SIEMENS AG

Description of PLC Examples for

SINUMERIK 828D

Important:
The sample programs are freeware. Any user can use, copy and forward this program free of charge. The
authors and owners of this program take no responsibility whatsoever for the functionality and compatibility
of this software. Use of the software is at the user's own risk.
Since this software is free of charge, there is no warranty and no entitlement to error correction and hotline
support.

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General considerations when configuring a new PLC project

Use only PLC subroutines and data blocks from the same toolbox CD. Don’t replace or add single subroutines or
data blocks.

MCP 310 and MCP483 got different input / output images. Further is the arrangement of feed control different in
milling and turning.
The symbol table IS_MCP in examples MCP_xx is adapted to the arrangement for the respective technology.
Please begin your project with the selection of the MCP and add in this project other subroutines.
All SBRs for magazine or tool management relate to first magazine, first tool holder and first loading point.

SBR 228 SWAP_DW

The SWAP_DW SBR exchanges byte-order of a floating point number from big endian to little endian.

SBR 229 Hand-wheel HW_HHU_Mill

This example manages the interface between HMI and PLC to activate hand-wheel in WCS (DB3200.DBX100x.x)
or MCS (DB380x.DBB4) and jog keys on hand held unit (HHU).

Please see following conditions if you use a HHU:

The hand-wheel signals need to be taken to X143 of the PPU as first hand-wheel.
Keys for axis selection, jog, rapid movement and function keys needs to interfacing on X51, X52 and X55 on MCP
with standard addresses.
The emergency and enabling buttons should be used in safety/enabling circuit of the machine.
Call SBR HW_HHU_Mill always after MCP and JOG_MCP SBR.

Function description:

Position 0 on axis selection key set HHU inactive. Hand-wheel functions may be selected on HMI.
Switch on axis Z…5 activates HHU. The selected axis can be displayed with PLC alarm (in example alarm 700236).
Machine function 1 INC is selected.
Rapid traverse button switch to machine function 100 INC. Other INC functions are not realized.

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With traversing keys + / - the selected axis can traversed continuous.

Switchover the hand-wheel for machine axis (MCS) or geometry axis (WCS) is achieved by switchover MCS/WCS
on HMI.
Function keys F1-F3 are disposal for free using.
Axis selection, traversing keys and switchover MCS/WCS on MCP are blocked if HHU is active

SBR 230 TMM_Cancel_Job

This Subroutine manages cancel instruction to tool management and reset acknowledgment errors. SBR
TMM_Cancel_Job is part of example TMM_Mill. If you use this SBR in other projects make sure that DB9902
TM_ACK has acknowledgment step 2 with status 3 or change the acknowledgment bits inside the SBR.

SBR 231 Emergency_stop

This subroutine needs data block EMG_STOP (DB9052). Data block DB9052 is contained in this project.
Please copy this data block into your project.

CAUTION

Please check whether this subroutine complies with all the relevant safety requirements.

This subroutine handles the emergency stop sequence, as well as the power on and off sequence of the drive
SINAMICS S120.
For detailed information about drive SINAMICS S120, please refer to SINAMICS S120 documents.

Signals:
Input E_KEY: PLC Input from emergency stop key
Input T_RDY_LM: PLC Input from line module X21 Pin 1
Input HWL_ON: any hardware limit is active
Input Axis_stopped: all axis stand still, can be used to make sure that spindle standstill before disable the drive
system
Output OFF1: Output to set OFF1 and give pulse enable
Output OFF3: Output to set OFF3
Outputs E_Key_pressed, Drive_not_ready and HW_Limit_active: Outputs for set alarms.

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SBR 232 SR_EMG_STOP

This subroutine needs data block EMG_STOP (DB9052). Data block DB9052 is contained in this project.
Please copy this data block into your project.

CAUTION

Please check whether this subroutine complies with all the relevant safety requirements.

This subroutine handles the emergency stop sequence by using a safety relay combination with undelayed and
delayed relay contacts (hardware solution).
Only one emergency stop subroutine may be active in the OB1, either Emergency_stop or SR_EMG_STOP.
The spindle stop signal is not monitoring. The delayed time from the safety relay contact must have a value > drive
stop time from the most powerful drive (e.g. time spindle stop time).
The SINAMICS controlled the line contactor via the Active Line Module.
By using a Smart Line Module without DRIVE CLIQ the line contactor is controlled by the safety relay.

Signals:
Input LM_RDY: Line module with DRIVE CLiQ 828D X132.8 ready to power up; by using line module without
DRIVE CLiQ must be ONE
Input OFF3_K1_Cont: OFF3 quick stop from 828D X122.2
Input OFF1_K2_Cont: OFF1 from 828D X122.1
Input HWL_active: any of hardware limit switches is active (NO)
Input ON_Key_cust: Customer Key for flag ON safety relay
Input LM_Infop: infeed operation line module with (without line module must be one)
Input E_Key_cust: Emergency Stop key (NO)
Input LC_Replay_Cont: Replay from Line contactor
Output SR_ON: On flag for safety relay
Output OFF1_T: Terminal output to subroutine Axis_enable
Output OFF3_T: Terminal output
Output Drive_Power_Alarm: Alarm from Drive power up
Output EMG_button_pushed: Emergency stop button is pushed
Output LC_signal_error: No checkback signal from line contactor

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SBR 233Axis_enable

SBR Axis_enable matches to examples MCP_483/310... and Emergency_stop.

Signals OFF1, Feed Stop active and Spindle Stop active are taken from DB9052 and DB9053.
Please copy this data blocks into your project or use your own signals.

SBR manages ax enabling, feed stop /spindle stop for all axes and first spindle.
If more spindles exist please manage in a separate SBR.

SBR 234 Prog_control

This subroutine needs data block Prog_control (DB9051).

Please copy this data block into your project.

This subroutine manages program control signals from HMI to NC interface.

Signals:
Program test
Dry run
Programmed stop
Handweel Offset
Skip Block

SBR 235 MCP_483

uses additional one SBR JOG_MCP483_x

This subroutine needs data block DB_Common (DB9053). Data block DB9053 is contained in this project.
Please begin a new project with one MCP example. Symbol Table IS_MCP matches only for this example.

This example manages on base Manual PPU, chapter 7.1, signals NC-->PLC and PLC -->NC.

Signals:
Operating Mode (Jog, Jog-Ref, MDA, Auto) and machine functions (Inc, Repos, Teach In)
Program control (NC Start, NC Stop, NC Reset, Single Block)

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Key-operated switch
WCS/MCS

SBR 236 Jog_MCP_483_M

MCP483 for milling machines

This subroutine needs data block DB_Common (DB9053). Data block DB9053 is contained in this project.
Please begin a new project with one MCP example. Symbol Table IS_MCP matches only for this example.

This example manages on base Manual PPU, chapter 7.1, signals NC-->PLC and PLC -->NC.

Signals:
Feed start/stop (send to DB9053, interface is managed in SBR Axis_enable)
Feed control with override switch
Spindle start/stop (send to DB9053, interface is managed in SBR Axis_enable)
Spindle control with override switch
Direction keys with rapid traverse override

SBR input Spindle1_Axis: enter here the machine axis number of the first spindle (to manage the spindle
override).

SBR 237 Jog_MCP_483_T_f

MCP483 for turning machines in front of turning center

This subroutine needs data block DB_Common (DB9053). Data block DB9053 is contained in this project.
Please begin a new project with one MCP example. Symbol Table IS_MCP matches only for this example.

This example manages on base Manual PPU, chapter 7.1, signals NC-->PLC and PLC -->NC.

Signals:
Feed start/stop (send to DB9053, interface is managed in SBR Axis_enable)
Feed control with combined ax and direction key and override feed/rapid traverse

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Spindle start/stop (send to DB9053, interface is managed in SBR Axis_enable)

Spindle control with override switch
rapid traverse key

SBR input Spindle1_Axis: enter here the machine axis number of the first spindle
(to manage the spindle override).

SBR 238 Jog_MCP_483_T_b

MCP483 for turning machines in behind the turning center

This subroutine needs data block DB_Common (DB9053). Data block DB9053 is contained in this project.
Please begin a new project with one MCP example. Symbol Table IS_MCP matches only for this example.

This example manages on base Manual PPU, chapter 7.1, signals NC-->PLC and PLC -->NC.

Signals:
Feed start/stop (send to DB9053, interface is managed in SBR Axis_enable)
Feed control with combined ax and direction key and override feed/rapid traverse
Spindle start/stop (send to DB9053, interface is managed in SBR Axis_enable)
Spindle control with override switch
rapid traverse key

SBR input Spindle1_Axis: enter here the machine axis number of the first spindle
(to manage the spindle override).

SBR 239 MCP_310

uses additional one SBR JOG_MCP310_x

This subroutine needs data block DB_Common (DB9053). Data block DB9053 is contained in this project.
Please begin a new project with one MCP example. Symbol Table IS_MCP matches only for this example.

This example manages on base Manual PPU, chapter 7.1, signals NC-->PLC and PLC -->NC.

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Signals:
Operating Mode (Jog, Jog-Ref, MDA, Auto) and machine functions (Inc, Repos, Teach In)
Program control (NC Start, NC Stop, NC Reset, Single Block)
Key-operated switch
WCS/MCS

SBR 240 Jog_MCP_310_M

MCP310 for milling machines

This subroutine needs data block DB_Common (DB9053). Data block DB9053 is contained in this project.
Please begin a new project with one MCP example. Symbol Table IS_MCP matches only for this example.

This example manages on base Manual PPU, chapter 7.2, signals NC-->PLC and PLC -->NC.

Signals:
Feed start/stop (send to DB9053, interface is managed in SBR Axis_enable)
Feed control with override switch
Spindle start/stop (send to DB380x.DBB5006 and DB9053, interface is managed in SBR Axis_enable)
Spindle control with toggle keys
Direction keys with rapid traverse override
SBR input Spindle1_Axis: enter here the machine axis number of the first spindle
(to manage the spindle override).

SBR 241 Jog_MCP_310_T_f

MCP310 for turning machines in front of turning center

This subroutine needs data block DB_Common (DB9053). Data block DB9053 is contained in this project.
Please begin a new project with one MCP example. Symbol Table IS_MCP matches only for this example.

This example manages on base Manual PPU, chapter 7.2, signals NC-->PLC and PLC -->NC.

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Signals:
Feed start/stop (send to DB9053, interface is managed in SBR Axis_enable)
Feed control with combined ax and direction key and override feed/rapid traverse
Spindle start/stop (send to DB380x.DBB5006 and DB9053, interface is managed in SBR Axis_enable)
Spindle control with toggle keys
rapid traverse key

SBR input Spindle1_Axis: enter here the machine axis number of the first spindle
(to manage the spindle override).

SBR 242 Jog_MCP_310_T_b

MCP310 for turning machines in behind the turning center

This subroutine needs data block DB_Common (DB9053). Data block DB9053 is contained in this project.
Please begin a new project with one MCP example. Symbol Table IS_MCP matches only for this example.

This example manages on base Manual PPU, chapter 7.2, signals NC-->PLC and PLC -->NC.

Signals:
Feed start/stop (send to DB9053, interface is managed in SBR Axis_enable)
Feed control with combined ax and direction key and override feed/rapid traverse
Spindle start/stop (send to DB380x.DBB5006 and DB9053, interface is managed in SBR Axis_enable)
Spindle control with toggle keys
rapid traverse key

SBR input Spindle1_Axis: enter here the machine axis number of the first spindle
(to manage the spindle override).

SBR 243 TMM_Mill

SBR Tool_Change_mill needs data blocks Toolchange(DB9056), TM_CTS(DB9900), TM_VTS(DB9901) and

TM_ACK(DB9902) out this example.

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This SBR match to flow chart and description of the procedure in commissioning manual chapter 9.8 Application
example for milling machine…
The program steps in flow chart correspond to the labels in SBR Tool_Change_mill. The subroutine will set all
necessary acknowledgments.
Please insert on inputs Stepx_done the signals, which reports the mechanical movements.
The acknowledgments will set with a positive transition on SBR input. SBR output Stepx_prepared means: start
respective step.
In this example are the outputs Stepx_prepared direct wired to the inputs. This circuit makes a short run through the
sequence.

SBR 243 TMM_Mill don’t manages manual tools.

Signals:
Input Step2_done till Step14_done: wait for report step is done
Output Step: actual step number
Output Error_status: Feedback from DB4100.DBW104. see commissioning manual chapter 9.2.2
Output Ack_error: Signal from TMM to PLC acknowledgment error
Output Change_in_run: Tool change is running, on DB4300.DBX0.0 is a job pending
Output Step4_prepared till Step14_prepared: start respective step

SBR 244 Tool_relocate

This subroutine needs data blocks DB TM_ACK (DB9902).

Please add this Data Block out Instructions/Libraries/Special Data Blocks with double click into your project.

SBR Tool_relocate manages the acknowledgement to tool management for load, unload, relocate and position
magazine.
In DB9902 (TM_ACK) is as second acknowledgment step needed:
Transfer step number of the new tool = 0
Transfer step number of the old tool = 0
Status at NCK = 3
Please see second transfer step in this example.

Signals:
Input Job: job on interface from first loading point

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Input Job_done: user program send to SBR job is done

Input Job_cancel: PLC-Input to cancel the job
Output Ack_ok: Signal from TMM to PLC acknowledgment ok
Output Ack_error: Signal from TMM to PLC acknowledgment error
Output Error_status: Feedback from DB4100.DBW104. see commissioning manual chapter 9.2.1

The acknowledgment from tool change is to manage in a separate SBR.

SBR 245 Mag_Dir

This subroutine needs data blocks MAG_DIR (DB9057).

Please copy this data block into your project.

SBR Mag_Dir calculates when a positioning of a new magazin place is required the pre-index
position and the direction for short way for a turret or chain magazin.

Signals:
Input Num_place: number of magazine locations
Input Required_Place: target position in positioning job from TMM, you can use here DB9058.DBW4 from SBR
Turret if this SBR is also used
Input current_Place: here is the actual location number as integer needed.
Input Calc_new: starts a new calculation
Output P_INDXo: location number one place before the target position is reached, can be used to start indexing
process
Output DIR: direction for the short way to target position, = 1: for CW; 0: for CCW
Output Calc_is_done: signal to start magazine movement, if SBR Turret is used: connect to Rev_can_Start Input

SBR 246 Turret

This subroutine needs data blocks DB_Turret (DB9058).

Please copy this data block into your project. In DB9058.DBW0 have you set the number of magazine locations (is
not provided in SBR).
DB9058:DBW2 must be provided with the actual location number from the magazine. DB9058.DBW4 is set in this
SBR with the target position out of the TMM job.

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SBR Turret controls by plc output controlled turret drive. In case the turret gets a request to turn from a tool
management job and the enabling signal to start movement (Rev_can_Start) is true the output signal Turn_cw or
Turn_ccw is true till target position is reached. The output signal In_Pos can be used to set the acknowledgement to
tool management. With input Dir_short_way may be the direction get selected. Dir_short_way = 1 turns CW,
Dir_short_way = 0 turns CCW. You can use to decide the direction the SBR MAG_DIR. The output DIR can
provide input Dir_short_way from SBR Turret. Output Calc_is_done from MAG_DIR can provide the
Rev_can_Start input from SBR Turret.
Input Jog_Rev_CW or Jog_Rev_CCW start manually revolver movement in case no request from TMM is pending.

Signals:
Input Rev_can_Start: magazine is ready to start positioning, direction was judged
Input Jog_Rev_CW and Jog_Rev_CCW are PLC Inputs for manually movement
Input Dir_short_way: = 1: for CW; = 0: for CCW, can get calculated from SBR MAG_DIR
Input Curr_Place: the SBR needs here the information about the actual location number as integer
Output TMM_new_pos_req: there is an new job from TMM with positioning request, signal to start in SBR
MAG_DIR a new calculation
Output Turn_cw: output to plc, turn magazine clockwise
Ouput Turn_ccw: output to PLC, turn magazine counterclockwise
Output In_Pos: End position out TMM job is reached, with this signal you can set acknowledgement to TMM

SBR 247 Hand-wheel

This example manages the interface between HMI and PLC to activate hand-wheel in WCS (DB3200.DBX100x.x)
or MCS (DB380x.DBB4).
SBR Handweel doesn’t support hand-wheel activation from HHU.

SBR248 Star_Delta
This subroutine needs data block Val_Star_Delta (DB9059).
Please copy this data block into your project.

The building block serves to case shift of the Contactor for Star"Y" - Delta motors and the DDS.

Signals:
Spindel_No: Here will the ax number for the spindle entered.

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Standard for Turning is "3"

Standard for Milling is "4"
TimerVal: Here will the delay time between disconnection "Y" and connection "Delta" in "ms" entered.
Typing "0" are 100ms activates
YDelta: The switchover is done with the signal "YDelta". Standardsignal is "DB390[x].4002.5
speed threshold 2 (p2155.[0-15]) and
hysteresis speed 2 (p2140.[0-15])
No_Param: Here will entered the number of parameter set for DDS (0-4)
"0" is standard ---->DB380[x].4001.3 motor_A
"1" ---->DB380[x].4001.0 para_A "2" ----->DB380[x].4001.1 para_B
"3"----->DB380[x].4001.2 para_C "4"---->DB380[x].4001.4 motor_B
Y: output for contactor of Star
Delta: output for contactor of delta

SBR 249 ASUP

This subroutine needs data block DB_ASUP (DB9060).

Please copy this data block into your project.

This example manages the user interface between NC and PLC for initialization and starting the PLCASUP1_SPF
and PLCASUP2_SPF.
The interface and handshaking requirements are described in:
Function Manual Basic Functions Sinumerik 840Dsl/ 828D , chapter
14.6.2 Program instance services and
14.6.5 Starting ASUBs.

The example call from SBR ASUP occupied Alarm 243 till Alarm 246 (DB1600.DBX30.2 - DB1600.DBX30.5)

program flow:
The SBR ASUP contains for each PLC ASUP two input signals and five output signals.

Signal description for ASUP1 initialization:

ASUP1_initialize: starts the initialization via PI service. In the example call the initialization is started after the
first PLC cycle.

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ASUP1_ini_Error: Error in Job, initialization is failed

ASUP1_ini_Done: Job completed, ASUP1 is initialized

Signal description for ASUP1 start:

ASUP1_Start: starts PLCASUP1_SPF, please note the necessary conditions for start
(see Function Manual chapter 14.6.5), example call encloses no interlock conditions!
ASUP1_Run_out: signal is 1 during PLCASUP1_SPF is running
ASUP1_Error_out: signal is 1 if ASUP cannot be executed or the ASUP is not initialized.
ASUP1_done_out: PLCASUP1 is finished without error, ASUP completed

same signals exist for PLCASUP2

SBR 250 Service_Planner

This subroutine needs data blocks SP_INI(DB9903) and SP_ACT(DB9904).

Please add this Data Blocks out Instructions/Libraries/Special Data Blocks with double click into your project.

This example manages the user interface between HMI and PLC for service planner.
The interface and handshaking requirements are described in:
Commissioning Manual Sinumerik 828D Turning and Milling, chapter 8.1 Service Planner.

SBR Service_Planner occupied Alarm 100 till Alarm 163 (DB1600.DBX12.3 - DB1600.DBX20.2)

SBR 251 Easy_Extend

This subroutine needs data block EE_IFC(DB9905).

Please add this Data Block out Instructions/Libraries/Special Data Blocks with double click into your
project.

Further are user Data Blocks EE_IFC_Passwd_Option_1 and EE_IFC_Passwd_Option_2 necessary.

Please copy this data blocks out this project into your project.

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This example manages the communication between HMI and PLC for easy extend script. The SBR supports the
password tag.
The example matches to easy extend configuration as:

<AGM>
<!-- Option MD -->
<OPTION_MD name = "plc/db9061.dbw0" index="0" />
<OPTION_MD name = "plc/db9061.dbw2" index="1" />
<OPTION_MD name = "plc/db9061.dbw4" index="2" />
<OPTION_MD name = "plc/db9061.dbw6" index="3" />
....
....
<DEVICE>
<list_id>1</list_id>
.....
<!-- Password input required to protect Option -->
<password refvar="plc/db9062.dbd0" />
....
....
<DEVICE>
<list_id>2</list_id>
....
<!-- Password input required to protect Option -->
<password refvar="plc/db9062.dbd8" />
....
....
<SET_INACTIVE>
....
<!-- Delete saved Password -->
<DATA name = "plc/db9061.dbx8.0"> 1 </DATA>
....
....

See also the structure of DB9061 and DB9062.

You find for every device one network.

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If you want to define a numerical password, change in first row the default password 123456.
The network compares on HMI supplied password with the value in first row and set in case of correct input
the option bit in DB9061.
The dialog between HMI and PLC for set active and set inactive is without any condition realised. PLC gives
the data handshaking requirements only back to HMI.
You can add there your own logic if necessary.
With DB9061.DBX8.0 and up you can delete the saved password if you set the associated bits from easy
extend script.

SBR 252 Write_NC_Parameter

This subroutine needs data block NC_Parameter (DB9063).

Please copy this data block into your project.

The PLC user program can read or write a maximum of eight variables from the NCK area
via the PLC/NCK interface "Read/write NC variable".

This example writes one NC-variable (parameter R0=99)

You find a description in: Function Manual Basic Functions / 14.6.1 Read/write NC variables

SBR 253 Read_NC_Parameter

This subroutine needs data block NC_Parameter (DB9063).

Please copy this data block into your project.

The PLC user program can read or write a maximum of eight variables from the NCK area via the PLC/NCK
interface "Read/write NC variable".

This example reads one NC-variable (parameter R0)

You find a description in: Function Manual Basic Functions / 14.6.1 Read/write NC variables

Signals:

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Input Read_word: Reading Data is Word and not REAL

Output Done: Job reading NC Parameter is done without error, reading data are valid, wait with next call from
SBR253 till this signal is true.
Output Error: Error in Job

SBR 254 Pos_PLC_Axis

Description from PLC axis control in: Function Manual Base Functions, chapter 14.6.4 PLC axis control

SBR 255 Turn_PLC_Spindle

Description from PLC axis control in: Function Manual Base Functions, chapter 14.6.4 PLC axis control

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Subroutine Numbers and occupied memory

SBR Nummer Name DB Timer Alarm

255 Turn_PLC_Spindle
254 Pos_PLC_Axis
253 Read_NC_Parameter 9063 248
252 Write_NC_Parameter 9063 247
251 Easy_Extend 9062
9061
9905
250 Service_Planner 9903 100-163
9904
249 ASUP 9060 246-243
248 Star_Delta 9059 127

247 Hand-wheel
246 Turret 9058
245 Mag_Dir 9057
244 Tool_relocate 9902 242
243 TMM_Mill 9056 241
9900
9901
9902
242 Jog_MCP_310_T_b 9053
241 Jog_MCP_310_T_f 9053
240 Jog_MCP_310_M 9053
239 MCP_310 9053
238 Jog_MCP_483_T_b 9053
237 Jog_MCP_483_T_f 9053
236 Jog_MCP_483_M 9053
235 MCP_483 9053
234 Prog_control 9051
233 Axis_Enable 9053 125
9052
232 SR_EMG_STOP 9052 126 239
238
237
231 Emergency_stop 9052 240
239
238
230 TMM_Cancel_Job 9902
229 Hand-wheel_HHU_Mill 9053 124 237
228 SWAP_DW

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