Siemens SINUMERIK 802S Start-Up Download

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Table of Contents

vii

SINUMERIK 802S
6FC5 597–2AA00–0BP2 (01.02)

4.7.1

Entering the general machine data

4-82

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

4.7.2

Starting up the axes

4-84

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

4.7.3

Starting up the spindle

4-94

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

4.7.4

Completing the start–up

4-101

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

4.7.5

Starting up the cycles

4-101

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

4.8

Series machine start-up

4-102

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

Software Update

5-105

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

5.1

Updating the system software using a PC/PG

5-105

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

5.2

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

5-107

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

5.3

Update errors

5-108

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

Technical Appendix

6-109

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

6.1

List of machine and setting data

6-109

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

6.1.1

Display machine data

6-109

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

6.1.2

General machine data

6-110

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

6.1.3

Channel-Specific Machine Data

6-111

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

6.1.4

Axis-specific machine data

6-112

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

6.1.5

Setting data

6-119

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

6.2

PLC user interface signals

6-120

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

6.2.1

Address ranges

6-120

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

6.2.2

Retentive data area

6-121

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

6.2.3

NCK signals

6-122

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

6.2.4

Channel signals

6-124

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

6.2.5

Axis/spindle signals

6-131

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

6.2.6

Signals from/to MMC

6-135

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

6.2.7

Machine control panel signals (MCP signals)

6-137

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

6.2.8

PLC machine data

6-138

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

6.2.9

User alarm

6-140

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

6.3

PLC user program for turning (UPGMTURN)

6-142

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

6.3.1

Function

6-142

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

6.3.2

PLC machine data

6-143

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

6.3.3

Input/output configuration

6-145

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

6.3.4

Description of the logics

6-149

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

6.3.5

UPGMTURN program structure

6-153

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

6.4

Application note: Unipolar spindle control

6-156

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

Manual Machine

7-157

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

7.1

Hardware and software requirements for the installation

7-157

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

7.2

Loading the software

7-158

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

7.3

Switching the user interface

7-160

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

7.4

Switching the language

7-160

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

7.5

Additional machine data

7-161

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

7.6

Input limitations with regard to the user interface

7-161

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

7.7

Operation without machine control panel (MCP)

7-162

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

7.8

I/O assignment in the standard PLC program

7-162

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

7.8.1

Assignment of the digital inputs:

7-162

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

7.8.2

Assignment of the digital outputs:

7-164

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

7.9

Default assignment of special data for the “Manual machine”

7-165

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

Summary of Contents for SINUMERIK 802S

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

Page 2: ......

Page 3: ...ware Version SINUMERIK 802S as from 3 01 2002 Edition SINUMERIK 802S Start Up Numerical Control System 1 Installing the Control System2 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 2001 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: ...perating elements on the ENC unit 2 40 3 Installing the STEPDRIVE C Drives 3 41 3 1 Installing and removing the STEPDRIVE C drive modules 3 41 3 2 Cabling 3 43 3 3 Starting up the drive modules 3 45 3 4 Error messages and error elimination 3 46 4 Start Up 4 47 4 1 General 4 47 4 1 1 Access levels 4 48 4 1 2 Structure of machine data MD and setting data SD 4 49 4 1 3 Handling machine data 4 51 4 1 ...

Page 7: ... 6 2 4 Channel signals 6 124 6 2 5 Axis spindle signals 6 131 6 2 6 Signals from to MMC 6 135 6 2 7 Machine control panel signals MCP signals 6 137 6 2 8 PLC machine data 6 138 6 2 9 User alarm 6 140 6 3 PLC user program for turning UPGMTURN 6 142 6 3 1 Function 6 142 6 3 2 PLC machine data 6 143 6 3 3 Input output configuration 6 145 6 3 4 Description of the logics 6 149 6 3 5 UPGMTURN program st...

Page 8: ...Table of Contents viii SINUMERIK 802S 6FC5 597 2AA00 0BP2 01 02 notice ...

Page 9: ... tools with stepper motor drives S stepper Hardware components It consists of the following hardware components S ENC Control component for a maximum of 3 stepper motor 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 ma...

Page 10: ...5 9 6 S F F A U Pg Pg 0 N P 1 T D R A L _ G E M Q INS 3 VM H O OP020 MCP External spindle drive Stepper motors X X Z Z DC24V X1 AXIS X2 SPINDLE X3 ECUODER X4 OPI X9 RS232 X8 X10 MPG DI X20 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 Fig 1 1 SINUMERIK 802S hardware components turning variant ...

Page 11: ...PLC user program cyclically Integrated PLC user program intended to adjust the SINUMERIK 802S to the machine functions see also Descrip tion of Functions Integrated User Program for SINUMERIK 802S S Toolbox WinPCIN transfer program for a PC PG programming device to transfer user data and programs Text manager Cycle kit for loading into the control system using WinPCIN User program library Technolo...

Page 12: ...SINUMERIK 802S Control System 1 1 Components of the SINUMERIK 802S 1 12 SINUMERIK 802S 6FC5 597 2AA00 0BP2 01 02 Warning To avoid data loss the operator must carry out data saving see Section 4 1 4 ...

Page 13: ...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 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 Component Dim...

Page 14: ...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 15: ...ntrol 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 want to con...

Page 16: ...rol System 2 1 Installing and removing the SINUMERIK 802S 2 16 SINUMERIK 802S 6FC5 597 2AA00 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: ...es ENCD 15 pin D Sub female connector for connecting a position encoder incremental RS422 S X8 RS232 drive interface V24 9 pin D Sub connector S X9 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 BEROs DI 10 pin front connector for connecting fast inputs inclu...

Page 20: ... Handwheels Sensor BERO Sensor Actor Power Supply P24 M 6FX6002 3AB01 6FX6002 2CD01 6FX6002 2BB01 1 16 1 16 1 4 6FX6002 1AA01 RS232 Machine Control Panel Wire 1 0 2 5 Wire 0 14 1 5 Wire 0 14 1 5 Flat or round cable 6FX6002 1AA02 6FX6002 3BA31 Wire 0 14 1 5 P24 M DC24V RS232 OPI AXIS SPINDLE ENCODER MPG DI IN 0 7 IN 8 15 OUT0 7 OUT8 15 IN M IN M L OUT M L M X1 X8 X9 X2 X3 X4 X10 X20 X2003 X2004 X20...

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: ...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 I 18...

Page 23: ...CD Frame OPCP2 LCD Clock OPRXD OP Receive Data OPTXD OP Transmit Data OPCTS OP Clear to Send ENRXD ECU Receive Data ENTXD ECU Transmit Data ENRTS ECU Request to Send 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 Connector pin assignment on the ENC side Feed drive interface ...

Page 24: ... OPD0 I 16 OPD1_N I 4 OPD1 I 17 OPD2_N I 5 OPD2 I 18 OPD3_N I 13 25 6 OPD3 I 19 OPCP1_N I 7 OPCP1 I 20 OPCP2_N I 8 OPCP2 I 21 OPS_N I 9 OPS I 22 OPTXD_N O 1 14 10 OPTXD O 23 OPRXD_N I 11 OPRXD I 24 OPCTS_N I 12 OPCTS I 25 P24_OP VI 13 M_OP VI Signal names PULS 1 4 PULS 1 4 _N Clock pulse true and negated DIR 1 4 DIR 1 4 _N Direction signal true and negated EN 1 4 EN 1 4 _N Servo enable true and ne...

Page 25: ...on S EN ENABLE This signal is activated by the control system when the cyclic control mode is initiated Signal ON Secondary power control enabled Signal OFF Motor dead No readiness Signal parameters All signals for stepper drives are output to the RS422 standard via differential signal cable drivers All outputs are eletcronically protected against short circuit and thermal overload Table 2 4 Elect...

Page 26: ...with analog interface Signals One voltage and one enable signal is provided S SW SETPOINT Analog voltage signal in the range of 10 V to output a speed setpoint S BS REFERENCE SIGNAL Reference potential analog ground for the setpoint signal internally connected to the log ics ground S RF SERVO ENABLE Relay contact pair used to switch the enable signal for the power section e g a SIMODRIVE unit This...

Page 27: ...system X4 Pin assignment of the connector on the ENC side Measuring system interface incremental encoder Connector designation X4 ENCD Connector type 15 pin D Sub female connector Table 2 8 Pin assignment of the X4 female connector X4 Pin Signal Type Pin Signal Type 1 9 M VO 2 10 N I 3 11 N_N I 8 15 4 P5_MS VO 12 B_N I 15 5 VO 13 B I 1 9 6 P5_MS VO 14 A_N I 1 7 M VO 15 A I 8 Signal names A A_N Tra...

Page 28: ...al N as true and negated signal Ua0 Ua0 Max output frequency 1 5 MHz Phase offset between tracks A and B 90 30 Current consumption max 300 mA Cable lengths The maximum cable length depends on the specification of the encoder supply and on the transmission frequency When using preassembled cables from SIEMENS the following va lues may not be exceeded to ensure interference free operation Table 2 9 ...

Page 29: ...ctor Table 2 11 Pin assignment of connector X8 X8 Pin Name Type Pin Name Type 1 6 DSR I 2 RxD I 7 RTS 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 12 Cable for WinPCIN Pin a...

Page 30: ...designation X10 MPG Connector type 10 pin mini Combicon plug connector Table 2 13 Pin assignment of connector X10 X10 Pin Name Type 1 A1 I 2 A1_N I 3 B1 I 1 4 B1_N I 5 P5_MS VO 6 M5_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 neg...

Page 31: ...gated signal Ua2 Ua2 Max output frequency 500 kHz Phase offset between tracks A and B 90 30 Supply 5 V max 250 mA 2 3 7 Connecting NCREADY X20 Pin assignment of the connector on the ENC side BERO input interface Connector designation X20 DI Connector type 10 pin plug connector Table 2 14Pin assignment of connector X20 X20 Pin Name Type 11 NCRDY_1 K 12 NCRDY_2 K 11 13 reserved DI 14 reserved DI 15 ...

Page 32: ...for digital inputs Signal type VI Voltage input DI Input 24 V signal K Switching contact 4 BERO inputs These inputs are 24 V P switching Either switches or non contact sensors such as inductive sensors BEROs can be connected When using the BERO as a reference point switch the following fixed assignment will apply BERO1 X axis BERO3 Z axis ...

Page 33: ...age range 3 5 V or input open Signal delay 0 1 15 µs Signal delay 1 0 150 µs NC READY output Readiness in the form of a relay contact NO must be integrated into the EMERGENCY STOP circuit Table 2 16 Electrical parameters of the NCREADY relay contact Parameter Max Unit DC switching voltage 50 V Switching current 1 A Switching power 30 VA X20 11 X20 12 NCREADY L EMERGENCY STOP Machine control voltag...

Page 34: ...or the digital inputs Connector designation X2003 X2004 IN Connector type 10 pin plug connector Table 2 17 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 In...

Page 35: ...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 19 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 36: ...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 37: ...cal isolation to IEC 204 1 Section 6 4 PELV Table 2 21 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 22 Pin connector assignment of screw type ter minal b...

Page 38: ...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 ECU DI O16 Grounding bar to chassis Installation in a c...

Page 39: ...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 40: ...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 S1 ECU DI O16 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 1 Start ...

Page 41: ...ips of the upper fastening bracket 3 Screw in the lower fastening screws and tighten all screws Note The modules should be installed such that a clearance of at least 10 cm is left above below and between the modules dimension a The drive modules however can be mounted directly side by side a 10 mm provided they are ventilated with an air stream greater than equal to 1 m s Do not install devices w...

Page 42: ...lling and removing the STEPDRIVE C drive modules 3 42 SINUMERIK 802S 6FC5 597 2AA00 0BP2 01 02 Mounting dimensions 34 12 90 a ÎÎÎÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎÎÎÎ Washer lock washer 286 307 7 80 100 Fig 3 1 Mounting dimensions ...

Page 43: ...IR ENA ENA RDY ZPH 24V 24V GND PE L N PE A A B B C C D D E E PE RDY TMP FLT DIS CURR 1 CURR 2 RES DIR PULS PULS DIR DIR ENA ENA RDY ZPH 24V 24V GND PE L N PE Drive of axis 1 Drive of axis 2 Preassembled cable 6FX6 002 3BA31 1xx0 SINUMERIK 802S X2 Motor cable yellow white blue red orange green gray black brown purple P1 P1N D1 D1N E1 E1N P2 P2N D2 D2N E2 E2N Motor connection anal to axis 1 yellow b...

Page 44: ...ndary side Connecting the motor end cables S To connect the cables remove the terminal box cover 3 screws S Use the cable with the order no 6FX6 002 5AA51 S On the drive end connect the cable shield to the housing such that an electrical connec tion is provided via the appropriate strain relief clamp and clamp the braided shield to PE S On the motor side braid the shield provided it with a cable s...

Page 45: ...current is set too large for the motor the motor can be damaged due to overtemperature Start up sequence 1 Connect the mains voltage and if necessary also the 24 V supply voltage 2 Check the DIS LED 3 Activate the ENABLE signal via the control system power up the control system The yellow DIS LED goes out and the green RDY LED is lit The drive is ready the motor is powered If the PULSE signal is p...

Page 46: ...l system Pulse frequency too high motor is out of step Motor load too large or slug gish DIS yellow the only LED that is lit Drive ready motor not powe red Activate ENABLE signal via CNC FLT red is lit There is one of the following errors Overvoltage or undervoltage Short circuit between the motor phases Short circuit between motor phase and ground Measure 85 V operating vol tage Check cable conne...

Page 47: ... 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 802S 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 48: ...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 49: ... off the SINUMERIK 802S S NEW_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 ...

Page 50: ...Start Up 4 1 General 4 50 SINUMERIK 802S 6FC5 597 2AA00 0BP2 01 02 If no physical units are applicable to the MD the field contains a ...

Page 51: ...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 52: ...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 53: ...oper mechanical installation with tight electrical connections 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 LEERER MERKER 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 us...

Page 54: ...a The PLC area of retentive bit memories is explicitly erased The control system changes to the JOG Ref point approach mode and the yellow LED DIAG flashes see Fig LEERER MERKER 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 swit...

Page 55: ...rogramming 4 2 1 Boot messages Displays on the screen When the control system is booting test patterns or boot information are displayed on the screen as progress displays After the control system has booted without errors it changes to the JOG Ref point appro ach mode and the yellow DIAG LED see Fig 4 1 flashes Boot errors Boot errors are displayed either on the screen or via the LED see Fig 4 1 ...

Page 56: ...ions 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 ERROR BOOT 4 Replace the hardware components 5 Inform the hotline if necessary ERROR NO BOOT2 ERROR NO SYSTEM ERROR LOAD NC NO SYSTEM LOADER ERROR LOAD NC CHECKSUM ERROR ERROR LOAD NC DECOMPRESS ERROR ERROR LOAD NC INTERNAL ERROR 1 ...

Page 57: ...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 802S comes to the user with a simulation program included The SAMPLE user program ...

Page 58: ...pported 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 SAMPLE user program for simple turning machines which is store...

Page 59: ...ed 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 The start up switch PLC Stop can be activated either during operation or power up The debug mode see Operation and Programming Chapter 7 causes t...

Page 60: ...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 active irrespective of the number of active alarms Depending on the type of the alarm re...

Page 61: ...es the NC Start Inhibited signal to the NCK after the user program has been executed S SHOWALARM This alarm has no alarm response bit0 bit5 0 Priority of cancel conditions The cancel conditions have the following 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...

Page 62: ...sent the alarm occurs again User alarm activation User interface Int inter face Feed disable in the NCK is active for all axes as long as the PLC user alarm is active Alarm handler Feed disable active User program Example Feed disable 0 User alarm with feed disable Alarm handler Module Analyze user alarm PLC cycle Fig 4 2 User alarm with Feed Disable alarm response Configuring user alarms Each ala...

Page 63: ...eration Programming Chapter 7 S using the Toolbox 802SC Text Manager The procedure is described in the Toolbox readme file Alarm texts are structured as follows Alarm number Flag 1 Flag2 Text Note The text must be put in inverted commas Adhere to the given text structure Table 4 5 Example Alarm Number Flag 1 Flag 2 Text 700000 0 0 User alarm 1 700000 0 0 1st user alarm text is assigned by the user...

Page 64: ...p the PLC 4 64 SINUMERIK 802S 6FC5 597 2AA00 0BP2 01 02 700031 0 0 32nd user alarm the text is assi gned by the user Number The alarm text must be here Comment line does not appear in the dia log window of the Operator Panel ...

Page 65: ...value S F 4 byte floating point number User alarm text examples S 700000 Only user alarm number S 700001 Hardware limit switch X axis S 700002 D Only variable as an integer decimal number S 700003 Alarm number with fixed alarm text and variable X S 700004 U Alarm number with variable and fixed alarm text S 700005 Rotation monitoring of axis active U Operator panel display 700005 Rotation monitorin...

Page 66: ...mber for configurable key assignment 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Included separately Available as accessories Spindle override 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 ...

Page 67: ...sible therefore no programming errors will rsult during the operation S The data process information must be managed by the user in accordance with the parti cular type Example Information 1 T value DWord 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 ti...

Page 68: ...itute a switch through which the current can flow Current however will only flow through a normally open contact if the contact is closed logical value 1 Current will flow through a normally closed contact 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 a...

Page 69: ...9 0 0 9 000 000 999 symbolic 8 digit Table 4 9 S802S Ranges of operands Accessed by Memory Type SINUMERIK 802SC Bit Byte bit V 14000000 0 79999999 7 I 0 0 7 7 Q 0 0 7 7 M 0 0 127 7 SM 0 0 0 6 T 0 15 C 0 31 L 0 0 59 7 Byte 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...

Page 70: ...e 0 data o k 1 data lost SM 0 3 POWER ON first PLC cycle 1 following cycles 0 SM 0 4 60 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...

Page 71: ...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 72: ...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 73: ...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 74: ...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 75: ...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 76: ...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 77: ...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 78: ...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 79: ...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 80: ...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 Programming Tool is compared with the project contained in the permanent memory load memory of the CNC Versions display Ca...

Page 81: ... 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 802S is now preset to the desired technology Example techmill ini Default 3 axes X Y and Z 1 spindle...

Page 82: ...ce 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 protection level 2 or 3 must be ent ered The following machine data ranges must be selected and modified if necessary using the appropriate softkeys S General ...

Page 83: ...ly 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 Circle end point monitoring constant 0 01 22000 Auxiliary function group aux fct no in channel 0 49 1 22010 Auxiliary function type aux fct no in channel 0 49 2203...

Page 84: ...this case the axis speed will depend on the path travel time of the axes X Z Its motion starts and ends together with the axes X Z The axis speed ho wever cannot be greater than the limit value defined for the additional axis If the additional axis is programmed in a separate block it will travel with the active feedrate F if G1 is programmed Both settable offsets G54 G57 and programmable offsets ...

Page 85: ...400 Schritte pro Schrittmotorumdrehung 1000 Steps per stepper motor revolution must be identical to MD 31020 32000 Maximum axis velocity 10000 30000 max axis velocity 32100 Traversing direction not control di rection 1 Reversal of direction of motion 32110 Sign actual value control direction encoder no 1 Measuring system reversal 32200 Servo gain factor control parameter set no 0 5 2 5 2 5 positio...

Page 86: ... MD 30240 3 MD 31400 10 000 MD 32260 1 200 rpm MD 32000 12 000 mm min Stepper motor frequency The parameterization is carried out using the machine data which have already been mentio ned after POWER ON The resulting stepper motor frequency is displayed with machine data MD 31350 Motor speed rpm S steps per stepper motor revolution MD 31350 Hz 60 s This frequency must correspond to MD 32000 Supple...

Page 87: ... position and in case of error the Error Rotation monitoring signal is created The rotation monitoring BERO must be overrun cyclically when the axes are traversed Usually a cyclically occurring BERO is used both referencing and for rotation monitoring It is possible to switch the BERO for rotation monitoring in parallel to the BERO for referenc ing It must however be made sure that the rotation mo...

Page 88: ...Typical motor characteristic for a stepper drive The optimum capacity utilization of such characteristics with a simultaneous overload protec tion can be achieved using the velocity dependent acceleration characteristic Bent accelera tion characteristic Activation In the AUTOMATIC mode the bent acceleration characteristic is always active The axis be havior is set via the parameterization of the c...

Page 89: ...lue depends on the motor characteristic t v a v MAX_ACCEL_REDUCTION_TYPE 0 constant Characteristic a v ared amax vred vmax vmax vred Characteristic v t Fig 4 7 Axial acceleration and velocity characteristics Velocities vmax MA_MAX_AX_VELO vred MA_ACCEL_REDUCTION_SPEED_POINT MA_MAX_AX_VELO Accelerations amax MA_MAX_AX_ACCEL ared 1 MA_ACCEL_REDUCTION_FACTOR MA_MAX_AX_ACCEL Service display of the axi...

Page 90: ...age oscilloscope to X3 9 pin plug connector Pin 1 setpoint 10V Pin 6 analog ground The axis setpoint value is switched using MD 31500 AXIS_NUMBER_FOR_MONITORING Example The axis setpoint value of the Z axis is to be output at connector X3 To this end enter the following value in the axis MD of the 3rd machine axis Sp Turning AXIS_NUMBER_FOR_MONITORING AX4 2 Z axis always has axis number 2 Milling ...

Page 91: ...ABLE 1 has bee set for the axis spindle With the function G331 G332 active parameter block n 0 5 of the axis of MD 32910 acting corresponding to the spindle gear stage automatically becomes active The gear stage is dependent on the spindle speed with M40 or is set directly via M41 M45 see also Section 4 5 3 Start up of the spindle Number Description Default Value 32900 Dynamic response adaptation ...

Page 92: ...parameter set 1 Supposed for spindle Kv MD 32200 POSCTRL_GAIN 1 0 5 is entered and for Z axis Kv MD 32200 POSCTRL_GAIN 1 2 5 is entered The searched entry for the Z axis in 1 1 MD 32910 DYN_MATCH_TIME 1 Kv 1 spindle Kv 1 z 1 1 60 0 5 2 5 1000 MD 32910 DYN_MATCH_TIME 1 0 0960 s If necessary for fine adaptation in practice a more exact value must be determined When traversing axis e g Z axis and spi...

Page 93: ...the traversing direction changes Activation The backlash compensation is active in all operating modes only after referencing Note Which step size is added to the backlash compensation value is determined by MD36500 ENC_CHANGE_TOL Leadscrew error compensation LEC Overview The compensation values are determined using the measured error characteristic and are entered in the control system using spec...

Page 94: ...f Functions S Approach the reference points in the axes Then start the NC program with the leadscrew error compensation table The reference points must then be approached once more to set the LEC active The LEC function is activated by setting the MD ENC_COMP_ENA BLE 0 1 for each machine axis Another possibility to create the LEC compensation table is by reading out the LEC file from the NC via th...

Page 95: ...ual value No setpoint output to connector X2 Value 1 The setpoint signals are output to X3 Real rotation of the spindle is possible 30240 Value 0 Value 2 Spindle modes The following modes are possible for the spindle S Control mode M3 M4 M5 S Oscillating mode to assist gearbox change S Positioning mode SPOS MD for spindle Number Explanation Default Value 30130 Output type of setpoint setpoint bran...

Page 96: ...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 acceleration 0 ...

Page 97: ...00 Number of recognized zero mark errors during monitoring 100 Zero mark monitoring off encoder HW monitoring off 0 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 SD for spindle Number Explanation Default Value 43210 Progr spin...

Page 98: ...revolution Increments rev Incr rev s 31080 Numerator resolver gearbox Motor rev s Load rev s 31070 Denominator resolver gearbox Encoder rev s Encoder rev s 31060 Numerator load gearbox control parameter set no 0 5 Motor rev s Motor rev s 31050 Denominator load gearbox control parameter no 0 5 Load rev s Load rev s Example 1 for encoder matching Spindle with square wave encoder 500 pulses mounted d...

Page 99: ...olution 4 2 048 pulses 360 deg 1 1 000 pulses deg 1 1 1 43 945 Internal resolution One encoder increment corresponds to 43 945 internal increments One encoder increment corresponds to 0 043945 degrees finest positioning possibility Spindle setpoint adaptation To adapt the spindle setpoint and its gear stage the following axis MD and interface signals are relevant Number Description 32010 Rapid tra...

Page 100: ...h in the simulation mode MD 30130 0 and with drive MD 30130 1 Reciprocation mode for gear change The reciprocation mode of the spindle is intended to facilitate the gear change For the reci procation mode the following axis MD and interface signals are relevant Number Description 35400 Reciprocation speed 35410 Acceleration when reciprocating 35430 Start direction in reciprocation 35440 Reciprocat...

Page 101: ...l To save the data which have been set during the start up an internal data saving is requi red To this aim set access level 7 end customer otherwise access level 2 will also be saved Press the softkey Delete passw The access level will be reset 3 Carry out internal data saving Press the Save data softkey 4 7 5 Starting up the cycles Sequence of operations When loading cycles into the control syst...

Page 102: ...the 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 S...

Page 103: ... 802S 6FC5 597 2AA00 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 104: ...Start Up 4 7 Commissioning 4 104 SINUMERIK 802S 6FC5 597 2AA00 0BP2 01 02 ...

Page 105: ...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 106: ...nd of the update and errors if any are displayed on the PG PC 6 At the end of the update switch off the control system 7 Turn the start up switch to position 1 switch on the control system 8 Booting with default values 9 Prior to next POWER ON start up switch to 0 position Note Reload the externally saved user standard data via V24 ...

Page 107: ... 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 control to slave control control system to be updated via V24 interface Update sequence 1 Turn the hardware start up switch of both control systems to position 2 software update ...

Page 108: ...m 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 s...

Page 109: ... 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 110: ...mal 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 3 0 126 BYTE 282 MM_V24_PPI_ADDR_MMC Decimal PPI address of the HMI POWER...

Page 111: ...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 POWER ON _always 0 DWORD 2 7 14512 USER_DATA_HEX n kB User data Hex 0 31 POWER ON 0 0 0xFF BYTE 2 7 14514 USER_DATA_FLOAT n User data Float 0 7 POWER ON 0 0 DOUBLE 2 7 14516 USER_DATA_P...

Page 112: ...ning 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 branch 0 POWER ON _always 0 0 2 BYTE 2 7 30200 NUM_ENCS Anzahl der Geber 1 oder kein Geber für die Spindel RESTART 1 0 1 BYTE 2 7 30240 ENC_TYPE Type of actual valu...

Page 113: ...WER 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 increment with INC handwheel RESET 31100 BERO_CYCLE Steps for monitoring rotatio...

Page 114: ...on POWER ON _always 1 1 1 DWORD 2 7 32110 ENC_FEEDBACK_POL Sign actual value control direction encoder no POWER ON _always 1 1 1 DWORD 2 7 32200 POSCTRL_GAIN 1000 min Servo gain factor control parameter set no 0 5 NEW CONF _always 2 5 2 5 2 5 1 0 0 plus DOUBLE 2 7 32260 RATED_VELO rev min Rated motor speed setpoint branch 0 NEW CONF _always 3000 0 0 plus DOUBLE 2 7 32300 MAX_AX_ACCEL mm s 2 rev s ...

Page 115: ...00 0 0 0 plus DOUBLE 2 7 34040 REFP_VELO_SEARCH_MARKER mm min rev min Creep speed encoder no RESET _always 300 0 0 0 plus DOUBLE 2 7 34050 REFP_SEARCH_MARKER_REVERSE Direction reversal to reference cams encoder no RESET _always 0 BOOLEAN 2 7 34060 REFP_MAX_MARKER_DIST mm deg Maximum distance to reference mark Max distance to 2 reference marks for distance coded measuring systems RESET _always 20 0...

Page 116: ...Maximum speed for gear change gear stage no 0 5 NEW CONF _always 500 500 1000 2000 4000 8000 0 0 plus DOUBLE 2 7 35120 GEAR_STEP_MIN_VELO rev min Minimum speed for gear change gear stage no 0 5 NEW CONF _always 50 50 400 800 1500 3000 0 0 plus DOUBLE 2 7 35130 GEAR_STEP_MAX_VELO_LIMIT rev min Maximum speed of gear stage gear stage no 0 5 NEW CONF _always 500 500 1000 2000 4000 8000 0 0 plus DOUBLE...

Page 117: ...uring reciprocation 0 2 As last direction of rotation zero speed M3 3 M3 direction 4 M4 direction RESET _always 0 0 4 BYTE 2 7 35440 SPIND_OSCILL_TIME_CW s Reciprocation time for M3 direction NEW CONF _always 1 0 0 0 plus DOUBLE 2 7 35450 SPIND_OSCILL_TIME_CCW s Reciprocation time for M4 direction NEW CONF _always 0 5 0 0 plus DOUBLE 2 7 35510 SPIND_STOPPED_AT_IPO_START Feedrate enable for spindle...

Page 118: ...rameter set no 0 5 NEW CONF _always 11500 11500 11500 11500 0 0 plus DOUBLE 2 7 36300 ENC_FREQ_LIMIT Hz Encoder limit frequency POWER ON _always 300000 0 plus DOUBLE 2 7 36302 ENC_FREQ_LIMIT_LOW Encoder limit frequency at which encoder is switched on again Hysteresis NEW CONF _always 99 9 0 100 DOUBLE 2 7 36310 ENC_ZERO_MONITORING Zero mark monitoring encoder no 0 1 0 Zero mark monitoring off enco...

Page 119: ...tion Standard value Minimum value Maximum value D type User class 41110 JOG_SET_VELO mm min Axis speed for JOG Immediately _always 0 0 0 0 plus DOUBLE 4 4 41200 JOG_SPIND_SET_VELO rev min Speed for spindle JOG mode Immediately _always 0 0 0 0 plus DOUBLE 4 4 43210 SPIND_MIN_VELO_G25 rev min Progr spindle speed limitation G25 Immediately _always 0 0 0 0 plus DOUBLE 4 4 43220 SPIND_MAX_VELO_G26 rev ...

Page 120: ...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 121: ... 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 122: ... level 26000000 Acknowl EMER EMER GENCY 4 5 6 7 GENCY STOP STOP 26000001 Request remaining distances to go by the axes Request re maining ac tual dis tances to 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 tempe...

Page 123: ...yte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Mode Mode 30000000 Reset Change lock JOG MDA AUTOM Machine function 30000001 REF TEACH IN 30000002 30000003 3100 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 ...

Page 124: ...000004 H G F E D C B A Rapid traverse override 3 32000005 H G F E D C B A Feed 1 Rapid tra verse Program level 32000006 override override Delete Read in Feed enabled enabled abortion distance to go disabled lock NC stop NC stop 32000007 axes plus NC stop to block NC start NC start spindle limit inhibited Notes 1 Feed override enabled Even if the feed override is not enabled 100 the 0 position is a...

Page 125: ...e lock stop 2 1 Axis 1 in WCS 32001001 Machine function continu ous 1000 INC 100 INC 10 INC 1 INC 32001002 32001003 Axis 2 in WCS 32001004 Traversing keys Rapid Traversing key lock Feed Activate handwheel traverse override Stop 2 1 Axis 2 in WCS 32001005 Machine function continu ous 1000 INC 100 INC 10 INC 1 INC 32001006 32001007 Axis 3 in WCS 32001008 Traversing keys Rapid traverse Traversing key...

Page 126: ... 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 stop of ma alarm All axes All axes stop of ma chining present channel specific present stopped refer enced 33...

Page 127: ...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 128: ...A00 0BP2 01 02 Transfer of auxiliary functions from the NC channel 2500 Auxiliary functions from NCK chan nel r Data block Interface PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Modify de 25000000 coded M func M func tions 0 99 25000001 Modify T funct 1 25000002 25000003 ...

Page 129: ... functions 25001001 M15 M14 M13 M12 M11 M10 M9 M8 Dynamic M functions 25001002 M23 M22 M21 M20 M19 M18 M17 M16 Dynamic M functions 25001012 M99 M98 M97 M96 25001013 25001014 25001015 Notes Static M functions must be generated by the PLC user from the dynamic M functions Dynamic M functions are decoded by the basic program M00 to M99 Transferred T functions 2500 T functions from NCK channel r Data ...

Page 130: ...Technical Appendix 6 2 PLC user interface signals 6 130 SINUMERIK 802S 6FC5 597 2AA00 0BP2 01 02 25002004 25002008 25002012 ...

Page 131: ...t 4 Bit 3 Bit 2 Bit 1 Bit 0 Feed override 380x0000 H G F E D C B A Axes 380x0001 Override Position Follow up spindle enabled encoder 1 mode lock Distance to go 380x0002 Clamping spindle Servo process running reset enable Speed 380x0003 spindle speed limitation Traversing keys Rapid traverse Feed Activate handwheel 380x0004 Travers ing stop plus minus override key lock Spindle stop 2 1 Machine func...

Page 132: ...80x1000 Ref point approach axis plus minus plus minus 380x1001 axis 380x1002 axis 380x1003 axis Signals to spindle 3803 Signals to 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 Gear is Actual gear stage 38032000 changed spindle C B A Spindle feed 38032001 Invert override spindle M3 M4 valid Set direction of rotation 38032002 Recipro cating Recipro ca...

Page 133: ...spindle 3900 3903 Signals from axis spindle r Data block Interface NCK PLC Byte Bit 7 Bit 6 Bit 5 Bit 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 390x0001 Current controller controller Position controller stopped active active active n nmin 390x0002 3...

Page 134: ...ion pulse 390x1003 axis Signals from spindle 3903 Signals from spindle r Data block Interface NCK PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Set gear stage 39032000 Change gear spindle C B A Actual di rection Spindle Set Set Speed 39032001 of rotation within set speed speed limit spindle CW range increased limited exceeded Active spindle mode Tapping 39032002 Control Recipro cating P...

Page 135: ... 390x5003 Axis actual value and distances to go VD570 Data block Interface NCK PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 570x0000 Axis actu al values 570x0004 Axis actual values 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 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 B...

Page 136: ...6 Bit 5 Bit 4 Bit 3 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 hand...

Page 137: ...ol panel signals MCP signals Status signals from MCP 1000 Signals from 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 Axi...

Page 138: ... Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 L6 L5 L4 L3 L2 L1 11000000 11000001 6 2 8 PLC machine data INT values MD 14510 USER_DATA_INT 4500 Signals from NCK r Data block Interface NCK 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 ...

Page 139: ... value BYTE 45001003 Hex value BYTE 45001030 Hex value BYTE 45001031 Hex value BYTE FLOAT values MD 14514 USER_DATA_FLOAT 4500 Signals from NCK r Data block Interface NCK PLC Byte 45002000 Float value REAL 4 bytes 45002004 Float value REAL 4 bytes 45002008 Float value REAL 4 bytes 45002012 Float value REAL 4 bytes 45002016 Float value REAL 4 bytes 45002020 Float value REAL 4 bytes 45002024 Float v...

Page 140: ...arm 700002 45003031 Alarm reaction clear criterion of alarm 700031 6 2 9 User alarm Alarm activation 1600 Alarm activation r w Data block Interface PLC MMC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Activation of alarm no 16000000 700007 700006 700005 700004 700003 700002 700001 700000 Activation of alarm no 16000001 700015 700014 700013 700012 700011 700010 700009 700008 Activation of a...

Page 141: ...6001004 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 Bit 3 Bit 2 Bit 1 Bit 0 Feed lock Read in disable NC start inhibited 16002000 PLC STOP NOT AUS of all axes 16002001 1...

Page 142: ...UPGM TURN that comes with the tool must not necessarily be the same as the version that comes with the control system The user can thus use this PLC project as a basis for his own PLC project 6 3 1 Function The PLC user program UPGMTURN processes all necessary signals from and to the NC and the machine control panel MCP and monitors the EMERGENCY STOP function UPGMTURN handles axis and spindle sig...

Page 143: ...der the Parameter menu The PLC machine data for parameterizing the integrated user program are described in the following Tables During start up of the SINUMERIK 802S the PLC machine data must be set according to the machine tool used The parameters come into effect with the next restart POWER ON The function of all 16 inputs and 16 outputs of the SINUMERIK 802C basic variant can be set by means o...

Page 144: ...emask input not used 1 input is used Output valid 0 demask output not used 1 output is used Input output 0 active 0 All signals use positive logic as standard i e logic 1 active 24V 1 When connecting to systems with negative logic i e logic 0 active 0V MCP customer key valid 0 Demask MCP customer keys not used 1 MCP customer key is used Rotation monitoring active 0 Rotation monitoring function is ...

Page 145: ...tiple of 100 ms MD14510 2 Spindle brake hold time Time required to activate the spindle brake a multiple of 100 ms The spindle brake is activated either by Spindle Stop from the machine control panel or by the M05 function in the NC part program MD14510 3 4 Lubrication interval time For automatic lubrication a multiple of 1 minute must be entered for the lubrication interval and a multiple of 100 ...

Page 146: ... User K2 Spindle jogging User K3 Increase spindle speed User K4 Manual tool change User K5 Start manual lubrication User K6 Cooling ON OFF toggle switch User K7 Reset alarm output User K8 not assigned User K9 not assigned User K10 not assigned Outputs X2005 O0 0 Spindle start CW direction of rotation M3 O0 1 Spindle start CCW direction of rotation M4 O0 2 Spindle stop with brake O0 3 Coolant contr...

Page 147: ... In the event a limit switch is overrun all axes are stopped and only the axis resulted in responding of the limit switch can be traversed to the opposite direction in JOG mode S Referencing delayed reference point approach requires a cam switch on the inputs I1 4 for the X axis and I1 5 for the Z axis In addition a reference point switch BERO must be connected to the NCK input X20 to ensure that ...

Page 148: ...ually initiated lubrication process When you press the 5 key the output signal for lubrication is activated for one interval set in the PLC machine data S 6 Coolant ON OFF toggle key only in JOG mode S 16 Reset alarm output After the alarm source has been removed the alarm output O0 7 can be deactivated by pressing 16 acknowledge alarm Description of the output signals S O0 0 Control contact Spind...

Page 149: ...Control output for lubrication system S O0 7 Alarm output This signal can be used for controlling the step switching drives or for display 6 3 4 Description of the logics Spindle control S Input signals M03 M04 M05 from part program M41 M42 M43 M44 from part program Spindle CW CCW Stop from machine control panel Spindle from machine control panel Spindle from machine control panel S Output signals...

Page 150: ...AUTO mode Speed stage 1 identical to M41 Speed stage 2 identical toM42 Speed stage 3 identical to M43 Speed stage 4 identical to M44 With speed stage 1 With speed stage 2 With speed stage 3 With speed stage 4 O1 4 active O1 5 O1 6 O1 7 inactive O1 5 active O1 4 O1 6 O1 7 inactive O1 6 active O1 4 O1 5 O1 7 inactive O1 7 active O1 4 O1 5 O1 6 inactive Note n means active Toolholder control S Input ...

Page 151: ...UPGMTURN control Precondition Result S In AUTO mode when M07 or M08 has been output S In AUTO mode when M09 has been output S Coolant control active S Coolant control inactive S In JOG mode when Cooling ON OFF C6 has been pressed for the first time S when the key has been pressed for another time S Coolant control active S Coolant control active inactive Lubricant control S Input signals Manual lu...

Page 152: ...arm output is inactive UPGMTURN alarms The UPGMTURN carries out plausibility checks In the event of any inconsistencies PLC alarms are displayed on the user interface Alarm Cause 700000 No turret reversal time specified PLC MD 14510 1 0 Error Toolholder clamping time 700001 Programmed T number than MD Programmed tool T number greater than set in PLC MD 14510 0 700002 Turred does not clamped Toolho...

Page 153: ...h Subroutine 5 Reserved Subroutine 6 Axis control for Z axis Axis Enable Reference cam switch Hardware limit switch Subroutine 7 Spindle control Subroutine 8 reserved for spindle Subroutine 9 reserved for spindle Subroutine 10 Turret control Subroutine 11 Checking tool position Subroutine 12 Tool change Subroutine 13 Tool position monitoring Subroutine 14 Turret clamping Subroutine 16 Cooling and ...

Page 154: ...2 0 1 Turret start CW M2 1 1 Turret in position and starts CCW M2 2 1 Delay timer starts M2 3 1 Manual tool change button pressed M2 4 1 Turret position changed M2 5 M2 6 M2 7 MB3 MB4 MB5 Feedrate override MB7 Reserved used for Shift Instr MB6 Jog Increment MW8 Input Buffer for I0 0 I0 7 MW9 Input Buffer for I1 0 I1 7 MW10 Output Buffer for Q0 0 Q0 7 MW11 Output Buffer for Q1 0 Q1 7 MW12 Buffer fo...

Page 155: ...2 Turret position buffer MD36 Buffer for programmed T funktion MD40 Current turret position MD44 Toolholder position TIMER T0 TON for the spindle brake time control T1 TON for the turret reversal time control T2 TON for the lubricating time control COUNTER C0 for the 1 min timer for lubricating interval control ...

Page 156: ...int is output from the NC but the direction signal is switched form the PLC i e the user program must ensure that the new direction signal is only provided if the spindle has stopped Rotation may only be started again if the direction signal has been out put from the PLC Position controlled spindle operation SPOS G331 G332 LCYC84 is not possible with unipolar spindle control N10 M5 Spindle Stop N2...

Page 157: ...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 158: ... 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 159: ... 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 i...

Page 160: ...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 161: ...lue for Cut meters Lubrication MD 14510 1 MN_USER_DATA_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 ...

Page 162: ...d for subsequent I O assign ments where currently only 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 clos...

Page 163: ... 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 164: ...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 165: ...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 166: ...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 167: ...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 168: ...Manual Machine 7 9 Default assignment of special data for the Manual machine 7 168 SINUMERIK 802S 6FC5 597 2AA00 0BP2 01 02 notice ...

Page 169: ...em X4 2 27 Connection diagram 2 20 E ENC and operator panel power supply X1 2 37 G Grounding 2 38 Grounding diagram 2 38 I Installing and Dismantling the SINUMERIK 802C 2 15 Integrated user program 6 142 Interfaces and cables 2 18 L LEDs and operating elements on the ENC unit 2 40 M Manual machine Default assignment 7 165 I O assignment 7 162 Installation 7 157 Machine data 7 161 Switching the lan...

Page 170: ...Index Index 170 SINUMERIK 802S 6FC5 597 2AA00 0BP2 01 02 notice ...

Page 171: ...2AA00 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 172: ......

Page 173: ... 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 174: ...ithout prior notice Order No 6FC5597 2AA00 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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