Description of Functions
Description of Functions 11.2003 Edition
sinumerik
SINUMERIK 802D
SINUMERIK 802D base line

Preface, Table of Contents
EMERGENCY STOP (N2)
1
Axis Monitoring (A3)
2
Velocities, Setpoint/Actual-Value
Systems, Closed-Loop Control
(G2)
3
Acceleration (B2)
4
Spindle (S1)
5
Rotary Axes (R2)
6
Transverse Axes (P1)
7
Reference Point Approach (R1)
8
Manual Traversing and Hand-

11.03 Edition
SINUMERIK 802D
Description of Functions
SINUMERIK

Documentation
Printing history
Brief details of this edition and previous edition 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 Unrevised reprint with new Order No.. . . . .
C Revised edition with new status. . . . . .
If actual changes have been made on the page since the last edition, this is indicated by
a new edition coding in the header on that page.
Edition Order No. Remarks
11.00 6FC5 697-2AA10-0BP0 A
10.02 6FC5 697-2AA10-0BP1 C
11.03 6FC5 697-2AA10-0BP2 C
This Manual is included on the documentation on CD ROM (DOCONCD)
E
Trademarks
SIMATICr, SIMATIC HMIr, SIMATIC NETr, SIROTECr, SINUMERIKr and SIMODRIVEr are registered
trademarks of Siemens. Third parties using for their own purpose any other names in this document which
refer to trademarks might infringe upon the rights of trademark owners.
This publication was produced with Interleaf V 7.
The reproduction, transmission or use of this document or its
contents is not permitted without express written authority.Offenders
will be made liable for damages. All rights, including rights created by
patent grant or registration of utility model or design, are reserved.

The following notations and abbreviations are used in this Documentation:
S PLC interface signals -> IS ”Signal name” (signal data)
Example: IS ”Feed override“ (VB380x 0000)
The variable byte is in the range “at axis“, “x” stands for the axis: 0 axis 1
1 aixs 2
n axis n+1.
S Machine data -> MD MD_NR: MD_NAME
S Setting data -> SD SD_NR: SD_NAME
S The headlines of the individual chapters/sections are added by a code designation in brak-
kets (e.g. Chapter 1: EMERGENCY STOP (N2)). This code designation is used in referen-
ces to individual Chapters/Sections.
Explanation of the code designations
In the chapters/sections of each Description of Functions, the data and/or signals are explai-
ned which are important for the function discussed. Within these explanations provided in the
form of tables, some terms and abbreviations are used, which are explained here.
Default value:
This is the default value of the machine/setting data when loading the standard machine data.
Range of values (minimum/maximum values):
specifies the input limits. If no range of values is specified, the data type defines the input li-
mits, and the field is marked with ”***”.
Preface
vi
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6FC5 697-2AA10-0BP2 (11.03) (DF)
Activation of changes:
Changes in machine data, setting data or the like come not immediately into effect in the con-
trol system. The conditions for activation are therefore always specified. The possibilities used
are listed below by their priority:
S POWER ON (po) Turning off/turning on the power supply
or softkey “StartUp/Normal” on HMI

as a hexadecimal value: 0000 to FFFF
S BYTE
Integer values (8-bit value)
Input limits from -128 to +127 (decimal), as a hexadecimal value: 00 to FF
S BOOLEAN
Boolean value: TRUE (1) or FALSE (0)
S STRING
consisting of a maximum of 16 ASCII characters (uppercase letters, digits and underscore)
Preface
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6FC5 697-2AA10-0BP2 (11.03) (DF)
Example machine data
36210 CTRLOUT_LIMIT[0]
MD number Maximum speed setpoint
Default: 110.0 Min. input limit: 0.0 Max. input limit: 200.0
Change valid after NEW_CONF Protection level: 2/7 Unit: %
Data type: DOUBLE Valid from SW release:
Meaning:
Alarms
For detailed explanations on occurring alarms, please refer to:
References: ”Diagnostics Guide“.
Contents
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6FC5 697-2AA10-0BP2 (11.03) (DF)
Contents
1 EMERGENCY STOP (N2) 1-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Brief description 1-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 EMERGENCY STOP sequence 1-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.2 Axis/spindle-specific machine data 2-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8.3 Channel-specific machine data 2-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8.4 Axis/spindle-specific setting data 2-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2) 3-49. . . . . . . . . .
3.1 Velocities, traversing ranges, accuracies 3-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1 Velocities 3-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.2 Traversing ranges 3-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.3 Input/display resolution, computational resolution 3-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.4 Standardization of physical quantities of machine and setting data 3-52. . . . . . . . . . . . . . . . . . .
3.2 Metric/inch scaling system 3-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1 Conversion of the scaling system using the part program 3-53. . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2 Switching over the scaling system manually 3-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Setpoint/actual-value system 3-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.1 General 3-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
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6FC5 697-2AA10-0BP2 (11.03) (DF)
3.3.2 Drives connected to Profibus DP 3-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.3 Speed setpoint and actual-value assignment 3-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.4 Speed setpoint output 3-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.5 Actual-value processing 3-63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Closed-loop control 3-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Data description (MD, SD) 3-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.1 General machine data 3-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.2 Channel-specific machine data 3-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.3 Axis-specific machine data 3-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 Signal descriptions 3-76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7 Data fields, data lists 3-77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7.1 Interface signals 3-77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.9.3 Spindle-specific setting data 5-116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.10 Signal descriptions 5-118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.10.1 Axis/spindle-specific signals 5-118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11 Data fields, lists 5-127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.1 Interface signals 5-127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.2 Machine data 5-128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
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6FC5 697-2AA10-0BP2 (11.03) (DF)
5.11.3 Setting data 5-129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Rotary Axes (R2) 6-131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 General 6-131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Modulo 360 degrees 6-133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Programming rotary axes 6-134. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.1 Rotary axis with active modulo conversion 6-134. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.2 Rotary axis without modulo conversion 6-135. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Data descriptions (MD, SD) 6-136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.1 Axis/spindle-specific machine data 6-136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Data fields, lists 6-138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.1 Machine data 6-138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.2 Setting data 6-138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Transverse Axes (P1) 7-139. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Defining a transverse axis 7-139. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Diameter programming 7-139. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Constant cutting rate: G96 7-140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Reference Point Approach (R1) 8-141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 Fundamentals 8-141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Referencing using incremental measuring systems 8-143. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 Referencing using absolute encoders 8-146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.6.4 Axis/spindle-specific signals 9-180. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.7 Data fields, lists 9-183. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.7.1 Interface signals 9-183. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.7.2 Machine data 9-184. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.7.3 Setting data 9-184. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Operating Modes, Program Mode (K1) 10-185. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1 Brief description 10-185. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2 Operating modes 10-186. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2.1 Mode change 10-187. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2.2 Possible functions in the individual operating modes 10-188. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2.3 Monitoring functions in the individual operating modes 10-189. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2.4 Interlocks in the individual operating modes 10-190. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3 Execution of a part program 10-191. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.1 Program mode and part program selection 10-191. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.2 Starting the part program or part program block 10-191. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.3 Part program interruption 10-192. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.4 RESET command 10-193. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.5 Program control 10-194. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.6 Program status 10-194. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.7 Channel status 10-195. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.8 Reactions to operator or program actions 10-196. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.9 Example of time diagram for a program sequence 10-197. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4 Program test 10-198. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4.1 General remarks on program test 10-198. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4.2 Program execution without axis movements (PRT) 10-198. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4.3 Program execution in single block mode 10-199. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4.4 Program execution with Dry Run Feed (DRY) 10-200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4.5 Block search: Execution of certain program sections 10-201. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4.6 Skipping part program blocks (SKP) 10-203. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4.7 Graphical simulation 10-204. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.5.2 Axis/spindle-specific signals 11-245. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.6 Data fields, lists 11-248. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.6.1 Interface signals 11-248. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.6.2 Machine data/setting data 11-248. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 Continuous -Path Mode, Exact Stop and LookAhead (B1) 12-249. . . . . . . . . . . . . . . . . . . . . .
12.1 Brief description 12-249. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.2 General 12-250. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.3 Exact Stop 12-251. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.4 Continuous path mode 12-252. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.4.1 General 12-252. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.4.2 Velocity reduction according to the overload factor 12-253. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.4.3 Velocity reduction for jerk limitation on the path 12-254. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.4.4 Machine axis-specific jerk limitation 12-255. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.5 LookAhead 12-256. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.6 Data descriptions (MD, SD) 12-258. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.6.1 Channel-specific machine data 12-258. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.6.2 Axis-specific machine data 12-258. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.7 Signal descriptions 12-259. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.7.1 Channel-specific signals 12-259. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.7.2 Axis-specific signals 12-259. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.8 Data fields, lists 12-260. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.8.1 Interface signals 12-260. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.8.2 Machine data 12-260. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 Output of Auxiliary Functions to the PLC (H2) 13-261. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.1 Brief description 13-261. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.2 Programming of auxiliary functions 13-262. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.3 Transfer of values and signals to the PLC interface 13-263. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.4 Division of auxiliary functions into groups 13-264. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.5 Behavior on block search 13-265. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.6 Description of the auxiliary functions 13-266. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14.8.2 Machine data 14-290. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 Measuring (M5) 15-291. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.1 Brief description 15-291. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.2 Hardware requirements 15-292. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.2.1 Probes that can be used 15-292. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.2.2 Connecting the probe 15-293. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.3 Channel-specific measuring 15-295. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.3.1 Measuring mode 15-295. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.3.2 Measurement results 15-295. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.4 Measuring accuracy and testing 15-296. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.4.1 Measuring accuracy 15-296. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.4.2 Sensing probe function test 15-296. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.5 Tool gauging in JOG 15-298. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.6 Supplementary conditions 15-301. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.7 Data descriptions (MD, SD) 15-302. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.8 Signal descriptions 15-303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.9 Data fields, lists 15-305. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.9.1 Interface signals 15-305. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.9.2 Machine data 15-305. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 Compensation (K3) 16-307. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.1 Brief description 16-307. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.2 Backlash compensation 16-308. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.3 Interpolatory compensation 16-309. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.3.1 General 16-309. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.3.2 Leadscrew error compensation (LEC) 16-310. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.3.3 Special features of interpolatory compensation 16-313. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.4 Following error compensation (feedforward control) 16-314. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.4.1 General 16-314. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.4.2 Speed feedforward control 16-315. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.5 Data descriptions (MD, SD) 16-316. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18.7 Data fields, lists 18-358. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18.7.1 Interface signals 18-358. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18.7.2 Machine data/setting data 18-358. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 Various Interface Signals (A2) 19-359. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19.1 Brief description 19-359. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19.2 Signals from PLC to NCK 19-360. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19.3 Signals from NCK to PLC 19-364. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19.4 Signals from PLC to HMI 19-368. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19.5 Signals from HMI to PLC 19-370. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 PLC User Interface 20-371. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20.1 Address ranges 20-371. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20.2 User data 20-373. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20.2.1 User data 1 20-373. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20.2.2 User Data 2 20-373. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20.2.3 Retentive data area 20-373. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20.3 User alarm 20-374. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20.3.1 User alarm: Enabling 20-374. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20.3.2 Variable for alarm 20-374. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20.3.3 Active alarm reaction 20-375. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20.4 Signals from/to HMI 20-375. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20.4.1 Program control signals from HMI (retentive area) 20-375. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20.4.2 General selection/status signals from MMC (retentive area) 20-377. . . . . . . . . . . . . . . . . . . . . . . . .
Contents
xv
SINUMERIK 802D, 802D base line
6FC5 697-2AA10-0BP2 (11.03) (DF)
20.4.3 General selection/status signals to MMC (retentive area) 20-377. . . . . . . . . . . . . . . . . . . . . . . . . . . .
20.5 Auxiliary function transfer from NC channel 20-378. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20.5.1 Decoded M signals (M0 - M99) 20-378. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20.5.2 T functions transferred 20-379. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-17
SINUMERIK 802D, 802D base line
6FC5 697-2AA10-0BP2 (11.03) (DF)
EMERGENCY STOP (N2)
1.1 Brief description
Important
We would like to draw the machine manufacturer’s attention to his duty to observe the rele-
vant international and national standards (see notes on standards further below in the text).
The SINUMERIK 802D supports the machine manufacturer in implementing the EMER-
GENCY STOP function according to the specifications in this Description of Functions. The
EMERGENCY STOP function (tripping, sequence and acknowledgement) is the sole and only
responsibility of the machine manufacturer.
Note
The following standards are relevant for the EMERGENCY STOP function:
S
EN 292 Part 1
S
EN 292 Part 2
S
EN 418
S
EN 60204 Part 1:1992 Section 10.7
The VDE 0113 Part 1 is only valid for a transition period and is replaced by EN 60204.
EMERGENCY STOP in the control system
The following arrangements are provided in the control system to support the machine manu-
facturer in implementing the EMERGENCY STOP function:
S Initiation of the EMERGENCY STOP sequence in the NC via the PLC input.
S The EMERGENCY STOP sequence in the NC will decelerate all axes and spindles in the
NC as fast as possible.
S The EMERGENCY STOP status cannot be canceled by unlocking the EMERGENCY

36620: SERVO_DISABLE_DELAY_TIME (servo enable cutout delay) has been elapsed.
In this context, make sure that 36620: SERVO_DISABLE_DELAY_TIME must be specified
at least as large as MD 36610: AX_EMERGENCY_STOP_TIME.
Sequence on the machine
The EMERGENCY STOP sequence on the machine is exclusively defined by the machine
manufacturer. The following must be observed in conjunction with the sequence in the NC:
S The sequence in the NC is started using the IS ”EMERGENCY STOP“ (V2600 0000.1).
After the axes and spindles have been stopped, the power supply must be interrupted acc.
to EN418.
S The sequence in the NC has no influence on the PLC I/Os (digital outputs). If you wish
individual outputs to have a certain status in case of EMERGENCY STOP, the machine
manufacturer must implement the appropriate functions in the PLC program.
Important
To interrupt the power supply, is the sole and only responsibility of the machine manufacturer.
If you wish the sequence in the NC in case of EMERGENCY STOP not to be carried out as
defined, the IS “EMERGENCY STOP” (V2600 0000.1) may not be set until an EMERGENCY
STOP status defined by the machine manufacturer in the PLC user program is reached. Until
the IS “EMERGENCY STOP” is not yet set and no other alarm is pending, all IS are active in
the NC. Thus, any manufacturer-specific EMERGENCY STOP status is possible.
EMERGENCY STOP (N2)
1.3 EMERGENCY STOP acknowlededgement
1-19
SINUMERIK 802D, 802D base line
6FC5 697-2AA10-0BP2 (11.03) (DF)
1.3 EMERGENCY STOP acknowlededgement
Acknowledging EMERGENCY STOP
The EMERGENCY STOP status will only be reset if first the IS “Acknowledge EMERGENCY
STOP” (V2600 0000.2) and then the IS “Reset” (V3000 0000.7) is set. When doing so, make
sure that the IS ”Acknowledge EMERGENCY STOP” and the IS ”Reset” must be set together
at least as long as the IS “EMERGENCY STOP active” (V2700 0000.1) has been reset (see

The PLC I/Os must be brought again by the PLC user program to the appropriate status requi-
red to operate the machine.
Reset
It is not possible to reset the EMERGENCY STOP status with the IS ”Reset” (V3000 0000.7)
alone (see diagram above).
EMERGENCY STOP (N2)
1.4 Data descriptions (MD, SD)
1-20
SINUMERIK 802D, 802D base line
6FC5 697-2AA10-0BP2 (11.03) (DF)
Power ON
Power ON (turning off/turning off the power supply) will clear the EMERGENCY STOP status,
except the IS ”EMERGENCY STOP” (V2600 0000.1), which remains set.
1.4 Data descriptions (MD, SD)
Axis-specific machine data
36620 SERVO_DISABLE_DELAY_TIME
MD number Servo enable cutout delay
Default: 0.1 Min. input limit: 0.02 Max. input limit: ***
Change valid after NEW_CONF Protection level: 2/2 Unit: s
Data type: DOUBLE Valid from SW release:
Meaning: Maximum time delay for cancellation of “Servo enable” after faults.
The speed enable (servo enable) of the drive is canceled internally in the control system at the
latest after a set delay time if the axis / spindle is moving.
The entered delay time acts due to the following events:
S in case of errors resulting in immediate axis stop
S if the IS “Servo enable” is canceled from the PLC.
Once the actual speed reaches the zero speed range (MD 36060: STANDSTILL_VELO_ TOL),
“Servo enable” is disabled for the drive.
The time should be set as large as the axis / spindle needs to come to a standstill from maximum
traversing velocity or speed.

IS ”EMERGENCY STOP active” (V2700 0000.1)
V2600 0000.2 Acknowledge EMERGENCY STOP
Interface signal Signal(s) to NC (PLC - - -> NC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge
change 0 - ->1
The EMERGENCY STOP status will only be reset if first the IS ”Acknowledge EMERGENCY
STOP“ and then the IS ”Reset” (V3000 0000.7) are set. When doing so, make sure that the IS
“Acknowledge EMERGENCY STOP” and the IS ”Reset” must be set together at least as long
as the IS ”EMERGENCY STOP active” (V2600 0000.1) has been reset.
Resetting the EMERGENCY STOP status:
D resets the IS ”EMERGENCY STOP active”;
D connects “Servo enable”;
D sets the IS ”Position control”;
D sets the IS ”802-Ready”;
D lcears alarm 3000;
D aborts the part program execution.
Related to .... IS ”EMERGENCY STOP” (V2600 0000.1)
IS ”EMERGENCY STOP active” (V2700 0000.1)
IS ”Reset” (V3000 0000.7)
V2700 0000.1 EMERGENCY STOP active
Interface signal Signal(s) to NC (PLC - - -> NC)
Edge evaluation: no Signal(s) updated: cyclically Signal(s) valid from SW release:
Signal state 1 or edge
change 0 - ->1
The NC is in the EMERGENCY STOP status.
Related to .... IS ”EMERGENCY STOP” (V2600 0000.1)
IS ”Acknowledge EMERGENCY STOP” (V2600 0000.2)
EMERGENCY STOP (N2)
1.6 Data fields, lists

S Monitoring of static limitations
- Limit switch monitoring
- Work area monitoring
2
Axis Monitoring (A3)
2.2 Motion monitoring functions
2-24
SINUMERIK 802D, 802D base line
6FC5 697-2AA10-0BP2 (11.03) (DF)
2.2 Motion monitoring functions
2.2.1 Contour monitoring
Function
The principle of functioning of the contour monitoring is based on the permanent comparison
of measured actual position value and the actual position value calculated from the NC posi-
tion setpoint. To calculate the following error in advance, a model is used which simulates the
dynamic properties of the position control including feedforward control.
To make sure that the monitoring system does not respond already in the case of slight
speed variations (caused by load changes), a tolerance band is permitted for the maximum
contour deviation.
If the permissible actual value deviation entered in MD 36400: CONTOUR_TOL (contour mo-
nitoring tolerance band) is exceeded, an alarm is output, and the axes are stopped.
Activation
The contour monitoring is active for axes and a position-controlled spindle.
Effect
If the contour error is too large, the following will occur:
S Alarm 25050 ”Contour monitoring” is output.
S The axis/spindle concerned is stopped with rapid stop (with open position feedback loop)
via a speed setpoint ramp.
The duration of the braking ramp is defined in the MD 36610: AX_EMER-
GENCY_STOP_TIME (duration of braking ramp in case of error statuses).