Siemens SINUMERIK 802C Manual Download Page 7

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Table of Contents

vii

SINUMERIK 802C
6FC5 597–3AA20–0BP2 (01.02)

Software Update

5-91

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1

Updating the system software using a PC/PG

5-91

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2

Updating the system software incl. user data without using a PC/PG

5-92

. . . . . . . . . . . . . . . . . .

5.3

Update errors

5-93

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Appendix

6-94

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1

List of machine and setting data

6-94

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.1

Display machine data

6-94

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.2

General machine data

6-96

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.3

Channel-specific machine data

6-96

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.4

Axis-specific machine data

6-97

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.5

Setting data

6-103

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2

PLC user interface signals

6-105

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.1

Address ranges

6-105

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.2

Retentive data area

6-106

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.3

NCK signals

6-107

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.4

Channel signals

6-108

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.5

Axis/spindle signals

6-113

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.6

Signals from/to MMC

6-116

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.7

Machine control panel signals (MCP signals)

6-118

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.8

PLC machine data

6-119

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.9

User alarm

6-120

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

Application note: unipolar spindle control

6-123

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Manual Machine 7-125

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1

Hardware and software requirements for the installation

7-125

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2

Loading the software

7-126

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3

Switching the user interface

7-128

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4

Switching the language

7-128

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5

Additional machine data

7-129

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.6

Input limitations with regard to the user interface

7-129

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.7

Operation without machine control panel (MCP)

7-130

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8

I/O assignment in the standard PLC program

7-130

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8.1

Assignment of the digital inputs:

7-130

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8.2

Assignment of the digital outputs:

7-132

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.9

Default assignment of special data for the “Manual machine”

7-133

. . . . . . . . . . . . . . . . . . . . . . . .

Summary of Contents for SINUMERIK 802C

Page 1: ...Start Up 01 2002 Edition SINUMERIK 802C ...

Page 2: ......

Page 3: ...Software Version SINUMERIK 802C 3 01 2002 Edition SINUMERIK 802C Start Up Numerical Control System 1 Installing the Control System 2 Installing the Drives 3 Start Up 4 Update 5 Technical Appendix 6 Manual Machine 7 Index ...

Page 4: ...f 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 liable for demages All rights including rights created by patent grant or registration of utility model or design are reserved Siemens AG 2002 All rights reserved Other functions not described ...

Page 5: ...n means that an undesirede event or status can occur if the appropriate note is not observed Note is used to draw your special attention to an important information on the product the handling of the product or the corresponding part of the documentation Qualified personnel Start up and operation of a device may only be carried out by qualified personnel Qualified personnel as refer red to in the ...

Page 6: ...NC 2 38 3 Installing the Drives 3 39 4 Start Up 4 41 4 1 General 4 41 4 1 1 Access levels 4 42 4 1 2 Structure of machine data MD and setting data SD 4 43 4 1 3 Handling machine data 4 44 4 1 4 Data saving 4 44 4 2 Turning on and booting the control system 4 46 4 2 1 Boot messages 4 48 4 3 Starting up the PLC 4 49 4 3 1 Commissioning of the PLC 4 49 4 3 2 Start up modes of the PLC 4 51 4 3 3 PLC a...

Page 7: ... Channel signals 6 108 6 2 5 Axis spindle signals 6 113 6 2 6 Signals from to MMC 6 116 6 2 7 Machine control panel signals MCP signals 6 118 6 2 8 PLC machine data 6 119 6 2 9 User alarm 6 120 6 3 Application note unipolar spindle control 6 123 7 Manual Machine 7 125 7 1 Hardware and software requirements for the installation 7 125 7 2 Loading the software 7 126 7 3 Switching the user interface 7...

Page 8: ...Table of Contents viii SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 notice ...

Page 9: ... machine tools with stepper motor drives Hardware components It consists of the following hardware components S ENC Control component for a maximum of 3 analog axes and an analog interface for a main spindle drive ENC Economical Numerical Control S OP020 NC operator panel with graphics display and keyboard S MCP machine control panel S DI O16 16 binary inputs outputs each extendable to max 64 by u...

Page 10: ... configuration Software components The SINUMERIK 802C comprises the following software components which can be ordered S System software on the permanent flash memory of the ENC Boot software loads the remaining system software from the permanent memory into the user me mory DRAM and starts the system MMC software Man Machine Communication implements all operating functions NCK software NC Kernel ...

Page 11: ...es Programming tool S Update diskettes Update program with operator prompting system 802C system software packed for loading and programming the SINUMERIK 802C via an update program User data User data are S Machine data S Setting data S Tool data S R parameters S Zero offsets S Compensation data S Part programs S Standard cycles Data saving Modified user data are saved for at least 50 h after pow...

Page 12: ...issipation of DI O16 15 7 7 W W W Start up current 2 6 A Basic configuration of ENC OP020 MCP and DI O16 all outputs open current consumption for any further DI O16 connected will increase by 0 05 A each at nominal load Weight Table 1 2 Weight Component Weight g ENC component 900 g DI O16 component 350 g OP020 component 1 800 g MCP component 1 200 g Dimensions Table 1 3 Component dimensions Compon...

Page 13: ...g e g cubicle is absolutely necessary for operation Transport and storage conditions Table 1 5 Transport and storage conditions Parameter Temperature range Transport 40 70 C Storage 20 55 C Permissible relative air humidity 5 95 without condensation Air pressure 700 1 060 hPa Transport height 1 000 3 000 m Free fall in transport package v 1 200 mm Protective quality and degree of protection Class ...

Page 14: ...SINUMERIK 802C Control System 1 2 Technical data 1 14 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 ...

Page 15: ...achine control panel can be provided with a spindle override switch and an emergency stop button If these are not required the openings must be covered with the supplied self adhesive covers 1 Mount the spindle override switch 2 Install the operator panel and the machine control panel 3 Connect the panel using ribbon cable 4 Install the DIN rail 5 Connect the ENC and DI O components Note If you wa...

Page 16: ...rol System 2 1 Installing and removing the SINUMERIK 802C 2 16 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 Warning Before removing the control components always first make sure that the system is discon nected from the mains ...

Page 17: ...components F A 482 15 200 80 250 170 8 234 8 154 4 8 Mounting Holes Ñ Ñ Ñ Ñ Ñ Ñ SubD 45 80 120 20 40 40 300 142 142 8 57 2 32 5 125 DC24V X1 ERR DIAG POK L M L M X2003 X2005 X2004 X2006 0 1 2 3 4 5 6 7 M L 0 1 2 3 4 5 6 7 M 8 9 10 11 12 13 14 15 M L 8 9 10 11 12 13 14 15 M IN OUT RS232 X2 SPINDLE X5 ENCODER3 X6 OPI X8 AXIS X7 X10 MPG DI X20 ENCODER2 X4 ENCODER1 X3 Fig 2 1 Mounting dimensions for S...

Page 18: ...04 X2006 0 1 2 3 4 5 6 7 M L 0 1 2 3 4 5 6 7 M 8 9 10 11 12 13 14 15 M L 8 9 10 11 12 13 14 15 M IN OUT ECU DI O16 DC24V X1 RS232 X2 SPINDLE X5 ENCODER3 X6 OPI X8 AXIS X7 X10 MPG DI X20 ERR DIAG POK PE L M M ENCODER2 X4 ENCODER1 X3 S2 S3 D15 Fig 2 2 User interfaces OP020 MCP LCD signal connector Rear Rear X1001 X1002 X1009 X1202 X1201 CFL Fig 2 3 Rear of machine control panel and operator panel ...

Page 19: ...a spindle drive with analog interface S X7 drive interface AXIS 50 pin sub D socket connector for connecting the power sections for a maximum of four analog drives including spindle S X8 operator terminal interface OPI 25 pin D Sub female connector for connecting the operator terminal S X10 handwheel interface MPG 10 pin front connector for connecting the handwheels S X20 digital inputs DI 10 pin ...

Page 20: ...E ANALOG MOTOR SPINDLE DRIVE SPINDLE MOTOR ENCODER Hand Wheels Sensor Actor Power Supply P24 M 1 16 1 16 RS232 Machine Control Panel Wire 1 0 2 5 Wire 0 14 1 5 Wire 0 14 1 5 flat or round cable P24 M DC24V RS232 OPI AXIS SPINDLE ENCODER ENCODER MPG DI IN 0 7 IN 8 15 OUT0 7 OUT8 15 IN M L OUT M L M X1 X2 X8 X7 X6 X10 X20 X2003 X2004 X2005 X2006 X1009 X1001 X1002 X1201 X1202 1 1 NC READY X3 X5 Fig 2...

Page 21: ...tpoint si gnal from low frequency interference we recommend not to ground the shield on the drive side The preassembled cable offered as accessories provides optimum protection against interfe rence General procedure Proceed as follows to connect the individual components 1 Connect the cables to the components as shown in Fig 2 4 2 Fix the sub D connector in place using the knurled screws 2 3 1 Co...

Page 22: ...I 1 14 10 ENRXD I 23 ENTXD_N O 11 ENTXD O 24 ENRTS_N O 12 ENRTS O 25 P24_OP VO 13 M_OP VO Connector pin assignment on the OP side Operator panel interface Connector designation X1009 OP020 Connector type 25 pin sub D plug connector Table 2 2 Pin assignment of connector X1009 X1009 Pin Signal Type Pin Signal Type 1 14 P24_OP VI 2 M_OP VI 15 OPD0_N I 3 OPD0 I 16 OPD1_N I 4 OPD1 I 17 OPD2_N I 5 OPD2 ...

Page 23: ...end P24_OP DC24V M_OP Ground Signal level RS422 LVDS Signal type VO Voltage output VI Voltage input O Output I Input 2 3 2 Connecting the feed drives and the spindle X7 Connector pin assignment on the ENC side Feed drive interface Connector designation X7 AXIS 1 4 Connector type 50 pin sub D plug connector Table 2 3 Pin assignment of connector X7 X7 Pin Signal Type Pin Signal Type Pin Signal Type ...

Page 24: ...11 28 44 12 29 45 13 30 46 14 RF1 1 K 31 47 RF1 2 K 15 RF2 1 K 32 48 RF2 2 K 16 RF3 1 K 33 49 RF3 2 K 17 RF4 1 K 50 RF4 2 K Signal names SWn Setpoint BSn Reference potential for setpoint RFn 1 RFn 2 Servo enable contact Signal level RS422 Signal type O Signal output Axis assignment 1 X axis 2 Y axis 3 Z axis 4 Spindle ...

Page 25: ...white yellow 4 14 37 white green 4 56 Drives with analog interface Signals One voltage and one enable signal each is output S SWn SETPOINT Analog voltage signal in the range 10 V to output a speed setpoint S Sn REFERENCE SIGNAL Reference potential analog ground for the setpoint signal internally connected to logic ground S RFn SERVO ENABLE Relay contact pair controlling the enable of the power sec...

Page 26: ...the connector on the ENC side Measuring system interface incremental encoder Connector designation X3 X6 ENCODER Connector type 15 pin sub D plug connector Table 2 7 Pin assignment of the female connector X3 X6 X3 X6 Pin Signal Type Pin Signal Type 1 9 M VO 2 10 N I 3 11 N_N I 8 4 P5_MS VO 12 B_N I 15 5 VO 13 B I 1 9 6 P5_MS VO 14 A_N I 7 M VO 15 A I 8 Signal names A A_N Track A true and negated B...

Page 27: ...The maximum cable length depends on the specifications of the encoder power supply and on the transmission frequency To provide fault free operation make sure that the following values are not exceeded when using preassembled interconnecting cables from SIEMENS Table 2 8 Maximum cable lengths depending on the encoder power supply Supply Voltage Tolerance Current Consumption Max Cable Length 5 V DC...

Page 28: ...O 1 6 3 TxD O 8 CTS I 5 9 4 DTR O 9 5 M VO Signal description RxD Receive data TxD Send data RTS Request to send CTS Send enable DTR Standby output DSR Standby input M Ground Signal level RS232 12 V Signal type I Input O Output VO Voltage output Cable for WinPCIN Table 2 11 Cable for WinPCIN Pin assignment of the Sub D connector 9 Pin Name 25 Pin 1 Shield 1 2 RxD 2 3 TxD 3 4 DTR 6 5 M 7 6 DSR 20 7...

Page 29: ...5_MS VO 7 A2 I 8 A2_N I 10 9 B2 I 10 B2_N I Signal names A1 A1_N Track A true and negated handwheel 1 B1 B1_N Track B true and negated handwheel 1 A2 A2_N Track A true and negated handwheel 2 B2 B2_N Track B true and negated handwheel 2 P5_MS 5 2 V supply voltage for handwheels M Supply ground Signal level RS422 Signal type VO Voltage output I Input 5 V signal Handwheels Two electronic handwheels ...

Page 30: ... input interface Connector designation X20 DI Connector type 10 pin plug connector Table 2 13Pin assignment of connector X20 X20 Pin Name Type 11 NCRDY_1 K 12 NCRDY_2 K 11 13 reserved DI 14 reserved DI 15 reserved DI 16 reserved DI 17 reserved DI 18 reserved DI 20 19 reserved VI 20 20 reserved VI Signal names NCRDY_1 2 NC Ready NCREADY contacts 1 2 Signal type K Switching contact NC READY output R...

Page 31: ...switching voltage 50 V Switching current 1 A Switching power 30 VA X20 11 X20 12 NCREADY L EMERGENCY STOP Machine control voltage Fig 2 5 The NCREADY contact will switch off the control voltage in case of danger 2 3 7 Connecting the digital inputs and outputs X2003 X2006 Connector pin assignment Interface for the digital inputs Connector designation X2003 X2004 IN Connector type 10 pin plug connec...

Page 32: ...Table 2 15 Connector pin assignment X2003 Pin Name Type 1 2 DI0 I 3 DI1 I 4 DI2 I 5 DI3 I 6 DI4 I 7 DI5 I 8 DI6 I 9 DI7 I 10 M24 V X2004 Pin Name Type 1 2 DI8 I 3 DI9 I 4 DI10 I 5 DI11 I 6 DI12 I 7 DI13 I 8 DI14 I 9 DI15 I 10 M24 V Signal names DI0 15 24 V digital inputs Signal type V Voltage input I Input 24 V signal ...

Page 33: ...signal voltage range 3 5 V or input open Signal delay 0 1 0 5 3 ms Signal delay 1 0 0 5 3 ms Connector pin assignment Interface for digital outputs Connector designation X2005 X2006 OUT Connector type 10 pin plug connector Table 2 17 Connector pin assignment X2005 Pin Name Type 1 1P24 V 2 DO0 O 3 DO1 O 4 DO2 O 5 DO3 O 6 DO4 O 7 DO5 O 8 DO6 O 9 DO7 O 10 1M24 V X2006 Pin Name Type 1 2P24 V 2 DO8 O 3...

Page 34: ...lectrical parameters of the digital outputs Parameter Value Unit Note 1 signal nominal voltage Voltage drop 24 max 3 V V 1 signal output current 0 5 A Simultaneity factor 0 5 per 16 outputs 0 signal leakage current max 2 mA Connecting sensors and actuators X2003 X2005 X2004 X2006 0 1 2 3 4 5 6 7 M L 0 1 2 3 4 5 6 7 M 8 9 10 11 12 13 14 15 M L 8 9 10 11 12 13 14 15 M IN OUT Fig 2 6 Connecting the d...

Page 35: ...cal isolation to IEC 204 1 Section 6 4 PELV Table 2 19 Electrical parameters of the load power supply Parameter Min Max Units Conditions Voltage range mean value 20 4 28 8 V Ripple 3 6 Vss Non periodic overvoltage 35 V 500 ms cont 50 s recovery Rated current consumption 1 A Starting current 2 6 A Pin connector assignment on the ENC side Table 2 20 Pin connector assignment of screw type ter minal b...

Page 36: ...l In the case of cubicle installation the grounding points must be connected to the grounding bar see Fig 2 7 DC24V X1 ERR DIAG POK L M L M X2003 X2005 X2004 X2006 0 1 2 3 4 5 6 7 M L 0 1 2 3 4 5 6 7 M 8 9 10 11 12 13 14 15 M L 8 9 10 11 12 13 14 15 M IN OUT RS232 X2 SPINDLE X5 ENCODER3 X6 OPI X8 AXIS X7 X10 MPG DI X20 ENCODER2 X4 ENCODER1 X3 ENC DI O16 Grounding bar to chassis Installation in a c...

Page 37: ...entrally see Fig 2 8 DC24V X1 ERR DIAG POK L M L M X2003 X2005 X2004 X2006 0 1 2 3 4 5 6 7 M L 0 1 2 3 4 5 6 7 M 8 9 10 11 12 13 14 15 M L 8 9 10 11 12 13 14 15 M IN OUT RS232 X2 SPINDLE X5 ENCODER3 X6 OPI X8 AXIS X7 X10 MPG DI X20 ENCODER2 X4 ENCODER1 X3 ECU DI O16 Grounding bar to chassis Installation in a separate unit Shielded signal cable OP020 MCP LCD signal connector CFL Fig 2 8 Grounding d...

Page 38: ...OUT ENC DI O16 DC24V X1 RS232 X2 SPINDLE X5 ENCODER3 X6 OPI X8 AXIS X7 X10 MPG DI X20 ERR DIAG POK PE L M M ENCODER2 X4 ENCODER1 X3 S2 S3 D15 Fig 2 9 User interfaces ERR red Group error This LED indicates an error condition of the ENC POK green Power OK The power supply is ready DIAG yellow Diagnostics This LED indicates various diagnosis states Under normal operating conditions this LED flashes 1...

Page 39: ...3 39 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 Installing the Drives Lesehinweis Manufacturer documentation of the drives 3 ...

Page 40: ...Installing the Drives 3 40 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 ...

Page 41: ... mechanical and electrical installation of the equipment must be completed Note Installationnotes are to be found in Chapter LEERER MERKER S The control system with its components has powered up without errors Start up sequence The SINUMERIK 802C can be strated up as follows 1 Check whether the ENC has powered up 2 PLC start up 3 Technology setting 4 Set general machine data 5 Set axis machine spe...

Page 42: ...perator setter 5 User IS from PLC NCK 6 User IS from PLC NCK 7 User IS from PLC NCK Protection levels 2 3 The protection levels 2 and 3 require a password The passwords can be changed after acti vation For example if the passwords are no longer known the control system must be reini tialized booting in Start Up Switch position 1 This will reset all passwords to the default set tings for this softw...

Page 43: ...EW_CONF cf Activate MD softkey on the operator panel RESET key on machine control panel MCP Modifications at the block limits are possible while the program is running S RESET re RESET key on the machine control panel MCP or M2 m30 at the end of the program S IMMEDIATELY im after entering a value Protection level To display machine data protection level 4 or higher must be activated Start up or ma...

Page 44: ...V24 interface S Making backup copies and reading in reading out data via the V24 interface These back up copies contain machine data line check sums and machine data numbers Aborting when loading MD If incorrect machine data files are read into the control system an alarm is output At the end of reading an alarm with the number of errors is displayed 4 1 4 Data saving Saving data internally The da...

Page 45: ...a backup copy has been loaded appears Saving data externally In addition to the internal data backup the user data of the control system can and must also be saved internally External data saving requires a PC PG programming device with V24 interface and the WinPCIN tool included in the tool box External data saving should be performed whenever substantial changes in the data have been made as wel...

Page 46: ...ctions supply voltages connections for shielding and grounding S Turn on the control system Note Providing memory and start up switch S1 are set correctly see Fig 2 9 the control system boots Start up switch S1 hardware The ENC is provided with a start up switch to assist start up of the control system This switch can be actuated using a screw driver Table 4 2 Start up switch settings Position Mea...

Page 47: ... see Fig 2 9 This initial state is the precondition for error free start up of the control system When the control system is already turned on start up is also possible in the Diagnosis menu see User Manual Normal booting Start up switch position 0 Result User data exist no boot error Control system changes to JOG Ref point approach mode yellow LED DIAG see Fig 4 1 flashes Data in user memory faul...

Page 48: ... are displayed either on the screen or via the LED see Fig 4 1 in the following The ERR flashes and the DIAG LED does not flash ERR DIAG POK Fig 4 1 LED Table 4 3 Boot errors Error Message Remedial Action ERROR EXCEPTION 1 Check the connections of the plugged or connected modules PLC D IO modules ERROR DRAM 2 Switch off the control system and back on again POWER ON 3 Carry out a software update ER...

Page 49: ...ol using the pro gramming language S7 200 in conjunction with ladder diagrams LAD A ladder diagram is a graphical programming language to represent electrical circuit diagrams This Documentation describes the program structure and the instruction set of the PLC in de tail 4 3 1 Commissioning of the PLC The SINUMERIK 802C comes to the user with a simulation program included The SAMPLE user program ...

Page 50: ...desired key and check your setting by pressing the key Supported keys S Mode selection S Axis keys S NC keys Note S The Increment key is only active in the JOG mode The toggle function can be used to set in crements in the range between 1 and 1 000 Check the response by pressing the axis direction keys S Reference Point is not supported Standard user program The control system comes with the SAMPL...

Page 51: ...pt active PLC MD Restart and debug mode User program Stop Unchanged Accept active PLC MD Restart with simulation Simulation pro gram Run Unchanged Accept active PLC MD Overall reset User program Run Deleted Accept active PLC MD Overall reset and de bug mode User program Stop Deleted Accept active PLC MD Diagnosis Start up Start up switch NCK softkey Diagnosis Start up Start up switch PLC softkey T...

Page 52: ...le It stores or deletes the alarms in the alarm list according to their occurrence The first alarm in the list is generally the alarm last occurred If more than 8 alarms occur the first seven alarms occured are displayed and the last one with the highest cancel priority is displayed Alarm response and cancel criterion Furthermore the PLC manages the alarm responses The alarm responses are always a...

Page 53: ...ing priority S POWER ON CLEAR system alarms highest priority S CANCEL CLEAR system alarms S SELF CLEARING system alarms S POWER ON CLEAR user alarms S CANCEL CLEAR user alarms S SELF CLEARING user alarm lowest priority System alarms see Diagnostics Guide User alarms The user interface 1600xxxx provides the user with two sub ranges for setting a user alarm S Sub range 0 4 x 8 bits to set user alarm...

Page 54: ...arm response Configuring user alarms Each alarm is assigned a configuration byte The user alarms can be configured by the user in machine data 14516_MN_USER_DATA_PLC_ALARM Default setting MD 14516 0 SHOW ALARM SELF CLEARING user alarm Configuration byte structure S Bit0 bit5 Alarm responses S Bit6 bit7 Cancel criterion Alarm responses Bit0 bit 5 0 Showalarm default Bit0 1 NC Start inhibited Bit1 1...

Page 55: ...1 700000 0 0 1st user alarm text is assigned by the user 700001 0 0 2nd user alarm text is assigned by the user 700002 0 0 3rd user alarm text is assigned by the user 700003 0 0 4th user alarm text is assigned by the user 700004 0 0 5th user alarm text is assigned by the user 700005 0 0 6th user alarm text is assigned by the user If no user alarm text is assigned by the user the operator panel wil...

Page 56: ...0003 Alarm number with fixed alarm text and variable X S 700004 U Alarm number with variable and fixed alarm text S 700005 Rotation monitoring of axis active U Operator panel display 700005 Rotation monitoring of axis active 1 or 700005 Rotation monitoring of axis active 3 4 3 4 Machine control panel MCP layout The machine control panel in the standard version has been configured for simple turnin...

Page 57: ...e switch and Emergency Stop button 1 27 keys 1 27 see user interface Fig 4 3 Layout of the machine control panel Y Y horizonal turning machine vertical milling machine Fig 4 4 Examples for the assignment of the axis keyboard 4 3 5 PLC programming The PLC user program is created using the PLC 802 Programming Tool The Documentation S7 200 Automation System System Manual describes how this tool is op...

Page 58: ...Word memory size 32 bit Information 2 Override Byte memory size 8 bit User data Byte 0 DWord Information 1 Byte 4 Byte Information 2 The user is not allowed to access both of these data at the same time otherwise the rele vant data access rules must be observed S Furthermore the data direction in the memory model alignment and the data type must be observed for all data Example Flag bit MB0 1 MB3 ...

Page 59: ...act or a negated contact NOT if the contact is open logical value 0 S Coils constitute a relay or an output which is updated by the signal flow S Boxes constitute a function e g a timer counter or arithmetic operation which is carried out at the moment when the signal flow reaches the box A network consists of the elements mentioned above forming a closed circuit The current flows from the left co...

Page 60: ...e VB 14000000 79999999 IB 0 7 QB 0 7 MB 0 127 SMB 0 LB 0 59 AC 0 3 Word VW 14000000 79999998 IW 0 6 QW 0 6 MW 0 126 T 0 15 C 0 31 LW 0 58 AC 0 3 Double Word VD 14000000 79999994 ID 0 4 QD 0 4 MD 0 124 LD 0 56 AC 0 3 Table 4 10 Special Flag SM Bit Definition SM Bits Description SM 0 0 Flags with defined ONE signal SM 0 1 Initial position first PLC cycle 1 following cycles 0 SM 0 2 Buffered data los...

Page 61: ... s cycle alternating 0 for 30 s then 1 for 30 s SM 0 5 1 s cycle alternating 0 for 0 5 s then 1 for 0 5 s SM 0 6 PLC cycle alternating one 0 cycle then one 1 cycle 4 3 6 Instruction set A detailed description of the instructions is to be found in the help system of the PLC 802 Pro gramming Tool Help Contents and Index SIMATIC LAD Instructions and in the Docu mentation S7 200 Automation System CPU2...

Page 62: ...S S_Bit V I Q M T C L n 1 Reset 1 Bit prior 0 no reset prior 1 or Bit R S_Bit V I Q M T C L n 1 OTHER BOOLEAN INSTRUCTIONS Instruction Ladder Symbol Valid Operands Edge Up prior close 1 PLC cycle P Edge Down prior close 1 PLC cycle N Logical Not prior 0 later 1 prior 1 later 0 NOT No operation NOP n n 0 255 BYTE COMPARES Unsigned Instruction Ladder Symbol Valid Operands Load Byte And Byte Or Byte ...

Page 63: ...COMPARES Signed Instruction Ladder Symbol Valid Operands Load DWord And DWord Or DWord a b close a b open a b D a VD ID QD MD AC Constant LD b VD ID QD MD AC Constant LD Load DWord And DWord Or DWord a b close a t b open a b D Load DWord 3 And DWord 3 Or DWord 3 a b close a u b open a b D REAL WORD COMPARES Signed Instruction Ladder Symbol Valid Operands Load RWord And RWord Or RWord a b close a b...

Page 64: ...T0 T15 Timer Of Delay If TValue PT Tbit 1 TOF Txxx PT IN Enable IN S0 Txxx T0 T15 Preset PT VW T C IW QW MW AC Constant 100 ms T0 T15 COUNTER Instruction Ladder Symbol Valid Operands Count Up CU Value 1 R 1 Reset If CValue PV Cbit 1 CTU Cxxx CU R PV Cnt Up CU S1 Reset R S0 Cxxx C0 31 Preset PV VW T C IW QW MW AC Constant LW Count Up Down CU Value 1 CD Value 1 R 1 Reset If CValue PV Cbit 1 CTUD CD ...

Page 65: ...AC Constant LD Out VD ID QD MD AC LD Multiply If EN 1 b a x b MUL IN1 IN2 OUT EN ENO Enable EN In VW T C IW QW MW AC Constant LW Out VD ID QD MD AC LD Divide If EN 1 b b a Out 16 bit remainder Out 2 16 bit quotient DIV IN1 IN2 OUT EN ENO Enable EN In VW T C IW QW MW AC Constant LW Out VD ID QD MD LD Add Subtract Real Numbers If EN 1 b a b b b a ADD_R IN1 IN2 OUT EN ENO Enable EN In VD ID QD MD AC ...

Page 66: ...te AND Byte OR Byte XOR If EN 1 b a AND b b a OR b b a XOR b WAND_B IN1 IN2 OUT EN ENO Enable EN In VB IB QB MB AC Constant LB Out VB IB QB MB AC LB Word AND Word OR Word XOR If EN 1 b a AND b b a OR b b a XOR b WAND_W IN1 IN2 OUT EN ENO Enable EN In VW T C IW QW MW AC Constant LW Out VW T C IW QW MW AC LW DWord AND DWord OR DWord XOR If EN 1 b a AND b b a OR b b a XOR b WXOR_DW IN1 IN2 OUT EN ENO...

Page 67: ...t LD Out VD ID QD MD AC LD Count VB IB QB MB AC Constant LB CONVERSION OPERATIONS Instruction Ladder Symbol Valid Operands Convert Double Word Integer to a Real If EN 1 convert the double word in teger i to a real number o DI_REAL IN OUT EN ENO Enable EN In VD ID QD MD AC Constant LD Out VD ID QD MD AC LD Convert a Real to a Double Word In teger If EN 1 convert the real number i to a double word i...

Page 68: ...D AC Constant LD Out VD ID QD MD AC LD Move Real If EN 1 copy i to o MOV_R IN OUT EN ENO Enable EN In VD ID QD MD AC Constant LD Out VD ID QD MD AC LD Swap Bytes If EN 1 exchange MSB and LSB of w SWAP IN EN ENO Enable EN In VW IW QW MW T C AC LW 4 3 7 Programm organization Each programmer should divide the user program into several closed program sections sub routines The S7 200 programming langua...

Page 69: ...in their validity even after POWER ON can be stored in this area The user can use the PLC MD see user interface to load his program with default data or to parameterize various program sections 4 3 9 Interface to the control system This interface can be selected on the operator panel using the softkeys Diagnosis Start up STEP7 connect The V24 interface remains active even after restart or normal p...

Page 70: ...can save or copy PLC applications in the control system or overwrite them by an other PLC project This is possible using the S Programming Tool 802 S WinPCIN binary file PLC project PLC user texts PLC machine data PT PLC 802 WINPCIN Toolbox PLC application Series start up Download Upload Compare 802D Permanent memory Fig 4 5 PLC applications in the control system ...

Page 71: ...he PLC 802 Programming Tool Step 7 connect on Read out the project from the control system to reconstruct the current project in the PLC 802 Programming Tool S Series start up Start up Data using the tool PCIN PLC MD PLC Project and user alarm texts Data Out S Read out PLC applications using the Tool PCIN PLC Project information and user alarm texts Data Out Compare The project in the PLC 802 Prog...

Page 72: ...stem S Turn on the control system and wait until it has booted without errors S Press the Start data inp softkey in the Services menu use the V24 default interface set tings S Select the technology machine data file techmill ini included in the toolbox required for milling and transfer it to the PG PC using WinPCIN S After the file has been transferred correctly carry out POWER ON S The SINUMERIK ...

Page 73: ...the relevant chapters sections of this manual The machine data and interface signals are described in detail in the descriptions of functions to which reference is made in the relevant lists Note The general machine data are selected such default values that only a few machine data parameters have to be modified Entering the machine data MD Before the machine data can be entered the password for p...

Page 74: ... task factor for main run 2 11100 Number of auxiliary function groups 1 11200 Standard machine data loaded on next Power On OH 11210 MD backup of changed MD only 0FH 11310 Threshold for direction change of handwheel 2 11320 Handwheel pulses per detent position handwheel number 0 1 1 20210 Maximum angle for compensation blocks with TRC 100 20700 NC Start disable without reference point 1 21000 Circ...

Page 75: ...s fed back internally as an actual value No set point output at connector X7 Value 2 The setpoint signals for stepper motor operation are output at connector X7 Real axis traversal is possible using a stepper motor 30240 Value 0 Value 3 Internal pulse feedback from setpoint out put to actual value input ON Machine data for axes and spindle Number Explanation Default Va lue 30130 Output type of set...

Page 76: ...et 0 35100 Maximum spindle speed 10000 35110 Maximum speed for gear change gear stage no 0 5 500 35120 Minimum speed for gear change gear stage no 0 5 50 35130 Maximum speed of gear stage gear stage no 0 5 500 35140 Minimum speed of gearsetp gear stage no 0 5 5 35150 Spindle speed tolerance 0 1 35160 Spindle speed limitation from PLC 1000 35220 Speed for reduced acceleration 1 0 35230 Reduced acce...

Page 77: ...f recognized zero mark errors during monitoring 100 Zero mark monitoring off encoder HW monitoring off 0 36400 Contour Tol 1 36610 Duration of the deceleration ramp for error states 0 05 36620 Cutout delay servo enable 0 1 36700 Automatic drift compensation 0 36710 Drift limit value for automatic drift compensation 1 36720 Drift basic value 0 Matching encoder to axis spindle Machine data for encod...

Page 78: ...ments per de gree MD 310 20 4 360 degrees Inter nal reso lution M D 3 1 0 7 0 MD31080 1 0 0 0 5 0 0 4 1 360 1 1000 Inter nal reso lution 1 8 0 One encoder increment corresponds to 180 internal increments One encoder increment cor responds to 0 18 degrees minimum positioning step Example 2 for encoder matching Spindle with rotary encoder on motor 2 048 pulses internal multiplication 4 2 speed sta g...

Page 79: ...e data list below contains the default machine data with their recommended set tings with the analog motor axes connected After they have been set the axis are ready to be traversed as far as the machine data are concerned and only fine settings have to be done Number Description Default Value Setting or Remark 30130 Output type of setpoint setpoint branch 0 0 1 30240 Type of actual value ac quisi...

Page 80: ...d output voltage 80 The speed defined in MD32260 is reached at the setpoint of 8 V 32260 Rated motor speed set point branch 0 3000 Motor speed 34070 Reference point positio ning velocity 300 Positioning velocity when referencing 34200 Type of position measu ring system 1 Zero pulse on encoder track 1 Zero pulse 36200 Threshold value for veloc ity monitoring control pa rameter set no 0 5 11500 Thre...

Page 81: ... speed characteristic MD32250 MD32260 In addition the continuous characteristic of the speed when passing zero is also imperative Service display of the axis behavior Servo Trace To provide axis service the Servo Trace function is integrated in the Diagnosis menu which can be used for graphical representation of the axis setpoint speed The Trace function is selected in the Diagnosis Service displa...

Page 82: ...ion Default Value 32900 Dynamic response adaptation 0 32910 Time constant of dynamic adaption control parameter set no 0 5 0 0 Determination of value The dynamic value of the spindle is stored for each individual stage in MD 32200 POSCTRL_GAIN n as closed loop gain An adaptation of the axis to these values must be made in MD 32910 DYN_MATCH_TIME n in accordance with the following instruction 1 1 M...

Page 83: ...MATCH_TIME 1 0 0954 s 0 5 2 437 1000 In practice this value can be optimized To this aim the thread is first tested with compensa ting chuck and the calculated values Then the values should be modified sensitively such that the difference path in the compensating chuck approximates to zero Now the POSCTRL_GAIN values displayed on the service display for axis and spindle should be identical Note If...

Page 84: ...if the following requirements are met S The number of compensation intermediate points must be defined They are only active after Power ON MD MM_ENC_MAX_POINTS Caution Changing the MD MM_CEC_MAX_POINTS t or MM_ENC_COMP_MAX_POINTS au tomatically reorganizes the NC user memory when the control system is booting All user data stored in the user memory e g drive and MMC machine data tool offsets part ...

Page 85: ..._COMPLETE_EEC by means of the editor e g in the PCIN OUT pro gram Then re read the edited file into the control system Approach the reference point in the axes and set MD ENC_COMP_ENABLE 0 1 The LEC is thus activated 4 7 3 Starting up the spindle Overview With the SINUMERIK 802C the spindle is a subfunction of the entire axis functionality The machine data of the spindle are therefore to be found ...

Page 86: ...age set of parameters 1 Note The field containing the parameter 0 is not used for the spindle machine data Machine data for setpoint and actual values Setpoints MD 30130 CTRLOUT_TYPE AX4 1 Actual values MD 30200 NUM_ENCS AX4 0 Spindle without encoder MD 30200 NUM_ENCS AX4 1 Spindle with encoder MD 30240 ENC_TYPE AX4 2 Interface signals of the spindle Interface signals Speed change 39032000 Bit 3 A...

Page 87: ...irection 35450 Reciprocation time for M4 direction Interface signals Change gear 39032000 bit 3 Reciprocation speed 38032002 bit 5 Reciprocating by PLC 38032002 bit 4 Set direction of rotation CCW 38032002 bit 7 4 7 4 Completing the Start Up After start up of the control system by the machine manufacturer the following should be ob served prior to delivery to the final customer 1 Change the defaul...

Page 88: ... Carry out internal data saving Press the softkey Save data 4 7 5 Cycle start up Sequence of operations When loading cycles into the control system adhere to the following sequence of operations 1 Save tool offset data and zero offsets either on the FLASH or on the PG programming device These data can be selected in the Services menu by pressing the Data outp data soft key 2 Load all files of the ...

Page 89: ...e SINUMERIK 802S X8 Make the following settings in the WinPCIN tool Binary format Receive data Select the path where you want to save your data Save The PC PG will set itself to Receive and will wait for data from the control system Enter the password for protection level 2 in the control system Call the Services RS232 setting menu Select the Start up data line from the Services menu and press Sta...

Page 90: ...802C 6FC5 597 3AA20 0BP2 01 02 Series machine start up file The series machine start up file contains S machine data S R parameters S display and alarm text files S display machine data S PLC user program S main programs S subroutines S cycles ...

Page 91: ...owing S Update software 2 diskettes S A PG PC with V24 interface COM1 or COM2 and an appropriate cable Update procedure As far as not yet done carry out external data saving before you update your updating system software see Section 4 1 4 Data Saving 1 Turn the hardware start up switch to position 2 software update on permanent memory 2 Start the update file on your PC PG by calling UPD_802 BAT o...

Page 92: ...ta from one control system directly to another control system This can be necessary after updating the system software of a CNC and subsequent reloa ding the recovered user data series start up file into this control system in order to bring furt her control systems to the same condition This reduces the time needed for the transfer Precondition Cable connection from master control system source c...

Page 93: ... software via V24 S Data already in receive buffer send from PC side started too early S Error when erasing the FLASH memory S Error when writing to the FLASH memory S Inconsistent data incomplete or faulty S Repeat update S Check link between control system and PC PG S Check diskette SINUMERIK 802S UPDATE NO DATA Update without programming the code FLASH completed no data received transfer not st...

Page 94: ... to 4294967300 SIGNED DWORD Integer values from 2147483650 to 2147483649 WORD Hex values from 0000 to FFFF DWORD Hex values from 00000000 to FFFFFFFF FLOAT DWORDReal values from 8 43 10 37 to 3 37 1038 6 1 1 Display machine data Number MD Name Representation Name Miscellaneous Activated User Class w r Unit Standard value Minimum value Maximum value Data type 202 MM_FIRST_LANGUAGE Decimal Foregroun...

Page 95: ...s directory Immediately 2 3 0 3 0 7 Byte 277 MM_USER_CLASS_PLC_ACCESS Decimal User class access PLC project Immediately 2 3 0 3 0 7 Byte 278 MM_NCK_SYSTEM_FUNC_MASK Decimal Option data to enable system specific functions POWER ON 2 2 0 0 0 15 Byte 280 MM_V24_PPI_ADDR_PLC Decimal PPI address of the PLC POWER ON 3 3 0 2 0 126 BYTE 281 MM_V24_PPI_ADDR_NCK Decimal PPI address of the NCK POWER ON 3 3 0...

Page 96: ... ON _always 0x0F BYTE 2 7 11210 UPLOAD_MD_CHANGE_ONLY HEX Saving only of modified MD value 0 complete no difference RESTART 0x0F BYTE 2 7 11310 HANDWH_REVERSE Threshold for direction change handwheel POWER ON _always 2 0 0 plus BYTE 2 7 11320 HANDWH_IMP_PER_LATCH Handwheel pulses per detent position handwheel number 0 1 POWER ON _always 1 1 DOUBLE 2 7 14510 USER_DATA_INT n kB User data INT 0 31 PO...

Page 97: ...OL_CHANGE_MODE New tool compensation for M function POWER ON _always 0 0 1 BYTE 2 7 27800 TECHNOLOGY_MODE Technology in the channel value 0 milling value 1 turning NEW CONF 1 0 1 BYTE 2 7 6 1 4 Axis specific machine data Number MD Name Unit Name Miscellaneous Activated HW function Standard value Minimum value Maximum value D type User class 30130 CTRLOUT_TYPE Output type of setpoint setpoint branc...

Page 98: ...DRIVE_AX_RATIO_NUMERA Numerator load gearbox control parameter set no 0 5 POWER ON _always 1 1 1 1 1 1 1 2147000000 DWORD 2 7 31070 DRIVE_ENC_RATIO_DENOM Denominator resolver gearbox encoder no POWER ON _always 1 1 2147000000 DWORD 2 7 31080 DRIVE_ENC_RATIO_NUMERA Numerator resolver gearbox encoder no POWER ON _always 1 1 2147000000 DWORD 2 7 31090 JOG_INCR_WEIGHT mm de grees Evaluation of an incr...

Page 99: ...polatory compensation encoder no 0 1 POWER ON _always 0 BOOLEAN 2 7 32900 DYN_MATCH_ENABLE Dynamic response adaptation NEW_CONF 0 0 1 BYTE 2 7 32910 DYN_MATCH_TIME Time constant of dynamic adaption control parameter set no 0 5 NEW_CONF 0 0 0 plus DOUBLE 2 7 32920 AC_FILTER_TIME s Smoothing factor time constant for adaptive control POWER ON _always 0 0 0 0 plus DOUBLE 2 7 33050 LUBRICATION_DIST mm ...

Page 100: ...et of incremental measuring systems with equidistant zero marks RESET _always 0 0 0 0 plus DOUBLE 2 7 34100 REFP_SET_POS mm deg Reference point value irrelevant for distance coded system 0 3 RESET _always 0 0 0 0 DOUBLE 2 7 34110 REFP_CYCLE_NR Sequence of axes in channel specific referencing 1 No obligatory reference point for NC Start 0 No channel specific reference point approach 1 15 Sequence i...

Page 101: ...W CONF _always 30 30 25 20 15 10 2 DOUBLE 2 7 35210 GEAR_STEP_POSCTRL_ACCEL rev s 2 Acceleration in position control mode gear stage no 1 5 NEW CONF _always 30 30 25 20 15 10 2 DOUBLE 2 7 35220 ACCEL_REDUCTION_SPEED_POINT Factor Speed for reduced acceleration RESET _always 1 0 0 0 1 0 DOUBLE 2 7 35230 ACCEL_REDUCTION_FACTOR Factor Reduced acceleration RESET _always 0 0 0 0 0 95 DOUBLE 2 7 35240 AC...

Page 102: ... deg Zero speed tolerance NEW CONF _always 0 2 0 0 plus DOUBLE 2 7 36040 STANDSTILL_DELAY_TIME s Delay zero speed monitoring NEW CONF _always 0 4 0 0 plus DOUBLE 2 7 36050 CLAMP_POS_TOL mm deg Clamping tolerance NEW CONF _always 0 5 0 0 plus DOUBLE 2 7 36060 STANDSTILL_VELO_TOL mm min rev min Maximum velocity speed axis spindle stopped NEW CONF _always 5 0 014 0 0 plus DOUBLE 2 7 36100 POS_LIMIT_M...

Page 103: ...ays 0 1 0 0 plus DOUBLE 2 7 36610 AX_EMERGENCY_STOP_TIME s Duration of the deceleration ramp for error states NEW CONF _always 0 05 0 0 plus DOUBLE 2 7 36620 SERVO_DISABLE_DELAY_TIME s Cutout delay servo enable NEW CONF _always 0 1 0 0 plus DOUBLE 2 7 36700 DRIFT_ENABLE Automatic drift compensation NEW CONF _always 0 BOOLEAN 2 7 36710 DRIFT_LIMIT Drift limit value for automatic drift compensation ...

Page 104: ...25 Immediately _always 0 0 0 0 plus DOUBLE 4 4 43220 SPIND_MAX_VELO_G26 rev min Progr spindle speed limitation G26 Immediately _always 1000 0 0 plus DOUBLE 4 4 43230 SPIND_MAX_VELO_LIMS rev min Spindle speed limitation with G96 Immediately _always 100 0 0 plus DOUBLE 4 4 52011 STOP_CUTCOM_STORE Alarm response for TRC and feedforward stop Immediately 1 0 1 BOOLEAN 4 4 ...

Page 105: ...e of digital outputs Q0 0 to Q7 7 M Flags M0 0 to M127 7 SM Special flags SM0 0 to SM 0 6 see below AC ACCU AC0 AC3 Generating the V address range Type Identifier DB No Range No Channel Axis No Subrange Offset Addressing 10 10 79 00 00 99 0 0 9 000 000 999 symbolic 8 digit Definition of special flag bits SM read only SM Bits Description SM 0 0 Flags with a defined ONE signal SM 0 1 Initial positio...

Page 106: ... written nor evaluated by the user All fields with a 0 contain the value logic Variable access rights r is used to mark a read only range r w is used to mark a read write range 6 2 2 Retentive data area 1400 Retentive Data r w Data block Interface NCK PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 User Data 14000000 User Data 14000001 User Data 14000002 User Data 14000062 User Data 14000...

Page 107: ... Protection level 26000000 Acknowl EMER EMER GENCY 4 5 6 7 GENCY STOP STOP Request Request 26000001 distances to go by actual dis tances to the axes go by the axes 26000002 26000003 2700 General signals from NCK r Data block Interface NCK PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 EMER 27000000 GENCY STOP STOP active 27000001 27000002 Drive ready Ambient NCK 27000003 tempera ture ala...

Page 108: ...0 Mode signals from NCK r Data block Interface NCK PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Active mode 31000000 READY JOG MDA AUTOM Active machine function 31000001 REF TEACH IN 6 2 4 Channel signals Control signals to NC channel 3200 Signals to NCK channel r w Data block Interface PLC NCK Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Activate Activate Activate 32000000 dry...

Page 109: ...ay code with 31 MD for weighting 3 Rapid traverse override 31 positions Gray code with 31 MD for weighting 4 Single Block Use the softkey to select Single Block Type Preselection SBL1 SBL2 see User Manual Control signals to axes in the WCS 3200 Signals to NCK Channel r w Data block Interface PLC NCK Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Axis 1 in WCS 32001000 Traversing keys Rapid t...

Page 110: ...om NC channel 3300 Signals from NCK channel r Data block Interface NCK PLC Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 33000000 M0 M1 active Program Block Revolu 33000001 test M2 M30 search tional feed Referenc ing active active active active active 33000002 Channel state Program state 33000003 inter rupted inter rupted Reset active aborted stopped waiting running NCK alarm NCK 33000004 with s...

Page 111: ...eel active plus minus 2 1 Axis 1 in WCS 33001001 Machine function continu ous 1000 INC 100 INC 10 INC 1 INC 33001002 33001003 Axis 2 in WCS 33001004 Traversing command Handwheel active plus minus 2 1 Axis 2 in WCS 33001005 Active machine function continu ous 1000 INC 100 INC 10 INC 1 INC 33001006 33001007 Axis 3 in WCS 33001008 Traversing command Handwheel active plus minus 2 1 Axis 3 in WCS 33001...

Page 112: ... Bit 0 Modify de 25000000 coded M func M func tions 0 99 25000001 Modify T funct 1 25000002 25000003 Decoded M signals M0 M99 2500 M functions from NCK channel r Data block Interface NCK Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Dynamic M functions 25001000 M7 M6 M5 M4 M3 M2 M1 M0 Dynamic M functions 25001001 M15 M14 M13 M12 M11 M10 M9 M8 Dynamic M functions 25001002 M23 M22 M21 M20 M19...

Page 113: ...ns 2500 T functions from NCK channel r Data block Interface PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 25002000 T function 1 DINT 25002004 25002008 25002012 6 2 5 Axis spindle signals Signals to axis spindle Common signals to axis spindle 3800 3803 Signals to axis spindle r w Data block Interface PLC NCK Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Feed override 380x0000 H G ...

Page 114: ...achine function 380x0005 continu 1000 100 10 1 ous INC INC INC INC 380x0006 380x0007 Signals to axis 3800 3802 Signals to axis r w Data block Interface PLC NCK Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Delay Ref point 2nd software limit switch Hardware limit switch 380x1000 approach axis plus minus plus minus 380x1001 axis 380x1002 axis 380x1003 axis Signals to spindle 3803 Signals to s...

Page 115: ...4 Bit 3 Bit 2 Bit 1 Bit 0 Position reached Refer Encoder Spindle 390x0000 with exact with exact enced synchro limit fre quency no axis pos fine pos coarse nized 1 exceeded 1 Speed Axis spindle Follow up active 390x0001 Current controller controller Position controller stopped active active active n nmin 390x0002 390x0003 Motion command Handwheel active 390x0004 plus minus 2 1 Active machine functi...

Page 116: ...f rotation within set speed speed limit spindle CW range increased limited exceeded Active spindle mode Tapping 39032002 Control Recipro cating Position ing without compen sating spindle mode mode mode chuck 39032003 spindle 6 2 6 Signals from to MMC Program control signals from MMC retentive area see also signals to channel V32000000 1700 MMC signals r Data block Interface MMC PLC DBB Bit 7 Bit 6...

Page 117: ... Bit 2 Bit 1 Bit 0 18000000 Machine function 18000001 TEACH IN 18000002 18000003 General selection status signals from MMC retentive area 1900 MMC Signals r Data block Interface MMC PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 19001000 MMC PLC 19001001 MMC PLC 19001002 MMC PLC 19001003 Axis number for handwheel 1 MMC PLC Machine axis B A 19001004 Axis number for handwheel 2 MMC PLC Mac...

Page 118: ...om MCP r Interface MCP PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 8 7 6 5 4 3 2 1 10000000 JOG INC free free free free free free 16 15 14 13 12 11 10 9 10000001 Axis key Spindle Spindle Spindle MDA SBL AUTO REF start stop start 24 23 22 21 20 19 18 17 10000002 Axis key Axis key Axis key Axis key Axis key Axis key Axis key Axis key 27 26 25 10000003 0 0 0 0 0 NC NC STOP NC RE START SE...

Page 119: ...K PLC Byte 45000000 Int value WORD 2 bytes 45000002 Int value WORD 2 bytes 45000004 Int value WORD 2 bytes 45000006 Int value WORD 2 bytes 45000060 Int value WORD 2 bytes 45000062 Int value WORD 2 bytes HEX values MD 14512 USER_DATA_HEX 4500 Signals from NCK r Data block Interface NCK PLC Byte 45001000 Hex value BYTE 45001001 Hex value BYTE 45001002 Hex value BYTE 45001003 Hex value BYTE 45001030 ...

Page 120: ...ytes 45002028 Float value REAL 4 bytes HEX BYTE values MD 14516 USER_DATA__PLC_ALARM 4500 Signals from NCK r Data block Interface NCK PLC Byte 45003000 Alarm reaction clear criterion of alarm 700000 45003001 Alarm reaction clear criterion of alarm 700001 45003002 Alarm reaction clear criterion of alarm 700002 45003031 Alarm reaction clear criterion of alarm 700031 6 2 9 User alarm Alarm activation...

Page 121: ...ariable for alarm 1600 Variable for alarm r w Data block Interface PLC MMC Byte 16001000 Variable for alarm 700000 16001004 Variable for alarm 700001 16001008 Variable for alarm 700002 16001116 Variable for alarm 700029 16001120 Variable for alarm 700030 16001124 Variable for alarm 700031 Active alarm response 1600 Active alarm response r Data block Interface PLC MMC Byte Bit 7 Bit 6 Bit 5 Bit 4 B...

Page 122: ...UMERIK 802C 6FC5 597 3AA20 0BP2 01 02 Axis actual value and distances to go 5700 5704 Signals from axis spindle r Data block Interface PLC MMC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 570x0000 Axis actual value REAL 570x0004 Axis distance to go REAL ...

Page 123: ...nt output is provied by the NC but switching of the direc tion signal is provided by the PLC In other words It must be ensured by the user program that the new direction signal is only provided if the spindle has stopped A new rotation start may only be provided after the direction signal has been output by the PLC Position controlled spindle mode SPOS G331 G332 LCYC84 is not possible with unipo l...

Page 124: ...Technical Appendix 6 3 Application note unipolar spindle control 6 124 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 This sheet has been left empty for your notes ...

Page 125: ...trol panel because of the keys for entering the pass word The following components are required to install the Sinumerik 802S C MM software S PG PC or laptop with CD ROM drive and serial interface V24 S V24 data cable S OP 020 operator panel standard operator panel not always required with subsequent installations provided that the Manufacturer protection level is still enabled in the control S Ju...

Page 126: ... the software To ensure successful installation it is imperative to observe the sequence described below S Start the WinPCIn software on your PG PC or laptop S Use an appropriate interface cable to connect the X2 interface of the Sinumerik V24 inter face to COM 1 on the PG PC or laptop S Turn on the control system S Use the key to switch to the Data area S Press the Diagnosis function key S Press ...

Page 127: ...Power ON The user interface for the manual machine is installed The installation of the Manual Machine user interface is now completed Now however the relevant default data are not yet set for machine data tool data MGUDs and for the PLC program These data default data must be loaded into the control system by transferring an appropria tely adapted initial ini To this end either use the initial in...

Page 128: ...assword input screenform S Enter the password 1111 and press the key to confirm S Press the key once more and then press the OK function key to switch to the stan dard user interface From Siemens standard to Manual Machine To switch back to the Manual Machine screenform proceed as follows S Press the key to switch to the main selection screenform S Press the to extend the function key bar S Press ...

Page 129: ...TA_INT 1 Lubrication time x 100ms MD 14510 2 MN_USER_DATA_INT 2 Lubrication pause x 100ms Spindle shutdown in Chuck key position MD 14510 0 MN_USER_DATA_INT 0 Time monitoring Spindle positioning x 100ms MD 14514 1 MN_USER_DATA_FLOAT 1 Starting speed Spindle positioning MD 14514 2 MN_USER_DATA_FLOAT 2 Tolerance window Spindle positioning MD 35160 4 MA_SPIND_EXTERN_VELO_LIMIT 2 Spindle speed limitat...

Page 130: ...ly modules of the DI O16 type can be used 7 8 1 Assignment of the digital inputs 1st module I 0 0 Reference switch X axis X2003 Pin 2 DI 0 I 0 1 Reference switch Z axis X2003 Pin 3 DI 1 I 0 2 Limit position X axis X2003 Pin 4 DI 2 I 0 3 Limit position Z axis tailstock collision switch X2003 Pin 5 DI 3 I 0 4 X2003 Pin 6 DI 4 I 0 5 Chuck guard closed X2003 Pin 7 DI 5 I 0 6 Lubrication filling level ...

Page 131: ... 7 Handwheel evaluation bit 2 X2004 Pin 9 DI 15 3rd module I 4 0 Spindel override bit 1 X2003 Pin 2 DI 0 I 4 1 Spindel override bit 2 X2003 Pin 3 DI 1 I 4 2 Spindel override bit 3 X2003 Pin 4 DI 2 I 4 3 Spindel override bit 4 X2003 Pin 5 DI 3 I 4 4 Feed override bit 1 X2003 Pin 6 DI 4 I 4 5 Feed override bit 2 X2003 Pin 7 DI 5 I 4 6 Feed override bit 3 X2003 Pin 8 DI 6 I 4 7 Feed override bit 4 X2...

Page 132: ...9 DO 7 O 1 0 Ready X2006 Pin 2 DO 8 O 1 1 X2006 Pin 3 DO 9 O 1 2 X2006 Pin 4 DO 10 O 1 3 Lubrication axes X2006 Pin 5 DO 11 O 1 4 X2006 Pin 6 DO 12 O 1 5 X2006 Pin 7 DO 13 O 1 6 X2006 Pin 8 DO 14 O 1 7 X2006 Pin 9 DO 15 2nd module O 2 0 Spindle contactor control X2005 Pin 2 DO 0 O 2 1 X2005 Pin 3 DO 1 O 2 2 Bypass axis limit switch X2005 Pin 4 DO 2 O 2 3 X2005 Pin 5 DO 3 O 2 4 X2005 Pin 6 DO 4 O 2...

Page 133: ...t of special data for the Manual machine Machine data MD 12010 MN_OVR_FACTOR_AX_SPEED 1 0 1 MD 12010 MN_OVR_FACTOR_AX_SPEED 2 0 2 MD 12010 MN_OVR_FACTOR_AX_SPEED 3 0 3 MD 12010 MN_OVR_FACTOR_AX_SPEED 4 0 4 MD 12010 MN_OVR_FACTOR_AX_SPEED 5 0 5 MD 12010 MN_OVR_FACTOR_AX_SPEED 6 0 6 MD 12010 MN_OVR_FACTOR_AX_SPEED 7 0 7 MD 12010 MN_OVR_FACTOR_AX_SPEED 8 0 8 MD 12010 MN_OVR_FACTOR_AX_SPEED 9 0 9 MD 1...

Page 134: ...MN_OVR_FACTOR_FEEDRATE 15 1 2 MD 12030 MN_OVR_FACTOR_FEEDRATE 16 1 2 MD 12030 MN_OVR_FACTOR_FEEDRATE 17 1 2 MD 12030 MN_OVR_FACTOR_FEEDRATE 18 1 2 MD 12030 MN_OVR_FACTOR_FEEDRATE 19 1 2 MD 12030 MN_OVR_FACTOR_FEEDRATE 20 1 2 MD 12030 MN_OVR_FACTOR_FEEDRATE 21 1 2 MD 12050 MN_OVR_FACTOR_RAPID_TRA 1 0 1 MD 12050 MN_OVR_FACTOR_RAPID_TRA 2 0 2 MD 12050 MN_OVR_FACTOR_RAPID_TRA 3 0 3 MD 12050 MN_OVR_FAC...

Page 135: ...14 MD 18150 MN_MM_GUD_V ALUES_MEM 30 MD 20150 MC_GCODE_RESET_VALUES 7 2 MD 20150 MC_GCODE_RESET_VALUES 14 2 MD 20150 MC_GCODE_RESET_VALUES 27 1 MD 31090 MA_JOG_INCR_WEIGHT AX1 0 0005 MD 32084 MA_HANDWH_STOP_COND AX1 H2ff MD 32084 MA_HANDWH_STOP_COND AX3 H2ff MD 35040 MA_SPIND_ACTIVE_AFTER_RESET AX4 1 MD 35160 MA_SPIND_EXTERN_VELO_LIMIT AX4 18 Setting data MD 41110 SN_JOG_SET_VELO 500 MD 41120 SN_J...

Page 136: ...Manual Machine 7 9 Default assignment of special data for the Manual machine 7 136 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 ...

Page 137: ...g the spindle drive X3 2 26 Connection diagram 2 20 E ENC and operator panel power supply X1 2 35 Encoder matching to spindles 4 77 G Grounding 2 36 Grounding diagram 2 36 I Installing and Dismantling the SINUMERIK 802C 2 15 Interfaces and cables 2 18 L LEDs and operating elements on the ENC unit 2 38 M Machine and Setting Data Unit 4 43 Manual machine 7 125 Default assignment 7 133 I O assignment...

Page 138: ...Index Index 138 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 notice ...

Page 139: ...3AA20 0BP2 Edition 01 02 Should you come across any prin ting errors when reading this publi cation please notify us on this sheet Suggestions for improvement are also welcome SIEMENS AG A D MC BMS Postfach 3180 D 91050 Erlangen Tel 49 180 5050 222 Hotline Fax 49 9131 98 2176 Documentation Mailto motioncontrol docu erlf siemens de Telefax Suggestions and or corrections ...

Page 140: ......

Page 141: ... SINUMERIK 802S SINUMERIK 802C Turning Milling Technical Manual Description of Functions SINUMERIK 802S Truning Milling Technical Appendix Turning SINUMERIK 802S SINUMERIK 802C Turning Milling General Documentation Catalog SINUMERIK 802S SINUMERIK 802C SINUMERIK 802S SINUMERIK 802C SINUMERIK 802S SINUMERIK 802C SINUMERIK 802C Turning Milling Technical Appendix Turning ...

Page 142: ...ithout prior notice Order No 6FC5597 3AA20 0BP2 Printed in the Federal Republic of Germany Siemens AG Automatisierungs und Antriebstechnik Motion Control Systems Postfach 3180 D 91050 Erlangen Bundesrepublik Deutschland www ad siemens de ...

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