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1. NC Side Cable Drive Side PIN Core Color Signal Name PIN 14 black 1st axis 1 9 47 brown 1 65 34 red 1 4 1 orange 1 56 pe 15 yellow 2nd axis 2 9 48 green 2 65 9 9 2 blue 2 14 35 purple 2 56 16 gray 3rd axis 3 9 49 pink 3 65 3 9 36 white black 3 14 TOU 3 white brown 3 56 17 white red Spindle 4 9 50 white orange 4 65 4 white yellow 4 14 37 white green 4 56 Drives with analog interface Signals One voltage and one enable signal each is output SWn SETPOINT Analog voltage signal in the range 10 V to output a speed setpoint Sn REFERENCE SIGNAL Reference potential analog ground for the setpoint signal internally connected to logic ground RFn SERVO ENABLE Relay contact pair controlling the enable of the power section e g of a SIMODRIVE drive unit controlled via a PLC program Signal parameters The setpoint is output as an analog differential signal Table 2 5 Electrical parameters of the signal outputs for step switching drives Parameter Min Max Unit Voltage range 10 5 10 5 V Output current 3 3 mA SINUMERIK 802C 6FC5 597 20 2 01 02 2 25 Installing the Control System 23 Connecting the individual components Relay contact Table 2 6 Electrical parameters of the relay contacts RFn 1 and RFn 2 Parameter Max Unit Switching
2. 80 Mounting Holes Ds Te 120 o o Je a EN n a R 8 215 0 5 15 j 20 sls lt gt 15 40 Fig 2 1 Mounting dimensions for SINUMERIK 802 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 2 17 Installing the Control System 2 2 Interfaces and cables 2 2 Interfaces and cables Position of the interfaces and front panel elements ECU _ DI O16 ENCODER1 ENCODER2 X4 S8 or RS232 ENCODERS SPINDLE AXIS X2 X5 X6 X7 X8 Fig 2 2 User interfaces LCD signal connector Fig 2 3 Rear of machine control panel and operator panel 2 18 SINUMERIK 802C 6FC5 597 20 2 01 02 Installing the Control System Interfaces 2 2 Interfaces and cables ENC X1 power supply terminals DC24
3. o o to chassis Grounding bar Fig 2 8 Grounding diagram for MCP OP020 installation in a panel SINUMERIK 802C 6FC5 597 20 2 01 02 2 37 Installing the Control System 2 6 LEDs and operating elements on the ENC 2 6 LEDs and operating elements on the ENC Error and status LEDs There are three LEDs on the front panel of the ENC ENC _ DI O16 ENCODER1 ENCODER2 x S OOOOOOOOOOQ OOOOOO00000 c S8 4 Fo 8 9 4 1 DC24V X1 0000000000 0000000000 8 RS232 SPINDLE AXIS OPI X2 X5 X6 X7 X8 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 up switch S3 This rotary switch is intended to assist start up Position 0 Normal operation Positions 1 4 Start up cf also Section 4 2 Table 4 2 SINUMERIK 802C 2 38 6FC5 597 3AA20 0BP2 01 02 Installing the Drives 3 E Lesehinweis Manufacturer documentation of the drives SINUMERIK 802C 6FC5 597 20 0 2 01 02 3 39 SINUMERI
4. Data block Interface PLC NCK Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Gear is Actual gear stage 38032000 changed spindle B Spindle feed SINUMERIK 802C 6 114 6FC5 597 20 2 01 02 Technical Appendix 38032001 spindle Invert M3 M4 6 2 PLC user interface signals override valid 38032002 spindle Set direction of rotation CCW CW Recipro cating speed Recipro cating by PLC 38032003 spindle General signals from axis spindle Data block Byte 390x0000 Spindl e override Position with exact pos fine reached with exact pos coarse E Refer enced synchro nized 1 D Interface NCK Encoder limit fre quency exceeded 1 Spindle no axis 390x0001 Current controller active Speed controller active Position controller active Axis spindle stopped n M Follow up active 390x0002 390x0003 390x0004 Motion command plus minus Handwheel active 390x0005 continu ous Active machine function 1000 INC 390x0006 390x0007 Signals from axis Data block Byte 390x1000 7 6 5 4 Interface 2 Bit 0 L axis
5. exem ERR kr er le sla 4 68 4 3 8 Data organizatlon vre de RED ERGO 4 69 4 3 9 Interface to the control system 2 4 69 4 3 10 Testing and monitoring the user program 4 69 4 4 PLC applications 4 70 4 5 User Interface eph Ire epe kt deerit e ttem bier 4 72 4 6 Technology Setting sce e reb eee lg bees UP MER ER CR 4 72 4 7 atte Let cac E APO PR S dead t org t rfe an 4 73 4 7 1 Entering the general machine data 4 73 4 7 2 Starting up the axes iux oe eet e et ait Gara ate er a lh ed 4 75 4 7 3 Starting up the spindle 4 85 4 7 4 Completing the Start Up 4 87 4 7 5 YS NU 4 88 4 8 Series machine start up 4 89 SINUMERIK 802C 6FC5 597 20 2 01 02 Table of Contents 5 Software Update lle 5 91 5 1 Updating
6. Table 4 1 Protection level concept Protection Le Disabled via Data Area vel 0 Siemens reserved 1 Siemens reserved 2 Password EVENING default Machine manufacturer 3 Password CUSTOMER default Authorized operator setter 4 No password or Authorized operator setter user IS from PLC NCK 5 User IS from PLC User IS from PLC 7 User IS from PLC 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 software version If the password is deleted protection level 4 is applicable The password remains set until it is reset using the Delete password softkey POWER ON will not reset the password Protection levels 4 7 Protection level 4 is automatically set when no password is entered If required the protection levels 4 7 can be set from the user program via the user interface See Section 6 1 1 Display Machine Data Note How to set the access levels is described in the User s Guide Operation and Programming SINUMERIK 802C 4 42 6FC5 597 20 2 01 02 Start Up 4 1 General 4 1 2 Structure of machine data MD and setting data SD Number and
7. X1002 1001 ANALOG DRIVE ANALOG MOTOR SPINDLE DRIVE SPINDLE ENCODER ENCODER 62 Hand Wheels NC READY ENCODER DI O16 IN 0 7 Wire 0 14 1 5 IN 8 15 OUTO 7 Wire 0 14 1 5 OUT8 15 M P24 M P24 Power Supply Fig 2 4 SINUMERIK 802C connection diagram 1 Ribbon cable included in scope of supply SINUMERIK 802C 2 20 6FC5 597 3AA20 0BP2 01 02 Installing the Control System 2 3 Connecting the individual components 2 3 Connecting the individual components Connecting the components Note Use only shielded cable and make sure that the shield is connected to the metal or metal pla ted connector casing on the control side For the purpose of isolating the analog setpoint si gnal from low frequency interference we recommend 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 Connecting the operator panel Connector pin assignment on the ENC side Operator panel interface Connector designation
8. Warning To avoid data loss the operator must carry out data saving see Section 4 1 4 SINUMERIK 802 6FC5 597 20 2 01 02 1 11 SINUMERIK 802C Control System 1 2 Technical data 1 2 Technical data Connected load Table 1 1 Connected load Parameter Min Typ Max Unit Supply voltage 20 4 28 8 V Ripple 3 6 Vss Current consumption from 24 V 1 A Power dissipation of ENC 15 W Power dissipation of OP020 7 W Power dissipation of MCP s Power dissipation of DI O16 7 W E Start up current 26 A Basic configuration of ENC OP020 and DI O16 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 3500 OP020 component 1 800 g MCP component 1 200 g Dimensions Table 1 3 Component dimensions Component Dimensions HxWxD mm ENC component 125 x 200 x 118 DI O component 125 x 80x 118 OP020 component 300 x 250 x 50 MCP component 300 x 170 x 50 SINUMERIK 802C 6FC5 597 20 2 01 02 SINUMERIK 802C Control System Environmental operating conditions Table 1 4 Environmental operating conditions 1 2 Technical data Parameter Temperature range 0 55 C Permissible relative humidity 5 95 without condensati
9. Fig 2 6 Connecting the digital inputs and outputs SINUMERIK 802C 6FC5 597 20 2 01 02 Installing the Control System and operator panel power supply X1 2 4 2 4 ENC and operator panel power supply X1 Screw type terminal block The 24 V DC load power supply unit required for supplying ENC and operator terminal is con nected to screw type terminal block X1 Characteristics of the load power supply The 24 V DC voltage must be generated as a functional extra low voltage with safe electrical 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 e 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 block X1 Terminal 1 PE PE 2 M Ground 3 L DC 24 V 4 M Ground The contacts 2 4 are connected internally in the device Operator panel The operator panel does not possess a separate power supply connection It is powered from the ENC via the signal cables SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 2 35 Installing the Control System 2 5 Grounding 2 5 Grounding Ground connections The following ground connections m
10. Alarm handler Module Analyze user alarm PLC cycle Feed disable in the NCK is active for all axes as long as the PLC user alarm is active Fig 4 2 User alarm with Feed Disable alarm 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 gt SHOW ALARM SELF CLEARING user alarm Configuration byte structure Bit0 bit5 Alarm responses Bit6 bit7 Cancel criterion Alarm responses BitO 1 Biti 1 Bit2 1 Bit3 1 Bit4 1 5 Cancel criteria Bit6 bit7 0 1 Bit 21 4 54 BitO bit 5 0 Showalarm default NC Start inhibited Read in disable Feed disable for all axes EMERGENCY STOP PLC Stop Reserved SELF CLEARING alarm default CANCELCLEAR alarm POWERONCLEAR alarm SINUMERIK 802C 6FC5 597 20 2 01 02 Start Up Alarm texts The user has two possibilities to define his own alarms 4 3 Starting up the PLC using the Edit PLC txt softkey cf Operation Programming Chapter 7 using the Toolbox 802SC Text Manager The procedure is described in the Toolbox readme file Alarm texts are structured as follows Alarm number Text Note The text must be put in inverted commas 7 Adhere to the given text structure Table 4 5 Example
11. 5 3 Update errors Table 5 1 Update errors 5 8 Update errors Error Text Explanation ERROR Error when updating the system software via V24 UPDATE Data already in receive buffer send from PC side started too early Error when erasing the FLASH memory Error when writing to the FLASH memory Inconsistent data incomplete or faulty SINUMERIK Update without programming the code FLASH 8025 completed no data received transfer not started UPDATE NO DATA Remedial Action Repeat update Check link between control system and PC PG Check diskette SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 5 93 Technical Appendix 6 1 Data type 6 1 1 Number Representation Unit 202 Decimal 0 203 Decimal 0 206 Decimal 0 207 Decimal 0 6 94 BOOLEAN BYTE DOUBLE DWORD STRING UNSIGNED WORD List of machine and setting data Machine data bit 1 or 0 Integer values from 128 to 127 Real and integer values from 4 19 10 307 to 1 67 10308 Integer values from 2 147 109 to 2 147 109 Character string max 16 characters consisting of upper case letters with digits and underscore Integer values from 0 to 65536 SIGNED WORD Integer values from 32768 to 32767 UNSIGNED DWORD SIGNED DWORD WORD DWORD Integer values from 0 to 4294967300 Integer values from 2147483650 to 2147483649 Hex values from 0000 to FFFF Hex values from 000
12. Notes 4 Static M functions must be generated by the PLC user from the dynamic M functions Dynamic M functions are decoded by the basic program MOO to M99 Transferred T functions 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 22 6 2 5 Axis spindle signals Signals to axis spindle Common signals to axis spindle nterface PLC gt NOK Bit 4 Bit 3 i Feed override 380x0000 H D Axes 380x0001 Override Position Follow up spindle enabled encoder 1 mode lock SINUMERIK 802 6FC5 597 3AA20 0BP2 01 02 6 113 Technical Appendix 6 2 PLC user interface signals Clamping Delete process distance 380x0002 running to go Servo spindle enable reset Speed 380x0003 spindle speed limitation Traversing keys Rapid Travers Feed Activate handwheel traverse ing Stop override key Spindle plus minus lock stop 380x0004 Machine function 380x0005 continu 1000 ous INC 380x0006 380x0007 Signals to axis Byte Bit 7 i i i Bit 3 Bit 2 Bit 1 Bit 0 Delay 2nd software limit Hardware limit switch Ref point switch 380x1000 axis plus minus plus 380x1001 axis 380x1002 axis 380x1003 axis Signals to spindle
13. always 31090 mm de grees 32000 always 32010 mm min rev min _always 32020 mm min rev min _always 32070 _always 32100 _always 6 98 List of machine and setting data ENC IS LINEAR Direct measuring system linear scale encoder no POWER ON 0 ip il BOOLEAN 2 7 ENC GRID POINT DIST Division period for linear scales encoder no POWER ON 0 01 0 0 plus DOUBLE 2 7 ENC RESOL Encoder markings per revolution encoder no POWER ON 2048 0 0 plus DWORD 2 7 LEADSCREW PITCH Pitch of leadscrew POWER ON 10 0 0 0 plus DOUBLE 2 7 ENC IS DIRECT Encoder mounted directly to the machine encoder no POWER ON 0 Ju Sb BOOLEAN 2 7 DRIVE AX RATIO DENOM Denominator load gearbox control parameter no 0 5 POWER ON 1 1 1 1 1 1 1 2147000000 DWORD 2 7 DRIVE_AX_RATIO_NUMERA Numerator load gearbox control parameter set no 0 5 POWER ON 1 1 1 1 1 1 1 2147000000 DWORD 2 7 DRIVE ENC RATIO DENOM Denominator resolver gearbox encoder no POWER ON 1 1 2147000000 DWORD 2 7 DRIVE ENC RATIO NUMERA Numerator resolver gearbox encoder no POWER ON 1 1 2147000000 DWORD 2 7 JOG INCR WEIGHT Evaluation of an increment with INC handwheel RESET MAX AX VELO Maximum axis velocity NEW CONF 10000 0 0 plus DOUBLE 2 7 JOG VELO RAPID Rapid treverse in jog mode RESET 10000 0 0 plus DOUBLE 2 7 JOG VELO Jog axis velocity RESET 2000 0 0 plus DOUBLE 2 7 CORR VELO Axis veloc
14. Alarm Number 700000 0 Flag 1 Flag 2 Text User alarm 1 700000 00 1st user alarm text is assigned by the user 700001 00 2nd user alarm text is assigned by the user 700002 00 3rd user alarm text is assigned by the user 700003 00 4th user alarm text is assigned by the user 700004 00 5th user alarm text is assigned by the user 700005 00 6th user alarm text is assigned by the user If no user alarm text is assigned by the user the operator panel will display only the alarm number The 96 character in the alarm text is the code for the additional variable The variable type is the representation type of the variable 70003100 32nd user alarm the text is assigned by the user Number The alarm text must be here Comment line does not appear in the dialog window of the Operator Panel SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 4 55 Start Up 4 3 Starting up the PLC 4 3 4 4 56 The following variable types are possible 90 Integer decimal number 1 Integer decimal number U Unsigned decimal number 960 Integer octal number X Integer hexadecimal number Binary representation of 32 bit value 96 F 4 byte floating point number User alarm text examples e 700000 Only user alarm number 700001 Hardware limit switch X axis e 700002 960 Only variable
15. PLC Bit 2 18000001 Machine function TEACH IN 18000002 18000003 General selection status signals from MMC retentive area Data block Byte 19001000 PLC Bit 7 Interface MMC Bit 4 Bit 3 PLC Bit 2 19001001 MMC PLC 19001002 MMC PLC 19001003 MMC PLC Machine axis number for h B andwheel 1 A 19001004 PLC Machine axis number for h B andwheel 2 A 19001005 PLC 19001006 PLC SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 6 117 Technical Appendix 6 2 PLC user interface signals Control signals to operator panel retentive range Interface PLC Bit 3 Data block Byte Bit 4 19005001 19005002 19005003 6 2 7 Status signals from MCP Machine control panel signals MCP signals Interface 10000000 8 JOG 7 6 Bit 4 5 free Bit 3 4 free free 2 free 10000001 16 Axis key 15 Spindle start 14 Spindle stop 13 Spindle start 12 MDA 11 SBL 10 AUTO 9 REF 10000002 24 Axis key 23 Axis key 22 Axis key 21 Axis key 20 Axis key 19 Axis key 18 Axis key 17 Axis key 10000003 27 NC START 2
16. 0 5 is entered for axis 7 MD 32200 POSCTRL GAIN 1 2 5 is entered The searched entry for the Z axis in 1 1 MD 32910 DYN MATCH Ispindle lz 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 spindle the exact value for POSCTRL_GAIN is dis played on the service display MD 32900 DYN_MATCH_ENABLE must be set to 1 Example service display for Z axis with POSCTRL_GAIN 2 437 in 1 000 min Exact calculation 1 1 60 MD 32910 DYN_MATCH_TIME 1 i 0 0954 5 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 MD 32900 DYN MATCH ENABLE has been set to 1 for the drilling axis it should also be set to 1 for all interpolating axes This increases the traversing accuracy along the con tour However the entries for these axes in MD 32910 DYN MATCH TIME n must be left at the value 0 compensation The falsification of axis travel due to mechanical backlash can be compensated cf Technical Ma
17. MD32020 1 VELO 1 lt 32050 1 JOG REV VELO 1 7 129 Manual Machine 7 7 Operation without machine control panel MCP 7 7 Operation without machine control panel MCP If you wish to run the control system without machine control panel MCP then connect a jumper between pin 24 and pin 5 to connector X1002 on the installed operator panel other wise the cotnrol system will not power up 7 8 I O assignment the standard PLC program The standard PLC program supplied with the Toolbox is designed 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 10 0 Reference switch X axis X2003 Pin 2 DIO 10 1 Reference switch Z axis X2003 Pin DI 1 10 2 Limit position X axis X2003 Pin 4 DI 2 10 3 Limit position Z axis tailstock collision switch X2003 Pin 5 DI 3 10 4 2003 6 014 10 5 Chuck guard closed X2003 Pin 7 DI 5 10 6 Lubrication filling level X2003 Pin 8 DI 6 10 7 Lubrication pressure X2003 Pin 9 DI 7 11 0 2004 2 DI8 114 Protective door closed X2004 Pin 3 DI 9 11 2 Drive ready X2004 Pin 4 DI 10 11 3 121 monitoring of drive tripped X2004 Pin 5 DI 11 11 4 X2004 Pin 6 DI 12 11 5 X2004 Pin 7 DI 13 11 6 Spindle jogging key X2004 Pin 8 DI 14 11 7 X2004 Pin 9 DI 15 SINUMERIK 802C 7 130 6FC5 597 3AA20 0BP2 01 0
18. 1 ES 4 SINUMERIK 802C 6FC5 597 20 2 01 02 6 115 Technical Appendix 6 2 390x1001 axis PLC user interface signals 390x1002 axis Lubrica tion pulse 390x1003 axis Signals from spindle Data block Byte 39032000 spindle Interface Change gear C Set gear stage B A 39032001 spindle Actual di rection of rotation CW Spindle within set range Set speed increased Set speed limited Speed limit exceeded 39032002 spindle Acti Control ve spindle m Recipro cating mode ode Position ing mode Tapping without compen sating chuck 39032003 spindle 6 2 6 Signals from to MMC Program control signals from MMC retentive area see also signals to channel V32000000 Data block DBB 17000000 MMC gt PLC Dry run feed selected 01 selected Interface MMC PLC 17000001 MMC PLC Program test selected Feed override for rapid traverse selected 17000002 6 116 Select Skip SINUMERIK 802C 6FC5 597 20 2 01 02 Technical Appendix MMC gt 6 2 PLC user interface signals 17000003 MMC gt PLC Dynamic mode signals from MMC Data block Byte 18000000 Bit 4 Interface MMC Bit 3
19. 2 1 33001005 continu ous Axis 2 i Active machine function n WCS 1000 INC 100 INC 33001006 33001007 33001008 Traversing plus command minus Axis 31 Handwheel active 2 1 33001009 continu ous Axis Active machine function n WCS 1000 INC 100 INC 33001010 33001011 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 6 111 Technical Appendix 6 2 PLC user interface signals Transfer of auxiliary functions from the NC channel Werace PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Modify de coded M func tions 0 99 25000000 25000001 Modify T funct 1 25000002 25000003 Decoded M signals MO M99 Data block Interface Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Dynamic M functions 25001000 7 6 5 4 M3 M2 M1 MO Dynamic functions 25001001 15 14 M13 M12 M11 M10 M9 M8 Dynamic M functions 25001002 M23 M22 M21 M20 M19 M18 M17 M16 Dynamic M functions 25001012 99 98 97 96 25001013 SINUMERIK 802C 6 112 6FC5 597 20 2 01 02 Technical Appendix 6 2 PLC user interface signals 25001014 25001015
20. 1 MD 12010 MN OVR FACTOR SPEED 12 1 05 MD 12010 MN OVR FACTOR SPEED 13 1 1 MD 12010 MN OVR FACTOR AX SPEED 14 1 2 MD 12010 MN OVR FACTOR AX SPEED 15 1 2 MD 12010 MN OVR FACTOR AX SPEED 16 1 2 MD 12010 MN OVR FACTOR SPEED 17 1 2 MD 12010 MN OVR FACTOR SPEED 18 1 2 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 7 133 Manual Machine 7 9 Default assignment of special data for the Manual machine MD 12010 MN FACTOR SPEED 19 1 2 MD 12010 MN OVR FACTOR SPEED 20 12 MD 12010 MN FACTOR 21 1 2 MD 12030 MN FACTOR FEEDRATE I 0 1 MD 12030 MN FACTOR FEEDRATE 0 2 MD 12030 FACTOR FEEDRATE 3 0 3 MD 12030 FACTOR FEEDRATE 0 4 MD 12030 MN FACTOR FEEDRATE S 0 5 MD 12030 FACTOR FEEDRATE 6 0 6 MD 12030 FACTOR FEEDRATE 7 0 7 MD 12030 MN FACTOR FEEDRATE 8 0 8 MD 12030 MN FACTOR FEEDRATE S 0 9 MD 12030 MN OVR FACTOR FEEDRATE 10 0 95 MD 12030 MN OVR FACTOR FEEDRATET 11 1 MD 12030 MN OVR FACTOR FEEDRATE 12 1 05 MD 12030 MN FACTOR FEEDRATE 13 14 MD 12030 MN FACTOR FEEDRATE 14 12 MD 12030 MN OVR FACTOR FEEDRATE 1
21. 35400 Reciprocation speed 35410 Acceleration when reciprocating 35430 Start direction in reciprocation 35440 Reciprocation time for M3 direction 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 default password for access level 2 from EVENING to your own password If the machine manufacturer uses the password EVENING for access level 2 during the start up work the password must be changed Press the softkey Change passw Enter the new password and press OK to confirm Note the password in the Manufacturer Documentation SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 4 87 Start Up 4 7 Commissioning 2 Reset the access level 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 final 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 softkey Save data 4 7 5 Cycle start up Sequence of operations When
22. Download Upload Compare 4 4 PLC applications Download Upload Copy Compare This function is used to write the transferred data to the permanent memory load memory of the control system Download the PLC project using the PLC 802 Programming Tool Step 7 connect on Series start up using the WinPCIN tool PLC MD PLC project and user alarm texts Data In The loaded PLC user program is transferred from the permanent memory to the user memory when the control is booted next time it will be active from this moment The PLC applications can be saved using the PLC 802 Programming Tool or the tool PCIN Upload PLC project using the 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 Series start up Start up Data using the tool PCIN PLC MD PLC Project and user alarm texts Data Out Read out PLC applications using the Tool PCIN PLC Project information and user alarm texts Data Out 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 Calling via the softkey Diagnosis Service Display Version Project The transmitted project including user program which is active in the PLC after the control System has powered up The programmer can use the first comment line in the program title of the PLC 802 Pro gra
23. Invert Byte If EN 1 EN VB IB MB AC Constant LB VB IB QB MB AC LB Invert Word If EN 1 EN VW T C IW QW MW Constant LW VW T C IW QW MW LW Invert DWord If EN 1 EN VD ID QD MD Constant LD VD ID QD MD AC LD 4 66 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 Start Up 4 3 Starting up the PLC SHIFT AND ROTATE OPERATIONS Instruction Ladder Symbol Valid Operands Shift Right If EN 1 Enable EN Shift Left a a SR c bits VB IB QB MB AC Constant LB a a SL c bits VB IB QB MB AC VB IB QB MB AC Constant LB Shift Right If EN 1 EN Shift Left a aSRcbits VW T C IW QW MW AC Constant LW SL c bits VW T C IW QW MW AC LW VB IB QB MB AC Constant LB DWord Shift R If EN 1 EN DWord Shift L a a SR c bits VD ID QD MD AC Constant LD a a SL c bits VD ID QD MD AC LD VB IB QB MB AC Constant LB Instruction Valid Operands Convert Double Word Integer to a Real Convert a Real to a Double Word In If EN 1 convert the double word in teger i to a real number o If EN 1 convert the real number i to EN VD ID QD MD AC Constant LD VD ID QD MD AC LD EN VD ID QD MD AC Constant LD teger a double word inte VD ID QD MD AC LD ger o PROGRAM CONTROL FUNCTIONS Instruction Valid Operands Jump to Label Label
24. N10 M5 Spindle stop N20 G4 F15 Dwelling if necessary spindle must have stopped safely what can also be provided by the PLC user program N30 M23 M23 will be the new direction signal N40 S200 New spindle speed and start of rotation N100 M5 Spindle stop PLC programming according to the particular conditions and requirements taking into account what was mentio ned below M23 and M24 for example are the M commands for the direction signals and must be eva luated accordingly by the user program then the direction signal must be set SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 6 123 Technical Appendix 6 3 Application note unipolar spindle control This sheet has been left empty for your notes SINUMERIK 802C 6 124 6FC5 597 3AA20 0BP2 01 02 Manual Machine 7 This description should be understood as an addition to the Start up Guide for the Sinumerik 8025 Therefore only the special features of the Sinumerik 8025 with regard to the Manual machine user interface will be described here 7 1 Hardware and software requirements for the installation Hardware Notice To ensure that the software is installed successfully when installing the software both for the first time and whenever installing new software in the future if the Manufacturer protection level is not enabled in the control system the 802C standard operator panel OP 020 is re
25. X8 OP020 Connector type 25 sub D plug connector SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 2 21 Installing the Control System 2 3 Connecting the individual components Table 2 1 Pin assignment of connector X8 X8 Pin Signal Type Pin Signal Type 1 14 P24 OP 2 _ VO 15 3 OPDO O 16 OPD1 N O 4 OPD1 17 OPD2N lo 7 T 5 OPD2 O 18 OPD3_N O 6 OPD3 O 19 O 7 20 OPCP2N O 5 8 OPCP2 21 8 TE EE 9 OPS 22 ENRXD_N iS 10 ENRXD 23 ENTXD 11 ENTXD O 24 ENRTSN 12 ENRTS O 25 P24 OP VO 13 Connector pin assignment on the 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 OPDO 3 OPDO 16 OPD1 4 OPD1 17 OPD2 pn 5 OPD2 18 OPD3 pee s 6 OPD3 19 OPCPI_N I 2 7 20 OPCP2 N I 5 8 OPCP2 21 OPS N 25 9 5 22 OPTXDN O n Sc A 10 OPTXD O 23 OPRXD I 11 OPRXD 24 OPCTSN I 12 OPCTS 25 24 13 VI 2 22 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 Installin
26. quired in addition to the machine control panel because of the keys for entering the pass word The following components are required to install the Sinumerik 802S C MM software Software PG PC or laptop with CD ROM drive and serial interface V24 V24 data cable 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 Jumper on connector 1002 pin 24 gt pin 5 if no machine control panel MCP is con nected The following requirements must be fulfilled and the following components must be provided SINUMERIK 802C PG PC or laptop with operative WinPCIN program if not yet installed install it from the Toolbox CD ROM with up to date toolbox for Sinumerik 8025 MM At least software version 03 01 06 8025 or higher must be installed on the Sinumerik 802S C otherwise the operating system must be updated 6FC5 597 20 2 01 02 7 125 Manual Machine 7 2 7 2 Loading the software Loading the software Preparatory work If an operator panel other than the standard operator panel OP 020 is installed on the machine and an initial or subsequent installation is carried out with which not the Manu facturer protection level is set in the control system then the currently installed operator panel must be replaced by the standard operator panel OP 020 If
27. 1 I I LI 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 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 SINUMERIK 802C 6 120 6FC5 597 3AA20 0BP2 01 02 Technical Appendix 6 2 PLC user interface signals 700012 700011 16000002 Activation of alarm no 700023 700022 700021 700020 700019 700018 700017 700016 16000003 Activation of alarm no 700031 700030 700029 700028 700027 700026 700025 700024 Variable for alarm Data block Byte 16001000 16001004 16001008 16001116 16001120 16001124 Interface PLC MMC Variable for alarm 700000 Variable for alarm 700001 Variable for alarm 700002 Variable for alarm 700029 Variable for alarm 700030 Variable for alarm 700031 Active alarm response Data block Byte 16002000 Interface PLC MMC Feed Read in NC start lock disable inhibited of all axes Bit 7 16002001 16002002 16002003 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 6 121 Technical Appen
28. 11 15 4 Rapid traverse override axes X2004 Pin 6 DI 12 15 5 Star handle 0 position X2004 Pin 7 DI 13 15 6 Cycle start key X2004 Pin 8 DI 14 15 7 Cycle stop key X2004 Pin 9 DI 15 All inputs marked with a possess an inverted logics i e their meanings refer to the signal status LOW and with all of the remaining inputs to the signal status HIGH SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 7 131 Manual Machine 7 8 assignment in the standard PLC program 7 8 2 Assignment of the digital outputs 1st module 00 0 2005 2 DOO O 0 1 Pulse enable drive I RF module X2005 Pin 3 DO 1 00 2 Pulse enable drive X2005 Pin 4 DO2 00 3 Coolant pump ON X2005 Pin 5 DO 3 00 4 Secondary power ON X2005 Pin 6 DO 4 00 5 Fault general X2005 Pin 7 DO 5 00 6 Fault lubrication X2005 Pin 8 DO6 00 7 X2005 Pin 9 DO 7 01 0 Ready X2006 Pin 2 DO 8 O 1 1 X2006 Pin 3 DO9 O1 2 X2006 Pin 4 DO 10 O1 3 Lubrication axes X2006 Pin 5 DO 11 01 4 2006 6 DO 12 01 5 2006 7 DO 13 016 2006 8 DO 14 O 1 7 X2006 Pin 9 DO 15 2nd module O2 0 Spindle contactor control X2005 Pin 2 DOO O2 1 X2005 Pin 3 DO 1 O22 Bypass axis limit switch X2005 Pin 4 DO2 O23 X2005 Pin 5 DO3 O24 X2005 Pin 6 DO 4 02 5 2005 7 DO5 02 6 X2005 Pin 8 DO 6 02 7 X2005 Pin 9 DO 7 03 0 X2006 Pin 2 DO 8 03 1 X2006 P
29. 7 2 7 2 7 2 7 2 7 2 7 2 7 N 2 7 N 2 7 2 7 2 7 SINUMERIK 802C 6FC5 597 20 0 2 01 02 Technical Appendix 6 1 List of machine and setting data 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 0 0 plus DOUBLE 2 7 8000 35140 GEAR STEP MIN VELO LIMIT rev min Minimum speed of gearsetp gear stage no 0 5 NEW CONF always 5 5 10 20 40 80 0 0 plus DOUBLE 2 7 35150 SPIND DES VELO TOL Factor Spindle speed tolerance RESET always 0 1 0 0 1 0 DOUBLE 2 7 35160 SPIND EXTERN VELO LIMIT rev min Spindle speed limitation from PLC NEW CONF always 1000 0 0 plus DOUBLE 2 7 35200 GEAR STEP SPEEDCTRL ACCEL rev s 2 Acceleration in speed control mode gear stage no 0 5 NEW CONF always 30 30 25 20 15 10 2 by 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 NE 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 ACCEL TYPE DRIVE Type of acceleration RESET 0 0 1 BO
30. Conditional Return from Subroutine Conditional End If EN 1 go to la bel n Label marker for the jump If EN 1 exit the subroutine If EN 1 END minates the main Scan Enable ter Enable EN WORD 0 127 WORD 0 127 EN EN SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 4 67 Start Up 4 3 Starting up the PLC PROGRAM CONTROL FUNCTIONS Instruction Ladder Symbol Valid Operands Subroutine If EN 7 go to sub n Label Constant 0 63 routine n SBR EN x1 x2 x3 x optional paramet MOVE FILL AND FIND OPERATIONS Instruction Ladder Symbol Valid Operands Move Byte If EN 1 Enable EN copy i to o VB IB QB MB AC Constant LB VB IB QB MB AC LB Move Word If EN 1 EN copy i to o VW T C IW QW MW AC Constant LW VW T C IW QW MW AC LW Move DWord If EN 1 EN copy i to o VD ID QD MD AC Constant LD VD ID QD MD AC LD Move Real If EN 1 EN copy i to o VD ID QD MD AC Constant LD VD ID QD MD AC LD Swap Bytes If EN 1 SWAP Enable EN exchange MSB and EN ENO In VW IW QW MW T C AC LW LSB of w IN 4 3 7 Programm organization 4 68 Each programmer should divide the user program into several closed program sections sub routines The 57 200 programming language allows the user to create structured user pro grams There are two program types main programs and subroutines Eight p
31. MD 14510 MN USER DATA INT 0 300 MD 14510 MN USER DATA INT 1 20 MD 14510 MN USER DATA INT 2 600 MD 14514 MN USER DATA 0 1000 MD 14514 MN USER DATA FLOAT 1 22 MD 14514 MN USER DATA FLOAT 2 15 MD 18118 MN MM NUM GUD MODULES 2 MD 18120 MN NUM NAMES 14 MD 18150 MN MM GUD VALUES MEM 30 MD 20150 MC RESET VALUES 7 2 MD 20150 MC RESET VALUES 14 2 MD 20150 MC GCODE RESET VALUES 7 1 MD 31090 JOG INCR WEIGHT AX1 0 0005 MD 32084 HANDWH STOP COND AXI H2ff MD 32084 MA_HANDWH_STOP_CONDIAX3 H2ff MD 35040 MA SPIND ACTIVE AFTER RESET AX4 1 MD 35160 MA SPIND EXTERN VELO LIMIT AX4 18 Setting data MD41110 SN JOG SET VELO 500 MD 41120 SN JOG REV SET VELO 0 2 MD 41130 5 JOG ROT AX SET VELO 100 MD 41200 SN JOG SPIND SET VELO 100 MD 42100 SC DRY RUN FEED 10 MD 42440 SC FRAME OFFSET INCR PROG 0 MD 42442 SC TOOL OFFSET INCR PROG 0 MD 43300 SA ASSIGN FEED PER REV SOURCE AX4 0 R parameters R 4 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 7 135 SINUMERIK 802C 6FC5 597 20 2 01 02 Index Index A Access levels 4 42 Boot messages 4 48 C Configuration of the RS232 interface connection X8 2 27 Connecting handwheels X10 2 29 Connecting NCREADY X20 2 30 Connecting the digital inputs and outputs X2003 X2006 2 31 Connecting the Feed Drive
32. STEP7 connect V24 interface remains active even after restart or normal power up The connection STEP7 connect active to the control system can be checked in the PLC 802 Programming Tool menu PLC Information If the interface is active e g the active PLC mode Run Stop is displayed in this window Testing and monitoring the user program The user program can be analyzed or checked for errors using the following methods PLC Status menu PCU e Status list menu e PLC 802 Programming Tool see Help menu gt Contents and Index Debugging or docu mentation 57 200 Automation System Section Testing and Monitoring Your Program SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 4 69 Start Up 4 4 PLC applications Download Upload Copy Compare 4 4 PLC applications Download Upload Copy Compare The user can save or copy PLC applications in the control system or overwrite them by an other PLC project This is possible using the Programming Tool 802 e WinPCIN binary file PT PLC 804 Download Upload Compare Permanent memory 1 PLC project 2 3 PLC user PLC machine texts data 2 Toolbox 1112113 Series start up WINPCIN Fig 4 5 PLC applications in the control system 4 70 SINUMERIK 802C 6FC5 597 20 2 01 02 Start Up
33. are thus stable over a PLC cycle The user program can be created by means of the PLC 802 Programming Tool using the pro gramming language 57 200 in conjunction with ladder diagrams LAD A ladder diagram is graphical programming language to represent electrical circuit diagrams This Documentation describes the program structure and the instruction set of the PLC in de tail Commissioning of the PLC The SINUMERIK 802C comes to the user with a simulation program included The SAMPLE user program is stored in the permanent memory This sample program and the documentation are included in the SINUMERIK 802SC Toolbox component PLC802SC Li brary The simulation program is intended for the first function test of the control system after assem bling the control Internal simulation program The simulation program is integral part of the 802C system software The simulation program allows operation of the control system without digital input and output modules The user pro gram processes all firmly defined keys and the default setting of the axis keyboard default Axes and spindle are switched to simulation mode No real axis movement is carried out The Axis Spindle Disable user signal is set for each axis For this reason the movements of the axes and of the spindle are simulated virtually The user can use this program to test the inter relation of the components Operator Panel Machine Control Panel ENC SINUMERIK 802
34. assignment Interface for digital outputs Connector designation X2005 X2006 OUT Connector type 10 pin plug connector Table 2 17 Connector pin assignment Pin Name Type 1 1P24 DOO DO1 DO2 DO4 DO5 DO6 DO7 1M24 O lt O OOP O O O O lt 2006 I 5 Name 2P24 DO8 DO9 DO10 DO11 DO12 DO13 DO14 DO15 2M24 O lt ooooloooo lt A o SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 2 33 Installing the Control System 2 3 Connecting the individual components Signal names DOO 15 Digital outputs 24V 0 5A Signal type V Voltage input Output 24 V signal Table 2 18 Electrical parameters of the digital outputs Parameter Value Unit Note 1 signal nominal voltage 24 V Voltage drop max 3 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 2 34 X2005 T z 1 o o coro 410 A QooooGQGQoQoQooooqoqqooo X2006
35. gree 360 degrees MD31080 Inter reso 310 D lution 20 3 4 1 0 7 0 360 1 1000 Inter 5 1 reso 0 8 lution 0 0 4 1 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 ges exist Gear stage 1 Motor spindle 2 5 1 Gear stage 2 Motor spindle 1 1 SINUMERIK 802C 6FC5 597 20 2 01 02 Start Up 4 7 Commissioning Gear stage 1 Internal 360 degrees MD31080 MD31050 i resolution MD M M 310 D D 0 20 3 3 0 4 1 1 0 0 0 i 7 6 n 0 0 r d e 9 Internal 360 degrees 1 1 ib t resolution 4 1 1 00 7 2 04 pul 3 8 se 5 5 9 Ses de 4 g 5 One encoder increment corresponds to 43 945 internal increments One encoder increment corresponds to 0 043945 degrees minimum positioning step Machine data default settings for analog motor axes The machine 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 Output type of setpoint 0 1 setpoint
36. has to be adapted according to the particular mechanical conditions Too high gain will result in vibrations too low gain in a too high following error It is imerative that the drive observes the set 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 display Servo Trace operating area cf User Manual Operation Dynamic adaptation for thread G331 G332 Function The dynamic response of spindle and involved axis for the function G331 G332 thread inter polation can be adapted to the slower control loop Usually this concerns the Z axis which is adapted to the more inert response of the spindle If an exact adjustment is carried out it is possible to sacrifice of a compensating chuck for tapping At least higher spindle speeds smaller compensation paths can be achieved SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 4 81 Start Up 4 7 Commissioning Activation The values for the adaptation are entered in MD 32910 DYN MATCH TIME n usually for the axis The adaptation is only possible if MD 32900 DYN MATCH ENABLE 1 has bee set for the axis spindle With active funct
37. limit frequency 300000 36302 T limit frequency at which encoder is switched on again Hystere 99 9 Zero mark monitoring encoder no 0 1 0 Zero mark monitoring off encoder HW monitoring on 36310 1 99 gt 100 Number of recognized zero mark errors 0 during monitoring 100 Zero mark monitoring off encoder HW monitoring off 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 encoder adjustment Number Description Spindle 31040 Encoder mounted directly to the machine encoder no 0 1 31020 Encoder markings per revolution encoder no Incr rev Incr rev 31080 Numerator resolver gearbox encoder no Motor revs Load rev 31070 Denominator resolver gearbox encoder no Enc revs Enc revs 31060 Numerator load gearbox control parameter set 0 5 Motor revs Motor revs 31050 Denominator load gearbox control parameter no 0 5 Load revs Load revs SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 4 77 Start Up 4 7 4 78 Commissioning Example 1 for encoder matching Axis with rotary encoder 500 pulses mounted directly on the motor The internal multiplica tion factor is 4 The internal computational resolution amounts to 1 000 increments per de
38. 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 selected technology path from the toolbox diskette into the control sy stem via the V24 interface 3 Carry out POWER ON 4 Reload the recovered data SINUMERIK 802C 4 88 6FC5 597 3AA20 0BP2 01 02 Start Up 4 7 Commissioning 4 8 Series machine start up Functionality The objective of series machine start up is after commissioning in order to bring another control system connected to the same ma chine type with minimum effort to the condition as after commissioning or under service conditions after replacing hardware components to bring a new control System to the initial state with minimum effort Precondition To carry out commissioning a PC PG provided with a V24 interface for data transfer from to the control system is necessary In the PC PG the PCIN tool must be used Sequence of operations 1 Create the series machine start up file transfer from the control system to the PC PG Make a V24 cable connection between the PC PG COM port and the SINUMERIK 8025 X8 Make the following settings in the WinPCIN tool Binary format Receive data Select the path where you want to save
39. name Machine data MD and setting data SD are differed either by numbers or names Both the number and the name are displayed on the screen Parameters Activation Activation Protection level Unit Standard value Range of values The activation levels are listed according to their priority Any data changes come into effect after POWER ON po switching on off the SINUMERIK 8025 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 RESET re RESET key on the machine control panel MCP or M2 m30 at the end of the program IMMEDIATELY im after entering a value Protection level To display machine data protection level 4 or higher must be activated Start up or machine data input generally requires protection level 2 or higher password EVE Unit Depending on the MD SCALING SYSTEM IS the physical units of the MD are set as follows MD10240 1 MD10240 0 mm in mm min in min m s in s m s3 in s3 mm rev in rev If no physical units are applicable to the MD the field contains a SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 4 43 Start Up 4 1 General Note The default setting of the machine data is MD10240 SCALING SYSTEM IS METRIC 1 metric With the INCH scaling system MD10240 0 MD203 4 di
40. no machine control panel MCP is connected to the installed operator panel then con nect a jumper pin 24 2 pin 5 to the connector X1002 of the operator panel otherwise the control system will not power up Use an appropriate cable to connect PG PC or laptop on which an operative WinPCIN program is installed to the V24 interface of the Sinumerik connector X2 Supplementary installation conditions If a language other than the first language is installed switch to the second language English to install the Manual machine Installing the software 7 126 To ensure successful installation it is imperative to observe the sequence described below Start the WinPCIn software on your PG PC or laptop 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 Turn on the control system Use the key to switch to the Data area Press the Diagnosis function key Press the Start up function key Use the key to extend the menu range Press the Set passw function key Type EVENING and press the OK function key Make sure that the message Access level Manufacturer is displayed otherwise repeat the password input Select the key to switch back to the Data area Press the Services function key Press the Settings fucntion key Press the V24 binary function key Accept the settings displayed in the WinPCIN soft
41. 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 connect several DI O16 components it may be necessary to remove the right hand connector from the housing 6 Slide the components onto the DIN rail tilt it down and screw it tight Removing the control system The control components are removed as described above in the reverse order SINUMERIK 802C 6FC5 597 20 2 01 02 2 15 Installing the Control System 2 1 Installing and removing the SINUMERIK 802C Warning Before removing the control components always first make sure that the system is discon nected from the mains SINUMERIK 802C 2 16 6FC5 597 3AA20 0BP2 01 02 Installing the Control System 2 1 Installing and removing the SINUMERIK 802C Mounting dimensions The dimensions shown below are important for installing the control components 250 170 300 CT SubD
42. the machine data and not the part programs is not pos sible Saving data internally Use the ETC key to extend the menu in the Diagnosis Start up menu and press the Save data softkey Loading data from an internal data backup Boot the control system using the start up switch position 3 If the data in the backed up memory area are lost on POWER ON the data saved in the permanent memory area are automatically reloaded into the memory Note The note 4062 Data 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 well as always at the end of start up External data backup variants 1 The data record is read out completely creating the series start up file This is intended for series start up or to restore the control system status after replacing hardware compo nents or after data loss 2 Files are read in or read out by areas The following user data can be selected as indivi dual files Data Machine data Setting data Tool data R parameters Zero offset Compensation data LEC Part programs Standard cycles SINUMERIK 802C
43. the system software using a PC PG 5 91 5 2 Updating the system software incl user data without using a 5 92 5 3 Update errors sis ie eee ees epp phukoq eee ds 5 93 6 Technical 6 94 6 1 List of machine and setting 6 94 6 1 1 Display machine 1 6 94 6 1 2 General machine data 6 96 6 1 3 Channel specific machine 6 96 6 1 4 Axis specific machine data 6 97 6 1 5 Selling ala nu eite a da SO Ext 6 103 6 2 PLC user interface 6 105 6 2 1 0 sodes bett teer desuper rosa 6 105 6 2 2 Retentive data area 6 106 6 2 3 NOK signals neta ah aaa es 6 107 6 2 4 Channel signals 5 rene cer enne hben senes RV RUE 6 108 6 2 5 Axis spindle signals ood eet ele eer e e I tone 6 113 6 2 6 Signals from to ec erbe renale ree ee eH ee ter Ge a
44. 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 Start data outp to output the series machine start up file 2 Reading in the series machine start up file into the SINUMERIK 8025 SINUMERIK 802C Enter the V24 interface settings as described under 1 Press the Data In Start button in the Service menu The control system is thus ready to receive data Use the PCIN tool in the PC PG to select the series start up file from the DATA OUT menu and start data transfer The control system is brought to RESET with rebooting three times during and at the end of data transfer On completion of error free data transfer the control system is completely configured and ready to operate 6FC5 597 3AA20 0BP2 01 02 4 89 Start Up 4 7 Commissioning Series machine start up file 4 90 The series machine start up file contains machine data R parameters display and alarm text files display machine data PLC user program main programs subroutines cycles SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 Software Update 5 5 1 Updating the system software using a PC PG General The following reasons may require a system software update You wish to install new system software new software versi
45. 0 MM V24 PPI ADDR MMC PPI address of the HMI 4 0 MM V24 PPI MODEM ACTIVE Modem active 0 0 MM V24 PPI MODEM BAUD Modem baud rate 7 5 MM V24 PPI MODEM Modem parity 0 0 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 126 126 126 6 1 List of machine and setting data Immediately Byte Immediately Byte Immediately Byte Immediately Byte Immediately Byte Immediately Byte POWER ON Byte POWER ON BYTE POWER ON BYTE POWER ON BYTE Immediately BYTE Immediately BYTE Immediately BYTE 2 3 2 3 2 3 2 3 2 3 2 3 2 2 3 3 3 3 3 3 3 3 3 3 3 3 6 95 Technical Appendix 6 1 List of machine and setting data 6 1 2 General machine data Number MD Name Unit Name Miscellaneous HW function Standard value Minimum value 10074 PLC IPO TIME RATIO PLC task factor for main run 2 1 10240 SCALING SYSTEM IS METRIC Basic system metric always 1 rd 11100 AUXFU MAXNUM GROUP ASSIGN Number of auxiliary functions distr amongst aux fct groups always 1 1 11200 INIT MD HEX Standard machine data loaded on next Power On always OxOF 11210 UPLOAD MD CHANGE ONLY HEX Saving only of modified MD value 0 complete no difference OxOF 11310 HANDWH REVERSE Threshold for direction change handwheel always 2 0 0 11320 HANDWH IMP PER LATCH Handwheel pulses per detent position handwheel number 0 1 always T 14510 USER DATA INT n k
46. 00000 to FFFFFFFF FLOAT DWORD Real values from 8 43 10 37 to 3 37 1039 Display machine data 1 3 3 MD Name Name Miscellaneous Activated User Class w r Standard value Minimum value Maximum value Data type MM FIRST LANGUAGE Foreground language Power On 2 8 1 2 Byte MM DISPLAY RESOLUTION Display resolution Power On 2 3 0 5 Byte MM USER CLASS WRITE TOA GEO User class Write tool geometry Immediately 2 3 0 7 Byte MM USER CLASS WRITE TOA WEAR User class Write tool wear data Immediately 2 3 0 7 Byte 3 SINUMERIK 802C 6FC5 597 20 2 01 02 Technical Appendix 208 Decimal 0 210 Decimal 0 216 Decimal 0 217 Decimal 0 219 Decimal 0 277 Decimal 0 278 Decimal 0 280 Decimal 0 281 Decimal 0 282 Decimal 0 283 Decimal 0 284 Decimal 0 285 Decimal 0 MM USER CLASS WRITE ZOA User class Write settable zero offset 3 0 7 MM USER CLASS WRITE SEA User class Write setting data 3 0 7 MM USER CLASS WRITE RP User class Write R parameters d 0 7 MM USER CLASS SET V24 User class Set V24 3 0 7 MM USER CLASS DIR ACCESS User class access directory 3 0 MM USER CLASS PLC ACCESS User class access PLC project 3 0 7 MM SYSTEM FUNC 5 Option data to enable system specific functions 0 0 MM V24 PPI ADDR PLC PPI address of the PLC 2 0 MM V24 PPI ADDR NCK PPI address of the NCK 3
47. 00004 E D Rapid traverse override 3 32000005 H G E D C B Feed 1 Rapid tra Program Delete Read in override verse level distance disabled enabled override abortion to go enabled 32000006 NC stop axes plus spindle NC stop to block limit 32000007 NC start NC start inhibited Notes 1 Feed override enabled Even if the feed override is not enabled 100 the 0 position is active 2 Feed override 31 positions Gray code with 31 MD for weighting 3 4 Rapid traverse override 31 positions Gray code with 31 MD for 96 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 Data block Byte Bit 7 Interface PLC gt Bit 6 Bit 2 32001000 Traversing keys Rapid traverse override Axis 1 i Traversing key lock n WCS Feed stop Activate handwheel 2 32001001 continu ous Axis 1 i n WCS 1000 INC Machine 100 INC function 10 INC 32001002 32001003 32001004 Traversing keys Rapid traverse override Axis 2 i Traversing key lock n WCS Feed Stop Activate handwheel 2 32001005 continu ous Axis 21 Machine n WCS function 1000 INC 100 INC 32001006 32001007 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 6 109 Technical Appen
48. 10 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 0 5 500 35140 Minimum speed of gearsetp gear stage no 0 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 0 35300 Position control switch on speed 500 35350 Direction of rotation when positioning 3 35400 Reciprocation speed 500 35410 Acceleration during reciprocating 16 35430 Starting direction during reciprocation 0 35440 Reciprocation time for M3 direction 1 35450 Reciprocation time for M4 direction 0 5 35510 Feedrate enable for spindle stopped 0 36000 Exact positioning coarse only 0 04 SPOS 36010 Exact positioning fine only 0 01 SPOS 36020 Delay exact positioning fine only 1 SPOS SINUMERIK 802C 6FC5 597 20 2 01 02 Start Up 4 7 Commissioning Number Explanation n ue 36030 Zero speed tolerance only 0 2 SPOS 36040 Delay zero speed monitoring only 0 4 SPOS 36050 Clamping tolerance only 0 5 SPOS 36060 Maximum velocity speed axis spindle stopped 5 axis only 0 0138 SPOS spindle Threshold value for velocity monitoring control parameter set 0 5 11500 36200 taxis 31 94 spindle 36300 Encoder
49. 1000 0 0 0 REFP MOVE DIST Reference point distance target point for distance coded system 2 0 REFP MOVE DIST CORR Reference point offset absolute offset distance coded 0 0 CAM SHIFT plus plus plus Electr cam offset of incremental measuring systems with equidistant zero marks 0 0 0 0 REFP SET POS Reference point value irrelevant for distance coded system 0 0 0 0 0 REFP CYCLE NR Sequence of axes channel specific referencing 1 No obligatory reference point for NC Start 0 No channel specific reference point approach 1 15 Sequence in channel specific reference point approach 1 4 ENC REFP MODE Type of position measuring system plus 31 0 No ref point appr if an absolute encoder exists SET POS accepted 1 Zero pulse on encoder track 1 0 GEAR STEP CHANGE ENABLE Gear change possible Spindle has several gear steps 0 m SPIND ACTIVE AFTER RESET Own spindle reset 0 T SPIND VELO LIMIT Maximum spindle speed 10000 0 0 GEAR STEP MAX VELO Maximum speed for gear change gear stage no 0 5 500 500 1000 2000 4000 0 0 8000 6 plus plus RESET RESET RESET RESET RESET POWER ON RESET RESET RESET POWER ON POWER ON POWER ON POWER ON NEW CONF DOUBLE BOOLEA DOUBLE DOUBLE DOUBLE DOUBLE DOUBLE DOUBLE DWORD BYTE BOOLEA BOOLEA DOUBLE DOUBLE 2 7 2 7 2 7 2
50. 2 Manual Machine 7 8 assignment in the standard PLC program 2nd module 12 0 Retract axis bypass limit switch X2003 Pin 2 DIO 12 1 Q21 230V power supply missing X2003 Pin DI 1 12 2 X2003 Pin 4 DI2 12 3 Q4 Motor circuit breaker coolant pump tripped X2003 Pin 5 DI3 12 4 Q2 Motor circuit breaker spindle external ventilation tripped X2003 Pin 6 DI 4 12 5 Coolant pump is ON X2003 Pin 7 DI5 12 6 Single block active X2003 Pin 8 DI6 12 7 EMERGENCY STOP X2003 Pin 9 DI7 13 0 X2004 Pin 2 DI8 13 1 X2004 Pin DI 9 13 2 X2004 Pin 4 DI 10 13 3 2004 5 DI 11 13 4 Spindle CCW rotation X2004 Pin 6 DI 12 13 5 Spindle CW rotation X2004 Pin 7 DI 13 13 6 Handwheel evaluation bit 1 X2004 Pin 8 DI 14 13 7 Handwheel evaluation bit 2 X2004 Pin 9 DI 15 3rd module 14 0 Spindel override bit 1 X2003 Pin 2 DIO 14 1 Spindel override bit 2 X2003 Pin DI 1 14 2 Spindel override bit 3 X2003 Pin 4 DI 2 14 3 Spindel override bit 4 X2003 Pin 5 DI 3 14 4 Feed override bit 1 X2003 Pin 6 014 14 5 Feed override bit 2 X2003 Pin 7 DI 5 14 6 Feed override bit 3 X2003 Pin 8 DI 6 14 7 Feed override bit 4 X2003 Pin 9 DI 7 15 0 Star handle axis direction X2004 Pin2 DI 8 15 1 Star handle axis direction X X2004 Pin 3 DI 9 15 2 Star handle axis direction Z X2004 Pin 4 DI 10 15 3 Star handle axis direction Z X2004 Pin 5 DI
51. 2 36 2 6 LEDs and operating elements the ENC 2 38 Installing the Drives 3 39 Start UPa usa als Saam inisa 4 41 4 1 Generals aee Sedan degen nt ee 4 41 4 1 1 Access level ii 5 Being NUES pauk OR 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 e dete 4 44 4 2 Turning on and booting the control system 4 46 4 2 1 Boot MESSAGES ese ett ted tale eee DP des 4 48 4 3 Startirig upithe PLG chee re reb ed ber PR due 4 49 4 3 1 Commissioning of the PLC 4 49 4 3 2 Start up modes of the PEG laine eene eee ea 4 51 4 3 3 PEG alarms ence tr nb ore LEE ebrei dune 4 52 4 3 4 Machine control panel MCP layout 4 56 4 3 5 PEG programming donee Ende nue eed reed e rd ed 4 57 4 3 6 InstructlOn Set ceed SAN susu eska bass 4 61 4 3 7
52. 5 1 2 MD 12030 5 FACTOR FEEDRATE 16 1 2 MD 12030 OVR FACTOR FEEDRATE 17 12 MD 12030 MN FACTOR FEEDRATE 18 12 MD 12030 MN OVR FACTOR FEEDRATE 19 1 2 MD 12030 MN OVR FACTOR FEEDRATE 20 12 MD 12030 MN FACTOR FEEDRATE 1 12 MD 12050 OVR FACTOR RAPID TRA 1 0 1 MD 12050 MN FACTOR RAPID TRA 2 0 2 MD 12050 MN FACTOR RAPID TRA 3 0 3 MD 12050 MN FACTOR RAPID 0 4 MD 12050 MN FACTOR RAPID TRA 5 0 5 MD 12050 OVR FACTOR RAPID TRA 6 0 6 MD 12050 MN FACTOR RAPID TRA 7 0 7 MD 12050 MN FACTOR RAPID TRA B8 0 8 MD 12050 MN FACTOR RAPID TRA 9 0 9 MD 12050 OVR FACTOR RAPID TRA 10 0 95 MD 12050 MN FACTOR RAPID TRA 11 1 MD 12050 MN FACTOR RAPID TRA 12 1 MD 12050 MN FACTOR RAPID TRA 13 1 MD 12050 MN FACTOR RAPID TRA 14 1 MD 12050 MN FACTOR RAPID TRA 15 1 MD 12050 MN FACTOR RAPID TRA 16 1 MD 12050 MN FACTOR RAPID TRA 17 1 MD 12202 MN PERMANENT FEED 0 350 MD 12202 MN PERMANENT FEED I 1000 7 134 SINUMERIK 802C 6FC5 597 20 2 01 02 Manual Machine 7 9 Default assignment of special data for the Manual machine MD 12202 MN PERMANENT FEED 2 2000 MD 12202 MN PERMANENT FEED 3 3500
53. 6 NC STOP 25 NC RE SET 10000004 Feed override C 10000005 Control signals to MCP ass PLG gt MCP pindle override C 6 118 SINUMERIK 802 6FC5 597 20 2 01 02 Technical Appendix 6 2 PLC user interface signals 11000000 11000001 6 2 8 PLC machine data INT values MD 14510 USER DATA INT Data block Interface gt PLC ine aeNGK PLO T Int value WORD 2 bytes Int value WORD 2 bytes Int value WORD 2 bytes Int value WORD 2 bytes An 17 a a HEX values MD 14512 USER DATA HEX Data block 45001000 Hex value BYTE 45001001 Hex value BYTE 45001002 Hex value BYTE 45001003 Hex value BYTE 45001030 Hex value BYTE 45001031 Hex value BYTE SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 6 119 Technical Appendix 6 2 PLC user interface signals FLOAT values MD 14514 USER DATA FLOAT Data block 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 value REAL 4 bytes 45002028 Float value REAL 4 bytes HEX BYTE values MD 14516 USER DATA ALARM Interface NCK gt B
54. 6FC5 597 3AA20 0BP2 01 02 4 45 Start Up 4 2 Turning on and booting the control system Saving data externally Use the Services Data outp menu to transfer the following user data as individual files to an external PC via the V24 interface Loading data from an external data backup into the control system Press the Start data inp softkey in the Services menu 4 2 Turning on and booting the control system Approach Inspect the system visually for proper mechanical installation with tight electrical connections supply voltages connections for shielding and grounding 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 Meaning 0 Normal power up 1 Power up with default machine data user data determined by the software version System software update Power up with saved data PLC stop Reserve Assigned WwW Assigned The switch position comes into effect with next power up and is displayed on the screen when the control system powers up SINUMERIK 802C 4 46 6FC5 597 20 2 01 02 Start Up 4 2 Turning on and booting the contro
55. 9 POWER ON always T STRING 2 7 22030 AUXFU ASSIGN VALUE Auxiliary function value aux fct channel 0 49 POWER ON always 0 DWORD 2 7 22550 TOOL 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 branch 0 POWER ON always 0 0 2 2 7 30200 ENCS Anzahl der Geber 1 oder kein Geber f r die Spindel RESTART 1 0 1 BYTE 2 7 30240 ENC TYPE Type of actual value acquisition actual position value encoder no POWER ON 0 Simulation 2 Square wave generator standard encoder pulse multiplication 3 Encoder for stepper motor always 0 0 0 4 BYTE 2 7 30350 SIMU AX VDI OUTPUT Output of axis signals with simulation axes POWER ON always 0 S um BOOLEAN 2 7 30600 FIX POINT POS mm de Fixed value positions of axis with G75 position no POWER ON grees always 0 0 DOUBLE 2 7 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 6 97 Technical Appendix 6 1 31000 always 31010 mm always 31020 always 31030 mm always 31040 always 31050 always 31060 always 31070 always 31080
56. B User data INT 0 31 always 0 14512 USER DATA HEX n kB User data Hex 0 31 0 0 14514 USER DATA FLOAT n User data Float 0 7 0 0 14516 USER DATA PLC ALARM n 5 User data Hex Alarm bit O 31 0 0 6 1 3 Channel specific machine data Number MD Name Unit Name Miscellaneous HW function Standard value Minimum value 6 96 Activated Maximum value 50 50 plus OxFF OxFF POWER ON POWER ON POWER ON POWER ON RESTART POWER ON POWER ON POWER ON POWER ON POWER ON POWER ON Activated Maximum value D type DWORD User class 2 7 BOOLEAN 2 7 BYTE BYTE BYTE BYTE DOUBLE DWORD BYTE DOUBLE BYTE D type 2 7 2 7 2 7 2 7 2 7 2 7 2 7 2 7 2 7 User class SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 Technical Appendix 6 1 List of machine and setting data 20210 CUTCOM CORNER LIMIT Degrees Maximum angle for compensation blocks with TRC POWER ON always 100 0 0 150 DOUBLE 2 7 20700 REFP NC START LOCK NC Start disable without reference point RESET always 1 0 1 BOOLEAN 2 7 21000 CIRCLE ERROR CONST mm Circle end point monitoring constant POWER ON always 0 01 0 0 plus DOUBLE 2 7 22000 AUXFU ASSIGN GROUP Auxiliary function group aux fct no in channel 0 49 POWER ON _always 1 1 15 2 7 22010 AUXFU ASSIGN Auxiliary function type aux fct no in channel 0 4
57. BLE DOUBLE DOUBLE DOUBLE BOOLEAN DOUBLE DOUBLE DWORD D type DOUBLE DOUBLE 2 7 2 7 2 7 2 2 2 7 2 7 2 7 2 7 2 7 2 7 2 7 User class 4 4 4 4 6 103 Technical Appendix 6 1 List of machine and setting data 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 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 SINUMERIK 802C 6 104 6FC5 597 3AA20 0BP2 01 02 Technical Appendix 6 2 PLC user interface signals 6 2 PLC user interface signals The following tables of the user interface signals between PLC and NC and vice versa are handled by the integrated fixed user program These signals can be displayed using PLC Status in the Diagnosis Start Up PLC Status menu 6 2 1 Address ranges Operand Identifier Description Range V Data V0 0 to V79999999 7 see below T Timers TO to T15 Counters to C31 Image of digital inputs 10 0 to 17 7 Q Image of digital outputs Q0 0 to Q7 7 M Flags MO 0 to M127 7 SM Special flags SMO 0 to SM 0 6 see below AC ACCU ACO AC3 Generat
58. C 6FC5 597 3AA20 0BP2 01 02 4 49 Start Up 4 3 Starting up the PLC Approach Set MD20700 to zero e Use the Diagnosis StartUp switch PLC softkey to select Simulation You can check the current setting via Diagnosis Service display Version PLC applica tion Select the desired key and check your setting by pressing the key Supported keys Mode selection B Axis keys 0090 UWL e NC keys agao Note 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 Reference Point is not supported Standard user program The control system comes with the SAMPLE user program for simple turning machines which is stored in the permanent memory SINUMERIK 802C 4 50 6FC5 597 3AA20 0BP2 01 02 Start Up 4 3 2 Start up modes of the PLC The PLC can activate its start up modes from two places Table 4 4 Normal power up Position 0 Power up with default values Position 1 Power up with saved data Position 3 PLC Stop after POWER ON Position 4 Diagnosis Start up Start up switch NCK softkey Start up modes Operator Panel Start Up Menu NCK start up Normal power up Power up with default values Power up with saved data PLC start up Restart Restart and debug mode Restart with simulation Overall reset Over
59. K 802C 6FC5 597 20 2 01 02 Start Up 4 4 1 General Start up requirements The following is required User s Guide Operation and Programming SINUMERIK 802C PC PG programming device only for data saving and series start up Toolbox on CD CD is either supplied with the control system or can be ordered separately Contents see also p 1 11 The mechanical and electrical installation of the equipment must be completed Note Installation notes are to be found in Chapter LEERER MERKER 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 specific machine data Match encoder with spindle Match setpoint with spindle 6 Dry run for axes and spindle s 7 Drive optimization 8 Complete start up data saving SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 4 41 Start Up 4 1 General 4 1 1 Access levels Protection levels The SINUMERIK 802C provides a protection level concept for enabling data areas The pro tection levels range from 0 to 7 whereby 0 is the highest and 7 the lowest level The control system comes with default passwords for protection levels 2 and 3 If necessary these passwords can be changed by the appropriate authorized person
60. OLEAN 2 7 35300 SPIND POSCTRL VELO rev min Position control switch on speed NEW CONF always 500 0 0 plus DOUBLE 2 7 35350 SPIND POSITIONING DIR Direction of rotation when positioning RESET always 3 3 4 BYTE 2 7 35400 SPIND OSCILL DES VELO rev min _ Reciprocation speed NEW CONF always 500 0 0 plus DOUBLE 2 7 35410 SPIND OSCILL ACCEL rev s 2 X Acceleration during reciprocating NEW CONF always 16 2 ye DOUBLE 2 7 35430 SPIND OSCILL START DIR Starting direction during reciprocation RESET 0 2 As last direction of rotation zero speed M3 3 direction 4 MA direction always 0 0 4 BYTE 2 7 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 6 101 Technical Appendix 6 1 35440 S always 35450 S always 35510 always 36000 mm deg always 36010 mm deg always 36020 S always 36030 mm deg always 36040 S always 36050 mm deg always 36060 always 36100 mm deg always 36110 mm deg always 36120 mm deg always 36130 mm deg always 36200 mm min rev min _always 6 102 List of machine and setting data SPIND_OSCILL_TIME_CW Reciprocation time for M3 direction 1 0 SPIND_OSCILL_TIME_CCW Reciprocation time for M4 direction 0 5 SPIND_STOPPED_AT_IPO_START Feedrate enable for spindle stopped 0 STOP_LIMIT_COARSE Exact positioning coarse 0 04 STOP_LIMIT_FINE Exact positionin
61. R Switch off the control system and back on again POWER ON DRAM Carry out a software update ERROR Replace the hardware components BOOT 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 RB o m SINUMERIK 802C 4 48 6FC5 597 20 2 01 02 Start Up 4 3 General 4 3 1 4 3 Starting up the PLC Starting up the PLC The PLC is a store programmable logic controller for simple machines It has no hardware of its own and is used as a software PLC in the SINUMERIK 802C control system The task of the PLC is to control machine related functional sequences The PLC executes the user program cyclically A PLC cycle is always executed in the same sequence of order Update process image inputs outputs user interface timers Process communication requests Operator Panel PLC 802 Programming Tool Execute user program Evaluate alarms Output process image outputs user interface The PLC executes the user program cyclically starting from the first up to the final operation Access from user program is only carried out via the process image and not directly to the hardware inputs or outputs The hardware inputs and outputs are updated by the PLC at the beginning and at the end of program execution The signals
62. 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 Input Output Voltage output Table 2 11 Cable for WinPCIN Pin assignment of the Sub D connector 9 25 1 Shield 1 2 RxD 2 3 TxD 3 4 DTR 6 5 M 7 6 DSR 20 7 RTS 5 8 CTS 4 9 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 Installing the Control System 23 Connecting the individual components 2 3 5 Connecting handwheels X10 Pin assignment of the connector on the ENC side Handwheel interface Connector designation X10 MPG Connector type 10 pin mini Combicon plug connector Table 2 12 Pin assignment of connector X10 X10 Pin Name Type 1 A1 2 A1 1 1 4 1 O O 5 P5 MS VO O 6 M5MS vO 7 2 O 8 A2_N 10 9 B2 10 2 Signal names A1 A1 N Track A true and negated handwheel 1 B1 B1 N Track B true and negated handwheel 1 A2 2 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 Voltage output Input 5 V signal Handwheels Two electronic handwheels can be connected which must meet the following requirements Transmission method 5 V squ
63. Start Up 01 2002 Edition 01611405341 SINUMERIK 802C SIEMENS SIEMENS SINUMERIK 802C Start Up Valid for Control Software Version SINUMERIK 802C 01 2002 Edition 3 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 SINUMERIK Documentation Printing history Brief details of this edition and previous editions are listed below The status of each edition is shown by the code in the Remarks column Status code in the Remarks column 7 New documentation Unrevised reprint with new Order No Revised edition with new status If actual changes have been made on the page since the last edition this is indicated by a new edition coding in the header on the page Edition Order No 04 00 6FC5597 3AA20 0BP2 01 02 6FC5597 3AA20 0BP2 Remark A This Manual is included on the documentation on CD ROM DOCONCD Edition Order No 11 02 6FC5298 6CA00 0AG3 Trademarks Remark C SIMATIC SIMATIC SIMATIC NET SIROTEC SINUMERIK and SIMODRIVE are registered trademarks of Siemens Third parties using for their own purposes any other names in this document which refer to trademarks might infringe upon the rights of trademark owners This publication was produced with Interleaf V 7 The reproduction transmission or use of this document or its contents is not permitted
64. V 4 pin screw type terminal block for connecting the 24 V load power supply X2 RS232 interface V24 9 sub D plug connector X3 to X5 measuring system interfaces ENCODER three 15 sub D plug connectors for connecting incremental position encoders RS422 X6 spindle interface SPINDLE 9 sub D socket for connecting a spindle drive with analog interface X7 drive interface AXIS 50 sub D socket connector for connecting the power sections for a maximum of four analog drives including spindle X8 operator terminal interface OPI 25 pin D Sub female connector for connecting the operator terminal X10 handwheel interface MPG 10 pin front connector for connecting the handwheels X20 digital inputs DI 10 pin front connector for connecting the NC READY relay LEDs X2003 and X2004 10 pin front connector for connecting digital inputs X2005 and X2006 10 pin front connector for connecting digital outputs 3 LEDs for fault and status displays Operating elements Start up switch S SINUMERIK 802C 6FC5 597 20 2 01 02 2 19 Installing the Control System 2 2 Interfaces and cables Connecting cables The components are wired up as shown in the Connection Diagram 2 4 For the cables requi red please refer to the diagram below Wire 1 0 2 5 Machine RS232 Control Op Panel Panel 1 flat or round
65. W C IW QW MW Constant LW VW T C IW QW MW LW EN VD ID QD MD AC Constant LD VD ID QD MD AC LD EN VW T C IW QW MW AC Constant LW VD ID QD MD AC LD EN VW T C IW QW MW AC Constant LW VD ID QD MD LD EN VD ID QD MD AC Constant LD VD ID QD MD AC LD EN VD ID QD MD AC Constant LD VD ID QD MD AC LD SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 4 65 Start Up 4 3 Starting up the PLC INCREMENT DECREMENT Increment Decrement Byte Increment Decrement Word Instruction If EN 1 1 1 If EN 1 1 1 Ladder Symbol Enable Valid Operands EN VB IB QB MB AC Constant LB VB IB QB MB AC LB EN VW T C IW QW MW AC Constant LW VW T C IW QW MW LW Increment If EN 1 EN Decrement 1 VD ID QD MD Constant LD a a 1 ID QD MD AC LD LOGIC OPERATIONS Instruction Ladder Symbol Valid Operands Byte AND If EN 1 Enable EN Byte OR b aANDb VB IB QB MB AC Constant LB Byte XOR b aORb VB IB QB MB AC LB b aXORbD Word AND If EN 1 EN Word OR b aANDb VW IW QW MW LW Word XOR b aORb Constant VW T C IW QW MW AC LW b aXORb DWord AND If EN 1 EN DWord OR b aANDb VD ID QD MD AC Constant LD DWord XOR b aORb VD ID QD MD AC LD b aXORb
66. age may result if the appropriate pre cautions are not taken Caution indicates that minor personal injury or material damage may result if the appropriate precautions are not taken Caution without a warning triangle means that a material damage can occur if the appropriate precau tions are not taken Attention 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 safety notices provided in this Manual are persons who are authorized to start up ground and tag devices systems and circuits according to the relevant safety standards Usage as per intended purpose ZN Please observe the following Warning The device may only be used for the cases of application as intended by the Catalog and only in conjunction with third party devices and components recommended or approved by Siemens The proper and safe operation of the product requires transport storage and installation according to the relevant instructions and qualified operation and maintenance at the prescribed intervals SINUMERIK 802C 6 5 597 20 2 01 02 V Table
67. all reset and de bug mode PLC Program Selection Program Status User program User program User program Unchanged User program User program Simulation pro gram User program User program 4 3 Retentive Data Up Unchanged Deleted Saved data Unchanged Unchanged Unchanged Unchanged Deleted Deleted Starting up the PLC MD for the PLC in the User Interface Accept active PLC MD Standard PLC MD Saved PLC MD Accept active PLC MD Accept active PLC MD Accept active PLC MD Accept active PLC MD Accept active PLC MD Accept active PLC MD 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 the PLC to remain in PLC Stop after the control system has powered up All power up modes that have been set either via softkeys or via hardware start up switches will only come into effect after the next power up of the control system The hardware start up switch PLC STOP position 4 is active immediately The priority of the power up modes activated via the softkeys on the ope rator panel is higher than that of the hardware start up switches SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 4 51 Start Up 4 3 Starting up the PLC 4 3 3 Example Hardware start up switch position 3 e R
68. any prin ting errors when reading this publi cation please notify us on this sheet Suggestions for improvement are also welcome SINUMERIK 8025 802 Document Structure General Documentation Catalog SINUMERIK 8025 SINUMERIK 802C Turning Milling L User Manual Operation and Proaramming SINUMERIK 802S SINUMERIK 802 Turning a gt SINUMERIK 802S SINUMERIK 802C Milling L User Manual Diagnostics Guide gt SINUMERIK 802S SINUMERIK 802C Turning Milling LLL Technical Manual Start Up SINUMERIK 802S 2 Truning Milling Appendix Turning LY SINUMERIK 802C Turning Milling Technical Appendix Turning L 4 Technical Manual Description of Functions SINUMERIK 8025 SINUMERIK 802C Turning Milling L
69. are wave TTL level or RS422 Signals Track A as true and negated signal Track B as true and negated signal Ua SINUMERIK 802C 6FC5 597 20 2 01 02 2 29 Installing the Control System 23 Connecting the individual components Max output frequency 500 kHz Phase offset between tracks A and B 90 x30 Supply 5 V max 250 mA 2 3 6 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 13Pin assignment of connector X20 X20 Pin Name Type 11 NCRDY 1 12 NCRDY 2 11 13 reserved 01 14 reserved 2 15 reserved DI 16 reserved DI E 17 reserved 18 reserved 20 19 reserved VI 20 reserved VI Signal names NCRDY 1 2 NC Ready NCREADY contacts 1 2 Signal type K Switching contact NC READY output Readiness in the form of a relay contact NO must be integrated into the EMERGENCY STOP circuit 2 30 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 Installing the Control System Table 2 14 Electrical parameters of the NCREADY relay contact Connecting the individual components Parameter Max Unit DC switching voltage 50 V Switching current 1 A Switching power 30 VA EMERGENCY STOP X20 11 NCREADY X20 12 Machine c
70. art Up 4 3 Starting up the PLC WORD COMPARES Signed Instruction Ladder Symbol Valid Operands Load Word b close a a de T C IW QW MW AC Constant z m b tap T C IW QW MW AC Constant Load Word a gt b close a And Word gt a lt b open 4 gt gt B Load Word lt a lt b close a And Word a gt b open Or Word lt DOUBLE WORD COMPARES Signed Instruction Ladder Symbol Valid Operands Load DWord a bclose a a VD ID QD MD AC Constant LD And DWord Zb open rL b VD ID QD MD AC Constant LD Or DWord 5 Load DWord gt a 2 b close a And DWord gt a b open o Or DWord 5 Load DWord lt a b close a And DWord a b open ce Or DWord lt REAL WORD COMPARES Signed Instruction Ladder Symbol Valid Operands Load RWord z b close a a VD ID QD MD AC Constant LD And RWord b open L d b VD ID QD MD AC Constant LD Or RWord z x Load RWord gt a 2 b close a And RWord gt a b open L Or RWord gt Load RWord lt a b close a And RWord gt bopen Or RWord 5 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 4 63 Start Up 4 3 Starting up the PLC TIMER Instruction Ladder Symbol Valid Operands Timer Retentive EN 1 Start Enable IN On Delay EN 0 Stop 50 If Tv
71. as an integer decimal number 700003 Alarm number with fixed alarm text and variable X 700004 960 Alarm number with variable and fixed alarm text 700005 Rotation monitoring of axis active U Operator panel display 700005 Rotation monitoring of axis active 1 700005 Rotation monitoring of axis active 3 Machine control panel MCP layout The machine control panel in the standard version has been configured for simple turning ma chines 2 axes and one spindle The user can use the keys 1 6 and the associated LEDs the same applies to keys 1 6 for his own purposes The keys 16 24 should be used as axis keys see sample program SAMPLE The program mer can assign the axis keys depending on his particular machine type SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 Start Up 4 3 Starting up the PLC Layout when delivered from product release 2 Key number for configurable key assignment Ca a i a a a Included separately 1 27 keys 1 27 see user interface Available as accessories Spindle override switch and Emergency Stop button Fig 4 3 Layout of the machine control panel DOWD OB wea 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 57 200 Automatio
72. as in start up switch position 1 Any deviations from normal booting are displayed on the screen Booting with default machine data Start up switch position 1 Result The user memory area not loaded with default data is erased and the default machine data are loaded from the permanent memory into the user memory Booting with saved data Start up switch position 3 Result The user data backed up on the permanent memory are loaded into the user memory Contrast control See User s Guide Operation and Programming SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 4 47 Start Up 4 2 Turning booting the control system 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 in the following The ERR flashes and the DIAG LED does not flash Fig 4 1 Table 4 3 Boot errors Error Message Remedial Action ERROR 1 Check the connections of the plugged or connected modules EXCEPTION PLC D IO modules ERRO
73. atue PT TO T15 Tpi 1 Preset PT VW T C IW QW MW AC Constant 100 ms T0 T15 Timer On Delay EN 1 Start Enable IN EN 0 Stop 50 If Tvalue PT TO T15 Tpi 1 Preset PT VW T C IW QW MW AC Constant 100 ms T0 T15 Timer Of Delay If Tvalue lt Enable IN Tpit 1 TOF 50 10 715 Preset PT VW T C IW QW MW AC PT Constant 100 ms TO T15 COUNTER Instruction Ladder Symbol Valid Operands Count Up CU 7 Value 1 Cnt Up CU R 1 Reset Ped a eset If Cvalue 2 PV 50 1 Cxxx C0 31 Preset PV VW T C IW QW MW AC Constant LW Count Up Down CU 7 Value 1 Cnt Up CU CD 1 S2 R 1 Reset Cnt Dn a 1 Pv Reset R bit 50 Cxxx C0 31 Preset PV VW T C IW QW MW AC Constant LW Count Down If Cvalue 0 Cxxx Cnt Down CD Cbit 1 52 CD Reset R LD 50 PV Cxxx C0 31 Preset PV VW T C IW QW MW AC Constant LW SINUMERIK 802C 4 64 6FC5 597 20 0 2 01 02 Start Up 4 3 Starting up the PLC MATH OPERATIONS Instruction Word Add If EN 1 Word Subtract b a b b b a DWord Add If EN 1 DWord Subtract b a b b b a Multiply If EN 1 b axb Divide If EN 1 b b a Out 16 bit remainder Out 2 16 bit quotient Add If EN 1 Subtract b a b Real Numbers b b a Multiply If EN 1 Divide b axb Real Numbers b b a Ladder Symbol Enable Valid Operands EN V
74. branch 0 Type of actual value ac quisition actual position 30240 value encoder no 0 2 0 Simulation 2 Encoder external Encoder markings per re Steps per encoder revolu 31020 volution encoder no tion 31030 Pitch of leadscrew 10 Leadscrew pitch Denominator Load gear transmission 31050 box control parameter 1 g ratios no 0 5 SINUMERIK 802C 6 5 597 20 2 01 02 4 79 Start Up 4 7 Commissioning Number Description Default Value Setting or Remark Nominator load gearbox Load gear transmission 31060 control parameter no 1 ratios 0 5 MD31080 MD31050 Denominator resolver ge Load osartransmiesi n 31070 arbox control parameter 1 g no 0 5 Nominator resolver gear Load gear transmission 31080 box control parameter 1 ratios no 0 5 MD31080 MD31050 32000 Maximum axis velocity 10000 30 000 max axis velo city Traversing direction not Reversal of direction of 32100 aer 0 control direction movement Sign actual value control Measuring system rever 32110 ER 0 direction encoder no sal 32200 Servo gain factor control 10 1 0 position controller parameter set 0 5 gain Rated output voltage The speed defined in 32250 80 MD32260 is reached at the setpoint of 8 V 32260 Rated motor speed set 3000 Motor speed point branch 0 34070 Reference p
75. ch off the control system 7 Turn the start up switch to position 1 gt switch on the control system 8 9 Prior to next POWER ON start up switch to O position Booting with default values Note Reload the externally saved user standard data via V24 5 2 Updating the system software incl user data without using a PC PG General It is possible to transfer the entire contents of the memory of the control system including user data 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 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 on permament memory Carry out POWER ON for slave control system gt control system changes to the up date condition Various patterns appera on the screen After the patterns on the screen have disappeared switch on the master control system on the slave control 3 data blocks are transferred 5 92 SINUMERIK 802C 6FC5 597 20 2 01 02 Software Update
76. d 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 General machine data Axis machine data e Other machine data Display machine data SINUMERIK 802C 6FC5 597 20 2 01 02 4 73 Start Up 4 7 Commissioning Once entered these data are immediately written to the data memory The machine data are activated depending on the Activation setting of the appropriate ma chine data Section 4 1 2 Note Since these data are only stored in the memory backed up for a limited period of time a data backup is necessary see Section 4 1 4 Machine data The following machine data list contains all general and other machine data and setting data which can be changed if necessary Setting data 4 74 Number Description piii 10074 Division ratio of the PLC task factor for main run 2 11100 Number of auxiliary function groups 1 11200 Standard machine data loaded on next Power On 11210 MD backup of changed MD only OFH 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 fu
77. default criterion Cancel criteria are POWERONCLEAR The alarm is canceled by switching off switching on the control sy stem CANCELCLEAR The alarm is canceled by pressing the Cancel key or the Reset key analogously to NCK alarms SELF CLEARING The alarm is cleared because the cause resulting in the alarm has been eliminated or does not exist any longer Desired alarm responses are defined for each alarm in the PLC By default the PLC uses the SHOWALARM response bitO bit5 0 SINUMERIK 802C 6FC5 597 20 2 01 02 Start Up 4 3 Starting up the PLC Possible alarm responses are PLC Stop The user program is no longer executed the NC Ready relay drops out and the hardware outputs are disabled OUTDS EMERGENCY STOP The PLC provides the EMERGENCY STOP signal to the NCK in the user interface after the user program has been executed Feed disable The PLC provides the Feed Disable signal to the NCK in the user interface after the user program has been executed Read in disable The NCK provides the Read in Disable signal to the NCK in the user interface after the user program has been executed NC Start inhibited The PLC provides the NC Start Inhibited signal to the NCK after the user program has been executed SHOWALARM This alarm has no alarm response bit0 bit5 0 Priority of cancel conditions The cancel conditions have the following priority POWER ON CLEAR syste
78. dix 6 2 PLC user interface signals 32001008 Traversing keys Rapid traverse override Axis i Traversing key lock n WCS Feed stop 2 Activate handwheel 32001009 continu ous Axis 31 Machine n WCS function 1000 INC 100 INC 32001010 32001011 Status signals from NC channel Data block 33000000 M1 active Interface NCK 33000001 Program test active 2 M30 active Block search active Revolu tional feed active Referenc ing active 33000002 33000003 Reset Channel state inter rupted active aborted inter rupted Program state stopped waiting running 33000004 NCK alarm with stop of ma chining present NCK alarm channel specific present All axes stopped All axes refer enced 33000005 33000006 33000007 6 110 SINUMERIK 802C 6FC5 597 20 2 01 02 Technical Appendix 6 2 PLC user interface signals Status signals Axes in WCS Data block Byte 33001000 Traversing plus command minus Interface Handwheel active 2 1 33001001 continu ous Axis 1 i n WCS 1000 INC Machine 100 INC function 10 INC 33001002 33001003 33001004 Traversing plus command minus Axis 2 i Handwheel active
79. dix 6 2 PLC user interface signals Axis actual value and distances to go Data block Interface PLC MMC Byte 570x0000 Axis actual value REAL 570x0004 Axis distance to go REAL SINUMERIK 802C 6 122 6FC5 597 3AA20 0BP2 01 02 Technical Appendix 6 3 Application note unipolar spindle control Technical Appendix 6 3 Application note unipolar spindle control General With SINUMERIK 802C the spindle speed setpoint is generally output in the range from 10V through 10V S M3 4 A setpoint output with positive polarity only through 10V and an additional direction signal as it is required for unipolar frequency converters can be realized via appropriate programming in the NC part program and in the PLC user program additionally two M commands for switching the direction signal and M3 for starting rotation A direction reversal may only be carried out with setpoint zero spindle at standstill It should be taken into account that the setpoint 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 lar spindle control NC programming
80. e must be observed for all data Example Flag bit MBO 1 MB3 5 Flag byte MBO MB1 MB2 Flag word MW0 MW2 MW4 MW3 5 not permissible Flag double word MDO0 MD4 MD8 MD1 MD2 MD3 MD5 are not permissible Table 4 6 PLC data types permitted in the control system Data Type Size Address Range for Logic Operations Range for Arithmetical Opera Alignment tions BYTE 00 FF 0 255 WORD 0000 FFFF 32 768 32 767 DWORD 0000 0000 FFFF FFFF 2 147 483 648 Double 2 147 483 647 Word REAL 4 bytes 4 10737 1038 PLC project In any case the PLC 802 Programming tool manages one project logic operations symbols and comments The download function is intended to store all important information of a pro ject in a control system SINUMERIK 802C 4 58 6FC5 597 3AA20 0BP2 01 02 Start Up Starting up the PLC 4 3 control system is able store max 4 000 instructions and 1 000 symbols required PLC memory is influenced by the following components Number of instructions Number and length of the symbol names Number and length of the comments 57 200 ladder diagram A ladder diagram is a graphical programming language similar to electric circuit diagrams When creating a program using the ladder diagram form then you will work with graphical components to create the networks of your logics To create your program you can use the following e
81. e signals gt Bit 2 Acknowl EMER GENCY STOP EMER GENCY STOP 26000001 Request distances to go by the axes Request actual dis tances to go by the axes 26000002 26000003 Data block Byte Interface NCK Bit 1 27000000 EMER GENCY STOP active 27000001 27000002 Drive ready 27000003 SINUMERIK 802C Ambient tempera ture alarm 6FC5 597 3AA20 0BP2 01 02 NCK alarm present 6 107 Technical Appendix 6 2 Data block Byte 30000000 PLC user interface signals Interface PLC Bit 3 JOG Mode MDA 30000001 Machine functio TEACH IN 30000002 30000003 Byte 31000000 Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 JOG Bit 1 MDA Active mode AUTOM 31000001 6 2 4 Channel signals Control signals to NC channel Data block 32000000 Bit 6 Activate dry run feed Bit 5 Activate 01 Bit 4 Activate Single Block Interface PLC Active machine function REF gt NCK TEACH IN 32000001 Activate Program Test Activate Referenc ing 32000002 Activate Skip Block 32000003 6 108 SINUMERIK 802C 6FC5 597 20 2 01 02 Technical Appendix 6 2 PLC user interface signals Feed override 320
82. esis NEW CONF always 99 9 0 100 36310 ENC ZERO MONITORING Zero mark monitoring encoder no 0 1 NEW CONF 0 Zero mark monitoring off encoder HW monitoring on 1 99 2100 Number of recognized zero mark errors during monitoring 100 Zero mark monitoring off encoder HW monitoring off always 0 0 0 0 plus 36400 CONTOU TOL mm deg Contour monitoring tolerance band NEW CONF always 1 0 EN ris 36500 ENC_CHANGE_TOL mm deg Portion of distance for backlash working NEW CONF _always 0 1 0 0 plus 36610 AX_EMERGENCY_STOP_TIME S Duration of the deceleration ramp for error states NEW CONF always 0 05 0 0 plus 36620 SERVO DISABLE DELAY TIME S Cutout delay servo enable NEW CONF always 0 1 0 0 plus 36700 DRIFT ENABLE Automatic drift compensation NEW CONF always 0 ee 36710 DRIFT_LIMIT Drift limit value for automatic drift compensation NEW CONF always 1 000 0 0 plus 36720 DRIFT VALUE 96 Drift basic value NEW CONF always 0 0 38000 MM ENC COMP MAX POINTS Number of intermediate points for interpolatory compensation SRAM POWER ON always 0 0 0 5000 6 1 5 Setting data Number MD Name Unit Name Miscellaneous Activated HW function Standard value Minimum value Maximum value 41110 JOG SET VELO mm min Axis speed for JOG Immediately always 0 0 0 0 plus 41200 JOG SPIND SET VELO rev min Speed for spindle JOG mode Immediately always 0 0 0 0 plus SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 DOUBLE DOUBLE DWORD DOU
83. estart from operator panel gt Restart is active from next power up of the control system The Run mode activates the cyclic mode In the Stop mode the following actions are initiated All hardware outputs are disabled The NC Ready relay is inactive e No cyclic operation active user program is not executed e Process image is no longer updated frozen Emergency Stop active The user can also use the PLC 802 Programming Tool to start the Stop or Run modes A corrected or new project can only be loaded into the control system in the Stop mode The user program comes only into effect with next power up or when the Run mode is active PLC alarms The control system displays a maximum of 8 PLC alarms system alarms or user alarms The PLC manages the alarm information per PLC cycle 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 4 52 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 response the PLC triggers an appropriate response Each alarm requires a cancel criterion to be defined The PLC uses the SELF CLEARING criterion as
84. g fine 0 01 POSITIONING_TIME Delay exact positioning fine 1 0 STANDSTILL_POS_TOL Zero speed tolerance 0 2 STANDSTILL_DELAY_TIME Delay zero speed monitoring 0 4 CLAMP_POS_TOL Clamping tolerance 0 5 STANDSTILL_VELO_TOL 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Maximum velocity speed axis spindle stopped 5 0 014 POS LIMIT MINUS 1st software limit switch minus 100000000 POS LIMIT PLUS 1st software limit switch plus 100000000 POS LIMIT MINUS2 2nd software limit switch minus 100000000 POS LIMIT PLUS2 2nd software limit switch plus 100000000 AX VELO LIMIT Threshold value for velocity monitoring control parameter set no 0 5 11500 11500 11500 11500 0 0 0 0 plus plus plus plus plus plus plus plus plus plus NEW CON NEW CON RESET NEW CONF NEW CONF NEW CONF NEW CONF NEW CONF NEW CONF NEW CONF RESET RESET RESET RESET NEW CONF DOUBLE 2 7 DOUBLE 2 7 BOOLEAN 2 7 DOUBLE 2 7 DOUBLE 2 7 DOUBLE 2 7 DOUBLE 2 7 DOUBLE 2 7 DOUBLE 2 7 DOUBLE 2 7 DOUBLE 2 7 DOUBLE 2 7 DOUBLE 2 7 DOUBLE 2 7 DOUBLE 2 7 SINUMERIK 802C 6FC5 597 20 0 2 01 02 Technical Appendix List of machine and setting data 6 1 36300 ENC FREQ LIMIT Hz Encoder limit frequency POWER ON always 300000 0 plus 36302 ENC FREQ LIMIT LOW Encoder limit frequency at which encoder is switched on again Hyster
85. g the Control System 23 Connecting the individual components Signal names OPDYJ O 3 LCD Data O 3 LCD Latch OPS LCD 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 Voltage output VI Voltage input Output 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 Type Pin Signal Type Pin Signal Type VO 18 BS1 VO 1 2 3 4 5 6 7 8 9 1 SINUMERIK 802C 6FC5 597 20 2 01 02 2 23 Installing the Control System 23 Connecting the individual components Signal names SWn Setpoint BSn Reference potential for setpoint RFn 1 RFn 2 Servo enable contact Signal level 85422 Signal type Signal output Axis assignment 1 X axis 2 Y axis 3 Z axis 4 Spindle SINUMERIK 802C 2 24 6FC5 597 20 2 01 02 Installing the Control System 2 3 Connecting the individual components Table 2 4 Cable assignment for type 6FX2 002 3ADO01
86. i Default 3 axes X Y and Z 1 spindle no transversal axis G17 etc If you wish to reconfigure a SINUMERIK 8025 control system to turning carry out POWER ON with the default machine data start up switch position 1 Note All memory areas are initialized or loaded with stored default values machine data The basic configuration of the SINUMERIK 802C must be carried out during the commissio ning prior to the general configuration MD input This need not to be done when series start up is carried out The configured machine data are contained in the series start up file SINUMERIK 802C 6FC5 597 20 0 2 01 02 Start Up 4 7 4 7 Commissioning Commissioning Initializing the control system 4 7 1 Overview Turn on the control system The SINUMERIK 802C will load the standard machine data automatically Entering the general machine data To make your work easier the most important machine data of the individual subranges are listed If more detailed information is required the user is referred to 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 entere
87. in3 DO 9 03 2 X2006 Pin 4 DO 10 03 3 X2006 Pin 5 DO 11 03 4 X2006 Pin 6 DO 12 03 5 X2006 Pin 7 DO 13 03 6 X2006 Pin 8 DO 14 03 7 X2006 Pin 9 DO 15 SINUMERIK 802C 7 132 6FC5 597 3AA20 0BP2 01 02 Manual Machine 7 9 Default assignment of special data for the Manual machine 3rd module O 4 0 X2005 Pin2 DOO O4 1 PLC cycle time X2005 Pin 3 DO 1 04 2 2005 4 DO2 O 4 3 2005 5 DO 3 04 4 2005 6 DO 4 04 5 X2005 Pin 7 DO5 O 4 6 2005 8 DO6 O 4 7 X2005 Pin 9 DO7 O 5 0 X2006 Pin2 DO 8 5 1 2006 009 5 2 2006 4 DO 10 05 3 X2006 Pin 5 DO 11 05 4 X2006 Pin 6 DO 12 5 5 2006 7 DO 13 O 5 6 X2006 Pin 8 DO 14 5 7 2006 9 DO 15 7 9 Default assignment of special data for the Manual machine Machine data MD 12010 MN OVR FACTOR SPEED 1 0 1 MD 12010 MN OVR FACTOR AX SPEED 2 0 2 MD 12010 MN OVR FACTOR AX SPEED S 0 3 MD 12010 MN OVR FACTOR AX SPEED 4 0 4 MD 12010 MN OVR FACTOR AX SPEED S5 0 5 MD 12010 MN OVR FACTOR AX SPEED 6 0 6 MD 12010 MN OVR FACTOR SPEED T 0 7 MD 12010 MN OVR FACTOR AX SPEED S8 0 8 MD 12010 MN OVR FACTOR AX SPEED S 0 9 MD 12010 MN OVR FACTOR SPEED 10 0 95 MD 12010 MN OVR FACTOR AX SPEED t1
88. ing on the amount of data At the completion of this process the relevant machine data and in some cases also the standard PLC program must be adapted accordingly depending on the hardware confirgura tion SINUMERIK 802C 6FC5 597 20 2 01 02 7 127 Manual Machine 7 3 Switching the user interface Two PLC projects are contained in the Toolbox e ManMach MCPptp designed for use on the standard machine control panel ManMach 3DIO ptp designed as described in Section 7 8 with I O modules 7 3 Switching the user interface From Manual Machine to Siemens standard To switch to the Siemens standard user interface proceed as follows always start from the 2nd extension of the basic menu Press the key to call the password input screenform Enter the password 1111 and press the S key to confirm 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 Press the key to switch to the main selection screenform Press the to extend the function key bar Press the Man Mach function key to switch to the manual Machine screenform area 7 4 Switching the language In the Manual Machine operating area How to switch the language in the Manual Machine operating area is described in detail in the Operat
89. ing the V address range Type Range No Subrange Addressing Identifier Channel DB No Axis No 10 00 0 000 symbolic 10 79 00 99 0 9 000 999 8 digit Definition of special flag bits SM read only Description SM 0 0 Flags with a defined ONE signal SM 0 1 SM 0 2 Buffered data lost only valid in the first PLC cycle 0 data o k 1 data lost SM 0 3 Power first PLC cycle 1 following cycles 0 SM 0 4 60 s clock alternating 0 for 30 s then 1 for 30 s SM 0 5 1 s clock alternating 0 for 0 5 s then 1 for 0 5 s PLC cycle clock alternating one cycle 0 then one cycle 17 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 6 105 Technical Appendix 6 2 PLC user interface signals Note All empty user interface fields in the following tables are Reserved for SIEMENS and may neither be 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 Byte 14000000 14000001 14000002 14000062 14000063 SINUMERIK 802C 6 106 6FC5 597 3AA20 0BP2 01 02 Technical Appendix 6 2 3 NCK signals Data block Byte 26000000 Bit 7 Protecti Interface PLC Bit 4 Bit 3 6 2 PLC user interfac
90. ion G331 G332 parameter block n 0 5 of the axis of MD 32910 becomes automatically active which acts corresponding to the gear stage for the spindle The gear stage is dependent on the spindle speed with M40 or is directly set by M41 M45 see also Section 4 5 3 Start up of the spindle Defaul Number Explanation Value 32900 Dynamic response adaptation 0 32910 Time constant of dynamic adaption control parameter set no 0 5 0 0 Determination of value 4 82 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 MD 32910 MATCH TIME n Ky N Spindle Ky nlaxis The entry to be made in MD 32910 requires the time unit s The values of MD 32200 POSCTRL GAIN n for spindle and axis must be converted accordingly 1000 Kv n spinde POSCTRL GAlN n spindie 60 1000 Ky Naxis GAIN n axis 60 When using further gear stages with G331 G332 the adaptation must also be carried out in these parameter blocks SINUMERIK 802C 6FC5 597 20 2 01 02 Start Up Backlash Overview Funktion 4 7 Commissioning Example for adaptation of the dynamic response of the Z axis spindle 1st gear stage parameter block 1 for spindle K MD 32200 POSCTRL GAIN 1
91. istance start and end position in the received file N 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 COMP 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 under the axis machine data from MD35000 For this reason data have to be entered for the spindle too these data are descri bed for axis start up Note With SINUMERIK 802C the 4th machine axis SP is fixed for the spindle The spindle settings for the 4th machine axis are contained in the default machine data The spindle setpoint 10 V analog voltage signal is output to X7 The spindle measuring System must be connected to X6 Spindle modes The following modes are possible for the spindle e Control mode M3 M4 5 e Oscillating mode to assist gearbox change Positioning mode SPOS MD for spindle see MD for axis and spindle SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 4 85 Start Up 4 7 Commissioning SD for spindle Number Description pn e 43210 Progr spindle speed limitation G25 0 43220 Progr spindle speed limitation G26 1000 43230 Spindle speed limitation with G96 100 Spindle MD parameterization S
92. ity for handwheel override ext ZO cont dressing distance control RESET 50 0 0 plus DWORD 2 7 DIR Traversing direction not control direction POWER ON 1 1 1 DWORD 2 7 SINUMERIK 802C 6FC5 597 20 0 2 01 02 Technical Appendix 32110 always 32200 1000 min always 32250 96 always 32260 rev min always 32300 mm s 2 rev s 2 always 32450 mm always 32700 always 32900 32910 32920 S always 33050 mm deg always 34000 always 34010 always 34020 mm min rev min always 34030 mm deg always ENC FEEDBACK POL Sign actual value control direction encoder no 1 4 POSCTRL GAIN Servo gain factor control parameter set no 0 5 2 5 2 5 2 5 1 0 0 RATED_OUTVAL Ratedoutput voltage setprint brauch 0 80 0 0 RATED VELO Rated motor speed setpoint branch 0 3000 0 0 MAX AX ACCEL Axis acceleration 1 0 BACKLASH Backlash 0 000 ENC COMP ENABLE Interpolatory compensation encoder no 0 1 0 DYN MATCH ENABLE Dynamic response adaptation 0 0 DYN MATCH TIME Time constant of dynamic adaption control parameter set no 0 5 0 0 0 AC FILTER TIME Smoothing factor time constant for adaptive control 0 0 0 0 LUBRICATION DIST Traversing distance for lubrication from PLC 100000000 0 0 REFP CAM IS ACTIVE Axis with reference point cam 1 ek REFP CAM DIR IS MINUS Ap
93. l system Start up switch software In addition to the hardware start up switch the following functions can also be carried out in the Diagnosis Start up Start up switch menu Normal power up Start up switch position 0 e Power up with default machine data Start up switch position 1 Power up with saved data Start up switch position 3 These power up functions have a higher priority than the hardware start up switch Booting the control system When the control system is turned on for the first time an initial state of the control system is established automatically All memory areas are initialized and are loaded with previously stored default data 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 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 Control system changes to error JOG Ref point approach mode yellow LED DIAG see Fig 4 1 flashes Data in user memory Backed up user data are loaded from the permanent memory into faulty the user memory as in start up switch position 3 If no valid user data are in the permanent memory the default data are loaded
94. lements Contacts constitute 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 e Coils constitute a relay or an output which is updated by the signal flow 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 conductor bar in the ladder diagram symbolized by a vertical line at the left window through the closed contacts enabling coils or boxes Overview of commands Table 4 7 Operand identifers Operand ID Description Range V Data V0 0 to V79999999 7 see Table 4 8 Timers TO to T15 Counters CO to C31 Map of digital inputs 10 0 to 17 7 Q Map of digital outputs Q0 0 to Q7 7 M Flags MO 0 to M127 7 SM Special flags SMO 0 to SM 0 6 see Table 4 10 AC ACCU ACO AC3 Table 4 8 Generating the addresses for the V range see user interface Type Code Range No Subrange Offset Addressing DB No Channel Axis No 00 00 0 000 symbolic 00 79 00 99 0 9 000 999 8 digit SFOS 597 SAA20 08P2 01 02 4 59 Start Up 4 3 Starting u
95. m alarms highest priority CANCEL CLEAR system alarms SELF CLEARING system alarms POWER ON CLEAR user alarms CANCEL CLEAR user alarms SELF CLEARING user alarm lowest priority System alarms see Diagnostics Guide User alarms The user interface 1600 provides the user with two sub ranges for setting a user alarm Sub range 0 4 x 8 bits to set user alarms 0 1 edge Byte 0 Bit0 gt 1stuser alarm 700000 Byte 3 Bit7 gt 32nd user alarm 700031 Sub range 1 User alarm variables The respective bit sub range 0 with 0 1 edge change will activate a new user alarm Sub range 1 is intended for additional user information Sub range 2 can be used to analyze the active alarm responses Sub range 1 can only be read or written as a double word Sub range 2 can only be read You can delete self clearing alarms by resetting the respective bit in the variable range 1600 in sub range 0 1 0 edge The remaining user alarms are cleared by the PLC after detecting the respective cancel condi tion If the alarm is still present the alarm occurs again SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 4 53 Start Up 4 3 Starting up the PLC User alarm activation User interface gt gt Int inter face Alarm handler Feed disable active User program Example Feed disable 0 User alarm with feed disable
96. mming Tool for his own additional information in the version display see View Proper ties SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 4 71 Start Up 4 5 User Interface 4 5 4 6 Overview User Interface This interface includes all signals between NCK PLC and HMI PLC In addition the PLC de codes the auxiliary function commands for straightforward further processing in the user pro gram Technology Setting The SINUMERIK 802C is supplied with the default machine data as a control system for tur ning machines 2 axes 1 spindle If you wish to set another technology e g milling the rele vant machine data file must be loaded from the tool box into the control system The file with the technology machine data must be loaded after the control system has booted successfully but prior to commissioning Sequence of operations 4 72 To change the technology setting proceed as follows Make a V24 link between PG PC and the control system Turn on the control system and wait until it has booted without errors Press the Start data inp softkey in the Services menu use the V24 default interface set tings Select the technology machine data file techmill ini included in the toolbox required for milling and transfer it to the PG PC using WinPCIN e After the file has been transferred correctly carry out POWER ON The SINUMERIK 8025 is now preset to the desired technology Example techmill in
97. n System System Manual describes how this tool is operated for 57 200 802 Programming Tool is to be understood as a subset of this Documentation SINUMERIK 802C 6FC5 597 20 2 01 02 4 57 Start Up 4 3 Starting up the PLC Compared with the 57 200 MicroWin basic system please note the following The PLC 802 Programming Tool is delievered in the English language version The user program can only be programmed using ladder diagram Only a subset of the 57 200 programming language is supported The compilation of the user program is carried out either offline on a programming device PG PC or semi automatically when downloading into the control system The project can be loaded into the control system download tis also possible to load the project from the control system upload Direct data addressing is not possible therefore no programming errors will rsult during the operation 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 time otherwise the rele vant data access rules must be observed e Furthermore the data direction in the memory model alignment and the data typ
98. nction group aux fct no in channel 0 49 1 22010 Auxiliary function type aux fct no in channel 0 49 22030 Auxiliary function value aux fct no in channel 0 49 0 22550 New tool compensation for M function 0 Number Explanation pad 41110 Jog feedrate 0 41200 Spindle speed 0 42000 Start angle 0 42100 Dry run feedrate 5000 SINUMERIK 802C 6FC5 597 20 2 01 02 Start Up 4 7 2 Starting up the axes Overview 4 7 Commissioning The SINUMERIK 802C has up to three stepper motor feedrate axes X Y and Z The stepper motor drive signals are output at connector X7 for the X axis at pins 1 3 PULS1 DIR1 and axis at pins 4 6 PULS2 DIR2 and EN2 and for the Z axis at pins 7 9 PULS3 DIR3 and Simulation stepper motor drive Setpoint output and pulse feedback can be switched between simulation and drive operation using the axis MD 30130 CRTLOUT TYPE and 30240 Table 4 12 MD 30130 Simulation Value 0 To test the axis the actual value is fed back internally as an actual value No set point output at connector X7 Normal Operation 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 a
99. nd spindle Number Explanation 2 Vas 30130 Output type of setpoint setpoint branch 0 30200 Number of encoders 1 Type of actual value acquisition actual position value encoder no 30240 0 Simulation 0 2 Square wave generator standard encoder pulse multiplication 30350 Output of axis signals with simulation axes 0 31020 Encoder markings per revolution encoder no 2048 31030 Pitch of leadscrew 10 31040 Encoder mounted directly to the machine encoder no 0 31050 Denominator load gearbox control parameter no 0 5 1 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 4 75 Start Up 4 7 4 76 Commissioning Number Explanation vas 31060 Numerator load gearbox control parameter set no 0 5 1 31070 Denominator resolver gearbox encoder no 1 31080 Numerator resolver gearbox encoder no 1 32100 Traversing direction not control direction 1 32110 Sign actual value control direction encoder no 1 32200 Servo gain factor control parameter set no 0 5 1 32250 Rated output voltage 80 32260 Rated motor speed setpoint branch 0 3000 32700 Interpolatory compensation encoder no 0 1 0 33050 Traversing distance for lubrication from PLC 100 000 000 35010 Gear change possible Spindle has several gear steps 0 35040 Own spindle reset 0 35100 Maximum spindle speed 10000 351
100. nts notice SINUMERIK 802C viii 6FC5 597 20 2 01 02 SINUMERIK 802C Control System 1 1 1 Components of the SINUMERIK 802C What is SINUMERIK The SINUMERIK 802C is a microprocessor controlled numerical control system for simple machine tools with stepper motor drives Hardware components It consists of the following hardware components ENC Control component for a maximum of analog axes and an analog interface for a main spindle drive Economical Numerical Control e OP020 NC operator panel with graphics display and keyboard MCP machine control panel DI O16 16 binary inputs outputs each extendable to max 64 by using 4 modules SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 1 9 SINUMERIK 802C Control System 1 1 Components of the SINUMERIK 802C Fig 1 1 NCODEENTOD X3 X I5 GET Rio External analog drive SINUMERIK 802C hardware components example configuration Software components The SINUMERIK 802C comprises the following software components which can be ordered System software on the permanent flash memory of the ENC B
101. nual Description of Functions The axis specific actual value is corrected by the backlash compensation value MD32450 BACKLASH with each change of the traversing direction SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 4 83 Start Up 4 7 Commissioning Activation The backlash compensation is active in all operating modes only after referencing Leadscrew error compensation LEC Overview Function Activation AN 4 84 The compensation values are determined by means of the measured error curve and entered in the control system using special system variables during start up The compensation tables cf Technical Manual Description of Functions must be created in the form of NC programs The leadscrew error compensation LEC changes the axis specific actual position by the as sociated compensation value If the compensation values are too high an alarm message can be output e g contour moni toring speed setpoint limitation The LEC is only activated in all operating modes if the following requirements are met 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 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 pro g
102. of Contents Table of Contents vi SINUMERIK 802C Control 1 9 1 1 Components of the SINUMERIK 802 1 9 1 2 Technical data ee a 1 12 Installing the Control 2 15 2 1 Installing and removing the SINUMERIK 802C 2 15 2 2 oos ul RE n E E E REN RR EE 2 18 2 3 Connecting the individual components 2 21 2 3 1 Connecting the operator panel 2 21 2 3 2 Connecting the feed drives and the spindle 7 2 23 2 3 3 Connecting the measuring systems 2 26 2 3 4 Configuration of the RS232 interface connection X8 2 27 2 3 5 Connecting handwheels X10 2 29 2 3 6 Connecting NCREADY X20 2 30 2 3 7 Connecting the digital inputs and outputs 2003 X2006 2 31 2 4 ENC and operator panel power supply 1 2 35 2 5 Grouncdingssss ts mises bes tee d auf ME Eco Nt Solent ate dt
103. oint positio 300 Positioning velocity when ning velocity referencing Type of position measu ring system 34200 1 Zero pulse 1 Zero pulse on encoder track Threshold value for veloc Threshold monitoring for ity monitoring control pa 11500 velocity monitoring in the 36200 rameter set no 0 5 axis Threshold value for speed 31 94 ARM monitoring in the spindle To solve monitoring problems the following machine data must be set Number Description Default Value Setting or Remark 36000 Exact positioning coarse 0 04 Exact stop coarse 36010 Exact positioning fine 0 01 Exact stop fine 36020 ur exact positioning 1 0 Positioning dealy time Maximum velocity speed 5 0 Threshold velocity for axis spindle stopped Axis at standstill 20908 Threshold velocity f 0 013889 reshold velocity for Spindle at standstill 4 80 SINUMERIK 802C 6FC5 597 20 2 01 02 Start Up 4 7 Commissioning Parameterization example Servo gain Encoder 2500 10 000 pulses per motor revolution Load gear 1 1 Leadscrew pitch 10 mm Motor speed 1 200 rpm MD 30130 1 MD 30240 2 MD 31020 2500 MD 32250 80 MD 32260 1 200 rpm MD 32000 12 000 mm min The hardware of the drive must be set such that it will reach exactly 1 200 rpm at 8 V The servo gain default setting is 1 corresponds to 1mm following error at a velocity of 1m min The servo gain can or
104. on Air pressure 700 1 060 hPa The operating conditions comply with IEC 1131 2 Installation in a housing 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 lt 1 200 mm Protective quality and degree of protection Class of protection to IEC 536 No PE terminal required Foreign matter and water protection to IEC 529 for ENC and DI O16 IP 20 for 020 and MCP IP 54 front IP 00 rear SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 SINUMERIK 802C 6FC5 597 20 2 01 02 Installing the Control System 2 2 1 AN Approach Installing and removing the SINUMERIK 802C Warning Before performing any installation work always first make sure that the system is disconnec ted from the mains The modules contain electrostatically sensitive devices It must be ensured that persons without ESD protection never touch printed circuit boards or components when handling operator and machine control panels Prior to installation the machine control panel can be provided with a spindle override switch and an emergency
105. on e After hardware replacement if software versions other than the supplied are to be loaded Note In addition to the update procedure description below the update diskette also contains a description of the update procedure in the readme txt file Preconditions To change the system software of the SINUMERIK 8028 you will need the following Update software 2 diskettes APG PC with V24 interface COM1 or 2 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 802 on your diskette The installation is menu assisted 3 After the software has been prepared in the PC PG completely the message Transfer the selected appears on the display 4 Power On gt control system changes to the update condition Various patterns appear on the screen 5 After the patterns on the display of the SINUMERIK 8025 have disappeared start the transfer on the PC PG SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 5 91 Software Update 5 2 Updating the system software incl user data without using a PC PG The progress and the end of the update and errors if any are displayed on the PG PC 6 At the end of the update gt swit
106. ontents and Index SIMATIC LAD Instructions and in the Docu mentation 57 200 Automation System CPU22x System Manual SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 4 61 Start Up 4 3 Starting up the PLC Table 4 11 Instruction set BASIC BOOLEAN INSTRUCTIONS Instruction Ladder Symbol Valid Operands Load normal open n V Q M SM C L And n 1 close Or n 0 open Load Not normal close 4 n V I Q SM C L And Not n 0 close Or Not n 1 open Output prior 0 n 0 n n V l Q C L prior 1 n 1 Set prior 0 not set Bit S Bit V I Q M T C L 1 Bit s n 1 Reset prior 0 no reset Bit S Bt M T C L 1 Bit prior 1 or 7 1 OTHER BOOLEAN INSTRUCTIONS Instruction Ladder Symbol Valid Operands Edge Up prior close 1 PLC cycle Edge Down prior close 1 PLC cycle Logical Not prior O later 1 prior 1 later 0 255 No operation n n 0 BYTE COMPARES Unsigned Instruction Ladder Symbol Load Byte b close a a And Byte Zb open s Or Byte b p Load Byte gt a 2 b close a And Byte gt lt b open B Or Byte gt Load Byte lt a b close a And Byte gt b open Or Byte b Valid Operands VB IB QB MB SMB AC Constant LB VB IB QB MB SMB AC Constant LB 4 62 SINUMERIK 802C 6FC5 597 20 2 01 02 St
107. ontrol 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 connector SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 2 31 Installing the Control System 23 Connecting the individual components Table 2 15 Connector pin assignment X2003 Pin Name Type DIO DI2 014 015 016 DI7 M24 V O Q A o X2004 Name Type I 3 e DI8 DI9 DI11 0112 DI13 0114 0115 M24 V O Q Signal names DIO 15 24 V digital inputs Signal type V Voltage input Input 24 V signal SINUMERIK 802C 2 32 6FC5 597 3AA20 0BP2 01 02 Installing the Control System 2 3 Connecting the individual components Table 2 16 Electrical parameters of the digital inputs Parameter Value Unit Note 1 signal voltage range 15 30 V 1 signal current consumption 2 15 mA 0 signal voltage range 3 5 V or input open Signal delay 0 1 0 5 3 ms Signal delay 1 0 0 5 8 ms Connector pin
108. oot 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 implements all NC functions This software controls an NC channel with a maximum of 3 movement axes and a spindle PLC software Programmable Logic Control executes the integrated PLC user program cyclically Integrated PLC user program intended to adjust the SINUMERIK 802C to the machine functions see also Descrip tion of Functions Integrated User Program for SINUMERIK 8020 SINUMERIK 802C 6FC5 597 20 2 01 02 SINUMERIK 802C Control System User data 1 1 Components of the SINUMERIK 802C 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 Technological machine data files Programming tool 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 are Data saving Machine data Setting data Tool data R parameters Zero offsets Compensation data Part programs Standard cycles Modified user data are saved for at least 50 h after power off or power failure After then they might get lost
109. or s Guide Sinumerik 802S C Manal Machine in the Chapter Service Functions SINUMERIK 802C 7 128 6FC5 597 3AA20 0BP2 01 02 Manual Machine In the Siemens standard user interface Press the key to call the main selection screenform Press the Diagnosis function key 7 5 Additional machine data Press the key to extend the function key bar Press the Language changeover function key to switch to the alternative language 7 5 Additional machine data Limitations MD 14514 0 MN USER DATA FLOAT 0 Max input value for Cut meters Lubrication MD 14510 1 MN USER DATA INT 1 Lubrication time x 100ms MD 14510 2 MN USER DATA 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 SPIND EXTERN VELO LIMIT 2 Spindle speed limitation from PLC Spindle positioning 7 6 Input limitations with regard to the user interface Spindle Feedrate SINUMERIK 802C 0 lt speed 0 lt cut meters 0 lt Time feedrate 0 lt Revolutional feedrate 6FC5 597 3AA20 0BP2 01 02 lt MD 35100 4 SPIND VELO LIMIT 4 MD 14514 0 USER DATA FLOAT 4
110. p the PLC Table 4 9 S802C ranges of operands Accessed by Memory Type SINUMERIK 8025 Bit Byte bit V 14000000 0 79999999 7 0 0 7 7 Q 0 0 7 7 M 0 0 127 7 SM 0 0 0 6 0 15 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 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 lost applicable only to the first PLC cycle 0 data o k 1 data lost 4 60 SINUMERIK 802C 6FC5 597 20 2 01 02 Start Up 4 3 Starting up the PLC Table 4 10 FortsetzungSpecial Flag SM Bit Definition SM Bits Description POWER ON first PLC cycle 1 following cycles 0 60 s cycle alternating 0 for 30 s then 1 for 30 s 1 s cycle alternating 0 for 0 5 s then 1 for 0 5 s 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 C
111. pindle machine data are entered depending on the gear stages Each gear stage is assigned a parameter record The set of parameters corresponding to the current gear stage is selected Example 1st gear stage 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 AXA4 0 Spindle without encoder MD 30200 NUM ENCS AX4 1 Spindle with encoder 30240 TYPE AX4 2 Interface signals of the spindle Interface signals Speed change 39032000 Bit 3 Actual gear stage 38032000 bits 0102 No speed monitoring on gear change 38032000 bit 6 Speed is changed 38032000 Bit 3 Set gear stage 39032000 bits 0 to 2 Positioning mode 39032002 bit 5 Oscillating through PLC 38032002 bit 4 Oscillating mode 39032002 bit 6 Control mode 39032002 bit 7 4 86 SINUMERIK 802C 6FC5 597 20 0 2 01 02 Start Up 4 7 Commissioning Interface signals Traversing minus 39030004 bit 6 Traversing plus 39030004 bit 7 Reciprocation mode for gear change The reciprocation mode of the spindle is intended to facilitate the gear change For reciproca tion mode the following axis MD and interface signals are relevant Number Description Machine data
112. proach reference point in minus direction 0 REFP VELO SEARCH Reference point approach velocity 5000 0 0 0 REFP MAX CAM DIST Maximum distance to reference cam 10000 0 0 0 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 6 1 plus plus plus plus plus plus plus List of machine and setting data POWER ON DWORD 2 7 NEW CONF DOUBLE 2 7 NEW CONF DOUBLE 2 7 NEW CONF DOUBLE 2 7 NEW CONF DOUBLE 2 7 NEW CONF DOUBLE 2 7 POWER ON BOOLEAN 2 7 NEW CONF BYTE 2 7 NEW CONF DOUBLE 2 7 POWER ON DOUBLE 2 7 NEW CONF DOUBLE 2 7 RESET BOOLEAN 2 7 RESET BOOLEAN 2 7 RESET DOUBLE 2 7 RESET DOUBLE 2 7 6 99 Technical Appendix 6 1 34040 mm min rev min _always 34050 _always 34060 mm deg _always 34070 mm min rev min _always 34080 mm deg _always 34090 mm deg _always 34092 mm deg _always 34100 mm deg _always 34110 _always 34200 _always 35010 _always 35040 _always 35100 rev min _always 35110 rev min _always 6 100 List of machine and setting data REFP_VELO_SEARCH_MARKER Creep speed encoder no 300 0 0 0 REFP_SEARCH_MARKER_REVERSE Direction reversal to reference cams encoder no 0 MAX MARKER DIST Maximum distance to reference mark Max distance to 2 reference marks for distance coded measuring systems 20 0 0 0 REFP VELO POS Reference point positioning velocity
113. rams compensation tables etc are deleted Enter the compensation value for the intermediate point N in the compensation value table COMP 0 N Axi Select the distance between the individual intermediate points COMP STEP 10 Select the start position COMP MIN 0 Axi Define the end position COMP MAX 0 e Inthe NC set MD COMP 0 0 This is the only way to load the compen sation table The compensation values for the machine axes are entered into the memory by means of a part program see also example in the Manual Description of Functions SINUMERIK 802C 6FC5 597 20 2 01 02 Start Up 4 7 Commissioning 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 COMP ENA 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 the V24 interface MD MM ENC MAX POINTS must be set depending on the number of axes to be compensated Select Service using the softkey put the cursor to Data and press the Show softkey Then select Leadscrew Error using the cursor and press the Data Out softkey Enter compensation values intermediate point d
114. rogram levels are possible A PLC cycle can be a multiple of the control internal interpolation cycle IPO cycle The ma chine manufacturer must set the PLC cycle according to his her own requirements see ma chine data TIME RATIO The ratio IPO PLC of 1 1 is the fastest possible cyclic processing SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 Start Up 4 3 8 4 3 9 4 3 10 4 3 Starting up the PLC Example The programmer programs a sequence control in the main program using his own defined cycle counter The sequence control defines all cyclic signals in the subroutine UPO UP1 UP2 is called every two cycles and UP 3 controls all signals in steps of three cycles Data organization The data can be divided into three areas non retentive data retentive data machine data for the PLC All these machine data are active after POWER ON Most data such as process map timers and counters are non retentive data and deleted with each power up The user has a certain area available for the retentive data data range 14000000 140000xx All data that are wished to remain 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 Interface to the control system This interface can be selected on the operator panel using the softkeys Diagnosis Start up
115. s X2 2 23 Connecting the individual components 2 21 Connecting the Operator Panel 2 21 Connecting 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 Installing and Dismantling the SINUMERIK 802C 2 15 SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 Interfaces and cables 2 18 L LEDs and operating elements on the ENC unit 2 38 Machine and Setting Data Unit 4 43 Manual machine 7 125 Default assignment 7 133 assignment 7 130 Installation 7 125 Machine data 7 129 Switching the language 7 128 Switching the user interface 7 128 P Protection levels 4 42 S Spindel data Spindle modes 4 85 U Updating the System Software 5 91 Index 137 Index notice SINUMERIK 802C Index 138 6FC5 597 3AA20 0BP2 01 02 SIEMENS AG A amp D MC BMS Postfach 3180 D 91050 Erlangen Tel 49 180 5050 222 Hotline Fax 449 9131 98 2176 Documentation Mailto motioncontrol docu erlf siemens de From Name Company dept Street Zip code Telephone Telefax Suggestions and or corrections Suggestions Corrections for Publication Manual SINUMERIK 802C Manufacturer Documentation Start Up Order No 6FC5597 3AA20 0BP2 Edition 01 02 Should you come across
116. s true and negated signal 042 Ua2 Zero signal N as true and negated signal Uso 1 5 MHz 90 30 max 300 mA 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 5V DC 4 75 V 5 25 V 300 mA 25m 5V DC 4 75 V 5 25 V 220 mA 35m Table 2 9 Maximum cable lengths depending on the transmission frequency Encoder Type incremental 1 MHz Frequency Max Cable Length 10m 500 kHz 35m 2 3 4 Configuration of the RS232 interface connection X8 Pin assignment of the connector on the ENC side RS232 interface Connector designation Connector type SINUMERIK 802C 6FC5 597 3AA20 0BP2 01 02 X2 RS232 9 sub D plug connector 2 27 Installing the Control System 2 3 Connecting the individual components Cable for WinPCIN 2 28 Table 2 10 Pin assignment of connector X2 X8 Pin Name Type Pin Name Type 1 6 DSR 1 2 RxD 7 5 TxD o 8 5 4 DTR O 9 5 M VO Signal description
117. splay unit after the decimal Default data This is the default value for the machine or setting data Range of values minimum and maximum values specifies the input limits If no range of values is specified then the input limits are defined by the data type and the field is marked with 4 1 3 Handling machine data Handling methods Display Input via keys and V24 interface 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 data in the memory backed up for a limited period can be saved internally in the perma nent memory of the control system An internal data backup should be carried out if the control system has been switched off for more than 50 hours at least 10 min day with controller ON It is recommended to carry out internal data saving whenever important data changes have been made SINUMERIK 802C 4 44 6FC5 597 20 2 01 02 Start Up 4 1 General Note During the internal data backup a memory copy of the memory backed up for a limited time is made and stored in the permanent memory Selective data backup e g only
118. t be re installed e After the transfer has been completed press the Error log function key to check whether the OK message has been set for all data Carry out 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 ini adapted by the machine manu facturer or load when starting the project the default machine data record included in the file manmach cnf on the supplied CD ROM How to load the file manmach cnf default data record is explained in the following e After the control system has powered up press the key to call the interactive pass word screenform Enter the password 1111 and press the key to confirm Press the once more and use the OK function key to switch to the standard user interface The further sequence corresponds to that as described for the installation of the user interface for the Manual Machine see above The individual difference is that the file MM 2 ser must be transferred from the Toolbox During the transfer the control system reboots sometimes The whole process takes approx 5 minutes depend
119. ti 6 116 6 2 7 Machine control panel signals MCP signals 6 118 6 2 8 PEG machine data pee eem been eder eR 6 119 6 2 9 RE 6 120 6 3 Application note unipolar spindle control 6 123 7 Manual Machine ewe ERIT be ates ENEA 7 125 7 1 Hardware and software requirements for the installation 7 125 7 2 Loading the SoftWare ERR ep ree RR CH E Reni Raps 7 126 7 3 Switching the user interface 7 128 7 4 Switching the language Deer rb n ee 7 128 7 5 Additional machine data cscs Glee eat Eee emen uf a 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 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 1 7 132 7 9 Default assignment of special data for the Manual machine 7 133 SINUMERIK 802C 6FC5 597 20 2 01 02 vii Table of Conte
120. ust be implemented Busbar for ENC DI O e 020 operator panel Machine control panel MCP The ground connections for the 20 must take into account installation in the ma chine or a panel In the case of cubicle installation the grounding points must be connected to the grounding bar see Fig 2 7 MCP 020 Installation in a cu bicle or machine L LCD signal connector Shielded signal cable DI O16 amp to chassis Grounding bar Fig 2 7 Grounding diagram for MCP OPO20 installation in a cubicle or machine SINUMERIK 802C 2 36 6FC5 597 3AA20 0BP2 01 02 Installing the Control System 2 5 Grounding Panel installation requires that the ground connections on the MCP and 020 are connected together and to the panel frame The panel frame is grounded centrally see Fig 2 8 MCP OP020 Installation in a separate unit L LCD signal connector Shielded signal cable DI O16 amp
121. voltage 50 V Switching current 1 A Switching power 30 VA Cable length max 35 m 2 3 3 Connecting the measuring systems X3 X6 Pin assignment of the connector on the ENC side Measuring system interface incremental encoder Connector designation Connector type X3 X6 ENCODER 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 3 11 NN 8 4 P5 MS VO 12 BN 2 5 vo 13 B 9 a 6 P5 MS VO 14 AN 7 M VO 15 A 8 Signal names B BN N NN P5 MS M Signal level RS422 Signal 2 26 Track true and negated Track B true and negated Zero mark true and negated 5 2 V supply Supply ground Voltage output supply 5V input 5V signal SINUMERIK 802C 6FC5 597 20 0 2 01 02 Installing the Control System Connectable encoder types 23 Connecting the individual components Incremental 5 V encoders can be connected directly Characteristics The encoders must meet the following requirements Transmission method Max output frequency Phase offset between tracks A and B Current consumption Cable lengths Differential transmission with 5 V square wave signalsOutput signals Track A as true and negated signal U41 Track B a
122. ware V24 ini 19200 Bd 1 stop bit no parity 8 data bits Handshake RTS CTS Press the OK function key to accept the Sinumerik settings Use the WinPCIN software to start the transfer of the file manmach arc from the Toolbox CD ROM in some cases first the file has to be copied to the hard disk as not every WinPCIN version can access a CD ROM drive SINUMERIK 802C 6FC5 597 20 2 01 02 Manual Machine 7 2 Loading the software Press the Input start function key to start the data transfer on the control system Abox with the following question will appear on the control system Read in start up data If you wish to start this process press the OK function key to confirm e data transfer has been started successfully the message V24 input running is dis played The data transfer will take approx 15 minutes during this time it is imperative to prevent a power failure or an interruption of the data transfer If sometimes the message No text management available is displayed this is normal and can therefore be ignored Note Under no circumstances may a power failure or an interruption of the data transfer occur while the data transfer is running Otherwise a new power up of the control system can be sup pressed due to an uncontrolled interruption of the data saving in the flash memory In this case it is not possible to try to transfer the data once more the operating system mus
123. 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 9 Siemens AG 2002 All rights reserved Bestell Nr 6FC5597 3AA20 0BP2 Printed in the Federal Republic of Germany Other functions not described in this documentation might be executable in the control This does not however represent an obligation to supply such functions with a new control or when servicing We have checked that the contents of this document correspond to the hardware and software described Nonetheless differences might exist and therefore we cannot guarantee that they are completely identical The information contained in this document is however reviewed regularly and any necessary changes will be included in the next edition We welcome suggestions for improvement Subject to change without prior notice Siemens Aktiengesellschaft Safety notices ZN AN gt This Manual contains notices intended to ensure your personal safety and to avoid material damage The notices are highlighted by a warning triangle and depending on the degree of hazard represented as shown below Danger indicates that loss of life severe personal injury or substantial material damage will result if the appropriate pre cautions are not taken Warning indicates that loss of life severe personal injury or substantial material dam

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