Home

Start-Up 08/2003 Edition - Service, Support

1. 35430 SPIND OSCILL START DIR Starting direction during reciprocation RESET 0 2 As last direction of rotation zero speed M3 3 M3 direction 4 4 direction always 0 0 4 BYTE 2 7 35440 SPIND OSCILL TIME CW S Reciprocation time for direction NEW CONF always 1 0 0 0 plus DOUBLE 2 7 35450 SPIND OSCILL TIME CCW S Reciprocation time for M4 direction NEW CONF always 0 5 0 0 plus DOUBLE 2 7 35500 SPIND ON SPEED AT IPO START Feed enable for spindle in setp Range RESET always 1 0 2 BYTE 2 2 35510 SPIND STOPPED START Feedrate enable for spindle stopped RESET always 0 T S BOOLEAN 2 7 36000 STOP LIMIT COARSE mm Exact positioning coarse NEW CONF deg always 0 04 0 0 plus DOUBLE 2 7 36010 STOP LIMIT FINE mm Exact positioning fine NEW CONF deg always 0 01 0 0 plus DOUBLE 2 7 36020 POSITIONING TIME S Delay exact positioning fine NEW CONF always 1 0 0 0 plus DOUBLE 2 7 36030 STANDSTILL POS TOL mm Zero speed tolerance NEW CONF deg always 0 2 0 0 plus DOUBLE 2 7 36040 STANDSTILL DELAY TIME S Delay zero speed monitoring NEW CONF always 0 4 0 0 plus DOUBLE 2 7 36050 CLAMP POS TOL mm Clamping toler
2. Number MD Name Unit Name Miscellaneous Activated HW function Standard value Minimum value Maximum value D type User class 10074 PLC IPO TIME RATIO PLC task factor for main run POWER ON 2 1 50 DWORD 1 2 7 10240 SCALING SYSTEM IS METRIC Basic system metric POWER ON always 1 i BOOLEAN 2 7 11100 AUXFU MAXNUM GROUP ASSIGN Number of auxiliary functions distr amongst aux POWER groups always 1 1 50 BYTE 2 7 11200 INIT MD HEX Standard machine data loaded on next Power On POWER ON always OxOF 2 7 11210 UPLOAD MD CHANGE ONLY HEX Saving only of modified MD value 0 complete RESTART difference OxOF BYTE 2 7 11310 HANDWH REVERSE Threshold for direction change handwheel POWER ON _always 2 0 0 plus BYTE 2 7 11320 HANDWH_IMP_PER_LATCH Handwheel pulses per detent position handwheel POWER number O 1 always 1 1 DOUBLE 2 7 11346 HANDWH TRUE DISTANCE Handwheel POWER ON always 0 0 3 BYTE 2 2 14510 USER DATA INT n kB User data INT 0 31 POWER ON always 0 DWORD 1 2 7 14512 USER DATA HEX n kB User data Hex 0 31 POWER ON 0 0 OxFF BYTE 2 7 6 4 SI
3. 35150 SPIND DES VELO TOL Factor Spindle speed tolerance RESET always 0 1 0 0 1 0 DOUBLE 2 7 35160 SPIND EXTERN VELO LIMIT rev min Spindle speed limitation from PLC NEW CONF _always 1000 0 0 plus DOUBLE 2 7 35200 GEAR_STEP_SPEEDCTRL_ACCEL 5 2 Acceleration in speed control mode gear stage 0 5 NEW CONF _always 30 30 25 20 15 10 2 DE DOUBLE 2 7 35210 GEAR STEP POSCTRL ACCEL rev s 2 Acceleration in position control mode gear stage NEW CONF 1 5 always 30 30 25 20 15 10 2 Hil DOUBLE 2 7 35220 ACCEL REDUCTION SPEED POINT Factor Speed for reduced acceleration RESET always 1 0 0 0 1 0 DOUBLE 2 7 35230 ACCEL REDUCTION FACTOR Factor Reduced acceleration RESET always 0 0 0 0 0 95 DOUBLE 2 7 35240 ACCEL TYPE DRIVE Type of acceleration RESET 0 0 1 BOOLEAN 2 7 35300 SPIND POSCTRL VELO rev min Position control switch on speed NEW CONF _always 500 0 0 plus DOUBLE 2 7 35350 SPIND_POSITIONING_DIR Direction of rotation when positioning RESET _always 3 3 4 BYTE 2 7 35400 SPIND_OSCILL_DES VELO rev min Reciprocation speed NEW CONF _always 500 0 0 plus DOUBLE 2 7 35410 SPIND OSCILL ACCEL rev s 2 Acceleration during reciprocating NEW CONF always 16 2 dif DOUBLE 2 7 6 12 SINUMERIK 8025 base line Start Up Technical Appendix
4. Number Explanation Default Value 31060 Numerator load gearbox control parameter set 1 0 5 31070 Denominator resolver gearbox encoder 1 31080 Numerator resolver gearbox encoder no 1 32100 Traversing direction not control direction 1 32110 Sign actual value control direction encoder no 1 32200 Servo gain factor control parameter set 0 5 1 32250 Rated output voltage 80 32260 Rated motor speed setpoint branch 0 3000 32700 Interpolatory compensation encoder no 0 1 0 33050 Traversing distance for lubrication from PLC 100 000 000 35010 Gear change possible Spindle has several gear 0 steps 35040 Own spindle reset 0 35100 Maximum spindle speed 10000 35110 Maximum speed for gear change gear stage no 500 0 5 35120 Minimum speed for gear change gear stage no 50 0 5 35130 Maximum speed of gear stage gear stage no 500 0 5 35140 Minimum speed of gearstage gear stage no 5 0 5 35150 Spindle speed tolerance 0 1 35160 Spindle speed limitation from PLC 1000 35220 Speed for reduced acceleration 1 0 35230 Reduced acceleration 0 0 35300 Position control switch on speed 500 35350 Direction of rotation when positioning 3 35400 Reciprocation speed 500 35410 Acceleration during reciprocating 16 35430 Starting direction during reciprocation 0 35440 Reciproc
5. 1400 Retentive Data r w Data block Interface CNC PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 User Data 14000000 User Data 14000001 User Data 14000002 User Data 14000062 User Data 14000063 6 18 SINUMERIK 8025 base line Start Up Technical Appendix 6 2 3 CNC signals 2600 General signals to CNC r w Data block Interface PLC gt Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Protection level 26000000 Acknowl EMER 4 5 6 7 EMER GENCY GENCY STOP STOP Request Request 26000001 distances actual to go by distances the axes to go by the axes 26000002 26000003 2700 General signals from CNC r Data block Interface CNC gt PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 EMER 27000000 GENCY STOP active 27000001 27000002 Drive ready Ambient CNC 27000003 Tempera alarm ture present alarm SINUMERIK 802S base line 6 19 Start Up Technical Appendix 3000 Mode signals to CNC r w Data block Interface PLC CNC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Mode Mode 30000000 Reset Change lock JOG MDA AUTOM Machine function 30000001 REF TEACH IN 30000002 30000003 3100 Mode signals from CNC r Data block Interface CNC
6. 60 5 This frequency must correspond to MD 32000 Supplementary conditions Servo gain The default setting of the servo gain when controlling stepper motors without measuring system is K 2 5 MD 32200 limit approx 2 5 Max stepper motor frequency The max permissible stepper motor frequency is 500 kHz PLC interface signals when using a stepper motor in the controlled mode When using a stepper motor as an axis spindle the PLC interface signals have to be used as follows The Servo enable signal provided via the NC will not be used to turn off the drive Drive Enable is always active This pertains to the following signals 4 36 SINUMERIK 802 base line Start Up Start Up e Servo Enable e Positioning measuring system ON OFF e Parking e responses It is the user s own responsibility to cause the PLC that the appropriate stepper motor drive is brought to Safe Stop or is switched off Rotation monitoring of the stepper motor using BERO Overview Machine data Activation Error case A stepper motor will no longer follow the setpoint if the load torque becomes too large The rotation monitoring is intended to detect this faulty status At the moment when the BERO pulse occurs the stepper motor setpoint position is compared with the BERO actual position and in case of error the Error Rotation monitoring signal is created The rotation monitoring BERO must b
7. Instruction Ladder Symbol Valid Operands Word Add If EN 1 Enable Word Subtract b a b In VW C IW QW b b a MW AC Constant LW Out VW T C IW QW MW AC LW DWord Add If EN 1 Enable EN DWord Subtract b a b In VD ID QD MD b b a AC Constant LD Out VD ID QD MD AC LD Multiply If EN 1 Enable EN b axb In VW T C IW QW MW AC Constant LW Out VD ID QD MD AC LD Divide If EN 1 Enable EN Dab In VW T C IW QW Out MW AC Constant 16 bit remainder LW Out 2 Out VD ID QD MD LD 16 bit quotient Add If EN 1 Enable EN Subtract b a b In VD ID QD MD Real Numbers b b a AC Constant LD Out VD ID QD MD AC LD Multiply If EN 1 Enable EN Divide b axb In VD ID QD MD Real Numbers Constant LD Out VD ID QD MD AC LD INCREMENT DECREMENT Instruction Ladder Symbol Valid Operands Increment If EN 1 Enable Decrement 1 In VB 1 Constant LB Out VB IB QB MB AC LB Increment If EN 1 Enable Decrement 1 In VW T C IW QW Word 1 MW AC Constant LW Out VW T C IW QW MW AC LW Increment If EN 1 Enable Decrement 1 In VD ID QD MD 1 AC Constant LD Out VD ID QD MD AC LD 4 24 SINUMERIK 802S base line Start Up Start Up LOGIC OPERATIONS Instruction La
8. 0 255 wor BYTE COMPARES Unsigned Instruction Ladder Symbol Valid Operands Load Byte a b close a VB IB MB And Byte a b open SMB AC Constant Or Byte b LB Load Byte b close a b VB IB MB And Byte a lt b open 1 d SMB AC Constant Or Byte b LB Load Byte b close And Byte a gt b open lt H Or Byte SINUMERIK 8025 base line 4 21 Start Up Start Up 4 22 WORD COMPARES Signed Instruction Ladder Symbol Valid Operands Load Word b close a a VW T C IW QW And Word b open Fr MW AC Constant Or Word b LW Load Word al b close a b VW C IW QW And Word a lt bopen H MW AC Constant Or Word b LW Load Word b close a Word a gt b open lt H Or Word b DOUBLE WORD COMPARES Signed Instruction Ladder Symbol Valid Operands Load DWord a b close a a VD ID QD MD And DWord a b open 4 AC Constant LD Or DWord b b VD ID QD MD Load DWord a b close AC Constant LD And DWord a lt b open gt lt Or DWord 4 e Load DWord b close a And DWord a gt b open lt Or DWord E REAL WORD COMPARES Signed Instruction Ladder Symbol Valid Operands Load RWord b close a a VD ID QD MD And RWord a b open AC Constant LD Or RWord b VD ID QD MD Load RWord b close a AC Constant LD And R
9. gt Bit 2 Bit 1 Bit 0 380x5000 stepper motor Rotation monitoring 380x5001 stepper motor 380x5002 380x5003 SINUMERIK 802S base line Start Up 6 29 Technical Appendix General signals from axis spindle 3900 3903 Signals from axis spindle r Data block Interface CNC PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Position reached Referen Encoder Spindle 390x0000 with exact with exact ced limit no axis pos pos Synchro frequency fine coarse nized 1 exceeded 1 Speed Axis spin Follow up dle active 390x0001 Current controller Position stopped controller controller active active active n lt nq 390x0002 390x0003 Motion command Handwheel active 390x0004 plus minus 2 1 Active machine function 390x0005 Continu 1000 100 10 1 ous INC INC INC INC 390x0006 390x0007 Signals from axis 3900 3903 Signals from axis r Data block Interface CNC PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 390x1000 axis 390x1001 axis 390x1002 Lubrica axis tion pulse 390x1003 axis 6 30 SINUMERIK 8025 base line Start Up Technical Appendix Signals from spindle 3903 Signals from spindle r Data block Interface CNC PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3
10. 30 max 300 mA SINUMERIK 802 base line Start Up Cable lengths 2 3 3 Installing the Control System The maximum cable length depends on the specifications of the encoder power supply and on the transmission frequency To provide fault free operation make sure that the following values are not exceeded when using preassembled interconnecting cables from SIEMENS Table 2 6 Maximum cable lengths depending on the encoder power supply Supply Voltage Tolerance Current Consumption Sho 5V DC 4 75 V 5 25 V lt 300 mA 25m 5V DC 4 75 V 5 25 V lt 220 mA 35m Table 2 7 Maximum cable lengths depending on the transmission frequency Encoder Type Frequency Max Cable Length incremental 1 MHz 10m 500 kHz 35m Configuration of the RS232 interface connection X2 Pin assignment of connector on the CNC side RS232 interface Connector designation X2 RS232 9 pin sub D plug connector Table 2 8 Pin assignment of connector X2 Connector type Pin Name Pin Name Type 1 6 DSR 2 RxD 7 RTS 1 3 TxD 8 CTS 9 5 6 4 DTR 9 5 VO Signal description RxD Receive Data TxD Transmit Data RTS Request to send CTS Clear to send DTR Data Terminal Ready DSR Data Set Ready M Ground Signal level RS232 SINUMERIK 802S base line 2 11 Start Up Installing the Control System Cable for WinPCIN
11. then connect a 24 V voltage PELV to the 24 V and 24 V GND terminals SINUMERIK 802 base line Start Up Installing the STEPDRIVE 3 3 Starting up the drive modules Prerequisite e Proper connection of the cables as shown in Fig 3 2 Setting of the current accordance with the motor type using the DIL switch DIP switch gene Z1 gt 3 CURRI i B cunno p res XLI or 3 Motor Type CURR 1 CURR 2 Phase Curr Stepper Driver 55 Na n 9 Nm OFF STEPDRIVE C 25 Nm ON ON 5 00 A Warning AN If the current is set too large for the motor the motor can be damaged due to overtemperature Start up sequence 1 Connect the mains voltage and if necessary also the 24 V supply voltage 2 Check the DIS LED 3 Activate the ENABLE signal via the control system power up the control system The yellow DIS LED goes out and the green RDY LED is lit The drive is ready the motor is powered If the PULSE signal is provided by the control system with pulses then motor will rotate in the direction of rotation specified by the DIR signal Notice The DIP switch can be used to adapt the direction of rotation to the mechanics of the machine Never actuate the switch when the drive is powered SINUMERIK 802S b
12. 2 12 Signal type O VO Input Output Voltage output Table 2 9 Cable for WinPCIN Pin assignment of the Sub D connector 9 Pin Shield Name 25 Pin RxD TxD DTR M DSR RTS CTS BR OT DO Po O1 BR Oo Po 9 Pin Shield Name 9 Pin RxD TxD DTR DSR RTS CTS PO GO O01 BR Oo Po gt base line Sub D PC 9 Sub D 802 S C base line PC 9 pin Sub D 25 pin Sub D TxD RxD DSR 0 DTR CTS RTS ta ON t2 c0 mm 1 OW ta amp Fig 2 5 Communication connector RS232 X2 SINUMERIK 802 base line Start Up Installing the Control System 2 3 4 Connecting handwheels X10 Pin assignment of connector on the CNC side Handwheel interface Connector designation X10 MPG 10 pin mini Combicon plug connector Table 2 10 Pin assignment of connector X10 Connector type X10 Pin Name Type 1 A1 1 2 A1 3 B1 4 B1 5 5 5 VO 6 M5_MS VO 7 A2 8 A2 N 9 B2 10 10 2 Signal names A1 A1 N Track A true and negated handwheel 1 B1 B1 N Track B true and negated handwheel 1 A2 2 Track true and negated handwheel 2 B2 B2
13. Aborting when loading MD If incorrect machine data files are read into the control system an alarm is output At the end of reading an alarm with the number of errors is displayed 4 1 4 Data saving Internal data saving The data in the memory backed up for a limited period can be saved internally 4 4 in the permanent memory of the control system An internal data backup should be carried out if the control system has been switched off for more than 50 hours at least 10 min day with controller ON It is recommended to carry out internal data saving whenever important data changes have been made Notice During the internal data backup a memory copy of the memory backed up for a limited time is made and stored in the permanent memory Selective data backup e g only the machine data and not the part programs is not possible Saving data internally Use the ETC key to extend the menu in the Diagnosis Start up menu and press the Save data softkey Loading data from an internal data backup Boot the control system using the start up switch position 3 SINUMERIK 802 base line Start Up External data saving Start Up If the data in the backed up memory area is lost on POWER ON the data saved in the permanent memory area are automatically reloaded into the memory Notice The note 4062 Data backup has been loaded appears In addition to the internal data backup the user data of the control sy
14. PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Active mode 31000000 READY JOG MDA AUTOM Active machine function 31000001 REF TEACH IN 6 20 SINUMERIK 802 base line Start Up Technical Appendix 6 2 4 Channel signals Control signals to CNC channel 3200 Signals to CNC channel r w Data block Interface PLC CNC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Activate Activate Activate 32000000 dry run 01 Single feed Block Activate Activate 32000001 Program Referenc Test ing Activate 32000002 Skip Block 32000003 Feed override 32000004 H G F E D C B A Rapid traverse override 32000005 H G F E D C B A Feed Rapid Program Delete Read in Feed 32000006 override traverse level distance disabled lock enabled override abortion to go enabled CNC stop CNC stop 32000007 axes plus stop to block start oN Srail in inhibited spindle limit Notes D Feed override enabled Even if the feed verrideisnot enabled 210094 the 0 position is active 24 Feed override 31 positions Gray code with 31 MD for weighting 9 Rapid traverse override 31 positions Gray code with 31 MD for 96 weighting 4 Single Block Use the softkey to select Single Block Type Preselection SBL1 SBL2 see User Manual SINUMERIK 8025 base line Start Up 6 21 Technical Appendix Control signals to axes in
15. SRS Fig 3 1 Mounting dimensions SINUMERIK 8025 base line Start Up 3 2 Cabling Cable overview Installing the STEPDRIVE Connect the STEPDRIVE C C drive modules the BYG stepper motors and the SINUMERIK 8025 base line control system as shown in Fig 3 2 Drive of axis 2 1 2 8 E oO o E E E 5 Hr amp C uL CURR 1 BE GHR SINUMERIK 8025 DIR LS DR i M RDY or base line BOY Preassembled cable Or FLT L FELT 6FX2002 3AD02 1xx0 OF DIS L pis X P1 P2 d D2 Es a EIN N 230 85 VAC transformer 230VAC N PE Fig 3 2 Overview of cables Warning Prior to performing connection work always first make sure that the supply voltage is sw
16. 380x0001 Override Position Follow up spindle enabled encoder 1 mode lock Clamping Delete 380x0002 process distance Servo running to go enable spindle reset Speed 380x0003 spindle speed limitation Traversing keys Rapid Travers Activate handwheel 380x0004 traverse ing Stop plus minus override Spindle 2 1 lock stop Machine function 380x0005 Continu 1000 100 10 1 ous INC INC INC INC 380x0006 380x0007 Signals to axis 3800 3802 Signals to axis r w Data block Interface PLC CNC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Delay 2nd software limit switch Hardware limit switch 380x1000 Ref point axis plus minus plus minus 380x1001 axis 380x1002 axis 380x1003 axis 6 28 SINUMERIK 8025 base line Start Up Signals to spindle Technical Appendix 3803 Signals to spindle r w Data block Interface PLC CNC Byte Bit 7 Bit 6 Bit 5 Bit4 Bit 3 Bit 2 Bit 1 Bit 0 Gear is Actual gear stage 38032000 changed spindle C B A Spindle feed 38032001 Invert override spindle M3 M4 valid Set direction of rotation Recipro Recipro 38032002 cating cating spindle CCW CW speed by PLC Spindle override 38032003 spindle H G F E D Signals to stepper motor Byte 3800 3803 Data block Bit 7 Bit 6 Bit 5 Signals to axis spindle r w Interface PLC Bit 4 Bit 3
17. Data block Interface CNC PLC Byte 45003000 Alarm reaction clear criterion of alarm 700000 45003001 Alarm reaction clear criterion of alarm 700001 45003002 Alarm reaction clear criterion of alarm 700002 45003031 Alarm reaction clear criterion of alarm 700031 SINUMERIK 802 base line 6 37 Start Up Technical Appendix 6 2 9 User alarm Alarm activation 1600 Alarm activation r w Data block Interface PLC MMC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Activation of alarm no 16000000 700007 700006 700005 700004 700003 700002 700001 700000 Activation of alarm no 16000001 700015 700014 700013 700012 700011 700010 700009 700008 Activation of alarm no 16000002 700023 700022 700021 700020 700019 700018 700017 700016 Activation of alarm no 16000003 700031 700030 700029 700028 700027 700026 700025 700024 Variable for alarm 1600 Variable for alarm r w Data block Interface PLC MMC Byte 16001000 Variable for alarm 700000 16001004 Variable for alarm 700001 16001008 Variable for alarm 700002 16001116 Variable for alarm 700029 16001120 Variable for alarm 700030 16001124 Variable for alarm 700031 6 38 SINUMERIK 802 base line Start Up Active alarm response Technical Appendix 1600 Active alarm response r Data
18. SINUMERIK 802 base line Start Up SINUMERIK 8025 base line 1 Control System 1 1 Components of the SINUMERIK 8025 base line What is SINUMERIK 8025 base line The SINUMERIK 802S base line is a microprocessor controlled numerical control system for economic machine tools with stepper motor drives Hardware components The SINUMERIK 802S base line is a compact CNC unit It consists of the following areas see figure 1 1 seAuq deis S ERRA External spindle drive Step motors Fig 1 1 Components of SINUMERIK 8025 base line turning variant SINUMERIK 8025 base line 1 1 Start Up SINUMERIK 8025 base line Control System Software components The SINUMERIK 8025 base line comprises the following software components which can be ordered e System software on the permanent flash memory of the CNC Boot software loads the remaining system software from the permanent memory into the user memory DRAM and starts the system software Man Machine Communication implements all operating functions software NC Kernel implements all NC functions This software controls an NC channel with a maximum of 3 movement axes and a spindle software Programmable Log
19. Technical Appendix Notice If your system 802C base line equips with 611 drive s that are not configured the drive ready signal will not be available The result is you can not release emergency stop It is possible for you either to connect a high signal to 11 7 or simply specify MD14512 16 bit0 1 so that you can quit from emergency stop 6 54 SINUMERIK 802 base line Start Up Technical Appendix 6 4 Unipolar spindle A spindle that requires not a positive voltage of 10 volts but a positive voltage and separate binary sign signals for controlling is called unipolar spindle The voltage is output via the analog spindle setpoint output and the sign signals via binary outputs The 802SC base line is able to run a unipolar spindle Configuring 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 Special features SINUMERIK 8025 base line Start Up MD input value 0 Bipolar setpoint output with positive negative voltage The PLC output bits 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 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
20. The control system changes to the JOG Ref point approach mode and the yellow LED DIAG flashes see Fig 2 6 This initial state is the precondition for error free start up of the control system When the control system is already turned on start up is also possible in the Diagnosis menu see User Manual Normal booting Start up switch position 0 Booting with default machine data Start up switch position 1 Result User data exist no Control system changes to boot error JOG Ref point approach mode yellow LED DIAG see Fig 4 1 flashes Data in user memory Backed up user data are loaded from the permanent faulty memory into the user memory as in start up switch position 3 If no valid user data are in the permanent memory the default data are loaded as in start up switch position 1 Any deviations from normal booting are displayed on the screen Result The user memory area not loaded with default data is erased and the default machine data are loaded from the permanent memory into the user memory Booting with saved data Start up switch position 3 Contrast control Result The user data backed up on the permanent memory are loaded into the user memory See User s Guide Operation and Programming SINUMERIK 8025 base line 4 7 Start Up Start Up 4 2 1 Boot messages Displays on the screen When the control system is booting test patterns or boot infor
21. override override override override defined defined defined defined SINUMERIK 802S base line 6 35 Start Up Technical Appendix 6 2 8 PLC machine data INT values MD 14510 USER DATA INT 4500 Signals from Data block Interface CNC PLC Byte 45000000 Int value WORD 2 bytes 45000002 Int value WORD 2 bytes 45000004 Int value WORD 2 bytes 45000006 Int value WORD 2 bytes 45000060 Int value WORD 2 bytes 45000062 Int value WORD 2 bytes HEX values MD 14512 USER_DATA_HEX 4500 Signals from CNC Data block Interface CNC gt PLC Byte 45001000 Hex value BYTE 45001001 Hex value BYTE 45001002 Hex value BYTE 45001003 Hex value BYTE 45001030 Hex value BYTE 45001031 Hex value BYTE 6 36 SINUMERIK 802S base line Start Up Technical Appendix FLOAT values MD 14514 USER DATA FLOAT 4500 Signals from Data block Interface CNC PLC Byte 45002000 Float value REAL 4 bytes 45002004 Float value REAL 4 bytes 45002008 Float value REAL 4 bytes 45002012 Float value REAL 4 bytes 45002016 Float value REAL 4 bytes 45002020 Float value REAL 4 bytes 45002024 Float value REAL 4 bytes 45002028 Float value REAL 4 bytes HEX BYTE values MD 14516 USER DATA PLC ALARM 4500 Signals from
22. 0 Zero mark monitoring off encoder HW monitoring on 1 99 gt 100 Number of recognized zero mark errors during monitoring 100 Zero mark monitoring off encoder HW monitoring off always 0 0 0 0 plus DWORD 2 7 6 14 SINUMERIK 8025 base line Start Up Technical Appendix 36400 CONTOUR TOL mm Contour monitoring tolerance band NEW CONF deg always 1 0 dd ur DOUBLE 2 2 36500 ENC CHANGE TOL mm deg Portion of distance for backlash working NEW CONF always 0 1 0 0 plus DOUBLE 2 7 36610 AX EMERGENCY STOP TIME S Duration of the deceleration ramp for error states NEW CONF always 0 05 0 0 plus DOUBLE 2 7 36620 SERVO DISABLE DELAY TIME S Cutout delay servo enable NEW CONF always 0 1 0 0 plus DOUBLE 2 7 36700 DRIFT ENABLE Automatic drift compensation NEW CONF always 0 P ids BOOLEAN 2 7 36710 DRIFT LIMIT 96 Drift limit value for automatic drift compensation NEW CONF always 1 000 0 0 plus DOUBLE 2 7 36720 DRIFT VALUE 96 Drift basic value NEW CONF always 0 0 DOUBLE 2 7 38000 MM ENC COMP MAX POINTS Number of intermediate points for interpolatory POWER compensation SRAM _always 0 0 0 5000 DWORD 2 7 SINUMERIK 802S base line 6 15 Start Up Technical Appendix
23. 0 1 POWER ON always 0 PA BOOLEAN 2 7 32900 DYN MATCH ENABLE Dynamic response adaptation NEW CONF 0 1 BYTE 2 7 32910 DYN MATCH TIME Time constant of dynamic adaption control parameter set NEW CONF no 0 5 0 0 0 plus DOUBLE 2 7 32920 AC FILTER TIME S Smoothing factor time constant for adaptive control POWER ON always 0 0 0 0 plus DOUBLE 2 7 33050 LUBRICATION DIST mm Traversing distance for lubrication from PLC NEW CONF deg always 100000000 0 0 plus DOUBLE 2 7 34000 REFP CAM IS ACTIVE Axis with reference point cam RESET always 1 Eus Hus BOOLEAN 2 7 34010 REFP CAM DIR IS MINUS Approach reference point in minus direction RESET always abis bii BOOLEAN 2 7 SINUMERIK 8025 base line 6 9 Start Up Technical Appendix 34020 REFP VELO SEARCH CAM mm min Reference point approach velocity RESET rev min always 5000 0 0 0 plus DOUBLE 2 7 34030 REFP MAX CAM DIST mm Maximum distance to reference cam RESET deg always 10000 0 0 0 plus DOUBLE 2 7 34040 REFP VELO SEARCH MARKER mm min Creep speed encoder no RESET rev min always 300 0 0 0 plus DOUBLE 2 7 34050 REFP SEARCH MARKER REVERSE Direction reversal to reference cam
24. 0 3 0 7 Byte 219 MM USER CLASS DIR ACCESS Decimal User class access directory Immediately 2 3 0 3 0 7 Byte 243 V24 PG PC BAUD Bit PG Baud rate 300 600 1200 2400 4800 9600 Immediately 3 3 19200 38400 7 0 7 Byte 277 MM USER CLASS PLC ACCESS Decimal User class access PLC project Immediately 2 3 0 3 0 7 Byte 6 2 SINUMERIK 8025 base line Start Up Technical Appendix 278 MM NCK SYSTEM FUNC MASK Decimal Option data to enable system specific functions POWERON 12 2 0 0 0 15 Byte 280 MM V24 PPI ADDR PLC Decimal PPI address of the PLC POWERON 13 3 0 2 0 126 BYTE 281 MM V24 PPI ADDR NCK Decimal PPI address of the NCK POWERON 3 3 0 3 0 126 BYTE 282 MM V24 PPI ADDR MMC Decimal PPI address of the HMI POWERON 13 3 0 4 0 126 BYTE 283 MM V24 PPI MODEM ACTIVE Decimal Modem active Immediately 3 3 0 0 0 1 BYTE 284 MM V24 PPI MODEM BAUD Decimal Modem baud rate Immediately 3 3 0 7 5 9 285 MM V24 PPI MODEM PARITY Decimal Modem parity Immediately 3 3 0 0 0 2 BYTE 288 MM STARTUP PICTURE TIME Decimal Average time of start up picture visibility POWER 2 2 second 0 5 0 10 BYTE SINUMERIK 8025 base line 6 3 Start Up Technical Appendix 6 1 2 General machine data
25. 1 25000002 25000003 SINUMERIK 8025 base line 6 25 Start Up Technical Appendix Decoded M signals MO M99 2500 M functions from CNC channel r Data block Interface CNC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Dynamic M functions 25001000 M7 M6 M5 M4 M3 M2 M1 Dynamic M functions 25001001 M15 M14 M13 M12 M11 M10 M9 M8 Dynamic M functions 25001002 M23 M22 M21 M20 M19 M18 M17 M16 Dynamic M functions 25001012 M99 M98 M97 M96 25001013 25001014 25001015 Notes Static M functions must be generated by the PLC user from the dynamic M functions Dynamic M functions are decoded by the basic program to M99 6 26 SINUMERIK 8025 base line Start Up Technical Appendix Transferred T functions 2500 T functions from CNC channel r Data block Interface PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 25002000 T function 1 DINT 25002004 25002008 25002012 SINUMERIK 8025 base line 6 27 Start Up Technical Appendix 6 2 5 Axis spindle signals Signals to axis spindle Common signals to axis spindle 3800 3803 Signals to axis spindle r w Data block Interface PLC CNC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Feed override 380x0000 H G F E D
26. 4 31070 MD 31060 360 1 1 Internal resolution x 1000pulses deg 43 945 4 x 2048 1 1 One encoder increment corresponds to 43 945 internal increments encoder increment corresponds to 0 043945 degrees minimum positioning step Spindle setpoint adaptation To adapt the spindle setpoint and its gear stage the following axis MD and interface signals are relevant Number Description 32010 Rapid traverse in jog mode 32020 Jog axis velocity 35110 Maximum speed for gear change gear stage no 0 5 35120 Minimum speed for gear change gear stage no 0 5 35130 Maximum speed of gear stage gear stage no 0 5 35140 Minimum speed of gearstage gear stage no 0 5 35200 Acceleration in speed control mode gear stage no 0 5 31060 Numerator load gearbox control parameter set no 0 5 31050 Denominator load gearbox control parameter no 0 5 Interface signals Switch gear 39032000 bit 3 Actual gearstage 38032000 bits 0 through 2 No speed monitoring when switching the gear 38032000 bit 6 Gear has been switched 38032000 bit 3 Setpoint gear stage 39032000 bits 0 through 2 Positioning mode 39032002 bit 5 Reciprocation by PLC 38032002 bit 4 Reciprocation mode 39032002 bit 6 Control mode 39032002 bit 7 Traversing minus 39030004 bit 6 Traversing plus 39030004 bit 7 The default settings of th
27. 6 1 5 Setting data Number MD Name Unit Name Miscellaneous Activated HW function Standard value Minimum value Maximum value D type User class 41110 JOG SET VELO mm min Axis speed for JOG Immediately always 0 0 0 0 plus DOUBLE 4 4 41200 JOG SPIND SET VELO rev min Speed for spindle JOG mode Immediately _always 0 0 0 0 plus DOUBLE 4 4 43210 SPIND MIN VELO G25 rev min Progr spindle speed limitation G25 Immediately always 0 0 0 0 plus DOUBLE 4 4 43220 SPIND MAX VELO G26 rev min Progr spindle speed limitation G26 Immediately _always 1000 0 0 plus DOUBLE 4 4 43230 SPIND MAX VELO LIMS rev min Spindle speed limitation with G96 Immediately _always 100 0 0 plus DOUBLE 4 4 52011 STOP_CUTCOM_STORE Alarm response for TRC and feedforward stop Immediately 1 0 1 BOOLEAN 4 4 6 16 SINUMERIK 8025 base line Start Up Technical Appendix 6 2 PLC user interface signals The following tables of the user interface signals between PLC and CNC and vice versa are handled by the integrated fixed user program These signals can be displayed using PLC Status in the Diagnosis Start Up PLC Status menu 6 2 1 Address ranges Operand Identifier Description Range V Data V0 0 to V79999999
28. F z z mi FLX af slfe Fut Kloe ed bes iin alta Efe E x Wizi 379 e 5 e 181 9 e 22 1 7 i Fig 2 1 Mounting dimensions for 8025 base line SINUMERIK 802 base line Start Up Installing the Control System T 3 E E mS m 70 1 M 3540 15 4 1 270 _ 1 27740 15 ct 1 Thread plugging M4 or 25 hole 8x Fig 2 2 Mounting dimensions for 8025 base line SINUMERIK 802 base line 2 3 Start Up Installing the Control System 2 2 Interfaces and cables Position of the interfaces and elements 3s BEER IFTE EJ EJ E PHHHEHHHHH rien HIGHER z 5 x E 8 X102 X103 X104 X200 X201 x2 PINDLE MPG BERO DINO DIND DIN3 DIN4 DINS DOUTO DOUTA 85232 8 9 ok SIEMENS Fig 2 3 Rear of CNC system Interfaces CNC X1 power supply terminals DC24V 3 pin screw type term
29. Move DWord If EN 1 Enable EN copy i to o In VD ID QD MD AC Constant LD Out VD ID QD MD AC LD Move Real If EN 1 Enable EN copy i to o In VD ID QD MD AC Constant LD Out VD ID QD MD AC LD Swap Bytes If EN 1 SWAP Enable EN exchange MSB In VW IW QW MW T and LSB of w ENED C AC LW Program organization Each programmer should divide the user program into several closed program sections subroutines The S7 200 programming language allows the user to create structured user programs There are two program types main programs and subroutines Eight program levels are possible A PLC cycle can be a multiple of the control internal interpolation cycle IPO cycle The machine manufacturer must set the PLC cycle according to his her own requirements see machine data PLC TIME RATIO The ratio IPO PLC of 1 1 is the fastest possible cyclic processing Example The programmer programs a sequence control in the main program using his own defined cycle counter The sequence control defines all cyclic signals in the subroutine UP1 UP2 is called every two cycles and UP controls all signals in steps of three cycles SINUMERIK 8025 base line 4 27 Start Up Start Up 4 3 8 4 3 9 4 3 10 4 28 Data organization The data can be divided into three areas e non retentive data e retentive data machine data for the PLC All these machine data are active
30. SINUMERIK 8025 base line Start Up Contents Software Update Updating the system software using a PC PG Update errors 5 1 5 2 Technical Appendix 6 1 6 1 1 6 1 2 6 1 3 6 1 4 6 1 5 6 2 6 2 1 6 2 2 6 2 3 6 2 4 6 2 5 6 2 6 6 2 7 6 2 8 6 2 9 6 3 1 6 3 2 6 3 3 6 3 4 6 3 5 6 3 6 6 3 7 6 4 List of machine and setting data eee Display machine data eee emen General machine data eee eee miners RUE ES Ea Lata eae Channel specific machine data emen Axis specific machine data eene Setting data PLC user interface signals VR CRGA IA UP TA ER Re RARE HARE RARE FA aE Lee AHEAD E OE ade Address ranges Retentive data area eee meme meme meme misi mesi CNC signals gt Channel signals Axis spindle signals Signals from to eem meme mem emm mimis PES PES Machine control panel signals MCP signals PLC machine data eee mem meme mimis User alarm PLC user program for turning SAMPLE EORR CA UR eee rr erence ee eee Function veers Input output configuration emen Definition of user Keys meer nene PLC machine data eee eme meme memini nie nein nne SAMPLE program structure eee nee User alarm Start Up of SAMPLE program mmm Unipolar spindle
31. This is possible using the Programming Tool 802 e WinPCIN binary file PT PLC 802 Download Upload Compare PLC user texts WINPCIN Series start up Fig 4 5 PLC applications in the control system Download This function is used to write the transferred data to the permanent memory load memory of the control system Download the PLC project using the PLC 802 Programming Tool Step 7 connect on Series start up using the WinPCIN tool PLC MD PLC project and user alarm texts Data In SINUMERIK 802 base line 4 29 Start Up Start Up Upload Compare Versions display 4 30 The loaded PLC user program is transferred from the permanent memory to the user memory when the control is booted next time it will be active from this moment The PLC applications can be saved using the PLC 802 Programming Tool or the tool WINPCIN Upload PLC project using the PLC 802 Programming Tool Step 7 connect on Read out the project from the control system to reconstruct the current project in the PLC 802 Programming Tool Series start up Start up Data using the tool WINPCIN PLC MD PLC Project and user alarm texts Data Out Read out PLC applications using the Tool WINPCIN PLC Project information and user alarm texts Data Out The project in the PLC 802 Programming Tool is compared with the project contained in the permanent memory load memory of the CNC Calling via
32. Track B true and negated handwheel 2 P5 MS 5 2 V supply voltage for handwheels M Supply ground Signal level RS422 Signal type VO Voltage output Input 5 V signal Handwheels Two electronic handwheels can be connected which must meet the following requirements Transmission method 5 V square wave TTL level or RS422 Signals Track as true and negated signal U Track B as true and negated signal Max output frequency 500 kHz Phase offset between tracks A and B 90 30 Supply 5 V max 250 mA SINUMERIK 802 base line 2 13 Start Up Installing the Control System 2 3 5 Connecting BERO and NC READY X20 Pin assignment of connector on the CNC side 4 BERO inputs NC READY output 2 14 BERO input interface Connector designation X20 DI Connector type 10 pin plug connector Table 2 11 Pin assignment of connector X20 X20 Pin Signal Type 1 NCRDY 1 K 11 2 NCRDY 2 K O 3 I0 BERO1 DI 4 I1 BERO2 DI 5 12 DI 2 6 BERO4 DI 5 7 14 MEPU1 Not defined 8 MEPU2 Not defined 9 L VI O 10 L VI Signal description NCRDY 1 2 NC READY Contact max current is 2A at 150VDC or 125VAC 10 15 Fast digital input 0 5 BERO1 BERO4 BERO Input for axis 1 4 L Reference potential for digital input Signal type K Switching contact These inputs are 24V P switching Switches or non
33. 7 see below T Timers TO to T15 C Counters to C31 Image of digital inputs 10 0 to 17 7 Q Image of digital outputs Q0 0 to Q7 7 M Flags 0 0 to M127 7 SM Special flags 5 0 0 to SM 0 6 see below AC ACCU ACO AC3 Generating the V address range Type Range No EN Channel Axis No Subrange Offset Addressing 10 00 0 000 symbolic 10 79 00 99 0 9 000 999 8 digit Definition of special flag bits SM read only SM Bits Description SM 0 0 Flags with a defined ONE signal SM 0 1 Initial position first PLC cycle 1 following cycles 0 SM 0 2 Buffered data lost only valid in the first PLC cycle 0 data o k 1 data lost SM 0 3 Power On first PLC cycle 1 following cycles 0 SM 0 4 60 s clock alternating 0 for 30 s then 1 for 30 s SM 0 5 1 s clock alternating 0 for 0 5 s then 1 for 0 5 s SM 0 6 PLC cycle clock alternating one cycle 0 then one cycle 1 Notice All empty user interface fields in the following tables are Reserved for SIEMENS and may neither be written nor evaluated by the user All fields with a 0 contain the value logic Variable access rights r is used to mark a read only range r w is used to mark a read write range SINUMERIK 802 base line 6 17 Start Up Technical Appendix 6 2 2 Retentive data area
34. Bit 2 Bit 1 Bit 0 Set gear stage 39032000 Change gear spindle C B A Actual Spindle Set Set Speed direc tion 39032001 of within set speed speed limit rotation spindle range increased limited exceeded Active spindle mode Tapping 39032002 Control Recipro Position without cating ing compen sating spindle mode mode chuck 39032003 spindle Signals from Stepper motor 3900 3903 Signals from stepper motor r Data block Interface CNC PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Rotation 390x5000 monitoring Stepper error motor 390x5001 Stepper motor 390x5002 390x5003 SINUMERIK 802 base line 6 31 Start Up Technical Appendix Axis actual value and distances to go VD570 Signals from axis spindle r PLC variable Interface CNC PLC Byte Bit 7 Bit 0 570x0000 AXIS Axis actual values actual values 570 0004 Axis S dist nces Axis distances to go to go 6 32 SINUMERIK 802 base line Start Up Technical Appendix 6 2 6 Signals from to MMC Program control signals from MMC retentive area see also signals to channel V32000000 1700 MMC signals r Data block Interface MMC PLC DBB Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Dry run 17000000 f
35. Notice For installation refer to the installation notes provided in the section 2 The control system with its components has powered up without errors Start up sequence SINUMERIK 8025 base line can be strated up as follows 1 Check whether the ENC has powered up PLC start up Technology setting Set general machine data Set axis machine specific machine data Match encoder with spindle Match setpoint with spindle 6 Dry run for axes and spindle s Drive optimization 8 Complete start up data saving SINUMERIK 8025 base line 4 1 Start Up Start Up 4 1 1 Access levels Protection levels Protection levels 2 Protection levels 4 4 2 The SINUMERIK 802S base line provides a protection level concept for enabling data areas The protection levels range from 0 to 7 whereby 0 is the highest and 7 the lowest level The control system comes with default passwords for protection levels 2 and 3 If necessary these passwords can be changed by the appropriate authorized person Table 4 1 Protection level concept Disabled via Data Area 0 Siemens reserved 1 Siemens reserved 2 Password EVENING default Machine manufacturer 3 Password CUSTOMER default Authorized operator setter 4 No password or Authorized operator setter user IS from PLC gt 5 User IS from PLC 6 User IS from PLC gt 7 Us
36. OK appeared on the screen 6 the start up switch S3 to position 1 start up with standard data switch on the control system again 7 Prior to the next POWER ON gt start up switch to O position Notice Reload the externally saved user standard data via V24 SINUMERIK 8025 base line 5 1 Start Up Software Update 5 2 Update errors Table 5 1 Update errors Error Text Explanation Remedial Action ERROR Error when updating the system software e Repeat UPDATE via V24 update Data already in receive buffer send e Check link from PC side started too early between Error when erasing the FLASH control memory System and Error when writing to the FLASH PC PG memory e Check Inconsistent data incomplete or Toolbox faulty SINUMERIK Update without programming the code 8025 base FLASH completed no data received line transfer not started UPDATE NO DATA SINUMERIK 802 base line Start Up Technical Appendix 6 6 1 List of machine and setting data Data type BOOLEAN Machine data bit 1 or 0 BYTE Integer values from 128 to 127 DOUBLE Real and integer values from 4 19 x 10 597 to 1 67 x 10 DWORD Integer values from 2 147 x 10 to 2 147 x 10 STRING Character string max 16 characters consisting of upper case letters with digits and underscore UNSIGNED WORD Integer values from 0 to 65536 SIGNED WORD Integer values from 32768 to 32767
37. Start up current 4 A Weight Table 1 2 Weight Component Weight g CNC 4500 Dimensions Table 1 3 Component dimensions Component Dimensions LxWxD mm CNC 420 x 300 x 83 Environmental operating conditions Table 1 4 Environmental operating conditions Parameter Temperature range 0 55 Permissible relative humidity 5 95 without condensation Air pressure 700 1 060 hPa The operating conditions comply with IEC 1131 2 Installation in a housing e g cubicle is absolutely necessary for operation Transport and storage conditions Table 1 5 Transport and storage conditions Parameter Temperature range Transport 40 70 Storage 20 55 C Permissible relative air humidity 5 95 without condensation Air pressure 700 1 060 hPa Transport height 1 000 3 000 m Free fall in transport package 1 200 mm Protective quality and degree of protection Class of protection to IEC 536 No PE terminal required Foreign matter and water protection to IEC 529 For CNC IP 54 front IP 00 rear SINUMERIK 802 base line 1 3 Start Up SINUMERIK 8025 base line Control System 1 4 SINUMERIK 802 base line Start Up Installing the Control System 2 2 1 Installing and Dismantling the SINUMERIK 8025 base line Do not install when the equipment is under power The modules contain electrostatically sensitive devi
38. Up Technical Manual Description of Functions ESA Turning Start Up Milling
39. application program consisted of subroutine library It has two purposes be applied for machines directly the user can realize the functions only by setting PLC machine datas It acts as sample program to help users learn how to creat his own programs with the use of subroutine library Of course users can modify the program as well to meet their paticular needs All the inputs and outputs of the sample program are handled by filters The user can search for inputs and outputs without the use of filters for his own program consisted with subroutine library Measuring system 1 active Feed override to channel and axis active Validity of PLC parameter check Range of PLC parameter verification calling SBR31 USR INI Emergency stop control 6 40 Emergency stop button processing e Control the timing of T48 T63 and T64 of supply infeed module e Monitor status signals of infeed module T72 drive ready and 52 2 alarm these signals will also generated emergency stop SINUMERIK 802 base line Start Up Technical Appendix Processing MCP and HMI signals Axes control Operating mode selection NC start stop and reset Spindle manual operate control spindle CW CCW and Stop Traverse key layout according PLC parameters Selecting handwheel according to HMI interface SBR39 HW Axes enable and disable control including spindle Hardware limitation single or double hardware l
40. block Interface PLC MMC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Feed Read in start lock disable inhibited 16002000 PLC NOT of all axes STOP AUS 16002001 16002002 16002003 Axis actual value and distances to go 5700 5704 Signals from axis spindle r Data block Interface PLC MMC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 570 0000 Axis actual value REAL 570x0004 Axis distance to go REAL SINUMERIK 8025 base line 6 39 Start Up Technical Appendix 6 3 PLC user program for turning SAMPLE General A Purpose 6 3 1 Function PLC Initialization After the connection of individual components the related functions in PLC application must be commissioned first such as servo enable emergency stop hardware limit switch etc Only after all the safety functions are commissioned without error you may start NC parameters and drives SINUMERIK 8025 base line is pre loaded SAMPLE integrated PLC application program this application applies to SINUMERIK 802S base line or SINUMERIK 802C base line turning or milling technology The functions of PLC application can be configured through the setting of PLC machine data Notice All the PLC related safety functions Emergency stop hardware limit switch etc must be commissioned first Then NC parameters and drive parameters can be commissioned provided the safety functions become active SAMPLE PTP is a complete PLC
41. communication requests Operator Panel PLC 802 Programming Tool Evaluate alarms Output process image outputs user interface The PLC executes the user program cyclically starting from the first up to the final operation Access from user program is only carried out via the process image and not directly to the hardware inputs or outputs The hardware inputs and outputs are updated by the PLC at the beginning and at the end of program execution The signals are thus stable over a PLC cycle The user program can be created by means of the PLC 802 Programming Tool using the programming language S7 200 in conjunction with ladder diagrams LAD A ladder diagram is a graphical programming language to represent electrical circuit diagrams This Documentation describes the program structure and the instruction set of the PLC in detail Commissioning of the PLC The SINUMERIK 8025 base line comes to the user with a simulation program included The SAMPLE user program is stored in the permanent memory This sample program and the documentation are included in the SINUMERIK 802SC base line Toolbox component PLC802SC base line Library The simulation program is intended for the first function test of the control System after assembling the control Internal simulation program The simulation program is an integral part of the 8025 base line system software It allows operation of the cont
42. control via 07 M08 and 09 Coolant level and overload monitoring Track lubrication control Manual coolant start once by user key K5 delayed Time interval activated interval and time specified by PLC MD Clamp Unclamp For turning machine chuck clamping control For milling machine tool release control Motor brake release during drive optimizing Combined keys activated PLC MD to release motor brake during drive optimization only for 611U drive with SimoCom U Combined keys NN e amp gt Release brake WW Am amp gt motor braking An alarm to warn that motor brake is released during drive optimization 6 42 SINUMERIK 802 base line Start Up 6 3 2 Input signals description Input output configuration Technical Appendix Input Signals Description X100 For turning machine For milling machine 10 0 Hardware limit Hardware limit X4 10 1 Hardware limit Z Hardware limit Z 10 2 10 3 Z reference cam Z reference cam 10 4 Hardware limit X Hardware limit X 10 5 Hardware limit Z Hardware limit 2 10 6 Overload T52 for 611 infeed Overload T52 for 611 infeed module module 10 7 Emergency Stop key X101 11 0 Tool sensor T1 Spindle low gear in position 11 1 Tool sensor T2 Spindle
43. in channel specific reference point approach always 1 1 31 DWORD 2 7 34200 ENC REFP MODE Type of position measuring system POWER ON 0 No ref point appr if an absolute encoder exists REFP SET POS accepted 1 Zero pulse on encoder track always 1 0 6 BYTE 2 7 35010 GEAR STEP CHANGE ENABLE Gear change possible Spindle has several gear steps POWER ON always 0 pe ds BOOLEAN 2 7 35040 SPIND ACTIVE AFTER RESET Own spindle reset POWER ON always 0 s BOOLEAN 2 7 35100 SPIND VELO LIMIT rev min Maximum spindle speed POWER ON always 10000 0 0 plus DOUBLE 2 7 35110 GEAR STEP MAX VELO rev min Maximum speed for gear change gear stage no 0 5 NEW CONF always 500 500 1000 0 0 plus DOUBLE 2 7 2000 4000 8000 35120 GEAR STEP MIN VELO rev min Minimum speed for gear change gear stage no 0 5 NEW CONF always 50 50 400 800 0 0 plus DOUBLE 2 7 1500 3000 35130 GEAR STEP MAX VELO LIMIT rev min Maximum speed of gear stage gear stage 0 5 NEW CONF always 500 500 1000 2000 0 0 plus DOUBLE 2 7 4000 8000 35140 GEAR STEP MIN VELO LIMIT rev min Minimum speed of gearsetp gear stage no 0 5 NEW CONF always 5 5 10 20 40 80 0 0 plus DOUBLE 2 7 SINUMERIK 802 base line 6 11 Start Up Technical Appendix
44. interface after the user program has been executed NC Start inhibited PLC provides the Start Inhibited signal to the CNC after the user program has been executed SHOWALARM This alarm has no alarm response bitO bit5 0 Priority of cancel conditions System alarms The cancel conditions have the following priority POWER CLEAR system alarms highest priority CANCEL CLEAR system alarms SELF CLEARING system alarms POWER ON CLEAR user alarms CANCEL CLEAR user alarms e SELF CLEARING user alarm lowest priority see Diagnostics Guide User alarms The user interface 1600 provides the user with two sub ranges for setting a user alarm Sub range 0 4 x 8 bits to set user alarms 0 gt 1 edge Byte 0 BitO gt 1stuser alarm 700000 Byte 3 Bit7 gt 32nd user alarm 700031 Sub range 1 User alarm variables The respective bit sub range 0 with a 0 1 edge change will activate a new user alarm Sub range 1 is intended for additional user information Sub range 2 can be used to analyze the active alarm responses Sub range 1 can only be read or written as a double word Sub range 2 can only be read You can delete self clearing alarms by resetting the respective bit in the variable range 1600 sub range 0 1 0 edge The remaining user alarms are cleared by the PLC after detecting the respective cancel condition If the alarm
45. load the project from the control system upload Direct data addressing is not possible therefore no programming errors will result during the operation 5 The data process information must be managed by the user in accordance with the particular type Example Information 1 T value DWord memory size 32 bit Information 2 Override Byte memory size 8 bit User data Byte 0 DWord Information 1 Byte 4 Byte Information 2 The user is not allowed to access both of these data at the same time otherwise the relevant data access rules must be observed Furthermore the data direction the memory model alignment and the data type must be observed for all data Example Flag bit 0 1 3 5 Flag byte 0 1 2 Flag word MWO MW2 MW4 MW3 MW5 are not permissible Flag double word MDO MD4 MD8 MD1 MD2 MD3 MDS are not permissible 4 18 SINUMERIK 8025 base line Start Up Start Up Table 4 6 PLC data types permitted in the control system Data Type Size Range for Logic Operations din rd BOOL 1 bit 1 0 1 BYTE 1 byte 1 00 FF 0 255 WORD 2 bytes 2 0000 FFFF 32 768 32 767 DWORD 4 bytes 4 0000 0000 FFFF FFFF 2 147 483 648 Double 2 147 483 647 Word REAL 4 bytes 4 10 10 8 PLC project 57 200 ladder diagram In any case the PLC 802 Programming tool manages one project logic operations symbols and
46. 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 Contents Contents 1 SINUMERIK 8025 base line Control System oe 1 1 Components of the SINUMERIK 8025 base line 1 2 Technical data meminere rere nre 2 Installing the Control System eene 2 1 Installing and Dismantling the SINUMERIK 8025 base line meme 2 2 Interfaces and cables eee eem eee ere reer eer ere 2 3 Connecting the individual components x ER Pie RR En EY RC EU Pc 5 2 3 1 Connecting the feed drives and the spindle X7 mmn 2 3 2 Connecting the measuring systems 2 3 3 C
47. only possible if MD 32900 DYN MATCH ENABLE 1 has bee set for the axis spindle With the function G331 G332 active parameter block n 0 5 of the axis of MD 32910 acting corresponding to the spindle gear stage automatically becomes active The gear stage is dependent on the spindle speed with M40 or is set directly via M41 M45 see also Section 4 5 3 Start up of the spindle Number Description Default Value 32900 Dynamic response adaptation 0 32910 constant of dynamic adaption 0 0 control parameter set no 0 5 SINUMERIK 802 base line Start Up Note Start Up For axes involved in tapping or thread cutting the same parameter set number is activated as with the current gear stage of the spindle see Description of Functions Section 3 2 For example if a load gear is active for an axis then this transmission ratio numerator denominator must also be entered in all of the remaining parameter sets used for thread operations in addition to the parameter set with index 0 Determination of value The dynamic value of the spindle is stored for each individual stage in MD 32200 POSCTRL GAIN n as closed loop gain An adaptation of the axis to these values must be made in MD 32910 DYN MATCH TIME n in accordance with the following instruction 1 1 MD 32910 DYN MATCH TIMBE n _ K v n Spindle K v n axis The entry to be made in MD 32910 requires the time
48. p m 32300 MA MAX AX ACCEL 1 m s 2 77 rev s s 35220 ACCEL REDUCTION 1 SPEED POINT 35230 MA ACCEL REDUCTION 0 FACTOR The selection of the value depends on the motor characteristic MAX ACCEL REDUCTION TYPE 0 constant i Characteristi V vred vmax Fig 4 7 Axial acceleration and velocity characteristics Velocities Vmax MA MAX AX VELO ACCEL REDUCTION SPEED POINT x MA MAX AX VELO Accelerations MA ACCEL 1 MA ACCEL REDUCTION FACTOR MA MAX AX ACCEL Service display of the axis drive behavior Servo Trace SINUMERIK 8025 base line provides two possibilities to evaluate the axis drive behavor To provide axis service the Servo Trace function is integrated in the Diagnosis menu which can be used for graphical representation of the axis setpoint speed The Trace function is selected in the Diagnosis Service display Servo Trace operating area cf User s Guide Operation Axis value as an analog value For service purposes the axis setpoint value required for the stepper motor drive can additionally be provided as an analog value Using a storage oscilloscope this feature can be used to display the axis drive behavior when starting up individual axes To output the analog axis setpoint with SINUMERIK 8025 base line the D A converter of the spindle is used SINUMERIK 8025 base line 4 39 Start Up Start Up Connect t
49. the WCS 3200 Signals to CNC Channel r w Data block Interface PLC CNC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Axis 1 WCS 32001000 Traversing keys Rapid Traversin Feed Activate handwheel traverse g key override stop 2 1 Axis 1 WCS 32001001 Machine function Continu 1000 INC 100 INC 10 INC 1 INC ous 32001002 32001003 Axis 2 in WCS 32001004 Traversing keys Rapid Traversin Feed Activate handwheel traverse g key lock override Stop 2 1 Axis 2 in WCS 32001005 Machine function Continu 1000 INC 100 INC 10 INC 1 INC ous 32001006 32001007 Axis 3 in WCS 32001008 Traversing keys Rapid Travers Feed Activate handwheel traverse ing key override stop 2 1 Axis 3 in WCS 32001009 Machine function Continu 1000 INC 100 INC 10 INC 1 INC ous 32001010 32001011 6 22 SINUMERIK 8025 base line Start Up Status signals from channel Technical Appendix 3300 Signals from CNC channel r Data block Interface CNC PLC Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 33000000 M1 active Program Block Revolu 33000001 test M2 M30 search tional Referenc feed ing active active active active active 33000002 Channel state rogram state 33000003 Interrupt Interrupt ed ed Rese
50. the softkey Diagnosis Service Display Version PROJECT The transmitted project including user program which is active in the PLC after the control system has powered up The programmer can use the first comment line in the program title of the PLC 802 Programming Tool for his own additional information in the version display see View Properties SINUMERIK 802 base line Start Up 4 5 4 6 Overview Start Up User Interface This interface includes all signals between CNC PLC and HMI PLC In addition the PLC decodes the auxiliary function commands for straightforward further processing in the user program Technology Setting The SINUMERIK 8025 base line is supplied with the default machine data as a control system for turning machines 2 axes 1 spindle If you wish to set another technology e g milling the relevant machine data file must be loaded from the tool box into the control system The file with the technology machine data must be loaded after the control system has booted successfully but prior to commissioning Sequence of operations To change the technology setting proceed as follows Make a V24 link between and the control system Turn on the control system and wait until it has booted without errors Press the Start data inp softkey in the Services menu use the V24 default interface settings e Select the technology machine data file techmill ini included in the toolbo
51. unit s The values of MD 32200 POSCTRL GAIN n for spindle and axis must be converted accordingly KIN spinae POSCTRL_GAIN N spinde K nl POSCTRL GAIN n j When using further gear stages with G331 G332 the adaptation must also be carried out in these parameter blocks Example for adaptation of the dynamic response of the Z axis spindle 1st gear stage gt parameter block 1 for spindle K MD 32200 POSCTRL GAIN 1 0 5 is entered for axis Z K MD 32200 POSCTRL GAIN 1 2 5 is entered The searched entry for the Z axis in 1 1 MD 32910 DYN MATCH 1 Kv 1 Spindle Kv 1 z 1 1 X 60 MD 32910 MATCH TIME 1 770 0960s 0 5 2 5 1000 If necessary for fine adaptation in practice a more exact value must be determined When traversing axis e g Z axis and spindle the exact value for POSCTRL GAIN is displayed on the service display MD 32900 DYN MATCH ENABLE must be set to 1 Example service display for Z axis with POSCTRL GAIN 2 437 in 1 000 min Exact calculation 1 1 6 MD 32910 DYN MATCH TIME 1 X 0 0954 05 2437 1000 SINUMERIK 8025 base line 4 41 Start Up Start Up In practice this value can be optimized To this aim the thread is first tested with compensating chuck and the calculated values Then the values should be modified sensitively such that the differen
52. when delivered Key assignment LI ERR 2 k5 k6 k8 k9 kf k12 Available as accessory Emergency K1 K39 keys 1 39 Stop Switch see user interface Fig 4 3 Layout of machine control panel area SINUMERIK 802 base line 4 17 Start Up Start Up vw wez horizonal turning machine vertical milling machine Fig 4 4 Examples for the assignment of the axis keyboard 4 3 5 PLC programming The PLC user program is created using the PLC 802 Programming Tool The Documentation S7 200 Automation System System Manual describes how this tool is operated for S7 200 The PLC 802 Programming Tool is to be understood as a subset of this Documentation Compared with the 57 200 MicroWin basic system please note the following The PLC 802 Programming Tool is delievered in the English language version e The user program can only be programmed using ladder diagram Only subset of the 57 200 programming language is supported e compilation of the user program is carried out either offline on a programming device PG PC or semi automatically when downloading into the control system The project be loaded into the control system download It is also possible to
53. 0 70 75 80 85 90 95 100 105 110 115 120 0 1 Two times fast than standard The steps 096 296 696 1096 3096 5096 7096 8096 9096 10096 110 120 1 0 About three times fast than standard The steps are 096 496 10 40 70 85 100926 11095 120926 1 1 About four times fast than standard The steps are 096 295 1096 5096 8096 10096 12096 Bit 6 7 Define spindle override shift speed Bit7 Bit6 Spindle override shift speed 0 0 Standard speed The steps 50 55 60 65 70 75 80 85 90 95 1 00 105 110 115 120 0 1 Two times fast than standard steps 50 60 70 80 90 100 110 120 1 0 About three times fast than standard The steps 50 60 70 85 100 110 120 1 1 About four times fast than standard The steps 5096 6096 8096 10096 12096 SINUMERIK 8025 base line 6 47 Technical Appendix 6 48 MD14512 16 Bit 0 0 Bit 0 1 Bit 1 0 Bit 121 Bit 220 Bit 2 1 Bit 3 0 Bit 321 Bit 6 5 4 0 Bit 6 5 4 1 MD14512 17 Bit 2 1 0 0 Bit 2 1 0 1 Bit 6 5 4 0 Bit 6 5 4 1 MD14512 18 Bit 1 0 Bit 121 Bit 220 Bit 2 1 Bit 6 5 4 0 Bit 6 5 4 1 Bit 7 0 Bit 7 1 PLC normal operation default Start up mode Ready signal T72 from infeed module is not verified by PLC spindle disabled if no command amp stopped amp Spindle Stop key default spindle is disabled automatically if no command amp is stopped analog spindle
54. 0003 V16000000 3 X traverse keys not defined check MD14510 27 700004 V16000000 4 Y traverse keys not defined check MD14510 28 700005 V16000000 5 Y traverse keys not defined check 014510 29 700006 V16000000 6 Z4 traverse keys not defined check MD14510 30 700007 V16000000 7 Z traverse keys not defined check MD14510 31 700008 V16000001 0 Turret 4 wrongly defined MD14510 20 4 6 700009 V16000001 1 Turret clamping time undefined check MD14510 21 700010 V16000001 2 Turret monitoring time undefined check MD14510 22 700011 V16000001 3 Spindle brake time out range check MD14510 23 700012 V16000001 4 Lubricating interval out range check MD14510 24 700013 V16000001 5 Lubricating duration out range check MD14510 25 700014 V16000001 6 Inputs undefined check MD14512 0 amp MD1 4512 1 700015 V16000001 7 Outputs undefined check MD14512 4 amp MD 14512 5 Standard alarm defined In SAMPLE Alarm Alarm Description SBR 700016 V16000002 0 DRIVES NOT READY TOUCH 1 ON MCP 33 700017 V16000002 1 ALARM FOR INFEED MODULE 700018 V16000002 2 700019 V16000002 3 700020 V16000002 4 700021 V16000002 5 SPINDLE START IMPOSSIBLE WHILE UNCLAMPED 35 700022 V16000002 6 UNCLAMPING IMPOSSIBLE WHILE SPINDLE RUN 49 700023 V16000002 7 PROGRAMMED TOOL gt MAX TURRET ON 46 TURRET 700024 V16000003 0 TOOL NOT FOUND MONITORING TIME UP 700025 16000003 1 NO POSITION SIGNALS FROM TURRET 700026 V16000003 2 MOTOR B
55. 29 Definition Y axis traverse key position Unit Range between 22 30 but not 26 14510 30 Definition Z axis traverse key position Unit Range between 22 30 but not 26 145101311 Definition Z axis traverse key position Unit Range between 22 30 but not 26 SINUMERIK 8025 base line 6 49 Start Up Technical Appendix 6 3 5 SAMPLE program structure Definition of subrouti I O signal processing Principle of I O filter 6 50 ne In this SAMPLE program the user can complile subroutines from 0 to 30 and the function of the individual subroutine is described in the subroutine library See below MAIN OB1 Seq SBR subroutines 1 62 Input amp output signals filtering IWO QWO MW100 MW102 2 32 PLC initialization gt SBR31 customer initialization 3 33 Emergency Stop 4 38 signal process SBR34 Traverse key control gt SBR39 Handwheel select via HMI 5 40 XYZ and spindle enable disable 6 44 Coolant control 7 45 Lubrication control 8 35 Contactor spindle or analog spindle 0 10V or 10V setpoint 9 41 Turret control 10 49 Clamping and unclamping control SAMPLE is designed to meet the different wiring on the machine tools i e any input can be connected as Normal Open or Normal Close All input and output signals have been filtered by SBR62 FILTER The filtering is carried out accor
56. 5 base line Start Up Table 4 7 Operand identifers Operand ID Description Range V Data V0 0 to V79999999 7 see Table 4 8 T Timers TO to T15 C Counters to C31 Map of digital inputs 10 0 to 17 7 Q of digital outputs Q0 0 to Q7 7 M Flags MO 0 to M127 7 SM Special flags 5 0 0 to SM 0 6 see Table 4 10 AC ACCU ACO AC3 4 19 Start Up 4 20 Table 4 8 Generating the addresses for the V range see user interface Type Code DB No 00 00 79 Subrange Offset Addressing 00 0 000 symbolic 00 99 0 9 000 999 8 digit Table 4 9 8025 base line ranges of operands Accessed by Memory Type SINUMERIK 8025 base line Bit Byte bit V 14000000 0 79999999 7 0 0 7 7 Q 0 0 7 7 M 0 0 127 7 SM 0 0 0 6 T 0 15 C 0 31 L 0 0 59 7 Byte VB 14000000 79999999 IB 0 7 QB 0 7 MB 0 127 SMB 0 LB 0 59 AC 0 3 Word VW 14000000 79999998 IW 0 6 QW 0 6 MW 0 126 T 0 15 0 31 LW 0 58 0 3 Double Word VD 14000000 79999994 ID 0 4 QD 0 4 MD 0 124 LD 0 56 AC 0 3 Table 4 10 Special Flag SM Bit Definition SM Bits Description SM 0 0 Flags with defined ONE signal SM 0 1 Initial position first PLC cycle 1 following cycles 0 SM 0 2 Buffered data lost ap
57. APA FR EN Ee Ew 4 2 Turning and booting the control system PINE 4 2 1 Boot MESSAGES rr nere reinen rene nene nennen 4 3 Starting up the PLC misi mienne rennen 4 3 1 Commissioning Of the PLO 35r rr tenir hero hcec inae eed gt 4 3 2 Start up modes of the PLC emm 4 3 3 Pl e Ere Ga ae FUR Jon Ee 4 3 4 Machine control panel area layout PER Eee Pn n ERA 4 3 5 PLC programming 4 3 6 Instruction meme nnmis 4 3 7 Program organization emere mener menie nenne nennen 4 3 8 Data organization RL daa 4 3 9 Interface to the control 4 3 10 Testing and monitoring the user program eene 4 4 PLC applications Download Upload Copy Compare eme 4 5 User Interface eene emen nemen mimis remeare nnn 4 6 Technology Setting 4 7 Commissioning 47 1 Entering the general machine data eem 4 7 2 Starting up the AXES eee eene memini emisse meminere eremi rie rene nien 4 7 3 Starting up the spindle eem memememmememe meme 4 7 4 Completing the Start Up eee 4 7 5 Cycle Start Up eene nne 4 8 Series machine start Up rane FO e naar nig Pa F R n b fn rade n er enl e
58. D 1 2 7 32110 ENC FEEDBACK POL Sign actual value control direction encoder no POWER ON always 1 1 1 DWORD 2 7 32200 POSCTRL GAIN 1000 min Servo gain factor control parameter set no 0 5 NEW CONF always 2 5 2 5 2 5 1 0 0 plus DOUBLE 2 7 32250 RATED_OUTVAL Ratedoutput voltage setprint brauch 0 NEW CONF always 80 0 0 10 DOUBLE 2 7 32260 RATED VELO rev min Rated motor speed setpoint branch 0 NEW CONF always 3000 0 0 plus DOUBLE 2 7 6 8 SINUMERIK 8025 base line Start Up Technical Appendix 32300 MAX AX ACCEL mm s 2 Axis acceleration NEW CONF rev s 2 always 1 0 de DOUBLE 2 7 32420 JOG AND POS JERK ENABLE Enable axial jerk limitation NEW CONF always 0 His T BOOLEAN 2 2 32430 JOG AND POS JERK s Axial jerk NEW CONF always 1000 mm s 3 10 pd DOUBLE 2 2 2777 77 degrees s 3 32450 BACKLASH mm Backlash NEW CONF always 0 000 bi DOUBLE 2 7 32700 COMP ENABLE Interpolatory compensation encoder no
59. MERIK 8025 base line Start Up Installing the Control System 2 5 LEDs and Other Elements on CNC Error and status LEDs There are three LEDs on the front panel of the CNC SINUMERIK 8028 basa ihe x cu un xl all sfe 5 all al Fig 2 6 Operator panel and user interfaces ERR red Group error This LED indicates an error condition of the CNC POK green Power OK The power supply is ready DIA yellow Diagnostics This LED indicates various diagnosis states Under normal operating conditions this LED flashes 1 1 SINUMERIK 802 base line 2 21 Start Up Installing the Control System Start up switch S3 This rotary switch is intended to assist start up Position 0 Normal operation Positions 1 4 Start up cf also Section 4 2 Table 4 2 Fuse F1 This design allows users to replace the fuse very conveniently when the fuse is broken S2 and D15 They are provided only for debugging internally Grounding Screw In order to ensure the system functions correctly and safely the CNC must be grounded through the grounding screw on the rear side of CNC 2 22 SINUMERIK 802 base line Start Up Installing the STEPDRIVE 3 General The SINUMERIK802S base line c
60. NGE MODE New tool compensation for M function POWER ON always 0 0 1 2 7 SINUMERIK 8025 base line 6 5 Start Up Technical Appendix 27800 TECHNOLOGY MODE Technology in the channel value 0 milling 1 NEW CONF turning 1 0 1 BYTE 2 7 6 1 4 Axis specific machine data Number MD Name Unit Name Miscellaneous Activated HW function Standard value Minimum value Maximum value D type User class 30130 CTRLOUT TYPE Output type of setpoint setpoint branch 0 POWER ON _always 0 0 2 2 7 30134 IS UNIPOLAR OUTPUT O Setpoint output is unipolar 0 POWER ON always 0 0 2 BYTE 2 2 30200 NUM ENCS Anzahl Geber 1 oder kein Geber f r die Spindel RESTART 1 0 1 BYTE 2 7 30240 ENC TYPE Type of actual value acquisition actual position value POWER encoder no 0 Simulation 2 Square wave generator standard encoder pulse multiplication 3 Encoder for stepper motor always 0 0 0 4 BYTE 2 7 30350 SIMU AX VDI OUTPUT Output of axis signals with simulation axes POWER ON always 0 itio TIR BOOLEA 2 7 30600 FIX_POINT_POS mm Fixed value positions of axis with G75 position no POWER ON de
61. NUMERIK 8025 base line Start Up Technical Appendix 14514 USER DATA FLOAT n User data Float 0 7 POWER ON 0 0 DOUBLE 2 7 14516 USER DATA PLC ALARM User data Hex Alarm bit O 31 POWER ON 0 0 OxFF BYTE 2 7 6 1 3 Channel specific machine data Number MD Name Unit Name Miscellaneous Activated HW function Standard value Minimum value Maximum value D type User class 20210 CUTCOM CORNER LIMIT Degrees Maximum angle for compensation blocks with TRC POWER ON always 100 0 0 150 DOUBLE 2 7 20700 REFP NC START LOCK NC Start disable without reference point RESET always 1 0 1 BOOLEA 2 7 N 21000 CIRCLE ERROR CONST mm Circle end point monitoring constant POWER ON always 0 01 0 0 plus DOUBLE 2 7 22000 AUXFU ASSIGN GROUP Auxiliary function group aux fct no in channel 0 49 POWER ON _always 1 15 BYTE 2 7 22010 AUXFU_ASSIGN_TYPE Auxiliary function type aux fct no channel 0 49 POWER ON always 25 STRING 2 7 22030 AUXFU ASSIGN VALUE Auxiliary function value aux fct no in channel 0 49 POWER ON _always 0 DWORD 1 2 7 22550 TOOL CHA
62. Pin Name Type 1 X o6 2 DIO DI 3 DI DI 9 0 4 DI2 DI apes 5 DIS DI 0 6 D14 DI 7 015 DI i 8 016 DI 7 0 9 DI7 Di 0 4 10 VI X101 Pin Name Type 1 X101 2 DI8 O 3 Dig DI 8 0 4 DI10 DI lt 5 0111 DI 11 0 6 DI12 DI DI13 DI dile 8 0114 DI 18 0 9 DI15 Di 0 4 10 VI X102 Pin Name Type 1 2 0116 Di 192 3 0117 16 0 4 DI18 DI PA E 5 0119 19 oO 6 DI20 DI X ciem umm 7 0121 DI 2 o 8 22 DI 23 9 DI23 DI Wo 10 M VI 2 16 SINUMERIK 8025 base line Start Up Installing the Control System X103 Pin Name Type 1 n c X103 2 0124 DI MEE 3 0125 DI 4 0126 DI 26 5 5 0127 oue 6 0128 DI 29 5 7 0129 DI Ms 8 DI30 DI Lo 9 DI31 DI 10 VI X104 Pin Name Type 1 2 0132 Di 3 0133 DI 32 0 4 DI34 DI gt 5 0135 35 OY __ 6 DI36 DI E an 7 DI37 DI oo 8 0138 DI 39 0 9 DI39 DI MEM 10 VI X105 Pin Name Type 1 n c 2 0140 Di 105 3 0141 DI 40 o 4 D142 DI 5 0143 01 43 G 6 0144 DI CE 7 0145 DI 46 o 8 0146 DI 47 o 9 DI47 DI ML I 10 M VI Sign
63. RAKE RELEASED FOR DRIVE 40 OPTIMIZATION 700027 V16000003 3 APPROACH REF POINT AGAIN AFTER ROT MONITORING 700028 V16000003 4 700029 V16000003 5 700030 V16000003 6 7000831 V16000003 7 6 52 SINUMERIK 8025 base line Start Up Technical Appendix 6 3 7 Start Up of SAMPLE program General When first power on of the system some important PLC machine datas must be set Precedure By first power on there will be one alarm Alarm 700000 with text Number Startup PLC machine data needed see description of PLC Lib display data Fig 6 2 Alarm screen form Set following PLC machine data 1 Define machine type MD14510 16 0 Lathe MD14510 16 1 Milling 2 Define Input and output MD14512 0 4 DI16 input enable and logic MD14512 4 7 DO16 output enable and logic 3 Define tranverse keys MD14510 26 X MD14510 27 X MD14510 30 Z MD14510 31 Z MD14510 28 Y when MD14510 16 1 MD14510 29 Y when MD14510 16 1 Shield E stop signal MD14512 16 0 1 disabled 5 Define application functions MD14512 11 Bit 7 1 Tool holder active for Turning 6 1 Spindle gear change active for Milling Bit 3 1 Spindle control active Bit 2 1 Unclamping control 1 1 Auto lubrication active Bit 0 1 Cooling active 6 Define system parameter MD14512 16 17 18 After setting the parameter will be active when the next power on of the system SINUMERIK 802 base line 6 53 Start Up
64. Start Up 08 2003 Edition SINUMERIK 8025 base line SIEMENS SIEMENS SINUMERIK 8025 base line SINUMERIK 8025 base line Control System 1 Start Up Installing the control system 2 Installing the STEPDRIVE 3 Technical Manual Start Up 4 Software Update Technical Appendix 6 Valid as from Control system Software version SINUMERIK 8025 base line 4 2003 08 Edition 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 New documentation B Unchanged reprint with new order number Revised edition of new issue Edition Order No Note 1999 02 6 5597 2 00 1 2002 01 6FC5597 2AA00 0BP2 2003 08 6FC5597 4AA01 0BPO Trademarks SIMATIC SIMATIC SIMATIC NET SIMODRIVE SINUMERIK and SIMOTION are registered trademarks of 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 softwar
65. UNSIGNED DWORD Integer values from 0 to 4294967300 SIGNED DWORD Integer values from 2147483650 to 2147483649 WORD Hex values from 0000 to FFFF DWORD Hex values from 00000000 to FFFFFFFF FLOAT DWORD Real values from 8 43 10710 3 37 x 1029 SINUMERIK 802 base line 6 1 Start Up Technical Appendix 6 1 1 Display machine data Number MD Name Representation Name Miscellaneous Activated User Class w r Unit Standard value Minimum value Maximum value Data type 202 MM FIRST LANGUAGE Decimal Foreground language Power On 2 3 0 1 1 2 Byte 203 MM DISPLAY RESOLUTION Decimal Display resolution Power On 2 3 0 3 0 5 Byte 206 MM USER CLASS WRITE TOA GEO Decimal User class Write tool geometry Immediately 2 3 0 3 0 7 Byte 207 MM USER CLASS WRITE TOA WEAR Decimal User class Write tool wear data Immediately 2 3 0 3 0 7 Byte 208 MM USER CLASS WRITE ZOA Decimal User class Write settable zero offset Immediately 2 3 0 3 0 7 Byte 210 MM USER CLASS WRITE SEA Decimal User class Write setting data Immediately 2 3 0 3 0 7 Byte 216 MM USER CLASS WRITE RPA Decimal User class Write R parameters Immediately 2 3 0 3 0 7 Byte 217 MM USER CLASS SET V24 Decimal User class Set V24 Immediately 2 3
66. Word a lt b open Or BWord b Load RWord b close a And RWord a gt b open s Or RWord 71 um SINUMERIK 8025 base line Start Up Start Up TIMER Instruction Ladder Symbol Valid Operands Timer Retentive EN 1 Start Too Enable Delay EN 0 Stop FONR 50 PT TO T15 1 N Preset VW T C IW QW MW AC PT Constant 100ms TO T15 Timer On Delay EN 1 Start Too Enable EN 0 Stop 50 If Tuas Txxx TO T15 bit a Preset PT VW T C IW QW MW Constant 100ms TO T15 Timer Of Delay If Tvaue lt Tox Enable bit 50 EN Tox TO T15 M Preset VW T C IW QW MW AC PT Constant 100ms TO T15 COUNTER Instruction Ladder Symbol Valid Operands Count Up CU 7 Value 1 Cnt Up CU R 1 Reset Cxxx S1 If Cy L PV Reset R 1 CU 50 31 R Preset PV V VW T C IW QW MW AC Constant LW Count Up Down CU 7 Value 1 Cnt Up CU CD 7 Value 1 S2 R 1 Reset Cxxx Cnt Dn CD If Cvaue L PV S1 CU CTUD Reset R CD 50 R Cxxx 0 31 ae Preset PV VW T C IW Qw MW AC Constant LW Count Down If 0 Cnt Down CD 1 62 Reset R CD S0 LD Co 31 PV Preset PV VW T C IW QW MW AC Constant LW SINUMERIK 8025 base line 4 23 Start Up MATH OPERATIONS
67. X axis 2 Y axis 3 Z axis 4 Spindle Table 2 2 Cable assignment for type 6FX2 002 3AD02 CNC Side Cable Drive Side PIN Core Color Signal Name PIN 5 black 1st axis P1 38 brown P1N 6 red D1 39 orange D1N 18 yellow E1 19 green E1N 40 White grey 2nd axis P2 969 7 Brown black P2N 205 41 Blue D2 959 8 Violet D2N 999 20 Grey 2 9 21 White E2N 9 9 9 white black 3rd axis P3 42 white brown P3N 10 brown red D3 S d 43 brown orange D3N 26 White red 27 White orange 17 White yellow Spindle 9 50 White green 65 4 White blue 14 37 White violet 56 SINUMERIK 8025 base line Start Up Installing the Control System Drives with analog interface Signals A voltage and an enable signal are output AOn SETPOINT Analog voltage signal in the range 10 V to output a speed setpoint e AGNDn REFERENCE SIGNAL Reference potential analog ground for the setpoint signal internally connected to logic ground e SEn SERVO ENABLE Relay contact pair controlling the enable of the power section e g of a step drive unit controlled via a PLC program Signal parameters The setpoint is output as an analog differential signal Table 2 3 Electrical parameters of the signal outputs for step switching drives Parameter Min Max Unit Voltage range 10 5 10 5 V Output current 3 3 mA Relay contact Table 2 4 Electrical parameters of the relay contact
68. a a SR c bits a a SL c bits SINUMERIK 802 base line 4 25 Start Up Start Up 4 26 CONVERSION OPERATIONS Instruction Convert Double If EN 1 convert Word Integer to the double word a Real integer i to a real Ladder Symbol DI REAL Valid Operands Enable In VD ID QD MD AC Constant LD number o Out VD ID QD MD AC LD Convert a Real If EN 1 convert Enable to a Word Integer Double the real number i to a double word integer o In VD ID QD MD AC Constant LD Out VD ID QD MD AC LD Instruction Valid Operands Jump to Label If EN 1 go to Enable EN Label label n WORD 0 127 Label Label marker for n Label WORD 0 127 the jump LBL Conditional If EN 1 exit the Enable Return from subroutine e Subroutine Conditional End If EN 1 END Enable terminates the eno main scan Subroutine If EN T go to Label Constant 0 63 subroutine n x1 x2 x3 x optional parameters SINUMERIK 802S base line Start Up 4 3 7 Start Up MOVE FILL AND FIND OPERATIONS Instruction Ladder Symbol Valid Operands Move Byte If EN 1 Enable copy i to o In IB MB AC Constant LB Out VB IB QB MB AC LB Move Word If EN 1 Enable copy i to o In VW C IW QW MW AC Constant LW Out VW T C IW QW MW AC LW
69. after POWER ON Most data such as process map timers and counters are non retentive data and deleted with each power up The user has a certain area available for the retentive data data range 14000000 140000xx All data that are wished to remain their validity even after POWER ON can be stored in this area The user can use the PLC MD see user interface to load his program with default data or to parameterize various program sections Interface to the control system This interface can be selected on the operator panel using the softkeys Diagnosis Start up STEP7 connect The V24 interface remains active even after restart or normal power up The connection STEP7 connect active to the control system can be checked in the PLC 802 Programming Tool menu PLC Information If the interface is active e g the active PLC mode Run Stop is displayed in this window Testing and monitoring the user program The user program can be analyzed or checked for errors using the following methods e PLC Status menu OP Status list menu 802 Programming Tool see Help menu gt Contents and Index Debugging or documentation 57 200 Automation System Section Testing and Monitoring Your Program SINUMERIK 802 base line Start Up Start Up 4 4 PLC applications Download Upload Copy Compare The user can save or copy PLC applications in the control system or overwrite them by another PLC project
70. al names DIO 47 24 V digital inputs Signal type VI Voltage input DI Input 24 V signal Table 2 15 Electrical parameters of the digital inputs Parameter Value Unit Note 1 signal voltage range 15 30 V 1 signal current consumption 2 15 mA 0 signal voltage range 3 5 V or input open Signal delay 0 gt 1 0 5 3 ms Signal delay 1 gt 0 0 5 3 ms SINUMERIK 8025 base line Start Up Installing the Control System 2 3 7 Connecting the digital outputs X200 X201 Connector pin assignment 2 18 Interface for digital outputs Connector designation X200 X201 Connector type OUT 10 pin plug connector Table 2 16 Connector pin assignment 20 5 200 1 24 VI DOO CW 1P24 DO1 CCW O cw 1 ccw DO2 DOS DO4 DO5 DO6 O1 BR Oo Po DO7 lt 29 5 201 2 24 DO8 9 DO10 DO11 DO12 DO13 DO14 CO NI O O1 BR Oo Po DO15 eo M lt lt Signal Description DOO DO15 DOO CW DO1 CCW 1P24 M 2P24 M Signal type VI Digital output 0 15 Max current 500mA Digital output 0 Unipolar Spindle CW Direction Max c
71. an be configured with STEPDRIVE C C or FM STEPDRIVE For the detailed description of FM STEPDRIVE please refer to the document on DOConCD ordering number 6FC5298 0CD00 0BG0 3 1 Installing and dismantling the STEPDRIVE C C drive modules A Installation Dismantling Warning Before installing the STEPDRIVE C C drive modules first always make sure that the equipment is disconnected from the mains To install the drive modules proceed as follows see Fig 3 1 1 Screw in the upper fastening screws M5 with washer and lock washer 2 Hang the module into the clips of the upper fastening bracket 3 Screw in the lower fastening screws and tighten all screws Notice The modules should be installed such that a clearance of at least 10 cm is left above below and between the modules dimension The drive modules however can be mounted directly side by side a gt 10 mm provided they are ventilated with an air stream greater than equal to 1 m s Do not install devices which are strongly heated during operation beneath the drive modules The drive modules are dismantled in the reverse order Warning When removing the drive modules always first make sure that the system is disconnected from the mains SINUMERIK 8025 base line 3 1 Start Up Installing the STEPDRIVE Mounting Dimensions 3 2 5 Washer lock washer
72. ance NEW CONF deg always 0 5 0 0 plus DOUBLE 2 7 SINUMERIK 8025 base line 6 13 Start Up Technical Appendix 36060 STANDSTILL VELO TOL mm min Maximum velocity speed axis spindle stopped NEW CONF rev min always 5 0 014 0 0 plus DOUBLE 2 7 36100 POS LIMIT MINUS mm 1st software limit switch minus RESET deg always 100000000 DOUBLE 2 7 36110 POS LIMIT PLUS mm 1st software limit switch plus RESET deg always 100000000 DOUBLE 2 7 36120 POS LIMIT MINUS2 mm 2nd software limit switch minus RESET deg always 100000000 DOUBLE 2 7 36130 POS LIMIT 52 mm 2nd software limit switch plus RESET deg always 100000000 DOUBLE 2 7 36200 AX VELO LIMIT mm min Threshold value for velocity monitoring NEW CONF rev min control parameter set no 0 5 always 11500 11500 0 0 plus DOUBLE 2 7 11500 11500 36300 ENC FREQ LIMIT Hz Encoder limit frequency POWER ON always 300000 0 plus DOUBLE 2 7 36302 ENC FREQ LIMIT LOW 96 Encoder limit frequency at which encoder is switched NEW CONF again Hysteresis always 99 9 0 100 DOUBLE 2 7 36310 ENC ZERO MONITORING Zero mark monitoring encoder no 0 1 NEW CONF
73. and O1 must not be used by the PLC PLC output bit 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 they are not any monitoring functions in the control system Not observing this fact will result in undesired reactions of the control system 6 55 Technical Appendix 6 56 SINUMERIK 802 base line Start Up SIEMENS AG A amp D MC BMS Postfach 3180 D 91050 Erlangen Tel 49 180 5050 222 Hotline Fax 449 9131 98 2176 Documentation Mailto motioncontrol docu erlf siemens de From Name Company dept Street Zip code Telephone Telefax Suggestions and or corrections Suggestions Corrections for Publication Manual SINUMERIK 8025 base line Manufacturer Documentation Start Up Order No 6 5597 4 01 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 8025 base line Document Structure General Documentation Catalog ID G Turning Milling User Manual Operation and Programming 4 rE a TE 00 Short Guide for O amp P 524 AAT Quick b d Start ase line Start
74. arbox encoder no POWER ON always 1 2147000000 DWORD 2 7 31090 JOG INCR WEIGHT mm Evaluation of an increment with INC handwheel RESET degrees 31100 BERO CYCLE Steps for monitoring rotation POWER ON 2000 10 10000000 DWORD 2 7 31110 BERO EDGE TOL Step tolerance for monitoring rotation POWER ON 50 10 10000000 DWORD 2 7 31350 FREQ STEP LIMIT Stepping rate at maximum velocity NEW CONF Hz 250000 0 1 4000000 DOUBLE 2 7 SINUMERIK 8025 base line 6 7 Start Up Technical Appendix 31400 STEP RESOL Steps per stepper motor revolution POWER ON 1000 0 plus DWORD 2 7 31500 AXIS NUMBER FOR MONITORING Display setpoint of this axis ollwert for servicing POWER ON 0 0 4 DWORD 2 7 32000 MAX_AX_VELO mm min Maximum axis velocity NEW CONF rev min _always 10000 0 0 plus DOUBLE 2 7 32010 JOG VELO RAPID mm min Rapid treverse in jog mode RESET rev min always 10000 0 0 plus DOUBLE 2 7 32020 VELO mm min Jog axis velocity RESET rev min always 2000 0 0 plus DOUBLE 2 7 32070 CORR VELO 96 Axis velocity for handwheel override ext ZO cont RESET dressing distance control always 50 0 0 plus DWORD 2 7 32100 AX MOTION DIR Traversing direction not control direction POWER ON always 1 1 1 DWOR
75. ase line Start Up 3 5 Installing the STEPDRIVE 3 4 Error messages and error elimination lame colto Meaning Remedy RDY green the only LED Drive ready If the motor does not rotate it can that is lit have the following causes No pulses are output by the control system Pulse frequency too high motor is out of step Motor load too large or sluggish DIS yellow the only LED Drive ready motor not powered Activate ENABLE signal via CNC that is lit FLT red is lit There is one of the following Measure 85 V operating voltage errors Check cable connections Overvoltage or undervoltage Short circuit between the motor phases J Short circuit between motor phase and ground TMP red is lit Overtemperature in the drive Drive defective replace all No LED is lit No operating voltage Check cable connections 3 6 SINUMERIK 8025 base line Start Up Start Up 4 4 1 General Start up requirements e The following is required User Manual Operation and Programming SINUMERIK 8025 base line PC PG programming device only for data saving and series start up Toolbox on CD The CD is either supplied with the control system or can be ordered separately Contents WINPCIN for data transfer via the V24 interface from to external PC PG Cycle pack Turning and Milling The mechanical and electrical installation of the equipment must be completed
76. ation time for direction 1 35450 Reciprocation time for M4 direction 0 5 35510 Feedrate enable for spindle stopped 0 36000 Exact positioning coarse 0 04 only SPOS 36010 Exact positioning fine 0 01 only SPOS 36020 Delay exact positioning fine 1 only SPOS 36030 Zero speed tolerance 0 2 only SPOS 36040 Delay zero speed monitoring 0 4 only SPOS SINUMERIK 802S base line Start Up 4 45 Start Up SD for spindle Number Explanation Default Value 36050 Clamping tolerance 0 5 only SPOS 36060 Maximum velocity speed axis spindle stopped 5 axis only 0 0138 SPOS spindle 36200 Threshold value for velocity monitoring control 11500 axis parameter set no 0 5 31 94 spindle 36300 Encoder limit frequency 300000 36302 Encoder limit frequency at which encoder is 99 9 switched on again Hysteresis 36310 Zero mark monitoring encoder no 0 0 1 0 Zero mark monitoring off encoder HW monitoring on 1 99 gt 100 Number of recognized zero mark errors during monitoring 100 Zero mark monitoring off encoder HW monitoring off 36610 Duration of the deceleration ramp for error states 0 05 36620 Cutout delay servo enable 0 1 36700 Automatic drift compensation 0 36710 Drift limit value for automatic drift compensation 1 36720 Drift basic value 0 Number Description Default Value 43210 Prog
77. ce path in the compensating chuck approximates to zero Now the POSCTRL GAIN values displayed on the service display for axis and spindle should be identical Notice If MD 32900 DYN MATCH ENABLE has been set to 1 for the drilling axis it should also be set to 1 for all interpolating axes This increases the traversing accuracy along the contour However the entries for these axes in MD 32910 DYN MATCH TIME n must be left at the value 0 Backlash compensation Overview Function Activation The falsification of axis travel due to mechanical backlash can be compensated cf Technical Manual Description of Functions The axis specific actual value is corrected by the backlash compensation value MD32450 BACKLASH with each change of the traversing direction The backlash compensation is active in all operating modes only after referencing Notice Which step size is added to the backlash compensation value is determined by MD36500 CHANGE TOL Leadscrew error compensation LEC Overview Function Activation 4 42 The compensation values are determined by means of the measured error curve and entered in the control system using special system variables during start up The compensation tables cf Technical Manual Description of Functions must be created in the form of NC programs The leadscrew error compensation LEC changes the axis specific actual position by the associated compe
78. ces It must be ensured that persons without ESD protection never touch printed circuit boards or components when handling operator and machine control panels Due to the compactness it is very convenient to install and dismantle the control system 1 Fixthe system in the machine control station 2 Screw the system in place with 8 M4 x 16 assembled screws The maximum allowed torque for the screws is 1 5 Nm Notice Prior to installation the machine control panel can be provided with an emergency stop button If it is not required the opening must be covered with the supplied self adhesive cover Dismantling the control system The control system is dismantled as described above in the reverse order Warning Do not dismantle when the equipment is under power SINUMERIK 8025 base line 2 1 Start Up Installing the Control System Mounting dimensions The dimensions shown below are important for installing the control system 420 4 o B 8025 base 9 SINIMERK p om A xi e k3 ks ke a ke ko ke x p we i a e IS 1 fin VA I f amp o 8 xis REE 1516 TT fexl 7 ed a rar l jij Giese sas Fad Fed
79. comments The download function is intended to store all important information of a project in a control system The control system is able to store max 4 000 instructions and 1 000 symbols The required PLC memory is influenced by the following components e Number of instructions e Number and length of the symbol names e Number and length of the comments A ladder diagram is a graphical programming language similar to electric circuit diagrams When creating a program using the ladder diagram form then you will work with graphical components to create the networks of your logics To create your program you can use the following elements Contacts constitute a switch through which the current can flow Current however will only flow through a normally open contact if the contact is closed logical value 1 Current will flow through a normally closed contact or a negated contact NOT if the contact is open logical value 0 Coils constitute a relay or an output which is updated by the signal flow Boxes constitute a function e g a timer counter or arithmetic operation which is carried out at the moment when the signal flow reaches the box A network consists of the elements mentioned above forming a closed circuit The current flows from the left conductor bar in the ladder diagram symbolized by a vertical line at the left window through the closed contacts enabling coils or boxes Overview of commands SINUMERIK 802
80. contact sensors e g inductive proximity switches BERO can be connected They can be used as switches for reference points for example BERO1 X axis BERO2 Z axis Table 2 12 Electrical parameters of the digital inputs Parameter Value Unit Note 1 signal voltage range 11 30 V 1 signal current consumption 6 15 mA 0 signal voltage range 3 5 V Or input open Signal delay 0 gt 1 15 us Signal delay 1 gt 0 150 us Readiness in the form of a relay contact NO must be integrated into the EMERGENCY STOP circuit SINUMERIK 802 base line Start Up Installing the Control System Table 2 13 Electrical parameters of the NCREADY relay contact Parameter Max Unit DC switching voltage 50 V Switching current 1 A Switching power 30 VA Pin number of X20 Fig 2 5 The NCREADY is an internal relay of NC It will open when NC is not ready and close after NC is ready for operation SINUMERIK 802 base line 2 15 Start Up Installing the Control System 2 3 6 Connecting the digital inputs X100 X105 Pin assignment for connector Interface for the digital inputs Connector designation X100 X101 X102 X103 X104 X105 IN Connector type 10 pin plug connector Table 2 14 Connector pin assignment X100
81. d Alarm response and cancel criterion Furthermore the PLC manages the alarm responses The alarm responses are always active irrespective of the number of active alarms Depending on the type of the alarm response the PLC triggers an appropriate response Each alarm requires a cancel criterion to be defined The PLC uses the SELF CLEARING criterion as default criterion Cancel criteria are 5 POWERONCLEAR The alarm is canceled by switching off switching on the control system CANCELCLEAR alarm is canceled by pressing the Cancel key or the Reset key analogously to CNC alarms SELF CLEARING The alarm is cleared because the cause resulting in the alarm has been eliminated or does not exist any longer Desired alarm responses are defined for each alarm in the PLC By default the PLC uses the SHOWALARM response bitO bit5 0 Possible alarm responses are 4 12 PLC Stop The user program is no longer executed the NC Ready relay drops out and the hardware outputs are disabled OUTDS EMERGENCY STOP PLC provides the EMERGENCY STOP signal to the CNC in the user interface after the user program has been executed SINUMERIK 802 base line Start Up Start Up Feed disable The PLC provides the Feed Disable signal to the in the user interface after the user program has been executed Read in disable provides the Read in Disable signal to the CNC in the user
82. d in the subroutine library he can complile a new subroutine from SBRO to SBR30 thus the function can be realized by calling it from main program When compiling the buffered 16 inputs and 16 outputs i e 0116 10 0 11 7 and DO16 Q0 0 Q1 7 among which M100 0 represents for 10 0 M102 0 for Q0 0 However the remaining 32 inputs can not use filter Of course if you compose your own PLC application directly from project file SUBR LIBRARY 802SC PTP a project with an empty MAIN you can use hardware l Os from the beginning Notice All inputs of SAMPLE are defined as NO high effective e g 10 7 is defined by SAMPLE as Emergency Stop 10 7 1 is intepreted as an effective Emergency Stop In case if 10 7 is wired as NC i e 0 is emergency stop Bit 7 of MD14512 2 must be set to 1 to inform FILTER In case you compose your own application using the building blocks provided in SUBR LIBRARY please take care of definition of each input of the subroutine NO or NC SINUMERIK 8025 base line 6 51 Start Up Technical Appendix 6 3 6 User alarm User alarm defined In SAMPLE Alarms Alarm Description SBR 700000 V16000000 0 Startup PLC MD needed see description of PLC Lib 31 700001 V16000000 1 700002 V16000000 2 traverse keys not defined check MD14510 26 70
83. dder Symbol Valid Operands Byte AND If EN 1 Enable Byte OR b aANDb In VB IB QB MB Byte XOR b aORb AC Constant LB b aXORD Out VB IB QB MB AC LB Word AND If EN 1 Enable Word OR b aANDb In VW C IW QW Word XOR b aORb MW AC Constant b aXORbD LW Out VW T C IW QW MW AC LW DWord AND If EN 1 Enable EN DWord OR b aANDb In VD ID QD MD DWord XOR b aORb AC Constant LD b aXORbD Out VD ID QD MD AC LD Invert Byte If EN 1 Enable EN In IB MB Constant LB Out VB IB QB MB AC LB Invert Word If EN 1 Enable In VW C IW QW MW AC Constant LW Out VW T C IW QW MW AC LW Invert DWord If EN 1 Enable In VD ID QD MD AC Constant LD Out VD ID QD MD AC LD SHIFT AND ROTATE OPERATIONS Instruction Ladder Symbol Valid Operands Shift Right If EN 1 Enable Shift Left a a SR c bits In VB IB QB MB a a SL c bits Constant LB Out VB IB QB MB AC Count VB IB QB MB AC Constant LB Shift Right If EN 1 Enable Shift Left a a SR c bits In VW T C IW QW MW a aSLc bits AC Constant LW Out VW T C IW QW MW AC LW Count VB IB QB MB AC Constant LB Enable EN In VD ID QD MD Constant LD Out VD ID QD MD AC LD Count VB IB QB MB AC Constant LB DWord Shift If EN 1 DWord ShiftL
84. defined as the direction of unipolar spindle and enable signals which are controlled by NCK Notice All input signals are treated in SAMPLE as Normal Open or called positive AN logic If an input is a Normal Close it should be specified via PLC MD as negative logic Spindle enable signals come from P17 SE4 1 and P50 SE4 2 Internal relay of X7 6 3 3 Definition of user keys User keys Fig 6 1 User keys on MCP area 6 44 SINUMERIK 8025 base line Start Up Definition of user keys Technical Appendix User keys description Key Turning Milling K1 Drive enable disable Drive enable disable K2 Chuck clamping unclamping Tool clamping unclamping K3 Not defined Not defined K4 Manual tool change Not defined K5 Manual lubrication start stop Manual lubrication start stop K6 Manual coolant start stop Manual coolant start stop K7 User defined User defined K8 User defined User defined K9 User defined User defined K10 User defined User defined K11 User defined User defined K12 User defined User defined LED Turning Milling LED1 Drive enabled Drive enabled LED2 Chuck clamped Tool clamped LED3 Not defined Not defined LED4 Tool changing Not defined LED5 Lubricating Lubricating LED6 Cooling Cooling LED7 User defined User defined LED8 User defined User defined LED9 User defined User defined LED10 User defined User defined LED11 User defined Us
85. ding to PLC MD14512 0 1 2 3 and 14512 4 5 6 7 with follow chart it is easily know the correspondence of internal inputs and outputs Therefore in SAMPLE M100 0 is a buffered input for 10 0 and M101 2 is for 11 2 M102 3 is for Q0 3 and M103 4 is for Q1 4 and so on All subroutines in LIBRARY are inputs output independent SINUMERIK 802 base line Start Up Modifications Technical Appendix Filter principle Input Filter dion ry is Y Filter Output 1002 _ gt 100 0 M10202 _ gt Q0 0 012 S gt 100 1 M102 1 gt gt Q0 1 10 22 gt 100 2 M10222 5 gt 00 2 10 32 X c 2M100 3 M10232 gt 00 3 04 gt 0 ar gt 100 4 1024 gt 0 2Q04 10 52 D gt M100 5 PLC 102 5 gt 00 5 0 6 2M1006 SAMPLE M102629 aj 2006 10 7 gt 2 gt M100 7 PROGRAM M102 7 gt Q 2 50077 HOo2 gt M101 0 M103 0 gt 201 0 9 gt M101 1 M103 12 201 1 22 gt 101 2 M10322 5 3012 1 35 gt 101 3 M103 3 gt X 3013 14 gt 0 cr 3M101 4 1034 gt Q 3014 15 gt i 3M101 5 M103 5 gt 301 5 1 65 2M101 6 M10362 a 201 6 17 gt Q 42 gt 1017 M103 7 gt Q 2 5017 If the user needs to realize a function not provide
86. e 50 pin sub D plug connector Table 2 1 Pin assignments of connector X7 X7 Pin Signal Type Pin Signal Signal Type 1 n c 18 ENABLE1 O 34 2 19 ENABLE1_N O 35 3 n c 20 ENABLE2 36 4 AGND4 21 ENABLE2 N O 37 4 5 PULS1 22 VO 38 PULS1_N O 6 DIR1 23 VO 39 DIR1_N 7 PULS2 N O 24 40 PULS2 8 DIR2 N JO 25 41 DIR2 O 9 PULS3 O 26 ENABLE3 O 42 PULSS3 N O 10 DIR3 O 27 ENABLE3 N O 43 DIR3 N 11 PULS4 28 ENABLE4 44 PULS4 12 DIRAN 29 4 N O 45 0184 13 30 46 14 31 47 15 32 48 16 33 49 17 SE4 1 50 5 4 2 SINUMERIK 8025 base line 2 7 Start Up Installing the Control System 2 8 Signal Stepper Interface PULSn PULSn N DIRn Analog Spindle Interface Aon AGNDn SEn 1 SEn 2 1 4 Signal Specification Description Stepper Clock Stepper Revolution Direction Stepper Enable Ground not to be connected when using differential signals Analog Command Value Analog Ground Servo Enable Relay Number of Axis 10 for Analog Outputs RS422 for Stepper Signals Axis assignment 1
87. e 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 Safety notices Qualified person Proper use A This Manual contains notices intended to ensure your personal safety as well 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 substantial 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
88. e overrun cyclically when the axes are traversed Usually a cyclically occurring BERO is used both referencing and for rotation monitoring It is possible to switch the BERO for rotation monitoring in parallel to the BERO for referencing It must however be made sure that the rotation monitoring is disabled when referencing and that the rotation monitoring BERO does not provide a signal or the referencing BERO is switched off when rotation monitoring is active The MD 31100 BERO CYCLE must contain the repetition cycle of the BERO in actual value increments The MD 31110 BERO EDGE TOL will take into account any tolerances in the BERO switching edge The speed monitoring is activated via the user interface signal 380x5000 0 It comes into effect for the appropriate axis only after referencing The error Rotation monitoring is signalled interface signal 390x5000 0 and the monitoring is switched off The reference point is lost To re enable rotation monitoring rereferencing is required Notice The error Rotation monitoring will also always occur if the stepper motor has been controlled incorrectly even if the speed monitoring is not enabled If deemed necessary the user must take appropriate measures to ensure that the stepper motor is shut down reliably SINUMERIK 8025 base line 4 37 Start Up Start Up Bent acceleration characteristic A characteristic feature of stepper motor drives is the drop of the available torque
89. e relevant lists Notice The general machine data are selected such default values that only a few machine data parameters have to be modified Entering the machine data MD Machine data 4 32 Before the machine data can be entered the password for protection level 2 or 3 must be entered The following machine data ranges must be selected and modified if necessary using the appropriate softkeys e General machine data e Axis machine data e Other machine data e Display machine data Once entered these data are immediately written to the data memory The machine data are activated depending on the Activation setting of the appropriate machine data Section 4 1 2 Notice Since these data are only stored in the memory backed up for a limited period of time a data backup is necessary see Section 4 1 4 The following machine data list contains all general and other machine data and setting data which can be changed if necessary SINUMERIK 802 base line Start Up Setting data Start Up Number Description Default Value 10074 Division ratio of the PLC task factor for main 2 11100 Number of auxiliary function groups 1 11200 Standard machine data loaded on next Power On 11210 MD backup of changed MD only OFH 11310 Threshold for direction change of handwheel 2 11320 Handwheel pulses per detent position handwheel 1 n
90. ee data transfer the control system is completely configured and ready to operate 4 51 Start Up Series machine start up file 4 52 The series machine start up file contains machine data R parameters display and alarm text files display machine data PLC user program main programs subroutines cycles Leadscrew error compensation data SINUMERIK 802 base line Start Up Software Update 5 5 1 Updating the system software using a PC PG General Preconditions Update procedure The following reasons may require a system software update e You wish to install new system software new software version After hardware replacement if software versions other than the supplied are to be loaded To change the system software of the SINUMERIK 8025 base line you will need the following Update software Toolbox PG PC with V24 interface or 2 and an appropriate cable As far as not yet done carry out external data saving before you update your updating system software see Section 4 1 4 Data Saving 1 Turn the start up switch S3 to position 2 software update on permanent memory 2 Run Winpcin make selection of binary format 115200 of baud rate then choose file named ENCO abb under the path system in toolbox CD 3 Power on gt message WAIT FOR SYSTEM SW appeared on the Screen Winpcin starts to transfer ENCO abb 5 Switch off system till UPDATE
91. eed M01 MMC gt selected selected PLC Program Feed 17000001 test override MMC gt Selected for rapid PLC traverse selected Select 17000002 Skip MMC gt Block PLC 17000003 MMC gt PLC Dynamic mode signals from MMC 1800 Signals from MMC r Data block Interface MMC PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 18000000 Machine function 18000001 TEACH IN 18000002 18000003 SINUMERIK 8025 base line 6 33 Start Up Technical Appendix General selection status signals from MMC retentive area 1900 Byte Data block Bit 7 Bit 6 Bit 5 MMC Signals r Interface MMC PLC Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 19001000 MMC gt PLC 19001001 MMC gt PLC 19001002 MMC gt PLC 19001003 MMC gt PLC Machine axis Axis number for han dwheel 1 B 19001004 MMC gt PLC Machine axis Axis number for han dwheel 2 B 19001005 MMC gt PLC 19001006 MMC gt PLC Control signals to operator panel retentive range Byte 1900 Data block Bit 7 Bit 6 Bit 5 Signals to operator panel Bit 4 Interface PLC Bit 3 gt Bit 2 r w Bit 1 Bit 0 19005000 OP key lock 19005001 19005002 19005003 6 34 SINUMERIK 8025 base line Star
92. encoder matching Spindle with rotary encoder 500 pulses mounted directly on the motor The internal multiplication factor is 4 The internal computational resolution amounts to 1 000 increments per degree 360 degrees MD 31080 Internal resolution X 1000 MD 31020 x 4 MD 31070 360 x 1 x 1000 Internal resolution 180 500 x4x 1 One encoder increment corresponds to 180 internal increments One encoder increment corresponds to 0 18 degrees minimum positioning step Example 2 for encoder matching Spindle with rotary encoder on motor 2 048 pulses internal multiplication 4 2 speed stages exist Gear stage 1 Motor spindle 2 5 1 Gear stage 2 Motor spindle 1 1 Gear stage 1 360 degrees MD 31080 MD 31050 Internal resolution X X x 1000incr deg MD 31020 x 4 MD 31070 MD 31060 360 1 1 Internal resolution X X x 1000pulses deg 17 5781 4 x 2048 1 2 5 One encoder increment corresponds to 17 5781 internal increments encoder increment corresponds to 0 0175781 degrees minimum positioning step SINUMERIK 802 base line 4 47 Start Up Start Up Gear stage 2 360 degrees MD 31080 MD 31050 Internal resolution x 1000incr deg 31020
93. er IS from PLC 3 The protection levels 2 and 3 require a password The passwords can be changed after activation For example if the passwords are no longer known the control system must be reinitialized booting in Start Up Switch position 1 This will reset all passwords to the default settings for this software version If the password is deleted protection level 4 is applicable The password remains set until it is reset using the Delete password softkey POWER ON will not reset the password 7 Protection level 4 is automatically set when no password is entered If required the protection levels 4 7 can be set from the user program via the user interface See Section 6 1 1 Display Machine Data Notice How to set the access levels is described in the User s Guide Operation and Programming SINUMERIK 802 base line Start Up 4 1 2 Number and name Activation Protection level Unit Default data Start Up Structure of machine data MD and setting data SD Machine data MD and setting data SD are differed either by numbers or names Both the number and the name are displayed on the screen Parameters Activation e Protection level e Unit e Standard value e Range of values The activation levels are listed according to their priority Any data changes come into effect after POWER switching on off the SINUMERIK 8025 base line NEW CONF cf Acti
94. er defined LED12 User defined User defined SINUMERIK 8025 base line Start Up 6 45 Technical Appendix 6 3 4 PLC machine data Definition of MD14512 The function of all 48 inputs and 16 outputs of the SINUMERIK 8025 base line basic variant can be set by means of the following parameters MD14512 USER DATA HEX Machine data PLC machine data Hex INDEX Bite Bit5 Bit4 Bits Bit2 Biti Input valid X100 Pin No 0 7 104 103 Input valid X101 Pin No 0 10 5 1 Input valid X100 Pin No 10 4 103 Input valid X101 Pin No 2 3 Output valid X200 Pin No Q 0 5 Q04 Q03 Output valid X201 Pin No 4 5 Output valid X200 Pin No 6 Q07 Q05 04 2 000 Output valid X201 Pin No 8 15 7 Q 1 7 Q 1 6 Q 1 5 Q 1 4 Q 1 3 Q 1 2 Q 1 1 Q 1 0 PLC sample configuration 11 Toolholder Gear Spindle Clamp Lubrication Coolant control change release Active Active Active Active Active Active Feed spindle override configuration 12 Spindle override Feed override Spindle Feed Override changeover speed changeover speed override override control mode Rotation monitoring active Spindle configuration 16 Z axis Y axis X axis Override Spindle Start up rotation rotation rotation switch enable Progress monitoring monitoring monitoring s
95. ese MD has been selected such that spindle motion is possible both in the simulation mode MD 30130 0 and with drive MD 30130 1 Reciprocation mode for gear change 4 48 The reciprocation mode of the spindle is intended to facilitate the gear change For reciprocation mode the following axis MD and interface signals are relevant SINUMERIK 802 base line Start Up Start Up MD Description 35400 Reciprocation speed 35410 Acceleration when reciprocating 35430 Start direction in reciprocation 35440 Reciprocation time for M3 direction 35450 Reciprocation time for M4 direction Interface signals Switch gear 39032000 bit 3 Reciprocation speed 38032002 bit 5 Reciprocation by PLC 38032002 Bit 4 Setpoint direction CCW bit 7 Setpoint direction CW 38032002 bit 6 Reciprocation mode 39032002 bit 6 Gear has been switched 38032000 bit 3 4 7 4 Completing the Start Up After start up of the control system by the machine manufacturer the following should be observed prior to delivery to the final customer 1 SINUMERIK 802S base line Start Up Change the default password for access level 2 from EVENING to your own password If the machine manufacturer uses the password EVENING for access level 2 during the start up work the password must be changed Press the softkey Change passw Ente
96. etup auto Cancella tion Feed motor with braking device Reference approach override inactive 17 Z axis Y axis X axis Z axis Y axis X axis Brake Brake Brake REF REF REF Pitch of hardware limit switch Technology setting 18 Emergen Z Y X Auto Drive Cy stop Single Single Single lubrication optimiza active switch for switch for switch for once when tion active Hardware Hardware Hardware power on limit swich limit swich limit swich 6 46 SINUMERIK 802S base line Start Up Technical Appendix Parameter Description MD14512 11 BitO 21 PLC subroutine COOLING will be executed Bit1 21 PLC subroutine LUBRICAT will be executed Bit2 21 PLC subroutine LOCK UNL will be executed Bit3 21 PLC subroutine SPINDLE will be executed Bit6 1 PLC subroutine GEAR will be executed Bit7 21 PLC subroutine TURRET1 will be executed MD14512 12 Bit 0 1 Feed and Spindle override controled by switchs Bit 0 0 Feed and Spindle override controled by trigger user keys Bit 2 1 Record the feed override value of the last machine turn off for the next startup Bit 220 Startup feed override is always 10096 Bit 321 Record the spindle override value of the last machine turn off for the next startup Bit 320 Startup spindle override is always 10096 Bit 4 5 Define feed override shift speed Bit5 Bit4 Feed override shift speed 0 0 Standard speed The steps are 0 1 5 2 4 6 8 10 20 30 40 50 6
97. grees always 0 0 DOUBLE 2 7 31000 ENC IS LINEAR Direct measuring system linear scale encoder no POWER ON always 0 we Mis BOOLEAN 2 7 6 6 SINUMERIK 8025 base line Start Up Technical Appendix 31010 ENC GRID POINT DIST mm Division period for linear scales encoder no POWER ON always 0 01 0 0 plus DOUBLE 2 7 31020 ENC RESOL Encoder markings per revolution encoder no POWER ON _always 2048 0 0 plus DWORD 2 7 31030 LEADSCREW PITCH mm Pitch of leadscrew POWER ON always 10 0 0 0 plus DOUBLE 2 7 31040 ENC IS DIRECT Encoder mounted directly to the machine encoder no POWER ON always 0 Mild we BOOLEAN 2 7 31050 DRIVE AX RATIO DENOM Denominator load gearbox control parameter 0 5 POWER ON always 1 1 1 1 1 1 1 2147000000 DWORD 2 7 31060 DRIVE AX RATIO NUMERA Numerator load gearbox control parameter set no 0 5 POWER always 1 1 1 1 1 1 1 2147000000 DWORD 2 7 31070 DRIVE ENC RATIO DENOM Denominator resolver gearbox encoder POWER ON always 1 1 2147000000 DWORD 2 7 31080 DRIVE ENC RATIO NUMERA Numerator resolver ge
98. he storage oscilloscope to X7 50 plug connector Pint setpoint 10V Pin6 analog ground The axis setpoint value is switched using MD 31500 AXIS NUMBER FOR MONITORING Example The axis setpoint value of the Z axis is to be output at connector X7 To this end enter the following value in the axis MD of the 3rd machine axis Sp Turning AXIS NUMBER FOR MONITORING AX4 2 Z axis always has axis number 2 Milling 5 NUMBER FOR MONITORING AX4 Z axis always has axis number 3 Notice With this setpoint assignment AXIS NUMBER FOR MONITORING unequal to 0 servo enable is always 0 After the measuring process but at least before the spindle setpoint value is connected to X7 the MD AXIS NUMBER FOR MONITORING AX4 0 must be set and the control system be switched off and back on again POWER ON Dynamic adaptation for thread G331 G332 Function Activation 4 40 The dynamic response of spindle and involved axis for the function G331 G332 thread interpolation can be adapted to the slower control loop Usually this concerns the Z axis which is adapted to the more inert response of the spindle If an exact adjustment is carried out it is possible to sacrifice of a compensating chuck for tapping At least higher spindle speeds smaller compensation paths can be achieved The values for the adaptation are entered in MD 32910 DYN MATCH TIME n usually for the axis The adaptation is
99. high gear in position 11 2 Tool sensor T3 Hardware limit Y 11 3 Tool sensor T4 Y reference cam 11 4 Tool sensor T5 Hardware limit Y 11 5 Tool sensor T6 Not defined 11 6 Over limit release for EMG Over limit release for EMG chain chain 11 7 Drive ready T72 for 611U Drive ready T72 for 6110 infeed module infeed module X102 X105 Not defined Output signals description Output Signals Description X200 For turning machine For milling machine Q0 0 Spindle CW Spindle CW 00 1 Spindle CCW Spindle CCW Q0 2 Coolant control Coolant control QO 3 Lubrication control Lubrication control Q0 4 Turret CW undefined Q0 5 Turret CCW undefined Q0 6 Chuck clamping Tool clamping Q0 7 Chuck unclamping Tool release X201 Q1 0 Undefined Spindle gear level low Q1 1 Undefined Spindle gear level high Q1 2 Undefined undefined Q1 3 Motor brake release Motor brake release Q1 4 Spindle brake Spindle brake Q1 5 Supply infeed T48 Supply infeed T48 Q1 6 Supply infeed T63 Supply infeed T63 Q1 7 Supply infeed T64 Supply infeed T64 SINUMERIK 8025 base line Start Up 6 43 Technical Appendix Note 1 Undefined when only a single hardware limit switch of each axis 2 When position turret is used 11 4 and 11 5 not defined 3 When MD30134 1 2 00 0 and 00 1 not be defined in PLC Meanwhile 0 0 and 00 1 are
100. hine axis are contained in the default machine data The spindle setpoint 10 V analog voltage signal is output to X7 The spindle measuring system must be connected to X6 The axis MD 30130 CTRLOUT TYPE and 30240 ENC TYPE can be used to Switch the setpoint output between simulation and axis operation Table 4 13 MD Simulation Normal Mode 30130 Value 0 Value 1 To test the spindle the spindle The setpoint signals are output to setpoint is internally fed back as X7 Real rotation of the spindle is an actual value No setpoint possible output to connector X7 30240 Value 0 Value 2 The following modes are possible for the spindle e Control mode 4 M5 e Oscillating mode to assist gearbox change e X Positioning mode SPOS Number Explanation Default Value 30130 Output type of setpoint Setpoint branch 0 30200 Number of encoders 1 30240 Type of actual value acquisition 0 actual position value encoder no 0 Simulation 2 Square wave generator standard encoder pulse multiplication 30350 Output of axis signals with simulation axes 0 31020 Encoder markings per revolution encoder no 2048 31030 Pitch of leadscrew 10 31040 Encoder mounted directly to the machine encoder 0 31050 Denominator load gearbox control parameter no 1 0 5 SINUMERIK 802 base line Start Up Start Up
101. ibed in the Toolbox readme file SINUMERIK 802S base line Start Up Alarm texts are structured as follows Start Up Alarm number Flag 1 Flag2 Text Notice The text must be put in inverted commas 47 Adhere to the given text structure Table 4 5 Example Alarm Number Flag 1 Flag 2 Text 700000 0 0 User alarm 1 700000004 1st user alarm text is assigned by the user 700001 00 2nd user alarm text is assigned by the user 700002004 3rd user alarm text is assigned by the user 70000300 Ath user alarm text is assigned by the user 70000400 user alarm text is assigned by the user 70000500 6th user alarm text is assigned by the user 700031 00 32nd user alarm the text is assigned by the user Number The alarm text must be here Comment line does not appear in the dialog window of the Operator Panel If no user alarm text is assigned by the user the operator panel will display only the alarm number The 96 character in the alarm text is the code for the additional variable The variable type is the representation type of the variable The following variable types are possible 96D Integer decimal number 96 Integer decimal number U Unsigned decimal number 0 Integer octal number 96X Integer hexadecimal number Binary representation of 32 bit value 96 4 byte floating point number SINUMERIK 8025 base line Star
102. ic Control executes the integrated PLC user program cyclically Integrated PLC user program intended to adjust the SINUMERIK 8025 base line to the machine functions see also Description of Functions Integrated User Program for SINUMERIK 8025 base line e Toolbox WinPCIN transfer program for a PC PG programming device to transfer user data and programs Text manager Cycle kit for loading into the control system using WinPCIN User program library Technological machine data files Programming tool e Update diskettes Update program with operator prompting system 8025 base line system software packed for loading and programming the SINUMERIK 8025 base line via an update program User data User data are e Machine data e Setting data e Tool data e R parameters offsets e Compensation data e Part programs e Standard cycles Data saving Modified user data are saved for at least 50 h after power off or power failure After then they might get lost Warning To avoid data loss the operator must carry out data saving see Section 4 1 4 1 2 SINUMERIK 802 base line Start Up SINUMERIK 8025 base line Control System 1 2 Technical data Connected load Table 1 1 Connected load Parameter Min Typ Max Unit Supply voltage 20 4 24 28 8 V Ripple 3 6 Vss Current consumption from 24 V 1 5 A Power dissipation of CNC 35
103. imit switch per axis possible And also possible for emergency stop chain Reference point cam monitoring Feedrate override can be inhibited by PLC MD during reference point approaching Rotation monitoring for stepper drive only activated by PLC MD Motor brake release control Contactor controlled spindle induction motor without converter Analog spindle control e Spindle enable and disable Spindle manual operation CW CCW and Stop in JOG mode Directly change over from to M04 or from 04 to during spindle program operation AUTO or MDA mode external brake signal is automatically output between to M04 changeover External spindle brake control If converter is to be used setpoint should be 10V or 0 10V For 0 10 converter Q0 0 is for CW enable and 00 1 for CCW enable For 10 converter its enable should be connected to For 8025 Pin5 and Pin 9 For 802C X7 Pin65 and Pin 9 Spindle manual operation CW CCW and Stop in JOG mode Spindle program operation AUTO or MDA mode Turret control for turning machine SINUMERIK 8025 base line Start Up Suitable for 4 or 6 position Hall Effect Device sensor turret Turret clamping time monitoring time can be specified by PLC MD Turret sensors monitoring During turret activate read in disable and Feedhold 6 41 Technical Appendix Coolant control Manual coolant on off using user key K6 toggle in JOG mode Program
104. in the upper speed range see Fig 4 6 M Nm Stepper motor Mmax 25 4 000 r p m 1 Nrea Reducing speed Maximum speed 10 20 40 60 80100 n 76 Fig 4 6 Typical motor characteristic for step switching drives The optimum capacity utilization of such characteristics with a simultaneous overload protection can be achieved using the velocity dependent acceleration characteristic Bent acceleration characteristic Activation In the AUTOMATIC mode the bent acceleration characteristic is always active The axis behavior is set via the parameterization of the characteristic For single motions in JOG mode the bent acceleration characteristic can be enabled via MD 35240 MA ACCEL TYPE DRIVE 1 default value 0 Notice The bent acceleration characteristic only be parameterized axis related The path traversing behavior results from the caluclation using the axes involved e MD 32420 AND JERK 0 Prerequisite for action of the bent acceleration characteristic in JOG Parameterization of the axis characteristic The axial course of the acceleration characteristic must be parameterized using the following machine data 4 38 SINUMERIK 802 base line Start Up Start Up Number MD Identifier Default Value linear circular 32000 MA MAX AX VELO 10 000 0 mm min 27 7 r
105. inal block for connecting the 24 V load power supply X2 RS232 interface V24 9 pin sub D plug connector X6 spindle interface ENCODER 15 pin sub D socket for connecting a spindle incremental position encoder RS422 XT drive interface AXIS 50 pin sub D socket connector for connecting the power sections for a maximum of four analog drives including spindle X10 handwheel interface MPG 10 pin front connector for connecting the handwheels X20 digital inputs DI 10 pin front connector for connecting BERO proximity switches 2 4 SINUMERIK 802 base line Start Up DIO Installing the Control System X100 to X105 10 pin front connector for connecting digital inputs X200 and X201 10 pin front connector for connecting digital outputs Operating elements Start up switch S3 Fuse Fuse F1 externally designed to allow users for convenient replacement S2 and D15 These elements are provided only for debugging internally SINUMERIK 8025 base line Start Up 2 5 Installing the Control System Connecting cables The components are wired up as shown in the Connection Diagram 2 4 For the cables required please refer to the diagram below DC24V AXIS SPINDLE ENCODER wire 11 0 2 0 mm option 6 2003 00500 RS232 communication Isolator with computer GFX8002 1AA01 1 0 BS 6 6002 5 51 1 0 6FX2002 3AD02 1 0 Stepdrive FM Stepdri
106. is still present the alarm occurs again SINUMERIK 8025 base line 4 13 Start Up Start Up User alarm activation Configuring Alarm texts 4 14 U Inter ser lt gt nal in interface terface Alarm handler Feed disable active Feed disable in the CNC is active for all axes as long as the PLC user alarm is active User program Example Feed disable 0 User alarm with feed disable Alarm handler Module Analyze user alarm PLC cycle Fig 4 2 User alarm with Feed Disable alarm response Each alarm is assigned a configuration byte The user alarms can be configured by user alarms the machine data 14516 MN USER DATA PLC ALARM Default setting MD 14516 0 gt SHOW ALARM SELF CLEARING user alarm Configuration byte structure e BitO0 bitb Alarm responses e Bit6 bit7 Cancel criterion Alarm responses BitO bit 5 0 Showalarm default Bito 1 NC Start inhibited Biti 1 Read in disable Bit2 1 Feed disable for all axes Bit3 1 EMERGENCY STOP Bit4 1 PLC Stop Bit5 Reserved Cancel criteria Bit6 bit7 0 SELF CLEARING alarm default Bit6 1 CANCELCLEAR alarm Bit7 1 POWERONCLEAR alarm The user has two possibilities to define his own alarms using the Edit PLC txt softkey See Operation Programming Chapter 7 using the Text Manager in Toolbox CD The procedure is descr
107. itched off With the supply voltage switched off hazardous voltages are present at the mains and motor connections Under no circumstances may these connection be touched in the ON condition otherwise loss of life or severe personal injury could be the consequence SINUMERIK 802S base line 3 3 Start Up Installing the STEPDRIVE Mains connection The device must be connected via an external fuse Fuse K6A for 1 axis K10A for max 2 axes If the transformer possesses a shielded winding this should be connected with low inductivity to PE Ground the transformer on the secondary side Connecting the motor end cables Pulse interface To connect the cables remove the terminal box cover 3 screws Use the cable with the order no 6FX6 002 5 51 On the drive end connect the cable shield to the housing such that an electrical connection is provided via the appropriate strain relief clamp and clamp the braided shield to PE On the motor side braid the shield provided it with a cable shoe and clamp it to the grounding screw To connect the drive pulse interface to the SINUMERIK 8025 base line use the preassembled cable order no 6FX2 002 3AD02 1xx0 On the drive side connect the cable shield to the housing such that an electrical connection is provided via the appropriate strain relief clamp 24V signal interface To evaluate the 24 V high side signals Zero Phase ZPM and or Drive ready RDY in the
108. key more than the setpoint the override shifts to 100 directly Unit 100ms Range 5 30 0 5 3 seconds if overrun the default is 1 55 14510 16 Definition Machine tool type Unit Range 0 Turning machine 1 Milling machine 22 not defined 14510 17 Definition Drive type Unit Range 0 stepper drive 1 analog drive SimoDrive 611 gt 2 not defined 14510 20 Definition number of positions on the turret Unit Range 4 6 8 note for SAMPLE only 4 6 permitted 14510 21 Definition monitor time turret change abort if destination tool not found within specified time Unit 0 1 second Range 30 200 3 20 second 14510 22 Definition Turret clamping time Unit 0 1 second Range 5 30 0 5 3 second 145101231 Definition Braking time of external brake mechanism of a contactor controlled spindle Unit 0 1 second Range 5 200 0 5 20 second 14510124 Definition Interval of track lubrication Unit 1 Minute Range 5 300 Minutes 14510 25 Definition Duration of lubrication Unit 0 1 second Range 10 200 1 20 second 14510126 Definition X axis traverse key position Unit Range between 22 30 but not 26 14510 27 Definition X axis traverse key position Unit Range between 22 30 but not 26 14510 28 Definition Y axis traverse key position Unit Range between 22 30 but not 26 14510
109. mation are displayed on the screen as progress displays After the control system has booted without errors it changes to the JOG Ref point approach mode and the yellow DIAG LED see Fig 4 1 Boot errors 4 8 flashes Boot errors are displayed either on the screen or via the LED see Fig 4 1 in the following The ERR flashes and the DIAG LED does not flash Fig 4 1 LED Table 4 3 Boot errors ERROR EXCEPTION ERROR DRAM ERROR BOOT ERROR NO BOOT2 ERROR NO SYSTEM ERROR LOAD NC SYSTEM LOADER ERROR LOAD NC CHECKSUM ERROR ERROR LOAD NC DECOMPRESS ERROR ERROR LOAD NC INTERNAL ERROR 1 Error Message Remedial Action Switch off the control system and back on again POWER ON Inform the hotline if necessary Carry out a software update Replace the hardware components SINUMERIK 8028 base line Start Up 4 3 General 4 3 1 Start Up Starting up the PLC The PLC is a store programmable logic controller for simple machines It has no hardware of its own and is used as a software PLC in the SINUMERIK 802C base line control system The task of the PLC is to control machine related functional sequences The PLC executes the user program cyclically A PLC cycle is always executed in the same sequence of order e Update process image inputs outputs user interface timers e Process
110. memory and start up switch S3 are set correctly see Fig 2 6 the control system boots Start up switch S3 hardware The is provided with a start up switch to assist start up of the control system This switch can be actuated using a screw driver Table 4 2 Start up switch settings Position Meaning 0 Normal power up 1 Power up with default machine data user data determined by the software version System software update Power up with saved data PLC stop Reserve Assigned Assigned AWIN The switch position comes into effect with next power up and is displayed on the screen when the control system powers up Start up switch software In addition to the hardware start up switch the following functions can also be carried out in the Diagnosis Start up Start up switch menu e Normal boot Start up switch position 0 e Boot with default machine data Start up switch position 1 e Boot with saved data Start up switch position 3 These power up functions have a higher priority than the hardware start up switch Booting the control system When the control system is turned on for the first time an initial state of the control system is established automatically All memory areas are initialized and are loaded with previously stored default data The PLC area of retentive bit memories is explicitly erased 4 6 SINUMERIK 802 base line Start Up Start Up
111. nsation value If the compensation values are too high an alarm message can be output e g contour monitoring speed setpoint limitation The LEC is only activated in all operating modes if the following requirements are met e The number of compensation intermediate points must be defined They are only active after Power ON MD MM_ENC_MAX_POINTS SINUMERIK 802S base line Start Up Start Up Caution Changing the MD MM or MM COMP MAX POINTS automatically reorganizes the NC user memory when the control system is booting All user data stored in the user memory e g drive and MMC machine data tool offsets part programs compensation tables etc are deleted Enter the compensation value for the intermediate point in the compensation value table COMP 0 N Axi Select the distance between the individual intermediate points COMP STEP 0 Axi Select the start position MIN 0 Axi Define the end position MAX 0 Axi e In the NC set MD COMP 0 0 This is the only way to load the compensation table The compensation values for the machine axes are entered into the NC memory by means of a part program see also example in the Manual Description of Functions e Approach the reference points in the axes Then start the NC program with the leadscrew error compensation table The reference poin
112. onfiguration of the RS232 interface connection X2 emen 2 3 4 Connecting handwheels X1 0 2 3 5 Connecting BERO and NC READY X20 eder toe atu ER ee 236 Connecting the digital inputs X100 X105 2 3 7 Connecting the digital outputs X200 X201 eT EXER TO Er RR 24 Power Supply for CNC X1 PEI dard RUNE CRAS TO dag dq P ao DAP 2 5 LEDs and Other Elements on 3 Installing the STEPDRIVE 222220222222 9 3 1 Installing and dismantling the STEPDRIVE drive modules 3 2 Cabling 3 3 Starting up the drive modules eene 4 Start Up TDI eee ere eer 4 1 General eee mmm mi rae reme nre rie nre nen 4 1 1 Access levels enemies neni rennen nen 4 1 2 X Structure of machine data MD and setting data SD ee 4 1 3 Handling of machine data eene mimm mie mienne nian 4 1 4 Data saving FIAT UEETEEEIA FIAT eer er FEN E EE ET
113. ositioning 300 Positioning speed when velocity referencing 34200 of position measuring 1 2 Single edge BERO System 4 Double edge BERO 0 No ref point appr if absolute encoder exists REFP SET POS accepted 1 Zero pulse on encoder track 2 BERO 3 Distance coded reference marks 4 Bero with two edges 5 BERO cam 36200 Threshold value for velocity 11500 Threshold value for monitoring control parameter set no 0 5 velocity monitoring SINUMERIK 8025 base line Start Up 4 35 Start Up To solve monitoring problems set the following machine data Number Description Default Value Setting or Remark 36000 Exact positioning coarse 0 04 0 5 36010 Exact positioning fine 0 01 0 1 36020 Delay exact positioning fine 1 0 4 36060 5 0 20 velocity speed axis spindle stopped Parameterization example Stepper motor 10 000 pulses per motor revolution Load gear 1 1 Leadscrew pitch 10 mm Motor speed 1 200 rpm MD 30130 2 MD 30240 3 MD 31400 10 000 MD 32260 1 200 rpm MD 32000 12 000 mm min Stepper motor frequency The parameterization is carried out using the machine data which have already been mentioned after POWER ON The resulting stepper motor frequency is displayed with machine data MD 31350 Motor speed rpm steps per stepper motor revolution MD 31350 2
114. plicable only to the first PLC cycle 0 data o k 1 data lost SM 0 3 POWER ON first PLC cycle 1 following cycles 0 SM 0 4 60 s cycle alternating 40 for 30 s then 1 for 30 s SM 0 5 1 s cycle alternating 0 for 0 5 s then 1 for 0 5 s SM 0 6 PLC cycle alternating one 0 cycle then one 1 cycle SINUMERIK 802 base line Start Up Start Up 4 3 6 Instruction set A detailed description of the instructions is to be found in the help system of the PLC 802 Programming Tool Help Contents and Index SIMATIC LAD Instructions and in the Documentation 57 200 Automation System CPU22x System Manual Table 4 11 Instruction set BASIC BOOLEAN INSTRUCTIONS Instruction Ladder Symbol Valid Operands Load normal open V 1 Q M SM L Bit And n 1 close Or n 0 open Load Not normal close Bit V Q M SM L And Not n 0 close Or Not n 1 open i Output prior 0 0 Bit V I Q M T C L prior 1 n 1 Set prior 0 not set Bit V I Q M T C L 1 Bit prior 1 or T 5 Reset prior 0 no reset Bit 1 Bit prior 1 or T 1 V 1 Q M T L OTHER BOOLEAN INSTRUCTIONS Instruction Ladder Symbol Valid Operands Edge Up prior 7 close 1 PLC cycle Edge Down prior 4 close 1 PLC cycle E Logical Not prior O later 1 prior 1 later 0 or No operation n
115. power up of the control system The hardware start up switch PLC STOP position 4 is active immediately The priority of the power up modes activated via the softkeys on the operator panel is higher than that of the hardware start up switches Example e Hardware start up switch position e Restart from operator panel gt Restart is active from next power up of the control system The Run mode activates the cyclic mode SINUMERIK 802S base line Start Up Start Up 4 3 3 In the Stop mode the following actions are initiated e hardware outputs are disabled e Ready relay is inactive e cyclic operation active user program is not executed e Process image is no longer updated frozen e Emergency Stop active The user can also use the PLC 802 Programming Tool to start the Stop or Run modes A corrected or new project can only be loaded into the control system in the Stop mode The user program comes only into effect with next power up or when the Run mode is active PLC alarms The control system displays a maximum of 8 PLC alarms system alarms or user alarms The PLC manages the alarm information per PLC cycle It stores or deletes the alarms in the alarm list according to their occurrence The first alarm in the list is generally the alarm last occurred If more than 8 alarms occur the first seven alarms occured are displayed and the last one with the highest cancel priority is displaye
116. provided with a V24 interface for data transfer from to the control system is necessary In the PC PG the WINPCIN tool must be used Sequence of operations 1 SINUMERIK 8025 base line Start Up Create the series machine start up file transfer from the control system to the PC PG Make a V24 cable connection between the PC PG COM port and the SINUMERIK 8025 base line X2 Select Binary format and the same baud rate both in the WinPCIN tool SINUMERIK 8025 base line communication setting menu Make the following settings in WINPCIN tool Receive data Select the path where you want to save your data Save The PC PG will set itself to Receive and will wait for data from the control system Enter the password for protection level 2 in the control system Call the Services RS232 setting menu Select the Start up data line from the Services menu and press Start data outp to output the series machine start up file Reading in the series machine start up file into the SINUMERIK 802S base line Enter the V24 interface settings as described under 1 Press the Data In Start button in the Service menu The control system is thus ready to receive data Use the WINPCIN tool in the PC PG to select the series start up file from the DATA OUT menu and start data transfer The control system is brought to RESET with rebooting three times during and at the end of data transfer On completion of error fr
117. r spindle speed limitation G25 0 43220 __ Progr spindle speed limitation G26 1000 43230 Spindle speed limitation with G96 100 Spindle MD parameterization Spindle machine data are entered depending on the gear stages Each gear stage is assigned a parameter record The set of parameters corresponding to the current gear stage is selected Example Notice 1st gear stage gt set of parameters 1 The field containing the parameter O is not used for the spindle machine data Machine data for setpoint and actual values 4 46 Setpoints MD 30130 CTRLOUT_TYPE AX4 1 Actual values MD 30200 NUM ENCS AX4 0 MD 30200 NUM_ENCSJ AX4 1 MD 30240 ENC_TYPE AX4 2 f Type of encoder Spindle without encoder Spindle with encoder SINUMERIK 8025 base line Start Up Start Up Matching encoder to spindle Machine data for encoder adjustment Number Description Spindle 31040 Encoder mounted directly to the machine 0 1 encoder no 31020 Encoder markings per revolution Incr rev Incr rev encoder no 31080 Numerator resolver gearbox Motor revs Load rev encoder no 31070 Denominator resolver gearbox Enc revs Enc revs encoder no 31060 Numerator load gearbox Motor revs Motor revs control parameter set no 0 5 31050 load gearbox Load revs Load revs control parameter no 0 5 Example 1 for
118. r the new password and press OK to confirm Note the password in the Manufacturer Documentation Reset the access level To save the data which have been set during the start up an internal data saving is required To this aim set access level 7 final customer otherwise access level 2 will also be saved Press the softkey Delete passw The access level will be reset Carry out internal data saving Press the softkey Save data 4 49 Start Up 4 7 5 Cycle start up Sequence of operations When loading cycles into the control system adhere to the following sequence of operations 1 Save tool offset data and zero offsets either on the FLASH or on the PG programming device These data can be selected in the Services menu by pressing the Data outp data softkey 2 Load all files of the selected technology path from the toolbox diskette into the control system via the V24 interface 3 Carry out POWER ON 4 Reload the recovered data 4 50 SINUMERIK 802 base line Start Up Start Up 4 8 Series machine start up Functionality The objective of series machine start up is after commissioning in order to bring another control system connected to the same machine type with minimum effort to the condition as after commissioning or e Under service conditions after replacing hardware components to bring a new control system to the initial state with minimum effort Precondition To carry out commissioning a PC PG
119. rol system even without connection to input and output terminals The user program processes all firmly defined keys and the default setting of the axis keyboard default Axes and spindle are switched to simulation mode No real axis movement is carried out The Axis Spindle Disable user signal is set for each axis For this reason the movements of both axes and spindle are simulated virtually The user can use this program to test the interrelation of the components integrated in CNC SINUMERIK 8025 base line 4 9 Start Up Start Up Approach Set MD20700 to zero Use the Diagnosis StartUp switch PL softkey to select Simulation You can check the current setting via Diagnosis Service display Version PLC application Select the desired key and check your setting by pressing the key Supported keys e Mode selection QO e Axis keys cz OEIL e ago Notice The Increment key is only active in the JOG mode The toggle function can be used to set increments in the range between 1 10 100 or 1000 Check the response by pressing the axis direction keys Reference Point is not supported Standard user program The control system comes with an universal program the customer can choose the technology mode Turning or Milling with PLC user machine data 4 10 SINUMERIK 8025 base line Start Up 4 3 2 The PLC can activate its start up modes from two places Table 4 4 Start up modes S
120. rsed together with the remaining axes If the additional axis is traversed in a program block that contains G1 or G2 G3 using the axes X Z then it will not be assigned a component of the feedrate F In this case the axis speed will depend on the path travel time of the axes X 2 Its motion starts and ends together with the axes X Z The axis speed however cannot be greater than the limit value defined for the additional axis If the additional axis is programmed in a separate block it will travel with the active feedrate F if G1 is programmed Both settable offsets G54 G57 and programmable offsets G158 are possible for the additional axis Tool offsets are not effective in this axis Simulation stepper motor drive Setpoint output and pulse feedback can be switched between simulation and drive operation using the axis MD 30130_CRTLOUT_TYPE and 30240 TYPE Table 4 12 MD Simulation Normal Operation 30130 Value 0 Value 2 To test the axis the actual value The setpoint signals for stepper is fed back internally as an motor operation are output at actual value No setpoint output connector X7 Real axis traversal at connector X7 is possible using a servo motor 30240 Value 0 Value 3 Internal pulse feedback from setpoint output to actual value input ON Machine data default settings for stepper motor axes 4 34 The machine data list bloew contains the default machine da
121. s Parameter Max Unit Switching voltage 50 V Switching current 1 A Switching power 30 VA Cable length max 35 m SINUMERIK 8025 base line 2 9 Start Up Installing the Control System 2 3 2 Pin assignment of the connector on the CNC side Measuring system interface incremental encoder Connector designation X6 Connector type Table 2 5 Pin assignment of the female connector X6 ENCODER Connecting the spindle measuring system X6 15 pin sub D plug connector Pin Signal Type Pin Signal Type 1 9 VO 2 10 2 3 n c 11 ZN 15 4 P5 MS VO 12 B_N 5 n C 13 B 9 6 P5 MS VO 14 7 VO 15 A 8 n C Signal names Description A B B Track B ZZN Zero Reference Mark P5 MS 5 2V Supply Voltage M Ground Signal Specification RS422 Signal type VO Voltage output supply 5V input 5V signal Connectable encoder types Characteristics 2 10 Incremental 5 V encoders can be connected directly The encoders must meet the following requirements Transmission method Differential transmission with 5 V square wave signals Output signals Track A as true and negated signal 0 1 U Track B as true and negated signal U Zero signal N as true and negated signal Ua Max output frequency 1 5 MHz Phase offset between tracks A and B Current consumption 90
122. s encoder no RESET always 0 TEE BOOLEAN 2 7 34060 REFP MAX MARKER DIST mm Maximum distance to reference mark Max distance to 2 RESET reference marks for distance coded measuring systems always 20 0 0 0 plus DOUBLE 2 7 34070 REFP VELO POS mm min Reference point positioning velocity RESET rev min always 1000 0 0 0 plus DOUBLE 2 7 34080 REFP MOVE DIST mm Reference point distance target point for distance coded RESET deg system always 2 0 DOUBLE 2 7 34090 REFP MOVE DIST CORR mm Reference point offset absolute offset distance coded POWER ON deg always 0 0 DOUBLE 2 7 34092 REFP CAM SHIFT mm Electr cam offset of incremental measuring systems with RESET deg equidistant zero marks always 0 0 0 0 plus DOUBLE 2 7 6 10 SINUMERIK 8025 base line Start Up Technical Appendix 34100 REFP SET POS mm Reference point value irrelevant for distance coded RESET deg system 0 3 always 0 0 0 0 DOUBLE 2 7 34110 REFP CYCLE NR Sequence of axes channel specific referencing RESET 1 No obligatory reference point for NC Start 0 No channel specific reference point approach 1 15 Sequence
123. stem can and must also be saved externally External data saving requires a PC PG programming device with V24 interface and the WinPCIN tool included in the tool box External data saving should be performed whenever substantial changes in the data have been made as well as always at the end of start up External data backup variants Saving data externally 1 The data record is read out completely creating the series start up file This is intended for series start up or to restore the control system status after replacing hardware components or after data loss 2 Files are read in or read out by areas The following user data can be selected as individual files Data Machine data Setting data Tool data R parameters Zero offset Compensation data LEC Part programs Standard cycles Saving data externally Use the Services Data outp menu to transfer the following user data as individual files to an external PC via the V24 interface Loading data from an external data backup into the control system Press the Start data inp softkey in the Services menu SINUMERIK 8025 base line 4 5 Start Up Start Up 4 2 Turning on and booting the control system Procedure e Inspect the system visually for proper mechanical installation with tight electrical connections supply voltages connections for shielding and grounding e on the control system Notice Providing
124. t Up 4 15 Start Up 4 16 User alarm text examples 700000 700001 700002 700003 700004 700005 Operator panel display or Only user alarm number Hardware limit switch X axis D Only variable as an integer decimal number Alarm number with fixed alarm text and variable X U Alarm number with variable and fixed alarm text Rotation monitoring of axis active U 700005 Rotation monitoring of axis active 1 700005 Rotation monitoring of axis active 3 SINUMERIK 8025 base line Start Up Start Up 4 3 4 Machine control panel area layout The machine control panel area in the standard version has been configured for economic turning machines 2 axes and one spindle The user can use the keys K1 K12 and the associated LEDs the same applies to keys K1 12 for his own purposes The keys K22 K30 should be used as axis keys see sample program SAMPLE The programmer can assign the axis keys depending on his particular machine type The keys K31 K36 are used as axis override and spindle override buttons Notice When delivery the SINUMERIK 802SC base line is provided with inserted stripes 10 provided 3 of them are inserted as standard for turning technology which consist of all the combinations for both turning and milling technologies It is also possible for the user to customize keys K1 K12 The method in details is explained in Toolbox Layout
125. t Up 6 2 7 Status signals from Machine control panel signals MCP signals Technical Appendix Signals from MCP r 1000 Interface MCP gt PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 K14 K13 K6 K5 K4 K3 K2 K1 10000000 JOG INC User User User User User User defined defined defined defined defined defined K22 K21 K20 K19 K18 K17 K16 K15 10000001 Axis key Spindle Spindle Spindle SBL AUTO REF start stop start 4 K30 K29 K28 K27 K26 K25 K24 K23 10000002 Axis key Axis key Axis key key Axis key Axis key Axis key Axis key K10 K9 K8 K7 K39 K38 K37 10000003 User User User User NC STOP NC defined defined defined defined START RESET Feed override 10000004 K12 K11 K35 K33 K31 User User Feed Feed Feed defined defined override override override 100 Spindle override 10000005 K36 K34 K32 Spindle Spindle Spindle override override override 100 Control signals to MCP 1100 Signals to MCP r w Interface PLC gt MCP Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 LED8 LED7 LED6 LED5 LED4 LED3 LED2 LED1 11000000 User User User User User User User User defined defined defined defined defined defined defined defined LED16 LED15 LED14 LED13 LED12 LED11 LED10 LED9 11000001 Spindle Feed Spindle Feed User User User User
126. t active aborted stopped waiting running CNC CNC 33000004 alarm alarm All axes All axes with channel stopped Referenc stop of specific ed machin present ing present 33000005 33000006 33000007 SINUMERIK 802S base line 6 23 Start Up Technical Appendix Status signals Axes in WCS 3300 Signals from CNC channel r Data block Interface CNC PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Axis 1 in WCS 33001000 Traversing Handwheel active command plus minus 2 1 Axis 1 in WCS 33001001 Machine function Continu 1000 INC 100 INC 10 INC 1 INC ous 33001002 33001003 Axis 2 WCS 33001004 Traversing Handwheel active command plus minus 2 1 Axis 2 WCS 33001005 Active machine function Continu 1000 INC 100 INC 10 INC 1 INC ous 33001006 33001007 Axis 3 in WCS 33001008 Traversing Handwheel active command plus minus 2 1 Axis 3 in WCS 33001009 Active machine function Continu 1000 INC 100 INC 10 INC 1 INC ous 33001010 33001011 6 24 SINUMERIK 802 base line Start Up Transfer of auxiliary functions from the channel Technical Appendix 2500 Auxiliary functions from CNC channel r Data block Interface PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Modify 25000000 decoded M functions 0 99 25000001 Modify T funct
127. ta and their recommended settings with stepper motor axes connected After the machine data have been set the stepper motor axes are ready to traverse as far as the machine data are concerned and only fine adjustments are required SINUMERIK 802S base line Start Up Start Up Number Description Default Setting or Remark Value 30130 Output type of setpoint 0 2 setpoint branch 0 30240 of actual value 0 3 acquisition actual position value encoder no 0 Simulation 3 Encoder for stepper motor 31020 Encoder markings per 1000 Steps per stepper motor revolution encoder no revolution 31030 Pitch of leadscrew 10 Leadscrew pitch 31050 Denominator load gearbox 1 Load and resolver 31060 parameter no 0 5 transmission ratios 31100 Steps for monitoring rotation 2000 Repetition cycle of BERO in measuring system increments 31400 Schritte pro 1000 Steps per stepper motor Schrittmotorumdrehung revolution must be identical to MD 31020 32000 Maximum axis velocity 10000 30000 max axis velocity 32100 Traversing direction not 1 Reversal of direction of control direction motion 32110 Sign actual value control 1 Measuring system direction encoder no reversal 32200 Servo gain factor control 2 5 2 5 position controller parameter set no 0 5 gain 32260 Rated motor speed setpoint 3000 Motor speed branch 0 34070 Reference point p
128. tart up modes of the PLC Start Up Start Up Operator Panel PLC Program Program Retentive Data MD Switch Start Up Menu Selection Status Backed Up Interface CNC start up Normal power Normal power up User program Run Unchanged Accept active up PLC MD Position 0 Power up with Power up with User program Run Deleted Standard PLC MD default values default values Position 1 Power up with Power up with User program Run Saved data Saved saved data saved data PLC MD Position 3 PLC Stop Unchanged Stop Unchanged Accept active after PLC MD ON Position 4 PLC start up Restart User program Run Unchanged Accept active PLC MD Restart User program Stop Unchanged Accept active and debug mode PLC MD Restart with Simulation Run Unchanged Accept active simulation program PLC MD Overall reset User program Deleted Accept active PLC MD Overall reset and User program Stop Deleted Accept active debug mode PLC MD Diagnosis Start up Start up switch CNC softkey Diagnosis Start up Start up switch PLC softkey The start up switch PLC Stop can be activated either during operation or power up The debug mode see Operation and Programming Chapter 7 causes the PLC to remain in PLC Stop after the control system has powered up All power up modes that have been set either via softkeys or via hardware start up switches will only come into effect after the next
129. ts must then be approached once more to set the LEC active The LEC function is activated by setting the MD COMP 0 1 for each machine axis Another possibility to create the LEC compensation table is by reading outthe LEC file from the NC via the V24 interface MD MM ENC MAX POINTS must be set depending on the number of axes to be compensated Select Service using the softkey put the cursor to Data and press the Show softkey Then select Leadscrew Error using the cursor and press the Data Out softkey Enter compensation values intermediate point distance start and end position in the received file N COMPLETE EEC by means of the editor e g in the WINPCIN OUT program Then re read the edited file into the control system Approach the reference point in the axes and set MD ENC COMP ENABLE 0 1 The LEC is thus activated SINUMERIK 8025 base line 4 43 Start Up Start Up 4 7 3 Starting up the spindle Overview Simulation spindle Spindle modes MD for spindle 4 44 With the SINUMERIK 8025 base line the spindle is a subfunction of the entire axis functionality The machine data of the spindle are therefore to be found under the axis machine data from MD35000 For this reason data have to be entered for the spindle too these data are described for axis start up Notice With SINUMERIK 8025 base line the 4th machine axis SP is fixed for the spindle The spindle settings for the 4th mac
130. umber 0 1 20210 Maximum angle for compensation blocks with 100 TRC 20700 NC Start disable without reference point 1 21000 end point monitoring constant 0 01 22000 Auxiliary function group aux fct no in channel 1 0 49 22010 Auxiliary function type aux fct no in channel 0 49 22030 Auxiliary function value aux fct no in channel 0 0 49 22550 tool compensation for M function 0 Number Explanation DefaultValue 41110 Jog feedrate 0 41200 Spindle speed 0 42000 Start angle 0 42100 Dry run feedrate 5000 SINUMERIK 8025 base line Start Up 4 33 Start Up 4 7 2 Starting up the axes Overview Additional axes The SINUMERIK 8025 base line has up to three stepper motor feedrate axes X Y and Z The stepper motor drive signals are output at connector X7 for the e Xaxis SW1 BS1 RF1 1 RF1 2 e SW2 BS2 RF2 2 RF2 2 e Zaxis SW3 BS3 RF3 1 RF3 2 Spindle SWA4 RF4 1 RF4 2 The 2nd axis in the axis order which when milling has the function of the Y axis can be used as an additional axis when turning This is achieved by loading one of the files turnax U ini or turnax V ini or turnax W ini from the Toolbox and enabling these data Which files are selected is dependent on the desired axis name U or V or W The additional axis is a linear axis with limited functionality compared with the axes X and Z It can be trave
131. urrent 500mA Digital output 1 Unipolar Spindle CCW Direction Max current 500mA Power supply for the digital outputs 0 7 Power supply for the digital outputs 8 15 Voltage input Output 24 V signal SINUMERIK 802 base line Start Up Installing the Control System Table 2 17 Electrical parameters of the digital outputs Parameter Value Unit Note 1 signal nominal voltage 24 V Voltage drop max 3 V 1 signal output current 0 5 A Simultaneity factor 0 5 per 16 outputs 0 signal leakage current max 2 SINUMERIK 802 base line 2 19 Start Up Installing the Control System 2 4 Power Supply for CNC X1 Screw terminal block The 24 V DC load power supply unit required for supplying CNC is connected to screw type terminal block X1 Characteristics of the load power supply The 24 V DC voltage must be generated as a functional extra low voltage with safe electrical Isolation to IEC 204 1 Section 6 4 PELV Table 2 18 Electrical parameters of the load power supply Parameter Min Max Units Conditions Voltage range mean value 20 4 28 8 V Ripple 3 6 Vss Non periodic overvoltage 35 V 500 ms cont 50 s recovery Rated current consumption 1 5 A Starting current 4 A Pin assignment on the CNC side Table 2 19 Pin assignment of screw terminal block X1 Terminal 1 PE PE M Ground 3 P24 DC 24 V 2 20 SINU
132. vate MD softkey on the operator panel RESET key on the operator panel Modifications at the block limits are possible while the program is running RESET re RESET key on the operator panel or 2 30 at the end of the program IMMEDIATELY im after entering a value To display machine data protection level 4 or higher must be activated Start up or machine data input generally requires protection level 2 or higher password EVENING Depending on the MD SCALING SYSTEM 16 METRIC the physical units of the MD are set as follows MD10240 1 MD10240 0 Mm in mm min in min m s in s m s in s mm rev in rev If no physical units are applicable to the MD the field contains a Notice The default setting of the machine data is MD10240 SCALING SYSTEM IS METRIC 1 metric This is the default value for the machine or setting data SINUMERIK 8025 base line 4 3 Start Up Start Up Range of values minimum and maximum values specifies the input limits If no range of values is specified then the input limits are defined by the data type and the field is marked with 4 1 3 Handling of machine data Handling methods Display Input via keys and V24 interface e Making backup copies and reading in reading out data via the V24 interface These back up copies contain machine data line check sums and machine data numbers
133. ve ke 6FX5002 2CD01 1 0 spindle drive e PX8002 28B01 1 0 7 andw IN wire 10 14 1 5 wire 10 14 1 5 mn wire 10 14 1 5 mm 24 24VDC Fig 2 4 Connection Diagram for SINUMERIK 802S base line 2 6 SINUMERIK 8025 base line Start Up Installing the Control System 2 3 Connecting the individual components Connecting the components Please note the following Notice Use only shielded cable and make sure that the shield is connected to the metal or metal plated connector casing on the control side For the purpose of isolating the analog setpoint signal from low frequency interference we recommend not to ground the shield on the drive side The preassembled cable offered as accessories provides optimum protection against interference General procedure Proceed as follows to connect the individual components 1 Connect the cables to the components as shown in Fig 2 3 2 Fixthe sub D connector in place using the knurled screws 2 3 1 Connecting the feed drives and the spindle X7 Pin assignments For connector on the CNC side Feed drive interface Connector designation X7 AXIS 1 4 Connector typ
134. with 10 setpoint default analog spindle with 0 10V setpoint MCP without spindle override switch default MCP with spindle override switch Rotation monitoring not active default Rotation monitoring activate only for 802S Reference point approaching with override active default Reference point approaching without override active Z Y X motor without brakes default Z Y X motor with brake note only one motor is permitted with brake input for SBR40 is disabled default Input for SBR40 is enabled l e OPTM 1 motor brake be released no lubrication at first power on default Once lubrication at first power on Z Y X has two limit switch default in case Bit 7 0 Z Y X has only one limit switch in case Bit 7 0 Hardware limit using PLC solution default Bit 6 5 4 is effective Hardware limit using hardware solution Emergency Stop Chain SINUMERIK 802S base line Start Up Technical Appendix Definition of MD 14510 MD14510 Machine data Index USER DATA INT PLC Machine Data Integer WORD 16 bits Integer 14510 12 Definition Time setpoint for feed spindle override Press and hold on feed spindle decrease key more than the setpoint the override shifts to 0 and 50 directly Unit 100ms Range 5 30 0 5 3 seconds if overrun the default is 1 55 14510 13 Definition Time setpoint for feed spindle override Press and hold on feed spindle 10096
135. x required for milling and transfer it to the PG PC using WinPCIN After the file has been transferred correctly carry out POWER ON SINUMERIK 8025 base line is now preset to the desired technology Example techmill ini Default 3 axes X Y and Z 1 spindle no transversal axis G17 etc If you wish to reconfigure a SINUMERIK 802S base line control system to turning carry out POWER ON with the default machine data start up switch position 1 Notice All memory areas are initialized or loaded with stored default values machine data The basic configuration of the SINUMERIK 802C must be carried out during the commissioning prior to the general configuration MD input This need not to be done when series start up is carried out The configured machine data are contained in the series start up file SINUMERIK 8025 base line 4 31 Start Up Start Up 4 7 Commissioning Initializing the control system Turn the control system SINUMERIK 8025 base line will load the standard machine data automatically 4 7 1 Entering the general machine data Overview To make your work easier the most important machine data of the individual subranges are listed If more detailed information is required the user is referred to the relevant chapters sections of this manual The machine data and interface signals are described in detail in the descriptions of functions to which reference is made in th

Start-Up 08/2003 Edition - Service, Support

Contents

Download Pdf Manuals

Related Search

Related Contents