage can result if the appropriate precautionsare not taken.

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CAUTION

This warning notice (with warning triangle) means that a minorpersonal injury can result if the appropriate precautions are not taken.

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CAUTION

This warning notice (without warning triangle) means that a materialdamage can result if the appropriate precautions are not taken.

NOTICE

This warning notice means that an undesired event or an undesiredstate can result if the appropriate notices are not observed.

Prerequisites and Visual Inspection 1

General Reset and Standard Start-up 2

PLC Installation 3

Machine Data Dialog (MDD - as from SW 3) 5

NC Machine Data (NC MD), NC Setting Data (NC SD) 6

Drive Machine Data (SIMODRIVE Drive MD) 7

PLC Machine Data (PLC MD) 8

Drive Servo Start-Up Application (as from SW 3) 9

Axis and Spindle Installation 10

Data Backup/CPU Replacement 11

Functional Descriptions 12

MMC Area Diagnosis 4

Index 13

Contents

1 Prerequisites and Visual Inspection . . . . . . . . . . . . . . . . . . . . . . 1–1

1.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11.2 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11.2.1 Information on module handling . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21.2.2 Grounding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–31.2.3 Position encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–31.2.4 Cable laying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–31.2.5 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–41.2.6 Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–41.2.7 Interference suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–41.2.8 Operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–41.2.9 Overall state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–41.2.10 Jumpering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–51.2.11 Position control, input and measuring system resolution . . . . . . . . . . 1–51.2.12 Input units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–51.3 Standard/Export version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–61.4 Installation Checklist 840C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–71.5 Voltage and functional tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–91.5.1 Self-test and system start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–91.6 Loading data into the NCK on starting up the control (as from SW 2) 1–11

2 General Reset and Standard Start-Up . . . . . . . . . . . . . . . . . . . . . 2–1

2.1 First installation and start-up of control (as from SW 3) . . . . . . . . . . 2–12.1.1 Erasing the S-RAM area of the NCK (as from SW 6) . . . . . . . . . . . . 2–12.2 Standard installation and start-up as flowchart (as from SW 3) . . . . . 2–22.3 Select general reset mode (as from SW 3) . . . . . . . . . . . . . . . . . . . 2–32.4 General reset (as from SW 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–42.5 Memory configuration (as from SW 3) . . . . . . . . . . . . . . . . . . . . . . 2–62.6 Loading machine data (as from SW 3) . . . . . . . . . . . . . . . . . . . . . . 2–82.7 Deselect general reset mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–102.8 Standard installation short version (up to SW 2) . . . . . . . . . . . . . . . 2–112.9 General reset (up to SW 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–132.10 Standard installation and start-up as flowchart (up to SW 2 only) . . . . 2–152.11 Enter PLC machine data (up to SW 2 only) . . . . . . . . . . . . . . . . . . . 2–162.12 Enter NC machine data (up to SW 2 only) . . . . . . . . . . . . . . . . . . . 2–172.13 Axis installation (simplified, up to SW 2 only) . . . . . . . . . . . . . . . . . . 2–182.14 Spindle installation (Example: one spindle, up to SW 2 only) . . . . . . . 2–19

3 PLC Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

3.1 General remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–13.2 PG function via MMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23.3 PLC general reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–53.4 Procedure for starting up the PLC . . . . . . . . . . . . . . . . . . . . . . . . . 3–53.5 PLC diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–83.5.1 LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–83.5.2 System initialization program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–93.5.3 ISTACK, detailed error coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–103.5.4 PLC status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–113.5.5 Timeout analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–133.6 Procedure for error search after PLC stop . . . . . . . . . . . . . . . . . . . 3–13

4 MMC Area Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1

4.1 General notes/Overviews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–14.1.1 Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–14.1.2 Simplified switchover between languages (as from SW 5) . . . . . . . . . 4–24.1.3 Printing screen hardcopies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–34.1.4 Selection of the Diagnosis area . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4

4.2 NC Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–84.2.1 Selection of service data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–104.2.2 Service data for the spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–11

4.3 Drive service displays for spindle (MSD) and axis (FDD) - (as from SW 3) 4–12

4.4 PC data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–214.4.1 Copying and editing PC data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–224.4.2 Configuration file CONFIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–254.4.2.1 Keywords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–264.4.2.2 Value ranges and default values . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–274.4.2.3 Format for log masks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–284.4.2.4 Reduce number of accesses to the hard disk (HD) . . . . . . . . . . . . . 4–294.4.3 BEDCONF configuration file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–304.4.3.1 Configuration file BEDCONF in directory Operation/Basic Setting . . . 4–314.4.3.2 Configuration file BEDCONF in directory OPERATION/PROGRAM . . 4–364.4.3.3 Configuration file BEDCONF in directory Operation/DIAGNOSIS . . . . 4–37

4.4.4 Color definition tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–384.4.4.1 10” color display (up to SW 4.4) 6FC5 103-0AB 2-0AA0 . . . . . . . . 4–384.4.4.2 New 19” operator panel as from SW 4.5(5)

6FC5 103-0AB - AA1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–414.4.4.3 Defining individual color tables (as from SW 5.4) . . . . . . . . . . . . . . . 4–43

4.4.5 Color mapping lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–44

4.4.6 Color settings for monochrome display . . . . . . . . . . . . . . . . . . . . . . 4–474.4.6.1 10” monochrome display (up to SW 4.4) 6FC5 103-0AB 2-0AA0 . . 4–474.4.6.2 9.5” monochrome display (as from SW 4.5) . . . . . . . . . . . . . . . . . . 4–47

4.4.7 Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–48

4.5 Activating options (as from SW 3) . . . . . . . . . . . . . . . . . . . . . . . . . 4–49

4.6 BACKUP with Valitek streamer/PC link . . . . . . . . . . . . . . . . . . . . . . 4–50

4.7 Customer UMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–55

4.8 Functions up to SW 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–564.8.1 NC data management (up to SW 2) . . . . . . . . . . . . . . . . . . . . . . . . 4–564.8.2 PLC data (up to SW 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–594.8.3 PCF files (up to SW 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–60

4.9 Equivalent keys on the PC keyboard and the operator panel . . . . . . . 4–65

5 Machine Data Dialog (MDD - as from SW 3) . . . . . . . . . . . . . . . . 5–1

5.1 General remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–15.1.1 General notes on operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–45.1.2 Fast switching between MDD and service display

(as from SW 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7

5.2 NC configuration and NC machine data (as from SW 3) . . . . . . . . . . 5–95.2.1 NC configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–95.2.2 NC machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–115.2.3 Setpoint-Actual value matching for axes and spindles . . . . . . . . . . . . 5–145.2.4 Measuring system adaptation for axes and spindles (as from SW 4) . 5–155.2.5 Copying a complete machine data block (as from SW 5.6) . . . . . . . . 5–17

5.3 PLC configuration and PLC machine data (as from SW 3) . . . . . . . . 5–185.3.1 PLC configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–185.3.2 PLC machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–20

5.4 Drive configuration and drive machine data (as from SW 3) . . . . . . . 5–225.4.1 Drive configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–225.4.2 Drive machine data for axes (FDD) and spindles (MSD) . . . . . . . . . . 5–235.4.3 Axis/spindle start-up for the digital drive (as from SW 3) . . . . . . . . . . 5–24

5.5 Cycles machine data (as from SW 3) . . . . . . . . . . . . . . . . . . . . . . . 5–27

5.6 IKA data (interpolation and compensation with tables - as from SW 3) 5–28

5.7 User displays (as from SW 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–305.7.1 Edit list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–31

5.8 File functions (as from SW 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–335.8.1 1st level: Machine configuration (as from SW 3) . . . . . . . . . . . . . . . 5–335.8.2 2nd level: Configuring the individual machine data areas

(as from SW 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–345.8.3 3rd level: Configuring withing the machine data areas of

individual machine data displays (as from SW 3) . . . . . . . . . . . . . . . 5–355.8.4 File functions (sequence of operation - as from SW 3) . . . . . . . . . . . 5–375.8.4.1 1st level: File functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–375.8.4.2 2nd level: File functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–385.8.4.3 3rd level: File functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–40

5.9 Procedure for altering configurations . . . . . . . . . . . . . . . . . . . . . . . 5–425.9.1 Standard installation of digital drives (as from SW 3) . . . . . . . . . . . . 5–425.9.2 Adding a 1-axis FDD module (as from SW 3) . . . . . . . . . . . . . . . . . 5–445.9.3 Replacing a 1-axis FDD module with a 2-axis FDD module

(as from SW 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–455.9.4 Replacing a 2-axis FDD module (9/18 A) with a

2-axis FDD module (18/36 A) - (as from SW 3) . . . . . . . . . . . . . . . . 5–465.9.5 Drive active or passive (as from SW 3) . . . . . . . . . . . . . . . . . . . . . . 5–475.9.6 Using a new motor type (as from SW 3) . . . . . . . . . . . . . . . . . . . . . 5–485.9.7 Reinstallation of existing and new drive components using the

existing drive files (TEA3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–495.9.8 Additional information when altering the configuration

(as from SW 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–505.10 Configuring the MDD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–515.10.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–515.10.2 Practical example for user adaptation list display . . . . . . . . . . . . . . . 5–535.10.3 Configuring the parameter set switchover in the list display . . . . . . . . 5–555.10.4 Printing the list module data (as from SW 5) . . . . . . . . . . . . . . . . . . 5–57

6 NC Machine Data (NC MD) NC Setting Data (NC SD) . . . . . . . . . 6–1

6.1 NC machine data (NC MD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–16.1.1 Entering NC machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–16.1.2 NC configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–26.1.3 Configuring information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–36.1.4 Breakdown of NC MDs/drive machine data . . . . . . . . . . . . . . . . . . . 6–56.2 General machine data (general data) . . . . . . . . . . . . . . . . . . . . . . . 6–66.3 Channel-specific MD (channel data) . . . . . . . . . . . . . . . . . . . . . . . . 6–316.4 Axis-specific MD 1 (axial data 1) . . . . . . . . . . . . . . . . . . . . . . . . . . 6–366.5 Spindle-specific MD (spindle data) . . . . . . . . . . . . . . . . . . . . . . . . . 6–656.6 Machine data bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–856.6.1 General MD bits (general bits) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–856.6.2 Spindle-specific MD bits (spindle bits) . . . . . . . . . . . . . . . . . . . . . . 6–1246.6.3 Channel-specific MD bits 1 (channel bits) . . . . . . . . . . . . . . . . . . . . 6–1366.6.4 Axis-specific MD bits 1 (axial bits 1) . . . . . . . . . . . . . . . . . . . . . . . . 6–1446.6.5 Leadscrew error compensation bits (compensation flags) . . . . . . . . . 6–154

6.6.6 Channel-specific MD bits 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1556.7 Axis-specific MD 2 (axial data 2) . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1586.7.1 Axis-specific MD bits 2 (axial bits 2) . . . . . . . . . . . . . . . . . . . . . . . . 6–1806.8 MDs for multi-channel display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1956.9 MDs for parameter set switchover . . . . . . . . . . . . . . . . . . . . . . . . . 6–1966.9.1 MDs for collision monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2056.10 MDs for flexible memory configuration . . . . . . . . . . . . . . . . . . . . . . 6–2116.11 Safety Integrated (SI) data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2166.12 Setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2176.12.1 NC setting data (NC SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2176.13 Cycles machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–230

7 Drive Machine Data (SIMODRIVE Drive MD) . . . . . . . . . . . . . . . . 7–1

7.1 611A main spindle drive machine data (MSD MD) (SW 3) . . . . . . . . 7–17.1.1 MSD MD input (SW 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–17.1.2 MSD MD (data description - SW 3) . . . . . . . . . . . . . . . . . . . . . . . . 7–17.2 611D feed drive machine data (SW 3) . . . . . . . . . . . . . . . . . . . . . . 7–477.2.1 FDD MD input (SW 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–477.2.2 FDD MD (data description - SW 3) . . . . . . . . . . . . . . . . . . . . . . . . . 7–477.3 611D drive machine data (FDD/MSD - as from SW 4) . . . . . . . . . . . 7–747.3.1 Drive MD input (as from SW 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–747.3.2 Drive MD (data description) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–747.4 FDD/MSD-specific diagnosis/service machine data (as from SW 3) . . 7–1677.4.1 Output of diagnosis/service machine data (as from SW 3) . . . . . . . . 7–1677.4.2 Servo service data (SSD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1677.4.3 Diagnosis/service MD (data description - as from SW 3) . . . . . . . . . 7–1687.5 Safety Integrated (SI) data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–177

8 PLC Machine Data (PLC MD) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1

8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–18.1.1 Entering PLC MD (up to SW 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–18.1.2 Breakdown of the PLC MD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–28.2 PLC MD for the operating system (system data) . . . . . . . . . . . . . . . 8–38.3 PLC MD for function blocks (FB data) . . . . . . . . . . . . . . . . . . . . . . 8–128.4 PLC MD for the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–128.5 PLC MD for the operating system (system bits) . . . . . . . . . . . . . . . . 8–138.6 PLC MD bits for function blocks (FB bits) . . . . . . . . . . . . . . . . . . . . 8–288.7 PLC MD bits for the user (user bits) . . . . . . . . . . . . . . . . . . . . . . . . 8–29

9 Drive Servo Start-Up Application (as from SW 3) . . . . . . . . . . . . 9–1

9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–19.1.1 Selection of/menu trees of drive servo start-up application . . . . . . . . 9–49.1.2 Softkeys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6

9.2 Measuing the drive servo loops (current, speed, position) . . . . . . . . . 9–119.2.1 Current control loop (axis and spindle - as from SW 3) . . . . . . . . . . . 9–139.2.2 Speed control loop (axis and spindle) - measurement parameters

(4 basic settings - as from SW 3) . . . . . . . . . . . . . . . . . . . . . . . . . . 9–149.2.3 Speed control loop (axis and spindle - as from SW 3) . . . . . . . . . . . 9–159.2.4 Position control loop (axis and spindle) - measurement parameters

(4 basic settings - as from SW 3) . . . . . . . . . . . . . . . . . . . . . . . . . . 9–169.2.5 Position control loop (axis and spindle - as from SW 3) . . . . . . . . . . 9–199.2.6 Position control loop (axis and spindle) - measurement parameters

(9 basic settings - as from SW 3) . . . . . . . . . . . . . . . . . . . . . . . . . . 9–20

9.3 Function generator (axis and spindle - as from SW 3) . . . . . . . . . . . 9–239.3.1 Function generator (axis and spindle) - signal parameters

(as from SW 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–249.3.2 Additional information (notes) on measurement and signal

parameters (as from SW 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–259.3.3 Signal waveforms of function generator (SW 3) . . . . . . . . . . . . . . . . 9–269.4 Mixed I/O configuration and digital-analog converter, DAC

(as from SW 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–339.5 Quadrant error compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–399.5.1 General comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–399.5.2 Circularity test (option - SW 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–399.5.3 Conventional quadrant error compensation (as from SW 2) . . . . . . . . 9–449.5.3.1 Installation without adaptation characteristic . . . . . . . . . . . . . . . . . . 9–449.5.3.2 Installation with adaptation characteristic . . . . . . . . . . . . . . . . . . . . . 9–489.5.4 Neural quadrant error compensation (QEC - SW 4) . . . . . . . . . . . . . 9–509.5.4.1 Start-up of neural QEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–559.5.4.2 Further optimization and intervention options . . . . . . . . . . . . . . . . . . 9–589.5.4.3 Power ON/OFF - monitoring function - special functions (SW 4) . . . . 9–639.6 SERVO trace (SW 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–649.6.1 Selection of measured signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–669.6.2 SERVO trace display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–68

10 Axis and Spindle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1

10.1 Determining sampling interval and interpolation time . . . . . . . . . . . . 10–110.2 Axis-specific resolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–410.2.1 General remarks on the axis-specific resolutions . . . . . . . . . . . . . . . 10–410.2.2 Input, display and position control resolution . . . . . . . . . . . . . . . . . . 10–410.2.3 Resolution block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–610.2.4 Resolution codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–710.2.5 Permissible resolution combinations . . . . . . . . . . . . . . . . . . . . . . . . 10–810.2.6 The influence of resolution on velocity . . . . . . . . . . . . . . . . . . . . . . 10–910.2.7 Maximum velocity for thread cutting . . . . . . . . . . . . . . . . . . . . . . . . 10–1110.2.8 Maximum traversing range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1210.2.9 Influence on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1510.2.10 Influence on the modes/function . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1510.3 BERO (SW 4 and higher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1810.4 Axis installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1910.4.1 Drive optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1910.4.1.1 Checking and setting the control direction of the feed axes . . . . . . . . 10–1910.4.1.2 Speed setpoint matching/tacho compensation . . . . . . . . . . . . . . . . . 10–2110.4.1.3 Servo gain factor KV NC MD 252* . . . . . . . . . . . . . . . . . . . . . . . . . 10–2410.4.1.4 Acceleration NC MD 276* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–2610.4.1.5 Jerk limitation (as from SW 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–2810.4.1.6 Position monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–3010.4.1.7 Dynamic contour monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–3110.4.2 Drift compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–3210.4.3 Axis traversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–3310.4.3.1 Traversing in jog mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–3310.4.3.2 Program-controlled traversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–3410.4.4 Reference point approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–3510.4.4.1 Reference point approach without automatic direction recognition . . . 10–3510.4.4.2 Reference point approach with automatic direction recognition . . . . . 10–3810.4.4.3 Program-controlled reference point approach . . . . . . . . . . . . . . . . . 10–3910.4.4.4 Referencing without programmed motion (with SW 4 and higher) . . . 10–4010.4.4.5 Setting reference dimension by a PLC request (SW 4 and higher) . . . 10–4110.4.5 Distance-coded reference marks . . . . . . . . . . . . . . . . . . . . . . . . . . 10–4310.4.5.1 Initial installation of distance-coded reference marks . . . . . . . . . . . . 10–45

10.5 Spindle installation, spindle functions . . . . . . . . . . . . . . . . . . . . . . . 10–4910.5.1 Open-loop control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–5110.5.2 Oscillation mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–5410.5.3 Positioning mode, M19, M19 through several revolutions . . . . . . . . . 10–5410.5.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–5410.5.3.2 Absolute positioning sequence (M19) . . . . . . . . . . . . . . . . . . . . . . . 10–5710.5.3.3 Incremental positioning sequence (M19 through several revolutions) . 10–6010.5.3.4 Method A and B in the NC-internal solution . . . . . . . . . . . . . . . . . . . 10–6210.5.3.5 Gain factor change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–6310.5.3.6 Aborting the positioning mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–6510.5.4 Curved acceleration characteristic (SW 4 and higher) . . . . . . . . . . . 10–6610.5.5 PLC intervention in spindle control . . . . . . . . . . . . . . . . . . . . . . . . . 10–69

11 Data Backup/CPU Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 11–1

11.1 Data area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–111.1.1 Ways of backing up data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–211.1.2 General notes on data backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–311.1.3 Saving/loading NCK data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–511.1.4 Data backup procedure via streamer . . . . . . . . . . . . . . . . . . . . . . . 11–711.1.5 Restarting after MMC CPU replacement . . . . . . . . . . . . . . . . . . . . . 11–811.1.6 Loading via V24 interface or FD-E2 . . . . . . . . . . . . . . . . . . . . . . . . 11–911.1.7 Loading from hard disk (control startup with user data) . . . . . . . . . . . 11–1011.1.8 CPU replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–15

12 Functional Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1

12.1 Leadscrew error compensation 6FC5 150-0AH01-0AA0 . . . . . . . . 12–112.1.1 Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–112.1.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1

12.2 Rotary axis function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1012.2.1 Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1012.2.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–10

12.3 Endlessly rotating axis (SW 4 and higher) . . . . . . . . . . . . . . . . . 12–1212.3.1 Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–12

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1212.3.2 Display of endlessly rotating axis . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1312.3.3 Reaction of endlessly rotating function to NC-STOP and NC-RESET . 12–13

12.4 Dwell in relation to axes or spindles . . . . . . . . . . . . . . . . . . . . . . 12–1412.4.1 Dead time compensation, NC MD 330 . . . . . . . . . . . . . . . . . . . . . . 12–1412.4.2 Extension of dwell (SW 5 and higher) . . . . . . . . . . . . . . . . . . . . . . . 12–1512.4.2.1 Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–15

12.5 Warm restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1612.5.1 Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1612.5.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–16

12.6 Coordinate transformation 6FC5 150-0AD04-0AA0 . . . . . . . . . . . 12–1812.6.1 Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1812.6.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1912.6.3 The transformation data set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–2012.6.3.1 Definition of machine data for coordinate transformation . . . . . . . . . . 12–2112.6.4 Transformation parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–2312.6.5 Machine data for fictitious axes . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–2612.6.6 NC PLC interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–2712.6.7 Explanation of the programming and operation of coordinate

transformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–2812.6.8 Examples of coordinate transformation . . . . . . . . . . . . . . . . . . . . . . 12–3012.6.8.1 Example of TRANSMIT coordinate transformation . . . . . . . . . . . . . . 12–3012.6.8.2 Example of 2D coordinate transformation . . . . . . . . . . . . . . . . . . . . 12–3112.6.8.3 Example of 3D coordinate transformation . . . . . . . . . . . . . . . . . . . . 12–3212.6.9 Transformation machine data change without warm restart . . . . . . . . 12–33

12.7 Spindle functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–3412.7.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–3412.7.2 Description of the spindle modes . . . . . . . . . . . . . . . . . . . . . . . . . . 12–3612.7.2.1 Open-loop control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–36

Selecting the open-loop control mode . . . . . . . . . . . . . . . . . . . . . . . 12–36Gear ratio changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–37Data required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–37

12.7.2.2 Oscillation mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–3812.7.2.3 Positioning mode (M19, M19 through several revolutions) . . . . . . . . . 12–38

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–38Selecting the positioning mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–39Data required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–39The positioning sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–40Gain factor change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–47Aborting the positioning mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–49Curved acceleration characteristic (SW 4 and higher) . . . . . . . . . . . 12–49

12.7.2.4 C axis mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–53General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–53Selection and deselection of the C axis mode . . . . . . . . . . . . . . . . . 12–54Block search via blocks with M functions for C axis ON/OFF . . . . . . 12–54C axis synchronization (SW 4 and higher) . . . . . . . . . . . . . . . . . . . . 12–54Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–54Synchronizing and referencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–55Initiating the C axis mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–58Encoder-specific resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–60Possible configurations for the C axis mode . . . . . . . . . . . . . . . . . . 12–61

12.8 Following error compensation for thread cutting . . . . . . . . . . . . 12–6412.8.1 Multiple thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–6412.8.2 Thread re-cutting/setting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–65

12.9 Thread cutting position controlled spindle (SW 2 and higher) . . 12–6612.9.1 Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–6612.9.2 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–6612.9.2.1 Switching on the function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–6712.9.2.2 Switching off the functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–6812.9.3 Parameter set switchover with thread functions . . . . . . . . . . . . . . . . 12–7012.9.4 Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–7012.9.5 Reset behaviour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–7012.9.6 Reading in G functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–7112.9.7 Interface signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–7112.9.8 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–71

12.10 FIFO/predecoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–7112.10.1 Rapid block change using FIFO function (up to SW 2 only) . . . . . . . . 12–7112.10.2 Control of predecoding (SW 5 and higher) . . . . . . . . . . . . . . . . . . . 12–7312.10.2.1 Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–73

12.11 Absolute encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–7412.11.1 SIPOS absolute encoder up to SW 4 . . . . . . . . . . . . . . . . . . . . . . . 12–7412.11.1.1 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–7412.11.1.2 Hardware requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–7412.11.1.3 Synchronizing the absolute encoder with the machine absolute system 12–7512.11.1.4 What happens on warm restart (POWER ON) . . . . . . . . . . . . . . . . . 12–7812.11.1.5 Special case ”Parking axis” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–7812.11.1.6 Absolute encoder error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–78

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–7912.11.1.7 SIPOS absolute encoder errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–8012.11.2 ENDAT absolute encoder (SW 5.2 and higher) . . . . . . . . . . . . . . . . 12–8112.11.2.1 Function features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–8112.11.2.2 Hardware requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–8212.11.2.3 Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–8212.11.2.4 Special features for large traversing ranges . . . . . . . . . . . . . . . . . . . 12–8412.11.2.5 Offset of the absolute encoder from the machine absolute system . . 12–8612.11.2.6 Behaviour on power on) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–9012.11.2.7 Special case ”Parking axis” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–9012.11.2.8 Absolute encoder error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–9012.11.3 Range extension with ENDAT absolute encoder (as from SW 6) . . . . 12–9012.11.3.1 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–9012.11.3.2 Storing absolute information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–9112.11.3.3 First start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–9312.11.3.4 Special start-up cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–9412.11.3.5 Start-up after data loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–94

12.12 Path dimension from PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–95General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–95

12.12.1 Execution of the function ”Path dimension from the PLC” . . . . . . . . 12–9512.12.2 Termination of the function ”Path dimension from the PLC” . . . . . . . 12–9612.12.3 Interruption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–9612.12.4 Meaning of NC MD 5008, bit 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–9712.12.5 Influence of the modes on the path dimension function from the PLC 12–9712.12.5.1 Path dimension from the PLC and JOG operating mode . . . . . . . . . . 12–9712.12.5.2 Path dimension from the PLC and MDA, TEACH IN and AUTOMATIC

modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–98Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–100

12.13 Indexing function from the PLC . . . . . . . . . . . . . . . . . . . . . . . . . 12–102General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–102

12.13.1 Division in set-up mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–10312.13.2 Division from the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–10312.13.3 Explanation of indexing function terms . . . . . . . . . . . . . . . . . . . . . . 12–10412.13.4 Machine data for the function ”Setup mode division related” . . . . . . 12–10712.13.5 Traversing an indexing axis to the reference point . . . . . . . . . . . . . . 12–10912.13.6 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–11012.13.7 Actual value display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–11012.13.8 PLC user interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–11212.13.9 Conditions for the function ”Setup mode division related” . . . . . . . . . 12–11212.13.10 Error messages from the NC to the PLC . . . . . . . . . . . . . . . . . . . . . 12–113

12.14 Dynamic feedforward control and setpoint smoothing filter . . . . 12–11312.14.1 Feedforward control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–11412.14.1.1 Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–11412.14.1.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–11412.14.2 Setpoint filter in drive (SW 4 and higher) . . . . . . . . . . . . . . . . . . . . . 12–115

12.15 Switchover measuring system 1 or 2 (SW 2 and higher) . . . . . . . 12–11612.15.1 Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–11612.15.2 Feed axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–11612.15.3 Measuring circuit monitoring and alarm processing . . . . . . . . . . . . . 12–11712.15.4 C axes to spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–117

12.16 Quadrant error compensation (SW 2 and higher) . . . . . . . . . . . . 12–11812.16.1 Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–11812.16.2 Parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–11812.16.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–11912.16.3.1 Installation without adaptation characteristic . . . . . . . . . . . . . . . . . . 12–12012.16.3.2 Installation with adaptation characteristic . . . . . . . . . . . . . . . . . . . . . 12–123

12.17 Axis converter/spindle converter (SW 2 and higher) . . . . . . . . . . 12–12512.17.1 Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–125

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–12512.17.2 Axis converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–12512.17.2.1 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–12512.17.2.2 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–12612.17.3 Spindle converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–12612.17.3.1 Description of functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–12612.17.3.2 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–12712.17.3.3 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–127

12.18 Functional description of gearbox interpolation (up to SW 3) . . . 12–12812.18.1 Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–12812.18.2 Brief description of GI functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–12912.18.2.1 Definition of leading and following drives . . . . . . . . . . . . . . . . . . . . . 12–12912.18.3 Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–13112.18.4 Link types with constant link factor . . . . . . . . . . . . . . . . . . . . . . . . . 12–13212.18.4.1 Setpoint link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–13212.18.4.2 Actual value link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–13312.18.4.3 Setpoint velocity/actual position link (SW 4 and higher) . . . . . . . . . . 12–133

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–133Parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–133Compensatory control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–134

12.18.5 Curve-gearbox interpolation (CGI) (SW 4 and higher) . . . . . . . . . . . . 12–13512.18.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–13512.18.5.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–13512.18.6 Variable cascading of GI following drives (SW 4 and higher) . . . . . . . 12–13812.18.7 Gearbox interpolation chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–13812.18.8 Following drive overlays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–13912.18.9 Influencing the following error . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–14012.18.10 Block search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–14112.18.11 GI monitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–14112.18.11.1 Monitoring for maximum velocity/speed and maximum acceleration . . 12–14212.18.11.1.1 Velocity/speed limitation of ELG following axex (as from SW 6.3) . . . 12–14312.18.11.2 Fine/coarse synchronism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–14612.18.11.3 ”Emergency retraction” message (SW 3) . . . . . . . . . . . . . . . . . . . . 12–14712.18.11.4 Maintaining the link in the event of faults (controlled follow-up)

(SW 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–14812.18.11.5 HW/SW limit switches of following drive . . . . . . . . . . . . . . . . . . . . . 12–14912.18.11.6 Special features relating to following axes . . . . . . . . . . . . . . . . . . . . 12–15012.18.11.7 Special features relating to following spindles . . . . . . . . . . . . . . . . . 12–15012.18.12 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–15012.18.12.1 Programming via NC part program . . . . . . . . . . . . . . . . . . . . . . . . . 12–15512.18.12.2 Programming via PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–15512.18.12.3 Programming via input display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–15512.18.12.4 Default settings via machine data . . . . . . . . . . . . . . . . . . . . . . . . . . 12–155

12.18.13 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–15612.18.13.1 Brief start-up of a GI grouping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–15612.18.13.2 Full start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–157

Set position control sampling times . . . . . . . . . . . . . . . . . . . . . . . . 12–158Drift and tacho compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–158General optimization of axes and spindles . . . . . . . . . . . . . . . . . . . . 12–159Setting the feedforward control . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–159Matching the dynamic response of the drives . . . . . . . . . . . . . . . . . 12–159Setting the GI machine data and the necessary PLC signals . . . . . . . 12–161Optimization of the compensatory controller . . . . . . . . . . . . . . . . . . 12–162Calculating the time constant for the parallel model . . . . . . . . . . . . . 12–163Entering the monitoring threshold values . . . . . . . . . . . . . . . . . . . . . 12–164Checking the GI programming functions . . . . . . . . . . . . . . . . . . . . . 12–165Setting the interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–166

12.18.14 Special cases of gearbox interpolation . . . . . . . . . . . . . . . . . . . . . . 12–16612.18.14.1 Synchronous spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–16612.18.14.2 Gantry axes; machines with forced coupling . . . . . . . . . . . . . . . . . . 12–17012.18.15 Gearbox interpolation status data . . . . . . . . . . . . . . . . . . . . . . . . . . 12–17412.18.15.1 Format of data list (SW 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–17412.18.16 Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–17512.18.16.1 Overview of application examples . . . . . . . . . . . . . . . . . . . . . . . . . . 12–17512.18.16.2 Hobbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–17512.18.16.3 Inclined infeed axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–177

12.19 Interpolation and compensation with tables and temperaturecompensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–181

12.19.1 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–18112.19.2 Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–18212.19.3 Interlocks and monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–18412.19.4 Temperature compensation TC . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–18712.19.4.1 Types of influence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–18712.19.4.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–18912.19.4.3 Data structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–18912.19.4.4 Activation of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–19012.19.5 Interpolation and compensation with tables . . . . . . . . . . . . . . . . . . . 12–19112.19.5.1 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–19312.19.5.2 Data structures and data assignment . . . . . . . . . . . . . . . . . . . . . . . 12–19412.19.5.3 Data access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–194

Data access via operator panel/machine data dialog . . . . . . . . . . . . . 12–195Data access via part program . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–195Data access via MMC/data transfer . . . . . . . . . . . . . . . . . . . . . . . . 12–199Data access via PLC (command channel, DB 41) . . . . . . . . . . . . . . 12–200

12.19.5.4 Activating IKA data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–20112.19.5.5 Overview of valid IKA data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–20212.19.5.6 IKA calculation sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–20412.19.5.7 Meaning of the data types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–20612.19.5.8 Links between IKA data areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–21012.19.5.9 Viewing the IKA data during programming . . . . . . . . . . . . . . . . . . . . 12–21112.19.5.10 Compensation beyond the working area . . . . . . . . . . . . . . . . . . . . . 12–211

12.20 Extended stop and retract (ESR) (SW 4 and higher) . . . . . . . . . . 12–212General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–212

12.20.1 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–21312.20.2 Parameterization, control and programming . . . . . . . . . . . . . . . . . . . 12–21312.20.3 Monitoring sources (error detection) . . . . . . . . . . . . . . . . . . . . . . . . 12–21512.20.4 Mains failure detection and mains buffering . . . . . . . . . . . . . . . . . . . 12–21612.20.4.1 Mains failure detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–21612.20.4.2 DC link overvoltage limitation (611D) . . . . . . . . . . . . . . . . . . . . . . . 12–21612.20.4.3 Mains buffering (611D only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–216

12.20.4.4 DC link undervoltage monitoring in 611D . . . . . . . . . . . . . . . . . . . . 12–21712.20.5 DC link buffering and monitoring of generator minimum speed limit . . 12–21812.20.5.1 DC link buffering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–21812.20.5.2 Monitoring for generator minimum speed limit . . . . . . . . . . . . . . . . . 12–21912.20.5.3 Communications/control failure . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–21912.20.5.4 840C/611D detects error/request and specifies "Extended stop and

retract" as autonomous drive function . . . . . . . . . . . . . . . . . . . . . . 12–21912.20.6 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–21912.20.6.1 Stopping as open-loop control function . . . . . . . . . . . . . . . . . . . . . . 12–22012.20.6.2 Stopping as autonomous drive function . . . . . . . . . . . . . . . . . . . . . . 12–22012.20.7 Retraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–222

Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–22212.20.7.1 Retraction as open-loop control function . . . . . . . . . . . . . . . . . . . . . 12–22412.20.7.2 Retraction as autonomous drive function (611D) . . . . . . . . . . . . . . . 12–22612.20.8 Configuration help for generator operation and emergency

retraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–22712.20.8.1 Special case voltage failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–22712.20.8.2 Activating autonomous drive emergency retraction in case of

PLC failure or 5 V undervoltage (as from SW 6.3) . . . . . . . . . . . . . . 12–231

12.21 Simultaneous axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–23212.21.1 Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–232

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–23212.21.2 Handwheel for simultaneous axes in automatic mode . . . . . . . . . . . . 12–232

12.22 Software cam (position measuring signals) . . . . . . . . . . . . . . . . 12–23412.22.1 Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–23412.22.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–234

12.23 Actual-value system for workpiece . . . . . . . . . . . . . . . . . . . . . . . 12–24012.23.1 Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–24012.23.2 Reference systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–24012.23.3 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–24112.23.4 Example of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–242

12.24 Travel to fixed stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–24312.24.1 Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–24312.24.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–24312.24.3 Travel to fixed stop with analog drives . . . . . . . . . . . . . . . . . . . . . . 12–24512.24.4 Travel to fixed stop with fixed clamping torque

(torque limitation via terminal 96) . . . . . . . . . . . . . . . . . . . . . . . . . . 12–24512.24.4.1 SIMODRIVE 611A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–24612.24.4.2 SIMODRIVE 611A MSD or SIMODRIVE 660 . . . . . . . . . . . . . . . . . . 12–24712.24.5 Travel to fixed stop with programmable clamping torque

(switchover of drive actuator to current-controlled operation) . . . . . . . 12–24812.24.5.1 SIMODRIVE 611A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–24812.24.5.2 SIMODRIVE 611A MSD or SIMODRIVE 660 . . . . . . . . . . . . . . . . . . 12–25012.24.6 Deselection of the function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–25112.24.7 Diagrams for selection/deselection of travel to fixed stop . . . . . . . . . 12–25212.24.7.1 Selection of travel to fixed stop (fixed stop is reached) ANALOG . . . . 12–25212.24.7.2 Selection of travel to fixed stop (fixed stop is not reached) . . . . . . . . 12–25312.24.7.3 Deselection of travel to fixed stop . . . . . . . . . . . . . . . . . . . . . . . . . 12–25412.24.7.4 Meaning of signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–25512.24.7.5 Travel to fixed stop with digital drives (SIMODRIVE 611D MSD/FDD) 12–256

12.25 Flexible memory configuration (SW 4 and higher) . . . . . . . . . . . 12–25812.25.1 Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–258

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–25812.25.2 System features, boundary conditions . . . . . . . . . . . . . . . . . . . . . . 12–25912.25.3 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–26012.25.4 Memory configuration on control power-up . . . . . . . . . . . . . . . . . . . 12–260

12.26 BERO interface (SW 4 and higher) . . . . . . . . . . . . . . . . . . . . . . . 12–269

12.27 Parameter set switchover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–27012.27.1 Parameter set switchover (up to SW 3) . . . . . . . . . . . . . . . . . . . . . 12–270

Axis parameter sets (NCK/SERVO) . . . . . . . . . . . . . . . . . . . . . . . . 12–270Spindle parameter sets (NCK/SERVO) . . . . . . . . . . . . . . . . . . . . . . 12–271FDD parameter sets (611D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–272MSD parameter sets (611D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–272

12.27.2 Parameter set switchover with SW 4 and higher (option) . . . . . . . . . 12–273”Position control” parameter group . . . . . . . . . . . . . . . . . . . . . . . . 12–274”Ratio” parameter group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–276Drive parameter group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–277

12.27.3 Switchover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–27712.27.4 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–27912.27.5 Operator inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–28012.27.6 Power ON, system start, power OFF, restart . . . . . . . . . . . . . . . . . . 12–28012.27.7 Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–280

12.28 High-speed data channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–28112.28.1 Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–28112.28.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–28112.28.3 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–28312.28.4 Format of interface data blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–28412.28.5 Configuration of a high-speed data channel . . . . . . . . . . . . . . . . . . . 12–28812.28.6 Fast synchronous data channel . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–28812.28.7 Use of a high-speed data channel . . . . . . . . . . . . . . . . . . . . . . . . . 12–28912.28.8 Overview of function identifiers and configuring parameters

(DB 2, DR 2 ... DR 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–290

12.29 Extension of inprocess measurement (SW 4 and higher) . . . . . . 12–298General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–298

12.29.1 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–29812.29.2 General hardware conditions for ”Extended measurement” . . . . . . . 12–301

12.30 Master/slave for drives, SW 4.4 and higher, option . . . . . . . . . . . 12–30412.30.1 Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–304

General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–30412.30.2 Difference to synchronous spindle/GI . . . . . . . . . . . . . . . . . . . . . . . 12–30512.30.3 Function description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–30512.30.4 Activating/deactivating the master/slave torque compensation

control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–30812.30.5 Response in the event of an error . . . . . . . . . . . . . . . . . . . . . . . . . 12–30912.30.6 Effects on existing functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–311

12.31 Dynamic SW limit switches for following axes . . . . . . . . . . . . . . 12–31212.31.1 Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–31212.31.2 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–312

12.32 Collision monitoring (as from SW 6) . . . . . . . . . . . . . . . . . . . . . . 12–31512.32.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–31512.32.2 Defining a protection zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–31512.32.3 Activation of collision monitoring of a protection zone . . . . . . . . . . . . 12–31612.32.4 The motion axes of a protection zone . . . . . . . . . . . . . . . . . . . . . . . 12–31712.32.5 Machine coordinate systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–31712.32.6 Adaptation of the protection zone to the active tool . . . . . . . . . . . . . 12–31812.32.7 Activating machine space adaptation . . . . . . . . . . . . . . . . . . . . . . . 12–31912.32.8 Reduction zone of a protection zone . . . . . . . . . . . . . . . . . . . . . . . 12–32012.32.9 Reduction factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–32112.32.10 Dead-time compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–32212.32.11 Protection zone collision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–32212.32.12 Collision alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–32312.32.13 Deselection of collision of monitoring of a protection zone . . . . . . . . 12–323

12.32.14 Example on a double-slide turning machine . . . . . . . . . . . . . . . . . . . 12–32412.32.15 Collision monitoring (as from SW 6.3) . . . . . . . . . . . . . . . . . . . . . . . 12–32912.32.15.1 Additive protection zone adjustment via setting data . . . . . . . . . . . . . 12–32912.32.15.2 Collision monitoring without reduction zone . . . . . . . . . . . . . . . . . . . 12–32912.32.15.3 Automatic protection zone adjustment for tool types > = 20

(as from SW 6.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–330

12.33 Description of function of current and speed setpoint filters . . . 12–33112.33.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–33112.33.1.1 Fourier analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–33512.33.1.2 Measurement range (bandwidth), measurement time . . . . . . . . . . . . 12–33512.33.1.3 Measurement procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–33612.33.2 Optimization of speed controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–33612.33.2.1 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–33712.33.2.2 Optimization of proportional gain of speed controller . . . . . . . . . . . . 12–33712.33.2.3 Optimization of integral-action component (reset time) of speed

controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–33712.33.3 Current setpoint filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–33812.33.3.1 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–33912.33.3.2 Scope of application of low pass as current setpoint filter . . . . . . . . . 12–34012.33.3.3 Scope of application of bandstops as current setpoint filter . . . . . . . . 12–34212.33.4 Speed-dependent current setpoint filter . . . . . . . . . . . . . . . . . . . . . 12–34712.33.4.1 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–34712.33.4.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–34712.33.5 Speed setpoint filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–34812.33.5.1 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–34812.33.5.2 Bandstops and low passes as speed setpoint filter . . . . . . . . . . . . . . 12–349

12.34 Actual value passive monitoring axis (as from SW 6.3) . . . . . . . . 12–35212.34.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–35212.34.2 Parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–35212.34.3 Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–35212.34.4 Alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–35212.34.5 Parameterization examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–353

12.35 Uninterruptible power supply (UPS) (as from SW 6.3)(Express shutdown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–354

12.36 Inch/metric switchover function (as from SW 6.3) . . . . . . . . . . . . 12–35912.36.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–35912.36.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–35912.36.3 System data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–35912.36.4 Inch/metric switchover function . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–36012.36.5 Inch/metric conversion function . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–36112.36.6 Deleting the conversion data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–36312.36.7 Error handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–36312.36.8 Configurability of the conversion . . . . . . . . . . . . . . . . . . . . . . . . . . 12–36412.36.9 List of descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–367

13 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

11.92 1 Prerequisites and Visual Inspection

1.1 Prerequisites

1 Prerequisites and Visual Inspection

1.1 Prerequisites

The following prerequisites must be fulfilled prior to initial start-up:

• Electrical and mechanical installation of the machine must have been completed and theaxes prepared for operation.

The following points must be confirmed by the customer!

• Customer PLC program operational