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1. MD STOP_LIMIT_FINE exact stop fine SINUMERIK 802S C base line 2 9 Description of Functions Continuous Path Control Exact Stop 2 10 SINUMERIK 802S C base line Description of Functions Velocity Setpoint Actual Value 3 System Closed Loop Control Brief description Velocities This Section describes the adjustment of e the measuring systems e the setpoint value system the positioning accuracy e the traversing ranges and e the axis velocities The maximum path axis velocity and spindle speed are affected by the machine and drive dynamics and the limit frequency for actual value sensing encoder limit frequency The maximum axis velocity is defined in machine data MAX_AX_VELO maximum axis velocity The maximum permissible spindle speed is set in MD SPIND_VELO_LIMIT maximum spindle speed In addition to the limitation by MD MAX_AX_VELO the control system limits the maximum path velocity on the situation with the following formula Progr path length in a part program blockimm or degrees 0 9 IPO cycle fs Vmax With a higher feedrate resulting from the programmed feedrate and the feed rate override the maximum path velocity is limited to V max This automatic feedrate limitation can lead to a drop in velocity over several blocks with programs generated by CAD systems with extremely short blocks Example IPO cycle 12 ms N10 GO X0 Z0 mm N20 GO X100 Z100 mm g
2. Related to IS Active machine function INC1 4 24 SINUMERIK 802S C base line Description of Functions Manual Traversing and Handwheel Traversing 4 8 3 Overview of Signals from Axis Spindle Machine Axis Signals to Axis Spindle VB Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 390x0004 Traversing keys Rapid Feed Activate handwheel plus minus Traverse Stop Spind 2 1 Override le Stop 390x0005 Active Machine function continuos 1000 100 10 1 INC INC INC INC SINUMERIK 802S C base line 4 25 Description of Functions Manual Traversing and Handwheel Traversing 4 8 4 Description of Signals from Axis Spindle Machine Axis V390x0004 0 and 1 Interface signal Handwheel active 1 to Signal s from axis spindle NCK gt PLC Edge evaluation no Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 These PLC interface signals are used to check back whether this axis is assigned to handwheel 1 or 2 or to none handwheel One axis can be assigned only one handwheel each at a time If several interface signals Activate handwheel are set the priority is Handwheel 1 before Handwheel 2 If the assignment is active the axis can be traversed with the handwheel in JOG mode Signal status 0 or edge change 1 gt 0 This axis is not assigned handwheel 1 or 2
3. Meaning Not with stepper motor axes In this MD enter the value of the speed setpoint at which the motor speed Default 3000 specified in MD RATED_VELOJn is reached as a percentage Application 1st example example s At a voltage of 5 V the drive reaches a speed of 1 875 rpm gt RATED_OUTVAL 50 RATED_VELO 1 875 rpm 2nd example At a voltage of 8 V the drive reaches a speed of 3 000 rpm gt RATED_OUTVAL 80 RATED_VELO 3 000 rpm 3rd example At a voltage of 1 5 V the drive reaches a speed of 562 5 rpm gt RATED_OUTVAL 15 RATED_VELO 562 5 rpm All three examples above are possible for one and the same drive inverter The ratio of the two values another to one is decisive and this is the same in all three examples The machine data index n is coded as follows setpoint branch 0 Related to MD RATED_OUTVAL n only makes sense in conjunction with MD RATED_VELOJn 32260 RATED_VELO n MD number Rated motor speed Max input limit plus Min input limit 0 Change effective after NEW_CONF U min Protection level 2 7 Unit Data type DOUBLE Valid as from SW version Meaning In this MD enter the speeed of the drive standardized on the part of the drive which is reached at the percentage speed specified in MD RATED _OUTVALfn The machine data index n is coded as follows setpoint branch 0 Default 0 Re
4. 380x0004 7 P PE EEEN IS Referenced synchronized 390 0000 4 Synchronous pulse Velocity Reference point approach velocity MD REFP_YELO_SEARCH_CAM Reference point cut off velocity MD REFP_VELO_SEARCH MARKER _ Ref approach speed MD REFP_VELO_POS Phase 1 Phase 2 Phase 3 Fig 8 1 Example of a sequence of interface signals IS BERO single edge evaluation Properties When traversing to the reference point cam phase 1 e Feed Override and Feed Stop are effective The machine axis can be stopped started with NC Stop NC Start e If the machine axis does not stop on the reference cam e g cam too short an appropriate alarm is output When synchronizing with the synchronous pulse phase 2 e The feed override is not effective a feed override of 100 applies If the feed override is 0 the movement is canceled Feed Stop is effective the axis will stop and an appropriate alarm is displayed e The machine axis cannot be stopped started with NC Stop NC Start SINUMERIK 802S C base line 8 3 Description of Functions Reference Point Approach Reference cam Reference cam adjustment A Referencing without reference point cam 8 4 When traversing to the reference point phase 3 e Feed Override and Feed Stop are effective The machine axis can be stopped started with NC Stop NC Start If the reference point offset is less than the braking path of the machi
5. G96 SINUMERIK 802S C base line 7 1 Description of Functions Face Axis 7 1 Radius Diameter Programming G22 G23 Functionality To machine part on turning machines it is common practice to program the position information for the X axis face axis as diameter dimension The control system will interpret this value as diameter only for this axis If necessary it is possible to change to radius programming in the program Programming G22 Radius input G23 Diameter input Diameter input Radius input x G22 Face axis x Face axis Longitudinal axis Longitudinal axis Fig 7 1 Diameter and radius input for the face axis Information G22 or G23 evaluates the end point specification for the X axis as radius or diameter specification A programmable offset with G158 X is always interpreted as radius specification Programming N10 G23 X44 Z30 for X axis diameter example N20 X48 225 G23 is still active N30 Z10 N11 0 G22 X22 Z30 Change to radius input for X axis from here N120 X24 Z25 N130 Z10 Setpoint actual If the function G23 is active for the face axis the position values in the workpiece value display coordinate system WCS are displayed as a diameter value The display in the machine coordinate system MCS is always carried out with radius dimension 7 2 SINUMERIK 802S C base line Description of Functions Face Axis 7 2 Constant Cutting Speed G96 Functionality Programming Information
6. SD not applicable Dry Run Feed function not activated Application example s Checking of traversed distances for new part programs Special cases The function may not be activated if a workpiece is to be machined Due to the errors activated dry run feed the maximum cutting speed of the workpiece could be exceeded so that workpiece and tool could be destroyed as a consequence 42000 THREAD_START_ANGLE SD number Thread start angle G33 Default 0 Min input limit 0 Max input limit plus Changes effective immediately Protection level Unit degrees Data type DOUBLE Valid as from SW version Meaning This setting data can be used for multiple thread cutting to set the offset of the individual threads This SD can be modified from the part program using the command SF If no SF is programmed in the G33 block of the part program the setting data is effective References Operation and Programming SINUMERIK 802S C base line 5 19 Description of Functions Program mode 5 6 Signal Descriptions vo0000000 7 Interface signal Edge evaluation no Selected mode JOG Signal s from MCP gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 Key for JOG mode is pressed Signal status 0 or edge change 1 gt 0 Key for JOG mode is not
7. Signal status 1 or edge change 0 gt 1 The PLC interface receives a check back signal with the information which machine function is active for the axes in JOG mode Depending on which machine function is active the response when pressing the traversing key or turning the handwheel is different Signal status 0 or edge change 1 gt 0 The respective machine function is not active Related to IS Machine function INC1 INC1000 for WCS axis 4 22 SINUMERIK 802S C base line Description of Functions 4 8 1 Manual Traversing and Handwheel Traversing Overview of Signals to Axis Spindle Machine Axis Signals to Axis Spindle VB Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 380x0004 Traversing keys Rapid Feed Activate handwheel plus minus Traverse Stop Spind 2 1 Override le Stop 380x0005 Machine function continuos 1000 100 10 1 INC INC INC INC 4 8 2 Description of Signals to Axis Spindle Machine Axis V380x0004 0 and 1 Interface signal Edge evaluation no Activate handwheel 1 to 2 Signal s to axis spindle PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 These PLC interface signals are used to define whether this axis is assigned to handwheel 1 or 2 or to none One axis can be assigned only one handwheel at a time If several interface
8. Start Up Milling
9. All accumulated auxiliary functions are output prior to the movement in a separate block as normal auxiliary functions Important If all auxiliary functions are to be accumulated during block search they must be assigned to one and the same auxiliary function group SINUMERIK 802S C base line Description of Functions Output of Auxiliary Functions to PLC 10 3 Description of Auxiliary Functions Application Scope of functions Application Scope of functions Special property M function The M functions can be used to activate various switching actions on the machine via the part program 5 M functions per part program block are possible e Value range of M functions 0 to 99 integer A minor part of the M functions is assigned by the control manufacturer a fixed functionality see User Manual Operation and Programming The remaining part is available to the machine manufacturer for free use T function The T function is used to load the appropriate tool for a certain machining section from the PLC Whether the tool change is to be carried out directly by means of the T command or a following M command can be set via machine data see User Manual Operation and Programming The programmed T function can be interpreted either as a tool No or as a tool magazine position No 1 T function per part program block is possible TO is reserved for the following function to remove the currently active
10. Power On User class 2 7 Unit Data type STRING Valid as from SW version Meaning The machine data AUXFU_ASSIGN_TYPE n auxiliary function type AUXFU_AS SIGN_VALUE n auxiliary function value and AUXFU_ASSIGN_GROUP n auxiliary function group are used to assign an auxiliary function type M T the associated exten sion and the auxiliary function value to an auxiliary function group MO 99 gt group f corsp to M99 Example Auxiliary function type Auxiliary function extension fixed Auxiliary function value Auxiliary function group MD AUXFU_ASSIGN_TYPE 0 ing MD AUXFU_ASSIGN_VALUE Q0 99 MD AUXFU_ASSIGN_GROUP O 5 0 Sth group By default MO M41 M2 M417 and M30 are assigned to group 1 by default M3 M4 MS are assigned to group 2 The index n of the machine data denotes the auxiliary function number 0 49 All auxiliary functions that are assigned to auxiliary function groups must be numbered in ascending order O 8 14st auxiliary function 1 82nd The three machine data used to assign an auxiliary function to an auxiliary function group must be assigned the same index n Default 0 Application see Chapter 6 example s Special cases If the auxiliary function value of an auxiliary function is less than O all auxiliary errors functions of this type and extension are assigned to one group Related to MD 11100 AUXFU_MAXNUM_GROUP_
11. After the spindle specific time which can be set in MD 36620 SERVO_ DISABLE_DELAY_TIME servo enable shutdown delay has elapsed servo enable is switched off It must be made sure that SERVO_ DISABLE _DELAY_TIME is at least as high as set in AX_ EMERGENCY_STOP TIME af oO Dh The EMERGENCY STOP sequence on the machine is exclusively defined by the machine manufacturer In conjunction with the sequence in the NC the following should be taken into account e The sequence in the NC is started with the IS EMERGENCY STOP V26000000 1 After the axes and spindles have come to standstill the power supply must be disconnected according to EN418 Important The disconnection of the power supply is the sole responsibility of the machine manufacturer e The sequence in the NC has no influence on the PLC interface modules digital outputs If individual outputs are to have a certain status in case of EMERGENCY STOP the machine manufacturer must provide for the respective functions in the PLC user program Important If you wish the sequence in the NC to be performed for EMERGENCY STOP not as defined the IS EMERGENCY STOP V26000000 1 may not be set prior to the EMERGENCY STOP status defined by the machine manufacturer in the PLC user program As long as the IS EMERGENCY STOP is not yet set and no other alarm is present all IS are active in the NC Any manufacturer specific EMERGENCY STOP status is thus possible SI
12. Min input limit 0 Max input limit 4 Change effective after Power On Protection level 2 7 Unit Data type BYTE Applies from SW version Meaning The spindle motor accelerates to the reciprocation speed defined in MD Reciprocation speed SPIND_OSCILL_DES_VELO using the IS Reciprocation speed The start direction is defined by MD SPIND_OSCILL_START_DIR if the IS Reciprocation by PLC is not set MD SPIND_OSCILL_START_DIR 0 gt Start direction against current direction of rotation MD SPIND_OSCILL_START_DIR 3 gt Start direction is M3 MD SPIND_OSCILL_START_DIR 4 gt Start direction is M4 MD not applicable all spindle modes other than reciprocation mode Related to MD SPIND_OSCILL_DES_VELO reciprocating speed IS reciprocating speed V38032002 5 IS reciprocating by PLC V38032002 4 35440 SPIND_OSCILL_TIME_CW MD number Reciprocation time for M3 direction Default 1 Min input limit 0 Max input limit plus 0 corresponds to a time of one interpolation clock MD IPO_SYSCLOCK_TIME_RATIO Change effective after Power On Protection level 2 7 Unit s Data type DOUBLE Applies from SW version Meaning The reciprocation time is effective in the M3 direction see illustration to MD SPIND_OSCILL_TIME CCW MD not applicable e all spindle modes other than reciprocation mode to e
13. Number of gear stages 9 14 Data for 5 gear stages can be entered into the control system The gear stages are defined by a minimum speed and a maximum speed for the gear stage and by a minimum speed and a maximum speed for automatic gear stage change The new gear stage is only output if the newly programmed speed setpoint cannot be realized with the current gear stage For simplification the oscillation times for gear stage change can be set directly in the 802S base line otherwise the oscillation function must be realized in the PLC The oscillation function is triggered by the PLC Gear stages for the spindle are used to step down the motor speed thus generating a high torque with low spindle speeds 5 gear stages can be projected for each spindle If the spindle motor is mounted directly 1 1 on the spindle or with a non variable gear ratio the MD GEAR_STEP_CHANGE_ENABLE gear stage change possible must be set to zero Motor speed vith automatic gearstage selection 1min the speed range is not fully used in gear stage 1 Max motor speed Spindle speed 1 min imax Zimin 22min The following can be set via MD Nimax Max spindle speed of 1st gear stage Qimh Min spindle speed of 1st gear stage for autom gear stage selection Qimax Max spindle speed of 1st gear stage for autom gear stage selection Nmax Max spindle speed of 2nd gear stage Gann Min spindle speed of 2nd gea
14. Positioning mode The IS to axis VB38031000 to 03 and from axis VB39031000 to 03 are invalid The IS to spindle VB38032000 to 03 and from spindle VB39032000 to 03 are valid Signal status 0 or edge change 1 gt 0 The machine axis is operated as an axis The IS to axis VB38031000 to 03 and from axis VB39031000 to 03 are valid The IS to spindle VB38032000 to 03 and from spindle VB39032000 to 03 are invalid Application example s Spindle override V39032000 3 Interface signal Edge evaluation yes Change gear stage Signal s from axis spindle PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 A gear stage can be set fixed by the part program M41 to M45 automatically by the programmed spindle speed M40 M41 to M45 The gear stage can be set in the part program by means of M41 to M45 as a fixed setting If as gear stage is set by M41 to M45 which is other than the current actual gear stage the IS Change gear stage and the IS Set gear stage A to C are set M40 The control system uses M40 is used in the part program to set the gear stage automatically A check is carried out to see in which gear stage the programmed spindle speed is possible S function If a gear stage other than the current actual gear stage is found the IS Change
15. SD not relevant for any other spindle modes than control mode Special cases errors The value in SD SPIND_ MIN_VELO_G25 can be modified by G25 S in the part program Operation from MMC The value in SD SPIND_ MIN_VELO_ G25 remains even after Reset or Power Off corresponding with SD SPIND_MAX_VELO_G26 SD SPIND_MAX_VELO_LIMS progr spindle speed limitation with G96 43220 SD number SPIND_MAX_VELO_G26 Progr spindle speed limitation G26 Default 1000 Min input limit 0 Max input limit plus Changes effective immediately Protection level Unit rev min Data type DOUBLE Valid as from SW version Meaning In SD SPIND_MAX_VELO_G26 a max spindle speed limitation is entered which may not exceeded by the spindle The NCK limits the spindle speed to this value SD not applicable spindle modes other than control mode to Special cases The value in SD SPIND_ MIN_VELO_G25 can be modified by errors G25 S in the part program Operation from MMC The value in SD SPIND_ MIN _VELO_ G25 remains even after Reset or Power Off Related to SD SPIND_MIN_VELO_G25 progr spindle speed limitation G25 SD SPIND_MAX_VELO_LIMS progr spindle speed limitation with G96 SINUMERIK 802S C base line Description of Functions 9 35 Spindle 43230 SPIND_MAX_VELO_LIMS SD number Progr spindle speed lim
16. and the IS Gear stage changed This informs the NCK that the appropriate gear stage has been activated successfully The gear stage change is considered completed spindle oscillation mode is deselected the spindle accelerates with the new gear stage to the last programmed spindle speed and the next block can be executed The IS Change gear stage is reset by the NCK and as a response the PLC user resets the IS Gear stage changed Signal status 0 or edge change 1 gt 0 no effect Signal not to spindle modes other than oscillation mode applicable Special cases If the PLC user feeds back another actual gear stage than fed back as the set errors gear stage from the NCK to the PLC the gear stage change is nevertheless considered completed and actual gear stage A to C is activated Related to IS Actual gear stage A to C V38032002 0 to 2 IS Set gear stage A to C V39032000 0 to 2 IS Change gear stage V39032000 3 IS Oscillation speed V38032002 5 SINUMERIK 802S C base line Description of Functions 9 37 Spindle V38032001 0 Interface signal Edge evaluation yes Feed override valid for spindle instead of spindle override Signal s from axis spindle PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 Instead of the spindle override value the
17. negative if the encoder runs after the machine part When 0 is entered the backlash compensation is ineffective After reference point approach the backlash compensation is active in all operating modes Special cases errors 32700 ENC_COMP_ENABLE 0 MD number LEC active n Default 0 Min input limit 0 Max input limit 1 Changes effective after Power On Protection level 2 7 Unit Data type BOOLEAN Valid as from SW version Meaning 1 The LEC is activated for the axis measuring system The LEC can be used to compensate lead screw errors and measuring system errors The function is internally only enabled if the respective machine data is referenced IS Referenced Synchronized 1 Write protection function compensation values active 0 The LEC for the axis is not active Related to MD MM_ENC_COMP_MAX_POINTS number of interpolation points with LEC IS Referenced Synchronized 1 36500 ENC_CHANGE_TOL MD number Portion of backlash Default 0 1 Min input limit 0 Max input limit plus Changes effective after NEW_CONF Protection level 2 7 Unit mm or degrees Data type DOUBLE Valid as from SW version Meaning Portion when provinding backlash value Related to MD BACKLASH 0 backlash compensation 6 10 SINUMERIK 802S C base line Description of Functions Compensation 36700 MD number
18. or M1 Command After the STOP command has been executed the IS Program status interrupted execution V33000003 3 is set The interrupted part program can be continued from the breakpoint by another START command Generally the following actions are carried out after STOP command Stopping part program execution at the end of the next block with NC Stop at block end MO M1 or single block the remaining STOP commands will stop program execution immediately Auxiliary functions of the current block which are not yet output at this moment will not be output The axes are stopped with successive stop of part program execution The block pointer stops on the breakpoint SINUMERIK 802S C base line 5 13 Description of Functions Program mode 5 44 RESET Command Channel status The RESET command can be executed in any channel status There is no command that can cancel this command Reset commands The following Reset command can be used IS Reset V3000000 7 Command RESET commands can be used to abort an active part program or part program execution block in MDA When the Reset command is executed the IS Channel status Reset V33000003 7 is set The part program can no longer be continued from the breakpoint All axes in the channel are in exact stop status After the Reset command the following actions are carried out 5 14 Part program preparation is stopped immediately The axes and t
19. Angular acceleration 1 rev s 1 rev s Linear jerk 1 m s 1 inch s Angular jerk 1 rev s 1 rev s Time 1s 1s Position controller loop gain 1 s 1 s Revolution feedrate 1 mm rev 1 inch rev Compensation value 1mm 1 inch Linear position Compensation value 1 degree 1 degree Angular position SINUMERIK 802S C base line 3 3 Description of Functions Velocity Setpoint Actual Value System Closed Loop Control 3 1 Setpoint Actual Value System 3 1 1 General Block diagram Setpoint output Actual value Sensing Simulation axes A control loop with the following structure can be configured for every closed loop controlled axis spindle for the stepper motor axes the encoder must be considered as an internal encoder IS positionmeasuring system Fig 3 1 Block diagram of a control loop One setpoint can be output for each axis spindle Setpoint output to the final control element is performed as an analog value for the spindle and axis with analog drive format 10 V For stepper motor axes signal output is provided for pulse and direction see Start Up Guide Section Connecting the Feed Drives A square wave generator standard increment quadrupling can be connected to the spindle axis No encoder is required for the stepper motor axes The speed control loop of an axis spindle can be simulated for testing purposes The axis traverses with a following error similarly to a real axis A
20. Default 0 DRIFT_ENABLE Automatic drift compensation Min input limit 0 Max input limit 1 Changes effective after NEW_CONF Protection level 2 7 Unit Data type BOOLEAN Valid as from SW version Meaning only with position controlled spindle or axis with analog drive MD DRIFT_ENABLE activates automatic drift compensation 1 Automatic drift compensation is active With automatic drift compensation the control system permanently calculates the additional drift value automatically which is required for the following error to come to zero compensation criterion 0 Automatic drift compensation is not active MD not applicable for non position controlled spindles TOR teas 36710 DRIFT_LIMIT MD number Drift limit value for automatic drift compensation Default 0 Min input limit 0 Max input limit plus Change valid after NEW_CONF Protection level 2 7 Unit of controlled quantity e g 10 V 8 100 Data type DOUBLE Valid as from SW version 3 Meaning This MD can be used to limit the amount of the drift additional value determined during the automatic drift compensation If the drift additional value exceeds the limit value entered in MD DRIFT_LIMIT alarm 25070 Drift value too large is displayed and the drift additional value is limited to this value MD not applicable MD DRIFT_ENABLE 0 to Rel
21. MD REFP_MOVE_DIST MD REFP YELO SEARCH CAM Reference point cam speed MD REFP_VELO_SEARCH_ MARKER Reference point cut off speed ml Synchronous Reference pulse point cam BERO 8 10 SINUMERIK 802S C base line Description of Functions Reference Point Approach 34090 REFP_MOVE_DIST_CORR 0 MD number Reference point offset Default 0 Min input limit Max input limit Changes effective after Power On Protection level 2 7 Unit mm degrees Data type DOUBLE Valid as from SW version Meaning After the synchronous mark has been detected the axis is positioned away from the synchronous mark by the distance REFP_MOVE_DIST REFP _MOVE_DIST_CORR When this distance is traversed the axis has reached its reference point REFP_SET_POS is transferred to the actual value During the traversing movement by REFP_MOVE_DIST REFP_MOVE _ DIST _CORR the override switches are effective REFP_CAM_SHIFT Electronic reference cam offset for incremental measuring systems with equidistant zero marks 34092 MD number Default 0 0 Min input limit 0 0 Max input limit Changes effective after Power On Protection level 2 7 Unit mm Data type DOUBLE Valid as from SW version Meaning When the reference cam signal is received zero mark search is started not immediately but with a delay corresponding to the distance REFP_CAM_SHIFT The repeatability of zero ma
22. Precondition This function requires a controlled spindle With the function G96 switched on the spindle speed is adapted to the diameter of the currently machined workpiece face axis such that the programmed cutting speed S at the tool edge remains constant spindle speed multiplied with diameter constant From the block with G96 the S word is interpreted as cutting speed G96 is modal and is active until it is canceled by another G function of the group G94 G95 G97 G96 S LIMS F Constant cutting speed ON G97 Constant cutting speed OFF AWL Explanation S Cutting speed unit m min LIMS Upper limit speed of spindle only effective with G96 F Feed specified with the unit mm rev as with G95 Note The feed F is interpreted here always in the unit mm rev If previously G94 was active instead of G95 a new appropriate F value must be entered D1 D2 diameter D1 x SD1 D2 x SD2 Dn x SDn constant Fig 7 2 Constant cutting speed G96 For more detail information refer to the User Manual Operation and Programming SINUMERIK 802S C base line 7 3 Description of Functions Face Axis 7 4 SINUMERIK 802S C base line Description of Functions Reference Point Approach 8 8 1 Fundamentals Why referencing To ensure that the control system finds machine zero exactly after it has been switched on the control must be synchronized with the measuring systems connected to the
23. The service display operating area Diagnosis displays the effective compe nsation value Fig Service axes Abs comp value in addition to the current actual position This display value is the total of the compensation value from LEC and backlash compensation The backlash compensation value occurred in the event of direction reversal of the axis concerned can be split over several sections This avoids specific axis errors as Caused by a too large jumps of the axis setpoint The contents of the axis MD36500 ENC_CHANGE_TOL are used to define the increment for the backlash compensation value MD32450 BACKLASH It should be taken into account that the backlash compensation is only included in calculation after n MD32450 MD36500 servo cycles Too high a time interval may cause zerospeed monitoring alarms If MD ENC_CHANGE_TOL is greater than MD BACKLASH the compensation is carried out in a servo cycle SINUMERIK 802S C base line 6 3 Description of Functions Compensation 6 2 Lead Error and Measuring System Error Compensation LEC Function Activation Compensation interpolation points Compensation table The lead error or measuring system error compensation in the following called LEC is an axial compensation With the LEC the axis specific actual position value is modified by the associated compensation value and traversed by the machine axis immediately A positive compensation value
24. Traversing command is provided for an axis or axis group when Feed blocking is canceled the traversing request is carried out immediately Special cases errors Feed blocking with active G33 without effect V32000006 6 Interface signal Edge evaluation no Rapid traverse override inactive Signal s to channel PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The rapid traverse override from 0 to max 100 entered in the PLC interface is active channel specifically Signal status 0 or edge change 1 gt 0 The rapid traverse override entered in the PLC interface is not considered When rapid traverse override is inactive the NC internally uses an override factor of 100 Special cases errors Rapid traverse override is disabled when G33 is active Related to IS Rapid traverse override 11 18 SINUMERIK 802S C base line Description of Functions Feeds V32000006 7 Interface signal Edge evaluation no Feed override active Signal s to channel PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The feed override 0 to max 120 entered in the PLC interface is active for path feed and thus automatically for the associated axes In JOG mode the feed override acts directly on the
25. V32000000 5 V33000000 5 PRT Program test V17000000 7 V32000001 7 V33000001 7 SINUMERIK 802S C base line Description of Functions 5 15 Program mode 5 4 6 Program Status The status of the selected program for the channel is displayed on the interface The program status is only displayed in AUTOMATIC mode and MDA In the remaining operating modes the program status is either aborted or interrupted Program states The following program states are possible e 1S Program status aborted V33000003 4 e 1S Program status interrupted V33000003 3 e 1S Program status stopped V33000003 2 e 1S Program status waiting V33000003 1 e 1S Program status running V33000003 0 Effects of comm The program status can be controlled either by activating various commands or ands signals via interface signals The Table below shows the resulting program status Supposed program status prior to the signal gt Program status running Table 5 5 Effects on the program status States of Program Execution Commands Aborted Interrupted Stopped Waiting Running IS Reset x IS NC Stop X IS NC Stop at block end X IS NC Stop axes and spindles X IS Read in disable IS Feed stop channel blocked IS Feed stop axis blocked Feed override 0 gt lt gt lt gt lt gt lt gt lt I
26. When the override is selected via the operator panel display ROV the IS Feed override for rapid traverse selected V17000001 3 is set transferred to the IS Rapid traverse override active V32000006 6 and the value of the IS Feed override VB1000004 from the machine control panel MCP is also transferred to the IS Rapid traverse override VB3200005 The channel specific feed and rapid traverse override are inactive when G33 G63 G331 and G332 are active One enable signal and one byte each for the feed override factor in per cent are provided for each axis in the PLC interface IS Feed override VB380x0000 IS Override active V380x0000 7 The axis specific feed override is inactive when G33 is active SINUMERIK 802S C base line 11 11 Description of Functions Feeds Spindle override Override active Override inactive Spindle override reference 11 12 One enable signal and one byte each for the spindle override factor in per cent are provided by the PLC interface IS Spindle override VB38032003 IS Override active V3803000 7 Another signal is provided IS Feed override for spindle active V38032001 0 which can be used by the PLC user program to set that the value of the IS Feed override VB38030000 is to be active The value from the machine control panel MCP is available in the IS Spindle override VB10000005 Spindle override is
27. 0 The limit frequency set in MD ENC_FREQ_LIMIT is not exceeded V390x5000 0 Interface signal Error Rotation monitoring Signal s from axis spindle NCK PLC Edge evaluation yes Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge evaluation 08 1 Error in rotation monitoring of this stepper motor axis further information see Chapter 14 3 Signal status 0 or edge change 120 No error in rotation monitoring of this stepper motor axis Related to IS Rotation monitoring ON OFF V380x5000 0 SINUMERIK 802S C base line Description of Functions Axis Spindle Monitoring 1 20 SINUMERIK 802S C base line Description of Functions Continuous Path Control Exact Stop 2 Brief description For continuous path control the CNC executes a part program successively block by block The next block is only executed if the functions of the currently active block are executed Different requirements made to the part to be machined such as contour accuracy machining time workpiece surface require different block change criteria Two behavior types are possible for the contour axes at the block ends The first type exact stop means that all contour axes must have reached the set target position depending on an exact stop criterion before the next block change is initiated In order to be able to fulfil this criterion the contour axes must red
28. 1 2 1 Encoder Limit Frequency Monitoring s srisrrsrrsrisrrariarrsrrarisrisriariarrariariariariariseia riaria rnA EISE 1 2 2 Zero Mark Monitoring ae ES ACH AACE EY BUTLER ie no LAWNS EAGLE KI PUNAA NNAS NGRV AU LALE Tae aLeRACR Aa eum nde ata eae 1 2 3 Hardware Errors srsrisrisrrsrrsriarinprarrariarinpin eta aR A LAR LA DESDE SPI A RIALS RISD ESP ES PIER IAP LAPIS PES PES PLA E Lae 1 3 Limit Switch Monitoring La iat ale Md Raa AA HI eli RaLdielala ce VAGNAe E EEE 1 4 Axis Monitoring Supplementary Conditions r tr srrsrrsrisrisrrariarrsriarisrisriariariariariserariariarian 1 5 Stepper Motor Rotation Monitoring Using BERO trisrrsrisrisrisrisriarisriariserarinrineiarinrinrinrise 1 6 Data Description Va eg Cha PaCS RUN RAAE Ale wale LENA E LRA TAU RIA Rae EEEE ET 1 7 Signal Description Pred Paar eG Reais CENA Hebe REGGIE KALE IA Rae LRAT Pah AE TAE Ane 2 Continuous Path Control Exact Stop ecient 2 1 General eee eee eee eee eee eee er eer eee ere re rer err es 2 1 1 Velocities EERE eee 2 1 2 Stopping for Synchronization Lea ea RN MRA LAE ie ARAN Aa ae eh aed aie AANA RA aR TE 2 2 Exact Stop DAO La ATEA ce EREE ain aa One narra PEERAA EE La Rua Lobe bea Raat ede aac dads Ga Ake eee 2 3 Continuous Path Control Mode re irrte tier trier rt ROH HHO HOO I DE REO E ODE RET EE ene ts mtr ntl 2 4 Data Description viriirirtr ter er EEE ERECT 25 Signal Description AEP a ATMO Gai EE Moe a Raph RR PAAA gins Me PAG aed DERRATE PAROA apoE Reea 3 Velocity Setpoint Actual
29. 11 19 Feeds 11 11 2 Signals to Axis Spindle VB380x0000 Interface signal Edge evaluation no Feed override axis specific Signal s to axis PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The axis specific feed override is output via the PLC in the form of a Gray code Switch Axial Feed Position Code Override Factor UN a L B e f oo1or_ 0 08 e f ono oa 9 o f omon 0 30 e j oo 0 60 o f o y oo Table 11 3 Gray code for axis specific feed override Related to IS Override active Note The signals for the spindle Spindle override VB38032003 and Feed override valid for spindle V38032001 0 are documented in Section LEERER MERKER 11 20 SINUMERIK 802S C base line Description of Functions Feeds V380x0001 7 Interface signal Edge evaluation no Override active Signal s to axis spindle PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 Feed override active The axis specific feed override from 0 to max 120 entered in the PLC interface is taken into account Spindle override active The spindle override from 0 to max 120 entered in the PLC is taken into account Signal status 0 or edge change 1 gt 0 The axis specific feed override or spindle override is inacti
30. Interrupted Signal status 0 or edge change 1 gt 0 No effect Signal not applicable to Channel status Reset Program status aborted Special cases errors All axes and the apindle which have not been triggered by a program or program block for example axes run by means of the traversing keys on the MCP do not decelerate to standstill with NC Stop axes plus spindles The program is continued form the breakpoint with NC Start The signal NC Stop exes plus spindles must be provided for at least one PLC cycle time es Signal NC Stop axes Signal NC Start Program running Axis running Spindle running Block executed OnaRWN aE Related to IS NC Stop at block end IS NC Stop IS Program status stopped IS Channel status interrupted SINUMERIK 802S C base line 5 29 Description of Functions Program mode V33000000 5 Interface signal Edge evaluation no MO M1 active Signal s from channel NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The part program block is executed the auxiliary functions are output and MOis in the user memory or M1 isin the user memory and IS Activate M01 is active The program status changes to Stopped Signal status 0 or edge change 1 gt 0 With IS NC Start With program
31. MD REFP SET POS Z Related to 8 12 SINUMERIK 802S C base line Description of Functions Reference Point Approach 34110 REFP_CYCLE NR MD number Axis order with channel specific referencing Default 0 Min input limit 1 Max input limit 5 Changes effective after Power On Protection level 2 7 Unit Data type BYTE Valid as from SW version Meaning 0 gt axis specific referencing no channel specific referencing for this axis Axis specific referencing is started for each machine axis separately by means of the IS Traversing keys plus minus V380x0004 If the machine data axes to be referenced in a certain order the operator must provide for the desired order prior to the start gt 0 channel specific referencing Channel specific referencing is started by means of the IS Activate referencing V32000001 0 The control system acknowledges the successful start by the IS Referencing active V33000001 0 Channel specific referencing can be used to reference each machine axis assigned to the channel to this aim the traversing keys plus minus are simulated internally in the control system The axis specific MD REFP_CYCLE_NR can be used to define the machine axis referencing order 1 The machine axis is started by channel specific referencing first The machine axis is started by channel specific referencing if all machine axes that are marked in MD REFP_CYCLE_NR with
32. On both ends of the traversing range one switch each can be installed which provides a Hardware Limit Switch Plus or Minus signal to the NC during approach via the PLC When the signal is detected as set alarm 021614 Hardware limit switch or is output and the axis is decelerated immediately The deceleration method is set by means of MD deceleration MODE_CHOICE deceleration response with hardware limit switch If servo enable for the Hardware Limit Switch signal is canceled the axis will react as explained in the Functional Description Diverse Interface Signals A2 Signal status 0 or edge change 1 gt 0 Normal status no HW switch responded Related to SINUMERIK 802S C base line Description of Functions Axis Spindle Monitoring V380x1000 3 and 2 Interface signal Edge evaluation no 2nd software limit switch plus or minus Signal s to axis spindle PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 2nd software limit switch for plus or minus direction is active 1st software limit switch for plus or minus direction is inactive In addition to the 1st software limit plus or minus the 2nd software limit switches plus or minus can be activated via these interface signals The position is defined via the MD POS_LIMIT_PLUS2 POS_LIMIT _MINUS2 2nd software limit switch plus 2n
33. SPIND_DES_VELO_TOL spindle speed tolerance V39032001 1 Interface signal Edge evaluation yes Set speed limited Signal s from axis spindle NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 If a spindle speed 1 min or a constant cutting speed m min or ft min has been programmed one of the following limit values has been exceeded Max speed of the set gear stage Max spindle speed Speed limitation by PLC interface Progr spindle speed limitation G26 e Progr spindle speed limitation with G96 The spindle speed is limited to the max limit value Signal status 0 or edge change 1 gt 0 If a spindle speed 1 min or constant cutting speed m min or ft min has been programmed no limit values have been exceeded Application example s The IS Set speed limited can be used to detect that the programmed speed cannot be reached The PLC user can either recognize this status as admissible and enable the path feed or he can block the path feed or the entire channel and IS Spindle within set range is processed SINUMERIK 802S C base line Description of Functions 9 45 Spindle V39032001 2 Interface signal Edge evaluation yes Set speed increased Signal s from axis spindle NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or
34. STANDSTILL_POS_TOL zero speed control Related to MD STANDSTILL_POS_TOL zero speed control 36050 CLAMP_POS_TOL MD number Clamping tolerance at interface signal Clamping active Default 0 5 Change effective after NEW_CONF Data type DOUBLE Meaning Min input limit 0 Max input limit plus Protection level 2 7 Unit mm degrees Valid as from SW version The interface signal Clamping process active V380x0002 3 activates clamping monitoring If the axis under monitoring is pushed out of the set position exact stop tolerance range by an amount greater than the clamping tolerance alarm 26000 Clamping monitoring is generated and the axis stopped Special cases The clamping tolerance must be greater than the Exact Stop Tolerance Range errors Coarse Related to IS Clamping process active SINUMERIK 802S C base line Description of Functions Axis Spindle Monitoring 36060 MD number Default 5 STANDSTILL_VELO_TOL Maximum velocity speed Axis spindle stopped Min inputn limit 0 Max input limit plus Change valid after NEW_CONF Protection level 2 7 Unit Linear axis mm min Spindle rom Data type DOUBLE Valid as from SW version Meaning This machine data defines the zero speed range for the axis velocity or spindle speed If the current actual velocity of the axis or the actual speed of the s
35. They are stopped for synchronization in case of PLC acknowledgment If acknowledgment by the PLC is required for an auxiliary function which is output prior to or after the end of a movement the axes are stopped at the end of the block if the subsequent blocks are not provided If the subsequent blocks cannot sufficiently fast be made available for execution the axes are stopped at the last approachable block end when the buffer is cleared If the NC program requires that the advance can be synchronized with the main run e g by means of the STOPRE instruction Clear buffer this implies a block related velocity reduction or exact stop When the axes are stopped for synchronization no contour errors occur However in particular in continuous path control mode stopping is not desired because relief cutting can occur SINUMERIK 802S C base line 2 3 Description of Functions Continuous Path Control Exact Stop 2 2 Exact Stop Exact stop activation Exact stop criteria 2 4 The Exact Stop function is used to wait for the contour axes running into the programmed block end point When all axes have reached the exact stop criterion the block change is carried out The velocity at the block transition is approximately zero This means e that all contour axes reach nearly standstill in the block end point without overshooting e The machining time is extended due to the waiting time for reaching the exact stop c
36. edge change 1 gt 0 Signal not applicable to AUTOMATIC mode and MDA Application example s The axis cannot be traversed in JOG mode if it is already traversed via the channel specific PLC interface as an axis Alarm 20062 is output Special cases Pitch axes Related to IS Traversing keys plus and minus for WCS axes IS Traversing keys blocked V380x0005 0 to 3 6 Interface signal Machine function INC1 INC10 INC100 INC1000 continuous Signal s to axis spindle PLC gt NCK Edge evaluation no Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 These interface signals are used to define how many increments are covered by the axis when the traversing keys are pressed or per latched position when the handwheel is turned or it is continuos mode JOG mode must be active As soon as the selected machine function is active this is reported to the PLC interface IS Active machine function INC1 If several machine function signals INC1 INC or Continuous traversing are selected on the interface at the same time no machine function is activated by the control system Signal status 0 or edge change 1 gt 0 The respective machine function is not selected If an axis is just traversing an increment the motion is also aborted by deselecting or changing the machine function
37. gt 0 The machine function REF is not active V32000000 4 Interface signal Edge evaluation no Activate single block Signal s to channel PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 In AUTOMATIC mode the program is executed in single block mode in MDA anyway only one block can be entered Signal status 0 or edge change 1 gt 0 No effect Application To test a new program it can first be run in single block mode in order to be example s able to check the individual program steps more exactly Special cases With tool radius compensation G41 G42 selected intermediate blocks errors are inserted if necessary With a series of G33 blocks single block mode is only active if Dry Run Feed is selected In SBL1 single block mode pure arithmetic blocks are not processed these are only processed in SBL2 The preselection of SBL1 or SBL2 is carried out via the Program Control softkey Related to IS Single block selected IS Program status interrupted References Section 5 2 V3200000 5 Activate M1 Interface signal Edge evaluation no Signal s to channel PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 When the program is run in AUTOMATIC mode or MDA M1 contained in the
38. motor axes In MD RATED_OUTVAL rated output voltage enter the value of the speed setpoint at which the motor speed specified in RATED_VELO rated motor speed as a percentage with reference to the maximum speed setpoint If the motor speed is not known it can be calculated from the desired axis velocity the leadscrew pitch MD LEADSCREW_PITCH and the gear ratio MD DRIVE_AX_RATIO_NUMERA n load gear numerator MD DRIVE_AX_RATIO_DENOM r load gear denominator as follows Vaxis FR Nmoto where the following applies Neaotor motor speed axe axis velocity leadscrew pitch MD LEADSCREW_PITCH R gear ratio where the following applies Re Number of motor revolutions _ORIVE AX_ RATIO NUMERAjn Number of load spinde revolutions DRIVE_AX_RATIO_DENOMfn SINUMERIK 802S C base line 3 5 Description of Functions Velocity Setpoint Actual Value System Closed Loop Control Accuracy Example of velocity matching with linear axis Actual value resolution 3 6 The accuracy of this setting substantially determines the quality of the traversing movement of an axis To achieve a sufficient control reserve of analog drives 80 90 of the desired maximum velocity of the axis should be reached at MD RATED_OUTVAL MD AX MOTION_DIR n Mp RATED_VELO n gt spindle Controller MD RATED_OUTVAL n MD DRIVE_AX_RATIO_NUMERA n Number of motor revs MD DRIVE_AX_RATIO_DENOM
39. the spindle goes on rotating When one of the functions e thread cutting G33 e tapping without compensating chuck G331 G332 e _ revolutional feed G95 e constant cutting speed G96 G97 Is programmed the spindle speed is automatically reduced to a value at which the active measuring system operates properly again If no measuring system is connected MD NUM_ENC 0 the speed actual value is internally derived from the speed setpoint and displayed Max encoder limit frequency undershot Distinctive features 9 22 If the max encoder limit frequency has been exceeded and then a speed is reached again which is below the value defined in MD ENC_FREQ_LIMIT_LOW smaller S value programmed spindle override switch changed etc the spindle automatically synchronizes itself with the next zero mark or the next BERO signal When the following functions are active the max encoder limit frequency cannot be exceeded Spindle operating mode Positioning mode Thread cutting G33 e Tapping without compensating chuck G331 G332 Revolutional feed G95 e Constant cutting speed G96 SINUMERIK 802S C base line Description of Functions Spindle 9 5 6 Target Position Monitoring Function IS Position reach ed with exact stop Block change at SPOS During positioning spindle is in spindle positioning mode a monitoring function checks how far the spindle i e its actual position is away
40. 1 are referenced 3 The machine axis is started by channel specific referencing if all machine axes that are marked in MD REFP_CYCLE_NR with 2 are referenced 4 Analogous for further machine axes 1 The machine axis is not started by channel specific referencing and NC Start is possible without referencing this axis Note The effect of an entry of 1 for all axes of a channel can be achieved by setting a channel specific MD REF_NC_START_LOCK NC Start inhibited without referencing to zero MD not to axis specific referencing applicable Related to IS Activate referencing V32000001 0 IS Referencing active V33000001 0 34200 ENC_REFP_MODE 0 MD number Position measuring system type Default 1 Min input limit 1 Max input limit 6 Changes effective after Power On Protection level 2 7 Unit Data type BYTE Valid as from SW version Meaning For referencing the position measuring systems installed can be divided into two groups using MD ENC_REFP_MODE position measuring system type 0 No reference point approach possible 1 Spindle or axis with analog drive Referencing with incremental measuring systems zero pulse on encoder track incremental rotatary measuring system 2 BERO with 1 edge detection for stepper motor 3 not available 4 Bero with 2 edge evaluation for stepper motor SINUMERIK 802S C base line 8 13 Descr
41. 2 V16001124 Variable for alarm 700031 2 V16002000 0 Active alarm response NC Start inhibited 2 V16002000 1 Active alarm response Read in disable 2 V16002000 2 Active alarm response Feed lock of all axes 2 V16002000 3 Active alarm response EMERGENCY STOP 2 V16002000 4 Active alarm response PLC STOP 2 SINUMERIK 802S C base line 15 7 Description of Functions List of Interface Signals 15 8 SINUMERIK 802S C base line Description of Functions SIEMENS AG A amp D MC BMS Postfach 3180 D 91050 Erlangen Tel 49 180 5050 222 Hotline Fax 49 9131 98 2176 Documentation Mailto motioncontrol docu erlf siemens de From Name Company dept Street Zip code Telephone Telefax Suggestions and or corrections Suggestions Corrections for Publication Manual SINUMERIK 802S 802C base line Manufacturer Documentation Description of Functions Order No 6FC5597 4AA11 OBPO Edition 08 03 Should you come across any prin ting errors when reading this publi cation please notify us on this sheet Suggestions for improvement are also welcome SINUMERIK 802S C base line Document Structure General Documentation Catalog ID G Turning Milling User Manual Operation and Programming a E a Sas Short Guide for O amp P Ka T Quick b a Start ase line Start Up Technical Manual Description of Functions Ea Turning
42. 3 e 1S Activate program test must not be set V32000001 7 e 1S NC Start inhibited must not be set V32000007 0 e 1S NC Stop at block end must not be set V32000007 2 e 1S NC Stop must not be set V32000007 3 e 1S NC Stop axes plus spindle must not be set V32000007 4 e IS EMERGENCY STOP must not be set V27000000 1 e Axis or NCK alarm must not be present The part program or part program block resp is executed automatically and the IS Channel status active V33000003 5 and the IS Program status running V33000003 0 are set The program is executed as long as the program end is reached or the channel is interrupted or aborted by a STOP or RESET command SINUMERIK 802S C base line Description of Functions Program mode Alarms The START command does not come into effect if the precondition is not fulfilled In this case one of the following alarms is output 10200 10202 10203 5 4 3 Interrupting a Part Program Channel status The STOP command can only be executed if the channel in question has the status Channel active V33000003 5 STOP commands There are different commands that stop program execution and set the channel status to Interrupted These commands are IS NC Stop at block end V32000007 2 IS NC Stop V32000007 3 IS NC Stop axes plus spindle V32000007 4 IS Single block V32000000 4 Programming command MO
43. 4 Axis 3 et l es oe _ i spindle Signals from NCK Fig 14 1 PLC NCK interface 14 2 SINUMERIK 802S C base line Description of Functions Various Interface Signals 14 2 Signals from PLC to NCK Access rights The access to programs data and functions is user oriented protected via 8 hierarchical user classes protection levels These are divided into e 4password levels for Siemens machine manufacturer and end user e 4 password levels for end user interface signals V26000000 4 to 7 This provides a multi stage safety concept to regulate the access rights see also Start Up Instructions Section Access Levels Table 14 1 Write protection User Class Method User Access to Examples 0 Pass SIEMENS All functions programs and data word 1 Pass SIEMENS Defined functions programs and data word Machine manuf e g Enter options 2 Pass Machine manuf Defined functions programs and data word e g major part of machine data 3 Pass End user Assigned functions programs and data word Service 4 IS End user Lower than user class 0 to 3 2600 Programmer defined by machine manufacturer or 0000 7 Setter end user 5 Is End user lower than user class 0 to 3 picked a 2600 qualified operator defined by end user g 0000 6 not programmed 6 IS End user Example 2600 qualified operator only program selection tool wear input 0000 5 who does not and input of zero offsets program 7 IS End user Ex
44. 7 Signal Description Signals to axis spindle V380x0002 3 Interface signal Edge evaluation no Clamping process active Signal s to axis spindle PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 Clamping process active Clamping monitoring is activated Signal status 0 or edge change 1 gt 0 Clamping process completed Clamping monitoring is taken over by zero speed control Related to MD CLAMP_POS_TOL clamping tolerance V380x0003 6 Interface signal Edge evaluation no Velocity spindle speed limitation Signal s to axis spindle PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The NCK limits the velocity spindle speed to the limit value entered in MD SPIND_EXTERN_VELO LIMIT Signal staus 0 or edge change 1 gt 0 No limitation active Related to MD SPIND_VELO_LIMIT max spindle speed MD SPIND_MAX_VELO_G26 programmed spindle speed limitation G26 MD SPIND_MAX_VELO_LIMS programmed spindle speed limitation G96 V380x1000 1 and 0 Interface signal Edge evaluation no Hardware limit switch plus and minus Signal s to axis spindle PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1
45. Axis specific monitoring functions monitoring functions active when positioning the spindle SW limit switches X X X X x x X SW limit switches X X X X x x X HW limit switches X x X xX X X x X X x X x xX xX HW limit switches X x x x X x X X X x X x Ix X Exact stop coarse fine X x x x X X x x xX x X x x xX Clamping tolerance X xX X xX X X x x X x Ix x x xX DAC limiting xX x X x x x x x x x x x x x Contour monitoring X X X X x X xX Spindle specific monitoring functions Speed limit exceeded x x x x xX Xx Spindle on stop X x x x X X x x xX x X x x xX Spindle synchronized X X X X xX X Speed within set range x Max permissible speed xX X xX X X xX Encoder limit frequency X X xX X xX xX x Monitoring is active in this status SINUMERIK 802S C base line 5 5 Description of Functions Program mode 5 1 4 Interlocks in the Individual Modes Overview of In the individual operating modes different interlocks can be active Interlocks Which interlocks can be activated in which operating mode and which operating condition is to be seen in the Table below lt 5 5 5 S oS O 2 lt 5 8 8 8 s amp lt x E gt 5 D gt Cc 3 5 5 D mo 5 D ko Q 0 D oD D ma 2 rot co O Oo oO ao oc O gt gt lt 2 B 5 gt o 8 o 5 o o O 2 o OD o gt gt 5s A
46. ENC_RESOL n increments per revolution with stepper motor axes MD STEP_RESOL MD LEADSCREW_PITCH leadscrew pitch MD MAX_AX_VELO maximum axis velocity The machine data index n is coded as follows MD DRIVE_AX_ control parameter block no 0 5 remaining MDs encoder no 0 Note These MDs are not required for encoder matching path evaluation However they must be entered correctly for setpoint calculation Otherwise the desired servo gain factor Ky will not be set In MD DRIVE_AX_RATIO_DENOM the load revolutions are entered and in MD DRIVE_AX_RATIO_NUMERA the motor revolutions mp ENC_IS_DIRECT 0 no encoder required for stepper motors is internally simulated encoder MD STEP_RESOL with stepper motor only Table Leadscrew poe i MEADSCREW_PITCH in gearbox spindle motor MD p DRIVE_AX_RATIO_NUMERA _ Number of motor rev s ENC_RESOL MD DRIVE_AX_RATIO_DENOM Number of spindle rev s Fig 3 3 Example Linear axis with rotary encoder mounted on the motor oad ENC_IS_DIRECT 1 Spindle chuck a wO ENC_ RESOL MD DRIVE_ENC_RATIO_NUMERA_ Number of load rev s MD DRIVE_ENC_RATIO_DENOM Number encoder rev s L Resolver gearbox gearbox Fig 3 4 Example Spindle with rotary encoder mounted on the machine Note MD ENC_FEEDBACK_POL actual value sign can be used to change the sign of actual value sensing and thus the control direction of
47. IS Spindle lock is provided analogously to axis lock in control mode no speed setpoints or in control mode no position actual values are output to the position controller any more The motion of the spindle is thus blocked The speed actual value display displays the speed setpoint Spindle lock can only be canceled by Reset or M2 and restart of the program If the interface signal Spindle lock is provided when the spindle is rotating the spindle is stopped as defined by its acceleration characteristic Signal status 0 or edge change 1 gt 0 normal position The position and speed setpoints are transferred to the position controller cyclically Cancellation of Axis spindle lock edge change 1 0 is only active if the spindle is on standstill i e no interpolation setpoint is present any longer The new motion will start with the new setpoints e g new program block with motion settings in AUTOMATIC mode Note different actual values between simulated and real axis Application example s The interface signals Axis lock and Spindle lock are used for testing NC part programs The machine axes and spindles may not carry out any traversing or rotational movement Special cases If Axis spindle lock is provided for an axis spindle the interface signals Servo errors enable Feed spindle stop and Hardware limit switches if any are
48. Meaning Output parameterization for stepper motor 32000 MD number Default 10000 MAX_AX_VELO Maximum axis velocity Min input limit 0 Max input limit Change effective after Power On Protection level 2 7 Unit mm min Umdr min Data type DOUBLE Valid as from SW version Meaning In this MD the limit velocity up to which the axis can accelerate must be entered rapid traverse limiting If rapid traverse is programmed this velocity is used for traversing The maximum admissible axis velocity is dependent on the dynamic properties of machine and drive as well as on the limit frequency of the actual value sensing SINUMERIK 802S C base line 3 15 Description of Functions Velocity Setpoint Actual Value System Closed Loop Control 32100 MD number Default 1 AX_MOTION_DIR Traversing direction Min input limit 1 Max input limit 1 Change effective after Power On Protection level 2 2 Unit Data type BYTE Valid as from SW version Meaning This MD can be used to reverse the traversing direction of the machine The control direction however is not reversed during this process i e the control remains stable Oor1 no direction reversal 1 Direction reversal 32110 ENC_FEEDBACK_POL n MD number Actual value sign control direction Default 1 Min input limit 1 Max input limit 1 Change effect
49. OVETV EW MEER 11 2 Feed F gt rrrsrrarrsrrarisrrsrrarrarisetariaria tiarra PIAEIAPIAFIAFIAPIAPINEIAPIAFIAFINPIAPIAEIAPIAPIAPIAPIAPINEIAEIAFOAE 11 3 Feed for Thread Cutting Q33 See eee eee eee eee eee eee 11 4 Feed for Tapping with Compensating Chuck GOZ isis tees cttber era riee ie erena tiame edad eke eae 11 5 Feed for Tapping without Compensating Chuck G331 G332 11 6 Rapid Traverse QO serie eter tent e ren ree errant EARLE READE APTA RAR LAP IA RESP ES PIA PI APLAR IAP ES PLS PIER IAPS R ISR PINE 11 7 Dry Run Feed ccrterterec reer tare a eer ee reer n een Rea EA TARTAR EAR LA PEA DEAD I AIA IA RIAD LSP LS DIARIES PIA P ES PIN EIS EISE 11 8 Velocity for Manual Traversing IPrg essed DEERE CNEAS IAR Nae ose eid AREE TENIKE TED IAE DEPI PIAE ETETE FEKTA 11 9 Feed Override REE 11 9 1 Feed Lock and Feed Spindle Stop DRE REAME AA KEERA RAAE ERAAN E EEEE LEE REA AEE ARIANA 11 9 2 Feed Override from Machine Control Panel rrrrrsrisrisrrsrisrisrisrisrisrisrisrisrisrisrisrisrisrisrise 11 10 Data Description CHa ee E rire be Sian A PIE LA EIR E PRET IAT orn ORI T 11 11 Signal DescriptioNS critter tert ere tia rrArIAKINFIAFNAPISPIAFAAPEAEIAFISPIAFIAPIAPIAFIAFISEIAPIA EIS EIAE 11 11 1 Signals to Channel gt rrrsrrsrisrisrisrisrispispisrisersrisr inris rrsPIAPINPINPIA PIAFIN PISPIN PINPIN PISPIN PIN EIS PISE 11 11 2 Signals to Axis Spindle LEASE E PATELE Tee E ELLEELLE ETLE IA Tee P eS a ERE 12 Tool Compensation aire ccc EE EE ESET TELE ES 12 1 TOOl RERRE RARE REESE
50. RSPR SCORES tO SC Este Stes te SCE steer este Ste steerer reer este steer rere steer este er este eres te er este er eereeresres 12 2 Data Description 13 EMERGENCY STOP gt gt eesssssrssrrsrisrrarrarisernersrinritrinrinr tarin nt eEa Ua EEA ES EEA EAP EA ELSE DS EDA EOS ELSES EDS ELE 13 1 General MER eee ee eee eee eee ee eee eee eT eee e reece eres e sree es 13 2 EMERGENCY STOP Tripping Mechanism 13 3 EMERGENCY STOP Sequence ee ee ee ee ee ee ee ee eee eee 13 4 EMERGENCY STOP Acknowledgement ir rn is 13 5 Data Description virierter tert er eet EERE EEE EEE ELE 13 6 Signal Description cirierterter tert EE EEE ETRE EL GE 14 Various Interface Signals fad shh pbinhbak eed ee cke tia RUaGORd PRRRaR a Sadi dad Halbeek adds ed daa aaOehMeeiediad ne 14 1 General Meee eee eee eee eee eee eee eee er eee e reer eee eee er rare 14 2 Signals from PLC to NCK 14 3 Signals from NCK to PLC 14 4 Signals from PLC to MMC 15 List of Interface Signals serreeerersrrsrrsrirersrrsrrsrinernnrsrrsrinernnrsrrsrinernnrsrrsrineinnrsrisrineinnrsrise 15 1 15 1 Interface Signals Cee OM Cet CA eR OE ee EMO PINEALE ANKENAI ENASI meta Crier 15 2 SINUMERIK 802S C base line V Description of Functions Axis Spindle Monitoring Brief description Any modern CNC must be provided with comprehensive monitoring mecha nisms to protect man and machine The monitoring functions available include the following e Motion monitoring functions Contour monitoring Positio
51. Related to IS Activate handwheel IS Handwheel selected V390x0004 7 and 6 Interface signal Traversing command plus and minus Signal s from axis spindle NCK gt PLC Edge evaluation no Signal s valid as from SW Signal s updated Version cyclically Signal status 1 or edge change 0 gt 1 A traversing movement is desired in the respective axis direction Depending on the operating mode the traversing command is triggered in different ways JOG mode by means of the traversing key plus or minus REF mode by means of the traversing key used for reference point approach AUT MDA mode A program block that contains a coordinate value for the respective axis is executed Signal status 0 or edge change 1 gt 0 At the moment no traversing request is provided in the axis direction in question or a traversing motion is completed e JOG mode The traversing command is reset depending on the interface signal Traversing keys plus and minus when traversing with the handwheel e AUT MDA mode The program block is executed and the following block does not contain a coordinate value for the axis in question Abortion by RESET etc IS Axis blocking provided Application Note If the clamping is only released with the traversing command example s continuous path control is not possible for these axes Re
52. System Error Compensation LEC 6 3 Drift Compensation Peirce Teter rere ee ee otter eer ee ey eer ee ree te er Serer ore 6 4 Data Descriptions LEIA OEE MARIE CRD Re mie MRA kde Me OMFS TOE ia a hoe aRa nD RRGAGDRE Face AXIS rire EEE EEE 7 1 Radius Diameter Programming G22 G23 7 2 Constant Cutting Speed QOG fetter ent tra Hr ear H One nO aU EERENS eVa EEEREN IAEE eta Reference Point Approach 8 1 Fundamentals r trrsrrsrisriarisrisriarisriArISFISPIAPISPIAFESFIAPIAPIAPIAFIAFIAPIAFIAPIAFIAFISPIAFISPIAFISEISEESE 8 2 Referencing AXES eee eee eee eee eee 8 3 Data Descriptions Jaca ALR d on APACE E A mond Sea DADE MARA ROR ela PAA EE Spindle slurs as eshucel bn eapeintueed ig Sr ecu gatee Nip hea Pe de a eters NY POA eta S GAR Ee ion sara d Gare WATS ees pm A A Padres 9 1 Spindle MOS rrrsrisriserarrsriaprapispiarinrinris ristis PES PIER IAEA RIA P ES PES PIA E IATA RISE ES PES ELAR LALA RLS ELSE 9 1 1 Spindle Control Mode er ter teeter teeter tartare errant a Ee Taran LAP LA PES PES PLA P IATA DIARIES ELSE LAPT A TART RESP Lae 9 1 2 Spindle Positioning Mode vriirierierte rr ee EEE LEE Ee 9 1 3 Spindle Positioning Mode sisrisrrsrerrrsrrarssrisnrarinrisrrarisrisnrarinrisrrarieriserarinrisrrarinriserarine 9 2 Referencing Synchronizing a a A be eiSaaE 9 3 Speed and Gear Stage Change AE AAA ENEAN ee er ee O eee ee er ee 9 4 Programming r trtrrisrrsriariariariariariA FIAFIA FIAFIAFISPIAFISFISPEAFISPINFESFIAPEAPEAPIAFIAPIAPIAFIA FIAFIA FINE 9 5 Spindle Moni
53. The present documentation describes the functionalities provided by the control system SINUMERIK 802S 802C base line in detail The Functions descriptions provide the information required for configuration and start up The Functional Descriptions provide information for e The planning engineer of the equipment e The PLC programmer when developing the PLC user program with the listed signals e The start up engineer after planning and designing of the equipment e The serviceman for checking and interpreting the status displays and alarms SINUMERIK 802S C base line Description of Functions Contents Contents 1 AXiS Spindle Monitoring ve EE ETE 1 1 Motion Monitoring FUNCIONS trsrrsrisrrsrisrisrrariarisriaristinPIARNAPIAFIAFISPIAENA PIA PIA FIA PIA Lae 1 1 1 Contour Monitoring E E E A A dig Ra Riacedla ada 1 1 2 Positioning Monitoring UE ar REEE OE Pia aed GY RISA OY EEEP PEENE TENANE TENE EEEIEE EEEE E EEEE 1 1 3 Zero Speed Control ceric rte reenter ee ree ree ree reer ee Pee PEE risers rinrin PIS PIAPEAPIAPNAPIS PIAFIN PLSD LAPIS LAPIS PISEISE 1 1 4 Clamping Monitoring virisricrirter tert EEE LEE 1 1 5 Set Speed Monitoring Melia MAPA AE eee MOAT Hee ones sane RNRT IA BAS Lee RGA ERROR DRE E 1 1 6 Actual Velocity Monitoring Jace Nal NR Lack Rae nde shea hae Viel URNA acR Ld Mia CAC eM a Hid E el daletbale da ac decioemale 1 2 Encoder Monitoring FUNCTIONS rirrrrrrsrrsrrrriariariarinprariariarisriserarrarisrisriarrarrariariariariarineiar
54. Value System Closed Loop Control 3 1 Setpoint Actual Value System aa ee ere ee ere ee 3 1 1 General eee eee eee eee ere e reer eee eee Tce err er eer eare 3 1 2 Speed Setpoint Output and Actual Value Processing tritrisrisrrsrisrrsrrarisrisrrarisriariariarisrisrise 3 2 Closed Loop Control Servo Gain trite riers ese r ee ee rb rE OHO E OE HOON OOH Inn PAA FEE rer rite 3 3 Velocity Control for Stepper MOtOr rit citieetesteiee erica eth EEA RIA tier tetas Gd eke ed ude eee 3 3 1 Knee Shaped Acceleration Characteristic i cicriccirtrtsrt crt crrrerr nitrites rrr erties nts retrncrii eines 3 3 2 Parameterization of the Stepper Motor Frequency vsritrisritrssrisrieriarisriarieriaeiariariarianianias 3 4 Data Description ire Meds hated hace nda Gee EAE EREE PEE EEE AEEA Paar eee Paar A Ne Red HAG ROY eed EAR 4 Manual Traversing and Handwheel Traversing E sna v exc ce edulis E bareree 4 1 General Properties of Manual Traversing in JOG Mode viririeriririrrtr eters 4 2 Controlling Manual Traversing via the PLC Interface is isrrirter terre rrr erent eiee 4 3 Continuous Traversing Head eA FON NRA RAINE AER Ge RR Aide AMR R Rd eae Midd ATT 4 4 Incremental Traversing INC csritrterter rr ee EERE 4 5 Handwheel Traversing in JOG Mode MERC e ee eee errr re 4 6 Special Features of Handwheel Traversing aCe RAHN Aen eae AUR Ses Ana Ra wate E Mace alee 4 6 1 Monitoring FUNCTIONS verter tere renee rete ee ene ree rE REAR EA PEARL ADEA DIAPER LAPIN DEAD ES PIAL ALAR ISDE
55. a rising edge of the reference cam has been detected again i e traversing starts only in the direction opposite to the direction set for the cam search MD REFP_CAM_DIR_IS_ MINUS The speed is defined by MD REFP_VELO_SEARCH_CAM A falling reference cam edge will stop the axis turn the direction of rotation and the search for the reference point cut off speed will be carried out with the first synchronous pulse Default 0 Related to MD REFP_SEARCH_MARKER_REVERSE MD REFP_CAM_DIR_IS_MINUS 34050 REFP_SEARCH_MARKER_REVERSE 0 MD number Reversal of direction on reference cam Min input limit 0 Max input limit 1 Changes effective after Power On Protection level 2 7 Unit Data type BOOLEAN Valid as from SW version Meaning This machine data can be used to set the search direction of the first synchronous pulse BERO zero mark synchr pulse ahead of or on the reference cam 0 Synchronization after falling reference cam edge The machine axis accelerates to the speed set in MD REFP_VELO_SEARCH_MARKER reference point cut off speed opposite to the direction specified in MD REFP_CAM_DIR_IS_MINUS reference point approach in minus direction When the reference point is left IS Reference point approach delay V380x1000 7 is reset the control system will synchronize itself with the first synchronous pulse BERO zero mark 1 Synchronization after rising refe
56. allow axis movement e g door not closed Spindle Stop in order to carry out tool change Special cases errors 11 22 SINUMERIK 802S C base line Description of Functions Tool Compensation 12 Brief description The SINUMERIK 802S 802C base line control system provide calculation of tool compensation data Length compensation Radius compensation Saving tool data in tool offset memory Tool coding by T numbers ranging from 0 to 32000 Definition of a tool by max 9 edges The edge is described by tool parameters Tool type Geometry Length Wear Length Geometry Radius Wear Radius Edge position with turning tools Tool change can be selected either immediately with T command or via M6 Tool radius compensation Compensation active for all interpolation types Linear Circular Compensation on external corners can be selected via transition circle G450 or intersection point of equidistants G451 Automatic detection of external internal corners Note Detail description see User Manual Operation and Programming SINUMERIK 802S C base line Description of Functions 12 1 Tool Compensation 12 1 Tool Selecting the tool Tool change immediately Tool change with M06 Note T value range Tool compensation 12 2 A tool is selected in the program by means of the T function Whether the new tool is changed i
57. axes Signal status 0 or edge change 1 gt 0 The feed override entered in the PLC interface will not be considered When the feed override is inactive the NC internally uses an override factor of 100 Special cases The feed override is inactive when G33 is active errors Related to IS Feed override V32001000 3 and z V32001008 3 Feed Stop axes in WCS Interface signal Signal s to channel PLC NCK Edge evaluation no Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The signal is only active in JOG mode traversing the axes in WCS The signal results in Feed Stop of the respective axis When an axis is traversing this signal results in controlled deceleration to standstill ramp stop No alarm message is output The position control remains i e the following error is reduced to zero If for an axis for which Feed Stop is present a traversing request is provided the traversing request remains This traversing request is carried out immediately at the moment when Feed Stop is canceled Signal status 0 or edge change 1 gt 0 The feed for the axis is active If a traversing request traversing command is provided for the axis when Feed Stop is canceled the traversing request is carried out immediately SINUMERIK 802S C base line Description of Functions
58. axis mode K factor loop gain 1 000 Data for 1st gear stage Monitoring functions 001 M40 speed 2 010 Data for 2nd gear stage Min max speed 3 011 Data for 3rd gear stage 4 100 Data for 4th gear stage 5 101 Data for 5th gear stage 110 111 Distinctive features To decelerate the spindle the PLC user need not set the IS Spindle Stop V38030004 3 The IS Spindle Reset V38030002 2 aborts gear stage change At the same time the programmed spindle speed and the programmed direction of rotation of the spindle are deleted After gear stage change the spindle will not accelerate to the programmed spindle speed Typical time sequence for gearchange with the spindle on standstill IS Control mode IS Oscillation mode Programmed value IS Gearstage changed IS Change gearstage IS Set gearstage 1 2 IS Spindle in set range IS Spindle on standstill IS Actual gearstage IS Oscillation speed 4st gear stage active 2nd gearstage active Internal feed blocking Spindle speed IS Spindle stop O S value t1 When 51300 is programmed the NCK detects a new gear stage 2nd gear stage sets the IS Change gear stage and blocks execution of the next part program block t2 The spindle is on standstil and oscillation oscillation by NCK is started The IS Oscillatio speed must be set on time t2 at the latest t3 The new gear stage is active The PLC user transfers the new actual ge
59. axis or spindle In axes context this process is called referencing It is also required for axes with stepper motors that do not have a position measuring system In this context the position measuring system is considered internally existing Operation of reference point approach Approach to the reference point can be started for each machine axis in the operating mode JOG Reference Point Approach by means of a direction key depending on the MD REFP_CAM_DIR_MINUS All further actions are carried out automatically When an axis is referenced it is displayed on the screen see User Manual Operation and Programming It is possible to reference all axes at the same time If the machine axes are to be referenced in a certain order either the operator must observe the specified order when starting or channel specific referencing is set Synchronization signal and reference cams The synchronization signal is usually provided by the zero pulse of an incremental encoder If no measuring system exists axis with stepper motor without position measuring system a BERO sensor ranging sensor is required This can be installed directly on the motor shaft or spindle In this case the pulses are provided during each revolution Another signal must be provided in order to differentiate which pulse is used to synchronize the axis This signal is provided from a reference cam The signals of the reference cam are also used to co
60. by the NCK and after the spindle has come to stop The position control is switched off The spindle is decelerated with the acceleration of speed controlled mode When the IS Oscillation speed is set the spindle starts oscillating with the oscillation acceleration MD SPIND_OSCILL_ACCEL If the IS Oscillation by PLC V38032002 4 is not set automatic oscillation in the NCK is carried out using the IS Oscillation speed The two times for the directions of rotation are entered in the MD SPIND_OSCILL_TIME_CW oscillation time for M3 direction and MD SPIND_OSCILL_TIME_ CCW oscillation time for M4 direction If the IS Oscillation by PLC is set the IS Oscillation speed will only output a speed in conjunction with the IS Set direction of rotation CW and CCW Oscillation i e permanent changing of the direction of rotation is carried out by the PLC user with the IS Set direction of rotation CCW and CW oscillation by PLC Signal status 0 or edge change 1 gt 0 The spindle does not oscillate Signal not to spindle operating modes other than oscillation mode applicable Application Oscillation speed is used to facilitate meshing of the new gear stage The example s spindle motor must permanently change its direction of rotation Related to IS Oscillation by the PLC V38032002 4 IS Set direction of rotation CCW V38032002 7 IS Set direction of rotatio
61. by the axes V26000001 2 then the distance to go is delivered for the axis concerned data format 4 byte floating point FLOAT 14 4 Signals from PLC to MMC Key lock V19005000 2 The IS Key lock can be used to lock 1 signal or unlock O signal SINUMERIK 802S C base line 14 9 Description of Functions Various Interface Signals 14 10 SINUMERIK 802S C base line Description of Functions List of Interface Signals 15 Brief description The following contains an overview of the interface signals exchanged between NCK PLC MMC PLC and the machine control panel MCP PLC For more detail information the list contains references on further documentation sections 1 xx Section xx of this Functional Description 2 Section Start Up of PLC of Start Up Instructions SINUMERIK 802S C base line 15 1 Description of Functions List of Interface Signals 15 1 Interface Signals Interface signal Name Ref Section General PLC gt NCK V26000000 1 EMERGENCY STOP 1 13 V26000000 2 Acknowledge EMERGENCY STOP 1 13 V26000000 7 to 4 User class 4 to 7 1 14 V26000001 1 Request axis actual values 1 14 V26000001 2 Request distances to go by the axes 1 14 General NCK gt PLC V27000000 1 EMERGENCY STOP active 1 13 V27000002 6 Drive ready 1 14 V2700000
62. frequency of thre incremental track Using a small value in ENC_FREQ_LIMIT_LOW it can be achieved that the encoder is turned on only below the limit frequency of the absolute track and therefore only references if this is admitted by the absolute track This referencing is done for spindles automatically 36310 MD number ENC_ZERO_MONITORING n Zero mark monitoring Default 0 Min input limit 0 Max input limit plus Change effective after NEW_CONF Protection level 2 7 Unit Data type DWORD Valid as from SW version Meaning This machine data is intended to activate zero mark monitoring and to define the number of illegal zero mark errors 0 no zero mark monitoring gt 0 number of detected errors at which monitoring is to be responded Examples ENC_ZERO_MONITORING 0O 2 1st error is ignored monitoring function responds with 2nd error After the encoder has been turned on the number of zero mark errors is reset to 0 SINUMERIK 802S C base line Description of Functions Axis Spindle Monitoring 36610 AX_EMERGENCY_STOP_TIME MD number Duration of deceleration ramp during error conditions Default 0 05 Min input limit 0 Max input limit plus Change effective after NEW_CONF Protection level 2 7 Unit s Data type DOUBLE Valid as from SW version Meaning The spindle is stopped with rapid stop open position control loop
63. immediately and the currently active block is no longer processed Only the axes are stopped without contour violation Any distances to go are only traversed after restart The program status changes to Stopped and the channel status changes to Interrupted Signal status 0 or edge change 1 gt 0 No effect Application example s The program is continued from the breakpoint with NC start P IS NC Stop IS NC Start Program running Axis running Block executed JEUPE Special cases errors The NC Stop signal must be provided for at least one PLC cycle time Related to IS NC Stop at block end IS NC Stop axes plus spindles IS Program status stopped IS Channel status interrupted 5 28 SINUMERIK 802S C base line Description of Functions Program mode V32000007 4 Interface signal Edge evaluation no NC Stop axes plus spindles Signal s to channel PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The currently active NC program is stopped immediately and the currently active block is no longer executed Any distances to go are only traversed after restart The axes and the spindle are stopped They are stopped by controlled deceleration The program status changes to Stopped and the channel status changed to
64. interp pts system variable When selecting the number of interpolation points or the distance between them the size of the compensation table and the required memory capacity of the buffered NC user memory SRAM which results from this should be taken into account 8 bytes are needed per compensation value interpolation point Special cases errors Caution After the MD MM_ENC_COMP_MAX_POINTS has been modified the buffered NC user memory is set up automatically during power up of the system During this process all data of the buffered NC user memory e g part programs tool offests etc get lost The alarm 6020 Machinen data modified memory mapping modified is signaled If the NC user memory cannot be mapped since the available total memory is not sufficient alarm 6000 Memory mapping carried out with standard machine data is signaled In this case as an alternative the NC user memory mapping is carried out with the default values of the standard machine data Related to MD ENC_COMP_ENABLE 0 SSFK active 6 12 SINUMERIK 802S C base line Description of Functions Face Axis r Brief description With control systems for turning machines the X axis is defined as face axis For these reason some special functions are bound to this axis e Radius diameter specification G22 23 The axis provides the actual path values for the function Constant cutting speed
65. is reduced up to the maximum speed of 10 rev s down to 7 degrees s MD not applicable errors resulting in quick stop Default for the axes Related to MD MAX_AX_ACCEL axis acceleration MD GEAR_STEP_SPEEDCTRL_ACCEL acceleration in speed control mode MD GEAR_STEP_POSCTRL_ACCEL acceleration in position control mode MD ACCEL_REDUCTION_SPEED_ POINT speed for reduced acceleration 35230 ACCEL_TYPE_DRIVE MD number Acceleration reduction ON OFF 802S base line 1 1 1 0 802C base line 0 0 0 0 Min input limit 0 Max input limit 1 Change valid after Power On Protection level 2 7 Unit Data type BOOLEAN Valid as from SW version Meaning Default setting of acceleration behavior for all traversing movements 0 No acceleration reduction 1 Acceleration reduction active Application of acceleration reduction recommended for stepper motor axes MD applicable to JOG_AND_POS_JERK_ENABLE 1 Related to MD JOG_AND_POS_JERK_ENABLE MD ACCEL_REDUCTION_TYPE MD ACCEL_REDUCTION_FACTOR MD ACCEL_REDUCTION_SPEED_POINT 4 16 SINUMERIK 802S C base line Description of Functions Setting data Manual Traversing and Handwheel Traversing 41110 SD number Default 0 JOG_SET_VELO JOG velocity for linear axes for G94 Min input limit 0 Max input limit plus Changes effective immediately Protection level Unit mm
66. is selected via the PLC the interface signal Activate dry run feed must be set from the PLC user program Signal status 0 or edge evaluation 1 gt 0 The programmed feedrate is used for traversing Active after Reset status Application example s Testing a part program with increased feedrate Related to IS Dry run feed selected V17000000 6 SD DRY_RUN_FEED dry run feed SINUMERIK 802S C base line 11 15 Description of Functions Feeds VB32000004 Interface signal Edge evaluation no Feed override Signal s to channel PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The feed override is set via the PLC in the form of a Gray code eaten cove _ Prato se Code Position Factor 1 00001 00 4 ooto 004 5 oot 006 6 0010 008 8 omoo 020 P onmo 030 12 roto 060 o 11001 0 90 _ Table 11 1 Gray coding for feed override Related to IS Feed override active V32000006 7 11 16 SINUMERIK 802S C base line Description of Functions Feeds VB32000005 Interface signal Edge evaluation nein Rapid traverse override Signal s to channel PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The rapid traverse overr
67. mark errors entered in MD ENC_ZERO_MONITORING 0 e Is reached while the measuring system is active alarm 25020 Zero mark monitoring is output The spindle is stopped with rapid stop see Section 1 1 1 1 6 SINUMERIK 802S C base line Description of Functions Axis Spindle Monitoring Error causes remedy e MD ENC_FREQ_LIMIT 0 encoder limit frequency set too high e Encoder cable damaged e Encoder or encoder electronics defective 1 2 3 Hardware Errors Function not applicable to stepper motor axes In case of errors the measuring circuit monitoring functions result in alarm 25000 25001 Hardware error Note In case of hardware errors in the measuring circuit the IS Referenced Synchr onized V390x0000 4 is canceled i e the axis spindle must be re referenced resynchronized SINUMERIK 802S C base line 1 7 Description of Functions Axis Spindle Monitoring 1 3 Limit Switch Monitoring Function Activation Effect Remedy Function Activation 1 8 2nd SW limit switch enabled via PLC HW limit switch Mechanical traversing end 1st SW limit switch EMERGENCY STOP Fig 1 1 Limit switches using the example of positive axis direction Hardware limit switches For each axis there is a hardware limit switch for each direction to prevent the slide from being pushed out of the slide bed If the hardware limit switch is overshot the PLC signals this to the NC
68. n Number of load spindle revs Fig 3 2 Speed setpoint processing An axis velocity of 15 000 mm min is to be achieved Leadscrew pitch s 10 mm U Gearbox motor rev s spindle rev s R 2 1 2 VawetR 15000272 Achs T mhn 3000 rev min nMan S S mm BVA rev The calculated motor speed must be entered in MD RATED_VELO n gt Machine data settings MD RATED_VELO 0 3 000 rev min MD RATED_OUTVAL 80 with analog drives only MD DRIVE_AX_RATIO_NUMERA Q 2 MD DRIVE_AX_RATIO_DENOM 0 1 MD LEADSCREW_PITCH 10 mm rev Actual value processing To ensure a correctly closed position control loop the control system must be informed of the actual value resolution The following axis specific machine data serve this purpose The MD marked with do not apply to stepper motor axes not equipped with an encoder The control system automatically calculates the actual value resolution from the settings made in the machine data MD ENC_IS_DIRECT n encoder directly installed on the machine MD DRIVE_ENC_RATIO_DENOM n denominator of load gearbox MD DRIVE_ENC_RATIO_NUMERAJn numerator of load gearbox MD DRIVE_AX_RATIO_DENOM n denominator of load gearbox MD DRIVE_AX_RATIO_NUMERAJn numerator of load gearbox SINUMERIK 802S C base line Description of Functions Velocity Setpoint Actual Value System Closed Loop Control MD STEP_RESOL steps per stepper motor revolution MD
69. parameter record no 0 5 Application see Section 2 3 example s Related to MD DYN_MATCH_ENABLE dynamic response adaptation SINUMERIK 802S C base line Description of Functions 3 19 Velocity Setpoint Actual Value System Closed Loop Control 3 20 SINUMERIK 802S C base line Description of Functions Manual Traversing and 4 Handwheel Traversing Setting up the Even modern numerically controlled machine tools must allow the axes to be machine traversed manually In particular when setting up a new machining program it is necessary to move the axes either by means of the traversing keys on the machine control panel or the electronic handwheel Clearing the tool After interrupting the program by certain events such as NC STOP RESET or mains power failure the machine operator must clear the tool from the current machining position manually This is usually done by means of the direction keys in JOG mode Contents The present Functional Description describes the following possibilities and features of manual traversing Continuous traversing in JOG mode Incremental method INC in JOG mode Traversing the axes using electronic handwheels accessories in JOG mode SINUMERIK 802S C base line 4 4 Description of Functions Manual Traversing and Handwheel Traversing 4 1 General Properties of Manual Traversing in JOG Mode JOG mode Machine functions Traversing Simultaneous Traversi
70. pressed Vv00000001 0 Interface signal Edge evaluation no Selected machine function REF Signal s from MCP gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 Key for REF is pressed Signal status 0 or edge change 1 gt 0 Key for REF is not pressed References FB Reference point approach voo000001 1 Interface signal Edge evaluation no Selected mode AUTOMATIC Signal s MCP gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 Key for AUTOMATIC mode is pressed Signal status 0 or edge change 1 gt 0 Key for AUTOMATIC mode is not pressed v00000001 3 Interface signal Edge evaluation Selected mode MDA Signal s from MCP gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 Key for MDA mode is pressed Signal status 0 or edge change 1 gt 0 Key for MDA mode is not pressed V17000000 5 Interface signal Edge evaluation no M01 selected Signal s from MMC gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 Activate Program Control M1 has been selected from the operator interface The function is thus not yet a
71. reached Exact Stop Coarse Transverse axes The X axis is the transversal axis When traversing this axis in JOG mode the following should be considered Continuous traversing When a transversal axis is traversed continuously there are no differences Incremental traversing Only the half of the distance of the selected increment size is traversed For example when the traversing key is pressed and INC10 is set the axis traverses by 5 increment values with refer to the radius 10 diameter increments Traversing with the handwheel Only the half of the distance per handwheel pulse is traversed when the axes are traversed by increments using the handwheel SINUMERIK 802S C base line 4 11 Description of Functions Manual Traversing and Handwheel Traversing 4 7 Data Description Machine data 11310 MD number MN_HANDWH_REVERSE Threshold for change of handwheel direction Default 2 Min input limit 0 Max input limit Change effective after Power On Protection level 2 7 Unit Data type BYTE Valid as from SW version Meaning 0 No immediate traversing in opposite direction gt 0 Immediate traversing in opposite direction if the handwheel is turned in the opposite direction at least by the specified number of pulses 11320 MD number Default 1 Change effective after Data type DOUBLE Meaning HANDWH_IMP_PER_LATCH n Handwheel pulses per latched position handwheel num
72. results in a movement of the associated machine axis in negative direction The amount of the compensation value is not limited and is also not monitored In order to avoid inadmissibly high velocities and accelerations of the machine axis due to the compensation the compensation values should be selected accordingly small Otherwise if large compensation values are selected other axis monitoring functions could cause alarm messages e g contour monitoring speed rated value limiting The LEC is only effective if the following preconditions are fulfilled The compensation values are stored in the NC user memory and effective after Power ON e The function was activated for the machine axis concerned MD ENC_COMP_ENABLE 0 1 This is at the same time write protection for the value table e The axis was referenced IS Referenced Synchronized 1 V390x0000 4 Once these conditions are fulfilled the axis specific actual position value is modified by the associated compensation value in all operating modes and traversed by the machine axis immediately If the reference gets lost thereafter for example since the encoder frequency has been exceeded IS Referenced Synchronized 1 0 compensation processing is switched off The number of reserved interpolation points of the compensation table must be defined for each machine axis and for each measuring system using the MD MM_ENC_COMP_MAX_POINTS and the memor
73. simulated on the operator interface by changing axis position values The axis position values for the display are generated from the calculated setpoints The part program is executed as normal Signal status 0 or edge change 1 gt 0 The program control Program test is not active Related to IS Activate program test IS Program test selected V33000003 0 Interface signal Edge evaluation no Program status Running Signal s from channel NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The part program has been started with IS NC Start and is running Signal status 0 or edge change 1 gt 0 Program stopped by M00 M01 or NC Stop or mode change The block is executed in single block mode End of program reached M2 Program aborted by Reset Current block cannot be executed Special cases errors The IS Program status running does not change to 0 when the workpiece machining is stopped by the following events Output of feed blocking or spindle blocking IS Read in disable Feed override to 0 Response of spindle and axis monitoring V33000003 1 Interface signal Edge evaluation no Program status Waiting Signal s from channel NCK gt PLC Signal s updated cyclically Signal s valid as from SW versi
74. simulation axis is defined by setting the two MD CTRLOUT_TYPE 0 setpoint output type and ENC_TYPE 0 actual value sensing type to 0 As soon as the standard machine data are loaded the axes become simulation axes SINUMERIK 802S C base line Description of Functions Velocity Setpoint Actual Value System Closed Loop Control Setpoint and actual value can be set to the reference point value by reference point approach It is also possible to define via the MD SIMU_AX_VDI_OUTPUT output of axis signals for simulation axes whether the axis specific IS are to be output to the PLC during simulation 3 1 2 Speed Setpoint Output and Actual Value Processing Control direction Traversing direction General Basic setting Control direction and traversing direction of the feed axes The MD ENC_FEEDBACK_POL n sign of actual value can be used to change the sign of actual value sensing and thus the control direction of position control The MD AX_MOTION_DIR traversing direction can be used to reverse the direction of movement of the axis without affecting the control direction of the position control Speed setpoint adjustment tacho adjustment The machine data RATED_VELOJ n determines the rated motor speed The MD RATED_VELO determines the rated motor speed MD RATED_OUTVAL rated output voltage tells the control system which speed setpoint voltage corresponds to which motor speed not with stepper
75. specific IS are set to 0 MD CTRLOUT_TYPE output mode of setpoint 1 Meaning 0 MD irrelevant bei Application MD SIMU_AX_VDI_OUTPUT 0 example s For example this prevents that the brake is opened when simulating an axis SINUMERIK 802S C base line 3 13 Description of Functions Velocity Setpoint Actual Value System Closed Loop Control 31000 ENC_IS_LINEAR n MD number Direct measuring system linear scale Default 0 Min input limit 0 Max input limit 1 Change effective after Power On Protection level 2 Unit Data type BOOLEAN Valid as from SW version Meaning 1 The encoder for actual position sensing is linear linear scale 0 The encoder for actual position sensing is rotary The machine data index is coded as follows encoder no 0 Further references 31020 ENC_RESOL n MD number Increments per revolution Default Min input limit 0 Max input limit plus 802S base line 1000 1000 1000 2048 802C base line 2500 2500 2500 2048 Change effective after Power On Protection level 2 7 Unit Data type DWORD Valid as from SW version Meaning In this MD the increments per encoder revolution must be entered The machine data index is coded as follows encoder no 0 31030 LEADSCREW_PITCH MD numb
76. speed V38032002 5 If only the IS Oscillation speed is set without setting a new gear stage no change to oscillation mode is carried out Oscillation is started by means of the IS Oscillation speed Depending on the functional sequence and the IS Oscillation by PLC V38032002 4 oscillation differentiates Oscillation by NCK e Oscillation by PLC For each direction of rotation the oscillation time for oscillation mode can be set in machine data Oscillation time in M3 direction in the following called t1 in MD SPIND_OSCILL_TIME_CW Oscillation time in M4 direction in the following called t2 in MD SPIND_OSCILL_TIME_CCW Phase 1 When the IS Oscillation speed V38032002 5 is provided the spindle motor accelerates to the speed set in MD SPIND_OSCILL_DES_VELO oscillation speed with oscillation acceleration The start direction is defined by MD SPIND_OSCILL_START_DIR start direction for oscillation The time t1 or t2 is started depending on which start direction is defined in MD SPIND_OSCILL_START_DIR Phase 2 When time t1 t2 has elapsed the spindle motor accelerates into the opposite direction to the speed set in MD SPIND_OSCILL_DES_VELO oscillation speed Time t2 t1 is started Phase 3 When time t2 t1 has elapsed the spindle motor accelerates into the opposite direction same direction as with phase 1 to the speed set in MD SPIND_OSCILL_DES_VELO Time t1 t2 i
77. spindle is closed the position control is active Speed controller active V390x0001 6 The speed controller for the axis spindle is closed speed control is active Current controller active V390x0001 7 The current controller for the axis spindle is closed current control is active 14 8 SINUMERIK 802S C base line Description of Functions Various Interface Signals Lubrication pulse V390x1002 0 The IS Lubrication pulse is sent from the NCK and changes its status once the axis spindle has covered a distance longer than entered in MD LUBRICATION_DIST distance to be traversed for lubrication from PLC Rotation monitoring error V390x5000 0 The signal Rotation monitoring error is set if the stepper motor was incorrectly controlled even if Rotation monitoring V380x5000 0 is not active The user must stop the drive safely In this case the reference point gets lost To continue work re referencing is required Axis actual values VD570x0000 software version 3 1 and higher If cyclic processing of the current actual value position has been requested for all axes via the IS Request axis actual values V26000001 1 then the actual position is delivered for the axis concerned data format 4 byte floating point FLOAT Distances to go by the axes VD570x0004 software version 3 1 If cyclic processing of the current distances to go has been requested for all axes via the IS Request distances to go
78. standstill from its maximum traversing velocity speed If the axis spidle is at a standstill Servo Enable for the drive is canceled immediately Application example s The speed control of the drive should be maintained for this time to ensure that the axis spindle can come to a standstill from its maximum traversing velocity speed For this time Servo Disable should be delayed for an axis spindle moving Special cases errors the brake ramp under error conditions MD AX_EMERGENCY_STOP_TIME CAUTION If the servo disable delay is set to low servo enable is already canceled although the axis is still traversing In this case it is suddenly stopped with setpoint 0 For this reason the time defined in this MD should be greater than the time of Related to IS Servoce enable V380x0002 1 MD AX_EMERGENCY_STOP_TIME time of brake ramp under error conditions SINUMERIK 802S C base line 13 7 Description of Functions EMERGENCY STOP 13 6 Signal Description V26000000 1 NOT AUS Interface signal Signal s to NC PLC gt NC Edge evaluation no Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The NC is set to the EMERGENCY STOP condition EMERGENCY STOP sequence in the NC starting the Signal status 0 bzw edge change 1 gt 0 e The NC is not in the EMERGENCY STOP condition e The EMERGENCY STOP conditio
79. starts The selection is carried out via MD ENC_REFP_MODE 4 Due to different delay times of the two BERO edges the synchronization point will not be exactly in the middle Using the same reference point cut off speed the single edge evaluation will result in better repeatabilities SINUMERIK 802S C base line Description of Functions Reference Point Approach 8 3 Data Descriptions Machine data 20700 REFP_NC_START_LOCK MD number NC Start inhibited without reference point Default 1 Min input limit 0 Max input limit 1 Changes effective after Reset Protection level 2 7 Unit Data type BOOLEAN Valid as from SW version Meaning 0 The IS NC Start V32000007 1 for starting part programs or part program blocks in AUTOMATIC or MDA is active even if one or all axes of the channel are not yet referenced In order to ensure that the axes nevertheless reach the correct position after NC Start the workpiece coordinate system WCS must always be adapted to the currently active machine coordinate system settable zero offset determination 1 NC Start only if all axes are referenced 30240 MD number FNG IYPE Default 0 Min input limit 0 Max input limit 5 Changes effective after POWER ON Protection level 2 7 Unit Data type BYTE Valid as from SW version Meaning Encoder type 0 Simulation 1 Used 2 Square wave encoder standard line number multiplied wit
80. target position is calculated the acceleration changes to GEAR_STEP_POSCTRL_ACCEL acceleration in position control mode Phase 4 The spindle decelerates with GEAR_STEP_POSCTRL_ACCEL from the calculated Brake point to the target position Phase 5 The position control remains active and keeps the spindle on the programmed position The IS Exact stop fine and Exact stop coarse are set if the distance between the spindle position and the programmed position spindle set position is less than the exact stop tolerance fine and coarse defined in the MD STOP_LIMIT_FINE and MD STOP_LIMIT_COARSE SINUMERIK 802S C base line Description of Functions Spindle Positioning from standstill Positioning from If you wish to position the spindle from standstill the following two cases are standstill differentiated e Case 1 The spindle is not synchronized This is the case if you wish to position the spindle after switching on the control system and the drive e Case 2 The spindle is synchronized This is the case if the spindle has been rotated by at least one spindle revolution with M3 or M4 prior to the first positioning and after control system and drive have been switched on and if the spindle has then be stopped with M5 synchronization with the zero mark Speed SPOS 180 1 rmin Position control switch on speed l zero mark SL Fig 9 4 Positioning with the spindle stopped and not synchron
81. the machine axis from running across the reference cam Related to Signals from axis spindle V390x0000 4 Interface signal Edge evaluation Referenced synchronized 1 Signal s from axis spindle NCK gt PLC Signal s updated Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 Axes If the machine axis has arrived on the reference cam during reference point approach the machine axis is referenced and the IS Referenced Synchro nized 1 is set Spindles After Power On a spindle is synchronized after a spindle revolution at the latest 360 degrees zero mark overrun or BERO responded Signal status 0 or The machine axis spindle with position measuring system 1 is not edge change 1 gt 0 referenced synchronized Related to IS Position measuring system 1 References SINUMERIK 802S C base line 8 15 Description of Functions Reference Point Approach 8 16 SINUMERIK 802S C base line Description of Functions Spindle Brief description 9 Depending on the machine type the following functions are possible for an analog NC controlled spindle e Setting the direction of rotation of spindle M3 M4 Setting the spindle speed S Spindle Stop without orientation M5 e Spindle positioning SPOS position controlled spindle required e Gear stage switchover M40 to M45 Thread cutting tap
82. the IS Error Rotation monitoring is signaled to the PLC V390x5000 0 The signal provides for edge evaluation signal and is only present as long as the PLC clock is provided At the same time the monitoring is automatically disabled and rereferencing is required Note The Error Rotation monitoring occurs whenever the stepper motor is incorrectly controlled even if the rotation monitoring is not enabled The user must make sure that the drive is switched off reliably Error Rotation monitoring means Drive off SINUMERIK 802S C base line 1 11 Description of Functions Axis Spindle Monitoring 1 6 Data Description Machine data 31100 BERO_CYCLEj n MD number Steps between two BERO edges for rotation monitoring of the stepper motor Default 2000 Min input limit 10 Max input limit 10 000 000 Change effective after POWER ON Protection level 2 7 Unit steps Data type DWORD Valid as from SW version Meaning For the rotation monitoring of the stepper motor The number of steps between two equal BERO cycles must be entered 31110 BERO_EDGE_TOL n MD number Tolerance of BERO edges for rotation monitoring of the stepper motor Default 50 Min input limit 10 Max input limit 10 000 000 Change valid after POWER ON Protection level 2 7 Unit steps Data type DWORD Valid as from SW version Meaning The number of steps of the stepper motor must be entered in
83. the actual speed If the actual speed deviates from the set speed by more than the spindle speed tolerance MD SPIND DES VELO_TOL spindle speed tolerance e the IS Spindle within set range V39032001 5 is set to zero e path feed is blocked internally by the NCK 9 5 3 Max Spindle Speed Max spindle speed For spindle monitoring Max spindle speed a max speed is defined which Speed limitation from PLC 9 20 may not be exceeded by the spindle The max spindle speed is entered in MD SPIND_MAX_VELO_LIMIT The NCK will limit the set spindle speed to this value If the spindle actual speed nevertheless exceeds the max spindle speed with consideration of the spindle speed tolerance MD SPIND_DES_VELO_TOL spindle speed tolerance a drive error is present and the IS Speed limit exceeded V39032002 0 is set In addition alarm 22100 is output and all axes and the spindle are decelerated The spindle speed can be limited to a certain value by means of the PLC This value is stored in MD SPIND EXTERN_VELO_UNIT and activated via the IS Velocity spindle speed limitation V38030003 6 SINUMERIK 802S C base line Description of Functions Spindle 9 5 4 Min Max Speed of Gear Stage Max speed The max speed of the gear stage is entered in MD GEAR_STEP_MAX_VELO LIMIT This set speed can never be exceeded in the activated gear stage When the programmed spindle speed is limited the IS Set speed limi
84. the position control SINUMERIK 802S C base line 3 7 Description of Functions Velocity Setpoint Actual Value System Closed Loop Control 3 2 Closed Loop Control Servo Gain Servo gain factor Parameter records of the position controller 3 8 For stepper motor axes the entered standard value set in MD POSCTRL_GAIN n should be kept For analog axes spindles the value should be adapted accordingly The machine data index n is coded as follows control parameter record no 0 5 However if the servo gain factor is too high instability overshooting and possible impermissibly high loads on the machine will result The maximum permissible servo gain factor depends on the following e Design and dynamics of the drive rise time acceleration and deceleration capabilities Quality of the machine elasticity vibration suppression e Position control cycle The servo gain factor is defined as follows ___Velocity m min KV Velocit m min Following error mm Unit of servo gain factor to VDI standard The position control can use 6 different parameter records They serve for quick adaptation of the position control to modified properties of the machine during operation e g _ inthe case of spindle gear change adaptation of the dynamic properties of an axis e g on tapping The following machine data can be changed by switching over the parameter record during operation MD D
85. their portion in the path result from this path Workpiece machining additionally requires a rotating spindle The spindle speed is set separately e g via the program with address S Apart from different machining tasks various positioning processes too are possible In this case the workpiece traverses along a straight line but not on the workpiece at the highest possible traversing rate Depending on the activated interpolation type and special G commands for feed preselection different feedrates velocities are used in the program The same applies to program dry run or manual traversing e Feed F with G1 G2 G3 G5 e Feed for thread cutting G33 e Feed for tapping with compensating chuck G63 e Feed for tapping without compensating chuck G331 G332 e Rapid traverse with GO e Dry run feed e Velocities for manual traversing of the axes Feed override For adaptation to modified technological conditions during machining or for testing purposes the programmed feed can be modified via operation PLC e g by turning the feed override switch or activating dry run feed SINUMERIK 802S C base line 11 1 Description of Functions Feeds 11 2 Feed F Functionality Programming Unit for F G94 G95 Programming example Unit for F with G96 G97 Note Maximum path velocity The feed F is the path velocity of the tool along the programmed workpiece contour The individual axis velocities result from the portion of
86. to program the feed override switch such that it is also active for rapid traverse When the function is active ROV is displayed in the status line The IS Feed override for rapid traverse selected V17000001 3 is set from the PLC to the MMC More detail description see Section 11 9 2 Feed override via Machine Control Panel SINUMERIK 802S C base line Description of Functions Feeds 11 7 Dry Run Feed Functionality A Selection Dry run feed This function is used for testing programs When the Dry Run function is active and the program started the feedrates programmed in conjunction with G1 G2 G3 G5 are replaced by the feed value programmed in SD DRY_RUN_FEED The dry run feed value is also valid instead of the programmed revolutional feed in program blocks with G95 However if the programmed feedrate is higher than the dry run feedrate the higher value is used Danger When the Dry Run Feed function is active workpiece machining is not allowed since the cutting speed of the tools might be exceeded and the workpiece or machine tool could be destroyed due to the modified feedrate values The operation with dry run feed is selected in the operator interface in the Program Control menu This sets the IS Dry run feed selected V17000000 6 to the PLC In addition the desired value for the dry run feed must be entered in the Setting Data menu With the function activated DRY is displaye
87. tool from the tool holder without loading a new tool SINUMERIK 802S C base line 10 3 Description of Functions Output of Auxiliary Functions to PLC 10 4 Data Description Machine data 11100 AUXFU_MAXNUM_GROUP_ASSIGN MD number Number of auxiliary functions distributed over the auxiliary function groups Default 1 Min input limit 1 Max input limit 50 Changes effective after Power On User class 2 7 Unit Data type BYTE Valid as from SW version Meaning In this MD the real number of auxiliary functions which have been distributed over the groups must be entered Only the customer specific machine data are relevant not the predefined auxiliary functions Application example s Related to MD 22010 AUXFU_ASSIGN_TYPE n 22000 AUXFU_ASSIGN_GROUP n MD number Auxiliary function group HiFunr 0 49 Default 1 Min input limit 1 Max input limit 15 Changes effective after Power On User class 2 7 Unit Data type BYTE Valid as from SW version Meaning see MD AUXFU_ASSIGN_TYPE n auxiliary fucntion type Application example s 10 4 SINUMERIK 802S C base line Description of Functions Output of Auxiliary Functions to PLC 22010 MD number Default AUXFU_ASSIGN_TYPE n Auxiliary function type HiFunr in channel 0 49 Min input limit Max input limit 16 characters Changes effective after
88. traverse override switch Signal status 0 or edge change 1 gt 0 The axis traverses with the set JOG velocity SD JOG_SET_VELO or MD JOG_VELO Signal not applicable to AUTOMATIC mode and MDA Reference point approach JOG mode Related to IS Traversing key plus and Traversing key minus for axis V32001000 7 and 6 V32001004 7 and 6 V32001008 7 and 6 Traversing keys plus and minus for WCS axis Interface signal Signal s to channel PLC gt NCK Edge evaluation yes Signal s valid as from SW version Signal s updated cyclically Signal status 1 or edge change 0 gt 1 In JOG mode the selected axis can be traversed in both directions by means of the traversing keys plus and minus Incremental traversing On signal status 1 the axis starts traversing by the set increment If the signal changes to 0 status before the increment is traversed the traversing movement is interrupted If the signal status is 1 again the traversing movement is continued As long as the increment is traversed completely the traversing movement of the axis can be stopped and continued several times as described above Continuous traversing If no INC dimension is selected the axis traverses as long as the traversing key is pressed If both traversing signals plus and minus are set at the same time no traversing movement is carried out or the traversing moveme
89. via a deceleration ramp of the set speed value if the following moitoring functions respond e Positioning monitoring e Zero speed control e Clamping monitoring e Set speed value monitoring e Actual speed value monitoring e Encoder limit frequency monitoring except for speed controlled spindle e Zero mark monitoring The duration for the reduction of the set speed value from the maximum set speed value to the set value 0 must be entered in the MD The duration until standstill depends on the current set speed value when a monitoring function responds Set speed value MD CTRLOUT_LIMIT e g current set speed value Current time until axis standstill T s AX EMERGENCY _STOP_TIME Fig 4 1 Deceleration ramp during error conditions Meaning With interpolating axes compliance with the contour during a deceleration phase is not guaranteed CAUTION If the duration of the deceleration ramp during error conditions is set too large servo enable will be canceled although the spindle is still moving It is then rapidly stopped with set speed value 0 For this reason the time in MD AX_EMERGENCY_STOP_TIME should be less than the time in MD SERVO_DISABLE_DELAY_TIME servo enable switch off delay Related to MD SERVO_DISABLE_DELAY_TIME Servo enable switch off delay MD CTRLOUT_LIMIT Maximum set speed value SINUMERIK 802S C base line 1 17 Description of Functions Axis Spindle Monitoring 1
90. with analog drive or stepper motor axis is depending on the acceleration characteristic defined for JOG in the axis specific machine data see Section NO TAG RESET or axis IS Delete distance to go Spindle Reset V380x0002 2 will cancel the traversing movement The existing set actual difference is deleted NC STOP will only interrupt the traversing movement Any set actual difference remains The distance to go is then covered by NC START Depending on the machine data HANDWH_REVERSE the response in case of traversing direction reversal is as follows e If the handwheel is moved in the opposite direction the resulting distance to be traversed is calculated and the end point calculated in this way approached as fast as possible If this end point is ahead of the point to which the moving axis can decelerate with the current traversing direction deceleration is carried out and the end point approached in the opposite direction Otherwise the newly calculated end point is approached immediately e If the handwheel is moved in the opposite direction by at least the number of pulses specified in the machine data the axis is decelerated as fast as possible and all pulses that come until the end of interpolation are ignored i e the axis is traversed again only after it has come to standstill on the setpoint end SINUMERIK 802S C base line Description of Functions Manual Traversing and Handwheel Traversing Response at the s
91. 0 spindle override is internally accepted as the last programmed spindle speed The spindle override switch is valid Note A separate spindle override switch is only installed on the machine control panel MCP as an option The spindle can always be decelerated by means of the IS Clear distance to go spindle reset CAUTION When G94 is active program execution is continued When G95 is active the axes are also stopped due to the missing feedrate and program execution also stops if G1 G2 is active SINUMERIK 802S C base line 9 3 Description of Functions Spindle 9 1 2 Spindle Positioning Mode When positioning mode SPOSz Block change Preconditions When the programmable function SPOS is active the spindle in positioning mode Spindle positioning to an absolute position 0 to 360 degrees on the shortest way The direction of positioning is defined either by the current direction of rotation of the spindle spindle rotates or automatically by the control system machine data spindle on standstill Programming with SPOS Block change is carried out if all functions programmed in the block have reached their end of block criterion e g axis traversing completed all auxiliary functions acknowledged from PLC and the spindle has reached its position IS Exact stop fine for the spindle V39030000 7 The spindle need not be synchronized e Spindle actual position encoder is a
92. 000002 0 Display As a feedback information that the Block Skip function is active SKP is displayed in the status line on the operator interface SINUMERIK 802S C base line 5 11 Description of Functions Program mode 5 4 Executing a Part Program Definition Control Feedback of the control Program mode means that either a part program is executed in AUTOMATIC mode or a program block is executed in MDA mode During program mode the program can be controlled by interface signals from the PLC Controlling is carried out via mode specific or channel specific interface signals The channel informs the PLC of its current program mode status via interface signals 5 4 1 Part Program Selection Channel status A part program can only be selected if the channel is in Reset status 5 4 2 Starting the Part Program or Part Program Block START command channel status Required signal states Command execution 5 12 The channel specific IS NC Start V32000007 1 which is commonly controlled from the MCP key NC Start starts program execution The START command is only executed in AUTOMATIC and MDA mode The channel must be either in the status Channel status Reset V33000003 7 or Channel status interrupted V33000003 6 The selected part program can now be enabled for execution using the START command The following enable signals can be used e 1S Ready must be set V31000000
93. 1 V380x1000 1 Hardware limit switch plus 1 1 V380x1000 2 2nd software limit switch minus 1 1 V380x1000 3 2nd software limit switch plus 1 1 V380x1000 7 Reference point approach delay 1 8 V38032000 0 to 2 Spindle Actual gear stage A to C 1 9 V38032000 3 Spindle Gear stage changed 1 9 V38032001 0 Spindle Feed override valid for spindle 1 9 V38032001 6 Spindle Invert M3 M4 1 9 V38032002 4 Spindle Oscillation by PLC 1 9 V38032002 5 Spindle Oscillation speed 1 9 V38032002 6 Spindle Set direction of rotation CW 1 9 V38032002 7 Spindle Set direction of rotation CCW 1 9 VB38032003 Spindle Spindle override override value 1 9 V380x5000 0 Stepper motor Speed monitoring 1 14 Axis spindle NCK gt PLC V390x0000 0 Spindle no axis 1 9 V390x0000 2 Encoder frequency exceeded 1 1 9 V390x0000 4 Referenced synchronized 1 1 8 V390x0000 6 Position reached with exact stop 1 2 V390x0000 7 Position reached with exact stop fine 1 2 V390x0001 3 Follow up active 1 14 V390x0001 4 Axis spindle on stop N lt Nmn 1 14 9 V390x0001 5 Position controller active 1 14 V390x0001 6 Speed controller active 1 14 V390x0001 7 Current controller active 1 14 V390x0004 0 Handwheel 1 active 1 4 V390x0004 1 Handwheel 2 active 1 4 V390x0004 6 Traversing command minus 1 4 V390x0004 7 Traversing command plus 1 4 V390x0005 0 Active machine function 1 INC 1 4 V390x0005 1 Active machine function 10 INC 1 4 V390x0005 2 Active machine function 100 INC 1 4 V390x0005 3 Activ
94. 3 0 NCK alarm present 1 14 V27000003 6 Air temperature alarm present 1 14 Operating modes PLC gt NCK V30000000 0 AUTOM 1 5 V30000000 1 MDA 1 5 V30000000 2 JOG 1 5 V30000000 4 Mode change blocked 1 5 V30000000 7 Reset 1 5 13 V30000001 0 Machine function TEACH IN 1 5 8 V30000001 2 Machine function REF 1 5 8 Operating modes NCK gt PLC V31000000 0 AUTOM active 1 5 V31000000 1 MDA active 1 5 V31000000 2 JOG active 1 5 V31000000 3 READY 1 5 V31000001 0 Machine function TEACH IN active 1 5 8 V31000001 2 Machine function REF active 1 5 8 Channel PLC gt NCK V32000000 4 Activate Single Block 1 5 V32000000 5 Activate M01 1 5 V32000000 6 Activate dry run feed 1 5 V32000001 0 Activate referencing 1 8 V32000001 7 Activate program test 1 5 V32000002 0 Activate Block Skip 1 5 VB32000004 Feed override override value 1 11 VB32000005 Rapid traverse override override value 1 11 V32000006 0 Feed lock 1 11 V32000006 1 Read in disable 1 5 V32000006 2 Delete distance to go channel specifically 1 14 V32000006 4 Program level abortion 1 5 V32000006 6 Feed override enabled 1 11 V32000006 7 Feed override enabled 1 11 V32000007 0 NC Start inhibited 1 5 V32000007 1 NC Start 1 5 V32000007 2 NC Stop at block end 1 5 V32000007 3 NC Stop 1 5 V32000007 4 NC Stop Axes plus spindle 1 5 V32001000 0 Axis 1 in WCS Activate handwheel 1 1 4 V32001000 1 Axis 1 in WCS Activate handwheel 2 1 4 V32001000 3 Axis 1 in WCS Feed Stop 1 11 15 2 SINUMERI
95. 4 0 to 1 V32001008 0 to 1 Activate handwheel 1 to 2 for axis in WCS Interface signal Signal s to channel PLC gt NCK Edge evaluation nein Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 These PLC interface signals are used to define whether the axis is assigned to handwheel 1 or 2 or to no handwheel Only one handwheel each can be assigned to one axis at a time If several interface signals Activate handwheel are set the priority is Handwheel 1 before Handwheel 2 If the assignment is active the axis can either be traversed in JOG mode using the handwheel or a DRF offset can be generated in AUTOMATIC or MDA mode Note Using handwheel 1 to 2 two axes can be traversed simultaneously Signal status 0 or edge change 1 gt 0 This axis is not assigned handwheel 1 or 2 Application The interface signal can be used to interlock axis control from the PLC user example s program by turning the handwheel Related to IS Handwheel active for axis V32001000 4 V32001004 4 V32001008 4 Traversing key for WCS axis blocked Interface signal Signal s to channel PLC gt NCK Edge evaluation no Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The traversing keys plus and minus have no effect for the axis in q
96. 7 is set The function is thus not yet activated Activation The function is activated via the IS Activate program test V32000001 7 Display As a feedback information that program test is active PRT is displayed in the status line on the operator interface and the IS Program test active V33000001 7 is set in the PLC Note Program execution without axis movements can also be activated together with the function Dry run feed SINUMERIK 802S C base line 5 7 Description of Functions Program mode 5 2 2 Program Execution in Single Block Mode Functionality Single block type A Application Selection Activation Display 5 8 The part program can be started via the IS NC Start V32000007 1 However the part program execution stops after each program block if the function Single block is active The program status changes to Program status stopped The channel status remains active Execution of the next part program block is started with NC Start The following single block types are differed e Action Single Block type SBL 1 With this single block type all blocks that trigger actions traversing movements auxiliary function outputs etc are executed separately If tool radius compensation is switched on G41 G42 the program stops after each intermediate block inserted by the control system In case of arithmetic blocks however the program execution does n
97. ASSIGN 22030 AUXFU_ASSIGN_VALUE n MD number Auxiliary function value HiFuNr 0 49 Max input limit Min input limit Changes effective after Unit Power On User class 2 7 Data type DWORD Valid as from SW version Meaning see MD AUXFU_ASSIGN_TYPE n auxiliary function type Application see Chapter 6 example s SINUMERIK 802S C base line Description of Functions 10 5 Output of Auxiliary Functions to PLC 10 5 Signal Description V25000000 0 and V25000001 4 Interface signal M function change T function change Signal s from channel NCK gt PLC Edge evaluation no Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 An M T information with a new value has been output to the interface in conjunction with the associated change signal The change signals indicate that the respective value is valid Signal status 0 or edge change 1 gt 0 The change signals are reset at the beginning of the next cycle by the PLC system program The value of the respective information is not valid VD25002000 Interface signal Edge evaluation no T function 1 Signal s from channel NCK gt PLC Signal e updated cyclically Signal s valid as from SW version Signal status 1 or edge evaluation 0 gt 1 This data makes available the T fu
98. Axis 3 in WCS Feed Stop 1 11 V32001008 4 Axis 3 in WCS Traversing key lock 1 4 V32001008 5 Axis 3 in WCS Rapid traverse override 1 4 V32001008 6 Axis 3 in WCS Traversing key 1 4 V32001008 7 Axis 3 in WCS Traversing key 1 4 V32001009 0 Axis 3 in WCS Machine function 1 INC 1 4 V32001009 1 Axis 3 in WCS Machine function 10 INC 1 4 V32001009 2 Axis 3 in WCS Machine function 100 INC 1 4 V32001009 3 Axis 3 in WCS Machine function 1000 INC 1 4 V32001009 6 Axis 3 in WCS continuous 1 4 Channel NCK gt PLC V33000000 5 MO M1 active 1 5 V33000001 0 Referencing active 1 8 V33000001 2 Revolutional feed active 1 11 V33000001 4 Block search active 1 5 V33000001 5 M2 M30 active 1 5 V33000001 7 Program test active 1 5 V33000003 0 Program status Running 1 5 V33000003 1 Program status Waiting 1 5 V33000003 2 Program status Stopped 1 5 V33000003 3 Program status Interrupted 1 5 V33000003 4 Program status Aborted 1 5 V33000003 5 Channel status Active 1 5 V33000003 6 Channel status Interrupted 1 5 V33000003 7 Channel status Reset 1 5 V33000004 2 All axes referenced 1 8 V33000004 3 All axes on standstill 1 2 V33000004 6 Channel specific NCK alarm present 1 14 SINUMERIK 802S C base line 15 3 Description of Functions List of Interface Signals Interface signal Name Ref Section
99. D TOOL_CHANGE_MODE 1 The new tool is prepared for change with the T function This setting is mainly used for machines with tool magazines in order to bring the new tool to the tool change position within the main machining time the machining is not aborted M6 is used to remove the old tool from the spindle and to load the new tool into the spindle SINUMERIK 802S C base line 12 5 Description of Functions Tool Compensation 12 6 SINUMERIK 802S C base line Description of Functions EMERGENCY STOP 13 Brief description Standard EN 292 2 In accordance with the basic safety requirements set forth by the EU Machine Guidelines on EMERGENCY STOP which are contained in Section 6 1 1 EN 292 2 machines must be equipped with an EMERGENCY STOP system Countries where the above mentioned guideline is not applicable must adhere to the guidelines for safety requirements on EMERGENCY STOP of the relevant country Exceptions No EMERGENCY STOP is required for machines on which an EMERGENCY STOP system would not reduce the risk or hazard because the EMERGENCY STOP system would neither reduce the stop time nor the required actions would reduce the risk machines which can be carried by hand or for hand controlled machines EMERGENCY STOP in the control system The control system assists the machine manufacturer in the realization of the EMERGENCY STOP function by the following The EMERGENCY STOP button is easily accessib
100. Description of Functions 08 2003 Edition SINUMERIK 802S base line SIEMENS SINUMERIK 802C base line SIEMENS SINUMERIK 802S base line SINUMERIK 802C base line Description of Functions Technical Manual Manufacturer Documentation Applies to Control system SINUMERIK 802S base line SINUMERIK 802C base line 2003 08 Edition Software version 4 4 Axis Spindle Monitoring Continuous Path Control Exact Stop Velocity Setpoint Actual Value System Manual Traversing and Handwheel Traversing Program Mode Compensation Transversal Axis Reference Point Approach Spindle Output of Auxiliary Functions to PLC Feeds Tool Compensation EMERGENCY STOP Diverse Interface Signals List of Interface Signals ol OO O lN amp a l o N 11 12 13 14 15 SINUMERIK Documentation Key to editions The editions listed below have been published prior to the current edition The column headed Note lists the amended sections with reference to the previous edition Marking of edition in the Note column A New documentation Bis Unchanged reprint with new order number C Revised edition of new issue Edition Order No Note 1999 02 6FC5597 2AA10 0BP1 A 2000 04 6FC5597 3AA10 0BP1 A 2002 01 6FC5597 3AA10 0BP2 Cc 2003 08 6FC5597 4AA11 OBPO A Trademarks SIMATIC SIMATIC HMI SIMATIC NET SIMODRIVE SINUMERIK and SIMOTION are registered trademarks o
101. ED_AT_IPO_START MD number Feed enable at spindle standstill Min input limit 0 Max input limit 1 Change valid after Power On Unit Protection level 2 7 Data type BOOLEAN Valid as from SW version Meaning 0 No influence on path interpolation 1 Ifa spindle is stopped in control mode M5 the path feed is only enabled if the spindle has stopped IS Axis spindle stopped V390x0001 4 is set Application see MD SPIND_ON_SPEED_AT_IPO_START example s Related to MD SPIND_ON_SPEED_AT_IPO_START feed enable for spindle in setpoint range 9 34 SINUMERIK 802S C base line Description of Functions Setting data Spindle 43210 SD number SPIND_MIN_VELO_G25 Progr spindle speed limitation G25 Default 0 Min input limit 0 Max input limit plus Changes effective immediately User class Unit Rev min Data type DOUBLE Valid as from SW version Meaning In SD SPIND_MIN_VELO_G25 a min spindle speed limitation is entered which must be reached by the spindle The NCK limits the spindle speed to this value The min spindle speed can only not be reached in the following cases Spindle override 0 M5 SO IS Cancel servo enable V3803002 1 S Reset V30000000 7 IS Clear distance to go Spindle Reset V38030002 2 18 Oscillation speed V38032002 5 Delete S value
102. ET If the programmed speed is higher than the stored speed the programmed speed is used for traversing Application Testing of programs example s Related to IS Activate dry run feed IS Dry run feed selected SINUMERIK 802S C base line 11 13 Description of Functions Feeds 11 11 Signal Descriptions Signals to NCK chan nel Enable Dry Run Feed Feed Override Rapid Traverse Override Feed Disable Rapid traverse override active Feed override active Feed Stop for Axis 1 in WCS Axis 2 in gt Axis 3 in Wes Signals to axis spindle Feed spindle override Override active Feed Stop Spindle Stop Fig 11 2 PLC interface signals for feeds 11 14 Channel SINUMERIK 802S C base line Description of Functions Feeds 11 11 1 Signals to Channel V32000000 6 Interface signal Edge evaluation no Activate dry run feed Signal s to channel PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge evaluation 0 gt 1 If the dry run feed is higher than the programmed feed the dry run feed defined by SD DRY_RUN_FEED is used for traversing instead of the programmed feedrate with G1 G2 G3 G5 Dry run feed is active after Reset status The interface signal is evaluated when NC Start is received and the channel has been in the Reset status Dry run feed can be selected from the PLC When dry run feed
103. G mode 4 4 The individual functions for manual traversing in JOG mode are mainly activat ed via the PLC interface In particular the following signals of the machine control panel MCP are relevant for manual traversing JOG mode selection e Machine functions INC1 Direction keys Feed override or spindle override If a spindle speed is to be specified for an analog spindle in JOG mode by operating a key on the machine control panel to rotate it in the specified direction or to stop it use the following procedure Choose the keys for Spindle CCW Spindle CW and Spindle Stop from the keys beneath the free keys on the machine control panel The PLC user program must assign the incoming key signals to the IS Traversing key plus or Traversing key minus V38030004 7 or 6 observing the following prerequisites e Only one of the signals may be set The signal remains also set when the key is released If the Spindle Stop key is pressed both traversing signals must be cleared Changing from Traversing key plus to Traversing key minus or vice versa is only possible via the Spindle Stop status both traversing signals cleared e If the IS Reset V30000000 7 is provided the spindle is stopped and the traversing signals must be cleared The spindle speed is set via operation using a setting data item Access to the setting data defining the spindle speed J
104. IK 802S C base line 3 11 Description of Functions Velocity Setpoint Actual Value System Closed Loop Control 3 4 Data Description 10240 MD number Default 1 SCALING_SYSTEM_IS_METRIC Metric scaling system Min input limit 0 Max input limit 1 Change effective after Power On Protection level 2 7 Unit Data type BOOLEAN Valid as from SW version Meaning This MD defines the system for scaling length dependent physical quantities used by the control system for data input output Internally all data are stored in the units 1 mm 1 degree and 1 sec When accessing from the part program from the operator panel or via external communication the scaling is carried out with the following units SCALING_SYSTEM_IS_METRIC 1 scaled in mm mm min m s m s mm rev SCALING_SYSTEM_IS_METRIC 0 scaled in inch inch min inch s2 inch s inch rev The choice of the scaling system also defines the interpretation of the programmed F value for linear axes metric inch G94 mm min inch min G95 mm rev inch rev After this machine data has been changed the control system must be rebooted otherwise related machine data that have physical units will be scaled not correctly Observe the following procedure e MD change by manual input gt Reboot and then enter the appropriate machine data with their physical units e MD are changed via the machine data file gt Reboot and then reload machine data fi
105. IMIT_FINE may not be set to a value equal to a greater than the MD STANDSTILL_POS_TOL zero speed tolerance Related to MD POSITIONING_TIME delay time exact stop fine SINUMERIK 802S C base line Description of Functions 2 7 Continuous Path Control Exact Stop 36020 POSITIONING_TIME MD number Delay time exact stop fine Default 5 0 Min input limit 0 Max input limit plus Change effective after NEW_CONF User class 2 7 Unit s Data type DOUBLE Valid as from SW version Meaning If a block is ended with exact stop the axis must have reached the exact stop fine coarse window within the positioning time Otherwise the positioning process is aborted with alarm 25080 Positioning monitoring The monitoring time is started with the interpolator end of the axis A position controlled spindle is also subject to this time related positioning monitoring In case of error alarm 25080 Positioning monitoring is output Alarm 25080 cancels the IS READY V31000000 3 and stops the axes position controlled spindle Related to MD STOP_LIMIT_COARSE exact stop coarse MD STOP_LIMIT_FINE exact stop fine 2 8 SINUMERIK 802S C base line Description of Functions 2 5 Continuous Path Control Exact Stop Signal Description V33000004 3 Interface signal Edge evaluation no All axes have stopped Signal s from channel NCK gt PLC Signal
106. IN_VELO LIMIT min speed of gear stage MD GEAR_STEP_MAX_VELO_LIMIT max speed of gear stage 35120 GEAR_STEP_MIN_VELO n MD number Min speed for gear stage change gear stage number 0 5 Default 50 50 400 8 3000 00 1500 Min input limit 0 Max input limit plus Changes effective after Power On Protection level 2 7 Unit rev min Data type DOUBLE Valid as from SW version Meaning In MD GEAR_STEP_MIN_VELO the min speed of the gear stage for automatic gear stage change M40 is entered For further description see MD GEAR_STEP_MAX_VELO Related to MD GEAR_STEP_MAX_VELO max speed for gear stage change MD GEAR_STEP_CHANGE_ENABLE gear stage change is possible MD GEAR_STEP_MIN_VELO LIMIT min speed of gear stage MD GEAR_STEP_MAX_VELO_LIMIT max speed of gear stage SINUMERIK 802S C base line 9 27 Description of Functions Spindle 35130 MD number Default 4000 8000 500 500 1000 2000 Min input limit 0 GEAR_STEP_MAX_VELO _LIMIT n Max speed of gears step gear stage number 0 5 Max input limit plus Changes effective after Power On Protection level 2 7 Unit rev min Data type DOUBLE Valid as from SW version Meaning In MD GEAR_STEP_MAX_VELO_LIMIT the max speed of the gear stage is entered This speed can never be exceeded in the active gear stage Special ca
107. K 802S C base line Description of Functions List of Interface Signals Interface signal Name Ref Section V32001000 4 Axis 1 in WCS Traversing key lock 1 4 V32001000 5 Axis 1 in WCS Rapid traverse override 1 4 V32001000 6 Axis 1 in WCS Traversing key 1 4 V32001000 7 Axis 1 in WCS Traversing key 1 4 V32001001 0 Axis 1 in WCS Machine function 1 INC 1 4 V32001001 1 Axis 1 in WCS Machine function 10 INC 1 4 V32001001 2 Axis 1 in WCS Machine function 100 INC 1 4 V32001001 3 Axis 1 in WCS Machine function 1000 INC 1 4 V32001001 6 Axis 1 in WCS continuous 1 4 V32001004 0 Axis 2 in WCS Activate handwheel 1 1 4 V32001004 1 Axis 2 in WCS Activate handwheel 2 1 4 V32001004 3 Axis 2 in WCS Feed Stop 1 11 V32001004 4 Axis 2 in WCS Traversing key lock 1 4 V32001004 5 Axis 2 in WCS Rapid traverse override 1 4 V32001004 6 Axis 2 in WCS Traversing key 1 4 V32001004 7 Axis 2 in WCS Traversing key 1 4 V32001005 0 Axis 2 in WCS Machine function 1 INC 1 4 V32001005 1 Axis 2 in WCS Machine function 10 INC 1 4 V32001005 2 Axis 2 in WCS Machine function 100 INC 1 4 V32001005 3 Axis 2 in WCS Machine function 1000 INC 1 4 V32001005 6 Axis 2 in WCS continuous 1 4 V32001008 0 Axis 3 in WCS Activate handwheel 1 1 4 V32001008 1 Axis 3 in WCS Activate handwheel 2 1 4 V32001008 3
108. LEAN Valid as from SW version Meaning If the spindle motor is mounted directly 1 1 on the spindle or with non variable gear ratio the MD GEAR_STEP_CHANGE_ENABLE gear stage change is possible must be set to zero Gear stage change with M40 to M45 is then not possible If the spindle motor is mounted on the spindle via a gearbox with interchangeable gearboxes the MD GEAR_STEP_CHANGE_ENABLE must be set to one The gearbox can have up to 5 gear stages which can be selected by M40 to M45 Related to MD GEAR_STEP_MAX_VELO max speed for gear stage change MD GEAR_STEP_MIN_VELO min speed for gear stage change The MD GEAR_STEP_MAX_VELO and MD GEAR_STEP_MIN_VELO must cover the entire speed range SINUMERIK 802S C base line 9 25 Description of Functions Spindle 35040 MD number Default 0 SPIND_ACTIVE_AFTER_RESET Spindle active after RESET Min input limit 0 Max input limit 1 Changes effective after Power On Protection level 2 7 Unit Data type BOOLEAN Valid as from SW version Meaning The MD Spindle active after RESET SPIND_ACTIVE_AFTER_RESET is used to set the response of the spindle after Reset and end of program M2 M30 It is only effective in spindle control mode MD SPIND_ACTIVE_AFTER_RESET 0 Control mode Spindle stops Program aborted Oscillation mode Alarm 10640 Stop during gear stage change not po
109. L_POS_TOL zero speed tolerance Axis is mechanically pushed out of position gt remedy cause 1 1 4 Clamping Monitoring Function If the axis is to be clamped on completion of the positioning process clamping monitoring can be activated by means of the IS interface signal Clamping active V380x0002 3 This might be necessary because during the clamping process the axis can be pushed further out of the set position than the zero speed tolerance The amount by which the set position is left is specified in MD CLAMP_POS_TOL clamping tolerance for interface signal clamping active Effect If the axis is pushed out of position beyond the clamping tolerance during clamping the following occurs Output of alarm 26000 Clamping monitoring e The axis spindle involved is stopped with rapid stop see Section 1 1 1 1 4 SINUMERIK 802S C base line Description of Functions Axis Spindle Monitoring 1 1 5 Set Speed Monitoring Function Set speed monitoring is used to check whether the physical limit of the spindle and axes equipped with analog drives 10V maximum voltage for set speed is exceeded Effect If the maximum set speed is exceeded the following occurs Output of alarm 25060 Set speed limitation e The axis spindle is stopped with rapid stop see Section 1 1 1 Error cause remedy e Tacho compensation has not been carried out correctly or there is a measuring circuit or drive error e Setpoin
110. L_REDUCTION_SPEED_POINT 0 7 the maximum speed is 3 000 rpm At v 2 100 rpm the acceleration reduction starts i e the maximum acceleration capability is utilized in the speed range 0 2 099 99 rpm From 2 100 rpm to the maximum speed a reduced acceleration is used MD 32000 MAX_AX_VELO maximum axis velocity MD 35130 GEAR_STEP_MAX_VELO_LIMIT maximum speed of gear stage MD 35230 ACCEL_REDUCTION_FACTOR reduced acceleration Related to SINUMERIK 802S C base line Description of Functions 4 15 Manual Traversing and Handwheel Traversing 35230 MD number Default 0 0 ACCEL REDUCTION FACTOR Reduced acceleration Min input limit 0 0 Max input limit 1 0 Change valid after Power On Protection level 2 7 Unit Factor Data type DOUBLE Valid as from SW version Meaning The machine data contains the factor by which the acceleration of the spindle axes is reduced with reference to the maximum speed velocity From the threshold speed velocity determined based on MD ACCEL_REDUCTION _SPEED POINT up to the maximum speed velocity the acceleration is reduced by the factor This application is recommended for stepper motor axes Example a 10 rev s v 2100 rom MD ACCEL_REDUCTION_ FACTOR 0 3 The acceleration deceleration is carried out in the speed range 0 2 099 99 rpm with an acceleration of 10 rev s From the speed 2 100 rpm onwards the acceleration
111. M3 M4 M5 M41 45 Fig 9 1 Spindle mode change Control mode gt Oscillation mode The spindle changes to oscillation mode if a new gear stage has been set either by automatic gear stage selection M40 in conjunction with a new S function or by M41 to M45 The spindle will only change to the oscillation mode if the new gear stage is other than the currently active gear stage Oscillation mode gt control mode When the new gear stage is set the IS Oscillation mode is reset and the mode changes to control mode with the IS gear stage changed The last programmed spindle speed S function is active again Control mode gt positioning mode If you wish to stop the spindle from rotation M3 or M4 with orientation or you wish to reorient the spindle from standstill M5 use SPOS to change to the positioning mode position controlled spindle required Positioning mode gt control mode If you wish to end spindle orientation use M3 M4 or M5 to change to control mode The last programmed spindle speed S function is active again Positioning mode gt Oscillation mode If you wish to end spindle orientation use M41 to M45 to change to oscillation mode When the gear stage change is completed the last programmed spindle speed S function and M5 control mode are active again SINUMERIK 802S C base line Description of Functions Spindle 9 1 1 Spindle Control Mode When control mod
112. MD STOP_LIMIT_FINE and MD STOP_LIMIT_COARSE The positioning process can be aborted by means of the IS Clear distance to go spindle reset The IS Clear distance to go spindle reset cannot be used to abort the spindle mode Positioning mode e The following machine data are used to define the accelerations MD SPIND_ POSCTRL_ACCEL acceleration in position control mode MD SPIND SPEEDCTRL_ACCEL acceleration in speed controlled mode The spindle override switch is valid The positioning SPOS is aborted with Reset The positioning is aborted with NC STOP SINUMERIK 802S C base line 9 9 Description of Functions Spindle 9 1 3 Spindle Positioning Mode What is meant by oscillation Preconditions Starting oscillation mode Oscillation time Oscillation by NCK 9 10 When oscillation mode is active the spindle motor rotates alternating in clockwise direction and counterclockwise direction This oscillation motion is supported by slight meshing of a new gear stage e No spindle actual position encoder required e Spindle need not be synchronized The spindle is in oscillation mode if a new gear stage is set either by automatic gear stage selection M40 or by M41 to M45 IS Change gear stage V39032000 3 is set The IS Change gear stage is only set if the new gear stage is other than the currently active gear stage Oscillation of the spindle is started with the IS Oscillation
113. NUMERIK 802S C base line Description of Functions EMERGENCY STOP 13 4 EMERGENCY STOP Acknowledgement Standard EN 418 The resetting of the EMERGENCY STOP tripping mechanism may only be possible as a result of an action on the EMERGENCY STOP tripping mechanism The resetting of the EMERGENCY STOP tripping mechanism alone may not trigger a restart command Restart of the machine may not be possible until all actuated EMERGENCY STOP tripping mechanisms have been reset manually separately and deliberately Acknowledge EMERGENCY STOP The EMERGENCY STOP status is only reset if first the IS Acknowledge EMERGENCY STOP V26000000 2 and then the IS Reset V30000000 7 are set When doing this make sure that the IS Acknowledge EMERGENCY STOP and the IS Reset must be set together and at least as long as the IS EMERGENCY STOP active V27000000 1 is reset see Fig 13 1 IS EMERGENCY STOP 26000000 1 IS Acknowledge EMERGENCY STOP Y26000000 2 IS EMERGENCY STOP active 27000000 1 IS RESET 30000000 7 D The IS Acknowledge EMERGENCY STOP is inactive The IS RESET is inactive The IS Acknowledge EMERGENCY STOP and RESET will reset EMERGENCY STOP active Fig 13 1 Resetting EMERGENCY STOP Resetting the EMERGENCY STOP status e resets the IS EMERGENCY STOP active e activates servo enable e sets the IS Position control active e sets the IS READY e de
114. OG SD JOG_SPIND_SET_VELO is granted via the Setting Data menu If this value 0 the value in MD JOG_VELO will also apply for the spindle When traversing the spindle in JOG mode the maximum speeds of the active gear stage MD GEAR_STEP_VELO LIMIT are taken into account SINUMERIK 802S C base line Description of Functions Manual Traversing and Handwheel Traversing 4 3 Continuous Traversing Selection Deselection Traversing keys Traversing commands When JOG is selected the machine function continuously active is automatically set in the axes in WCS and in the machine axes IS V33001001 6 V33001005 6 V33001009 6 V390x0005 6 In JOG mode it is also possible to activate continuous traversing via the PLC interface IS Machine function continuous for the axes in WCS V32001001 6 VB32001005 6 VB32001009 6 and for the machine axes VB380x0005 6 The Continuous Traversing function is deselected by selecting incremental traversing see Section 4 4 The Plus and Minus traversing will traverse the related axes in the desired directions PLC at NCK interface V32001000 7 6 V32001004 7 6 V32001008 7 6 or V380x004 7 6 If both traversing keys of an axis are actuated at the same time no traversing movement is carried out or the axis currently moving is stopped The axis will traverse as long as the traversing key signal is set if no axis limitation is reached beforehand When the signal i
115. PIND_DES VELO_TOL the path feed will be blocked If the actual speed exceeds the max spindle speed MD SPIND_MAX_VELO_LIMIT by more than the spindle speed tolerance MD SPIND_DES_VELO_TOL the IS Speed limit exceeded V39032001 0 is set and alarm 22050 Max speedreached is output All axes and spindles of the channel are decelerated MD not applicable to spindle mode Oscillation to spindle mode Positioning Fig 9 12 Speed imin MD SPIND_DES_VELO_TOL Upper spindle speed tolerance F n ne nn eens ene ene eee Setspeed Lower spindle speed tolerance Actual speed Time s Related to MD SPIND_ON_SPEED_AT_IPO_START feed enable for spindle within set range MD SPIND MAX_VELO_LIMIT max spindle speed IS Spindle within set range V39032001 5 IS Speed limit exceeded V39032001 0 Alarm 22050 Max speed reached SINUMERIK 802S C base line 9 29 Description of Functions Spindle 35160 MD number Default 1000 SPIND_EXTERN_VELO _ LIMIT Spindle speed limitation from PLC Min input limit 0 Max input limit plus Changes effective after Power On Protection level 2 7 Unit rev min Data type DOUBLE Valid as from SW version Meaning In MD SPIND_EXTERN_VELO_UNIT a limit value for the spindle speed is entered which is considered exactly at the moment when the IS Veloci
116. Power On Protection level 2 7 Unit mm Data type DOUBLE Valid as from SW version Meaning If the machine axis traverses a path set in MD REFP_MAX_CAM_DIST from the start positon in the direction of the reference cam without reaching the reference cam IS Reference point approach delay 380x1000 7 is reset the axis stops and alarm 20000 Reference cam not reached is output 8 8 SINUMERIK 802S C base line Description of Functions Reference Point Approach 34040 MD number Default 300 REFP_VELO_SEARCH_MARKER 0 Reference point cut off speed Min input limit 0 Max input limit plus Changes effective after Power On Protection level 2 7 Unit mm min Data type DOUBLE Valid as from SW version Meaning The axis traverses with this speed from the moment when the reference point cam is detected to the synchronization with the first synchronization pulse BERO zero mark gt phase 2 If MD REFP_SEARCH_MARKER_REVERSE 0 no reversal of direction due to falling reference cam edge The search is carried out immediately at this speed traversing direction always in the opposite direction to the direction set for cam search MD REFP_CAM_DIR_IS_MINUS This direction remains unaffected by the new reference cam edge If MD REFP_SEARCH_MARKER_REVERSE 1 reversal of direction by falling reference cam edge This speed will only be active if
117. RIVE_AX_RATIO_DENOM r load gearbox denominator MD DRIVE_AX_RATIO_NUMERA n load gearbox numerator MD POSCTRL_GAIN n servo gain factor MD AX_VELO_LIMIT n velocity monitoring threshold value MD DYN_MATCH_TIME n time constant of dynamic accommodation The machine data index n is coded as follows control parameter record 0 5 Parameter records for the spindle With the spindle each gear stage is assigned its own parameter record Depending on the IS Actual gear stage V380x2000 0 bis 2 the corresponding parameter record is activated Parameter records for axes For axes not involved in tapping or thread cutting parameter record 1 is activated index 0 in all cases For axes involved in tapping or thread cutting the same parameter record number is activated as with the current gear stage of the spindle SINUMERIK 802S C base line Description of Functions Velocity Setpoint Actual Value System Closed Loop Control 3 3 Velocity Control for Stepper Motors 3 3 1 Knee Shaped Acceleration Characteristic Parameterization of the axis characteristic Stepper motor drives only with SINUMERIK 802S base line A characteristic feature of stepper drives is the decay of the available torque in the upper speed range see Fig 3 5 Stepper motor Mmax max 4 000 rpm 1 40 6080100 n Ned Creep speed Nmax Maximum speed Fig 3 5 Typical motor characteristics of a stepper drive The optimum utiliz
118. S Spindle stop M2 in block X MO M1 in block IS Single block lt gt lt gt lt Auxiliary function output to PLC but not yet acknowledged 5 16 SINUMERIK 802S C base line Description of Functions Program mode 5 4 7 Channel Status The current channel status is displayed on the interface Due to the status the PLC can trigger certain responses or interlocks which can be configured by the manufacturer The channel status is displayed in all operating modes Channel states The following channel states are possible e 1S Channel status Reset V33000003 7 e 1S Channel status interrupted V33000003 6 e 1S Channel status active V33000003 5 Effects of comm The channel status can be controlled either by activating various commands or ands signals via interface signals The Table below shows the resulting channel status supposed status prior to the signal gt channel status active The Channel status active is reached when a part program or part program block is executed or the axes are traversed in JOG mode Table 5 6 Effects on channel status Channel Status after Command Signal Reset Interrupted Active IS Reset X IS NC Stop IS NC Stop at block end IS NC Stop axes and spindles IS Read in disable IS Feed stop channel blocked IS Feed stop axes blocked Feed override 0 IS Spindl
119. SPL S EIA PLE 4 6 2 MiscellaNGOUS trisrisrrsrisrrsrisrrsrisprartariarisriatiArNAFIAPIAFNAFIAFIAFIAPIAFINPISFISPIAPESPISPIAFESPISPEAPIAY 4 7 Data Description E E EETA 4 8 Signal Description PEE ERTAK EEEE EENEN E EAE EEEE E ERTER Le aie rian A EEA EIEE A PERERA EE 4 8 1 Overview of Signals to Axis Spindle Machine AX S etsrirriserrrisrisrrsriarisersrisrinerarisrrserarise 4 8 2 Description of Signals to Axis Spindle Machine AX S risrisrrsrisrrsrrarisriarisrisriariarisriariarise 4 8 3 Overview of Signals from Axis Spindle Machine Axis ertrrsrrsrisrrsrrsrisrisersrinrinriarinrreriarise 4 8 4 Description of Signals from Axis Spindle Machine Axis iriririrrirter terrier rine niee SINUMERIK 802S C base line III Description of Functions Contents Program Mode ververicrserierer ter EET ETT 5 1 Operating MODES tt srrsrisrrsristisrisria REE EEE TEE KISENA 5 1 1 Mode Change asia hae aang ede aceaate Me Malena ea a ne gilded ec Lace kf ea Rac a Ral CahRM ACP ALE E maa esMaeal T 5 1 2 Possible Functions in the Individual Modes sr rrirrisrisrisrisersrisrrarisrrsrrariarisrisersrisriariserariar 5 1 3 Monitoring Functions in the Individual Operating MOdeS trite rrr 5 1 4 Interlocks in the Individual MOdeS s srtsrrrrisrrsrrsrrsrrsenarisrtantenisrnurtantanierinriantanierieriarianier 5 2 Program TASER EEE EEL TEER TEER EER an ae 5 2 1 Program Execution Without Axis Movements Program Test 5 2 2 Program Execution in Single Block Mode Reena eee eee
120. Signal Description Signals to axis spindle V38030002 2 Interface signal Edge evaluation yes Clear distance to go Spindle Reset Signal s to axis spindle PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Edge change 0 gt 1 Irrespective of MD SPIND_ACTIVE_AFTER_RESET Spindle Reset is active for the individual spindle operating modes as follows Control mode Spindle stops Program is continued when G94 is active When G95 is active the axes are also stopped due to the missing feedrate and the program execution is thus also stopped if G1 G2 are active Spindle runs as with G94 and a following M and S value Further Oscillation mode Oscillation is aborted Axes go on running Program is continued with the currently active gear stage The following M value and a higher S value might set the IS Programmed speed too high Positioning mode is stopped Signal status 0 or edge change 1 gt 0 no effect Related to MD SPIND_ACTIVE_AFTER_RESET own Spindle Reset IS __ Reset V30000000 7 V38032000 2 Interface signal Edge evaluation yes Gear stage changed Signal s to axis spindle PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 When the new gear stage is active the PLC user sets the IS Actual gear stage A to C
121. Signal status 0 or edge change 1 gt 0 Program status Aborted is not present Special cases errors The IS Program status aborted indicates that the program can be continued by restart V33000003 4 Interface signal Edge evaluation no Program status Aborted Signal s from channel NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The program is selected but not started or the current program has been aborted by Reset Signal status 0 or edge change 1 gt 0 Program status Aborted is not present Related to IS Reset V33000003 5 Interface signal Edge evaluation no Channel status Active Signal s from channel NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 In this channel apart program or block is currently executed in Automatic mode or MDA atleast one axis is traversed in JOG mode Signal status 0 or edge change 1 gt 0 Channel status interrupted or Channel status Reset is present SINUMERIK 802S C base line 5 33 Description of Functions Program mode V33000003 6 Interface signal Channel status Interrupted Signal s from channel NCK gt PLC Edge evaluation no Signal s updated cyclically Sign
122. Stepper Motor Frequency Stepper motor frequency Stepper motor without encoder Stepper motor with encoder 1200rpm 10000 1 rev The maximum stepper motor frequency is defined with the machine data MD FREQ_STEP_LIMIT Hz This frequency must correspond to the MD MAX_AX_VELO axis velocity Example MD Determining MAX_AX_VELO and MD FREQ_STEP_LIMIT Motor speed 1 200 rpm Motor speed rpm Leadscrew pitch mm rev Axis velocity Load gearbox Load gearbox R 1 1 gt R 1 Leadscrew pitch 10 mm Steps per 360 C 10 000 The resulting frequency limit must be 1200rpm 10mm i 12000mm min gt MD MAX_AX_VELO 200000Hz gt MD FREQ_STEP_LIMIT 60s When a stepper motor without encoder is used the number of steps per 360 must also be entered in MD ENC_RESOL Example Stepper motor 10 000 pulses per motor revolution Load gearbox 1 1 Leadscrew pitch 10 mm Motor speed 1 200 rpm The following MD values result from this MD CTRLOUT_TYPE 2 setpoint output for stepper motor MD ENC_TYPE 3 stepper motor without encoder MD ENC_RESOL 0 10 000 no pulse quadrupling MD STEP_RESOL 10 000 MD FREQ_STEP_LIMIT Hz 200 000 Hz MD MAX_AX_VELO 12 000 mm min If the stepper motor is operated with encoder the encoder adaptation has to be carried out as with analog drives To determine the adaptation it should be taken into account that the encoder pulses are quadrupled SINUMER
123. The following auxiliary functions can be output to the PLC e Miscellaneous function M e Tool number T These functions come into effect at defined moments during program execution and are output to the PLC Per part program the following functions can be programmed e five M functions e one S function e one T function e one D function e one F function In one block max 10 auxiliary functions can be programmed e g N10 S3000 T1 D2 M3 M77 M87 If the permissible number of auxiliary functions per block is exceeded alarm 12010 is output Only after the PLC operating system has acknowledged all transferred auxiliary functions the NCK can output a new auxiliary function to the PLC A block is considered completed if the programmed movement is completed and the auxiliary function is acknowledged To this aim the part program execution is stopped by the NCK in order to ensure that no auxiliary functions get lost from the viewpoint of the PLC user program A path motion will only remain continuously if the auxiliary function is output during the motion and acknowledged before the path end SINUMERIK 802S C base line 10 1 Description of Functions Output of Auxiliary Functions to PLC 10 1 Auxiliary Function Groups Functionality Configuration The auxiliary functions of the auxiliary function groups M and T can be divided by means of machine data into auxiliary function groups An auxiliary function may only be as
124. V33000004 7 NCK alarm with processing stop present 1 14 V33001000 0 Axis 1 in WCS Handwheel 1 active 1 4 V33001000 1 Axis 1 in WCS Handwheel 2 active 1 4 V33001000 6 Axis 1 in WCS Traversing command minus 1 4 V33001000 7 Axis 1 in WCS Traversing command plus 1 4 V33001001 0 Axis 1 in WCS Machine function 1 INC 1 4 V33001001 1 Axis 1 in WCS Machine function 10 INC 1 4 V33001001 2 Axis 1 in WCS Machine function 100 INC 1 4 V33001001 3 Axis 1 in WCS Machine function 1000 INC 1 4 V33001001 6 Axis 1 in WCS continuous 1 4 V33001004 0 Axis 2 in WCS Handwheel 1 active 1 4 V33001004 1 Axis 2 in WCS Handwheel 2 active 1 4 V33001004 6 Axis 2 in WCS Traversing command minus 1 4 V33001004 7 Axis 2 in WCS Traversing command plus 1 4 V33001005 0 Axis 2 in WCS Machine function 1 INC 1 4 V33001005 1 Axis 2 in WCS Machine function 10 INC 1 4 V33001005 2 Axis 2 in WCS Machine function 100 INC 1 4 V33001005 3 Axis 2 in WCS Machine function 1000 INC 1 4 V33001005 6 Axis 2 in WCS continuous 1 4 V33001008 0 Axis 3 in WCS Handwheel 1 active 1 4 V33001008 1 Axis 3 in WCS Handwheel 2 active 1 4 V33001008 6 Axis 3 in WCS Traversing command minus 1 4 V33001008 7 Axis 3 in WCS Traversing command plus 1 4 V33001009 0 Axis 3 in WCS Machine function 1 INC 1 4 V33001009 1 Axis 3 in WCS Machine function 10 INC 1 4 V33001009 2 Axis 3 in WCS Machine function 100 INC 1 4 V33001009 3 Axis 3 in WCS Machine function 1000 INC 1 4 V33001009 6 Axis 3 in WCS continu
125. abortion by Reset Fig 1 data transfer to user memory 2 block executed 3 NC block with MO 4 M change signal 1 PLC cycle time 5 IS MO M1 active 6 IS NC Start Related to IS Activate M01 IS M01 selected V33000001 4 Interface signal Edge evaluation no Block search active Signal s from channel NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The block search function is active It has been selected and started via the operator interface Signal status 0 or edge change 1 gt 0 The block search function is not active Application The block search function can be used to jump to a certain block in the part example s program and start program execution only from this block 5 30 SINUMERIK 802S C base line Description of Functions Program mode V33000001 5 Interface signal Edge evaluation no M2 M30 active Signal s from channel NCK gt PLC Signal s updated cyclically Signal s valid as from version SW Signal status 1 or edge change 0 gt 1 NC block with M2 is completely executed If traversing movements are also programmed in this block the signal is only output when the target position is reached Signal status 0 or edge change 1 gt 0 No end or abortion of program Status
126. aces 1 from the PLC user program by means of the interface signal Servo enable normal case Application servo enable canceled before clamping the axis spindle SINUMERIK 802S C base line 14 5 Description of Functions Various Interface Signals 2 In case of various faults on the machine the drive the position measuring system or the control system servo enable is disabled in the control system internally Application Due to faults the moving axes must be stopped by rapid stop 3 internally in the control system in case of the following events EMERGENCY STOP is present on the PLC interface Servo Disable for a moving axis spindle e The spindle analog axis is decelerated to a standstill by quick stop with consideration of the MD AX_EMERGENCY_STOP_TIME duration of deceleration ramp in case of fault conditions Then alarm 21612 Servo enable reset during the motion is output The position control loop of axis spindle is opened Feedback to the PLC with the IS Position controller active V390x0001 5 0 signal In addition the servo enable delay timer MD SERVO_DISABLE_ DELAY_TIME servo enable shutdown delay is started Once the actual velocity has reached the standstill range servo enable is canceled Feedback to the PLC with the IS Speed controller active V390x0001 6 O signal Servo enable for the drive is disabled at least after the time set in MD SERVO_DISABLE_DELAY_TIME has elap
127. active when G33 is active however for accuracy reasons it should not be actuated Note A separate spindle override switch on the machine control panel MCP is provided as an option The override values set via selector switches on the machine control panel are immediately active in all operating modes and machine functions provided the IS Rapid traverse override active Feed override active or Override active are set An override value of 0 acts as a feed lock When the override is inactive above mentioned IS signals set to O the NC internally uses override factor 1 i e the override amounts to 100 The value entered in the PLC interface is not relevant The spindle override controls the programmed speed SINUMERIK 802S C base line Description of Functions Feeds 11 10 Data Description Setting data 42100 SD number DRY_RUN_FEED Dry run feed Default 5000 Min input limit 0 Max input limit plus Changes effective immediately User class Unit mm min Data type DOUBLE Valid as from SW version Meaning In this setting data the feed for the active dry run is entered The setting data can be modified via the operator panel in the operating area Parameter The entered dry run feed is always interpreted as the linear feed G94 If dry run feed is activated via the PLC interface not the programmed but the dry run feed is used after RES
128. after turning on the control system when starting an NC program Fig e LC T L o H PoS Foo 1 data transfer to user memory 2 block executed 3 NC block with M2 4 M change signal 1 PLC cycle time 5 IS M2 M30 active Application The PLC can detect the end of program execution by means of this signal and example s react on it Special cases The functions M2 and M30 are equivalent Only M2 should be used errors The IS M2 M30 active is statically provided after program end Not suitable for automatic sequential functions such as workpiece counting bar feed and many others For these functions M2 must be written in a separate block and either the word M2 or the decoded M signal must be used The last block of a program may not contain auxiliary functions that lead to read in disable SINUMERIK 802S C base line Description of Functions 5 31 Program mode V33000001 7 Interface signal Edge evaluation no Program test active Signal s from channel NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The program control Program test is active The internal signal Axes blocked is provided for all axes not spindles For this reason the machine axes do not move when a part program block or part program is executed However the axis movements are
129. al grouping interpolatory axis grouping SINUMERIK 802S 802C base line however possesses axes which are integrated in the geometrical grouping Therefore the IS Delete distance to go axis specifically will be ignored In this case use the IS Delete distance to go channel specifically V32000006 2 SINUMERIK 802S C base line Description of Functions Various Interface Signals Rotation monitoring stepper motor V380x5000 0 For rotation monitoring the stepper motor requires a BERO proximity switch Parallel connection with the BERO for referencing see Section Reference point approach or using the BERO for rotation monitoring is possible For this reason rotation monitoring is not active during reference point approach The BERO signals are used for reference point approach However when rotation monitoring is active no signals may be provided from the reference BERO The monitoring function checks whether the axis has reached the preset path increments with the set tolerance during one motor revolution Important axis machine data for rotation monitoring MD BERO_CYCLE and MD BERO_EDGE_TOL In case of error the IS Rotation monitoring error V390x5000 0 is set see also Start Up Instructions Section Axis Start Up SINUMERIK 802S C base line 14 7 Description of Functions Various Interface Signals 14 3 Signals from NCK to PLC Drive ready V27000002 6 The PLC receives a signal that al
130. al s valid as from SW version Signal status 1 or edge change 0 gt 1 The NC part program in AUTOMATIC mode or the block in MDA mode has been interrupted either by NC Stop NC Stop axes plus spindles NC Stop at block end programmed MO or M1 or single block mode The part program or the interrupted traversing movement can be continued after NC Start Signal status 0 or edge change 1 gt 0 Channel status active or Channel status Reset is present V33000003 7 Interface signal Channel status Reset Signal s from channel NCK gt PLC Edge evaluation no Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The signal is set to 2 as soon as the channel is in Reset status i e no processing is active Signal status 0 or edge change 1 gt 0 The signal is set to O as soon as soon as any processing is active in the channel e g execution of a part program or block search 5 34 SINUMERIK 802S C base line Description of Functions Compensation 6 Background The accuracy of machine tools is affected by deviations from the ideal geometry errors in the power transmission and in the measuring systems When large workpieces are machined temperature variations and mechanical forces often lead to a high loss in precision Generally some of these deviations can b
131. al s valid as from SW version Signal status 1 or edge change 0 gt 1 AUTOMATIC mode The selected NC program is started or continued If in program status Program interrupted data are transferred from the PLC to the NC these are immediately taken into account with NC Start MDA mode The entered part program block is enabled for execution and continued respectively Signal status 0 or edge change 1 gt 0 No effect Related to IS NC Start inhibited V32000007 2 Interface signal Edge evaluation no NC Stop at block end Signal s to channel PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The currently active NC program is stopped after the current part program block has been executed Remaining part as with IS NC Stop Signal status 0 or edge change 1 gt 0 No effect Related to IS NC Stop IS NC Stop axes plus spindles IS Program status stopped IS Channel status interrupted SINUMERIK 802S C base line 5 27 Description of Functions Program mode V32000007 3 Interface signal Edge evaluation no NC Stop Signal s to channel PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The currently active NC program is stopped
132. all axes to standstill in all operating modes Channel specific feed blocking is not active when G33 is active only for G63 G331 G332 The interface signal Feed Stop V32001000 3 and V32001008 3 sets the respective axes traversed in the workpiece coordinate system WCS in JOG mode to standstill The axis specific interface signal Feed Stop V380x0004 3 sets the respective machine axis to standstill The following applies to Automatic mode e If Feed Stop for one contour axis is provided all axes moved in the current block and involved in the contour complex are set to standstill In JOG mode only the axis concerned is set to standstill Axis specific Feed Stop is active when G33 is active but deviations from contour thread errors occur The interface signal Spindle Stop V38030004 3 sets the respective spindle to standstill Spindle Stop is active when G33 is active but deviations from contour thread errors occur SINUMERIK 802S C base line Description of Functions Feeds 11 9 2 Feed Override from Machine Control Panel General The operator can use the feed override switch to reduce or increase the traversing path feedrate relatively to the programmed feedrate in per cent right on the spot and with immediate effect The feedrates are multiplied with the override values The override possible for the path feed F ranges from 0 to 120 The rapid traverse override swit
133. ample 2600 trained operator no inputs and no program selection 0000 4 possible only machine control panel can be operated Request axis actual values V26000001 1 software version 3 1 and higher The cyclic provision of the current actual value positions is requested for all axes in the range VD570x0000 Request distances to go for the axes V26000001 2 software version 3 1 and higher The cyclic provision of the distances currently to go is requested for all axes in the range VD570x0004 Deletion of the distance to go channel specifically V32000006 2 software version 3 1 and higher The IS Delete distance to go channel specifically is only effective in the AUTOMATIC mode it is effective there for all axes programmed in the block With the rising edge of the interface signal these axes are stopped with ramp stop the following error if any will be reduced to zero The distance to go remaining up to the end of the block distance to go along the path is deleted then the next program block is started for execution SINUMERIK 802S C base line 14 3 Description of Functions Various Interface Signals Note After the axes have been stopped using the IS Delete distance to go the block preparation for the subsequent program block is carried out using the new positions Thus after Delete distance to go the axes will travel along another contour than originally defined in the part program It can b
134. an be set via menu assisted operation MMC When the handwheel softkey is pressed in the basic menu of JOG mode the Handwheel window is displayed In this window each handwheel can be assigned an axis and the handwheel be enabled or disabled SINUMERIK 802S C base line 4 7 Description of Functions Manual Traversing and Handwheel Traversing Handwheel selec tion from MMC Input frequency Velocity Acceleration Canceling the tra versing movement Traversing in the opposite direction 4 8 To activate the handwheel from the operator panel special data in the user interface between MMC and PLC are used This interface made available from the PLC basic program for handwheels 1 and 2 can be monitored and contains the following information the respective axis name X Y Z is replaced by an axis number 1 3 the axis number assigned to the handwheel IS Axis number of handwheel 1 VB19001003 IS Axis number of handwheel 2 VB19001004 the additional information Machine axis or Axis in WCS IS V19001003 7 or V19001004 7 The handwheel connections can receive handwheel pulses with a maximum input frequency of 100 kHz The velocity results from the pulses generated using the handwheel and from the pulse weighting Distance to be traversed per time unit This velocity is limited by the value set in the axis specific MD MAX_AX_VELO When traversing using the handwheel the acceleration axis
135. anges AUTOMATIC JOG MDA from Before Before AUTO MDA to Reset Interr Reset Interr Interr Reset Interr AUTOMATIC X X X JOG X X X X MDA X X X Possible mode changes are marked with an X If mode change request has been rejected by the system a respective error message is output This error message can be deleted without changing the channel status The IS Mode change blocked V30000000 4 can be used to prevent mode change Already the mode change request is suppressed SINUMERIK 802S C base line 5 3 Description of Functions Program mode 5 1 2 Possible Functions in the Individual Modes Overview of Which function in which operating mode and which operating condition can be functions selected is to be seen in the following Table Table 5 2 Possible functions in the individual operating modes lt 2 Q 5 g S lt amp E o lt 3 a 5 i d 2 7p a lt z 5 S Ja Jz Z9 se Sila amp 2 O 7 S 7 es He alal lol e lel Jla Sls Tig Sl 2 2 2 is Q i Qa Q olzlol lol lolzloig zlolLjo xis e g el g lol ic sl gll csl sl el sl slF si slEl asl ale O O0 O0 0 0 0 0 0 0 0 olo o lt Cc Cc ext Cc cc lt 2m4 Cc C Cc ox m T Cc Cc oO oO oO oO oO oO oO oO oO oO oO oO oO oO lt lt lt lt i
136. ar stage to the NCK and sets the IS Gear stage changed t4 As a reponse the NEK receives the IS Change gear stage ands oscillation enables the next part program block for exection and accelerates the spindle to the new Fig 9 9 Gear stage change with the spindle at a standstill SINUMERIK 802S C base line Description of Functions 9 17 Spindle 9 4 9 18 Programming The spindle can be dimensioned for the following programmable functions G95 G96 S LIMS G97 G33 G331 G332 G25 S G26 S G4 S Programming of M4 M5 S SPOS M40 M41 to M45 Revolutional feedrate Constant cutting rate in m min upper limit speed Cancel G96 and freeze last spindle speed Thread cutting Thread interpolation Programmable lower upper speed limit Dwell time in spindle revolutions Direction of rotation of spindle CW Direction of rotation of spindle CCW Spindle Stop without orientation Spindle speed in 1 min e g S300 Spindle positioning e g SPOS 270 Automatic gear stage selection for the spindle Select gear stage 1 to 5 for the spindle SINUMERIK 802S C base line Description of Functions Spindle 9 5 Spindle Monitoring Speed ranges Both the spindle monitoring functions and the currently active functions G94 G95 G96 G33 etc define the permissible speed ranges of the spindle Speed Max encoder limit frequency Max spindle speed Max spindle speed of current gea
137. are defined by setting the IS Set direction of rotation CCW and CW accordingly long Signal not to spindle modes other than oscillation applicable Application see IS Oscillation by PLC example s Special cases If both IS are set at the same time no oscillation speed is output errors If no IS is set no oscillation speed is output Related to IS Oscillation by the PLC V38032002 4 IS Oscillation speed _ V38032002 5 SINUMERIK 802S C base line 9 39 Description of Functions Spindle V38032002 5 Interface signal Edge evaluation no Oscillation speed Signal s to axis spindle PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 If you wish to carry out gear stage change IS Change gear stage V39032000 3 is set the spindle mode changes to oscillation mode Depending on at which moment the IS Oscillation speed V38032002 5 is set the spindle decelerates to standstill with different accelerations 1 The IS Oscillation speed is set before the IS Change gear stage is set by the NCK The spindle is decelerated to standstill with the acceleration of oscillation MD SPIND_ OSCILL_ACCEL If the spindle is on standstill oscillation is started immediately 2 The IS Oscillation speed is set after the IS Change gear stage has been set
138. are set Depending on at which moment the IS Oscillation speed V38032002 5 is set the spindle decelerates to standstill with the acceleration for oscillation or with the acceleration for speed controlled mode position control mode The next block in the part program after gear stage change by M40 and S value or M41 to M45 will not be executed same effect as the IS Read in disable V32000006 1 would be set Oscillation is switched on at the latest with the standstill of the spindle IS Axis spindle on standstill V39030001 4 using the IS Oscillation speed V38032002 5 When the new gear stage is active the PLC user sets the IS Actual gear stage V38032000 0 to 2 and Gear stage changed V38032000 3 The gear stage change is considered completed spindle mode Oscillation is deselected and a change to the parameter record of the new actual gear stage is carried out In the new gear stage the spindle accelerates to the last programmed spindle speed The next block in the part program can be executed The IS Change gear stage V39032000 3 is reset by the NCK and as a response the PLC user will reset the IS Gear stage changed V38032000 3 SINUMERIK 802S C base line Description of Functions Parameter record Spindle Each of the 5 gear stages is assigned a parameter record with the following assignment BE ace Data of the Data Block Contents 0 Data for
139. ated output voltage e Check smooth running of axes spindle Check machine data for traversing motions feed override acceleration max velocities 1 1 2 Positioning Monitoring Function To ensure that an axis is positioned within a given time the time configured in MD POSITIONING _TIME time delay exact stop fine is started on completion of the motion block position partial setpoint 0 at the end of movement and once this time has elapsed a check is made to see whether the following error is below the limit value for STOP_LIMIT_FINE Exact Stop Fine Effect If the limit value for Exact Stop Fine is not yet reached when the positioning monitoring time has elapsed the following action is performed e Alarm 25080 Positioning monitoring is output The axis spindle concerned is stopped with rapid stop see Section 1 1 1 Error cause remedy Position controller gain too small gt change machine data for position controller gain MD POSCTRL_GAIN n servo gain factor Positioning window exact stop fine positioning monitoring time and servo gain are not matched gt change machine data MD STOP_LIMIT_FINE exact stop fine MD POSITIONING_TIME delay time exact stop fine MD POSCTRL_GAIN n servo gain factor Note The size of the positioning window effects the block change time The smaller these tolerances are selected the longer the positioning task will take which in turn means a l
140. ated to MD DRIFT_ENABLE automatic drift compensation 36720 DRIFT_VALUE MD number Drift basic value Default 0 Min input limit 0 Max input limit Change valid after NEW_CONF Protection level 2 7 Unit Data type DOUBLE Valid as from SW version 3 Meaning The drift basic value entered in MD DRIFT_VALUE is always delivered as an additional speed value The drift basic value is always effective independently of MD DRIFT_ENABLE Whereas the automatic drift compensation is only effective for analog position controlled axes spindles the drift basic value is also effective for a speed controlled spindle not applicable SINUMERIK 802S C base line 6 11 Description of Functions Compensation 38000 MD number MM_ENC_COMP_MAX_POINTS 0 Number of interpolation points with LEC SRAM Default 0 Min input limit 0 Max input limit 5000 Changes effective after Power On Protection level 2 7 Unit Data type DWORD Valid as from SW version Meaning The number of interpolation points required for the LEC must be defined The required number can be calculated as follows using the defined parameters AA_ENC_COMP_MAX AA_ENC_COMP_MIN MD MM_ENC_COMP_MAX_POINTS 4 AA_ENC_COMP_STEP AA_ENC_COMP_MIN start position system variable AA_ENC_COMP_MAX end position system variable AA_ENC_COMP_STEP dist betw
141. ation of such characteristics with overload protection at the same time can be achieved with velocity dependent acceleration control This method called knee shaped acceleration characteristic can be used for both positioning and path movements The axis specific course of the acceleration characteristic must be paramet erized using the following machine data e MD MAX_AX_VELO Maximum axis specific velocity Vmax e MD ACCEL_REDUCTION_SPEED_POINT Threshold velocity of the acceleration decay with respect to MAX_AX_VELO Vea e MD MAX_AX_ACCEL Maximum axis specific acceleration amax e MD ACCEL_REDUCTION_FACTOR Factor of acceleration reduction with respect to MD MAX_AX_ACCEL aea The acceleration course is constant SINUMERIK 802S C base line 3 9 Description of Functions Velocity Setpoint Actual Value System Closed Loop Control Activation Path characteristic G64 block transition 3 10 Constant acceleration reduction Fig 3 6 Axis specific acceleration and velocity course Velocities Vmax MD MAX_AX_VELO Vea MD ACCEL_REDUCTION_SPEED_POINT x MD MAX_AX_VELO Accelerations amax MD MAX_AX_ACCEL ara 1 MD ACCEL_REDUCTION_FACTOR x MD MAX_AX_ACCEL Traversing the stepper motor axes in JOG mode This feature is always activated with MD ACCEL_TYPE_DRIVE 1 MD JOG_AND_POS_JERK_ENABLE 0 must be set The knee shaped acceleration characteristic is an axis specific default setti
142. ay not exceed the maximum permissible axis velocity machine data MAX_AX_VELO These machine data are not used for the programmed rapid traverse GOO MD not applicable to AUTOMATIC mode and MDA Related to MD MAX_AX_VELO maximum axis velocity IS Rapid traverse override IS Feed override SINUMERIK 802S C base line Description of Functions 4 13 Manual Traversing and Handwheel Traversing 32020 MD number Default 2000 JOG_VELO Conventional axis velocity Min input limit 0 Max input limit plus Change effective after Unit Linear axis mm min Power On Protection level 2 7 Data type DOUBLE Valid as from SW version Meaning The entered velocity applies to traversing in JOG mode with axis feed override position on 100 This velocity is only used if the general setting data for linear axes SD JOG_SET_VELO 0 In this case the axis velocity acts for continuous traversing incremental traversing INC1 handwheel traversing The entered value may not exceed the maximum permissible axis velocity machine data MAX_AX_VELO Spindles in JOG mode These machine data can also be used to set a spindle specific velocity for spindles when traversing in JOG mode provided SD JOG_SPIND_ SET_ VELO 0 However this velocity is affected by the spindle override switch Default 1 0 Application If differen
143. ber 0 1 Min input limit Max input limit Protection level 2 7 Unit Valid as from SW version MD HANDW_IMP_PER_LATCH is used to adapt the connected handwheels to the control system Enter the number of pulses per handwheel latched position generated by the handwheel The handwheel pulse weighting must be set for each existing handwheel 1 to 3 separately Using this adaptation each handwheel latched position acts in the same manner as a traversing key would have been pressed during incremental traversing A negative value results in direction reversal of the direction of rotation of the handwheel MD JOG_INCR_WEIGHT weighting of an axis increment with INC handwheel Power On Related to 11346 MD number HANDWH_TRUE_DISTANCE Handwheel travel or velocity specification Default 1 Min input limit 0 Max input limit 2 Change effective after Power On Degree of protection 2 7 Unit Data type BYTE Valid as from SW version 3 Meaning 0 The specifications of the handwheel are velocity specifications Deceleration at a standstill of the handwheel is on the shortest way 1 The specifications of the handwheel are travel specifications No pulses are lost Due to a limitation to the maximum admissible velocity the axes can follow up 2 not available SINUMERIK 802S C base line Description of Functions 4 12 Man
144. between machine and control system is lost Correct position control is no longer possible This state is signaled to the PLC Activation The encoder limit frequency monitoring function is always active when the encoder is switched on Effect When the limit frequency of an encoder is exceeded the following occurs e The IS Encoder limit frequency exceeded 1 V390x0000 2 is set The spindle continues running with speed control If the spindle speed is reduced so much that the lower encoder limit frequency is violated the spindle automatically synchronizes itself with the reference system of the measuring encoder again If the limit frequency of the measuring system of a position controlled axis is active alarm 21610 Frequency exceeded is output The axis spindle involved is stopped with rapid stop see Section 1 1 1 Remedy e Check encoder and encoder data 1 2 2 Zero Mark Monitoring Function not applicable to stepper motor axes Zero mark monitoring is used to check whether pulses have been lost between two zero mark passages of the actual position value encoder The number of detected zero mark errors after which the monitoring function must respond is entered in MD ENC_ZERO_MONITORING zero mark monitoring Activation The monitoring function is activated with MD ENC_ZERO_MONITORING 0 Every time the encoder is switched on counting of zero mark errors starts at 0 Effect If the number of zero
145. bsolutely necessary Positioning from rotation Positioning from rotation At the moment when positioning is started SPOS in the program the spindle can be in speed controlled mode This results in the following sequence Case 1 Spindle in speed controlled mode encoder limit frequency range exceeded Fig 9 2 Case 2 Spindle in speed controlled mode encoder limit frequency not exceeded Fig 9 3 SINUMERIK 802S C base line Description of Functions Spindle Speed 1 min Encoder limit frequency Position control switch on speed SPOS 160 Fig 9 2 Positioning form rotation with the programmed spindle speed and the actual spindle speed above the limit frequency of the spindle actual position encoder special case Spindle speed gt limit frequency of encoder Phase 1 Spindle rotates with a speed higher than the encoder limit frequency The spindle is not yet synchronized Phase 2 At the moment when the SPOS command becomes active the spindle starts deceleration of the spindle to the position controller switch on speed When the actual encoder limit frequency is lower than the set encoder limit frequency the spindle is synchronized The positioning mode is activated with the synchronization Phase 3 When the position controller switch on speed set in MD SPIND POSCTRL_VELO is reached the position control is switched on the distance to go to the target position is calculat
146. cal prerequisites to change to position control mode For this reason spindle positioning with SPOS must be programmed before tapping Detail description see User Manual Operation and Programming For tapping with G331 G332 the axis velocity for the thread length results from the programmed spindle speed S and the programmed thread lead However the maximum axis velocity defined by MD MAX_AX_VELO cannot be exceeded The feed F does not apply but remains stored SINUMERIK 802S C base line 11 5 Description of Functions Feeds 11 6 Rapid Traverse GO Rapid traverse motion GO is used for high speed positioning of the tool but not for direct workpiece machining All axes can be traversed at the same time This results in a straight path The maximum velocity rapid traverse for each axis is defined in machine data MD MAX_AX_VELO When only one axis traverses it traverses at rapid traverse rate When two axes are traversed at the same time the path velocity resulting velocity is selected such that both axes are traversed with the maximum possible path velocity For example if both axes are to be traversed with the same maximum velocity and have to cover the same path distance the path velocity 1 41 max axis velocity geometrical total of the two axis components The feed F is not relevant for GO but remains stored Rapid traverse override Via the operation gt Program Control softkey it is possible
147. cally Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 When the following functions are active the spindle is in control mode e Setting of direction of rotation of spindle M3 M4 or Spindle Stop M5 e M41 M45 or automatic gear stage change Interface signal Edge evaluation yes Related to IS Spindle mode Oscillation Mode V39032002 6 IS Spindle mode Positioning Mode V39032002 5 V39032002 6 Active spindle mode Oscillation mode Signal s from axis spindle NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The spindle is in oscillation mode if a new gear stage has been set either by automatic gear stage selection M40 or by M41 to M45 IS Change gear stage is set The IS Change gear stage is only set if the new gear stage is other than the currently active gear stage Related to IS Spindle mode Control Mode V39032002 7 IS Spindle mode Oscillation Mode V39032002 5 IS Change gear stage V39032000 3 9 46 SINUMERIK 802S C base line Description of Functions Spindle V39032002 5 Interface signal Edge evaluation yes Active spindle mode Positioning mode Signal s from axis spindle NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 When the follo
148. ch is used to slow down the traversing process when part programs are tested The override possible for the rapid traverse ranges from 0 to 100 The spindle override can be used to modify the spindle speed and the cutting speed with G96 An override between 50 and 120 is possible A modification is carried out with consideration of the machine specific acceleration and velocity limits without contour violation The overrides are active for the programmed values before the limits e g G26 are active Channel specific feed and rapid traverse override Axis specific feed override For feed and rapid traverse one enable signal each and one byte for the override factor in per cent are provided by the PLC interface IS Feed override VB32000004 IS Feed override active V32000006 7 IS Rapid traverse override VB32000005 IS Rapid traverse override active V32000006 6 The interface for the override value is entered from the machine control panel via the PLC in the form of a Gray code An active feed override applies to for all contour axes An active rapid traverse override is valid for all axes traversing at rapid traverse rate If no own rapid traverse override switch exists the feed override switch can be used in this case feed overrides of more than 100 are limited to 100 rapid traverse override Which override is to be active can be selected either via the PLC or from the operator panel
149. changed the Reset request is carried out and the alarm deleted if this is still present on the interface Note Only possibility of abortion IS Clear distance to go spindle reset V38030002 2 own spindle reset active 9 12 SINUMERIK 802S C base line Description of Functions Spindle 9 2 Referencing Synchronizing Why synchronizing In order to ensure that the control system finds the 0 degree position after Why referencing Synchronization sequence Max encoder freq uency exceeded Resynchronizing switching on the CNC must be synchronized with the position measuring system of the spindle This process is called synchronization Only a synchronized spindle can perform thread cutting e positioning Axes are synchronized via reference point approach This process is also called referencing see Section Reference Point Approach After the control system has been switched on the spindle can be synchronized as follows e The spindle is started with a spindle speed S function and a direction of rotation of the spindle M3 or M4 and synchronizes itself with the next zero mark of the position measuring system From standstill the spindle is positioned with SPOS The spindle accelerates to the positioning speed and synchronizes itself with the next zero mark of the position measuring system The spindle is then positioned to the programmed position Note During synchronization of the
150. control system has been conceived such that the traversing movement is aborted as soon as the first valid limit switch is reached The velocity control ensures that the deceleration process is started on time so that the axis stops exactly on the limit position e g software limit switches Fast Stop is only used to stop the axis if the hardware limit switches respond If the respective limit switch is reached an alarm message alarms 10620 10621 is output The control system then prevents further traversing in this direction The traversing keys and the handwheel for this direction remain without effect Important In order to activate the software limit switches the axis must first be referenced The axis can be traversed from a limit switch position to the opposite direction Machine manufacturer The way how an axis that has approached the limit position is cleared depends on the machine manufacturer Please refer to the Documentation of the machine manufacturer The velocity and acceleration used for manual traversing is defined axis specifically by the start up engineer via machine data The control system limits the values acting at the axes to the maximum velocity and acceleration settings SINUMERIK 802S C base line Description of Functions Manual Traversing and Handwheel Traversing 4 6 2 Miscellaneous Mode change JOG gt AUT or JOG gt MDA Mode change from JOG to AUT or MDA is only carried out if all axes have
151. ction is effective 30600 MD number Default 0 FIX_POINT_POS Fixed value positions of the axes with G75 Min input limit 0 Max input limit Changes effective after Power On Protection level 2 7 Unit mm degrees Data type DOUBLE Valid as from SW version Meaning In these machine data the fixed point position that is approached when G75 is programmed is specified for each axis Application Fixed point approach G75 X0 A dummy value in this case 0 must be example s specified for the axis References Operation and programming 5 18 SINUMERIK 802S C base line Description of Functions Setting data Program mode 42100 SD number Default 5000 DRY_RUN_FEED Dry run feed Max input limit plus Min input limit 0 Changes effective immediately Unit mm min Protection level Data type DOUBLE Valid as from SW version Meaning To check a part program with refer to the distance to be traversed without machining a workpiece the operator can activate the function Dry run feed via the operator interface Program Control softkey In this case instead of the programmed feedrate value the value of this setting data is used Rapid traverse feed values will not be modified The dry run feed value can be entered in the setting data menu This function is only active in AUTOMATIC mode and MDA
152. ctivated Signal status 0 or edge change 1 gt 0 Activate Program Control M1 has not been selected from the operator interface Related to IS Activate M01 IS MO M1 active 5 20 SINUMERIK 802S C base line Description of Functions Program mode V17000001 7 Interface signal Edge evaluation no Program test selected Signal s from MMC gt PLC Signal s updated cyclically Signal s version valid as from SW Signal status 1 or edge change 0 gt 1 The program control Program test has been selected from the operator interface The function is thus not yet activated Signal status 0 or edge change 1 gt 0 The program control Program test has not been selected from the operator interface Related to IS Activate program test IS Program test active V18000001 0 Interface signal Edge evaluation no Machine function TEACH IN Signal s from MMC gt PLC Signal s updated cyclically Signal s version valid as from SW Signal status 1 or edge change 0 gt 1 The machine function TEACH IN has been selected from the operator interface The function is thus not yet activated Signal status 0 or edge change 1 gt 0 The machine function TEACH IN has not been selected from the operator interface Related to IS machine function TEACH IN IS machi
153. d output voltage applies to analog drives spindle only MD RATED_VELO rated motor speed MD RATED_OUTVAL rated output voltage Encoder resolution 1 10 SINUMERIK 802S C base line Description of Functions Axis Spindle Monitoring 1 5 Stepper Motor Rotation Monitoring Using BERO Overview Modulo counter Activation Comparison The BERO proximity switch for rotation monitoring is connected in the same way as with referencing with BERO Parallel connection with the BERO for referencing or using the same for rotation monitoring is possible However during referencing either the rotation monitoring must be disabled or no switching edge may be provided from the reference BERO when rotation monitoring is active A modulo conter 1 modulo 1 revolution is provided to count the actual value increments The modulo count is stored as a machine data MD BERO_CYCLE Repetition cycle of the BERO edges in actual value increments The rotation monitoring can be enabled disabled via the IS Rotation monitoring V380x5000 0 When the BERO is overtraveled for the first time the module count is stored as the BERO zeroing value to zero the modulo counter With each further overtraveling of the BERO it is checked whether the contents of the modulo counter has its value in the vicinity of the stored BERO zero value A BERO tolerance can be taken into account via MD BERO_EDGE_TOL If the comparison yields a negative result
154. d on the status display see also Section 5 2 Program Test The dry run feed in SD DRY_RUN_FEED should be modified prior to program change start NC Start gt operation softkey Parameter Setting Data Any changes after program start have no effect Activation The interface signal Activate dry run is evaluated with NC Start if the channel was in Reset status SINUMERIK 802S C base line 11 7 Description of Functions Feeds 11 8 Velocity for Manual Traversing JOG mode Simultaneous traversing Velocity For traversing the axes by manual operation in the following called manual traversing JOG mode must be active JOG mode differentiates various JOG variants the so called machine functions e continuous traversing as long as the traversing key for the axis is pressed incremental traversing preselected number of increments In JOG mode all axes can be traversed at the same time If several axes are traversed simultaneously they are not involved in interpolation The velocity of a traversing movement of an axis in JOG mode is defined by a setting data SD JOG_SET_VELO JOG velocity in mm min The value can be entered via operation Softkey Parameter gt Setting Data If the value is zero the axis will traverse with the value of the axis machine data MD JOG_VELO Rapid traverse override Feed override When the rapid traverse override key is pressed together with t
155. d software limit switch minus Signal status 0 or edge change 1 gt 0 1st software limit switch for plus or minus direction is active 2nd software limit switch for plus or minus direction is inactive Interface signal Edge evaluation no Related to MD POS_LIMIT_PLUS POS_LIMIT_PLUS2 POS_LIMIT_MINUS POS_ LIMIT_MINUS2 software limit switch plus software limit switch minus V380x5000 0 Rotation monitoring Signal s to axis PLC NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge evaluation 08 1 Rotation monitoring active further information see Chapter NO TAG Signal status 0 or edge change 120 Rotation monitoring OFF Related to IS Error Rotation monitoring V390x5000 0 Signals from axis spindle V390x0000 2 Interface signal Edge evaluation no Encoder limit frequency exceeded 1 Signal s from axis spindle NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge evaluation 0 gt 1 The limit frequency set in MD ENC _FREQ_LIMIT encoder limit frequency is exceeded The reference point the synchronization for the position measuring system is lost IS Referenced Synchronized has signal status 0 Position control is no longer possible The spindle continues turning with speed control Signal status 0 or edge evaluation 1 gt
156. ddition to the hardware switch it is also possible to use a software limit switch The absolute position in the machine axis system of the positive range limit of each axis is entered The MD is effective after reference point approach if the IS 2nd software limit switch plus is not set MD not applicable the axis is not referenced IS 2nd software limit switch plus SINUMERIK 802S C base line Description of Functions Axis Spindle Monitoring 36120 POS_LIMIT_MINUS2 MD number 2nd software limit switch minus Default 100 000 000 Min input limit Max input limit Change effective after Power On Protection level 2 7 Unit mm degrees Data type DOUBLE Valid as from SW version Meaning Meaning as 2nd software limit switch plus but for the traversing range limit in the negative direction Which of the two software limit switches 1 or 2 is to be activated can be selected by an interface signal from the PLC e g V38011000 2 0 1st software limit switch minus for the 1st axis active V38011000 2 1 2nd software limit switch minus for the 1st axis active MD not applicable the axis is not referenced idee Related to IS 2nd software limit switch minus 36130 POS _LIMIT_PLUS2 MD number 2nd software limit switch plus Default 100 000 000 Min input limit Max input limit Change effective after Power O
157. deselecting or changing the machine function V33001000 0 and 1 V33001004 0 and 1 V33001008 0 and 1 Handwheel active 1 to 2 for WCS axis Interface signal Signal s from channel NCK gt PLC Edge evaluation no Signal s valid as from SW version Signal s updated cyclically Signal status 1 or edge change 0 gt 1 These PLC interface signals are used to report whether the axis is assigned to handwheel 1 or 2 or to none handwheel At this moment one axis can be assigned only one handwheel each If several interface signals Activate handwheel are set the priority is Handwheel 1 before Handwheel 2 If the assignment is active the axis can be traversed with the handwheel in JOG mode Signal status 0 or edge change 1 gt 0 This axis is not assigned handwheel 1 or 2 Related to IS Activate handwheel SINUMERIK 802S C base line Description of Functions 4 21 Manual Traversing and Handwheel Traversing V33001000 7 and 6 V33001004 7 and 6 V33001008 7 and 6 Interface signal Traversing command plus and minus for WCS axis Signal s from channel NCK gt PLC Edge evaluation no Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 A traversing motion is desired in the respective axis direction Depending on the operating mode the trav
158. dle modes other than reciprocation mode applicable _ Application Engaging of a new gear stage can be facilitated by reciprocating of the spindle example s motor since the gear wheels can thus better be meshed Special cases errors For the reciprocation speed defined in this MD the acceleration when reciprocating applies MD SPIND_OSCILL_ACCEL Default 16 Related to MD SPIND_OSCILL_ACCEL acceleration when reciprocating IS Reciprocation by PLC V38032002 4 IS Reciprocation speed V38032002 5 35410 SPIND_OSCILL_ACCEL MD number Acceleration when reciprocating Min input limit 0 Max input limit plus Change effective after Power On Protection level 2 7 Unit rev s Data type DOUBLE Applies from SW version Meaning The acceleration defined here is only effective for the output of the spindle speed MD SPIND_OSCILL_DES_VELO to the spindle motor The reciprocation speed is selected using the IS Reciprocation speed MD irrelevant for all spindle modes other than reciprocation mode Related to MD SPIND_OSCILL_DES_VELO reciprocation mode IS Reciprocation speed V38032002 5 IS Reciprocating by PLC V38032002 4 SINUMERIK 802S C base line 9 31 Description of Functions Spindle 35430 MD number Default 0 SPIND_OSCILL_START_DIR Start direction when reciprocating
159. e Preconditions General spindle reset Own spindle reset Own spindle reset The spindle is in control mode when the following functions are active constant spindle speed S M3 M4 M5 and G94 G95 G97 constant cutting speed G96 S M3 M4 M5 constant spindle speed S M3 M4 M5 and G33 Spindle need not be synchronized No spindle actual position encoder required for M3 M4 M5 in conjunction with feed F in mm min or inch min G94 A spindle actual position encoder is absolutely necessary for M3 M4 M5 in conjunction with revolutional feed G95 F in mm rev or inch rev constant cutting speed G96 G97 and tapping G33 The spindle can be stopped by means of the IS Delete distance to go spindle reset CAUTION When G94 is active the program execution is continued without any further actions MD SPIND_ACTIVE_AFTER_RESET is used to set the behavior of the spindle after Reset or end of program M2 M30 If MD SPIND_ACTIVE_AFTER_RESET 0 the spindle is immediately decelerated to a standstill with maximum acceleration The last programmed spindle speed and direction of rotation of the spindle are deleted If MD SPIND_ACTIVE_AFTER_RESET 1 own spindle reset is set the last programmed spindle speed S function and the last programmed direction of rotation of the spindle M3 M4 M5 are kept If constant cutting speed G96 is active prior to Reset or end of program the currently active cutting speed related to 10
160. e the axis traverses the remaining distance to go until it is zero The movement can be interrupted by releasing the traversing key Pressing the traversing key of the opposite direction remains without effect as long as the increment has not been traversed completely or the movement is aborted If you do not wish to traverse the entire increment the movement can be canceled either by pressing RESET or providing the axis interface signal Clear distance to go Spindle Reset V380x0002 2 SINUMERIK 802S C base line Description of Functions Manual Traversing and Handwheel Traversing 4 5 Handwheel Traversing in JOG Mode Selection Traversing Travel or velocity specifications Weighting Traversing commands Connection of JOG mode must be active In addition the operator must set the increment active during handwheel traversing INC1 INC10 The assignment axis handwheel must be carried out on the operator panel see Documentation Operation and Programming Turning the electronic handwheel traverses the respective axis in positive or negative direction depending on the desired direction of rotation Default settings for the handwheel movement to match it with the intended application can be defined using MD HANDWH_TRUE_DISTANCE handwheel travel or velocity specification Value 1 standard The handwheel default values are travel specifications No pulses will be lost Due to a limitation to th
161. e achieved by programming G90 in the block following after Delete distance to go that at least the programmed absolute position is approached In contrast the position which has originally been defined with G91 in the part program will no longer be reached in the subsequent block V380x0001 3 Interface signal Edge evaluation no Axis spindle lock Signal s to axis spindle PLC NC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 Axis lock Spindle lock The IS Axis spindle lock can only be used for testing purposes test status If the IS Axis lock is provided no position setpoints are output to the position controller of this axis the traversing movement of this axis is thus blocked The position control loop remains closed and the remaining following error is compensated If an axis is traversed with axis lock the actual position display will show the set position and the velocity actual value position even without real movement of the machine axis RESET IS V30000000 7 will set the position actual value display to the real actual value of the machine Traversing commands for this axis are still output to the PLC If the interface signal is canceled the associated axis can be traversed normally again If the interface signal Axis lock is provided for a traversing axis the axis is stopped with deceleration stop If the
162. e machine axis has stopped ahead of the reference cam it accelerates to the speed and direction specified in MD REFP_VELO SEARCH _CAM reference point approach speed irrespective of whether the traversing key plus minus is pressed If the wrong traversing key is pressed reference point approach will not be started If the machine axis stands on the reference cam it accelerates to the speed specified in MD REFP_VELO_SEARCH_CAM reference point approach speed and traverses in the direction opposite to the direction specified in MD REFP_CAM_DIR_IS_ MINUS A machine axis start point behind the reference cam must be ruled out 34020 MD number Default 5000 REFP_VELO_ SEARCH _CAM Reference point approach speed Min input limit 0 Max input limit plus Changes effective after Power On Protection level 2 7 Unit mm min Data type DOUBLE Valid as from SW version Meaning The reference point approach speed is the speed with which the machine axis traverses in the direction of the reference cam phase 1 after the traversing key has been pressed The maximum amount of this value must be set such that the axis can be decelerated to standstill before it reaches a hardware switch and comes to standstill on the reference cam 34030 MD number Default 10000 REFP_MAX_CAM_DIST Max distance to reference cam Min input limit 0 Max input limit plus Changes effective after
163. e machine function 1000 INC 1 4 V390x0005 6 Active machine function continuous 1 4 V390x1002 0 Lubrication pulse 1 14 V39032000 0 to 2 Spindle Set gear stage A to C 1 9 V39032000 3 Spindle Change gear stage 1 9 V39032001 0 Spindle Speed limit exceeded 1 9 V39032001 1 Spindle Set speed limited 1 9 V39032001 2 Spindle Set speed increased 1 9 V39032001 5 Spindle Spindle in set range 1 9 V39032001 7 Spindle Actual direction of rotation CW 1 9 V39032002 3 Spindle Tapping without compensating chuck 1 9 V39032002 5 Spindle Active spindle mode Positioning Mode 1 9 SINUMERIK 802S C base line 15 5 Description of Functions List of Interface Signals Interface signal Name Ref Section V39032002 6 Spindle Active spindle mode Oscillation Mode 1 9 V39032002 7 Spindle Active spindle mode Control Mode 1 9 V390x5000 0 Stepper motor Speed monitoring error 1 14 VD570x0000 Axis actual values data format FLOAT 1 14 VD570x0004 Distances to go by the axes data format FLOAT 1 14 MMC MMC gt PLC V17000000 5 M01 selected 1 5 V17000000 6 Dry run feed selected 1 11 V17000001 3 Feed override for rapid traverse selected 1 11 V17000001 7 Program test selected 1 5 V17000002 0 Select Skip Block 1 5 V18000001 0 Machine funktion TEACH IN 1 5 V19001003 0 to 1 Axis number for handwhe
164. e maximum admissible velocity it is possible that the axes follow up This should be taken into account in particular in the case of a high weighting of the handwheel pulses Value 0 The handwheel default values are velocity specifications Decelerating in the case of a handwheel standstill will be carried out using the shortest way The distance to be traversed which results from turning the handwheel depends on the following factors number of handwheel pulses received on the interface e active increment machine functions INC1 INC10 INC100 INC 1000 e pulse weighting of handwheel with general MD HANDWH_IMP _PER _LATCH handwheel pulses per latched position e _ weighting of an increment with INC handwheel axis specific MD JOG_ INCR_WEIGHT During the axis movement either the IS Traverse command or Traverse command V380x0004 7 or 6 is provided to the PLC depending on the direction of movement If the axis is already traversed via the traversing keys additional handwheel traversing is not possible Alarm 20051 Handwheel traversing not possible is output A maximum of 2 handwheels can be connected at a time It is thus possible to handwheels move max 2 axes by handwheels at the same time Handwheel It is possible to assign an axis a handwheel either in the machine MCS or in assignment the workpiece WCS coordinate system Which axis X Y Z is moved by turning handwheel 1 or 2 c
165. e measured during the start up of the machine and compensated during operation Compensations Because of the rising demands on the accuracy of machine tools state of the art CNCs posses intelligent functions for the compensation of essential errors The following compensations can be activated axis specifically Backlash compensation LEC lead error and measuring system error compensation The compensation functions can be set for every machine separately by means of machine data For a spindle with position control positioning mode or an axis with analog drive e automatic drift compensation can be activated SINUMERIK 802S C base line 6 1 Description of Functions Compensation 6 1 Backlash Compensation Mechanical backlash Effect Compensation Activation Positive backlash 6 2 The power transmission between a moved machine part and its drive e g reversal backlash of leadscrew is usually characterized by small backlashes since completely backlash free adjustment of the mechanics would result in a too high machine wear Furthermore backlash can occur between the machine part and the measuring system If indirect measuring systems are used for the axes spindles the mechanical backlash leads to a falsification of the travel For example in the case of reversal of the direction the axis will traverse by the amount of the backlash too less or too much see Fig 6 1 and Fig 6 2 The same a
166. e stop X M2 in block X MO M1 in block X IS Single block X Auxiliary function output to PLC X but not yet acknowledged Commands lt gt lt gt lt gt lt gt lt gt lt SINUMERIK 802S C base line 5 17 Description of Functions Program mode 5 5 Machine data Data Description 21000 MD number Default 0 01 CIRCLE_ERROR_COIS Circle end point monitoring constant Min input limit 0 Max input limit plus Changes effective after Power On Protection level 2 7 Unit mm Data type DOUBLE Valid as from SW version Meaning This machine data characterizes the permissible absolute circle difference With circle programming the radii from the programmed center point to the start point or end point are usually not the identical the circle is overdetermined The maximum permissible difference of these two radii which are accepted without alarm is determined by the greater value by the following data MD CIRCLE_ERROR_COIS Starting radius multiplied with 0 001 i e for smaller circles this tolerance is a fixed value MD CIRCLE_ERROR_COIS and for larger circles it is proportional to the starting radius Application example MD CIRCLE_ERROR_COIS 0 01 mm When these machine data and a radius 10 mm are used the constant is effective when the radius is gt 10 mm the proportional fa
167. e without measuring system 30240 ENC_TYPE n MD number Mode of actual value sensing actual position value Default 0 Min input limit 0 Max input limit 5 Change effective after Power On Protection level 2 7 Unit Data type BYTE Valid as from SW version Meaning In this MD the encoder type used must be entered 0 Simulation 2 Square wave generator standard quadrupling of increments 3 Encoder for stepper motor Values 1 2 5 not available The machine data index n is coded as follows encoder no 0 If an invalid encoder type is defined alarm 300009 Invalid measuring circuit type drive number measuring circuit number is output Simulation Machine functions can also be simulated with a measuring system connected Application example s 30350 MD number SIMU_AX_VDI_OUTPUT Output of axis signals with simulation axes Default 0 Min input limit 0 Max input limit 1 Change effective after Power On Protection level 2 7 Unit Data type BOOLEAN Valid as from SW version This machine data defines whether axis specific interface signals are output to the PLC during simulation 1 The axis specific IS of a simulated axis are output to the PLC It is thuis possible to test the PLC user program without drives connected The axis specific IS of a simulated axis are not output to the PLC All axis
168. ed e the acceleration has changed to GEAR_STEP_POSCTRL_ACCEL acceleration in position control mode Phase 4 The spindle decelerates from the calculated Brake point to the target position with GEAR_STEP_POSCTRL_ACCEL Phase 5 The position control remains active and keeps the position as programmed The IS Exact stop fine and Exact stop coarse are set if the distance between the spindle position and the programmed position spindle set position is less than the exact stop tolerance fine and coarse defined in the MD STOP_LIMIT_FINE and MD STOP_LIMIT_COARSE SINUMERIK 802S C base line 9 5 Description of Functions Spindle Encoder limit frequency Position control switch on speed SPOS 180 Fig 9 3 Positioning form rotation with the programmed spindle speed and the actual spindle speed below the limit frequency of the spindle actual position encoder special case Spindle speed less than encoder limit frequency 9 6 Phase 1 Spindle rotates with a speed less than encoder limit frequency The spindle is synchronized Phase 2 At the moment when the SPOS command becomes active the spindle starts to decelerate with the acceleration stored in MD GEAR_STEP_SPEEDCTRL_ACCEL to the position controller switch on speed Phase 3 When the position controller switch on speed stored in MD SPIND_POSCTRL_VELO is reached the position control is switched on e the distance to go to the
169. ed This speed will not be exceed The brake point start calculation detects the moment when the programmed spindle position can be exactly approached with the acceleration defined in GEAR_STEP_POSCTRL_ACCEL At the moment detected by the brake start point calculation in phase 1 the spindle decelerates to standstill with the acceleration defined in MD GEAR_STEP_POSCTRL_ACCEL acceleration in position control mode SINUMERIK 802S C base line Description of Functions Spindle Reset Distinctive features Spindle Phase 3 At the moment detected by the brake start point calculation in phase 3 the spindle decelerates to standstill with the acceleration defined in MD GEAR_STEP_POSCTRL_ACCEL acceleration in position control mode Phase 3a Already at the moment when the SPOS command becomes active the target point is so close that the spindle can no longer be accelerated to SPIND_POSCTRL_VELO The spindle will be decelerated to standstill with the acceleration defined in MD GEAR_STEP_POSCTRL_ACCEL acceleration in position control mode Phase 4 4a The spindle is on standstill and has reached its position Position control is active and keeps the spindle on its programmed position The IS Position reached with exact stop fine coarse are set if the distance between the spindle actual position and the programmed position spindle set position is less than the value of the exact stop tolerance fine and coarse defined in
170. edge change 0 gt 1 If a spindle speed 1 min or a constant cutting speed m min or ft min was programmed one of the following limit values has not been reached e Min speed of the set gear stage e Min spindle speed e Progr spindle speed limitation G25 The spindle speed is limited to the min limit value increased Signal status 0 or edge change 1 gt 0 If a spindle speed 1 min or constant cutting speed m min or ft min was programmed no limit values have been exceeded Application example s The IS Set speed increased can be used to detect that the programmed speed cannot be reached V39032001 0 Interface signal Edge evaluation yes Speed limit exceeded Signal s from axis spindle NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 If the actual speed exceeds the max spindle speed MD SPIND_MAX_VELO_ LIMIT by more than the spindle speed tolerance MD SPIND_DES_VELO_TOL the IS Speed limit exceeded is set and alarm 22050 output All axes and spindles of the channel are decelerated Interface signal Edge evaluation yes Related to MD SPIND_DES_VELO_TOL spindle speed tolerance MD SPIND_MAX_VELO_LIMIT max spindle speed Alarm 22050 Max speed reached V39032002 7 Active spindle mode Control mode Signal s from axis spindle NCK gt PLC Signal s updated cycli
171. eference point edge required for synchronization in the middle between two BERO signals or zero pulses is the best solution Warning If the reference cam is not adjusted exactly a false synchronous pulse BERO zero mark could be evaluated As a consequence the control system will assume a wrong machine zero and traverse the axes to the wrong positions the software limit switches will also be enabled for the wrong positions and can thus not protect the machine A machine axis does not require a reference point cam if it provides only one synchronous pulse over the entire traversing range If axes are referenced without cam the synchronization is carried out as follows only phases 2 and 3 SINUMERIK 802S C base line Description of Functions Sequence of motions e Synchronization with pulse e Approach to reference point Reference Point Approach The following Table shows the individual sequence of motions for referencing with without reference point cam Referencing Method with reference point cam Synchr Pulse Synchronous pulse ahead of cam reference point coordinate ahead of synchr pulse Sequence of Motions le RV A aaa Synchr pulse Cam Synchronous pulse on cam reference point coordinate after synchr pulse on cam with reversal with reversal MD REFP_SEARCH_MARKER_REVERS 1 Synchr pulse without reference cam Reference coo
172. el 1 A to B 1 4 V19001003 7 Ma chine axis is axis number for handwheel 1 1 4 V19001004 0 to 1 Axis number for handwheel 2 A to B 1 4 V19001004 7 Machine axis is axis number for handwheel 2 1 4 MMC PLC gt MMC V19005000 2 Key lock 1 14 Machine control panel MCP MCP gt PLC V10000000 0 to 5 Key T1 to T6 free 2 V10000000 6 Key T7 INC 2 V10000000 7 Key T8 JOG 2 V10000001 0 Key T9 REF 2 V10000001 1 Key T10 AUTO 2 V10000001 2 Key T11 SBL 2 V10000001 3 Key T12 MDA 2 V10000001 4 Key T13 spindle start 2 V10000001 5 Key T14 spindle stop 2 V10000001 7 Key T15 spindle start 2 V10000001 2 Key T16 free 2 V10000002 0 Key T17 free preferably axis key 2 V10000002 1 Key T18 free preferably axis key 2 V10000002 2 Key T19 free preferably axis key 2 V10000002 3 Key T20 free preferably rapid traverse axis key 2 V10000002 4 Key T21 free preferably axis key 2 V10000002 5 Key T22 free preferably axis key 2 V10000002 6 Key T23 free preferably axis key 2 V10000002 7 Key T24 free 2 V10000003 0 Key T25 NC RESET 2 V10000003 1 Key T26 NC STOP 2 V10000003 2 Key T27 NC Start 2 VB10000004 Feed override override value 1 11 VB10000005 Spindle override override value 1 11 Machine control panel MCP PLC gt MCP V11000000 0 to 5 LED L1 to L6 2 PLC machine data VW45000000 Int value 1 corresponding to MD USER_DATA_INT 2 VW45000002 Int value 2 correspondi
173. er Leadscrew pitch Default 10 Min input limit 0 Max input limit plus Change effective after Power On Protection level 2 7 Unit mm Umadr Data type DOUBLE Valid as from SW version Meaning In this MD the leadscrew pitch is entered 31040 ENC_IS_DIRECT n MD number Encoder is directly mounted on the machine Default 0 Min input limit 0 Max input limit 1 Change effective after Power On Protection level 2 7 Unit Data type BOOLEAN Valid as from SW version Meaning 1 The encoder for actual value sensing is directly mounted on the machine 0 The encoder for actual value sensing is mounted on the motor The machine data index is coded as follows encoder no 0 Special cases Invalid or illegal values can result in erroneous encoder resolutions since e g errors incorrect gear ratios are taken into account 31050 DRIVE_AX_RATIO_DENOM n MD number Load gearbox denominator Default 1 Min input limit 1 Max input limit 2 147 000 000 Change effective after Power On Protection level 2 7 Unit Data type DWORD Valid as from SW version Meaning In this MD the denominator of the load gearbox must be entered The machine data index is coded as follows control parameter record 0 5 Further references 3 14 SINUMERIK 802S C base line Description of Functions Velocity Setpoint Actual Value System Closed Loop Control 31060 MD number Default 1 DRIVE_AX_RATIO_NUMERA n Load gearbox den
174. erating mode SINUMERIK 802S C base line 5 1 Description of Functions Program mode 5 1 Operating Modes AUTOMATIC MDA JOG Activation Check back signals Possible machine functions Stop RESET The following operating modes are possible Automatic execution of part programs 1 program block can be executed Traversing of the axes by manual operation via handwheel or traversing keys channel specific signals and interlocks are ignored The desired operating mode is activated via the interface signals in VB30000000 If several operating modes are selected at the same time the following priority applies JOG high priority e MDA AUTOMATIC lower priority The active operating mode is indicated via the interface signals in VB 31000000 In JOG mode the following machine functions can be selected REF reference point approach The desired machine function is activated in IS VB30000001 IS interface signal The active machine function is indicated in IS VB31000001 The IS NC Stop V32000007 3 IS NC Stop axes and spindles V32000007 4 or NC Stop at block end V32000007 2 can be used to provide a stop signal Depending on the number of stop signals either only the axes or in addition the spindle or axes are stopped at the end of the block The IS Reset V30000000 7 aborts the active part program The following activities are carried out after the IS Reset is tri
175. ersing command is triggered in different ways JOG mode by means of the traversing key plus or minus REF mode by means of the traversing key used for reference point approach AUT MDA mode A program block that contains a coordinate value for the respective axis is executed Signal status 0 or edge change 1 gt 0 At the moment no traversing request is provided in the axis direction in question or a traversing motion is completed e JOG mode The traversing command is reset depending on the interface signal Traversing keys plus and minus when traversing with the handwheel REF mode when the reference point is reached e AUT MDA mode The program block is executed and the following block does not contain a coordinate value for the axis in question Abortion by RESET etc E IS Axis blocking provided Application To release axis clamping e g rotary tables example s Note If the clamping is only released with the traversing command no path control mode is possible with these axes Related to IS Traversing key plus and Traversing key minus for WCS axis V33001001 0 to 3 V33001005 0 to 3 V33001009 0 to 3 Active machine function for WCS axis INC1 INC 1000 continuous Interface signal Signal s from channel NCK gt PLC Edge evaluation no Signal s updated cyclically Signal s valid as from SW version
176. es referenced V33000004 2 is set Interface signal Edge evaluation yes Application The following possibilities are provided to reference the machine axes in a example s certain order D The operator must provide for the desired order before starting the movement D The PLC must check or define the order by itself during start D The function Channel specific referencing is used Related to IS Referencing active IS All axes to be referenced have been referenced 33000001 0 Referencing active Signal s to channel NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 Channel specific referencing has been started by means of the IS Referencing active and the successful start has been acknowledged by the IS Referencing active Channel specific referencing is running Signal status 0 or edge change 1 gt 0 D Channel specific referencing is completed D Axis specific referencing is running D No referencing active Signal not applicable to spindles Related to IS Activate referencing 8 14 SINUMERIK 802S C base line Description of Functions Reference Point Approach V33000004 2 Interface signal Edge evaluation no All axes to be referenced are referenced Signal s from channel PLC gt NCK Signal s updated cyclically Signal s valid as fr
177. ess exceeded a drive error is present and the IS Speed limit exceeded V39032001 0 is set In addition alarm 22050 Maximum speed reached is output and all axes and spindles of the channel decelerated precondition encoder is still operative Related to MD SPIND_DES_VELO_TOL spindle speed tolerance IS Speed limit exceeded 39032001 0 Alarm 22050 Maximum speed reached 9 26 SINUMERIK 802S C base line Description of Functions Spindle 35110 GEAR_STEP_MAX_VELO n MD number Max speed for gear stage change gear stage number 0 5 Default 500 500 1000 2000 Min input limit O Max input limit plus 4000 8000 Changes effective after Power On Protection level 2 7 Unit rev min Data type DOUBLE Valid as from SW version Meaning In MD GEAR_STEP_MAX_VELO the max speed of the gear stage required for automatic gear stage change M40 is entered The gear stages must be defined by MD GEAR_STEP_MAX_VELO and MD GEAR_STEP_MIN_VELO such that there are no gaps in the programmed spindle speed range between the gear stages Wrong GEAR_STEP_MAX_VELO gear stage 1000 GEAR_STEP_MIN_VELO gear stage 1200 Correct GEAR_STEP_MAX_VELO gear stage 1000 GEAR_STEP_MIN_VELO gear stage 950 Related to MD GEAR_STEP_MIN_VELO min speed for gear stage change MD GEAR_STEP_CHANGE_ENABLE gear stage change possible MD GEAR_STEP_M
178. ex x nom lt lt M oy a xy a lt x lt a cs olololololilololilolojliololol oo Functionalities Loading a part program from externals via sb sb sb sb sb sb sb sb Services Executing a part program block s s b s s b Block search s s b Reference point approach via part program sb sb command s Function cannot be started in this status b Function can be executed in this status 5 4 SINUMERIK 802S C base line Description of Functions 5 1 3 Monitoring Functions in the Individual Operating Modes Program mode Overview of mon In the individual operating modes different monitoring functions are active itoring functions seen in the following Table Table 5 3 Monitoring functions in the individual operating modes Which monitoring functions are active in which operating condition is to be 2 z lt 9 5 5 n lt x gt 5 O O 2 Q O S g 0 S s 5 E N c 2 O 5 5 lt Q f lt Q oO O gt 2 2 a gt 7p Fo Beet wot op Boe So oc gt Di ae Senge Susie oa gt 5s 85 5 ce 28 TBe2ee2 8 Tg eae E Su 5og S 5 O G D o o OG ODEO DED SOO ooo N E c E O C CS CcC c Cc Cc Coce cs Cc o c fC G c G lt c Do E Ce cH u OW OC GCE S S O oO Cc OC TC V WG co Cf Ss Se eS ve alae ee a E Ow O O OO Of O O20 O OO O ODO
179. f SIEMENS AG Other names in this publication might be trademarks whose use by a third party for his own purposes may violate the registered holder Copyright Siemens AG 2003 All right reserved Exclusion of liability The reproduction transmission or use of this document or its con We have checked that the contents of this document correspond to tents is not permitted without express written authority Offenders will the hardware and software described Nonetheless differences be liable for damages All rights including rights created by patent might exist and we cannot therefore guarantee that they are com grant or registration of a utility model are reserved pletely identical The information contained in this document is re viewed regularly and any necessary changes will be included in the next edition We welcome suggestions for improvement Siemens AG 2003 Subject to technical changes without notice Siemens Aktiengesellschaft SINUMERIK 802S 802C base line Preface Safety Guidelines This Manual contains notices intended to ensure your personal safety as well Qualified person Proper use A as to protect products and connected equipment against damage Safety notices are highlighted by a warning triangle and presented in the following categories depending on the degree of risk involved Danger Indicates an imminently hazardous situation which if not avoided will result in death or serious injury or in substan
180. f the entered exact stop is not possible The change to the next block can be influenced by the size of the block is not considered completed the axis cannot be traversed again alarm 25080 positioning monitoring is output after the time set in MD POSITIONING_TIME monitoring time exact stop fine has elapsed the direction of movement for the axis is displayed in the positioning display The exact stop window is also evaluated for the spindle in position controlled mode Special cases MD STOP_LIMIT COARSE may not be set to a value less than MD Default 0 01 errors STOP_LIMIT_FINE exact stop fine In order to achieve the same block change behavior as with the exact stop fine criterion the exact stop coarse window may be equal to the exact stop fine window The MD STOP_LIMIT_COARSE may not be set to a value equal to or greater than the MD STANDSTIL_POS_TOL zero speed tolerance Related to MD POSITIONING_TIME delay time exact stop fine 36010 STOP_LIMIT_FINE MD number Exact stop fine Min input limit 0 Max input limit plus Change effective after NEW_CONF User class 2 7 Unit mm degrees Data type DOUBLE Valid as from SW version Meaning See MD STOP_LIMIT_COARSE exact stop coarse Special cases The MD STOP_LIMT_FINE may not be set to a value greater than errors MD STOP_LIMIT_COARSE exact stop coarse The MD STOP_L
181. face signal Edge evaluation Active mode MDA Signal s from NCK NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 MDA mode is active Signal status 0 or edge change 1 gt 0 MDA mode is not active V31000000 2 Interface signal Edge evaluation no Active mode JOG Signal s from NCK NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 JOG mode is active Signal status 0 or edge change 1 gt 0 JOG mode is not active SINUMERIK 802S C base line 5 23 Description of Functions Program mode V31000001 0 Interface signal Edge evaluation no Active machine function TEACH IN Signal s from NCK NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The machine function TEACH IN is active in AUTOMATIC mode Signal status 0 or edge change 1 gt 0 The machine function TEACH IN is not active V31000001 2 Interface signal Edge evaluation no Active machine function REF Signal s from NCK NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The machine function REF is active in JOG mode Signal status 0 or edge change 1
182. feed is specified for the movement types G1 G2 G3 and G5 If the contour axes for these movements are programmed without feed alarm 10860 No feed programmed is output The feed override is effective for all contour axes together Rapid traverse GO is the function with which the maximum contour velocity can be reached When an axis is traversed with rapid traverse the maximum axis velocity of the axis limits the rapid traverse speed The rapid traverse override is effective for all axes together Zero cycle blocks are blocks whose path length is shorter than the path which can be traversed using the programmed set feed and the interpolator cycle For accuracy reasons the velocity is reduced such that at least one interpolator cycle is required for the path The velocity is thus equal to or less than the quotient of the block path length divided by the IPO cycle SINUMERIK 802S C base line Description of Functions Continuous Path Control Exact Stop 2 1 2 Stopping for Synchronization Irrespective of whether exact stop or continuous path control mode is selected the block change can be delayed by synchronization processes and thus cause the contour axes to stop In exact stop mode the contour axes are stopped at the end point of the current block In the same situation in continuous path control mode the axes are stopped at the next block end point at which they can be decelerated with compliance of their acceleration limits
183. feed override value VB38030000 is used Signal status 0 or edge change 1 gt 0 The feed override value is used Related to IS Spindle override VB38032003 IS Feed override VB38030000 IS Override active V38030001 7 see also Chapter Feedrates V38032001 6 Interface signal Edge evaluation yes Invert M3 M4 Signal s to axis spindle PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The direction of rotation of the spindle motor changes with the following functions M3 M4 SPOS from the movement not active with SPOS from the standstill Traversing the spindle in manual mode 9 38 SINUMERIK 802S C base line Description of Functions Spindle V38032002 0 to 2 Interface signal Edge evaluation yes Actual gear stage A to C Signal s to axis spindle PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 status controlled If the new gear stage is active the PLC user sets the IS Actual gear stage A to C and Gear stage changed This informs the NCK that the appropriate gear stage has been activated successfully The gear stage change is considered completed spindle oscillation mode is deselected the spindle accelerates with the new gear stage to the last programmed spindle speed and the next bl
184. for read in enable 10 Cancel read in disable Related to IS Program status running 5 26 SINUMERIK 802S C base line Description of Functions Program mode V32000006 4 Interface signal Edge evaluation yes Program level abortion Signal s to channel PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 With each edge change 0 gt 1 the currently processed program level subroutine level is immediately aborted The part program is continued from the breakpoint on the next higher program level Signal status 0 or edge change 1 gt 0 No effect Special cases errors The main program level cannot be aborted with this IS but only with the IS Reset V32000007 0 Interface signal NC Start inhibited Signal s to channel PLC gt NCK Edge evaluation no Signal s updated cyclically Signal s valid from SW version 1 1 Signal status 1 or IS NC Start is inactive edge change 0 gt 1 Signal status 0 or IS NC Start is active edge change 1 gt 0 Application This signal is used for example to suppress a new program execution due to example s missing lubricant Related to IS NC Start V32000007 1 Interface signal Edge evaluation yes NC Start Signal s to channel PLC gt NCK Signal s updated cyclically Sign
185. from the programmed spindle position target position To this aim two incremental values can be entered in MD STOP_LIMIT_COARSE exact stop limit coarse and MD STOP_LIMIT_FINE exact stop limit fine as an incremental path from the spindle set position Irrespective of the two limit values the spindle positioning accuracy is always as good as set by the connected spindle encoder backlash gearbox ratio etc m a f a w ia Position Exact stop limitfine i i Exact stop limit coarse Fig 9 11 Exact stop ranges of a spindle The two limit values defined by the MD STOP_LIMIT_COARSE and MD STOP _LIMIT_FINE exact stop coarse and fine are output to the PLC with the IS Position reached with exact stop coarse V39000000 6 and the IS Position reached with exact stop fine V39000000 7 When SPOS is used to position the spindle the block change is carried out depending on the target position monitoring with the IS Position reached with exact stop fine The remaining functions programmed in the block must also have reached their end of block criterion e g axes ready all auxiliary functions acknowledged from the PLC SINUMERIK 802S C base line 9 23 Description of Functions Spindle 9 6 Unipolar spindle Function Configuring Special features 9 24 A spindle that requires not only a positive voltage of 10 volts but a positive voltage and separate binary sign signals for controll
186. ge valid after Power On Protection level 3 3 Unit Data type BYTE Valid as from SW version Default 0 Meaning The path interpolation is not influenced 1 The path interpolation is only enabled if the spindle has reached the specified speed tolerance band is set via MD SPIND_DES _VELO_TOL 2 Function as with value 1 in addition Traversing axes are also stopped prior to machining start e g continuous path control mode G64 and change from rapid traverse GO to a machining block G1 G2 The path is stopped at the last GO block and will only start if the spindle is in the speed setpoint range Application MD SPIND_ON SPEED AT_IPO_START and this MD can be used to example s process the path feed as follows depending on the spindle actual speed control mode If the spindle is in the acceleration phase programmed set speed not yet reached the path feed is disabled If the actual speed deviates from the spindle speed by more than the spindle speed tolrance MD SPIND _DES_VELO_TOL the path feed is enabled Befindet sich die Spindel in der Bremsphase wird der Bahnvorschub gesperrt If the spindle is signaled as stopped IS Axis spindle stopped V390x0001 4 the path feed is enabled This control is not effective in blocks with GO Related to MD SPIND_DES_VELO_TOL spindle speed tolerance NST Spindle in set range V390x2001 5 35510 SPIND_STOPP
187. gear stage and the IS Set gear stage A to C are set When the signal 1 the text Waiting for gear stage change is displayed in the channel operating message line Special cases errors The IS Change gear stage is only set if the new gear stage is other than the currently active gear stage Related to MD GEAR_STEP_USED_IN_AX_MODE gear stage for rotary axis mode IS Set gear stage A to C V39032000 0 to 2 IS Actual gear stage A to C V38032000 0 to 2 IS Gear stage changed V38032000 3 SINUMERIK 802S C base line Description of Functions 9 43 Spindle V39032000 0 to 2 Interface signal Set gear stage A to C Signal s from axis spindle PLC gt NCK Edge evaluation yes Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 A gear stage can be set fixed by the part program M41 to M45 automatically by the programmed spindle speed M40 M41 to M45 The gear stage can be set in the part program by means of M41 to M45 as a fixed setting If as gear stage is set by M41 to M45 which is other than the current actual gear stage the IS Change gear stage and the IS Set gear stage A to C are set M40 The control system uses M40 is used in the part program to set the gear stage automatically A check is carried out to see in which gear stage the pr
188. ggered off Part program preparation is stopped immediately e Axes and spindles are stopped e The auxiliary functions of the currently active block which are not yet output at this moment are not output The block pointers are reset to the beginning of the respective part program e All Reset alarms are deleted from the display The Reset operation is completed with setting the IS Channel status RESET V33000003 7 Ready for operation Readiness for operation is signalled by the IS Ready V 31000000 3 SINUMERIK 802S C base line Description of Functions Program mode 5 1 1 Mode Change General Mode change errors Mode change blocked Mode change is requested and activated via the interface Note The control system will only change its mode if Channel status active is no longer present Mode change is only allowed if the machine stops In channel status Reset IS V33000003 7 e g after pressing the Reset key it is possible to change from one mode to another For example if you leave AUTO to change for JOG you must either return to AUTO or press Reset This makes a change AUTO JOG MDA impossible The same applies to MDA from which you cannot change nor directly neither indirectly to AUTO if the control system is not in Reset condition The mode changes possible depending on the current operating mode and the channel status are listed in the Table below Table 5 1 Mode ch
189. gt gt 2 gt o 5 cose Cree 2 0 5 E g sa Sg Eg S E8 BES O o ooo OF OG OE GD o OE DO Cc no Cc Cc Cc Cc Cc O Cc c Cc Cc Cc Cc Cc CcC c5 cCc Ca Ga a lt G Cc Cc Cc lt x Cc CTH OO o BE OS S oO Co Oo 8 oO Ko cD cQ g c c c cO ce OnO O oOo O Of O O23 O Oo O O O20 General interlocks Ready X x x x x x x x x x x x x x Mode change blocked xX x x x X x x X X x X x x xX Channel specific interlocks Feed Stop x x x x x x xX NC Start inhibited x x X x X x x X xX x x x x xX Read in disable X x x x x X x X xX xX X X x xX Axis specific interlocks Spindle blocked X x x x X x x X X x x x x xX Servo disable X x x x X x x X x xX X xX x xX Axis blocked X x X x X x x X xX xX X xX x xX Spindle specific interlocks Servo disable X x x x X x x X x x X X x Xx Spindle blocked x x x x x x x x x x x x x x x Interlock can be activated in this status 5 6 SINUMERIK 802S C base line Description of Functions Program mode 5 2 Program Test Objective To test or try a new part program various control functions are used These functions are designed such that the hazards to the machine during the test phase and the time required for testing are considerably reduced It is possible to activate several program test functions at the same time The following test options are described here e Program execution without axis
190. h four 3 Encoder for stepper motor BERO 4 Used 5 Used Related to 34000 REFP_CAM_IS_ ACTIVE MD number Axis with reference point cam Default 1 Min input limit 0 Max input limit 1 Changes effective after Power On Protection level 2 7 Unit Data type BOOLEAN Valid as from SW version Meaning Machine axes that have only one synchronous mark zero pulse BERO over their entire traversing range can be marked as machine axes without reference point cam by means of the MD REF_CAM_IS_ ACTIVE The machine axis marked in this way accelerates to the speed set in MD REFP_VELO_SEARCH_MARKER reference point cut off speed after the traversing key plus minus has been pressed and synchronizes with the zero mark During this process make sure that the start point is always ahead of the synchronous mark SINUMERIK 802S C base line 8 7 Description of Functions Reference Point Approach 34010 MD number Default 0 REFP_CAM_DIR_IS_ MINUS Reference point approach in minus direction Min input limit 0 Max input limit 1 Changes effective after Power On Protection level 2 7 Unit Data type BOOLEAN Valid as from SW version Meaning REF_CAM_DIR_IS_MINUS 0 Reference point approach in plus direction traversing key active REF_CAM_DIR_IS_MINUS 1 Reference point approach in minus direction traversing key active If th
191. he IS Program status interrupted V33000003 3 is set SINUMERIK 802S C base line Description of Functions Program mode 5 2 3 Program Execution With Dry Run Feed Functionality A Selection Activation Display The part program can be started via the IS NC Start V32000007 1 With the function activated the traversing velocities programmed in conjunction with G1 G2 G3 G5 are replaced by the feedrate value stored in SD DRY_RUN_FEED The dry run feed value is also applicable in program blocks with G95 instead of the programmed revolution feedrate Danger When the Dry Run Feed function is active workpiece machining is not allowed since the cutting speed of the tools could be exceeded or the workpiece or machine tool could be destroyed due to the modified feedrate values The operation with dry run feed is selected on the operator interface in the Program Control menu Together with the selection the IS Dry run feed selected V17000000 7 is set In addition the desired value for dry run feed must be entered in the Setting Data menu The function is thus not yet activated The function is activated via the IS Activate dry run feed V32000000 4 As a feedback information that dry run feed is active DRY is displayed in the status line on the operator interface SINUMERIK 802S C base line 5 9 Description of Functions Program mode 5 3 Processing of Certain Program Parts Functionalit
192. he position last programmed Otherwise no part program active the axis motion will start at the possibly changed new actual position IS Follow up mode 0 If the IS Servo enable is canceled the old position setpoint is kept If the axis is pressed out of its position a following error will result between position setpoint and position actual values which will be compensated when setting the IS Servo enable The axis motion will start at the setpoint position that existed before Servo enable was canceled The IS Follow up active V390x0001 3 will not be set here Clamping or zero speed monitoring is active Position measuring system 1 V380x0001 5 The spindle can be equipped with a position measuring system In this case the signal for the spindle must be set This signal is always required for axes with analog drives or stepper motor axes even if no measuring systems are connected for stepper motor axes Servo enable V380x0002 1 When servo enable for the drive is provided the position control loop for the axis spindle is closed The axis spindle is thus in position control mode When servo enable is canceled the position control loop is opened and with delay also the speed control loop of the axis spindle The IS Position controller active V390x0001 5 is set to 0 signal feed back Activation Setting and resetting of servo enable for the drive can be provided from the following pl
193. he spindle if any are decelerated Any auxiliary functions of the current block which are not yet output at this moment will not be output any more The block pointer is reset to the beginning of the part program All alarms are deleted from the display if they are not POWER ON alarms SINUMERIK 802S C base line Description of Functions 5 4 5 Selection Activation Feedback Program mode Program Control The user can control program execution via the operator interface The Program Control softkey can be used to select certain functions on the operator interface some signals affect interface signals of the PLC These interface signals are merely intended as selection signals from the operator interface They are not intended to activate the selected function To bring the selected functions into effect the respective signal states have to be transferred to another range of the data block In case of controlling from the PLC these signals must be set directly Some activated functions have a check back signal Table 5 4 Program control 3 Selection Activation Check Back eunetion Signal Signal Signal SKP Skippable block V17000001 0 V32000002 0 DRY Dry run feed V17000000 6 V32000000 6 ROV Rapid traverse v17000001 3 V32000006 6 override Preselection SBL1 single block type 1 SBL2 single block type 2 s Key Single block V00000001 2 V32000000 4 M1 Programmed stop V17000000 5
194. he traversing keys the movement is carried out at the rapid traverse rate defined by the axis specific MD JOG_VELO_RAPID axis velocity in JOG mode with rapid traverse override The velocity used for traversing in JOG mode can additionally be controlled by means of the axis feed override switch For more detailed information on manual traversing in JOG mode see Section Manual Traversing and Handwheel Traversing SINUMERIK 802S C base line Description of Functions Feeds 11 9 Feed Override Feed programming The illustration below shows the possibilities of feed programming and feed and feed override control override S value X axis radius IS Adivate dry un Stored SD DRY_RUN_FEED id al 3 w S value G96 e F value G97 T ig I o Spindle override from machine IS Adivate dry run feed Spindle set speed 100 G se Feed override Bie rom machine IS Rapid traverse override enabled pa nce IS Feed override enabled Path velocity xxx IS Override enabled Fig 11 1 Feed programming and feed override SINUMERIK 802S C base line 11 9 Description of Functions Feeds 11 9 1 Feed Lock and Feed Spindle Stop General Feed Lock Feed Stop for axes in WCS Axis specific Feed Stop Spindle Stop 11 10 In case of Feed Lock or Feed Spindle Stop the axes are brought to stop The path contour is not violated exception G33 block The interface signal Feed lock V32000006 0 sets
195. heir reference points are considered not referenced A respective alarm is displayed The monitoring function Software limit switches is only effective for referenced machine axes During reference point approach the axis specific accelerations are always within the specified values exception in case of alarms When referencing is started the direction key is only active for the direction stored in MD REFP_CAM_DIR_IS_MINUS Whether NC programs in the modes AUTOMATC or MDA can be started depends on the MD REFP_NC_START_LOCK If 1 is set the program can only be started if all axes to be referenced have been referenced The interface signal IS Referenced synchronized 1 V390x0000 4 displays whether an axis has been referenced SINUMERIK 802S C base line Description of Functions Reference Point Approach 8 2 Referencing Axes Time sequence The referencing sequence of axes with reference cams and of stepper motor axes without measuring system can be divided into three phases e Phase 1 Reference point approach Phase 2 Synchronization with synchronous pulse BERO signal with stepper motor axes or zero pulse of an incremental measuring system with axes equipped with an analog drive e Phase 3 Reference point approach Fig IS Reference point approach delay 380 1000 bit 7 e aN IS Traversing command plus 390 0004 7 tks TEPEN IS Traversing command minus 0390 x0004 6 IS Traversing key plus
196. ide is set via the PLC in the form of a Gray code Position 1 00 o0 n 5 om 0o 6 0 008 n 8 omno 020 po owm 0o30 12 oomo 0o60 17 11001 0o90 Table 11 2 Gray coding for rapid traverse override Related to IS Rapid traverse override active SINUMERIK 802S C base line 11 17 Description of Functions Feeds V32000006 0 Interface signal Edge evaluation no Feed blocking Signal s to channel PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The signal of one channel is active in all operating modes e If G33 thread is not present this signal leads to feed blocking of all axes involved in interpolation All axes are set to standstill without violation of the path contour Cancellation of feed blocking 0 signal will continue the interrupted part program e The position control remains i e the following error is reduced to zero traversing request is provided for an axis for which Feed Blocking is provided the traversing request remains This traversing request is carried out immediately at the moment when Feed blocking is canceled This is also applicable when the axis is involved in interpolation with other axes Signal status O or edge change 1 gt 0 e The feed is active for all axes of the channel If a traversing request
197. ing is called unipolar spindle The voltage is output via the analog spindle setpoint output and the sign signals via binary outputs SINUMERIK 802S 802C base line is able to run a unipolar spindle The Unipolar spindle mode is set via the axis machine data MD 30134 IS_UNIPOLAR_OUTPUT of the spindle There are 2 different modes for controlling the unipolar spindle MD input value 0 Bipolar setpoint output with positive negative voltage The PLC output bits OO and O1 may be used by the PLC MD input value 1 Unipolar setpoint output with positive voltage The PLC output bits OO and O1 must not be used by the PLC PLC output bit OO servo enable PLC output bit O1 negative direction of travel MD input value 2 Unipolar setpoint output with positive voltage The PLC output bits OO and O1 must not be used by the PLC PLC output bit OO servo enable positive direction of travel PLC output bit O1 servo enable negative direction of travel The spindle must be the 4th axis The binary outputs used for the unipolar spindle must not be used by the PLC This must be guaranteed by the user as there are not any monitoring functions in the control system Not observing this fact will result in undesired reactions of the control system SINUMERIK 802S C base line Description of Functions 9 7 Machine data Spindle Data Description 30134 MD number Default 0 IS _UNIPOLAR_OUTPUT 0 Setpoint
198. iption of Functions Reference Point Approach 36310 MD number ENC_ZERO_MONITORING Zero mark monitoring Default 0 Min input limit 0 Max input limit Change valid after NEW_CONF Protection level 2 7 Unit Data type DWORD Valid as from SW version Meaning This MD enables zero mark monitoring 0 No zero mark monitoring gt 0 Number of detected zero mark errors at which the monitoring function is to respond alarm output 100 In addition encoder monitoring is disabled alarms 25000 25001 Related to Interface signals Signal to from channel 32000001 0 Interface signal Edge evaluation yes Activate referencing Signal s to channel PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 Channel specific referencing is started with the IS Activate referencing The control system acknowledges the successful start by the IS Referencing active Channel specific referencing can be used to reference each machine axis assigned to the channel to this aim the traversing keys plus minus are simulated internally in the control system The _ axis specific MD REFP_CYCLE_NR axis order for channel specific referencing can be used to define the machine axis referencing order When all axes entered in MD REFP_CYCLE_NR have reached their reference point the IS All ax
199. it Data type BOOLEAN Valid as from SW version 3 Meaning enables the function of the axis specific jerk limiting for the operating modes JOG REF Related to MD JOG_AND_POS_MAX_JERK axial jerk MD ACCEL_TYPE_DRIVE acceleration reduction ON OFF 32430 JOG_AND_POS_MAX_JERK MD number Axial jerk Default 1000 0 Min input limit 0 0 Protection level 2 7 Max input limit Unit 0 1 m s rev s Valid as from SW version 3 The jerk limiting value limits the change of the axis acceleration in the modes JOG REF path interpolation and error conditions resulting in quick stop Change valid after Power On Data type DOUBLE Meaning MD not applicable Related to MD JOG_AND_POS_JERK_ENABLE default setting of axial jerk limiting 35220 MD number ACCEL_REDUCTION_SPEED_ POINT Speed for reduced acceleration Min input limit 0 0 max Input limit 1 0 Protection level 2 7 Unit Factor Valid as from SW version The machine data defines the threshold speed threshold velocity for the spindle axes from which the acceleration reduction is to start The defined maximum speed velocity is used as the reference The threshold value depends on the maximum values as a percentage This application is recommended for stepper motor axes Default 1 0 Change valid after Data type DOUBLE Meaning Power On Example MD ACCE
200. ited Permissible range from N OVN lt MM_ENC_COMP_MAX_POINTS 1 End position 6AA_ENC_COMP_MAX 0 AXi The end position is that axis position at which the compensation table for the axis concerned ends 8interpolation point k The compensation value associated to the end position is AA_ENC_COMP 0 k AXi For all positions greater than the end position the compensation value of interpolation point k is used The number of the required interpolation points is calculated as follows k AA_ENC_COMP_MAX AA_ENC_COMP_MIN AA_ENC_COMP wikhoMM_ENC_COMP_MAX_POINTS The following marginal conditions shall apply to the interpolation point with k MM_ENC_COMP_MAX_POINTS 1 gt he compensation table is used completely with k lt MM_ENC_COMP_MAX_POINTS 1 gt he compensation table is not completely used the compensation values in the table which are greater than k are ineffective with k gt MM_ENC_COMP_MAX_POINTS 1 gt he compensation table is limited by the control system internally by reducing the end position compensation values less than k are ineffective Caution When entering the compensation values it should be made sure that all A N interpolation points within the defined area a compensation value is associated i e that no gaps arise Otherwise for these interpolation points the compensation value will be used which remained at these points from previously made e
201. iting G96 Default 0 Min input limit 0 Max input limit plus Change valid immediately Protection level Unit _rev min Data type DOUBLE Valid as from SW version Meaning With constant cutting rate G96 in addition to the permanently active limits another limit is effective which is entered into this SD In addition this SD can be described in the part program with LIMS SD not applicable to all spindle functions except G96 constant cutting rate Application example s When parting and in the case of very small machining diameters as well as when constant cutting rate G96 is selected the spindle continues to accelerate with the workpiece turning machine and reaches an infinitely high set speed at the position of the transversal axis X 0 In such cases the spindle will accelerate to its max spindle speed of the current gear stage in some cases limited by G26 If you wish to limit the spindle to a smaller speed in particular with G96 SD SPIND MAX_VELO_LIMS must be set Special cases errors The value in SD SPIND_MIN_VELO_G25 can be changed by G25 S in the part program Operation from MMC The value in SD SPIND_MIN_VELO_G25 is kept even after reset oer Mains Off Related to SD SPIND_MAX_VELO_G26 max spindle speed SD SPIND_MIN_VELO_G25 min spindle speed 9 36 SINUMERIK 802S C base line Description of Functions 9 8 Spindle
202. itional speed setpoint is provided which consists of the following components see Fig LEERER MARKER 1 Drift basic value MD 36720 DRIFT_VALUE The value entered in MD 36720 DRIFT_VALUE is always added as an additional speed setpoint The drift basic value is always effective The input is always performed as a percentage with reference to the maximum controlled quantity 2 Automatic drift compensation MD 36700 DRIFT_ENABLE MD 36700 DRIFT_ENABLE 1 automatic drift compensation can be used to enable automatic drift compensation for position controlled axes spindle The control system will determine the required drift additional value at the standstill of the axes spindle IS Axis spindle stopped V390x0001 4 is active to make sure that the following error becomes 0 adjustment criterion The entire drift value is the total of drift basic value and drift additional value The automatic drift compensation for a position controlled spindle axis is carried out under the following conditions e _Axis spindle is at a standstill e No traversing request is present for the axis spindle The amount of the drift additional value calculated during the automatic drift compensation is internally limited with MD 36710 DRIFT_LIMIT drift limit value with automatic drift compensation If the drift additional value exceeds the value entered in MD DRIFT_LIMIT alarm 25070 Drift value too high is output and the drift additional va
203. ive after Power On Protection level 2 2 Unit Data type BYTE Valid as from SW version Meaning In this MD the evaluation direction of the encoder signals is entered Oor1 No direction reversal 1 Direction reversal The direction reversal also pertains to the control direction if the encoder is used for the position control The machine data index is coded as follows encoder no 0 Special cases errors If the wrong control direction is entered the axis can run away Depending on the setting of the corresponding limit values one of the following alarms is output Alarm 25040 Zero speed control Alarm 25050 Contour monitoring Alarm 25060 Speed setpoint limiting The corresponding limit values are described in References Chapter Axis Monitoring Functions If an uncontrolled setpoint step occurs when a drive is connected the control direction is possibly wrong 3 16 SINUMERIK 802S C base line Description of Functions Velocity Setpoint Actual Value System Closed Loop Control 32200 POSCTRL_GAIN n MD number Servo gain factor Default Min input limit 0 Max input limit 2000 802S base line 2 5 2 5 2 5 1 802C base line 1 1 1 1 Change effective after NEW_CONF Protection level 2 7 Unit 1 s Data type DOUBLE Valid as from SW version Meaning Do not change with stepper motor axes Positi
204. ized Case 1 Spindle not synchronized Phase 1 When SPOS is programmed the spindle will accelerate with the acceleration set in MD GEAR_STEP_SPEEDCTRL_ACCEL acceleration in speed controlled mode The direction of rotation is defined by the MD SPIND_POSITIONING_ DIR direction of rotation when positioning from standstill The spindle is synchronized with the next zero mark provided from the spindle actual value encoder and then changes to position control mode A monitoring function checks whether the zero mark is found within the distance defined by MD REFP_MAX_MARKER_DIST If the speed entered in MD SPIND_POSCTRL_VELO positioning speed is reached without synchronizing the spindle the spindle goes on rotating with the position controller switch on speed no more acceleration Phase 2 When the spindle is synchronized the position control is switched on The spindle goes on rotating not exceeding the speed set by MD SPIND_POSCTRL_VELO until the brake start point detects the programmed spindle with the defined acceleration Phase 3 At the moment detected by the brake start point calculation in phase 2 the spindle decelerates with the acceleration set in MD GEAR_STEP_ POSCTRL_ACCEL acceleration in position control mode to standstill SINUMERIK 802S C base line 9 7 Description of Functions Spindle Phase 4 The spindle is on standstill and has reached the programmed position The position control is active and
205. keeps the spindle on the programmed position The IS Position reached with exact stop fine coarse is set if the distance between the spindle actual position and the programmed position spindle set position is less than the exact stop tolerance fine and coarse defined in MD STOP_LIMIT_FINE and MD STOP_LIMIT_COARSE Speed 1 min Position controller switch on speed SPOS 180 Fig 9 5 Positioning with the synchronized spindle on standstill Case 2 Spindle is synchronized 9 8 Phase 1 The spindle is synchronized When SPOS is programmed the spindle is switched to position control mode The acceleration defined in MD GEAR_STEP_POSCTRL_ACCEL acceleration in position control mode becomes active The direction of rotation is defined by the distance to go The speed entered in MD SPIND_POSCTRL_VELO position control switch on speed is not exceeded The calculation of the distance to be traversed to the target position is carried out Traversing of the spindle to the programmed target point is carried out in an optimum time i e the target point is approached with maximum possible speed however not higher than SPIND_POSCTRL_VELO Depending on the respective marginal conditions the phases 1 2 3 4 and 1 3a 4a respectively are passed see Fig 9 5 Phase 2 In order to reach the target point it was accelerated to the speed entered in MD SPIND_ POSCTRL_VELO position control switch on spe
206. l not violating the path contour The interrupted part program is continued when Feed Stop is canceled e The position control remains i e the following error is reduced to zero If for an axis for which Feed Stop is present a traversing request is provided the traversing request remains This traversing request is carried out immediately at the moment when Feed Stop is canceled If the axis is involved in interpolation with other axes this also applies to these axes Spindle Stop e The spindle is decelerated to standstill along its acceleration curve In positioning mode the positioning process is interrupted by setting the signal Spindle Stop The above mentioned behavior with refer to single axes applies Signal status 0 or edge change 1 gt 0 Feed Stop e The feed for the axis is enabled If a traversing request traversing command is provided for the axis when Feed Stop is canceled the traversing command is carried out immediately Spindle Stop e The speed is enabled for the spindle e If Spindle Stop is canceled the spindle is decelerated to the previous speed setpoint with the acceleration characteristic or in positioning mode positioning is continued Application example s Feed Stop e The traversing movements of the machine axes are not started with Feed Stop if for example certain operating conditions apply to the axis which do not
207. l connected drives are ready for operation via the NCK NCK alarm present V27000003 0 The control system signals to the PLC that at least one NCK alarm is present The channel specific interface V33000004 7 can be interrogated whether this has caused a stop in processing Air temperature alarm V27000003 6 Ambient temperature or fan monitoring has responded Channel specific NCK alarm present V33000004 6 The control system signals to the PLC than at least one NCK alarm is present for the channel In which way the current program execution has been interrupted or aborted as a result of this can be derived from the IS NCK alarm with processing stop present V33000004 7 NCK alarm with processing stop present V33000004 7 The control system signals to the PLC that at least one NCK alarm is present for the channel which has interrupted or aborted the execution of the current program processing stop Follow up active V390x0001 3 software version 3 1 and higher Follow up mode is active for this axis Follow up in details see at IS Follow up mode V380x0001 4 Axis spindle on standstill V390x0001 4 The current actual velocity of the axis or the actual speed of the spindle is within the range defined as the standstill This range is defined by MD STANDSTILL_VELO_TOL max velocity speed for signal Axis spindle on standstill Position controller active V390x0001 5 The position controller for the axis
208. lash and friction while traveling a circular contour While traveling straight lines a contour error occurs because of the backlash outside the position control loop e g due to a tilting milling spindle This causes a parallel offset between the actual and the set contour The shallower the gradient of the straight line is the larger is the offset Non linear friction behavior of the slide guideways Effect If the following error is too large this has the following effect e Alarm 25050 Contour monitoring is output e The axis spindle involved is stopped with rapid stop Rapid stop The following applies to the spindle with SPOS motion and axes with analog drives Stop with open position control loop via a speed setpoint ramp function The duration of the deceleration ramp is defined in MD AX_EMERGENCY_STOP_TIME duration of the deceleration ramp for error states Stepper motor axes are stopped via an internal ramp If the axis is involved in interpolation with other axes these are also stopped by rapid stop with clearing the following error position partial setpoint 0 1 2 SINUMERIK 802S C base line Description of Functions Axis Spindle Monitoring Remedy The following applies to the spindle and axes with analog drives The real servo gain factor must be set to correspond to the required servo gain factor set via MD POSTCTRL_GAIN N Check MD RATED_VELO rated motor speed and MD RATED_OUTVAL r
209. lated to IS Traversing key plus and Traversing key minus 4 26 SINUMERIK 802S C base line Description of Functions Manual Traversing and Handwheel Traversing Active machine function INC1 INC 1000 continuous Signal s from axis spindle NCK gt PLC V390x0005 0 to 3 6 Interface signal Edge evaluation no Signal s updated cyclically Signal s valid as from SW version Signal status 1 or A check back signal with the information which machine function is active for edge change 0 gt 1 the axes in JOG mode is provided to the PLC interface Depending on the active machine function the response when pressing the traversing key or turning the handwheel is different Signal status 0 or The respective machine function is not active edge change 1 gt 0 Related to IS Machine function INC1 SINUMERIK 802S C base line 4 27 Description of Functions Manual Traversing and Handwheel Traversing 4 28 SINUMERIK 802S C base line Description of Functions Program Mode 5 Brief description Program mode means that part programs or part program blocks are executed in AUTOMATIC mode or MDA During block execution the program can be controlled by PLC interface signals Channel A channel is a unit in which a part program can be executed The system assigns the channel an interpolator with the associated program processing The channel is assigned a certain op
210. lated to MD RATED_VELOJn only makes sense in conjucntion with MD RATED_OUTVAL fn 32900 DYN_MATCH_ENABLE MD number Dynamic response adaptation Min input limit 0 Max input limit 1 Change effective after NEW_CONF Unit Protection level 2 7 Data type BOOLEAN Valid as from SW version Meaning The dynamic response adaptation can be used to set axes having different servo gain factors to the same following error using MD DYN_MATCH_TIME 1 Dynamic response adaptation is enabled 0 Dynamic response adaptation is disabled Application example s Related to MD DYN_MATCH_TIMEJn time constant of dynamic response acquisition 3 18 SINUMERIK 802S C base line Description of Functions Velocity Setpoint Actual Value System Closed Loop Control 32910 DYN_MATCH_TIME n MD number Time constant of dynamic response adaptation Default 0 01 Min input limit 0 Max input limit plus Change effective after NEW_CONF Protection level 2 7 Unit s Data type DOUBLE Valid as from SW version Meaning In this MD the time constant of the dynamic response adaptation of an axis must be entered Enter the difference of the equivalent time constant of the slowest control loop of the corresponding axis as the time constant The MD is only effective if MD DYN_MATCH_ENABLE 1 The machine data index is coded as follows control
211. le arranged on the machine control panel and marked by a red rim Red EMERGENCY STOP button with positive opening operation and provided with a mechanically operated self locking mechanism Triggering of EMERGENCY STOP sequence in the NC via the PLC input The EMERGENCY STOP sequence in the NC decelerates all axes and spindles as fast as possible In case of EMERGENCY STOP all machine functions controlled by the PLC can be in a settable safe condition EMERGENCY STOP status cancellation by unlocking the EMERGENCY STOP button is not possible Resetting the control device does not result in restart SINUMERIK 802S C base line 13 1 Description of Functions EMERGENCY STOP 13 1 General EMERGENCY STOP function 13 2 Important The machine manufacturer is herewith referred to the international and national standards see notes on the standards below in the text The SINUMERIK 802S base line supports the machine manufacturer in the realization of the EMERGENCY STOP function according to the conventions made in this Functional Description The realization of the EMERGENCY STOP function triggering Sequence acknowledgement is the sole responsibility of the machine manufacturer Note For the EMERGENCY STOP function you are referred in particular to the following standards e EN 292 Part 1 e EN 292 Part 2 e EN 418 EN 60204 Part 1 1992 Section 10 7 EN 418 EMERGENCY STOP is a function e intended to avert or red
212. le to make sure that the new physical units are taken into account When the machine data is changed alarm 4070 Scaling machine data changed is output 30130 MD number Default 0 CTRLOUT_TYPE n Output type of setpoint Min input limit 0 Max input limit 4 Change effective after Power On Protection level 2 7 Unit Data type BYTE Valid as from SW version Meaning This MD is used to enter the type of the speed setpoint output 0 Simulation no HW required 1 Standard differentiation via HW configuration 2 Stepper motor 3 4 not available The machine data index n is coded as follows setpoint branch 0 Application example s Simulation Machine functions can also be simulated when the drive is not connected 3 12 SINUMERIK 802S C base line Description of Functions Velocity Setpoint Actual Value System Closed Loop Control 30200 MD number Default 1 NUM_ENCS Number of encoders Min input limit 0 Max input limit 1 Change effective after Power On Protection level 2 7 Unit Data type BYTE Valid as from SW version Meaning This MD is only necessary if the position actual value sensing is to be carried out using a direct measuring system i e not with a motor installed measuring system and not with stepper motors 1 Spindle axis with direct measuring system on the machine 0 Spindl
213. letes alarm 3000 e aborts part program execution SINUMERIK 802S C base line 13 5 Description of Functions EMERGENCY STOP PLC interface The PLC interface system must be set by the PLC user program to such a system condition that the operation of the machine is possible Reset The IS Reset 30000000 7 alone will not reset the EMERGENCY STOP status see illustration above Power On Power On will delete the EMERGENCY STOP status except the IS EMERGENCY STOP V26000000 1 is still active 13 6 SINUMERIK 802S C base line Description of Functions EMERGENCY STOP 13 5 Data Description 36620 SERVO_DISABLE_DELAY_TIME MD number Servo disable delay time Default 0 1 Min input limit 0 02 Max input limit 1000 Change valid after NEW_CONF Protection level 2 7 Unit s Data type DOUBLE Valid as from SW version Meaning Maximum delay for Servo Disable after faults The speed enable servo enable of the drive is canceled internally in the control system after the set delay time at the latest provided the axis spindle is moving The entered delay time is active due to the following events e incase of errors resulting in an immediate stop of the axes e ifthe IS Servo enable is canceled from the PLC Once the actual speed reaches the standstill range MD STANDSTILL_VELO_ TOL Servo Enable is canceled for the drive The time should be set such that the axis spindle can come to a
214. limit plus Change effective after NEW_CONF Protection level 2 7 Unit mm degrees Data type DOUBLE Valid as from SW version Meaning This MD is used as a tolerance band for the following monitoring functions e On completion of a motion block position partial value 0 at the end of motion it is monitored whether the following error has reached the limit value for STANDSTILL_POS_TOL zero speed tolerance after the parameterizable STANDSTILL_DELAY_TIME delay time after zero speed control e On completion of a positioning process exact stop fine reached zero speed monitoring takes over positioning monitoring It is monitored whether the axis in MD STANDSTILL _POS_TOL zero speed tolerance moves from its position more than specified If the actual position is below or across the set position by the amount of the zero speed tolerance alarm 25040 Zero speed monitoring is output and the axis is stopped Special cases The zero speed tolerance must be greater than the Exact Stop Tolerance Range errors Coarse Related to MD STANDSTILL_DELAY_TIME delay time zero speed control 36040 STANDSTILL_DELAY_TIME MD number Delay time zero speed control Default 0 2 Min input limit 0 Max input limit plus Change effective after NEW_CONF Protection level 2 7 Unit s Data type DOUBLE Valid as from SW version Meaning See MD
215. lue is limited to this value The value is entered as a percentage with reference to the maximum of the controlled quantity 100 SINUMERIK 802S C base line Description of Functions Compensation DRIFT basic value MD 36700 DRIFT_ENABLE drift comp additional value Automatic MD 36710 DRIFT_LIMIT drift limit value Fig 6 4 Drift composition with set speed Service display The effect of the drift compensation can be checked using the displayed following error in the Operating area Diagnosis in the menu Service display On standstill of the spindle the displayed following error should be 0 Note When direct measuring systems are used and Automatic drift compensation is enabled MD DRIFT_ENABLE 1 this results in oscillation of the axis concerned due to the mechanical backlash Sometimes it can be better in such cases not to work with automatic drift compensation SINUMERIK 802S C base line 6 9 Description of Functions Compensation 6 4 Data Descriptions Machine data 32450 BACKLASH 0 MD number Backlash Default 0 Min input limit Max input limit Changes effective after NEW_CONF _ Protection level 2 7 Unit mm or degrees Data type DOUBLE Valid as from SW version Meaning Backlash between positive and negative traversing direction The input of the compensation value is positive if the encoder is in advance of the machine part normal case
216. lue is too low the speed cannot be below this speed The minimum speed can only not be reached by the signals commands states mentioned in the Section Min max speed of gear stage MD not applicable to e Spindle mode Oscillation mode e Spindle mode Positioning mode axis mode Application Smooth running of motor can no longer be ensured below the minimum example s speed Related to MD GEAR_STEP_MAX_VELO max speed for gear stage change MD GEAR_STEP_MIN_VELO min speed for gear stage change MD GEAR_STEP_CHANGE_ENABLE gear stage change is possible MD GEAR_STEP_MAX_VELO_LIMIT max speed of gear stage 9 28 SINUMERIK 802S C base line Description of Functions Spindle 35150 SPIND_DES VELO_TOL MD number Spindle speed tolerance Default 0 1 Min input limit 0 Max input limit 1 Changes effective after Power On Protection level 2 7 Unit factor Data type DOUBLE Valid as from SW version Meaning In the spindle operating mode Control mode the set speed programmed speed x spindle override with consideration of the limits is compared with the actual speed If the actual speed deviates from the set speed by more than the spindle speed tolerance MD SPIND_DES_VELO_TOL the IS Spindle within set range V39032001 5 is set to zero If the actual speed deviates from the set speed by more than the spindle speed tolerance MD S
217. m which are marked with a slash are skipped If several blocks are to be skipped this signal is only effective if it is written prior to decoding the first block best before NC Start Signal status 0 or edge change 1 gt 0 The marked part program blocks are not skipped Related to IS Skip block selected IS Program status stopped SINUMERIK 802S C base line 5 25 Description of Functions Program mode V32000006 1 Read in disable Interface signal Signal s to channel PLC gt NCK Edge evaluation no Signal s updated cyclically Signal s valid as from SW version Signal status 1 or The data transfer to the interpolator is stopped for the next block This signal is edge change 0 gt 1 only effective in AUTOMATIC and MDA Signal status 0 or The data transfer to the interpolator is enabled for the next block This signal is edge change 1 gt 0 only effective in AUTOMATIC and MDA Application If the auxiliary function must be completed before the next NC block is started example s e g for tool change automatic block change must be blocked by read in disable N21G MaOs _ X M 1 1 Reading into buffer 2 Block executed 3 Read in disable signal 4 Data transfer 5 Contents of interpolator 6 Output of auxiliary function 7 Data transfer to interpolator 8 Read in disable for tool change 9 Interrogation point
218. maximum axis velocity defined by MD MAX_AX_VELO cannot be exceeded The feed F is not relevant but remains stored The axis velocity for the thread length is calculated from the set spindle speed S and the programmed thread lead of this axis e g for a cylinder thread Fz mm min speed S rev min thread lead K mm rev NC STOP and Single Block are only active at the end of a thread chain Important The spindle speed override switch should remain unchanged when the thread is machined The feed override switch is not relevant for blocks with G33 SINUMERIK 802S C base line Description of Functions Feeds 11 4 Feed for Tapping with Compensating Chuck G63 Application Feed F G63 is a partial function for tapping with tap in a compensating chuck A position measuring system on the spindle is not required Detail description see User Manual Operation and Programming A new feed F for G63 must be programmed It must match with the selected spindle speed S programmed or set and the thread lead of the tap Feed F mm min speed S rev min x thread lead mm rev The compensating chuck compensates any path differences of the tap axis to a certain degree 11 5 Feed for Tapping without Compensating Chuck G331 G332 Application Axis velocity G331 tapping and G332 retraction from tapping can be used for tapping without compensating chuck However the spindle must have the technologi
219. min Data type DOUBLE Valid as from SW version Meaning Value unequal to 0 The entered velocity is used when linear axes are traversed in JOG mode The axis velocity acts for continuous traversing incremental traversing INC1 handwheel traversing The entered value is valid for all linear axes together and may not exceed the maximum permissible axis velocity MD MAX_AX_VELO Value 0 If O is entered in the setting data the MD JOG_VELO Conventional axis velocity acts as feed for the linear axes in JOG mode It is possible to assign each axis its own JOG velocity axis MD Default 0 Application The operator can use these setting data to assign an application specific JOG example s velocity Related to Axis specific MD JOG_VELO conventional axis velocity Axis specife MD MAX_AX_VELO maximum axis velocity 41200 JOG_SPIND_SET_VELO SD number JOG velocity for spindle Min input limit 0 Max input limit plus Changes effective immediately Unit rev min Protection level Data type DOUBLE Valid as from SW version Meaning Value unequal to 0 The entered velocity acts for spindles in JOG mode when traversing them manually using the traversing keys plus or minus The velocity acts for continuous traversing incremental traversing INC1 handwheel traversing The entered value applies to all spindles toge
220. mmediately with the T function depends on the setting in MD TOOL_CHANGE_MODE new tool compensation with M function MD TOOL_CHANGE_MODE 0 The new tool is changed immediately with the T function This setting is mainly used for turning machines with tool revolver MD TOOL_CHANGE_MODE 1 The new tool is prepared for tool change with the T function This setting is mainly used for machines with tool magazines in order to bring the tool to tool change position within the main machining time the machining is not interrupted M6 is used to remove the old tool from the spindle and load the new tool The actual tool change must be performed either by means of the PLC program or manually The control system calculates the appropriate tool offsets only at the appropriate time Note If a special tool has been activated it remains stored as the active tool even beyond the program end and after POWER ON If you change a tool manually you must also enter the change into the control system to make sure that the control system identifies the tool For example you can start a block with the new T word in MDA mode For the T function integer values between TO no tool and T32000 tool with number 32000 can be used A tool can have up to 9 tool edges The 9 tool edges are assigned to the D functions D1 to D9 p Fig 12 1 Example of tool T with 9 cutting edges D1 to D9 SINUMERIK 802S C base line Description of F
221. movements PRT program test e Program execution in single block mode SBL e Program execution with dry run feed DRY e Processing of certain program sections using block search e Skipping of certain program parts SKP 5 2 1 Program Execution Without Axis Movements Program Test Functionality The part program can be started and executed including auxiliary function outputs and dwell times via the IS NC Start if the Program Test function is active The only difference to real processing is that the axes spindle are merely simulated The safety function Software limit switch remains active The only difference to normal program execution is that an internal Axis Spindle Blocked signal is output for all axes i e the machine axes do not move and the actual values are internally generated from the setpoints which are not output The programmed velocities remain unchanged That means that the position and velocity specifications on the operator interface exactly correspond to those of normal part program execution The position control is not interrupted during this process so that it is not necessary to reference the axes after switching off Application The user can use this function to check the programmed axis position and the auxiliary outputs of a part program Selection This function is selected via the operator interface in the Program Control menu With the selection the IS Program test selected V17000001
222. n CW V38032002 6 9 40 SINUMERIK 802S C base line Description of Functions Spindle V38032002 4 Interface signal Edge evaluation yes Oscillation by the PLC Signal s to axis spindle PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 If the IS Oscillation by the PLC is not set automatic oscillation in the NCK is carried with IS Oscillation mode The two times for the directions of rotation are entered in the MD SPIND_OSCILL_TIME_CW oscillation time for M3 direction and MD SPIND_OSCILL_TIME_CCW oscillation time for M4 direction If the IS Oscillation by the PLC is set a speed with the IS Oscillation speed is only output in conjunction with the IS Set direction of rotation CW and CCW Oscillation i e permanent change of direction is carried out by the PLC user by means of the IS Set direction of rotation CCW and CW oscillation by the PLC Application If the gear stage cannot be activated during oscillation by the NCK instead of example s several tries it is possible to change to oscillation by the PLC When this possibility is used the two times for the directions of rotation can be modified by the PLC user as he wants This ensures that safe changing of the gear stage is possible even in case of bad toothed gear positions Related to MD SPIND_OSCILL_TIME_CW oscillation time fo
223. n Protection level 2 7 Unit mm degrees Data type DOUBLE Valid as from SW version Meaning This machine data can be used to specify a second SW limit switch position in positive direction in the machine axis system Which of the two SW limit switches 1 or 2 is to be active can be selected from the PLC by means of an interface signal e g V38011000 bit3 0 1st software limit switch plus for 1st axis active V38011000 bit 3 1 2nd software limit switch plus for 1st axis active MD not applicable axis is not referenced if Related to IS 2nd software limit switch plus 36200 AX_VELO_LIMIT n MD number Threshold value for velocity monitoring Default 11500 Min input limit 0 Max input limit plus Change effective after NEW_CONF Protection level 2 7 Unit mm min rev min Data type DOUBLE Valid as from SW version Meaning The threshold value of actual velocity monitoring is entered in this MD If the threshold value is exceeded alarm 25030 Actual speed alarm limit is output and the axes stopped Settings For the axes a value that is by 10 15 higher than set via MD MAX_AX_VELO maximum axis velocity should be selected The following should therefore be applicable to the threshold value of velocity monitoring MD AX_VELO_LIMIT n gt MD MAX_AX_VELO 1 1 1 15 For the spindle the value per gear stage should be selected by 10 15 highe
224. n addition to the traversing keys the movement is carried out with the rapid traverse speed set via the axis specific MD JOG_VELO_RAPID axis speed in JOG mode with rapid traverse override The axis velocity used for traversing in JOG mode can additionally be controlled using the axis specific feed override switch provided the axis specific IS Override enabled V380x0001 7 is set SINUMERIK 802S C base line Description of Functions Acceleration jerk Manual Traversing and Handwheel Traversing The axis acceleration is defined with the axis specific MD MAX_AX_ACCEL With manual traversing too the acceleration is possible according to a given characteristic The acceleration curve for the individual axes in JOG mode is defined with MD JOG_AND_POS_MAX_JERK acceleration change limited provided it is activated with MD JOG_AND_POS_JERK_ENABLE 1 For stepper motor axes it is recommended to use the knee shaped acceleration curve This is the default setting for SINUMERIK 802S base line It is enabled with MD ACCEL_TYPE_DRIVE 1 When doing so MD JOG_AND_POS_JERK_ENABLE 0 must be set Other machine data are provided to set the characteristic curve see also Section 3 3 1 SINUMERIK 802S C base line 4 3 Description of Functions Manual Traversing and Handwheel Traversing 4 2 Controlling Manual Traversing via the PLC Interface MMC NCK PLC interface MMC NCK PLC interface Example Spindle speed in JO
225. n is still active but can be reset with IS Acknowledge EMERGENCY STOP and IS Reset Interface signal Edge evaluation no Related to IS Acknowledge EMERGENCY STOP V26000000 2 IS EMERGENCY STOP active V27000000 1 V26000000 2 Acknowledge EMERGENCY STOP Signal s to NC PLC gt NC Signal s updated cyclically Signal s valid as from SW version Signal status 1 edge change 0 gt 1 or The EMERGENCY STOP condition will only be reset if first the IS Acknowledge EMERGENCY STOP is set and then the IS Reset V30000000 7 In this context it should be taken into account that the IS Acknowledge EMERGENCY STOP and the IS Reset must be set together at least until the IS EMERGENCY STOP active V26000000 1 has been reset Resetting the EMERGENCY STOP condition has the following effects e The IS EMERGENCY STOP active is reset Servo Enable is provided The IS Position control active is set The IS READY is set The alarm 3000 is deleted e The part program execution is canceled Related to IS EMERGENCY STOP V26000000 1 IS EMERGENCY STOP active V27000000 1 IS Reset V30000000 7 V27000000 1 Interface signal Edge evaluation no NOT AUS aktiv Signal s to NC PLC gt NC Signal s updated cyclically Signal s version valid as from SW Signal status 1 or edge change 0 g
226. n possible e Spindles without position encoder Related to IS Spindle on standstill 9 44 SINUMERIK 802S C base line Description of Functions Spindle V39032001 5 Interface signal Edge evaluation yes Spindle within set range Signal s from axis spindle NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The IS Spindler within set range signals whether the programmed and or limited if so spindle speed is reached In spindle mode Control mode the set speed programmed speed spindle override with consideration of the limits is compared with the actual speed If the actual speed deviates from the set spindle speed by less than the spindle speed tolerance MD SPIND_DES_VELO_TOL the IS Spindle within set range is set Signal status 0 or edge change 1 gt 0 The IS Spindle within set range signals whether the spindle is still in the acceleration phase In spindle mode Control mode the set speed programmed speed spindle override with consideration of the limits is compared with the actual speed If the actual speed deviates from the set speed by more than the spindle speed tolerance MD SPIND_DES VELO_TOL from the set speed the IS Spindler within set range is reset Signal not to spindle modes other than speed controlled mode control mode applicable Related to MD
227. n programmed with the syntax SPOS is longer than the traversing time of the contour axes The block change is carried out when exact stop fine of the positioning spindle is reached stopping for synchronization is required Auxiliary function output during traverse 2 6 In continuous path control mode with auxiliary function output and short traversing blocks the contour velocity is decelerated already prior to the acknowledgment by the PLC The axes are thus stopped at the end of the block in compliance with the acceleration limits Acknowledgment is waited there in order to continue the movement SINUMERIK 802S C base line Description of Functions 2 4 Machine data Continuous Path Control Exact Stop Data Description 36000 MD number Default 0 04 STOP_LIMIT_COARSE Exact stop coarse Max input limit plus Min input limit 0 Change effective after NEW_CONF User class 2 7 Unit mm degrees Data type DOUBLE Valid as from SW version Meaning An NC block is considered as completed if the actual position of the contour tolerance range If the actual position of a contour axis is not within this limit the NC block is not considered completed and further part program execution the entered value The greater the value is selected the earlier the block change is initiated If the set exact stop tolerance range is not reached axes is away from the set position by the value o
228. nction programmed in an NC block as soon as the T change signal is present Value range of T function 0 99 integer The T function remains until it is overwritten by a new T function Signal status 0 or edge change 1 gt 0 After power up of PLC Before a new auxiliary function is entered the other auxiliary functions are deleted Application example s Control of automatic tool selection Special cases errors TO is intended to remove the currently active tool from the tool holder no new tool is loaded default configuration of machine manufacturer VB25001000 to Interface signal Edge evaluation no Dynamic M functions MO M99 Signal s from channel NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge evaluation 0 gt 1 The dynamic M signal bits are set by decoded M functions Signal status 0 or edge evaluation 1 gt 0 During general auxiliary function output the dynamic M signal bits are acknowledged by the PLC system program after the user program has been completely executed once Application example s CW CCW rotation of spindle Coolant ON OFF SINUMERIK 802S C base line Description of Functions Feeds 11 11 1 Overview Feed types The feedrate is the machining speed with which the tools moves along the programmed workpiece contour path The individual axis speeds according to
229. ne axis from approach speedto the standstill the reference point is approached from the opposite direction What must be the minimum length of the reference cam The length of the reference cam must such that the deceleration process is stopped on the cam standstill on the cam when the cam is approached and the cam is left with reference point cut off velocity in the opposite direction leaving with constant velocity To calculate the minimum length of the cam the higher of the following speeds must be entered in the formula below Reference point approach speed or cut off speed Minimum lengti 2 V axis acceleration If the machine axis cannot stop on the reference cam IS Reference point approach delay V380x1000 7 is reset alarm 20001 is output Alarm 20001 can only occur if the reference cam is too short and the machine axis moves across the reference point during deceleration in phase 1 If the reference cam reaches up to the traversing end of the axis an inadmissible start point for referencing behind the cam is ruled out The reference cam must be adjusted exactly The time response that determines reference point detection by the control NCK depends on the following factors Switching accuracy of the reference point cam e Reference point switch delay normally closed contact Delay on PLC input PLC cycle time Internal processing time The practice has shown that the adjustment of the r
230. ne function TEACH IN active V30000000 0 Interface signal Edge evaluation no AUTOMATIC mode Signal s to NCK PLC gt NCK Signal s updated cyclically Signal s version valid as from SW Signal status 1 or edge change 0 gt 1 AUTOMATIC mode is selected from the PLC program Signal status 0 or edge change 1 gt 0 AUTOMATIC mode is not selected from the PLC program Signal not applicable to signal Mode change blocked is present Related to IS Active mode AUTOMATIC V30000000 1 Interface signal Edge evaluation no MDA mode Signal s to NCK PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 MDA mode is selected from the PLC program Signal status 0 or edge change 1 gt 0 MDA is not selected from the PLC program Signal not applicable to signal Mode change blocked is present Related to IS Active mode MDA SINUMERIK 802S C base line 5 21 Description of Functions Program mode V30000000 2 Interface signal Edge evaluation no JOG mode Signal s to NCK PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 JOG mode is selected from the PLC program Signal status 0 or edge change 1 gt 0 JOG mode is
231. ng Velocity Rapid traverse override Feed override 4 2 The following paragraphs will describe the generally applicable properties of manual traversing in JOG mode irrespective of the selected variant To traverse the axes manually further called manual traversing JOG mode must be active The currently active operating mode is reported to the PLC via the interface signal IS Active mode JOG V30000000 2 JOG mode divides into several JOG variants machine functions e continuous traversing e incremental traversing e traversing with handwheel Axes can be traversed in the following coordinate systems e Machine coordinate system MCS e Workpiece coordinate system WCS The currently active machine function is selected via the PLC interface There are separate PLC interfaces both for the axes in MCS axis specific and for the axes in WCS channel specific In JOG mode all axes can be traversed simultaneously When the axes are traversed simultaneously the axes do not interpolate with each other The velocity of the traversing movement in JOG mode is determined by the following values specifications SD JOG_SET_VELO JOG velocity with G94 for one axis SD JOG_SPIND_SET_VELO JOG velocity for spindle If the value of this SD is zero the value of MD JOG_VELO conventional axis velocity is used To limit the axis velocity MD MAX_AX_VELO is used If the rapid traverse override key is pressed i
232. ng for all stepper motor axes SINUMERIK 802S base line Path movement G1 G2 G3 With the SINUMERIK 802S base line the activation of the knee shaped acceleration characteristic for the path movement is carried out automatically when turning on by setting an internal machine data to the turn on setting of the G command DRIVE A switchover deselection is not possible in the program MD ACCEL_TYPE_DRIVE has no influence here No additional machine data exist for the path movement The characteristic comprises of the parameters of the axes involved depending on their portion in the path vector geometry A combination of axes with different acceleration courses is permitted Normal and tangent accelerations within knee shaped path sections are discussed together The path velocity is reduced as far as a maximum of 25 of the velocity dependent acceleration capability of the axes is required for the normal acceleration The residue is reserved for tangential acceleration i e braking and or acceleration on the path Axis specific velocity steps can occur at non tangential block transitions The path velocity at the block transition is reduced if an axis specific velocity portion is above the threshold velocity of the acceleration decay MD ACCEL_REDUCTION_SPEED_POINT SINUMERIK 802S C base line Description of Functions Velocity Setpoint Actual Value System Closed Loop Control 3 3 2 Parameterization of the
233. ng to MD USER_DATA_INT 2 be Int value corresponding to MD USER_DATA_INT 2 VW45000062 Int value 32 corresponding to MD USER_DATA_INT 2 VB45001000 Hex value 1 corresponding to MD USER_DATA_HEX 2 15 6 SINUMERIK 802S C base line Description of Functions List of Interface Signals Interface signal Name Ref Section VB45001001 Hex value 2 corresponding to MD USER_DATA_HEX 2 2 Hex value corresponding to MD USER_DATA_HEX 2 VB45001031 Hex value 32 corresponding to MD USER_DATA_HEX 2 VD45002000 Float value 1 corresponding to MD USER_DATA_FLOAT 4 bytes 2 VD45002004 Float value 2 corresponding to MD USER_DATA_FLOAT 4 bytes 2 es Float value corresponding to MD USER_DATA_FLOAT 4 bytes 2 VD45002028 Float value 8 corresponding to MD USER_DATA_FLOAT 4 bytes 2 Alarm response deletion criterion Alarm 700000 Eeroueee corresponding to MD USER_DATA_PLC_ALARM ae Alarm response deletion criterion Alarm 700001 Neamepere corresponding to MD USER_DATA_PLC_ALARM A Alarm response deletion criterion Alarm 70000 2J corresponding to MD USER_DATA_PLC_ALARM Alarm response deletion criterion Alarm 7000031 MeToodets corresponding to MD USER_DATA_PLC_ALARM a User alarm PLC gt MMC V16000000 0 to Activation of alarm No 700000 to 2J V16000003 7 No 700031 V16001000 Variable for alarm 700000 2 V16001004 Variable for alarm 700001 2 we Variable for alarm
234. ning monitoring Zero speed control Clamping monitoring Set speed monitoring e Encoder monitoring functions Encoder limit frequency Zero mark monitoring e Limit switch monitoring e Stepper motor rotation monitoring SINUMERIK 802S C base line Description of Functions 1 1 Axis Spindle Monitoring 1 1 Motion Monitoring Functions 1 1 1 Contour Monitoring Contour error Contour errors are caused by signal distortions in the position control loop A distinction is made between e Linear signal distortions These are caused by Speed or position controller not being set optimally Unequal servo gain factors for the feed axes involved in producing the contour If the servo gain factor of two axes involved in linear interpolation is equal the actual point follows the setpoint on the same contour but with a delay If the servo gain factors are not equal a parallel offset between set contour and actual contour occurs Unequal dynamic response of the feed drives Unequal drive dynamics leads to contour deviations in particular at contour changes Circles are distorted into ellipses due to unequal dynamics of the two feed drives e Non linear signal distortions These are caused by Activation of the current limitation within the machining range Activation of the limitation of the set speed Backlash within and or outside the position control loop Contour errors arise because of back
235. not active for the brakes of axis spindle Related to IS Program test active V3300000001 7 14 4 SINUMERIK 802S C base line Description of Functions Various Interface Signals Follow up mode V380x0001 4 software version 3 1 and higher If an axis spindle is in the follow up mode its setpoint position will always follow the current actual value position With follow up mode the position setpoint value is not specified by the interpolator but derived from the current actual position Since the position actual value of the axis is continued to be acquired it is not necessary to re reference the axis after cancellation of the follow up mode Zero speed clamping and positioning monitoring are not effective in the follow up mode Activation The IS Follow up mode is only relevant if servo enable is canceled for the drive e g via the IS Servo enable 0 signal or internally in the control system due to a fault or if servo enable is provided once more IS Follow up mode 1 If the IS Servo enable is canceled the position setpoint value of the appropriate axis will follow the actual value continuously This status is displayed via the IS Follow up active V390x0001 3 transmitted to the PLC If then the IS Servo enable is set again repositioning REPOSA approach with all axes along a straight line is carried out provided a part program is active internally in the control system to t
236. not selected from the PLC program Signal not applicable to signal Mode change blocked is present Related to IS Active mode JOG V30000000 4 Interface signal Edge evaluation no Mode change blocked Signal s to NCK PLC gt NCK Signal s updated cyclically Signal s version valid as from SW Signal status 1 or edge change 0 gt 1 No change from the currently active mode JOG MDA or Automatic possible Signal status 0 Mode change is possible Fig Mode selection AUTOMATIC mode Mode change blocked V30000000 7 Reset Interface signal Signal s to NCK PLC gt NCK Edge evaluation yes Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The channel is to change to RESET condition The currently active program is then in the program status Aborted All running axes and spindles are decelerated to standstill along their acceleration curve without contour violation The basic settings are set e g G functions The alarms are deleted if they are not POWER ON alarms Signal status 0 or edge change 1 gt 0 Channel status and program execution are not affected by this signal Related to IS Channel reset IS All channels in Reset status Special cases errors An alarm that cancels the IS Ready ensures that the channel is n
237. ns to the programmed curve or to make them tangentially Continuous path control has the following effects e Rounding of the contour corners Shorter machining times thanks to missing deceleration and acceleration processes required to reach the exact stop criterion Better cutting conditions due to more even velocity curve Continuous path control mode is recommended whenever e a contour is to be traversed as fast as possible the exact curve within an error criterion may deviate from the programmed curve in order to generate a continuous curve over the entire range In some cases it is necessary to generate exact stop in continuous path control mode in order to be able to execute consequential reactions In these situations the contour velocity is reduced to zero If auxiliary functions are output prior to the traversing movement the preceding block is only completed when the selected exact stop criterion is reached If auxiliary functions are output after the traversing movement these are output after the interpolator end of the block e If the function Clear buffer is programmed in the part program the preceding block is completed when the selected exact stop criterion is reached Velocity 0 in continuous path control mode Irrespective of the implicit exact stop the contour motion at the end of the block is decelerated to zero velocity if e the time required to position a spindle which has bee
238. nt is aborted The PLC interface signal Traversing key blocked can be used to block the effect of the traversing keys for each axis individually Signal status 0 or edge change 1 gt 0 Signal not applicable to in AUTOMATIC mode and MDA Related to IS Traversing key for axes blocked 4 20 SINUMERIK 802S C base line Description of Functions Manual Traversing and Handwheel Traversing V32001000 0 to 3 6 V32001004 0 to 3 6 V32001008 0 to 3 6 Machine function for WCS axis INC1 INC10 INC100 INC 1000 continuous Interface signal Signal s to channel PLC gt NCK Edge evaluation no Signal s valid as from SW version Signal s updated cyclically Signal status 1 or edge change 0 gt 1 These interface signals are used to define how many increments are covered by the axis when the direction key is pressed or the handwheel is turned or it is continuous mode When doing this JOG mode must be active Once the selected machine function is active this is reported to the PLC interface IS Active machine function INC1 If several machine function signals INC1 INC are selected on the interface no machine function is activated by the control system Signal status 0 or edge change 1 gt 0 The respective machine function is not selected If an axis is just traversing an increment the movement is also aborted by
239. ntries SINUMERIK 802S C base line 6 5 Description of Functions Compensation Example 6 6 Note e Table parameters that contain position information are interpreted with MD SCALING_SYSTEM_IS_METRIC 0 in inch The compensation table can only be loaded if the machine data ENC_COMP_ENABLE 0 is set Value 1 results in activation of the compensation and thus in write protection e Save your compensation values by selecting the softkey Save data in the operator interface Diagnosis gt Start up see also Operation and Programming The following example shows the compensation values specified for machine axis X by means of a part program _N_EECDAT_EEC_INI AA_ENC_COMP_STEP 0 X 1 0 AA_ENC_COMP_MIN 0 X 200 0 AA_ENC_COMP_MAX 0 X 600 0 AA_ENC_COMP 0 0 X 0 01 AA_ENC_COMP O 1 X 0 012 AA_ENC_COMP 0 800 X 0 02 M17 Compensation table for X Distance between interpolation points 1 0 mm Compensation starts at 200 0 mm Compensation ends at 600 0 mm 1st compensation value interpolation point 0 0 01mm 2nd compensation value interpolation point 1 0 012mm etc last compensation value interpolation point 800 0 020mm End of compensation table for X In this example the number of compensation interpolation points must be MIRO E NDAP aldAx 1P MN isSoutput The compensation table for this example requires 6 4 kBytes of the buffered NC u
240. ntrol the automatic sequence of reference point approach Synchronization can be performed with the rising edge of the BERO sensor single edge evaluation or with the BERO edge middle double edge evaluation If only one synchronization signal is provided over the entire traversing range no referencing cam is required MD REFP_CAM_IS_ACTIVE 0 To transfer the switching edge signal of the BERO to the control system a high speed input is required To this aim the SINUMERIK 802S base line provides the inputs on connector X20 connector for high speed inputs and the inputs on pin 13 for the X axis pin 14 for the X axis and pin 15 for the Z axis see Technical Manual Start Up The cam signal is acquired via a PLC input and transferred to the NC as an interface signal IS Reference point approach delay V 380x1000 7 SINUMERIK 802S C base line 8 1 Description of Functions Reference Point Approach Interface signals Special characteristics When the machine function REF in JOG mode IS Machine function REF V30000001 2 is active reference point approach is possible As a feedback information the IS Active machine function REF V31000001 2 must be present Axis specific reference point approach is started for each machine axis separately with the IS Traversing keys plus minus V380x0004 6 and 7 The IS Reset V30000000 7 aborts reference point approach All axes not yet reached t
241. o When traversing in JOG mode the axes are only traversed to the respectively ftware limit switch first active limit switch then the respective alarm is output Depending on the machine data HANDWH_REVERSE the response is as follows as long as the axis has not reached the end point as far as the setpoint is concerned The traverse path resulting from the handwheel pulses forms an effective end point used for the calculations to follow If this fictive end point is for example is 10 mm behind this limit these 10 mm must first be traversed in the opposite direction before the axis can carry out a real movement If you wish to traverse at a limit immediately in the opposite direction again the fictive distance to go can be cleared either by Clear distance to go or deselecting the handwheel assignment All handwheel pulses that lead to an end point behind the limit are ignored Moving the handwheel immediately in the opposite direction results in traversing in the opposite direction i e from the limit switch away SINUMERIK 802S C base line 4 9 Description of Functions Manual Traversing and Handwheel Traversing 4 6 Special Features of Handwheel Traversing 4 6 1 Monitoring Functions Limit switches Clearing the axis Maximum velocity and acceleration 4 10 The following limit switches are used for handwheel traversing e Software limit switches 1 and 2 axis must be referenced e Hardware limit switches The
242. o longer in Reset status In order to be able to change the operating mode Reset must be initiated 5 22 SINUMERIK 802S C base line Description of Functions Program mode V30000001 0 Interface signal Edge evaluation no Machine function TEACH IN Signal s to NCK PLC gt NCK Signal s updated cyclically Signal s version valid as from SW Signal status 1 or edge change 0 gt 1 The machine function TEACH IN is activated in AUTOMATIC mode Signal status 0 or edge change 1 gt 0 The machine function TEACH IN is not activated Signal not applicable to JOG mode is active V30000001 2 Interface signal Edge evaluation no Machine function REF Signal s to NCK PLC gt NCK Signal s updated cyclically Signal s version valid as from SW Signal status 1 or edge change 0 gt 1 The machine function REF is activated in JOG mode Signal status 0 or edge change 1 gt 0 The machine function REF is not activated Signal not applicable to JOG mode is active V31000000 0 Interface signal Edge evaluation no Active mode AUTOMATIC Signal s from NCK NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 AUTOMATIC mode is active Signal status 0 or edge change 1 gt 0 AUTOMATIC mode is not active V31000000 1 Inter
243. ock can be executed The actual gear stage is specified in coded form Each of the 5 gear stages is assigned a parameter record with the following assignment Parameter PLC Data of Data Block Contents Block No Interface 0 Data for axis mode Kv factor Monitoring functions 1 000 Data for 1st gear stage M40 speed 001 Min max speed 2 010 Data for 2nd gear stage 3 011 Data for 3rd gear stage 4 100 Data for 4th gear stage 5 101 Data for 5th gear stage 110 111 Special cases If the PLC user feeds back another actual gear stage to the NCK than fed back errors as the set gear stage to the PLC the gear stage change is nevertheless considered completed and actual gear stage A to C is activated Related to IS Set gear stage A to C V39032000 0 to 2 IS Change gear stage V39032000 3 IS Gear changed 38032000 3 IS Oscillation speed V38032002 5 Parameter records for gear stages V38032002 7 and 6 Interface signal Edge evaluation yes Set direction of rotation CW set direction of rotation CW Signal s to axis spindle PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 If the IS Oscillation by PLC is set the direction of rotation for the oscillation speed can be set by both IS Set direction of rotation CCW and CW The times for the oscillation motion of the spindle motor
244. ogrammed spindle speed is possible S function If a gear stage other than the current actual gear stage is found the IS Change gear stage and the IS Set gear stage A to C are set The set gear stage is output in coded form 1st gear stage 000 CBA 1st gear stage 001 2ndgearstage 0 3rd gear stage 0 4th gear stage 1 5th gear stage 1 invalid value 1 invalid value 1 O 0O O0O 1 1 0 0 1 1 Signal not to spindle modes other than oscillation applicable Related to IS Change gear stage V39032000 3 IS Actual gear stage A to C V38032000 0 to 2 IS Gear stage changed V38032000 3 V39032001 7 Interface signal Actual direction of rotation CW Signal s from axis spindle NCK gt PLC Edge evaluation yes Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 When the spindle rotates CW direction of rotation is signalled by the IS Actual direction of rotation CW 1 The actual direction of rotation is derived from the spindle actual position encoder Signal status 0 or edge change 1 gt 0 When the spindle rotates the CCW direction of rotation is signalled by the IS Actual direction of rotation CCW 0 Signal not e Spindle at a standstill IS Axis spindle on standstill 1 at a standstill applicable no evaluation of the direction of rotatio
245. om SW version Signal status 1 or edge change 0 gt 1 All axes of the channel which must be referenced are referenced MD REFP_NC_START_LOCK NC Start inhibited without reference point is zero If two position measuring systems are connected to an axis what would prevent the axis from being started the active measuring system must be activated in order to ensure that the axis is considered referenced Only if this signal is present NC Start for part program execution is accepted Axes to be referenced are all axes that in parking position position measuring systems inactive and servo enable canceled Signal status 0 or edge change 1 gt 0 One or several axes of the channel which must be referenced are not referenced Special cases errors The spindles of the channel have no effect on this IS Related to IS Referenced synchronized 1 IS Referenced synchronized 2 Signals to axis spindle V380x1000 7 Interface signal Edge evaluation no Reference point apporoach delay Signal s to axis spindle PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The machine axis is on the reference cam Signal status 0 or edge change 1 gt 0 The machine axis is ahead of the reference cam It is recommended to use an accordingly long reference cam to the traversing end in order to prevent
246. ominator Min input limit 1 Max input limit 2 147 000 000 Change effective after Power On Protection level 2 7 Unit Data type DWORD Valid as from SW version Meaning In this MD the numerator of the load gearbox must be entered The machine data index is coded as follows control parameter record 0 5 31070 MD number Default 1 DRIVE_ENC_RATIO_DENOM n Resolver gearbox denominator Min input limit 1 Max input limit 2147000000 Change effective after Power On Protection level 2 7 Unit Data type DWORD Valid as from SW version Meaning In this MD the denominator of the resolver gearbox must be entered The machine data index is coded as follows encoder no 0 31080 MD number Default 1 DRIVE_ENC_RATIO_NUMERA n Resolver gearbox numerator Min input limit 1 Max input limit 2147000000 Change effective after Power On Protection level 2 7 Unit Data type DWORD Valid as from SW version Meaning In this MD the numerator of the resolver gearbox must be entered The machine data index is coded as follows encoder no 0 31400 MD number Default 1000 STEP_RESOL Steps per stepper motor revolution Min input limit 0 Max input limit plus Change effective after Power On Protection level 2 7 Unit Data type DWORD Valid as from SW version
247. on Signal status 1 or edge change 0 gt 1 The currently active program has found a special program command in an NC block not available with SINUMERIK 802S base line Signal status 0 or edge change 1 gt 0 Program status waiting not present 5 32 SINUMERIK 802S C base line Description of Functions Program mode V33000003 2 Interface signal Edge evaluation no Program status Stopped Signal s from channel NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The NC part program has been stopped either by NC Stop NC Stop axes plus spindles NC Stop at block end programmed MO or M1 or single block mode Signal status 0 or edge change 1 gt 0 Program status Stopped is not present Related to IS NC Stop IS NC Stop axes plus spindles IS NC Stop at block end V33000003 3 Interface signal Edge evaluation no Program status Interrupted Signal s from channel NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 When changing the mode from AUTOMATIC or MDA mode with the program stopped to JOG the program status changes to Interrupted The program can then be continued from the breakpoint either in AUTOMATIC mode or MDA by pressing NC Start
248. on control gain so called KV factor Servo gain factor The input output unit for the user is m min mm This means that POSCTRL_GAIN n 1 corresponds to a following error of 1 mm with V 1 m min If O is entered the position controller is disconnected When entering the servo gain factor KV factor take into account that the gain factor of the whole position control loop also depends on other parameters of the controlled system It must therefore be distinguished between a desired servo gain factor MD POSCTRL_GAIN and a real servo gain factor that results on the machine Only if all parameters of the control loop are matched one to another correctly these servo gain factors are identical Note Interpolating axes that are to carry out a machining must possess the same gain i e the same following error at the same velocity The real KV factor servo gain factor can be checked using the following error in the service displays The machine data index is coded as follows control parameter record no 0 5 SINUMERIK 802S C base line 3 17 Description of Functions Velocity Setpoint Actual Value System Closed Loop Control 32250 MD number Default 80 80 80 100 RATED_OUTVAL n Rated output voltage Min input limit 0 Max input limit plus Change effective after NEW_CONF Protection level 2 7 Unit Data type DOUBLE Valid as from SW version
249. on to the control PLC as a PLC input In the PLC user program this PLC input must be passed on to the NC to the IS EMERGENCY STOP V26000000 1 Resetting of the EMERGENCY STOP button or the signal directly derived from it must be passed on to the control PLC as a PLC input In the PLC user program this PLC input must be passed on to the NC to the IS Acknowledge EMERGENCY STOP V26000000 2 SINUMERIK 802S C base line 13 3 Description of Functions EMERGENCY STOP 13 3 EMERGENCY STOP Sequence Standard EN 418 Sequence in the NC Sequence on the machine 13 4 After actuating the EMERGENCY STOP tripping mechanism the EMERGENCY STOP system must operate such that any impending hazards are averted or reduced as best as possible As best as possible means that the optimum deceleration rate and the appropriate stop category defined in EN 60204 based on a risk evaluation are selected The defined sequence according to EN 418 of the internal functions to bring the system to the EMERGENCY STOP status in the control system is as follows 1 Part program execution is interrupted all axes and spindles are decelerated The spindle and the axes is decelerated along a deceleration ramp defined by MD AX_EMERGENCY_STOP_TIME the stepper motor axes are decelerated along a fixed internal deceleration ramp IS READY V31000000 3 is reset IS EMERGENCY STOP active V27000000 1 is set Alarm 3000 is set
250. onger time before the next command can be executed SINUMERIK 802S C base line 1 3 Description of Functions Axis Spindle Monitoring 1 1 3 Zero Speed Control Function The zero speed control has the following functionality On completion of a motion block position partial value 0 at the end of the motion a check is made to see whether the following error has reached the limit for MD STANDSTILL_DELAY_TIME zero speed tolerance after a parameterizable delay set in MD STANDSTILL_POS_TOL delay time zero speed control On completion of the positioning process axis stop fine reached the zero speed control function takes over from the position monitoring function A check is made to see whether the axis is moving more than specified in MD STANDSTILL_POS_TOL zero speed tolerance from its position Zero speed control is activated when Exact stop fine is reached and theDelay zero speed control set in MD STANDSTILL_DELAY_TIME is still running Effect When the monitoring function responds it has the following effects e Output of alarm 25040 Zero speed monitoring e The axis spindle involved is stopped with rapid stop see Section 1 1 1 Error cause remedy e Servo gain too large oscillation of the control loop gt change machine data for servo gain with axes equipped with analog drives or spindle MD POSCTRL_GAIN n servo gain factor e Zero speed window too small gt change machine data MD STANDSTIL
251. order to tolerate the BERO edges occurring during the rotation monitoring 31350 FREQ_STEP_LIMIT MD number Maximum stepper motor frequency Default 250000 0 Min input limit 100 Max input limit 1 000 000 Change valid after NEW_CONF Protection level 2 7 Unit Hz Data type DOUBLE Valid as from SW version Meaning MD comes into effect with stepper motor drive maximum frequency that may occur with a stepper motor 36020 POSITIONING_TIME MD number Delay Exact stop fine Default 5 Min input limit 0 Max input limit plus Change effective after NEW_CONF Protection level 2 7 Unit s Data type DOUBLE Valid as from SW version Meaning The time after which the following error must have reached the limit value for Exact Stop Fine when the position is approached position partial setpoint 0 If this is not the case alarm 25080 Position monitoring is output and the axis concerned stopped The MD should be selected such that the monitoring function in normal mode does not respond since the entire traversing process acceleration constant traversing deceleration is monitored by other functions without gaps Related to MD STOP_LIMIT_FINE exact stop fine 1 12 SINUMERIK 802S C base line Description of Functions Axis Spindle Monitoring 36030 MD number Default 0 2 STANDSTILL_POS_TOL Zero speed tolerance Min input limit 0 Max input
252. ossible in each mode If during the preparation of a block it is found that the axis position to be approached is greater than the positive negative software limit switch one of the following alarms is output 10720 Software limit switch or 10620 Axis reaches software limit switch or If the position of a software limit switch is reached in JOG mode and you wish to travel further in this direction alarm 10621 Axis reached software limit switch or is output If the monitoring function responds the axis is decelerated with axis acceleration If an axis is involved in interpolation with other axes these axes will also be decelerated This can lead to contour violation The execution of the program is aborted The direction keys in approach direction are disabled Remedy e Move in the opposite direction in JOG mode e Correct the program SINUMERIK 802S C base line 1 9 Description of Functions Axis Spindle Monitoring 1 4 Axis Monitoring Supplementary Conditions To ensure that the monitoring functions operate correctly particular attention has to be paid to the machine data MD LEADSCREW PITCH lead screw pitch Gear ratio load gear encoder MD DRIVE_AX_RATIO_DENOM n load gear denominator MD DRIVE_AX_RATIO_NUMERA n load gear numerator MD DRIVE_ENC_RATIO_DENOM n measuring gear denominator MD DRIVE_ENC_RATIO_NUMERA n measuring gear numerator Motor spee
253. ot stop since arithmetic blocks do not trigger actions Decoding Single Block SBL 2 With this single block type all blocks of the part program including pure arithmetic blocks without traversing movements are executed one after another by NC Start Action Single Block SBL1 is the default setting after switching on Caution e Single Block in a series of G33 blocks is only active if Dry Run Feed is selected e Arithmetic blocks are not processed in Single Block mode only in Decoding Single Block mode SBL2 The user can use this function to execute a part program block by block in order to check the individual steps of processing If he has found the executed part program part correct he can request the next block Changing to the next part program block is carried out by NC Start Single Block mode is selected by means of the SBL key on the machine control panel With the selection the IS Single block selected V00000001 2 is set The function is thus not yet activated The preselection whether type SBL1 or SBL2 is carried out on the operator interface in the Program Control menu This function is activated via the IS Activate single block V32000000 4 As a feedback information that Single Block mode is active SBL1 or SBL2 is displayed in the respective field on the operator interface Once the part program execution has executed a part program block due to Single Block mode t
254. ous 1 4 V25000000 0 Decoded M function 0 99 modified 1 10 V25000001 4 T function 1 modified 1 10 V25001000 0 Dynamic M functions MO to M99 4 10 V25001012 3 VB25002000 T function 1 4 byte value 4 10 VB25002003 Axis spindle PLC gt NCK VB380x000 Feed override override value 1 11 V380x0001 3 Axes spindle lock 1 14 V380x0001 4 Follow up mode 1 14 V380x0001 5 Position measuring system 1 1 14 V380x0001 7 Override enable 1 11 V380x0002 1 Servo enable 1 14 V380x0002 2 Delete distance to go spindle reset 1 9 14 V380x0002 2 Clear distance to go Spindle Reset 1 9 V380x0002 3 Clamping process running 1 1 V380x0003 6 Velocity spindle speed limitation 1 1 V380x0004 0 Activate handwheel 1 1 4 V380x0004 1 Activate handwheel 2 1 4 V380x0004 3 Feed Stop Spindle Stop 1 11 V380x0004 4 Traversing key lock 1 4 V380x0004 5 Rapid traverse override 1 4 V380x0004 6 Traversing key minus 1 4 15 4 SINUMERIK 802S C base line Description of Functions List of Interface Signals Interface signal Name Ref Section V380x0004 7 Traversing key plus 1 4 V380x0005 0 Machine function 1 INC 1 4 V380x0005 1 Machine function 10 INC 1 4 V380x0005 2 Machine function 100 INC 1 4 V380x0005 3 Machine function 1000 INC 1 4 V380x0005 6 Machine function continuous 1 4 V380x1000 0 Hardware limit switch minus 1
255. output is unipolar Min input limit 0 Max input limit 2 Change valid after Power On Protection level 2 2 Unit Data type BYTE Valid as from SW release Meaning Application example s Unipolar output driver for unipolar analog drive actuators gt analog spindle With unipolar setting only positive speed setpoints are provided to the drive the sign of the speed setpoint is output separately in its own digital control signal 0 Bipolar output 10V with pos neg speed setpoint servo enable standard case The PLC output bits OO and O1 may be used by the PLC 1 Unipolar output 0 10V with enable and direction signals servo enable neg direction of travel The PLC output bits OO and O1 must not be used by the PLC PLC output bit OO servo enable PLC output bit O1 negative direction of travel 2 Negative direction of travel Unipolar output 0 10V with linked enable and direction of travel signals Servo enable pos direction of travel servo enable neg direction of travel The PLC output bits OO and O1 must not be used by the PLC PLC output bit OO servo enable positive direction of travel PLC output bit O1 servo enable negative direction of travel 35010 MD number Default 0 GEAR_STEP_CHANGE_ENABLE Gear stage change possible Min input limit 0 Max input limit 1 Changes effective after Power On Protection level 2 7 Unit Data type BOO
256. part program results in programmed stop Signal status 0 or edge change 1 gt 0 M1 in the part program does not result in programmed stop Related to IS M01 selected IS MO M1 active V17000000 5 V33000000 5 5 24 SINUMERIK 802S C base line Description of Functions Program mode V32000001 7 Interface signal Edge evaluation no Activate program test Signal s to channel PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 An internal Axis Blocked signal is provided for all axes not for the spindles For this reason the machine axes do not move when a part program block or part program is executed However the axes movements are simulated on the operator interface by changing axis position values The axis position values for the display are generated from the calculated setpoint values The part program is executed as usual Signal status 0 or edge change 1 gt 0 The execution of the part program is not affected by the Program Test function Related to IS Program test selected IS Program test active V32000002 0 Interface signal Edge evaluation no Skip block Signal s to channel PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 Blocks in a part progra
257. pindle is less than the entered value and if no more setpoints are output from the NC to the axis spindle the IS Axis spindle stopped V390x0001 4 is set ist MD STANDSTILL_VELO_TOL Mo still IS Axis spindle stopped 0 Application To stop the axis spindle controlled pulse enabling should only be carried out example s when the axis spindle is at a standstill Otherwise the axis would coast to stop Related to IS Axis spindle stopped V390x0001 4 36100 POS_LIMIT_MINUS MD number 1st software limit switch minus Default 100 000 000 Min input limit Max input limit Change effective after Power On Protection level 2 7 Unit mm degrees Data type DOUBLE Valid as from SW version Meaning Meaning as 1st software limit switch plus but for the traversing range limit in the negative direction The MD is effective after reference point approach if the PLC interface signal 2nd software limit switch minus is not set MD not applicable if the axis is not referenced Related to IS 2nd software limit switch minus 36100 POS LIMIT PLUS MD number 1st software limit switch plus Default 100 000 000 Min input limit Max input limit Change effective after Power On Protection level 2 7 Unit mm degrees Data type DOUBLE Valid as from SW version Meaning In a
258. ping G33 G331 G332 G63 e Revolutional feed G95 e Constant cutting speed G96 Programmable spindle speed limits G25 G26 LIMS Position transducer to be mounted either on the spindle or on the spindle motor e Spindle monitoring for min max speed active e Dwell time of spindle in revolutions G4 S Instead of the analog spindle it is also possible to use a switched spindle In this case the spindle speed S is not set from the program but for example via manual operation gearbox on the machine It is therefore also not possible to program speed limits The following can be set from the program e Setting the direction of rotation of spindle M3 M4 e Spindle Stop without orientation M5 Tapping G63 If this spindle possesses a position transducer the following additional functions are possible Thread cutting tapping G33 a Revolutional feed G95 When a switched spindle is used setpoint output for the spindle must be suppressed via machine data MD CTRLOUT_TYPE 0 SINUMERIK 802S C base line 9 1 Description of Functions Spindle 9 1 Spindle Modes Spindle modes Spindle mode change 9 2 An analog spindle controlled by the NC can be operated in three different spindle modes Control mode Oscillation mode Positioning mode Switchover between the spindle modes is carried out as follows Oscillation mode Change gear stage Gear stage changed SPOS
259. point approach JOG mode Related to IS Traversing key plus and Traversing key minus IS Axis feed spindle override SINUMERIK 802S C base line 4 23 Description of Functions Manual Traversing and Handwheel Traversing V380x0004 7 and 6 Interface signal Edge evaluation yes Traversing keys plus and minus Signal s to axis spindle PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 In JOG mode the selected axis can be traversed in both directions by means of the traversing keys Incremental traversing On signal status 1 the axis starts traversing by the set increment If the signal changes to 0 before the increment is traversed the traversing movement is interrupted If the signal status is 1 again the traversing movement is continued As long as the increment is traversed completely the traversing movement of the axis can be stopped and continued several times as described above Continuous traversing If no INC dimension is selected the axis will traverse as long as the key remains pressed If both traversing signals plus and minus are set at the same time no traversing movement is carried out or the traversing movement is aborted The PLC interface signal Traversing key blocked can be used to block the effect of the traversing keys for each axis separately Signal status 0 or
260. pplies to axes equipped with stepper motors without encoder The encoder are considered here as internally existing For backlash compensation the axis specific actual value is corrected by the backlash value with each change of the direction of the axis spindle This amount can be entered for each axis spindle in the MD BACKLASH reversal backlash during start up After reference point approach the backlash compensation is active in all operating modes The encoder is always in advance of the machine part e g table Because the actual position acquired by the encoder is thus also in advance of the real actual position the table will traverse too short see Fig 6 1 The backlash compensation value must be entered here as a positive value normal case Positive backlash normal case Encoder actual value is in advance of the real actual value table Table traverses too short Fig 6 1 Positive backlash normal case SINUMERIK 802S C base line Description of Functions Negative backlash Compensation value display Large compen sation values Compensation The encoder runs behind the machine part e g table the table will traverse too far see Fig 6 2 The compensation value must be entered as a negative value Negative backlash Toothed rack kl a Real actual value table is in advance of the encoder actual value Table traverses too far Fig 6 2 Negative backlash
261. pulse is used for synchronization otherwise a wrong machine zero is detected the max value in MD REFP_MAX_MARKER_DIST may not exceed the distance between two reference marks synchronous pulses 34070 REFP_VELO POS MD number Reference point positioning speed Min input limit 0 Max input limit plus Changes effective after Power On Unit mm min Protection level 2 7 Data type DOUBLE Valid as from SW version Meaning The axis traverses with this speed from the moment when the synchronous pulse is received to the moment when the reference point is reached reference point coordinate MD REFP_SET_POS 34080 REFP_MOVE_DIST 0 MD number Partial distance synchronous pulse lt gt reference point Default 2 0 Min input limit Max input limit Changes effective after Power On Protection level 2 7 Unit mm Data type DOUBLE Valid as from SW version Meaning After synchronization with the synchronous pulse the machine axis accelerates to the speed specified in MD REFP_VELO_POS reference point positioning speed and traverses a distance which results from adding the distances specified in MD REFP_MOVE_DIST and MD REFP_MOVE_DIST_CORR reference point offset gt phase 3 This distance determined by adding is exactly the distance between the detected synchronous pulse and the reference point MD REFP_SET POS 0 Speed
262. r M3 direction MD SPIND_OSCILL_TIME_CCW oscillation time for M4 direction IS Oscillation speed V38032002 5 IS Set direction of rotation CCW V38032002 7 IS Set direction of rotation CW V38032002 6 SINUMERIK 802S C base line Description of Functions 9 41 Spindle VB38032003 Interface signal Edge evaluation no Spindle override Signal s to spindle PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The spindle override is specified from the spindle gray coded The override value determines the percentage of the programmed speed setpoint output to the spindle restin Coe S Rar ae Code Position Factor 00010 0 60 5 omn 07 6 onm 075 8 ono 085 9 om 0o90 Table 9 1 Gray coding for spindle override Related to IS Override active V38030001 7 IS Feed override valid for spindle V38032001 0 9 42 SINUMERIK 802S C base line Description of Functions Spindle Signals from axis spindle V39030000 0 Interface signal Edge evaluation yes Signal status 1 or edge change 0 gt 1 Spindle no axis Signal s from axis spindle PLC gt NCK Signal s updated cyclically Signal s valid as from SW version The machine axis is operated as a spindle in the following spindle modes Control mode Oscillation mode
263. r stage for autom gear stage selection Qamax Max spindle speed of 2nd gear stage for autom gear stage selection Fig 9 7 Gear stage change with gear stage selection SINUMERIK 802S C base line Description of Functions Preselecting the gear stage M41 to M45 M40 Spindle Gear stages can be preset fixed by the part program M41 to M45 e automatically by the programmed spindle speed M40 When M40 is used for automatic gear stage selection with an S word the spindle must be in spindle control mode Otherwise the gear stage change will be refused and alarm 22000 set The gear stage can be specified as a fixed value by means of M41 to M45 Ifa gear stage other than the current actual gear stage is set the IS Change gear stage V39032000 3 and the IS Set gear stage A to C V39032000 0 to 2 are set The programmed spindle speed S function will then refer to this fixed gear stage If a spindle speed above the max speed of the fixed gear stage is programmed a limitation to the max speed of the gear stage is carried out and the IS Set speed limited V39032001 1 set M40 in the part program is used by the control system to set the gear stage automatically A check is performed to see in which gear stage the programmed spindle speed S function is possible If a gear stage is found which is other than the current actual gear stage the IS Change gear stage V39032000 3 and the IS Se
264. r than set via MD GEAR_STEP_MAX_VELO_LIMIT n maximum speed of gear stage The index n of the machine data is coded as follows Servo parameter block No 0 5 SINUMERIK 802S C base line 1 15 Description of Functions Axis Spindle Monitoring 36300 MD number Default 300000 ENC_FREQ_LIMIT n Encoder limit frequency Min input limit 0 Max input limit plus Change effective after Power On Protection level 2 7 Unit Hz Data type DOUBLE Valid as from SW version Meaning The encoder limit frequency is entered in this machine data 36302 MD number ENC_FREQ_LIMIT_LOW Encoder frequency for restart Default 99 9 Min input limit 0 Max input limit 100 Change valid after NEW_CONF Protection level 2 7 Unit Data type DOUBLE Valid as from SW version Meaning The encoder frequency monitoring uses a hysteresis ENC_FREQ_LIMIT defines the encoder limit frequency at which the encoder is turned off and ENC_FREQ_LIMIT_LOW defines the frequency at which the encoder is turned on again ENC_FREQ_LIMIT is specified directly in Hertz ENC_FREQ_LIMIT_LOW however is a portion of ENC_FREQ_LIMIT specified as a percentage Normally the default of MA_ENC FREQ _LIMIT_LOW is sufficient When absolute encoders with EnDat interface are used however the limit frequency of the absolute track is considerably lower than the limit
265. rdinate RY after synchr pulse Start RK Synchr pluse Vo Reference point approach velocity MD REFP_VELO_SEARCH_CAM Vu Reference point cut off speed MD REFP_VELO_SEARCH_MARKER Vp Reference point approach velocity MD REFP_VELO_POS Ry Reference point offset MD REFP_MOVE_DIST REFP_MOVE_DIST_CORR Rx Reference point coordinate MD REFP_SET_POSj 0 BERO signal For stepper motor axes only The respective actual value is stored when the selected edge of the BERO signals is received In order to achieve a good repeatability of the reference point the search SINUMERIK 802S C base line Description of Functions speed for the BERO edge may not exceed a certain maximum value which depends on the BERO type 8 5 Reference Point Approach Single edge evaluation Double edge evaluation 8 6 Single edge evaluation Axis direction Double edge evaluation Axis direction BERO Measuring grid B Synchronization point Fig 8 2 Synchronization point definition The positive edge of the BERO signal is interpreted as a synchronization mark The associated actual value is the synchronization point Edge selection is carried out via MD ENC_REFP_MODE 2 The positive and negative edges of the reference point BERO are acrossed one after the other and the respective actual values are recorded The average value is the synchronization point at which phase 2 ends and phase 3
266. reciprocating by PLC IS Reciprocating by PLC V38032002 4 set Related to MD SPIND_OSCILL_TIME_CCW reciprocation time for M4 direction MD IPO_SYSCLOCK_TIME_RATIO interpolator clock IS Reciprocation speed V38032002 5 IS Reciprocating by PLC V38032002 4 9 32 SINUMERIK 802S C base line Description of Functions Spindle 35450 SPIND_OSCILL_TIME_CCW MD number Reciprocation time for M4 direction Default 0 5 Min input limit 0 Max input limit plus 0 corresponds to a time of one interpolation clock MD IPO_SYSCLOCK_TIME_RATIO Change effective after Power On Protection level 2 7 Unit s Data type DOUBLE Applies from SW version Meaning The reciprocation time defined here is effective in M4 direction see illustration MD not applicable e all other spindle modes than reciprocation mode tO e reciprocating by PLC IS Reciprocating by PLC V38032002 4 set Speed l min Time 5 Reciprocation time Related to MD SPIND_OSCILL_TIME_CW reciprocation time for M3 direction MD IPO_SYSCLOCK_TIME_RATIO interpolator clock IS Reciprocation speed V38032002 5 IS Reciprocating by PLC V38032002 4 SINUMERIK 802S C base line 9 33 Description of Functions Spindle 35500 MD number Default 1 SPIND_ON_SPEED_AT_IPO_START Feed enable for spindle in set range Min input limit 0 Max input limit 2 Chan
267. ree 5 2 3 Program Execution With Dry Run Feed s tisrisrisrrsrrsrisersrrarispisriariarrariarisriariarisriariariariarise 5 3 Processing of Certain Program Parts rrrsrirrisrrsriarisrisriseiserarisrisrisrrsrisriarisrrarisrisrisriseise 5 3 1 Skipping Certain Part Program BIOCKS rier terrier nn Cr ie 5 4 Executing a Part Program PIENAAR INRIA ETES OIA IRRE HEL Bie RSE RNA OAE ART AERE ENINA eater eel awa 5 4 1 Part Program Selection sr srisrrsrrsrisrisristisriariatisrrArIAPINEIAFNAFIAFIAFISEIAFNA PIA PIAFIAPISEIAPIA PIAFIN 5 4 2 Starting the Part Program or Part Program BIOCK trisrtsrisrisrisrisrinrrarinrinersriarinriarinrreriarine 5 4 3 Interrupting a Part Program Raa Ra eS Oa E baa AS MUU Laide Iida aided EEA 5 4 4 RESET Command ccrssrtsrter teeter sense reer ear en ren pia ria nin ein Pea Ea TARTAR LAPIS P ESP E SPIE PIER IA PIS PINPIN PLA PLE 5 4 5 Program Control virierier err tiA PrAFIAKISEIAFIAPINPIAFNAPIAPIAFIAPIAEIAFISPISFIAPIAEIAFIAKISEEAE 5 4 6 Program StatUS rrrrrrsrisrisrisersersrisrisris ete ete Lara EARLE PES PES PLATA TAPIA PINPIN PIER I ALARA ES PES ELA PINE 5 4 7 Channel Status crricrrcrser scree reer en ree ree ree eee nae E eR EE EE EAR A REAR EA DEAD EA DIATE IAD IA DESPISE DIARIES PIER LSE ESE 55 Data Description ocr ee er era ee eee ee Tee err eee ee oe 5 6 Signal De SCriptions t sr srrsrisrisrrariaris tratita EEE EEE T ECL TECTED Compensation errr EEE EEE EEE EEE ETE 6 1 Backlash Compensation iricrer re LE 6 2 Lead Error and Measuring
268. rence cam edge The machine axis accelerates to the speed set in MD REFP_VELO_SEARCH_CAM reference point approach speed opposite to the direction specified in MD REFP_CAM_DIR_IS_MINUS When the reference point is left falling edge IS Reference point approach delay is reset the machine axis decelerates to standstill and traverses to the reference cam in the opposite direction with the speed specified in MD REFP_VELO_SEARCH_MARKER reference point cut off soeed When the reference point is reached IS Reference point approach delay 380x1000 7 is set the control system synchronizes itself with the first synchronous pulse BERO zero mark SINUMERIK 802S C base line 8 9 Description of Functions Reference Point Approach 34060 MD number Default 20 REFP_MAX_MARKER _DIST 0 Max distance to reference mark Min input limit 0 Max input limit plus Changes effective after Power On Protection level 2 7 Unit mm Data type DOUBLE Valid as from SW version Meaning Monitoring function If the machine axis starts traversing a distance specified in MD REFP_MAX_MARKER_DIST from the reference cam IS Reference point approach delay is reset without detecting the reference cam the axis stops and alarm 2002 is output Default 10000 Application If you wish to make absolutely sure that the control system detects that always example s the same synchronous
269. riterion Relief cutting can occur due to the waiting time for reaching the exact stop criterion The exact stop function is suited for exact traversing of contours Exact stop is not recommended if the exact contour within a criterion e g exact stop fine may differ from the programmed contour in order to achieve faster machining e absolute velocity tolerance is required The exact stop function can be selected in the NC program either by means of the command G60 or G09 The desired exact stop criterion should be specified with the associated program code prior to or with the selection G60 is modal and G09 is non modal G09 is used to interrupt the continuous path control mode Both exact stop functions will only be active with the selected exact stop criterion The exact stop function is deselected with continuous path control mode Exact stop fine This criterion is used to monitor whether the actual position of the axis is away from the set position within a certain path distance The size of the per permitted distance is stored in MD STOP_ LIMIT_FINE exact stop fine Exact stop coarse The same scope of functions as exact stop fine but the monitoring window is defined in MD STOP_LIMIT_COARSE exact stop coarse In order to achieve a faster block change as with the exact stop fine criterion the exact stop coarse window must be parametrized larger than the exact stop fine window SINUMERIK 802S C base line De
270. rk search can thus be ensured by defined zero mark selection even in case of temperature dependent extension of the reference cam Since the reference cam offset is calculated by the control system in the interpolation cycle the real cam offset is at least REFP_CAM_SHIFT and max REFP_CAM_SHIFT REFP_VELO_SEARCH_MARKERiinterpolation cycle The reference cam offset acts in the search direction of the zero mark The reference cam offset is only active if the cam REFP_CAM_IS_ACTIVE 1 is present Thermal extension Cam signal Zero mark search Zero marker i Cam signal REMEDY REFP_CAM_SHIFT with offset SINUMERIK 802S C base line 8 11 Description of Functions Reference Point Approach 34100 REFP_SET_POSj 0 MD number Reference point reference point coordinate Default 0 0 Min input limit Max input limit Changes effective after RESET Protection level 2 7 Unit mm degrees Data type DOUBLE Valid as from SW version Meaning The position value that is set as the current axis position after the synchronous mark has been detected and the distance REFP_MOVE_DIST REFP_MOVE_DIST_ CORR has been traversed Fig 12 xt ZMR R Clamping Z M Machine zero W Workpiece zero R Reference point XMR Reference point value in X direction MD REFP SET POS X ZMR Reference point value in Z direction
271. rser resolution of the two values determines the positioning accuracy of the control system The choice of input resolution interpolator and position control cycle have no effect on this accuracy The control system can use inch or metric systems The basic setting is defin ed in MD SCALING_SYSTEM_IS_METRIC basic system metric Depending on the setting in the MD all geometric values are interpreted either as metric or inch values All manual settings also refer to this basic setting e g handwheel INC feedrate as do zero offsets tool offsets etc and the associated displays In part programs the workpiece related specifications can be switched over between the measuring systems by means of G70 G71 The data affected by G70 G71 is described in the Programming Instructions SINUMERIK 802S C base line Description of Functions Velocity Setpoint Actual Value System Closed Loop Control Standardization of physical quantities in the machine and setting data Machine and setting data that contain physical quantities are interpreted as standard in the following input output units depending on the basic system used metric inch Input output units for standard basic Physical quantity system Metric Inch Linear position 1mm 1 inch Angular position 1 degree 1 degree Linear velocity 1 mm min 1 inch min Angular velocity 1 rev min 1 rev min Linear acceleration 1 m s 1 inch s
272. rstage Programmable spindle speed limitation G26 Programmable spindle speed limitation LIMS Programmable spindle speed limitation G25 Min spindle speed of current gear stage Spindle on standstill min 25 and G26 eed range of current gear stage ni cutting speed 3 Speed range of current gear stage P konsta Speed range of spindle oF spindle chuck i Speed range of current gear stage limited by IS Referenced synchronized IS Axis spindle on standstill n lt n S a Fig 9 10 Ranges of spindle monitoring functions speeds SINUMERIK 802S C base line 9 19 Description of Functions Spindle 9 5 1 Axis Spindle on Standstill n lt n Only if the axis spindle is on standstill i e the spindle actual speed is below a value which can be set in MD STANDSTILL_VELO_TOL certain functions such as tool change open machine door enable path feed etc are possible e If the spindle is at a standstill the IS Axis spindle stopped V39030001 4 is set The monitoring function is active in the three spindle modes 9 5 2 Spindle in Set Range Function The spindle monitoring function Spindle in set range checks whether the programmed spindle speed is reached the spindle is on standstill IS Axis spindle on standstill or still in the acceleration phase In the spindle control mode the set speed programmed speed spindle override with consideration of the active limits is compared with
273. s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 All axes and the position controlled spindle stop with interpolator end No further traversing movements will be carried out V390x0000 6 Interface signal Edge evaluation no Position reached with exact stop coarse Signal s from axis spindle NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The axis is in the respective exact stop the interpolator for the axis is no longer active set position reached Or the interpolator is not active since the control system is in RESET condition Reset button or end of program the contour movement has been ended with NC stop the spindle is in position control mode SPOS instruction and is on standstill Signal status 0 The axis is no longer in the respective exact stop Related to MD STOP_LIMIT_COARSE exact stop coarse V390x0000 7 Interface signal Edge evaluation no Position reached with exact stop fine Signal s from axis spindle NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 See IS Position reached with exact stop coarse Signal status 0 or edge change 1 gt 0 See IS Position reached with exact stop coarse Related to
274. s reset the axis is decelerated to a standstill and the movement is considered ended Once a traversing request is present for an axis the IS Traversing command or Traversing command V33001000 7 6 V33001004 7 6 V33001008 7 6 or V390x004 7 6 is output to the PLC depending on the direction of the movement SINUMERIK 802S C base line 4 5 Description of Functions Manual Traversing and Handwheel Traversing 4 4 Incremental Traversing INC Setting increments The path to be traversed by the axis is determined by so called increments also called incremental dimension Before the machine operator can traverse the axis he must set the desired increment The setting is done via the machine control panel Settable increments The operator can set up max four different increment steps that apply to all axes together INC1 INC10 INC100 and INC1000 Increment weighting The axis MD JOG_INCR_WEIGHT weighting of an axis increment with INC Traversing Canceling the trav ersing movement 4 6 handwheel is used to define the path weighting of one JOG increment Default setting is 1 incr 0 001 mm When the traversing key of the desired direction e g is pressed the axis starts traversing with the set increment When the traversing key is released before the increments have been traversed completely the movement is interrupted and the axis stops When the same traversing key is pressed once mor
275. s started Continuation with phase 2 SINUMERIK 802S C base line Description of Functions Oscillation by PLC End of oscillation mode Block change Spindle Reset Spindle When the IS Oscillation speed is active the spindle motor accelerates to the speed set in MD SPIND_OSCILL_DES_VELO oscillation speed with oscillation acceleration The direction of rotation is defined by means of the IS Set direction of rotation CCW and the IS Set direction of rotation CW The oscillation motion and the two times t1 and t2 time for CW and CCW rotation must be simulated in the PLC The IS Gearbox changed V38032000 3 informs the NCK that the new gear stage IS Actual gear stage is valid and oscillation mode is ended The actual gear stage should correspond to the set gear stage Oscillation mode is also ended if the IS Oscillation speed is still set The last programmed spindle speed S function and direction of rotation of the spindle M3 M4 or M5 are active again When the oscillation mode is ended the spindle is in control mode again All gear specific limit values min max speed of gear stage etc correspond to the values specified for the actual gear stage and are switched off on standstill of the spindle If the spindle has been changed to oscillation mode IS Change gear stage V39032000 3 is set part program execution remains stopped No new block is started for execution If
276. scription of Functions Exact stop criteria Activation Continuous Path Control Exact Stop Exact stop fine SET POSITION Axis direction Axis direction I plus minus Exact stop coarse ACTUAL POSITION Block change moment Actual value vith G602 ith G601 Exact stop coarse Exact stop fine Fig 2 2 Block change depending on the exact stop criteria The exact stop criteria can be selected in each NC part program block by means of the G codes e G601 exact stop fine e G602 exact stop coarse and are evaluated by means of the exact stop functions G60 or G09 An active criterion is deactivated by selecting another criterion Certain situations can imply exact stop in continuous path control which will then consider one of the three criteria see also implicit exact stop in Section 2 3 SINUMERIK 802S C base line Description of Functions 2 5 Continuous Path Control Exact Stop 2 3 Continuous Path Control Mode Implicit exact stop In continuous path control mode the contour velocity for block change at the end of the block is not decelerated to a velocity which allows the exact stop criterion to be reached The aim is to avoid higher axis deceleration of the contour axes at the block change moment in order to be able to change to the next block with possible the same contour velocity Continuous path control mode is used to smooth bent block transitions by local modificatio
277. sed CAUTION If servo enable shutdown delay is set too low servo enable is canceled even when the axis spindle is still traversing It is then suddenly stopped with setpoint zero e The position actual value of the axis spindle is still acquired by the control system This status of the axis spindle can only be changed after Reset Interpolatory axis grouping All axes involved in interpolation are stopped once servo enable is canceled for one of the axes involved in interpolation The axes are stopped as described above All axes of the geometrical axis grouping are stopped with rapid stop Furthermore alarm 21612 Servo enable reset during the motion is signaled In this case the NC program can no longer be continued Deletion of the distance to go spindle reset axis specifically V380x0002 2 14 6 software version 3 1 and higher extended to Delete distance to go axis specifically The effect of the IS on the spindle Spindle reset is described in Section 9 7 Effect with axes Delete distance to go axis specifically The effect is mode dependent With JOG If the interface signal is provided for one axis edge transition 0 gt 1 then this axis is stopped by ramp stop and its deletion to go deleted The following error if any will be reduced to zero With AUTOMATIC and MDA The rising edge of the interface signal IS is only effective with axes which are not integrated in the geometric
278. ser memory 8 bytes per compensation value SINUMERIK 802S C base line Description of Functions Compensation Compensation value Error curve Compensation curve linear interpolation between two interpolation points Compensation values of the compensation tables Refence point End position SAA_ENC_COMP_MAX Distance betw interp pts Compensation value of AA_ENC_COMP interpolation 5 100 200 300 1200 Axis position 0 1 2 Interpolation points 4 Linear interpolation Start position Number of interpolation pints S AA_ENC_COMP_MIN MD MM_ENC_COMP_MAX_POINTS Fig 6 3 Parameter of the compensation table system variables for LEC SINUMERIK 802S C base line 6 7 Description of Functions Compensation 6 3 Drift Compensation Drift Compensation DRIFT_LIMIT 6 8 It applies only to position controlled spindle not for axes with stepper motors The temperature dependent drift in analog components requires that analog speed control loops must be controlled with a speed rated value unequal to zero in order to reach standstill The position controller can only generate this speed rated value if a small following error arises on its input even on standstill The axis spindle will therefore leave its set position only slowly until the speed rated value that has been established due to the existing following error so large that it corresponds to the temperature drift To avoid this static error a small add
279. ses e With position control switched on the value is limited to 90 control errors reserve If the programmed S value is above the max gear stage the set speed is limited to the max speed of the currently active gear stage with gear stage selection M41 to M45 in addition the IS Programmed speed too high is set e If the programmed S value is above the max speed for gear stage change a new gear step is set with automatic gear stage selection M40 e If the programmed S value is above the max speed of the highest gear stage the speed is limited to the max speed of the highest gear stage with automatic gear stage selection M40 If the programmed S value has no matching gear stage no gear stage change is triggered Related to MD GEAR_STEP_MAX_VELO max speed for gear stage change MD GEAR_STEP_MIN_VELO min speed for gear stage change MD GEAR_STEP_CHANGE_ENABLE gear stage change is possible MD GEAR_STEP_MIN_VELO LIMIT min speed of gear stage 35140 GEAR_STEP_MIN_VELO LIMIT n MD number Min speed of gear stage gear stage number 0 5 Default 5 5 10 20 40 80 Max input limit plus Min input limit 0 Changes effective after Power On rev min Protection level 2 7 Unit Data type DOUBLE Valid as from SW version Meaning In MD GEAR_STEP_MIN_VELO_LIMIT the min speed of the gear stage is entered Even if the programmed S va
280. signals Activate handwheel are set the priority is Handwheel 1 before Handwheel 2 If the assignment is active the axis can be traversed with the handwheel in JOG mode or a DRF offset generated in AUTOMATIC or MDA mode Signal status O or edge change 1 gt 0 This axis is handwheel 1 or 2 not assigned Interface signal Edge evaluation no Application This interface signal can be used to interlock axis control by turning the example s handwheel from the PLC user program Related to IS Handwheel active V380x0004 5 Rapid traverse override Signal s to axis spindle PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 If the PLC interface signal Rapid traverse override is provided together with Traversing key plus or Traversing key minus the called axis traverses with rapid traverse The rapid traverse velocity is set in the machine data JOG_VELO_RAPID Rapid traverse override is active in JOG mode in the following cases continuous traversing J incremental traversing When rapid traverse override is active the velocity can be controlled by means of the axis feed override switch Signal status O or edge change 1 gt 0 The axis traverses with the set JOG velocity SD JOG_SET_VELO or MD JOG_VELO Signal not applicable to AUTOMATIC mode and MDA Reference
281. signed to one group Only one auxiliary function per block may be programmed Otherwise alarm 14760 is output A maximum of 15 auxiliary function groups can be defined These 15 auxiliary function groups can be assigned max 50 auxiliary functions per channel The pre assigned auxiliary functions are not yet considered in this number The real number of auxiliary functions distributed over the groups is entered in the NCK specific MD AUXFU_MAXNUM_GROUP_ASSIGN number of auxiliary functions distributed over the auxiliary function groups Assigned auxiliary functions are defined in the following machine data AUXFU_ASSIGN_TYPE n auxiliary function type AUXFU_ASSIGN_VALUE n auxiliary function value AUXFU_ASSIGN_GROUPIn auxiliary function group Pre assigned auxiliary function groups The pre assigned auxiliary function groups have the following behavior e Output at block end group 1 e Output prior to the movement group 2 Group 1 By default the auxiliary functions MO M1 and M2 are assigned to group 1 Group 2 By default the M functions M3 M4 and M5 are assigned to group 2 10 2 Behavior with Block Search Block search with calculation During block search with calculation all auxiliary functions assigned to a group are accumulated and output at the end of the block prior to the block at which program execution is continued except for group 1 MO M1 Always the last auxiliary function of a group is output
282. spindle the reference point value and the offset of the reference point are enabled If the spindle operated in spindle control mode reaches a speed high S value programmed higher than the max encoder limit frequency the max speed of the encoder may not be exceeded the synchronization gets lost The spindle goes on rotating but with reduced functionality The following functions will reduce the spindle speed as long as the active measuring system is below the encoder limit frequency Thread cutting G33 e Revolutional feed G95 e Constant cutting speed G96 G97 If the speed is below the max encoder limit frequency smaller S value programmed spindle override switch modified etc the spindle automatically synchronizes itself with the next zero mark or the next BERO signal If the encoder limit frequency is exceeded the IS Referenced synchronized 1 V39030000 4 is reset and the IS Encoder limit frequency 1 exceeded V39030000 2 set In the following cases the position measuring system of the spindle has to be resynchronized with the 0 degree position The position encoder is mounted on the motor a BERO on the spindle and gear stage change is carried out The synchronization is triggered internally if the spindle is in the new gear stage see Synchronization Sequence SINUMERIK 802S C base line 9 13 Description of Functions Spindle 9 3 Speed and Gear Stage Change Speeds Why gear stages
283. ssible Oscillation is not aborted Axes are stopped Program is aborted after gear stage change or Spindle Reset alarm is deleted Positioning mode is stopped MD SPIND_ACTIVE_AFTER_RESET 1 Control mode Spindle does not stop Program is not aborted Oscillation mode Alarm 10640 Stop during gear stage change not possible Oscillation is not aborted Axes not stopped Program is aborted after gear stage change the alarm is deleted and the spindle goes on rotating with the programmed M and S values Positioning mode is stopped The IS Clear distance to go Spindle Reset V38030001 2 is always active irrespective of MD SPIND_ ACTIVE_AFTER_RESET MD not applicable to spindle modes other than control mode Default 10 000 Related to IS Reset V30000000 7 IS Clear distance to go spindle reset V38030001 2 35100 SPIND_MAX_VELO_LIMIT MD number Max spindle speed Min input limit 0 Max input limit plus Changes effective after Power On rev min Protection level 2 7 Unit Data type DOUBLE Valid as from SW version Meaning In this MD the max spindle speed is entered which must not be exceeded by the spindle spindle chuck with workpiece or the tool The NCK limits the spindle speed to this value If the max spindle speed with consideration of the spindle speed tolerance MD SPIND_DES _VELO_TOL is neverthel
284. stage number 0 5 Min input limit 0 Max input limit plus Changes effective after Power On Protection level 2 7 Unit rev min Data type DOUBLE Valid as from SW version Meaning The acceleration in positon control mode must be set such that the current limit is not reached Default 500 Related to MD GEAR_STEP_SPEEDCTRL_ACCEL MD ACCEL_REDUCTION_SPEED_POINT 35300 GEAR_STEP_POSCTRL_ACCEL n MD number Position control threshold speed KKK Min input limit 0 Max input limit Change valid after Power On Schutzstufe 2 7 Unit rev min Data type DOUBLE Valid as from SW version Meaning When positioning a spindle not being in position control mode the position control is only connected when the spindle has reached the speed defined in MD SPIND_POSCTRL_VELO For the behavior of the spindle under various supplementary conditions positioning from the movement positoning from the standstill please refer to the Section Spindle Mode Positioning Mode Related to MD SPIND_POSITIONING_DIR direction of rotation when positioning from the standstill if no synchronization is provided 9 30 SINUMERIK 802S C base line Description of Functions Spindle 35350 MD number Default 3 SPIND_POSITIONING_DIR Direction of rotation when positioning from the standstill without reference Min input limit 3 Max inpu
285. t 1 The NC is in the EMERGENCY STOP condition Related to IS EMERGENCY STOP V26000000 1 IS Acknowledge EMERGENCY STOP V26000000 2 13 8 SINUMERIK 802S C base line Description of Functions Various Interface Signals 14 Brief description 14 1 Interfaces This Description of Functions describes the functionality of various interface signals which are of general significance and have not yet been described in any other descriptions of functions before General Signals and data between the PLC user program and e NCK numerical control kernel e MMC display unit e MCP machine control panel are exchanged via different data areas The PLC user program need not care for the exchange From user s point of view this is carried out automatically Cyclic signal exchange to NCK The control and status signals of the PLC NCK interface are updated cyclically These can be divided into the following groups see Fig 14 1 e General signals e Operating mode signals e Channel signals e Axis spindle signals The interface structure is described in detail in References Start Up Guide Chapter PLC Start Up SINUMERIK 802S C base line 14 1 Description of Functions Various Interface Signals PLC user General Signals to NC program Signals from NC Operating Signals to NCK i sas om Nek Signals from NCK Channel SS L l Signals from NCK Axis Spindle
286. t programmed path length in block 141 42 mm gt V max 141 42 mm 12 ms 0 9 10606 6 mm s 636 39 m min The following restriction applies to the minimum path or axis velocity 10 3 Calculation resolution degres ymin IPO cycle fs The calculation resolution amounts to 1 000 incr mm or incr degrees If the velocity drops below V min NO traverse movement takes place SINUMERIK 802S C base line 3 1 Description of Functions Velocity Setpoint Actual Value System Closed Loop Control Traversing ranges Positioning accu racy of the control Metric inch meas uring system basic system Converting the basic system Example IPO cycle 12 ms gt V min 10 3 1000 nm X 12 ms 0 005 min Value range for path feedrate F Metric system 0 001 F 999 999 999 mm min mm rev Inch system 0 001 F 399 999 999 inch min inch rev Value range for spindle speed S 0 001 S 999 999 999 rev min Table 3 1 Traversing ranges of the axes G71 mm G70 inch Range Range Linear axes X Z 999 999 999 399 999 999 Interpolation parameters I J K_ 999 999 999 399 999 999 The traversing range can be limited by software limit switches The positioning accuracy of the control system depends on the actual value resolution encoder increments mm or degrees and on the calculation accuracy internal increments mm or degrees The coa
287. t gear stage A to C V39032000 0 to 2 are set The automatic gear stage selection is carried out such that the programmed spindle speed is first compared with the min and max speed of the current gear stage If the comparison ends with a positive result no new gear stage is set In case of a negative result the comparison starting with gear stage 1 is carried out for all 5 gear stages as long as it ends with a positive result If the comparison is even in the 5th gear stage not positive no gear stage change is carried out The speed is either limited to the max speed of the current gear stage if necessary or increased to the minimum speed of the current gear stage and the IS Set speed limited V39032001 1 or Set speed increased V39032001 2 set SINUMERIK 802S C base line 9 15 Description of Functions Spindle Speed 1 min Max spindle speed Max speed of gearstage 2 Max speed for gear stage change 2 Max speed of gearstage 1 Max speed for gearstage change 1 Max speed for gearstage change 2 Min speed for gearstage 2 Min speed for gearstage change 1 Min speed for gearstange change 1 Fig 9 8 Example of speed ranges with automatic gear stage selection M40 Gear stage change with the spindle on standstill 9 16 When the new gear stage is selected by M40 and spindle speed or M41 to M45 the IS Set gear stage A to C V39032000 0 to 2 and IS Change gear stage V39032000 4
288. t limit 4 Changes effective after Power On Protection level 2 7 Unit Data type BYTE Valid as from SW version Meaning When SPOS is programmed the spindle changes to position control mode and accelerates with the acceleration defined by MD GEAR_STEP_POSCTRL_ACCEL acceleration in position control mode if no synchronization has been carried out The direction of rotation is defined by the MD SPIND_POSITIONING_DIR direction of rotation on positioning from standstill MD SPIND_POSITIONING_DIR 3 gt CW direction of rotation MD SPIND_ POSITIONING_DIR 4 gt CCW direction of rotation Related to MD SPIND_ POSCTRL_VELO position control switch on speed 35400 MD number SPIND_OSCILL_DES_ VELO Reciprocation speed Default 500 Min input limit 0 Max input limit Value in MD GEAR_STEP_MAX_VELO LI MIT Change effective after Power On Protection level 2 7 Unit rpm Data type DOUBLE Applies from SW version Meaning When reciprocating using the IS Reciprocation speed V38032002 5 a motor speed for the spindle motor has been specified This motor speed is defined in MD SPIND_OSCILL_DES_VELO The motor speed defined in this MD is independent of the current gear stage In AUTOMATIC and MDA screen forms the reciprocation speed is displayed in the Set Spindle window until the gear change is completed MD not to spin
289. t too large accelerations velocities 1 1 6 Actual Velocity Monitoring Function This is used to monitor the actual velocity for exceeding an admissible limit value entered in MD AX_VELO_LIMIT n threshold value for velocity monitoring Activation The actual velocity monitoring function is always active if the measuring circuit activated by IS Position measuring system V380x0001 5 provides actual values and is therefore still below the limit value It is active with e axes equipped with analog drives and stepper motor the used stepper motors have no real measuring system open loop controlled and position controlled spindles Effect If the Threshold for velocity monitoring is exceeded the following occurs e Output of alarm 25030 Actual velocity alarm limit The axis spindle involved is stopped with rapid stop see Section 1 1 1 Remedy e Check set speed cable e Check actual values e Check direction of rotation Check MD AX_VELO_LIMIT n threshold for velocity monitoring SINUMERIK 802S C base line 1 5 Description of Functions Axis Spindle Monitoring 1 2 Encoder Monitoring Functions 1 2 1 Encoder Limit Frequency Monitoring Function not applicable to stepper motor axes without encoder If the permissible limit frequency of a measuring system which is entered in MD ENC_FREQ_LIMIT 0 encoder limit frequency is exceeded the synchroniz ation of the position reference point
290. t velocities are required for the axes spindles in JOG mode the example s velocity can be defined axis specifically To this aim SD JOG_SET_VELO must be set to 0 Related to MD MAX_AX_VELO maximum axis velocity SD JOG_SET_VELO JOG velocity for G94 IS Feed override 32300 MAX_AX_ACCEL MD number Axis acceleration Min input limit 0 0 Max input limit Change valid after Power On Protection level 2 7 Unit m s rev s Data type DOUBLE Valid as from SW version Meaning The acceleration specifies a velocity change of the axis as a function of the time Different axes need not have the same acceleration The lowest acceleration value of the axes involved in the interpolation is taken into account Ask your machine manufacturer for which continuous braking and continuous acceleration your machine is suited This value is entered into this machine data The acceleration value is effective during each acceleration and or deceleration process MD not applicable to errors resulting in quick stop 4 14 Y mimin Rapid traverse same inclination SINUMERIK 802S C base line Description of Functions Manual Traversing and Handwheel Traversing 32420 MD number Default 0 JOG_AND_POS_JERK_ENABLE Default setting of axial jerk limitation Min input limit 0 Max input limit 1 Change valid after Power On Protection level 2 7 Un
291. ted V39032001 1 is set Min Speed The min speed of the gear stage is entered in MD GEAR_STEP_MIN_VELO_LIMIT The actual speed can never be below the set speed even if a too low S value is programmed The interface signal Set speed increased V39032001 2 is set The min speed of the gear stage is only active in speed controlled mode and can only fall below the set speed in the following cases e Spindle override 0 e M5 e SO IS Spindle Stop e IS Servo enable canceled e IS Reset IS Spindle Reset IS Oscillation speed NC STOP for axis spindle e IS Axis spindle blocked SINUMERIK 802S C base line 9 21 Description of Functions Spindle 9 5 5 Max Encoder Limit Frequency A Warning The max encoder limit frequency of the spindle actual position encoder is monitored by the control system exceeding possible The machine manufacturer must ensure by appropriate design of the components spindle motor gearbox resolver gearbox and the associated machine data that the max speed mechanical limit speed of the spindle actual position encoder cannot be exceeded Max encoder limit frequency exceeded If the spindle in spindle control mode or oscillation mode reaches a speed high S value programmed which is above the max encoder limit frequency the max mechanical limit speed of the encoder may not be exceeded the synchronization gets lost However
292. the axis path in the contour path The feed F is active for the interpolation types G1 G2 G3 G5 and remains active in the program until a new F word is written see User Manual Operation and Programming F Note For integer values the decimal point need not be specified e g F300 The unit of the F word is defined by G functions e G94 Feed F in mm min e G95 Feed F in mm rev of the spindle makes only sense if the spindle rotates N10 G94 F310 Feed in mm min N110S200M3 Spindle rotation N120 G95 F15 5 Feed in mm rev For turning machines the group with G94 G95 is extended by the functions G96 G97 for constant cutting speed ON OFF These functions have an additional influence on the S word When the function G96 is active the spindle speed is adapted to the diameter of the workpiece currently being machined face axis such that the programmed cutting speed S on the tool edge remains constant spindle speed multiplied with diameter constant From the block containing G96 the S word is interpreted as the cutting speed G96 is modally active until it is canceled by another G function of the group G94 G95 G97 The feed F is here always interpreted in the unit mm rev as with G95 When a G command that requires a new unit for the F word is changed the F value must be modified too The max path velocity results from the maximum velocities of the axes involved MD MAX_AX_VELO and their por
293. the defined axis Depending on the MMC interface signal Machine axis the interface to the machine axis or to the axis in WCS is used The following is applicable when assigning the axis name to the axis number IS Axis 1 i e axis X IS Axis 2 i e axis Y IS Axis 3 i e axis Z The following coding is used for the axis number Bit 1 Bit 0 Axis Number 0 o 0 1 1 1 o 2 1 1 3 Related to IS Axis V19001003 7 or V19001004 7 IS Activate handwheel V19001003 7 and V19001004 7 Axis for Handwheel 1 or 2 Interface signal Signal s from NC MMC gt PLC Edge evaluation no Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The operator has assigned the handwheel 1 2 directly on the operator panel This axis is a machine axis MCS For more information refer to IS Axis number Signal status 0 or edge change 1 gt 0 The operator has assigned the handwheel 1 2 an axis directly on the operator panel This axis is aWCS axis For more information refer to IS Axis number Related to IS Axis number VB19001003 ff IS Handwheel selected V19001003 6 4 18 SINUMERIK 802S C base line Description of Functions Manual Traversing and Handwheel Traversing V32001000 0 to 1 V3200100
294. the oscillation mode is ended with the IS Gear stage changed V38032000 3 part program execution is continued as shown in Fig 9 6 Any new blocks will be processed IS Gear stage changed Block change carried out Fig 9 6 Block change after oscillation mode The spindle can be decelerated by means of the IS Clear distance to go spindle reset V30000000 7 After standstill the spindle is in control mode The S word is deleted M5 activated SINUMERIK 802S C base line 9 11 Description of Functions Spindle Distinctive features e The acceleration is defined in MD SPIND_ OSCILL_ACCEL acceleration during oscillation e If the IS Oscillation speed V38032002 5 is reset the oscillation motion will stop However the spindle oscillation mode will not be left e The spindle override switch is disabled fixed to 100 An exception is only the position 0 e The IS Reset V30000000 7 will not abort oscillation mode When indirect measuring systems are used the synchronization gets lost Reset during gear stage change No spindle stop is possible due to IS Reset V30000000 7 IS NC Stop V32000007 3 e the spindle is in oscillation mode for gear stage change the IS Gear stage changed V38032000 3 is not yet present In these cases when Reset is selected the alarm 10640 Stop during gear stage change not possible After the gear stages have been
295. ther and may not exceed the maximum permissible velocity MD MAX_AX_VELO Value 0 If O is entered in the setting data the MD JOG_VELO conventional axis velocity acts as JOG velocity These machine data can be used to assign each axis its own JOG velocity axis MD When the spindle is traversed in JOG mode the maximum velocities of the active gear stage MD GEAR_STEP_VELO LIMIT are used SD not applicable axes Application The operator can use these setting data to set an application specific JOG example s velocity for spindles Related to Axis MD JOG_VELO conventional axis velocity MD GEAR_STEP_MAX_VELO_LIMIT maximum speed of gear stages SINUMERIK 802S C base line Description of Functions Manual Traversing and Handwheel Traversing 4 8 Signal Description VB19001003 and VB19001004 Axis Number for handwheel 1 or 2 Interface signals Signal s from NC MMC gt PLC Edge evaluation no Signal s updated cyclically Signal s valid as from SW version Signal meaning The operator can asign each handwheel an axil directly on the operator panel To this aim he defines the desired axis e g X The axis number relating to the axis with the information Machine axis axis IS is made available to the axis from the PLC basic program as MMC interface signals The PLC basic program sets thus the interface signal Activate handwheel for
296. tial property damage Warning Indicates a potentially hazardous situation which if not avoided could result in death or serious injury or in substantial property damage Caution Used with safety alert symbol indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury or in property damage Caution Used without safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage Notice Indicates important information relating to the product or highlights part of the documentation for special attention The unit may only be started up and operated by qualified person or persons Qualified personnel as referred to in the safety notices provided in this document are those who are authorized to start up earth and label units systems and circuits in accordance with relevant safety standards Please observe the following Warning The unit may be used only for the applications described in the catalog or the technical description and only in combination with the equipment components and devices of other manufacturers as far as this is recommended or permitted by Siemens This product must be transported stored and installed as intended and maintained and operated with care to ensure that it functions correctly and safely SINUMERIK 802S C base line Description of Functions Contents Preface Objective Target group
297. tion Machine data 20210 CUTCOM_CORNER_LIMIT MD number Maximum angle for compensation blocks for tool radius compensation Default 100 0 Min input limit 0 0 Max input limit 150 0 Changes effective after Power On User class 2 7 Unit degrees Data type DOUBLE Valid as from SW version Meaning In case of very sharp external corners long idle motions can occur when G451 is used This is the reason why an automatic change from G451 intersection point to G450 transition circle is carried out in the case of very sharp external corners The contour angle from which this automatic change intersection point gt transition circle is carried out can be set by means of this MD Long idle motions ad Contour angle 12 4 SINUMERIK 802S C base line Description of Functions Tool Compensation 22550 TOOL_CHANGE_MODE MD number New tool tool compensation with M6 Default 0 Min input limit 0 Max input limit 1 Changes effective after Power On User class 2 7 Unit Data type BYTE Valid as from SW version Meaning A tool is selected in the program by means of the T function Whether the new tool is changed immediately with the T function depends on the setting in the following machine data MD TOOL_CHANGE_MODE 0 The new tool is changed immediately with the T function This setting is mainly used for turning machines with tool revolver M
298. tion in the contour path The maximum axis velocity stored in the MD cannot be exceeded SINUMERIK 802S C base line Description of Functions Feeds Feed override for When circle contours are machined by milling tools and with tool radius circles G901 compensation G41 G42 switched on the feed on the cutter center point must be corrected if the programmed F value is to act on the circle contour With feed override G901 active internal and external circle machining are detected automatically The feed override can be switched off by G900 Interface signal When revolutional feed is active the IS Revolutional feed active V33000001 2 is set Alarms e If no F word for G1 G2 G3 G5 is programmed alarm 10860 is output No axis movement can be carried out When FO is programmed alarm 14800 is output e If the spindle is on standstill when G95 is active no axis movement can be carried out No alarm is output SINUMERIK 802S C base line 11 3 Description of Functions Feeds 11 3 Feed for Thread Cutting G33 Application Axis velocity NC STOP Single Block Information The function G33 can be used to machine threads with constant lead This function can also be used for tapping with compensating chuck Detail description see User Manual Operation and Programming For G33 threads the axis velocity for the thread length results from the set spindle speed and the programmed thread lead However the
299. toring r E LEE A EE A E AS EE E A A 9 5 1 Axis Spindle on Standstill N lt Nmin ee rr er AA 9 5 2 Spindle in Set Range IRA aac aloe GRA Le ee aime one ig co inary Lee A Geni aaa Leura annie 9 5 3 Max Spindle Speed trisrisrrrrisrisrrarisriartarisrisrisrINP IAFIAYISPIAPISFINPIAFEAFISPIAEISFINFIAPEAFIS KIEKIS 9 5 4 Min Max Speed of Gear Stage ia cnobe endl MALE nnRNSLRACed a BONE Perl ada REG EET 9 5 5 Max Encoder Limit Frequency AEREE RE A D RAE RPGR REEDE AP NAET ERA TIER MAM aR aE E Rea TRE 9 5 6 Target Position Monitoring Per E eer re E 9 6 Unipolar Spindle st srrsrisrrsrisrrsriariaristiarisrisFIAKNAEIAFIAKINPISENAPISPIAFIAPIAFIAFISPISPIAPIAPIAFIAKIS EESE 9 7 Data Description en Leto whaareiog bath rida EEEE CAERULEA PEE EENE RETE a Ra Raa ruth roar Dalen ee rum WRN Eu KAORI E 98 Signal Description Uri ore erie EINA NERINA NIAE eT ee re eee te ere ee ere ere eo SINUMERIK 802S C base line Description of Functions Contents 10 Output of Auxiliary Functions to PLC 10 1 Auxiliary Function GroUPS viritrirt ert rE EERE EEE 10 2 Behavior with Block Search rrirrisrisriserserarrarispiarrarisrisrinrisrisrisrisrisrisrrsriariarisrisriarinrine 10 3 Description of Auxiliary Functions 10 4 Data Description E L E A L E 10 5 Signal Description trrsrrsrrsrisriarisristiaris EEE ETTORE EIAPIA FISE 11 FeedS gt errsrrerrsrrsrrsrrerrerinrianteriarinnidntetieYAAPNAISEISYAAPIAHISEISFAAPIAPINEESFAAPKARINEESFAAPIARINEESEAAPIARIE EESE 11 1
300. ty speed limitation V38030003 6 is set The NCK limits the spindle speed to this value 35200 MD number GEAR_STEP_SPEEDCTRL_ACCEL n Acceleration in speed controlled mode gear stage number 0 5 Default 30 30 25 20 15 10 Min input limit 0 Max input limit plus Changes effective after Power On Protection level 2 7 Unit Rev s Data type DOUBLE Valid as from SW version Meaning The torque of the spindle in the lower speed range is constant and reduced from a certain defined speed upper speed range The lower speed range with the constant torque ends at a speed which must be entered in MD ACCEL_REDUCTION_SPEED_ POINT speed limit reduced acceleration If the spindle is in speed controlled mode the acceleration is entered in the lower speed range constant torque in MD GEAR_STEP_SPEEDCTRL_ ACCEL Special cases errors The acceleration in speed controlled mode MD GEAR_STEP_SPEEDCTRL_ ACCEL can be set higher than in position control mode MD GEAR_STEP_ POSCTRL_ACCEL acceleration in position control mode since no position control reserve must be considered Related to MD GEAR_STEP_POSCTRL_ACCEL acceleration in position control mode MD ACCEL_REDUCTION_SPEED_POINT speed limit reduced acceleration 35210 MD number Default 30 30 25 20 15 10 GEAR_STEP_POSCTRL_ACCEL n Acceleration in position control mode gear
301. ual Traversing and Handwheel Traversing 31090 MD number Default 0 001 JOG_INCR_WEIGHT Weighting of an increment with INC handwheel Min input limit Max input limit Change effective after Protection level 2 7 Unit Linear axis mm Power On Data type DOUBLE Valid as from SW version Meaning The entered value defines the traverse distance of an increment which is used when traversing an axis via the JOG keys either in incremental mode or with the handwheel The distance traversed by the axis with incremental dimension each time when the key is pressed or per handwheel latched position is defined by the following parameters MD JOG_INCR_WEIGHT weighting of an axis increment with INC handwheel Selected increment size INC1 INC1000 A negative value results in a reversal of the direction weighting of the direction keys or of the direction of rotation of the handwheel MD not applicable to AUTOMATIC mode and MDA 32010 MD number Default 10000 JOG_VELO_RAPID Conventional rapid traverse Min input limit 0 Max input limit plus Change effective after Protection level 2 7 Unit Linear axis mm min Power On Data type DOUBLE Valid as from SW version Meaning The entered axis velocity applies to traversing in JOG mode with the Rapid Traverse Override key pressed and axis feed override 100 The entered value m
302. uce impending or existing danger for persons as well as damage to the machine or material triggered as a single action by one person if normal stop is not the appropriate action for the intended purpose In the sense of EN 418 hazards can be caused by functional inconsistencies malfunctions of the machine unacceptable properties of the material operator faults e normal operation SINUMERIK 802S C base line Description of Functions EMERGENCY STOP 13 2 EMERGENCY STOP Tripping Mechanism Standards EN 418 According to EN418 EMERGENCY STOP tripping mechanisms must be arranged within the reach of the operator or any other persons who consider the operation of the EMERGENCY STOP tripping mechanisms necessary Among other types the following tripping mechanisms can be used e Mushroom buttons push button operated switches e Wires wire ropes lines bars e Knobs e In special cases foot operated switches without protection cover All EMERGENCY STOP tripping mechanisms must be mechanically self locking and be arranged within reach EMERGENCY STOP The Siemens machine control panel MCP for 802S base line is provided with button a mushroom button push button operated switch with positive opening operation further called EMERGENCY STOP button Reference Technical Manual Start Up Instructions EMERGENCY STOP The actuation of the EMERGENCY STOP button or a signal directly derived on NC from it must be passed
303. uce the contour velocity with each block change what however means a delay of the block change The second type continuous path control mode is a try to avoid deceleration of the contour velocity in order to change to the next block with possibly the same contour velocity The following function description describes the features and possibilities of the Exact Stop function and the Continuous Path Control Mode SINUMERIK 802S C base line 2 1 Description of Functions Continuous Path Control Exact Stop 2 1 General Contour axes 2 1 1 Velocities Feed Feed override Rapid traverse Rapid traverse override Velocity for zero cycle blocks 2 2 Contour axes are all machining axes guided by an interpolator which determines the contour points such that e all axes involved start at the same time e each of the axes involved traverse with the correct velocity ratio e all axes reach the programmed target position at the same time Depending on the particular contour e g circle the accelerations of the individual axes can be different Contour axes are subject to the axis specific velocity limit values and acceleration limit values The programmed feed F corresponds to the feedrate It is modal and is programmed as a velocity e g in the units mm min or inch min with G94 or in mm rev or inch rev with G95 The feed represents the geometric total of the feedrates of the axes involved in the interpolation The
304. uestion For example traversing the axis in JOG mode using the traversing keys on the MCP is not possible If traversing key blocking is activated while the axes are traversed the axis is stopped Signal status 0 The traversing keys plus and minus are enabled Application It is thus possible to interlock traversing of the axis in JOG mode via the example s traversing keys from the PLC user program depending on the operating condition Related to IS Traversing key plus and Traversing key minus for axis SINUMERIK 802S C base line Description of Functions 4 19 Manual Traversing and Handwheel Traversing V32001000 5 V32001004 5 V32001008 5 Rapid traverse override for WCS axis Interface signal Signal s to channel PLC gt NCK Edge evaluation nein Signal s valid as from SW version Signal s updated cyclically Signal status 1 or edge change 0 gt 1 When the PLC interface signal Rapid traverse override is provided at the same time when the Traversing key plus or Traversing key minus are pressed the respective axis will traverse with rapid traverse The rapid traverse velocity is defined by the machine data JOG_VELO_RAPID The rapid traverse override is active in JOG mode with the following variants continuous traversing 5 incremental traversing With rapid traverse override active the velocity can be controlled by the rapid
305. unctions D function Selecting the edge on tool change Activating the tool compensation Tool Compensation The tool edge is programmed with D1 edge 1 to D9 edge 9 The tool edge always refers to the currently active tool An active tool edge D1 to D9 without active tool TO is not active Tool edge DO deselects all tool compensations of the active tool After programming a new tool new T number and changing this tool the following possibilities to select the edge are provided 1 The edge number is programmed 2 The edge number is not programmed D1 is active automatically by default D1 to D9 are used to activate the tool compensation of a tool edge for the active tool However tool length compensation and tool radius compensation become active at different moments e The tool length compensation TLC is realized with the first traversing movement of the axis in which the TLC is to be active This traversing movement must be a linear interpolation GO G1 e The tool radius compensation TRC becomes active by programming G41 G42 in the active plane G17 G18 or G19 The selection of TRC by G41 G42 may only be performed in a program block with GO rapid traverse or G1 linear interpolation Tool radius See User s Manual Operation and Programming Section Tool and Tool compensation Compensation SINUMERIK 802S C base line 12 3 Description of Functions Tool Compensation 12 2 Data Descrip
306. ve When the override is inactive the NC internally uses an override factor of 100 Exceptions are the 1st switch position for a Gray coded interface The override factors entered in the PLC are used here For the Gray coded interface the value entered in the machine data for the 1st interface is output as the override value Special cases In spindle operating mode Oscillation mode the spindle override is errors always supposed with 100 e The spindle override acts on the programmed values before the limits e g G26 become active e The feed override is inactive when G33 is active Related to IS Feed override and IS Spindle override SINUMERIK 802S C base line Description of Functions 11 21 Feeds V380x0004 3 Interface signal Edge evaluation no Feed Stop Spindle Stop axis specific Signal s to axis spindle PLC gt NCK Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The signal is active in all operating modes Feed Stop e This signal causes the respective axis to be stopped When an axis is traversing this signal results in controlled deceleration to standstill ramp stop No alarm message is output e This signal results in Feed Stop of all path axes involved in interpolation if Feed Stop is provided for one of the path axes In this case all axes are brought to standstil
307. via the IS Hardware limit switch plus minus V380x1000 1 0 and the motion of all axes is stopped HW limit switch monitoring is active in all operating modes after the control system has powered up e When a hardware switch is overshot in either direction alarm 21614 Hardware limit switch or is triggered e The direction keys in approach direction are disabled Move in the opposite direction in JOG mode Correct the program Software limit switches The software limit switches are intended to delimit the maximum treasuring range of each individual axis in normal mode 2 software limit switch pairs are provided for each machine axis which are defined via MD POS_LIMIT_PLUS POS_LIMIT_MINUS POS_LIMIT_PLUS2 POS_LIMIT_MINUS2 1st or 2nd software limit switch plus minus in the machine axis system Software limit switch monitoring is active in all modes after reference point approach e The position of the software limit switches can be approached SINUMERIK 802S C base line Description of Functions Axis Spindle Monitoring The 2nd software limit switch can be activated via the interface signal 2nd software limit switch plus minus V380x1000 3 2 from the PLC in order to reduce the working area for example if a tailstock is swinged into position The change becomes active immediately The first software limit switch plus minus is then deactivated Responses The following responses are p
308. wing function is active the spindle is in positioning mode SPOS Related to IS Spindle mode Control Mode V39032002 7 IS Spindle mode Oscillation Mode V39032002 6 V39032002 3 Interface signal Edge evaluation yes Tapping without compensating chuck active Signal s from axis spindle NCK gt PLC Signal s updated cyclically Signal s valid as from SW version Signal status 1 or edge change 0 gt 1 The tapping function G331 G332 is active No response has been provided or the spindle specific signals such as IS Spindle Reset IS Invert M3 M4 IS Spindle within set range IS Set speed increased have not been updated Note During tapping without compensating chuck the following functions should not be used Cancel IS Servo enable Set IS Feed Stop Set IS Reset SINUMERIK 802S C base line 9 47 Description of Functions Spindle 9 48 SINUMERIK 802S C base line Description of Functions Output of Auxiliary Functions to PLC 1 0 Brief description Functions block Block change Continuous path control mode For machining workpieces on a machine tool in addition to axis positions and interpolation types the CNC can also set technological functions feed spindle speed gear stage tool change and functions to control additional equipment on the machine tool e g sleeve open gripper clamp chuck etc
309. y Selection activation Feedback 5 3 1 Skipping Functionality Selection 5 10 If only a certain program section is to be checked the Block Search function can be used to jump to the beginning of the program section concerned After block search the program can be started via the IS NC Start to be provided 2x V32000007 1 Block Search is selected and activated on the operator interface in AUTOMATIC mode As a feedback information that Block Search is active the IS Block search active V33000001 4 is set Note For more information on the Block Search function see Documentation Operation and Programming Certain Part Program Blocks When testing or starting up new programs it is useful to skip certain part program blocks in the program execution Main program subroutine Block just being exe cuted Skipping blocks N40 and N50 during pro gram execution N100 N110 N120 M2 Fig 5 1 Skipping part program blocks The Block Skip function is selected on the operator interface in the Program Control menu Together with the selection the IS Skip block V17000002 0 is set In addition a slash must be set in front of the blocks see Fig 5 1 The function is thus not yet activated SINUMERIK 802S C base line Description of Functions Program mode Activation The function is activated via the IS Activate block skip V32
310. y required for this must be reserved MM_ENC_COMP_MAX_POINTS 0 AXi with AX1 X axis AX3 Z axis The position related compensation values for the axes are stored in a compensation table in the form of system variables The following measuring system specific parameters must be defined for the table see Fig 6 3 Distance between the interpolation points AA_ENC_COMP_STEP 0 AXi The distance between the interpolation points defines the distance between the compensation values of the associated compensation value table meaning e and AXi see above Start position AA_ENC_COMP_MIN 0 AXi The start position is the axis position at which the compensation table for the axis concerned starts 8 interpolation point 0 SINUMERIK 802S C base line Description of Functions Compensation The compensation value associated to the start position is AA_ENC_ COMP 0 0 AXi For all positions less than the start position the compensation value of interpolation point 0 is used not applicable to tables with modulo Compensation value for interpolation point N of the compensation table AA_ENC_COMP e N AXi The compensation value for each individual interpolation point axis position must be entered into the table The interpolation point N is limited by the number of the maximum possible interpolation points of the associated compensation table MM_ENC_COMP_MAX_POINTS The amount of the compensation value is not lim

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