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SINUMERIK 802D SINUMERIK 802D base line

1. B A 6 dt IN E Io Mm B side view E ti m ed o E E E E 24V DC Bu PI A J Jumper AD o M5ground terminal MM M5ground terminal Fig 2 10 User interface on the PCU e 24V DC Power supply connection X8 3 pin screw terminal connection for connecting the 24 V load power supply e Profibus X4 9 pin D Sub socket connector for connecting Profibus e COMI RS232 interface X6 9 pin D Sub connector The COM2 port does not have any function e Handweels 1 to 3 X14 X15 X16 15 pin D Sub connector for connecting the handwheels e Keyboard Keyboard connection X10 6 pin mini DIN e Reset button e Jumper X311 e 4 LEDs for error and status displays behind the front hatch Interface on the keyboard e Keyboard connection 6 pin mini DIN SINUMERIK 802D 802D bl Start up IBN 08 05 E
2. id lr d i d Edo i o e i l R M da il PP 72 48 pe met input output module SIMODRIVE 611UE closed loop control module PROFIBUS DP option module Fig 1 1 Hardware components of the SINUMERIK 802D SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 1 11 The SINUMERIK 802D Control System 1 2 Technical specifications 1 2 Technical specifications Connected loads Table 1 1 Connected loads Parameters min typ max Unit Supply voltage 20 4 28 8 V Ripple 3 6 Vss 24 V current consumption 1 A Power dissipation of the PCU including KB 50 W Power dissipation of the MCP s5 W Power dissipation of the PP 72 48 11 W SS Starting current total 2 6 A Basic configuration from PCU KB MCP and PP 72 48 all outputs open with nominal load Weight Table 1 2 Weight Component Weight PCU 4 9 kg KB 1 7 kg MCP 1 5 kg PP 72 48 1 2 kg Dimensions Table 1 3 Dimensions of the individual components Component Dimensions WxHxD mm PCU 310 x 330 x 85 KB horizontal design 310x 175 x 32 KB vertical design 172 x 330 x 32 MCP 170 x 330 x 128 PP 72 48 194 x 325 x 35 SINUMERIK 802D 8
3. 2 1 Installing and removing the SINUMERIK 802D 19 Ka Pe 19 ere 3 3 8 S gt uw eo ez ase c SO 7j 4 ZSvt 9v dn rN le 1 618 o o ro E 2 E 8 8 St 2 5 amp c sa 8 lt Z HE St a gt o 0 2305 Fig 2 6 Drilling pattern for the keyboard vertical layout for installation alongside the PCU SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 2 21 Installing the Control System 2 1 Installing and removing the SINUMERIK 802D 19 19 E o of 7 21 5 9 3 S 5 gt 3 2 8 2 3 19 S 2 pee 302 2 8 ER i M E Bo 09 4 e ae e 223 M I 7 e a 3 P Ee 15 145 15 309 4 295 6 000 00 eo DOO OO 000 OO i DOUQ ip COOC 1547 DODODO Jo DN DODODO DDDODO CO E DoLE 13 8 e Hood AN Fa o eg er Fig 2 7 Mounting dimensions for the keyboard horizontal layout for installation beneath the PCU SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 2 22 6FC5 697 2AA00 1BP5 Installing the Control System 2 1 In
4. SINUMERIK 802D SINUMERIK 802D Turning Milling User Documentation Diagnostics Guide A SINUMERIK 802D Turning Milling LV Manufacturer Service Documentation Start up So SINUMERIK 802D SIMODRIVE 611UDocument Turning ation Milling Manufacturer Service Documentation Description of Functions SINUMERIK 802D Turning Milling
5. 8 SL st S v 60 s j ECH 2 sss GGGOCBIGO UI Of lt lt a 2 O a A ost al E H O O j O O gel u RE EI R Fig 2 1 PCU mounting dimensions SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 2 16 6FC5 697 2AA00 1BP5 Installing the Control System 2 1 Installing and removing the SINUMERIK 802D Panel cutout Panel cutout 0 5 pr 302 0 15 295 281 8 2950 0 15 0 15 0 1 312 152 2 1 M4 rivet down insert nut or M4 extruded hole 8x 286 6 2 Drill holes for fixing the position o 5 2 mm 2x Fig 2 2 Drilling pattern for the PCU SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 2 17 Installing the Control System 2 1 Installing and removing the SINUMERIK 802D 90 Er U ox sy e 08 El e nn L T Te GI DU gb E O z CR KE 6 EIE li DO EE KH USR H E ect ves u Fig 2 3 Mounting dimensions for the machine control panel MCP 2 18 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Installing the Control System 2 1 Installing and removing the SINUMERIK 802D
6. IPA A OF o o ds jo oO jo 2 x oO gt i o e ed z e 2 0 g c PT e z Ye o m Ko A beg tig o 58 N or E ON T x S Fig 2 4 Drilling pattern for the machine control panel MCP SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 2 19 Installing the Control System 2 1 Installing and removing the SINUMERIK 802D 172 2 u E 3 J j Al n En 1 E sa 172 2 165 Y CH O DODODOO DO L DOOOOOD Ol 000000 00 IR O OOOOOI 3 1j CC OO I sa g0000d 000 al oO 000000 CC til A 0 V q G D Eb Fig 2 5 Mounting dimensions for the keyboard vertical layout for installation alongside the PCU SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 2 20 6FC5 697 2AA00 1BP5 Installing the Control System
7. N will cancel the process without formatting Y will start the formatting once Input is pressed After completion of formatting further PC cards can be formatted Format another NC card N Y Y After changing the card the process restarts from the beginning N Quits the process Perform a POWER ON for the control system turn off and back on again the CNC Note The 8 MB NC card from Siemens with system software for the update also contains a file system with a residual memory capacity of approx 900 kB If the Sinucopy program from Siemens is installed on your PC you can create a file system up to 2MB on an empty NC card A larger area is not managed by the control system SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 6 107 Series Machine Start Upand Data Backup 6 4 Data backup in case of backlight failure 6 4 Data backup in case of backlight failure In case of backlight failure menu assisted operation is no longer possible for the control system If a backlight failure has occurred on the control system an external data backup can be performed on PC using a special command To this end activate the V24 connection to a PC as described in Section 6 1 settings binary format baud rate 19200 After turning on the control system issue the command CTRL S Thus a series machine start up with the last current data is output SINUMERIK 802D 802D bl Star
8. ETE L CS aways Jo do me 11320 HANDWHL IMP PER LATCH 0 5 9 H1 CTT T EE Co ls L 11346 HANDWH TRUE DISTANCE 9 H1 Qansunesi vrave or speca peat n _ rowno awas Jo lo 8 2 Jere Jj 13060 DRIVE TELEGRAM TYPEIO 8 3 G2 Re ij Standard message frame type for Profibus DP POWER ON 102 102 102 102 102 DWORD 13070 DRIVE FUNCTION MASK O 8 ET GE Se EE LL oOo er ERES 13080 DRIVE TYPE DPI0 8 G L T SOS o o S E oo DEM sd MEAS PROBE LOW ACTIVE O 15 M5 IE E e Detection of probe deflection delay time POWER ON SINUMERIK 802D 802D H Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 8 119 Machine and Setting Data 802D 8 1 List of machine data ato USER DATA INTIOL 151 A ES een O CTE TS SS was jo a lee CTI 1 SSS me USER DATA HEXIO Sg EEE o Tm O O p 37 Ee SE pe OIE 14514 USER DATA FLOAT O 7 19 ESMAS COTO ma Do doo ene Jam Joore Ir 14516 USER DATA PLC ALARM O 31 ta 77777 LT TS ETA o foso BYTE 17530 TOOL_DATA_CHANGE_COUNTER E tota ergo ori Tsomenon ae aways do In oo owow 18080 MM TOOL MANAGEMENT MASK 14 W1 Memory reservation for tool management step by step SRAM Bust je JE jm e Type of D number for programming POWER ON aways fo lo Dorr ESSES 8 1 3 Channel specific machine data Cross ref
9. lL eme 1 4130 JOG ROT AX SET VELO 9 H1 was ss les 9 fome 1 41200 JJOG SPIND SET VELO 9 H1 was fome BEE SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 8 137 Machine and Setting Data 802D 8 2 Setting data 42000 THREAD START ANGLE 10 K1 ms Je Me ome oi 42010 THREAD RAMP DISPI0 1 10 K1 aways aa je pose 42100 DRY RUN FEED 10 K1 m 42110 DEFAULT FEED Default value for path feedrate aways lo qm l LEE 42120 APPROACH FEED mm min 42162 EXTERN DOUBLE TURRET DIST External NC progr language 42440 FRAME OFFSET INCR PROG 42442 TOOL OFFSET INCR PROG mas IE em SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 8 138 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D 8 2 Setting data 42444 TARGET BLOCK INCR PROG ES eraon mode ater io searen waa imetty m awas Ji JJ ETE 42480 STOP CUTCOM STOPRE EET was Ie 1e E 42490 CUTCOM G40 STOPRE EEE Retraction behavior of TRC with preprocessing stop aways lo le qm BOOLEAN RE EG 42494 CUTCOM ACT DEACT CTRL gl Approach and retraction behavior in tool radius compensation DWORD p DA 42750 ABSBLOCK ENABLE Taan Jimeseey ae awas ft BOEN 42940 TOOL LENGTH CONST 14 W1 Change of tool length compensation when changing the plane aways
10. 3540 SPIND OSCILL ACCEL 5 81 awas 16 Jang Te DOBLE 0 35430 SPIND OSCILL START DIR 5 1 REES mas Qe Je Ee 35440 SPIND OSCILL TIME CW 5 S1 s ReoproatenimeforMadreeien _ _ __ L was ke o TE fome 35450 SPIND OSCILL TIME CCW 5 1 DEE ECO o CE CE E EEE 86500 JSPIND ON SPEED AT IPO START 5 S1 gt Fedemetrsmdemsspnme es was le 18 lee 35510 SPIND STOPPED AT IPO START 5 1 E Tresdensionihihesnndesume es a was bo IF ow SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 9 157 Machine and Setting Data 802D base line 9 1 List of machine data seso DRI VELO LMT El EE Maximum speeds when tapping NEW CONF 10000 10000 10000 36000 STOP LIMIT COARSE 2 A3 mas os le ewe 1 36010 STOP LIMIT FINE 2 A3 NEW CONF DOUBLE ESA 36020 POSITIONING_TIME 2 A3 eamm O L A was ks IE ewe 1 36030 STANDSTILL POS TOL 2 A3 was ls IE oe 1 36040 STANDSTILL DELAY TIME 2 A3 DREES e EE les A 36050 CLAMP POS TOL 2 A3 was ss IE ewe 1 36060 STANDSTILL VELO TOL 2 A3 Threshold value for Axis stopped signal NEW CONF or mmm Po o ee 36100 POS LIMIT MINUS 2 A3 NEW CONF 100000000 DOUBLE 36110 POS LIMIT PLUS 2 A3 Las ees seer 1 36120 POS LIMIT MINUS2 2 A3 2nd
11. Bed Diag ESB o gt bersicht Status Dr cken Sie F1 um Hilfe zu erhalten fio08 2005 16 23 40 7 Parameterize digital outputs OO A and O1 A to Selection via PROFI BUS SimoCom U Q 802D Te Spindel 61 1UE PB 21 Antriebsnt 2 par Datei Bearbeiten Inbetriebnehmen Bedienen Diagnose Extras Hilfe inss RM RIP ts Are Oe A AS me p I diges Ausg nge Verdrahtung ri B Q 802D Te Spindel 611UE PB Konfiguration Eunktionsbeschrebung Mechanik Begrenzungen Hille Hille Digitale Eing nge Digitale Ausg nge Analoge Ausg nge berwachung Regler Verfahrs tze PROFIBUS Parametrierung Spindelpositionieren Filtereinstellungen Stromsolmert Fitereinstellungen Drehzahlsoliei Motordatenoptimierung Ansteuerung ber PROFIBUS Invertiert A vere EA Ja P par Bed Bl diag E bersicht Status Dr cken Sie FI um Hilfe zu erhalten DIT 10 08 2005 16 24 51 7 Save RESET Analog spindle SP machine axis 3 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 4 73 Starting up the Spindle 4 7 4 7 Analog axis spindle with TTL encoder via ADI4 Analog axis spindle with TTL encoder via ADI4 Both rotary and linear 5V TTL square wave encoders can be connected to SINUMERIK 802D With this ADIA
12. Max spindle speed Max spindle acceleration Machine data settings MD 31050 1 MD 31060 2 MD 35100 9000 MD 35130 9000 MD 35200 60 MD 36200 9900 9 000 r p m 60 rev s For the spindle it can be necessary to adapt the following additional machine data Table 4 2 Additional machine data MD Name Default va Unit Recommendation remark lue 34000 REFP CAM IS ACTIVE 1 O without reference point cam 34060 REFP MAX MARKER DIST 20 degrees 720 two spindle revolutions 34110 REFP CYCLE NR 1 5 0 The spindle is not involved in chan nel specific referencing 35300 SPIND POSCTRL VELO 500 r p m 36000 STOP LIMIT COARSE 0 04 degrees 0 4 36010 STOP LIMIT FINE 0 01 degrees 0 1 36030 STANDSTILL POS TOL 0 2 degrees 1 36060 STANDSTILL VELO TOL 0 0139 r p m 1 interface signal Axis spindle stop ped V390x 0001 4 36400 CONTOUR TOL 1 degrees 3 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 4 63 Starting up the Spindle 4 2 Digital spindle drive with spindle actual value encoder TTL mounted directly on the motor 4 2 Digital spindle drive with spindle actual value encoder TTL mounted directly on the motor Procedure e Parameterize the spindle as specified in Table 4 1 e Connect the TTL encoder to X472 on the SIMODRIVE 611 UE closed loop control module for the spindle e Change the message frame type of
13. P b Ed GEAR STEP CHANGE POSITION 0 5 9 SPIND DEFAULT MODE Spindle park position O 1 Speed controlled mode with without position control 2 Pos mode 3 Axis mode SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 8 132 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D 8 1 List of machine data 35030 SPIND DEFAULT ACT MASK 5 S1 Time of activation for spindle park position 0 POWER ON 1 Progr start 2 Reset M2 M30 RESET 2 2 aways ooo loos Leg os 85040 SPIND ACTIVE AFTER RESET 5 S1 E omsmdemstt romeo a aways Jo fe 35100 SPIND VELO LIMIT r p m Maximum spindle speed POWER ON always 10000 0 DOUBLE 35110 GEAR STEP MAX VELOJO 5 5 S1 NEW CONF rp 500 500 1 000 de dk GEAR STEP MIN VELOJOJ 5 50 50 400 800 1 500 3 000 500 500 1 000 2 000 4 000 8 000 GEAR STEP MIN VELO LIMIT O 5 35210 JGEAR STEP POSCTRL ACCELIO 5 30 0 30 0 25 0 20 0 SS 35300 JSPIND POSCTRL VELO Position controller starting speed NEW CONF 500 0 DOUBLE SINUMERIK 802D 802D H Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 8 133 Machine and Setting Data 802D 8 1 List of machine data 35310 SPIND_POSIT_DELAY_TIME O 5 5 1 je Posttonngdelgyime Tuevconr e 35350 SPIND POSITIONING DIR 5 S1 e JOresionafrtsonuhenpestimng qe a awas fe 35400 SPIND OSCILL DES VE
14. fet Number of auxiliary functions in AuxF groups POWER ON A jt E fowom EEE me UPLOAD MD CHANGES ONLY E mr lee E ere 11240 PROFIBUS SDB NUMBER 3 G2 oran mer H a Loo 0 Jo Je lee jJ 11250 PROFIBUS SHUTDOWN TYPE E REES mas CO Po El 11310 HANDWH REVERSE 9 H1 CO ETE POWERON ie oro IRE Sp SF 11320 HANDWHL IMP PER LATCH 0 5 9 H1 Tranduteelpusesprlockngpostien JFowERoN Do enne Ci 1 11346 HANDWH TRUE DISTANCE 9 H1 ina vrave or speed peat n H D ie b le NR O SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 9 147 Machine and Setting Data 802D base line 9 1 List of machine data 13070 DRIVE FUNCTION MASK 0 8 POWER ON Geer A Eo E ibis 13200 MEAS PROBE LOW ACTIVEI0 15 M5 Jay range tin pore OOOO OWEN ss Pf JI L BORN 3 3 USER DATA INT 0 31 ERES Do Es E on Do as Bee al Eo El y E Cd eae CTE E per AE o fm A BE dp en USER PATA FORTI i TJ CO orn T H ar lo Laang aam pouse Cs EE X USER DATA PLC ALARM O 31 309 O CT own Gr 9 1 3 Channel specific machine data Cross refe rence to the relevant sec MD identifier tion chapter in the Des cription of Functions x me Read write pro 20050 JAXCONF GEOAX ASSIGN TABIO 2 7 097 aomen gemennas OO
15. 700005 Axis monitoring active U Display 700005 Axis monitoring active 1 or 700005 Axis monitoring active 3 5 4 PLC programming The PLC user program is created using the PLC 802 Programming Tool The handling of this tool for an S7 200 is described in the documentation SIMATIC S7 200 Automation System Manual The PLC 802 Programming Tool constitutes a subset of this documentation Compared to the S7 200 MicroWin base system the following is to be observed The user program can only be programmed in ladder diagram Only a subset of the S7 200 programming language is supported The compilation of the user program is performed offline on a PG PC or automatically when downloading into the control system The project can be loaded into the control system download It is also possible to load the project from the control system upload Indirect data addressing is not possible Thus no programming errors will occur during the runtime The user must manage the data and process information type specifically Example Information 1 T value Memory size DWord 32 bit Information 2 Override Memory size Byte 8 bit User data Byte O DWord information 1 Byte 4 bytes information 2 The user must not access this data together otherwise he should have to observe the data access Furthermore the alignment of the data in the memory model and their types must be ob served for all data SINUMERIK 802D 802
16. GEN Velocity when searching for the reference mark RESET ae nm m 0 fome 34050 REFP SEARCH MARKER REVERSEIO 8 R1 psemendowweenm ner m mes fe Je e exem 1 34060 REFP MAX MARKER DIST 0 8 R1 mw mo JE ee 34070 REFP VELO POS 8 R1 1 000 0 mm min Se SE 34080 HEFP MOVE DIST 0 8 R1 Reference point distance RESET SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 8 131 Machine and Setting Data 802D 8 1 List of machine data 34090 REFP MOVE DIST CORR 0 8 R1 we jo e E wwe 0 34092 REFP CAM SHIFTIOJ 8 R1 ww lee ee 1 eme 1 34093 REFP CAM MARKER DIST 0 8 R1 awas Jon pos TI 34100 REFP SET POSIO 3 8 R1 aways In JI Jm Jose LI 34110 REFP CYCLE NR 8 R1 gt Jorge otares wnenreerencng C as me Ho E me 1 SS 34200 ENC REFP MODE 0 8 R1 Teemme OOO O L CS pe y awas Ji Jo ls OE Jj 34210 ENC_REFP_STATE 0 8 R1 keste encoder spina sinus mme am 34220 ENC ABS TURNS MODULO 6 R2 Deeg geess Iewen aways Jam fo owo po 34990 ENC ACTVAL SMOOTH TIME 0 RER am aways Ing Jon Jos pos 35000 SPIND ASSIGN TO MACHAX 5 81 E Jassonmensprde mechneaie _ O pown ws kl LE tre o im 35010 GEAR STEP CHANGE ENABLE 5 1 E Gewsmecwgepsse H 2 Faye fe o po
17. LW Load Word gt a gt b close a And Word a lt bopen Or Word gt Load Word asb close a And Word lt a gt bopen lt E Or Word DOUBLE WORD COMPARES Signed Instruction Ladder Symbol Valid Operands Load DWord a b close a a VD ID QD MD AC Constant LB And DWord a b open E b VD ID QD MD AC Constant LB Or DWord b Load DWord gt a 2 b close a And DWord gt a lt b open D Or DWord gt Load DWord lt asb close a And DWord lt a gt bopen D E Or DWord lt REAL WORD COMPARES Signed Instruction Ladder Symbol Valid Operands Load RWord a b close a a VD ID QD MD AC Constant LD And RWord ab open R b VD ID QD MD AC Constant LD Or RVVord b Load RWord gt a 2 b close a And RWord gt a lt b open A Or RWord gt p Load RWord lt a lt b close a And RWord lt a gt b open A Or RWord lt p 5 90 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Starting up the PLC 5 4 PLC programming TIMER Instruction Ladder Symbol Valid Operands Timer Retentive On EN 1 Start Enable IN Delay EN 0 Stop So If Tvalue gt PT TXXX TO T31 Tpit 1 Preset PT VW T C IW QW MW AC Constant 100ms TO T15 10 ms T16 T39 Timer On Delay EN 1 Start Enable IN EN 0 Stop S0 If Tvalue 2 PT Tox TO T31 Tpit 1 Preset PT VW T C IW QW MW AC Constant 100ms TO
18. RESET Parameterize analog output 75 A 15 to DAC1 signal from PROFIBUS PPO MD 36000 STOP LIMIT COARSE AX3 10 MD 36010 STOP LIMIT FINE AX3 10 MD 36030 STANDSTILL POS TOL AX3 10 MD 36400 CONTOUR TOLJAX3 40 Symmetrize analog output MD 36720 DRIFT VALUE 0 3891 4 72 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Starting up the Spindle 4 6 Analog spindle via 611 U E with with spindle actual value encoder mounted directly on the motor Table 4 7 Settings for the example cont d Transport axis X1 machine axis 1 SimoCom U Q 802D Te Spindel 61 1UE PB 21 Antriebsnr 2 par Datei Bearbeiten Inbetriebnehmen Bedienen Diagnose Extras Hilfe o ss adc o eg 08 e RAAR AA TE me alz Analoge Ausg nge Q 802D Te Spindel 611UE PB Konfiguration Mechanik Begrenzungen Digitale Eing nge Digitale Ausg nge berwachung Regler Verfahrs tze PROFIBUS Parametrierung Spindelpositionieren Filtereinstellungen Stromsollwert 1545 Signal DAUT aus PROFIBUS PPO Offset T Shtat O Bl ttung 100 ms Iv bersteuerungsschutz dese Auslastung feinnormiert E Offset 0 Shiftfaktor 0 Gl ttung 0 0 ms TY bersteuerungsschutz MERDA Normierung 100 0 Eunktionsbeschreibung T Expertenmodus Filtereinstellungen Drehzahlsollwe Motordatenoptimierung gt P Par
19. e Bit 1 Continuous path control e Bit 0 Linear path control SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Start Up ISO Mode with 802D only 10 2 Machine data 10 2 3 Spindle positioning M19 The spindle position for M19 is defined in the 43240 M19 SPOS setting data 10 2 4 Blueprint programming for the turning technology only With loading the SETISO T INI file the names in the machine data have been fixed for the angle A for the radius R and for the cnamfer C when working with blueprint program ming Important Do not assign the names for other purposes e g axis name A 10 2 5 Tool compensation for the turning technology only Use the 10880 EXTERN DIGITS TOOL NO machine data to define the number of digits for the tool number Keep or reenter the default value 2 Value 2 corresponds to the 2 decade tool number Use the 10900 EXTERN TOOLPROGR MODE machine data to define the type of tool and tool compensation programming Keep the default value 0 Thus the following programming rule shall apply for the turning technology The tool and the tool call are divided into 2 X 2 decades The first 2 decades define the tool number The values TO1XX T32XX are permissible Max 32 tools can be defined The second 2 decades are used to activate or deselect the tool compensation The values TXX00 and TXXO1 are permissible Value TXXO1 means Tool active Value TXX00 means
20. mmea a EE wor 45 0 DEFAULT SCALE FACTOR AXIS E Vasi ett cat factor win ve sn E m ma Te CA o Spindle speed when starting the spindle via VDI interface signals immediately 48202 sPIND CONSTCUT S EES Specify constant cutting rate for master spindie aways Ing Jr l DOUBLE y 43210 SPIND MIN VELO G25 5 S1 was Jo m E fome 1 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 9 161 Machine and Setting Data 802D base line 9 2 Setting data 43220 SPIND MAX VELO G26 5 S1 1000 0 DOUBLE 43230 SPIND_MAX_VELO_LIMS 5 S1 C Te o o 43400 WORKAREA PLUS ENABLE 2 A3 Wong te tan act inte postive dreon mmedmay m mas IO Pp CAS ETS 43410 WORKAREA MINUS ENABLE 2 A3 Jena aca Ina sve n meneame arenon Iesse am aways Jo JJ Boon po 43420 WORKAREA LIMIT PLUS 2 A3 always 1000000 Ir Jr powe O 43430 WORKAREA LIMIT MINUS 2 A3 100000000 DOUBLE SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 9 162 6FC5 697 2AA00 1BP5 Start Up ISO Mode with 802D only 1 0 10 1 1 Setup To use the ISO 66025 programming the SINUMERIK 802D Control Setup Files are offered for start up as part of the Toolbox Software These files which can be loaded into the control system are intended maker the start up easier The following variants are offered 1 ISO T Turning technology
21. 100000000 DOUBLE EEE 43500 FIXED STOP SWITCH ae AR Fct Travel to fi 43510 FIXED STOP TORQUE 17 F1 Gen A EL Fct Travel to fi SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 8 140 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D base line 9 Data type BOOLEAN BYTE STRING WORD UNSIGNED WORD INTEGER DWORD UNSIGNED WORD DOUBLE Boolean value 1 TRUE or O FALSE 8 bit value as an INTEGER value 128 127 as a hexadecimal value 00 FF as a character as per ASCII character set e g a Sequence of characters max 16 16 bit value as an INTEGER value 32768 32767 as a hexadecimal value 0000 FFFF 16 bit value as an INTEGER value 0 65535 as a hexadecimal value 0000 FFFF 16 bit value here defined locally INTEGER value 32768 32767 32 bit value as an INTEGER value 2147483648 2147483647 as a hexadecimal value 0000 0000 FFFF 32 bit value as an INTEGER value 0 4294967295 as a hexadecimal value 0000 0000 FFFF FFFF 64 bit value floating point value 4 19 10907 1 67 10308 Range of values minimum maximum value If no range of values is specified the data type will determine the input limits and the filed will be marked with 799 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 9 141 Machine and Setting Data 802D base line 9 1 List of mac
22. 19 1m 2 0 Input 20 Im 2 1 Input 21 Im 2 2 Input 22 1m 2 3 Input 23 1m 2 4 Input 24 1m 2 5 Input SINUMERIK 802D 802D H Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 2 31 Installing the Control System 2 3 Connecting the individual components Table 2 3 Pin assignment of the connectors X111 X222 X333 cont d Pin Signal Type Pin Signal Type 25 Im 2 6 Input 26 Im 2 7 Input 27 not connected 28 not connected 29 not connected 30 not connected 31 On 0 0 Output 32 On 0 1 Output 33 On 0 2 Output 34 On 0 3 Output 35 On 0 4 Output 36 On 0 5 Output 37 On 0 6 Output 38 On 0 7 Output 39 On 1 0 Output 40 On 1 1 Output 41 On 1 2 Output 42 On 1 3 Output 43 On 1 4 Output 44 On 1 5 Output 45 On 1 6 Output 46 On 1 7 Output 47 DO VCC 48 DO VCC COM input for O n 0 0 O n 1 7 sup COM1 input for O n 0 0 O n 1 7 supply ply 49 DO VCC 50 DO VCC COM input for O n 0 0 O n 1 7 sup COM1 input for O n 0 0 O n 1 7 supply ply N Danger The 24V power supply for digital outputs DOCOM1 must be designed as a functional ex tra low voltage with safe isolation to EN 60204 1 Note The 24V voltage for the digital outputs must be connected to all 4 pins 47 48 49 50 Make sure that the interconnecting cable between the power supply and the supply voltage inputs pins 47
23. 50 does not exceed a permissible length of max 10 m The connectors X111 X222 and X333 have the same assignment but the VO areas are off set by 3 bytes inputs or 2 bytes outputs cf Table 2 4 Table 2 4 PP 72 48 1 PP 72 48 2 Profibus address 9 Profibus address 8 X111 X222 X333 X111 X222 X333 IB 0 3 6 9 12 15 Input Byte 1 4 7 10 13 16 2 5 8 11 14 17 OB 0 2 4 10 Output Byte 1 3 5 7 9 11 M 0 3 6 9 12 15 n 0 2 4 6 8 10 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 2 32 6FC5 697 2AA00 1BP5 Installing the Control System 2 4 Connecting the SIMODRIVE 611U drive unit 2 3 5 Connecting the ADI4 module For the relevant data for connecting the ADI4 module please refer to the documentation ADIA Analog Drive Interface for 4 Axes Product Manual For the configuration please observe the specifications on the Toolbox Note Make sure that your ADI4 module has firmware release 01 02 02 2 4 Connecting the SIMODRIVE 611U drive unit For the relevant information regarding the configuration of the interfaces and for connecting the components of the drive unit please refer to the Documentation SIMODRIVE 611UE SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 2 33 Installing the Control System 2 5 2 5 Connecting the Profibus Connecting the Profibus All stations are connected to each other via Profibus
24. Grounding rail Fig 2 16 Grounding diagram for installing PCU and MCP SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 2 36 6FC5 697 2AA00 1BP5 Installing the Control System 2 7 Power supply of PCU X8 and PP 72 48 X1 2 7 Power supply of PCU X8 and PP 72 48 X1 Screw terminal block Connect the 24 V DC load power supply required for the power supply to the screw terminal block X8 or X1 Features of the load power distribution AN Danger The 24 V DC must be generated as a functional extra low voltage with safe electrical isolation to IEC 204 1 Section 6 4 PELV and be grounded by the user make a connection from the PELV signal M to the central grounding point of the system Table 2 6 Electrical parameters of the load power supply Parameter min max Unit Conditions Voltage range mean value 20 4 28 8 V Ripple 3 6 Vss Duration ET 500 ms Non periodic overvoltage 35 V 50 s recovery time Rated current consumption 1 A Starting current 2 6 A Table 2 7 Pin assignment of the screw terminal block X8 X1 Terminal Signal Description 1 P24 24 V DC 2 M Ground GND 3 PE Note Make sure that the interconnecting cable between the power supply and the supply voltage connection screw terminal block X1 does not exceed a permissible length of max 10 m SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 2 37
25. I Explanation Both the position and the size of the representation are handed over during initialization The position of the coordinate system can be influenced by the parameter Axis direction in the header of the file The following positions are possible Position X Z 0 to the top to the right 1 to the top to the left 2 downwards to the right 3 downwards to the left 4 to the right upwards 5 to the left upwards 6 to the right downwards 7 to the left downwards The positions of the elements must be specified in position 4 mathematic coordinate system The simulation will then automatically convert the representation to the relevant system SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 9 144 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D base line 9 1 List of machine data e Jeonrour mask SS aas TOOL LIST PLACE NO Do L T am Ummdmey e EEE CI ES NO Baud rate for modem connection immediately foe l O fo 3 Parity for modem connection immediately Oe ye ze vaa PPI MODEM STOPBIT EE Po fo po fl Lil Number of data bits for connection to a modem immediately ES h E fn 5 0 sz mH po A Color settings title bar focus window foreground 8 fo ye HM COL TITLE FOCUS BACK ESSE AH ls AA 360 SPINDLE LOAD DISPL1 decimal Activate utilization display for spindle 1 immediately INTEGER 361 MEAS TOOL CHANGE decimal Input enable for T D no
26. IBN 08 05 Edition 6FC5 697 2AA00 1BP5 5 87 Starting up the PLC 5 4 PLC programming Table 5 5 802D Operand Ranges Access Method Valid Operand Ranges for Programming 802D Word Access VW 1000 0000 7999 9998 T 0 39 C 0 31 IW 0 16 QW 0 10 MW 0 382 AC 0 3 KW Constant Double Word Access VD 1000 0000 7999 9994 ID 0 14 QD 0 8 MD 0 380 AC 0 3 AC 0 3 KD Constant Table 5 6 Special bit memory SM Bit Definition SM bits Description SM 0 0 Bit memory with defined ONE signal SM 0 1 Initial position first PLC cycle 1 subsequent cycles 0 SM 0 2 Buffered data lost only valid in the first PLC cycle data o k 1 data lost SM 0 3 POWER ON first PLC cycle 1 subsequent 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 The user can only view the statement list STL in PT802 under View STL This type of representation see Table Mnemonic shows the sequential processing SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 5 88 6FC5 697 2AA00 1BP5 Starting up the PLC 5 4 2 Explanation of the stack operations Table 5 7 INSTRUCTIONS Set 5 4 PLC programming BASIC BOOLEAN INSTRUCTIONS prior 1 later O
27. IBN 08 05 Edition 8 122 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D 8 1 List of machine data 22020 JAUXFU ASSIGN EXTENSION 0 63 13 H2 gt ESTE CI 2 aways Jonn lo lee lee 22030 AUXFU ASSIGN VALUEIO 63 13 H2 Clees TT se mas foco Te o 22040 AUXFU PREDE GROUP E EE proERON m mm bo fo Ie Je 22050 AUXFU PREDEF TYPE ges EELER ax ES EST EEE 2200 AUXFU_PREDEF_EXTENSION EE DEER ma elen 22070 AUXFU PREDEF VALUE 0 63 ees Proseminar tron vare Jeqenon e aways LLJ jfowwm es AUXFU ASSOC Mo VALUE EE O amamen torporem O power um Ja Je ora m 22256 Lu ASSOC Mi VALUE Ema gt Tndanonaltneionsforsanduonaisen Poweron mas ER ES ES wee 1 22400 S VALUES ACTIVE AFTER RESET 5 1 SwenabemenaterntStr owen ae was ll soon 1 4 a TRAFO_CHANGE_M_CODE 18 M1 M cose when sienna te varstomaron yee romeno Trans 22550 TOOL CHANGE MODE 14 W1 Newoolconpensston win Torm turoro pomenon mas b fo O po less 1 22910 WEIGHTING FACTOR FOR SCALE pai E intentan tr esi air romeo ae mas b m E Isa oi LActivation for axial scaling factor G51 POWER ON always Jo JI Jm Booe y SINUMERIK 802D 802D H Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 8 123 Machine and Setting Data 802D 8 1 List of machine data E icmtomad
28. Master is the PCU and slaves are the SIMODRIVE 611 UE and the PP 72 48 The baud rate of the clock synchronous Profibus is fixed to 12 Mbaud and cannot be changed Converters for optical fiber cable OLMs OLPs or repeaters are not permitted Profibusinterface 2 34 Socket type 9 pin D Sub socket connector Max cable length 100 m at 12 Mbaud Table 2 5 Female connector pin assignment Pin Signal Meaning Pin Signal Meaning 1 Shield 6 VP Supply voltage for the terminators P P5V 2 Reserved 7 Reserved 3 RxD TxD P Receive send data 8 RxD TxD N Receive send data o o plus B line red minus A line green o 0 4 CNTR P Control signal for the 9 CNTR N Repeater control si 6 9 repeater direction gnal direction con control trol 5 DGND Data transfer potential ground to 5V Note Use the recommended Profibus connectors only They are designed such that the ongoing P branch is disconnected when the terminator is connected The PB master PCU should be connected at the start of the PB line Make sure that the terminating resistors are only connected at the first and at the last sta tions Line A green Line B red SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Installing the Control System 2 5 Connecting the Profibus ON A1 NS A2 B2 PP 72 48 Fig 2 15 General design of a Profi
29. Stop deleted Acceptance of and debug mode gram the active PLC MD Hardkey System Softkey Start up switch NCK Hardkey System Softkey Start up switch PLC is loaded from the permanent memory into the RAM 5 80 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Starting up the PLC 5 2 Start up modes of the PLC Thanks to the debug mode see Operation and Programming Chapter 7 the PLC remains in PLC Stop after booting of the control system All start up modes set via softkey only come into effect when the control system is booted the next time The Run mode activates the cyclic operation The following actions are triggered in the Stop mode All hardware outputs are disabled Profibus DP is inactive No cyclic operation the active user program is not executed The process image is no longer refreshed it is frozen EMERGENCY STOP active Only in the Stop mode can the user load a corrected or new project into the control system The user program only becomes effective when the control system is booted the next time or if the Run mode is selected SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 5 81 Starting up the PLC 5 3 5 3 PLC alarms PLC alarms The control system displays max 8 PLC alarms system alarms or user alarms The PLC manages the alarm information per PLC cycle It saves cancels the alarms ac
30. Terminal 15 to be connected to Terminal OO A to be connected to X472 to be connected to e g terminal 56 analog setpoint input e g terminal 14 analog setpoint input e g terminal 65 servo enable TTL encoder 5V NC machine data MD 13060 DRIVE TELEGRAM TYPE 0 0 0 corresponds to drive number 1 MD 13070 DRIVE FUNCTION MASKIO 8000 with the 802D only valid from software release higher than 2 1 5 0 corresponds to drive number 1 MD 30110 CTRLOUT MODULE NR 0 AX3 1 drive number of the transport axis MD 30120 CTRLOUT_NR 0 AX3 2 MD 30130 CTRLOUT_TYPE O AX3 1 MD 30220 ENC MODULE NR 0 AX3 1 drive number of the transport axis MD 30230 ENC INPUT NR 0 AX3 2 MD 30240 ENC TYPE 0 AX3 1 MD 31020 ENC RESOL 0 AX3 2500 number of increments of the TTL encoder MD 32110 ENC FEEDBACK POL 0 AX3 1 if necessary invert the actual value MD 32250 RATED OUTVAL 0 AX3 100 MD 32260 RATED VELO 0 AX3 9000 adjust the analog interface MD 34060 REFP MAX MARKER DIST 0 AX3 360 MD 35300 SPIND POSCTRL VELO 50 speed at which the position controller becomes active with SPOS Drive data If necessary adapt the monitoring data P890 Activate angular encoder encoder interface 4 P922 Message frame selection PROFIBUS 104 Save RESET P915 8 Process data setpoint assignment PB 50103 P915 9 Process data setpoint assignment PB 50107 P922 Message frame selection PROFIBUS 0 Save
31. To create a complete data backup for a machine it is sufficient to create the series machine start up file SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Series Machine Start Upand Data Backup 6 2 Data backup Variants of external data backup 1 2 Reading out the data completely Series machine start up The files are read out read in by areas If the cursor is positioned on the Start up data PC line all user data are transferred together The following user data can be selected as individual files Data Machine data Setting data Tool data R parameters Work offset Compensation data leadscrew error compensation LEC Part programs Standard cycles User cycles PLC programs binary file Performing the external data backup In the System gt menu Data VO RS232 settings select Text format In WINPCIN select also Text format In the System menu Data VO Data selection transfer the user data either area by area or as individual files via the V24 interface to an external PC Loading externally saved files into the control system In the System gt menu Data I O select the Read in softkey 6 2 3 External data backup via NC card Important Make sure that a flash file system max 2 MB possible is formatted on the NC card see Section 6 3 Never insert or remove the NC card when the PCU is connected to the mains Do not insert or r
32. cording to their times of occurrence The first alarm in the list is always the alarm last oc curred If more than 8 alarms have occurred the first seven alarms and the newest alarm with the highest cancel priority are displayed Alarm response and cancel criteria 5 82 In addition the alarm responses are managed by the PLC The alarm responses always come into effect irrespective of the number of active alarms Depending on the type of the alarm response the PLC will trigger the required action A cancel criterion must be defined for each alarm The PLC uses the cancel criterion SELF CLEARING by default see Configuring user alarms Cancel criteria are e POWERONCLEAR The alarm is canceled by turning off turning on the control system POWER ON e GANCELCLEAR The alarm is canceled by pressing the Cancel key or the Reset key analogously to the NCK alarms e SELF CLEARING The alarm is canceled since the alarm cause is no longer present The cancel conditions have the following priority e POWERON CLEAR system alarms highest priority e CANCEL CLEAR system alarms e SELF CLEARING system alarms e POWERON CLEAR user alarms CANCEL CLEAR user alarms e SELF CLEARING user alarm lowest priority The responses to be triggered by the alarm in question in the PLC are defined for each alarm The PLC uses the alarm response SHOWALARM by default Alarm responses are e PLC stop The user program
33. up to 4 drives with analog setpoint interface can be connected Measuring systems that can be connected Configuration 4 74 e Incremental TTL encoder for the number of increments see Tables 4 9 4 10 difference transfer using 5 V square wave signals RS422 standard With 5 analog axes 2 ADI4 modules must be used Depending on the encoder pulse num ber selected from Table 4 9 or 4 10 either SDB 1 ADI4 or SDB 2 ADI4 must be loaded The ADI4 modules have the Profibus addresses 15 and 16 assigned as follows Table 4 8 Assignment of the PB addresses MD 11240 PB slave PB address Drive number 0 PP module 1 9 1_ADI4 or 2 ADI4 are loa PP module 2 8 ded E 1st ADI4 drive 1 16 1 Drive 2 2 Drive 3 3 Drive 4 4 2nd ADI4 drive 1 15 5 Drive 2 6 Drive 3 7 Drive 4 8 The following tables show the fixed assignment of the axes to the TTL encoders which can be connected Table 4 9 SDB 1 ADI4 PROFIBUS address 16 Axis 1st axis 2nd axis 3rd axis 4th axis Increments 2500 2500 2500 1024 PROFIBUS address 15 Axis 1st axis 2nd axis 3rd axis 4th axis Increments 1024 18000 9000 2500 Table 4 10 SDB 2_ADI4 PROFIBUS address 16 Axis 1st axis 2nd axis 3rd axis 4th axis Increments 2048 2048 2048 1024 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Starting up the Spindle Table 4 10 SDB 2 ADIA contd Analog a
34. 0 2 i Frm Jetoroine bas toi for tne 18 TRACYL eege Jeng Fet ee 24850 TRACYL_ROT_AX_OFFSET_2 E Fct Peripheral Fct Peripheral 24860 TRACYL ROT SIGN IS PLUS 2 ESSE Sion othe oy ai forthe 20 H mEwcowe am Fct Peripheral 24870 TRACYL BASE TOOL 2 0 2 Eg mm et an bas otr e ang TRACY vanstormaton wewco Fct BA 24900 TRANSMIT ROT AX OFFSET 1 18 M1 Fet Transmit Fet Transmit 24910 JTRANSMIT ROT SIGN IS PLUS 1 18 M1 Sante ota as r et TRANSMIT Rama JueWCONE Fet Transmit 24911 TRANSMIT POLE SIDE FIX 1 18 M1 Limitation of the working area in front of behind the pole 1st TRANSMIT Fet Transmit 24920 TRANSMIT BASE TOOL 1 0 2 18 M1 EE Ee SINUMERIK 802D 802D H Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 8 125 Machine and Setting Data 802D 8 1 List of machine data Offset of the rotary axis for the 2nd TRANSMIT transformation NEW CONF 2 2 Fet Transmit E Fet Transmit 24960 TRANSMIT ROT SIGN IS PLUS 2 AA noe rta axe forthe and TRANSMIT vanstomaton _ wewcowe 22 Fet Transmit Limitation of the working area in front of behind the pole 2ndTRANSMIT NEW CONF 2 2 Fet Transmit 24970 TRANSMIT BASE TOOL 2 0 2 Say E 27100 ABSBLOCK FUNKTION MASK Parameterize block display vvith absolute values POWER ON always 0x0 0 DWORD ze TECHNOLOGY mose TJ EE E H ECG Deg H o LIE CT f
35. 12 PB address 13 PB address 15 The table below shows an overview illustrating possible applications and the machine data assignment Table 4 11 SDB DMS1 ADI4 PROFIBUS address 15 Axis ist axis 2nd axis 3rd axis 4th axis Increments 2500 2500 2500 2500 Setpoint 1 2 3 4 Drive no MD 30110 Actual value 6 7 8 9 Drive no MD 30220 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Starting up the Spindle 4 8 Digital axis spindle with direct measuring system TTL via ADI4 Table 4 12 SDB DMS2 ADI4 PROFIBUS address 15 Axis 1st axis 2nd axis 3rd axis 4th axis Increments 5000 5000 5000 5000 Setpoint 1 2 3 4 Drive no MD 30110 Actual value 6 7 8 9 Drive no MD 30220 The axes are assigned correspondingly as per the particular application ical Note for the reader Toolbox siemense txt and ADI4 SDB for DMS pdf SINUMERIK 802D 802D H Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 4 77 Starting up the Spindle 4 8 Digital axis spindle with direct measuring system TTL via ADI4 This sheet has been left empty for your notes SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 4 78 6FC5 697 2AA00 1BP5 Starting up the PLC 5 General The PLC is intended to control machine related functional sequences It is realized as a software PLC The user progr
36. 6 Setting the Profibus address Certain bus configurations have already been prepared for SINUMERIK 802D The required configuration can be set via MD 11240 PROFIBUS SDB NUMBER In all cases the con figuration constitutes the maximum configuration It is not necessary to connect all stations Table 3 2 MD 11240 PB DP station slave PB address Drive number 3 PP module 1 9 PP module 2 8 u Single axis power section 10 5 Single axis power section 11 6 Twin axis power section Drive A 12 1 Drive B 2 4 PP module 1 9 PP module 2 8 Single axis power section 10 5 Twin axis power section Drive A 12 1 Drive B 2 Twin axis power section Drive A 13 3 Drive B 4 5 PP module 1 9 PP module 2 8 Single axis power section 20 1 Single axis power section 21 2 Twin axis power section Drive A 13 3 Drive B 4 Single axis power section 10 5 6 PP module 1 9 u PP module 2 8 Single axis power section 20 1 Single axis power section 21 2 Single axis power section 22 3 Single axis power section 10 5 0 PP module 1 9 E PP module 2 8 Note The assignment between PB address and drive number is fixed and cannot be changed Set now the MD 11240 PROFIBUS SDB NUMBER according to your particular bus config uration Parameterize the PB addresses of the PB stations SIMODRIVE 611 UE and PP module as specified in the table above SINUMERIK 80
37. 6 106 6 107 series start up file 6 105 Start up prerequisites 3 41 Start up sequence 3 41 Start up modes of the PLC 5 84 Starting up the spindle 4 63 T Technical specifications connected loads 1 12 dimensions 1 12 PP 72 48 1 14 weight 1 12 Terminal configuration of the RS232 interface 2 30 Toolbox 1 9 Transport axis 4 75 U User alarms 5 87 alarm texts 5 88 configuring 5 87 effect 5 87 User data 1 10 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 To Suggestions SIEMENS AG Corrections A amp D MC BMS For publication manual Postfach 3180 SINUMERIK 802D D 91050 Erlangen SINUMERIK 802D base line Tel 49 0 180 5050 222 hotline Fax 49 0 9131 98 63315 documentation E mail motioncontrol siemens com Manufacturer Documentation Commissioning Manual From Order No 6FC5697 2AA00 1BP4 Name 08 05Edition SEmpany Dept Should you come across any printing Address errors when reading this publication please notify us on this sheet Zip code Suggestions for improvement are also welcome Telephone Telefax Suggestions and or corrections SINUMERIK 802D 802D base line Document Structure General Documentation Catalog A SINUMERIK 802D Turning Milling LV User Documentation Operation and Programming
38. 8 2 Default settings for the axis machine data for the feed axes The following machine data list summarizes all default data or their recommended settings with SIMODRIVE 611 UE PROFIBUS drives connected 611 Once they have been set the axes are ready to traverse and only a fine adjustment refer ence point approach software limit switches position controller optimization speed feedfor ward control lead error compensation must be performed See FB SINUMERIK 802D Description of Functions Note For feed axes only parameter set 1 index 0 is used Index 1 5 must only be para meterized when using the parameter switching function see FB Chapter 3 with G331 Ri gid tapping or for G33 see FB Chapter 11 MD Name Default va Unit Remark lue 31030 LEADSCREW PITCH 10 mm Leadscrew of the ballscrew Load gear transmission ratio 31050 DRIVE AX RATIO DENOM 1 Revolutions of the ballscrevv 31060 DRIVE AX RATIO NUMERA 1 Motor revolutions 32000 MAX AX VELO 10000 mm min Maximum axis velocity 32300 MAX AX ACCEL 1 m s Maximum axis acceleration 34200 ENC_REFP_MODE 1 1 Incremental encoder Motor order no 1Fx6xxx xxxxx xAxx O EnDat encoder Motor order no 1Fx6xxx xxxxx xExx 36200 AX VELO LIMIT 11500 mm min Threshold value for velocity monitoring setting rule MD 36200 1 15 x MD 32000 Example Motor with incremental encoder Gear tran
39. Byte If EN 1 EN a a VB IB QB MB AC Constant LB VB IB QB MB AC LB Invert Word FEN 1 Enable EN a a In VW T C IW QW MW AC Constant LW Out VW T C IW QW MW AC LW Invert DWord If EN 1 Enable EN a a In VD ID QD MD AC Constant LD Out VD ID QD MD AC LD Instruction Valid Operands Shift Right HEN 1 EN Shift Left a a SR c bits VB IB QB MB AC Constant LB a a SL c bits VB IB QB MB AC VB IB QB MB AC Constant LB Shift Right HEN 1 EN Shift Left a a SR c bits VW T C IW QW MW AC a a SL c bits Constant LW VW T C IW QW MW AC LW VB IB QB MB AC Constant LB DWord Shift R If EN 1 EN DWord Shift L a a SR c bits VD ID QD MD AC Constant LD a a SL c bits VD ID QD MD AC LD VB IB QB MB AC Constant LB Instruction Valid Operands Convert Double Word Integer to a Real Convert a Real to a Double Word Integer If EN 1 convert the double word integer i to a real number o If EN 1 convert the real number i to a double word integer o EN VD ID QD MD AC Constant LD VD ID QD MD AC LD EN VD ID QD MD AC Constant LD VD ID QD MD AC LD 5 94 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Starting up the PLC 5 4 PLC programming PROGRAM CONTROL FUNCTIONS Jump to Label Label from Subroutine tine Conditional End Conditional Return R
40. Installing the Control System 2 8 2 8 2 38 Displays on the PCU Displays on the PCU Fours LEDs are installed on the front side of the PCU Fig 2 17 Displays on the PCU alongside the PC card slot ON green NC yellow WD red PB yellow Power On Sign of life of the NC flashing Process monitoring Profibus SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Installing the Control System 2 9 Displays on the PP 72 48 2 9 Displays on the PP 72 48 The status display is realized via 4 LEDs POWER green Power On READY red EXCHANGE green PP 72 48 is ready no cyclic data exchange PP 72 48 is ready cyclic data exchange is performed OVTEMP red Overtemperature display SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 2 39 Installing the Control System 2 9 Displays on the PP 72 48 This sheet has been left empty for your notes SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 2 40 6FC5 697 2AA00 1BP5 Commissioning 3 3 1 General Start up prerequisites e You will need the following SINUMERIK 802D User Documentation SINUMERIK 802D Description of Functions APC for commissioning and data backup Tools installed from the Toolbox CD WinPCIN PLC802 Programming Tool SimoCom U Text Manager is installed using
41. No operation Instruction Ladder Symbol Valid Operands Load normal open n V l Q M SM T C L And n 1 close Or n 0 open Load Not normal close A n V Q M SM T C L And Not n 0 close Or Not n 1 open Output prior 0 n 0 n n V 1 Q M T C L prior 1 n 1 Set prior O not set Bit S Bit V 1 Q MT C L 1 Bit prior 1 or 7 s n 1 Reset prior 0 no reset Bit S Bit V 1 Q MT C L 1 Bit prior 1 or 7 G n 1 OTHER BOOLEAN INSTRUCTIONS Instruction Valid Operands Edge Up prior 7 close 1 PLC cycle Edge Down prior N close 1 PLC cycle Logical Not prior 0 later 1 n 0 255 BYTE COMPARES Unsigned Instruction Ladder Symbol Valid Operands Load Byte a bclose a a VB IB QB MB SMB AC Constant And Byte ab open 8 LB Or Byte b b NS IB QB MB SMB AC Constant Load Byte z a2 b close a And Byte gt a b open B amp Or Byte gt b Load Byte lt a lt b close a And Byte lt a gt b open 8 Or Byte lt b SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 5 89 Starting up the PLC 5 4 PLC programming WORD COMPARES Signed Instruction Ladder Symbol Valid Operands Load Word a b close a a VW T C IW QW MW AC Constant And Word a b open LW Or Word b b VW T C IW QW MW AC Constant
42. RR RR RR RR RR RR RR RR RARR RR RR AR RR RR Ra 2 15 2 1 Installing and removing the SINUMERIK 802D ee ee ee ee ee ee ee ee ee de 2 15 2 2 Interfaces and lines cs nes SERE RR ace E es bee E EE 2 25 2 3 Connecting the individual components 2 29 2 3 1 Connecting the keyboard ia 2 29 2 3 2 Connecting handwheels to the PCU aaa 2 29 2 3 3 Terminal configuration of the RS232 interface COM1 on the PCU 2 30 2 3 4 Connecting the I Os to PP op 2 31 2 3 5 Connecting the ADI4 module 2 33 2 4 Connecting the SIMODRIVE 6110 drive unit aaa 2 33 2 5 Connecting the Profibus 0 cece ccc eee 2 TE TR E e t 2 34 2 6 Grounding ir BREER GEE DEE evade RD hae pgs uia nuas IE Ph EE des 2 36 2 7 Power supply of PCU X8 and PP 72 48 GI 2 37 2 8 Displaysion the PCU u e eu ge aed Ge da k 2 38 2 9 Displays on the PP 72 48 mri RE e d dh e ha DA 2 39 3 Commissioning ik endri ii de ete 3 41 3 1 General zi suc dd e RE e Li DAT EDO ENG 3 41 3 1 1 Access level Snar yi EE 3 42 3 1 2 Structure of machine data MD and setting data SD 3 43 3 2 Turning on and booting the control system i aaa 3 44 3 3 Language seting sis jest rr banda ote SE peed DER T a dada paia dade 3 45 3 4 Setting the technology 3 46 3 5 Entering the machine data 3 48 3 6 Setting the Profibus address 3 49 3 7 Starting Up the PEG re e r lora td 3 51 3 8 Starting up the axes spindle 3 52 3 8 1 Setpoint actual valu
43. Stop bit 1 Software XON XOFF OFF Hardware RTS CTS ON Timeout Os BIN format ON Call the Receive Data menu in the PC enter the file name any archive name and star the transfer The PC will switch to receive and is awaiting data from the control system The control system requires the password for protection level 2 In the System gt Data I O gt RS232 settings menu make the same settings as in the WINPCIN tool and save them Select the Start up data PC gt line from the Data I O menu and use Read out to read out the series machine start up file 2 Reading in the series start up file from the PC into the SINUMERIK 802D Make the relevant settings for the V24 interface on the PC as specified under 1 Select the Start up data PC gt line from the Data UO menu and use Read in to read in the series machine start up file The control system is now ready to receive Use WINPCIN on your PC to open the series machine start up file from the Send Data menu starting the data transfer Once reading in has started confirm the start of the series machine start up in the control system The control system reboots several times both during and at the end of the data trans fer After an error free data transfer the control system is in a fully configured operat ing condition SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Series Machine Start Upand Data Backup 6 1 Series machine st
44. Tool not active Example T0201 Tool 2 with tool compensation selected Attention Each tool is assigned offset memory 01 as a fixed memory T0200 Tool 2 without tool compensation selected The 20360 TOOL PARAMETER DEF MASK machine data can be used to define whether the input of the tool wear data is to be taken into account in radius or diameter dimensions Bit O Take into account the tool wear in radius dimension Bit 1 Take into account the tool wear in diameter dimension SINUMERIK 802D 802D bi Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 10 165 Start Up ISO Mode with 802D only 10 3 Functions 10 3 Functions ISO dialect for SINUMERIK 802D Programmable functions to ISO 66025 Turning Variant Milling Variant A B C E E ass ss oo Circular interpolation CW Circular interpolation COW o Jet Loading work offset tool offsetcompleted aB Programming of polar coordinates OFF G20 20 70 G20 G70 Inch input system Tala 621 671 Reference point approach for 2nd 3rd 4th ref point G32 33 33 EEN Thread cutting with constant lead Tool radius compensation left of the contourON Tool radius compensation right of the contourON aaa SES Positive tool length compensation ON Do 84 Negative tool length compensation ON DO e ETE QEF gegee A CR G Te TT SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 10 166 6FC5 697 2AA00 1BP5 Start Up ISO Mode with 802D only 10 3 Fu
45. activation type and the unit are displayed on the screen of the con trol system Activation The activation stages are listed according to their priority If any data is changed it comes into effect after e POWER ON po Turning off turning on the SINUMERIK 802D e NEW CONF cf With RESET at the PLC interface V3000 0000 7 e RESET re With RESET at the PLC interface V3000 0000 7 or at the end of the pro gram M2 M30 e IMMEDIATELY im After input of the value Protection level For start up or machine data input usually protection level 2 is required Unit system of units Depending on MD 10240 SCALING SYSTEM IS METRIC the physical units of the ma chine data MD differ as follows MD 10240 1 MD 10240 0 mm inch mm min inch min m s2 inch s m s3 inch s3 mm rev inch rev If there are machine data with no physical unit assigned the relevant field remains empty Note The default setting is MD 10240 SCALING_SYSTEM IS METRIC 1 metric SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 3 43 Commissioning 3 2 Turning on and booting the control system 3 2 Turning on and booting the control system Procedure Check the system visually for correct mechanical design and check that all electrical connections are performed cor rectly connected voltages connection of shielding and grounding Connect the control system
46. and user alarm texts Dataln or the NC card Reading out PLC applications using the WINPCIN tool or theNC card PLC project and user alarm texts analogously to the series machine start up DataOut This function compares the project contained in the PLC 802 Programming Tool with the project loaded in the permanent memory load memory in the control system Version display This function is called using the SYSTEM hardkey Service Display Versionsoftkeys Project The transferred project including the user program which is active in the user memory of the PLC after booting of the control system The programmer can use the start of the first comment line in the comment of OB1 in the PLC 802 Programming Tool for his own supplementary information in the version display see View Properties SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 5 99 Starting up the PLC 5 6 User interface 5 6 User interface This interface comprises all signals exchanged between NCK PLC and HMI PLC In addi tion the PLC decodes all auxiliary function commands for processing in the user program EA Note for the reader FB Sinumerik 802D Description of Functions Chapter 20 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 5 100 Series Machine Start Upand Data Backup 6 6 1 Series machine start up Functionality The objective of the machine start up is e to bring another cont
47. aways Di Lamm 2147000 bworm E Denominator of attached gearbox POWER ON awas Ji Ji 2700000 DWORD c7 j Numerator of attached gearbox POWER ON 2147000000 2147000000 DWORD DO 31070 DRIVE ENC RATIO DENOM O 3 G2 TMessrmggearordenammair feeweres 2 E H Imewmm foworn SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 9 152 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D base line 9 1 List of machine data 31080 DRIVE ENC RATIO NUMERAIO 3 G2 O memon Tromemon ae ws Je po meme oues ESSA Trace specification for die axial Vdi signals POWER ON Fct With as et Maximum axis velocity NEW CONF H M 32010 JOG VELO RAPID 9 H1 o Rapid traverse in the JOG mode RESET wel Horn mm min een JOG VELO sem mm min s rpm JOG axis velocity RESET 2000 Iba ql 32100 JAX MOTION DIR 3 G2 gt emaon aona romeo as DWORD 32110 ENC_FEEDBACK_POL 0 3 G2 Sn aus vals konroldrecien T ee e ho po o SSS NC POSCTRL GAIN O 5 3 G2 mm EE aways ttt Jo Lamm pos BJ 32210 POSCTRL INTEGR TIME PERES nin en o oo IA ewme 32220 POSCTRL INTEGR ENABLE E vm ws Oh lem S 32300 MAX AXACCEL sem mm s 2 rev s 2 Axis acceleration NEW CONF E A mm s 2 always a 77 rev s 2 E NN E das 32420 JOG AND POS JERK ENABLE 4 B2 Qabe s eiiron Teeser aa was fo 19 Elfos SINUMERIK 802D 8
48. be totally ruled out Nonetheless differences might exist and therefore we cannot guarantee that they are completely identical The information given in this publication is reviewed at regular intervals and any corrections that might be necessary are made in the subsequent editions Siemens AG Copyright O Siemens AG 2005 Automation and Drives 6FC5697 2AA00 1BP5 Postfach 4848 90437 N RNBERG Siemens AG 2005 GERMANY Subject to change without prior notice Preface SINUMERIK Documentation The SINUMERIK Documentation is organized in 3 levels e General Documentation e User Documentation e Manufacturer Service Documentation For detailed information regarding further publications about SINUMERIK 802D as well as for publications that apply for all SINUMERIK control systems e g Universal Interface Mea suring Cycles please contact your Siemens branch office A monthly overview of publications with specification of the available languages can be found on the Internet at http www siemens com motioncontrol Follow the menu items Support Technical Documentation Overview of Publications The Internet edition of DOConCD DOConWEB can be found at http www automation siemens com doconweb Addressees of the documentation Standard scope Hotline The present documentation is aimed at the machine tool manufacturer This publication pro vides detailed information required for the machine tool manufacturer
49. in the Tool gauging window immediately Byte 362 SPINDLE LOAD DISPL2 decimal Activate utilization display for spindle 2 immediately INTEGER 363 SPINDLE LOAD BAR LIM2 decimal Activate utilization display for the spindle limit value 2 immediately 9999999 INTEGER SINUMERIK 802D 802D H Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 9 145 Machine and Setting Data 802D base line 9 1 364 List of machine data SPINDLE LOAD BAR LIMS decimal Activate utilization display for the spindle limit value 3 immediately 365 9999999 SPINDLE LOAD BAR MAX INTEGER decimal Utilization display for the spindle maximum immediately 366 120 0 SPINDLE LOAD BAR COL1 INTEGER decimal Utilization display color for the spindle range 1 immediately 367 10 0 SPINDLE LOAD BAR COL2 Byte decimal Utilization display color for the spindle range 2 immediately 368 SPINDLE LOAD BAR COL3 Byte decimal Utilization display color for the spindle range 3 immediately 369 PROBE MODE Byte decimal Measuring system type 1 Probe 2 Opt measuring technique immediately 370 TOOL REF PROBE AXIS1 INTEGER decimal Absolute position of probe X immediately 371 999999 999 999999 999 TOOL_REF_PROBE_AXIS2 DOUBLE decimal Absolute position of
50. probe Y immediately 372 999999 999 999999 999 TOOL_REF_PROBE_AXIS3 DOUBLE decimal Absolute position of probe Z immediately 373 999999 999 999999 999 MEAS_SAVE_POS_LENGTH2 DOUBLE decimal Activate tool gauging select Save Pos softkey for all values immediately 374 TOOL WEAR LIMIT VALUE Byte decimal Limit value for wear control during input immediately 375 USER CLASS READ CUS DIR DOUBLE decimal Protection level for Read user cycles immediately 0 376 USER CLASS WRITE CUS DIR Byte decimal Protection level for Write user cycles immediately 0 377 USER CLASS WRITE TO MON DAT Byte decimal Protection level for Tool monitoring immediately 0 9 146 Byte SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D base line 9 1 List of machine data 9 1 2 General machine data Cross refe rence to the relevant sec MD identifier tion chapter in the Des cription of Functions Read write pro Default value Data type 10000 AXCONF MACHAX NAME TABIO 31 Dessen rom se Long oo o L me Too 10074 PLC IPO TIME RATIO E TT H 2 1 fo ort P ma ke TJ E 10240 SCALING SYSTEM IS METRIC 3 G2 E meen Trom non e Doo Do EE IE fo o 11100 AUXFU MAXNUM GROUP ASSIGN
51. subroutine library SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 5 79 Starting up the PLC 5 1 Commissioning the PLC 5 1 Commissioning the PLC By default the user program of the SINUMERIK 802D only consists of a NOP no opera tion instruction and is stored in the permanent memory The user program addressing the particular requirements of the machine is to be created by the user himself 5 2 Start up modes of the PLC Table 5 1 Start up modes Selection Reaction PCU PCU PT PLC 802 PLC Program Retentive MD for the Switch on Start up menu PC program status data PLC in the menu 802D preselec battery bak user interface 802D tion ked NCK start up Normal booting Normal booting User pro Run unchanged Acceptance of gram the active PLC MD Booting Booting User pro Run deleted Default PLC with default va with default values gram MD lues Booting Booting User pro Run saved Saved PLC MD with saved data with saved data gram data PLC stop PLC stop unchanged Stop unchanged Acceptance of after POWER ON possible ei the active PLC ther in Run MD or in Stop PLC start up Cold restart Run after User pro Run unchanged Acceptance of Stop gram the active PLC MD Cold restart User pro Stop unchanged Acceptance of and debug mode gram the active PLC MD Overall reset User pro Run deleted Acceptance of gram the active PLC MD Overall reset User pro
52. the 802D Toolbox menu item The mechanical and electrical installation of the system must be completed Starting up the SIMODRIVE 611 UE drive with the Profibus option module inserted Start up sequence To commission the SINUMERIK 802D proceed as follows 1 O a A ON Check that the PCU boots Set the language Set the required technology Set the general machine data Start up the PLC Set the axis spindle specific machine data Match the encoder to the axis spindle Match the setpoint to the axis spindle 7 Perform a dry run for the axes and for the spindle 8 Optimize the drive Complete the commissioning perform a data backup SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 8 41 Commissioning 3 1 General 3 1 1 Access levels Protection levels The SINUMERIK 802D provides a concept of protection levels for enabling data areas There are the protection levels O to 7 whereby O is the highest and 7 the lowest level The protection levels can be set for certain function areas e g program editor using the display machine data USER CLASS When the control system is delivered certain default passwords are already set for the protection levels 1 to 3 If necessary the appropriate authorized person can change these passwords Table 3 1 Protection level concept Protection Locked by Area level 0 Siemens reserved 1 Pass
53. to start up the SINU MERIK 802D control system The present Instruction Manual describes the functionality of the standard scope Any amendments made by the machine manufacturer are documented by the machine manufac turer Other functions not described in this documentation can possibly also be performed on the control system However the customer is not entitled to demand these functions when the new equipment is supplied or servicing is carried out If you have any questions do not hesitate to call our hotline A amp D Technical Support Tel 49 0 180 5050 222 Fax 49 0 180 5050 223 Internet http www siemens de automation support request If you have any questions suggestions corrections regarding the Documentation please send a fax to the following number or an e mail to the following address Fax 49 0 9131 98 63315 E mail motioncontrol docu siemens com Fax form see return fax form at the end of this publication SINUMERIK 802D 802D bi Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Preface Internet address http www siemens com motioncontrol SINUMERIK 802D 802D bl Start up IBN 08 05 Edition iv 6FC5 697 2AA00 1BP5 Contents Contents 1 The SINUMERIK 802D Control System 1 9 1 1 Components of the SINUMERIK 802D aaa 1 9 1 2 T chnical specification si ja ri choad de n RID MEd eed edd a Ven 1 12 2 Installing the Control System x x x x K K kk
54. 02D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 The SINUMERIK 802D Control System Ambient conditions during operation Table 1 4 Ambient conditions during operation 1 2 Technical specifications Parameters Temperature range 0 50 C Permissible relative humidity 5 95 Ye not condensing Air pressure 700 1 060 hPa The conditions during operation comply vvith IEC 1131 2 The control system is to be intended for installation in a housing e g cubicle Transport and storage conditions Table 1 5 Transport and storage conditions Parameter Temperature range 20 60 C Permissible relative humidity 5 95 not condensing Air pressure 700 1 060 hPa Transport height 1 000 3 000 m Free fall in transport package lt 1 200 mm PP 72 48 lt 1 000 mm Protective quality and degree of protection Class of protection to IEC 536 No connection to protective conductor terminal is required Protection from foreign matter and penetrating water to IEC 529 e Forthe PCU IP 65 front IP 00 rear e Forthe keyboard IP 65 front IP 00 rear e Forthe MCP IP 54 front IP 00 rear e PP 72 48 IP 00 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 The SINUMERIK 802D Control System 1 2 Technical specifications PP 72 48 Table 1 6 Digital inputs Parameter min typ m
55. 02D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 9 153 Machine and Setting Data 802D base line 9 1 List of machine data 32430 JOG AND POS MAX JERK 4 B2 Mud Ep Memes Jor nome 3 32450 BACKLASHIOJ 16 K3 ws Jo ee les 1 32630 FFW ACTIVATION MODE 16 K3 E Feederwardcontl can ve aonais tom me progam RESET a aways ho ud vam IRE Pod 32640 STIFFNESS CONTROL ENABLE EE E fomamesimmccn L T not 810D CCU1 S42 STIFFNESS CONTROL CONFIG Lo ot erdynamistimeseconve Iewen CC IS CIO CN CS AA SE Dyn stiffness control Delay POWER ON Profibus adapter 0 0015 DOUBLE DO 32700 ENC COMP ENABLE 0 16 K3 Pence ero cemsnsvon L T e mas p E eomm 1 32810 EQUIV_SPEEDCTRL_TIME O 5 Ze DEE 0 003 0 003 0 003 33050 JLUBRICATION DIST ta Distance to be traversed f lubrication pulse PLC signal NEW CONF 100000000 DOUBLE EEE 34000 REFP CAM IS ACTIVE 8 R1 E wewmewexeptem Reset e was Je 9 I9 ET 34010 REFP CAM DIR IS MINUS 8 R1 Reference point approach in the negative direction RESET POE a Dual 5 000 i Ammin 34030 REFP MAX CAM DIST 8 R1 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 9 154 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D base line 9 1 List of machine data 34040 REFP VELO SEARCH MARKER 0 8 R1 Velocity when searching for the referen
56. 2 ISO M Milling technology When commissioning a SINUMERIK 802D using the ISO 66025 Programming additional function observe the following order and procedure 1 Perform a Power up with default data in the Start up mode 2 After restarting the control system set the password EVENING 3 Set the V24 interface and WINPCIN to the binary format Important Depending on the technology a difference must now be made between turning and milling variants 10 1 1 Turning variant 4 Transfer the setISO T CNF file for the turning variant to the control system With loading the setISO T CNF file the System B Programming System has been activated and defined as the default setting Remark The ISO SYSTEM B is deemed to be the most widely used ISO programming dia lect In addition to the ISO System B default setting the system can be adapted individually to other variants of DIN 66025 programming using the following start up aids By reloading the ISO A T file the ISO System A programming language is activated By reloading the ISO C T file the ISO System C programming language is activated SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 10 163 Start Up ISO Mode with 802D only 10 2 Machine data 10 1 2 10 2 10 2 1 10 2 2 10 164 Milling variant 4 Transfer the setlSO M CNF file for the milling variant to the control system With loading the setlSO M CNF file the IS
57. 2D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 3 49 Commissioning 3 6 Setting the Profibus address Example 1 Example 2 PCU PP 72 48 3 50 To parameterize the drive use the SimoCom U Parameterization and Commissioning Tool You will need the following documentation SIMODRIVE 611 UE Description of Functions Turning machine with one PP module one twin axis power section X and Z axes and the spindle as the single axis power section Table 3 3 MD 11240 PB station slave PB address Drive number 3 PP module 1 9 Single axis power section 10 5 Twin axis power section Drive A 12 1 Drive B 2 Milling machine with two PP modules two single axis power sections X Z axes one twin axis power section Y C axis and one spindle as a single axis power section Table 3 4 MD 11240 PB station slave PB address Drive number 5 PP module 1 9 PP module 2 8 V Single axis power section 20 1 Single axis power section 21 2 Twin axis power section Drive A 13 3 Drive B 4 Single axis power section 10 5 Slave 12 from example 1 has been fully replaced by slaves 20 and 21 Is master at PROFIBUS address cannot be changed Is slave at PROFIBUS max two PP modules can be connected The addresses are set us ing DIL switch S1 on the PP module SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Comm
58. 358 JHmi COL SK FORE pa Color settings softkey foreground POWER ON lo joo te Color settings softkey background POWER ON lr joo fete 360 SPINDLE LOAD DISPL1 decimal Activate utilization display for spindle 1 immediately INTEGER 361 USER MEAS TOOL CHANGE decimal Input enable for T D no in the Tool gauging window immediately Byte 362 SPINDLE LOAD DISPL2 decimal Activate utilization display for spindle 2 immediately INTEGER SINUMERIK 802D 802D H Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 8 115 Machine and Setting Data 802D 8 1 List of machine data 363 SPINDLE LOAD BAR LIM2 decimal Activate utilization display for the spindle limit value 2 immediately 9999999 INTEGER 364 SPINDLE LOAD BAR LIM3 decimal Activate utilization display for the spindle limit value 3 immediately 100 0 9999999 INTEGER 365 SPINDLE_LOAD_BAR_MAX decimal Utilization display for the spindle maximum immediately 120 0 INTEGER 366 SPINDLE LOAD BAR COL1 decimal Utilization display color for the spindle range 1 immediately Byte 367 SPINDLE LOAD BAR COL2 decimal Utilization display color for the spindle range 2 immediately Byte 368 SPINDLE LOAD BAR COL3 decimal Utilization display color for the spindle range 3 immediately Byte 369 PROBE MODE decimal Measuring system type 1 Probe 2 Opt measuring technique imme
59. 5 Edition 6FC5 697 2AA00 1BP5 1 9 The SINUMERIK 802D Control System 1 1 Components of the SINUMERIK 802D SimoCom U Parameterization and Commissioning Tool for Drives SIMODRIVE 611 UE Firmware PLC 802 Programming Tool Note Please always observe the readme file supplied with the Toolbox It provides up to date information User data The user data include e Machine data e Setting data e Tool data e R parameters e Work offsets e Offset data e Part programs e Standard cycles e PLC user program e PLC alarms Note After turning off or in case of power failure changed user data are stored for at least 50 h Thereafter they can be lost if they are not permanently stored by appropriate operator ac tions see Section 6 2 1 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 1 10 6FC5 697 2AA00 1BP5 The SINUMERIK 802D Control System 1 1 Components of the SINUMERIK 802D KB operator panel PCU Machine control panel control system MCP Goo AO III 1 ajaja i ar e nem OR E zen 208 CDD D i OU DOO ODO O i Ol DOO oooO OUD Ot ODO DOO CIO 9
60. 7 2AA00 1BP5 vil Contents Platz ftir Notizen oa SINUMERIK 802D 802D bl Start up IBN 08 05 Edition VIII 6FC5 697 2AA00 1BP5 The SINUMERIK 802D Control System 1 1 1 Components of the SINUMERIK 802D Hardware components PCU Panel Control Unit Component of the control system for max 4 axes and one spindle with graphical display softkey menu and NC card slot KB keyboard horizontal or vertical design MCP Machine control panel PP 72 48 Profibus I Os 72 digital inputs 48 digital outputs ADI4 analog drive interface for 4 axes Drive module SIMODRIVE 611UE closed loop control module PROFIBUS DP option module Software components System software on the permanent flash memory ofthe PCU Boot software starts the system Human Machine Interface HMI realizes all operator functions NCK software NC Kernel realizes all NC functions It controls one NC channel with up to 5 axes 2 of them can be configured as spindles Programmable Logic Control PLC executes the integrated PLC user program cyclically Toolbox Setup files for turning and milling Configuration file for transformations with turning Cycle package for turning and milling WINPCIN transfer program for transferring user data and programs between PC and NC Reloadable languages Text manager PLC user library SINUMERIK 802D 802D bl Start up IBN 08 0
61. 8 Range of values minimum maximum value If no range of values is specified the data type will determine the input limits and the filed will be marked with 799 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 8 111 Machine and Setting Data 802D 8 1 List of machine data 8 1 List of machine data 8 1 1 Display machine data Cross ref to the relevant MD identifier chapter in the Description of Functions Read write pro Default value Data type 202 FIRST LANGUAGE p o fo IE RM toi 2 DISPLAY RESOLUTION EE p 1s po Efe oi ao DISPLAY RESOLUTION INCH E p 1 E E EEE 205 JDISPLAY RESOLUTION SPINDLE Es Of fe Protection level for Write tool geometry immediately oe SA Ga ESTA 9 USER CLASS WRITE TOR WEAR PA je Je Je e HS 2410 USER CLASS WRITE ZOA 0520507 A ies A ad WETE AAA a2 USER CLASS WRITE SEA ms JUSER CLASS READ PROGRAM Es ee E ee cf 21a USER CLASS WRITE PROGRAM E p s prt deme 215 USER CLASS SELECT PROGRAM EE p 1s Je E BE SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 8 112 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D 8 1 List of machine data 217 USER CLASS WRITE CYCLES EE E ps ses p Ti o miss EA 218 USER CLASS WRITE RPA Protection level for Write R parameters 3 3 je 0 TE REH 219 USER CLASS SET V24 es E jo le fo r ere EEE e USER CLASS DI
62. 802D 802D bl Start up IBN 08705 Edition 6FC5 697 2AA00 1BP5 Starting up the Spindle 4 6 4 6 Example Analog spindle via 611 U E with with spindle actual value encoder mounted directly on the motor Analog spindle via 611 U E with with spindle actual value en coder mounted directly on the motor The analog spindle function uses the analog output of the SIMODRIVE 611 UE closed loop control module as the setpoint output and die the encoder interface X472 as the actual value input for a TTL encoder A digital feed axis is used as the transport axis for the set point and actual values of the analog spindle The servo enable for the analog spindle is output via the digital outputs and the analog set point via terminal 75 A 15 of the transport axis There are three modes 1 MD 30134 IS UNIPOLAR OUTPUT 0 Bipolar spindle 10V Digital output O0 A gt Servo enable 2 MD 30134 IS UNIPOLAR OUTPUT 1 Unipolar spindle 0 410V enable and direction signals Digital output OO A gt Servo enable Digital output 01 A Direction of rotation 3 MD 30134 IS UNIPOLAR OUTPUT 2 Unipolar spindle 0 10V CW enable CCW enable Digital output O0 A gt CW enable Digital output 01 A gt CCW enable Important In case of RESET a setpoint is output at the analog output of the 611 UE closed loop con trol module It is therefore imperative to connect the servo enable for the analog spindle to terminal
63. ANDWHEEL1 X14 HANDWHEEL2 X15 HANDWHEELS X16 15 pin D Sub socket connector Max cable length 3m Table 2 1 Pin assignment of the socket connectors X14 X15 X16 X14 X15 X16 Pin Signal typ Pin Signal typ 1 1P5 V 9 1P5 V 2 1M V 10 N C 3 JA 11 1M V 8 1 4 A 12 INC 5 NC 13 N C 15 9 6 B 14 N C 7 B 15 NC 8 NC Signal names A A pulse A Inverted A pulse B B pulse B Inverted B pulse 1P5 5V power supply 1M Ground SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 2 29 Installing the Control System 2 3 Connecting the individual components Signal type V Voltage output Handwheels Three electronic handwheels can be connected these must meet the following requirements Transmission technique 5 V square wave signals TTL level or RS422 Signals Track A as true and negated signal Uz1 Ua1 Track B as true and negated signal Ua Uae Max output frequency 500 kHz Phase shift of the A tracks to B 90 x30 Power supply 5 V max 250 mA 2 3 3 Terminal configuration of the RS232 interface COM1 on the PCU RS232 interface COM1 Connector designation COM X6 Connector type 9 pin D Sub plug connector Max cable length 15m Table 2 2 Pin assignment of the COM1 socket connector X6 COMI X6 Pin Name typ Pin Name typ 1 DCD I 6 DSR I 1 5 2 RXD
64. BE PerameiezatenefineTuneionrplaeemenn POWERON ap Lous fo In wor 10760 G53 TOOLCORR Emp wemesswmasm Te uenon ar mas Je IE lol wwe WETEN ESE TT Defrtonofte contolaytemtonecenied Joen er LE wee A Pig 2 E E E JI e ro 10881 MM_EXTERN_GCODE_SYSTEM cae soswweGcxensem SSCS WEN External NC progr language Po Po Po Be ES 10882 NC USER EXTERN GCODES TABJ O 59 Say Ustouser seaeG commands ot an exeat NC anguege Poweron se was oo di SG CS 10884 EXTERN_FLOATINGPOINT_PROG ar evaustonafvalespregrammeswinautdeamaipans POWERON se awas Ji JJ BOLEN JL y 10886 EXTERN INCREMENT SYSTEM gemi eanas romo t aways Jo JJ Boon 10888 EXTERN DIGITS TOOL NO Se E rara fort number rowenon te mas o To Et SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 8 118 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D 8 1 List of machine data 10890 EXTERN TOOLPROG MODE E Programming of tool change when working with an external language POWER ON 0x00000000 0x00000000 OXFFFFFFFF DWORD as 11100 AUXFU MAXNUM GROUP ASSIGN 13 H2 E uesamBaynebmiAwrgne romo as hus ME po ie o Al O me UPLOAD MD CHANGES o le EEE CT fm 1 11240 PROFIBUS SDB NUMBER 3 G2 E mre O LT TS ee aways Jo In e Jm jJ as PROFIBUS SHUTDOWN TYPE EE EE E e ax fo Jp Eme 11310 HANDWH REVERSE 9 H1
65. Byte 0 Bit 0 gt NC start inhibited Bit 1 gt Read in disable Bit 2 gt Feed disable for all axes Bit 3 gt EMERGENCY STOP Bit 4 gt PLC STOP By using subarea 2 the user can evaluate the active alarm responses this subarea is read only Self clearing user alarms must be canceled by the user by resetting the appropriate bit in subarea 0 1 gt 0 edge Other user alarms are canceled by the PLC after detecting the relevant cancel condition for the appropriate user alarms If the bit of the user alarm however is still present the alarm recurs Effect of a user alarm User alarms have a higher priority than the appropriate signal in the user interface e g NC start inhibited read in disable feed disable and EMERGENCY STOP SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 5 83 Starting up the PLC 5 3 PLC alarms Configuring user alarms Alarm texts 5 84 A configuration byte is provided for each alarm The user alarms can be configured by the user in the machine data 14516 USER DATA PLC ALARM Default setting of MD 14516 0 63 0 gt SHOWALARM SELF CLEARING user alarm Structure of a configuration byte e BitO bit5 Alarm responses e Bit6 bit7 Cancel criteria 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 reserv
66. C memory project Series machine start up Toolbox PES application PLC application NC card WINPCIN Series machine start up Li Fig 5 1 PLC applications in the control system are SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Starting up the PLC Download 5 5 PLC applications Download Upload Copy Compare This function writes the transmitted data to the permanent memory load memory of the control system Download from the PLC project using the PLC 802 Programming Tool Step 7 connect on Machine series start up using the WINPCIN tool PLC MD PLC project and user alarm texts Dataln or the NC card Reading in PLC applications using the WINPCIN tool or theNC card PLC project and user alarm texts analogously to the series machine start up Dataln When the control system is powered up next time the loaded PLC user program is transferred from the permanent memory to the user memory and is active in the con trol system from this moment Upload The PLC applicationscan be saved from the permanent memory of the control system using the either PLC 802 Programming Tool WINPCIN or the NC card Compare Upload from the PLC project using the PLC 802 Programming Tool Step 7 connect on Reading out the project from the control system and thus reconstructing the current proj ect in the PLC 802 Programming Tool Machine series start up Start up data using the WINPCIN tool PLC MD PLC project
67. D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 5 85 Starting up the PLC 5 4 PLC programming Example Memory bits MBO 1 MB3 5 Memory bytes MBO MB1 MB2 Memory word MWO MW2 MWA MW3 MWS5 are not permissible Memory double words MDO MD4 MD8 MD1 MD2 MD3 MDS are not permissible Table 5 2 PLC data types permitted in the control system Data type Size Address Range for logical operations Range for arithmetical operations alignment BYTE 00 FF 0 255 VVORD 0000 FFFF 32 768 32 767 DWORD 4 bytes 4 0000 0000 FFFF FFFF 2 147 483 648 Double 2 147 483 647 Word 4 REAL 4 bytes 10 97 1038 PLC project The PLC 802 Programming Tool always manages one project combinational logic symbols and comments All important information of a project can be stored in the control system via a download The information is transmitted from the control to the PC via upload The control system can save max 6 000 instructions and 1 500 symbols The PLC memory required 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 S7 200 Ladder Diagram The addresses and operations can be defined using the representation type International When using the ladder diagram the user programs his program in networks Each network corresponds to a certain logic reflecting a certain sequence Th
68. G00 xxxx incremental encoder 6FX8002 2CH00 xxxx EnDat encoder to the encoder interface X412 of the 611UE closed loop control module and parameterize the drive for the direct measuring system using SimoCom U Special feature If a probe is connected when using a direct measuring system the probe must be connected on the SIMODRIVE 611UE to the X454 interface terminal I0 B and parameterized via drive parameter P672 with signal number 80 Furkien Engangstenme 0B BL BE Fig 3 1 Settings for P672 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 3 55 Commissioning 3 8 Starting up the axes spindle Parameterization using the Drive Configuration Wizard in case of identical number of incre ments The number of increments of the motor encoder is identical to the number of increments of the direct rotary measuring system Welches direkte Me system verwenden Sie Daten eingeben basch sd Rotatorisches Me system t inkrementell C Absolut EnDat 4 gt Geberstrichzahl poe Zur ck Weiter gt Abbrechen Hilfe lt Zur ck Weiter gt Abbrechen Hilfe Fig 3 2 Display Adaptations in the Expert list Wert Einheit Wirksam 1001h Bits gt F4 DiektesMe ytemakimeren Jee DM Geberondenumme 9 Poem DEI TEE H Jee Creses Messen of Jee DM MuitumufisungAbschamengeber TH Jee DM SingletumAufisungAbschawengebe H Poweri
69. I 7 RTS O o o 3 TXD 08 hers zur 6 9 4 DTR O 9 RI I 5 1M V Signal description DCD Data Carrier Detect RxD Receive Data V24 TxD Transmit Data V24 RTS Request To Send CTS Clear To Send DTR Data Terminal Ready DSR Data Send Ready RI Ring Indicator 1M Signal Ground SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 2 30 6FC5 697 2AA00 1BP5 Installing the Control System 2 3 Connecting the individual components Signal type Input O Output V Voltage output Cable assignment for the RS232 interface 9 pol 25 pol 9 pol 9 pol 1 1 1 2 2 3 3 3 2 4 4 6 5 5 6 6 4 T T 8 8 8 T Fig 2 14 Cable assignment Pin assignment of the D Sub female connectors 2 3 4 Connecting the I Os to PP 72 48 To connect the machine control panel to the PP 72 48 X111 X222 use ribbon cable see Fig 2 13 Max cable length 15 m Pin assignment of the connectors on the PP 72 48 side Connector designation X111 X222 X333 Connector type 50 pin plug connector Table 2 3 Pin assignment of the connectors X111 X222 X333 Pin Signal Type Pin Signal Type 1 M GND 2 24V Output output for m 0 0 m 2 7 3 m 0 0 Input 4 I m 0 1 Input 5 m 0 2 Input 6 m 0 3 Input 7 m 0 4 Input 8 m 0 5 Input 9 m 0 6 Input 10 Im 0 7 Input 11 Im 1 0 Input 12 Im 1 1 Input 13 Im 1 2 Input 14 Im 1 3 Input 15 Im 1 4 Input 16 Im 1 5 Input 17 Im 1 6 Input 18 Im 1 7 Input
70. IBN 08 05 Edition 4 68 6FC5 697 2AA00 1BP5 Starting up the Spindle 4 5 Digital spindle without encoder with external TTL encoder 4 5 Digital spindle without encoder with external TTL encoder It is also possible to configure a motor without encoder standard motor non Siemens mo tor as the spindle motor The external TTL encoder is used to acquire the spindle speed This configuration should not be used for positioning Due to the lack of speed acquisition at the spindle motor the spindle is always in the toque controlled operation This may result in thermal problems and inaccuracies Merely the TTL encoder is connected to the 611UE controller module via the angular en coder interface The KTY of the motor can be evaluated at the encoder interface X411 via pins 13 and 25 4 5 1 Parameterization using the Expert List Table 4 5 Parameters to be entered in the Expert List Parameters Text Value Remark 890 Activating the angular encoder enco 4 Save Power On Reset der interface 922 PROFIBUSmessage frame selection 0 Save Power On Reset 915 6 Process data setpoint assignment 50017 916 6 Process data act value assignment 50018 916 7 Process data act value assignment 50019 916 8 Process data act value assignment 50019 916 9 Process data act value assignment 50020 916 10 Process data actual value assign 50020 Save Power On Reset ment 1006 Encoder interface
71. LC programming Instruction Ladder Symbol Valid Operands Divide HEN 1 Enable EN b b a VW T C IW QW MW AC Out Constant LW 16 bit remainder VD ID QD MD LD Out 2 16 bit quotient Add HEN 1 EN Subtract b a b VD ID QD MD AC Constant LD Real Numbers b b a VD ID QD MD AC LD Multiply If EN 1 EN Divide b axb VD ID QD MD AC Constant LD Real Numbers b b a VD ID QD MD AC LD Instruction Valid Operands Increment If EN 1 EN Decrement a a 1 VB IB QB MB AC Constant LB Byte a a 1 VB IB QB MB AC LB Increment If EN 1 EN Decrement a a 1 VW T C IW QW MW AC Word a a 1 Constant LW a a VW T C IW QW MW AC LW Increment If EN 1 EN Decrement a a 1 VD ID QD MD AC Constant LD a a 1 VD ID QD MD AC LD LOGIC OPERATIONS Instruction Ladder Symbol Valid Operands Byte AND If EN 1 EN Byte OR b aANDb VB IB QB MB AC Constant LB Byte XOR b aORb VB IB QB MB AC LB b aXORb Word AND HEN 1 EN Word OR b aAND D VW T C IW QW MW AC Word XOR b aORb Constant LW b aXORb VW T C IW QW MW AC LW SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 5 93 Starting up the PLC 5 4 PLC programming Instruction Ladder Symbol Valid Operands DWord AND If EN 1 Enable EN DWord OR b aANDb VD ID QD MD AC Constant LD DWord XOR b aORb VD ID QD MD AC LD b aXORb Invert
72. LO 5 S1 Faways oo ooe 1 1 35410 SPIND OSCILL ACCEL 5 S1 ww fie leer ewe l 35430 SPIND OSCILL START DIR 5 S1 Sewesesowenmepoan fe e ways Jo Jo fe E 35440 SPIND OSCILL TIME CW 5 S1 DEES aways fo lm Jm oe LI 35450 SPIND OSCILL TIME CCW 5 S1 Ee CA d aways los Jl BLE ES 88500 SPIND ON SPEED AT IPO START 5 S1 E osa nabo side er aa awas Ji Jo 1 2 fe j 35510 SPIND STOPPED AT IPO START 5 1 Feed enable wih he spe C 1 as was ks le Ie soes 1 5555 DRIL VELO MTOE EE Maximum speeds when tapping NEW CONF 10000 10000 10000 36000 STOP LIMIT COARSE 2 A3 mas os E 36010 STOP LIMIT FINE 2 A3 NEW CONF 36020 POSITIONING TIME 2 A3 E Bate qe s was ks IE oe 1 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 8 134 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D 8 1 List of machine data 36030 STANDSTILL POS TOL 36040 STANDSTILL DELAY TIME ze GLAMP POS TOL Clamping tolerance NEW CONF 2 2 DOUBLE 36060 STANDSTILL VELO TOL 2 A3 Threshold value for Axis stopped signal NEW CONF 5 0 mm min 0 01388 r p m RE RN 36100 POS LIMIT MINUS 1st software limit switch minus NEW CONF 2 2 100000000 DOUBLE 36110 POS LIMIT PLUS 1st software limit switch plus NE
73. NUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Commissioning 3 3 Language setting 3 3 Language setting English is set for both the foreground and background languages You can change the lan guages by loading new language files from the toolbox using the Text Manager The functions provided by the Text Manager are described in its help file Sequence Establish a V24 connection between the PC and the PCU COM1 Turn on the control system and wait until the control system has completed its booting sequence without errors In the System operating area set the password for protection level 2 Preselect the gt BIN format from the RS232 settings operating area In the System operating area Data I O gt menu item position the cursor on the line Start up data PC Select the Read in softkey Start the Text Manager on your PC Use the Text Manager to select the relevant language file for your foreground or back ground language and transfer it to the control system Restart the NC The desired language is now set Note Make sure that the settings for the interface parameters of the PCU and of the PC are the same SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 3 45 Commissioning 3 4 Setting the technology 3 4 Setting the technology Sequence 3 46 Note The SINUMERIK 802D is delivered vvith default machine data Load th
74. O Milling Programming System with the option of switching between inch and metric via G20 G21 has been activated and defined as a function In addition to this default setting the inch metric switching option with G70 G71 can be de fined as a function by reloading the ISOG70 M file The technology and the type of ISO 66025 programming are now defined for the SINUM ERIK 802D Important The procedure described above is obligatory for start up in the SINUMERIK 802D ISO mode Machine data To adapt the SINUMERIK 802D to the ISO 66025 programming the following machine data are provided Decimal point programming Use the 10884 EXTERN FLOATINGPOINT PROGRAMMING machine data to select whether or not the axis programming is to be performed using decimal point notation e Bit 1 means notation without decimal point Example GO G90 X10 The X axis is traversed absolutely to the position 10 millimeters inch degrees e Bit 0 means notation with decimal point Example GO G90 X10 The X axis is traversed absolutely to the position which is defined in the machine data MN INT INCR PER MM or MN INT INCR PER DEC as the incremental resolution Value 1000 means axis position 0 1 millimeter inch degrees Linear path control at rapid traverse rate GOO The 20732 EXTERN GO LINEAR MODE machine data can be used to select whether the axes approach their programmed end position with interpolation or on the shortest path when using GOO
75. OO pown e es Qe Je dee o SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 9 148 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D base line 9 1 List of machine data 20070 AXCONF MACHAX USEDJO 3 19 Machine axis nur eanas Tromeron ae 20080 AXCONF CHANAX NAME TABIO 13 19 Nameotohenneisusinmechme _ _ row 2 SPIND_DEF_MASTER_SPIND 20090 20094 SPIND_RIGID_TAPPING_M_NR 20108 PROG_EVENT_MASK EXACT POS MODE Go TO G1 20700 REFP NC START LOCK Nesatdebewiureermepon RESET 20730 GO LINEAR MODE E raro pena romanos mas RE CIRCLE ERROR CONST 10 K1 Factor for circle end point monitoring POWER ON SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 9 149 Machine and Setting Data 802D base line 9 1 List of machine data 21020 WORKAREA WITH TOOL RADIUS 2 A3 E memdewiwo mse ron RESET 22 aways lo JJ Boon po 200 AU ASSIGN GROUP s 22 AUXFU_ASSIGN_GROUP 0 63 zus EET ET 22010 AUXFU ASSIGN TYPEI0 63 13 H2 E ta aten e 7 ae awas desne string 22020 AUXFU ASSIGN EXTENSIONIOI I63 13 H2 DO seubzooAUXUASSGNTYE ROMERO ae aways Jonn lo lee lee o 22030 JAUXFU ASSIGN VALUEIO 63 13 H2 Leier T e always 0000 Je Jm ooo LI mus AUXFU ASSOC Mo VALUE E O mra mtneonstorprogemsoo rowno ma ER E le Addit
76. OO A of the transport axis Important Transport axis can only be drive A of the spindle axis power section with PB address 10 and drive number 5 or drive A of the twin axis module with PB address 12 and drive number 1 see also Table 2 3 When configuring the axes first define the transfer axis and then the analog spindle Exam ple X Z SP A Only the X or Z axis may be configured as a transfer axis The example below will use the first machine axis X1 as the transport axis X1 will be drive A on a 611 UE closed loop control module with PROFIBUS address 12 In the 802D the spindle is parameterized as the third machine axis SP standard data re cord for turning This spindle is an analog spindle with 10V interface The maximum speed in 9 000 r p m at 10 V in this example SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 4 71 Starting up the Spindle 4 6 Analog spindle via 611 U E with with spindle actual value encoder mounted directly on the motor Only the additional machine data required for starting up an analog spindle will be dealt with in the following The general machine data for configuring an analog spindle are listed in the table below Table 4 7 Settings for the example Transport axis X1 machine axis 1 Analog spindle SP machine axis 3 Connections required between the transport axis X1 and the analog spindle SP Terminal 75 A to be connected to
77. R ACCESS A je 1s 19 Id l1 22 USER GLASS PLC ACCESS EE je JE po m lm I 223 JUuser CLASS WRITE PWA ERES E x nno 27 sSf SE BE Ba PG Baud rate 300 600 1200 2400 4800 9600 19200 38400 po po e E LJ ITA TE CO AUN E A A fe md BEER se DD o ip IE le il 289 CTM SIMULATION TIME NEW POS 10 K1 je Jm In 40 wreeerR 290 CTM POS COORDINATE SYSTEM 10 K1 Oe 291 CTM CROSS AX DIAMETER ON 10 K1 po Cb po qpu LRE 292 CTM Got DIAMETER ON 10 K1 pc proc capo Mrs gt d O User oriented G group for position display immediately SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 8 113 Machine and Setting Data 802D 8 1 List of machine data User oriented G group for position display immediately jo ERR INTEGER User oriented G group for position display immediately 30s G GROU E User oriented G group for position display 3 7 je ja po mo inter p ll User oriented G group for position display immediately o jJ iv INTEGER User oriented G group for position display external language immediately ml t 100 INTEGER RR User oriented G group for position display external language immediately je 000 INTEGER ESA User oriented G group for position display external language immediately User oriented G group for position display external language 3 7 EECH User oriented G group for position di
78. R AE DO Acualaertresderype T H H mq p o Po p Ie 30270 ENC_ABS_BUFFERING n 0 max number of encoders 1 Be Absoteenooder Trversngrangeemenien_ oWERoN mas jo TE Tae sosoo nor A SC Qesari sie T ag ma p II PR ET 30310 ROT IS MODULO 6 R2 x jj Modulo conversion for rotary axis spindle POWER ON SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 9 151 Machine and Setting Data 802D base line 9 1 List of machine data 30320 DISPLAY IS MODULO 6 R2 EE Display modulo 360 degrees for rotary axis POWER ON aways jo qm qm BOOLEAN KH 80350 SIMU AX VDI OUTPUT 3 G2 fake srt tor aaa ie romeo ae bo E Isa 30600 FIX POINT POS 0 a aways oo mote 31000 ENC IS LINEAR 3 G2 Drac measures aa owen ee aways Jo JJ Boon 31010 ENC GRID POINT DIST 3 G2 aways Jon In JI ooe j 31020 ENC RESOL 0 3 G2 REES aways Log Jr JI Jooo 31030 LEADSCREW PITCH 3 G2 was lo Eos BEE 31040 ENC IS DIRECTIOI 3 G2 CS Encoder mounted directly on the machine POWER ON aways jo qm o qm BOOLEAN gt x 1 Encoders installed at the attached gearbox POWER ON aways jo qm e BOOLEAN EEE 31050 DRIVE AX RATIO DENOMIO 15 3 G2 aeaa Trono ee always i In 2107000 JoworD 31060 DRIVE_AX_RATIO_NUMERAJO 5 3 G2 E gero meros H a
79. SIEMENS SINUMERIK 802D SINUMERIK 802D base line Commissioning Manual Valid for Control system Software version SINUMERIK 802D 2 SINUMERIK 802D base line 1 08 2005 Edition The Control System Installing the Control System Commissioning Starting up the Spindle Starting up the PLC Series Machine Start up Data Backup Software Update 802D Machine and Setting Data 802D base line Machine and Setting Data Start up ISO mode 10 Safety information E This Manual contains information which you should carefully observe to ensure your own personal safety and the prevention of material damage The notices are highlighted by a warning triangle and depending on the degree of hazard represented as shown below Danger indicates that death or severe personal injury will result if proper precautions are not taken Warning indicates that death or severe personal injury can result if proper precautions are not taken Caution with a warning triangle indicates that minor personal injury can result if proper precautions are not taken Caution without a warning triangle means that material damage can occur if the appropriate precautions are not taken Attention indicates that an undesired event or status can occur if the appropriate note is not observed If several hazards of different degrees occur the hazard with the highest degree must always be given prefe rence H a
80. T15 10 ms T16 T39 Timer Of Delay If Tyalue lt PT Enable IN Tbit 1 Txxx SO TOF Tox TO T31 Preset PT VW T C IW QW MW AC Constant 100ms TO T15 10 ms T16 T39 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 5 91 Starting up the PLC 5 4 PLC programming Word Add Word Subtract DWord Add DWord Subtract Multiply HEN 1 b a b b b a If EN 1 b a b b b a If EN 1 b axb Enable COUNTER Instruction Ladder Symbol Valid Operands Count Up CU Z Value 1 Cnt Up CU R 1 Reset S1 If Cvalue gt PV Reset R Cne 29 Cxxx C0 31 Preset PV VW T C IW QW MW AC Constant LW Count Up Down CU 7 Value 1 Cnt Up CU CD 7 Value 1 S2 R 1 Reset Cnt Dn CD If Cvalue 2 PV S1 Cbit 1 Reset R SO Cxxx C0 31 Preset PV VW T C IW QW MW AC Constant LW Count Down If Cvalue 0 Cnt Down CD Reset R CD CTD SO LD Cxxx C0 31 PV Preset PV VW T C IW QW MW AC Constant LW MATH OPERATIONS Instruction Ladder Symbol Valid Operands EN VW T C IW QW MW AC Constant LW VW T C IW QW MW AC LW EN VD ID QD MD AC Constant LD VD ID QD MD AC LD EN VW T C IW QW MW AC Constant LW VD ID QD MD AC LD 5 92 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Starting up the PLC 5 4 P
81. TYPIX 103 n set interface with encoder X drive number 1 1 and encoder 2 30230 ENC INPUT O 2 Encoder 2 actual value X412 31020 ENC RESOL 0 Number of increments for rot encoder 31040 ENC IS DIRECT O 0 Encoder 2 is mounted directly on the motor 1 Encoder 2 is mounted on the load 32110 ENC FEEDBACK POLO 1 default 1 Reverse direction of rotation 34200 ENC REF MODEI0 1 Incr encoder 0 EnDat 13070 DRIVE FUNKTION MASKIX 8000 only applies with SW gt 2 1 X drive number 1 3 8 4 Default settings for the axis machine data for the spindle With SINUMERIK 802D the spindle is a subfunction of the entire axis functionality The ma chine data of the spindle are therefore to be found amongst the axis machine data MD 35xxx A description of the basic setting for the spindle can be found in Chapter 4 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 3 59 Commissioning 3 9 Completing the start up 3 9 Completing the start up After the start up by the machine manufacturer has been completed it is recommended to carry out a data backup prior to delivery to the end customer 1 Performing an internal data backup at least protection level 3 required Selectthe Save data softkey 2 Resetting the access level Select the Delete passw softkey 3 10 Service display for the axis drive behavior Servo Trace For axis service the Servo trace function has been implemented in
82. T_MODE 5 56 Spindle park position O 1 Speed controlled mode with without position control 2 Pos mode 3 RESET Axis mode o ii 35030 SPIND DEFAULT ACT MASK Time of activation for spindle park position 0 POWER ON 1 Progr start 2 Reset M2 M30 35040 SPIND ACTIVE AFTER RESET 5 S1 35100 SPIND_VELO_LIMIT rev min Maximum spindle speed POWER ON always 10000 0 DOUBLE 35110 GEAR STEP MAX VELOIOI 5 5 S1 500 500 1000 2000 35120 GEAR_STEP_MIN_VELO 0 5 5 S1 50 50 400 800 3130 GEAR STEP MAX VELO LIMITIO 5 B 500 500 1000 2000 35140 GEAR STEP MIN VELO LIMITI0 5 5 1 was 552m fome 6 35150 SPIND DES VELO TOOL 5 S1 O emgoen OOO O i S e mas e o o o EST TA EA SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 9 156 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D base line 9 1 List of machine data 35160 SPIND EXTERN VELO LIMIT 5 S1 aways 1000 qm JI ooe o EE GEAR STEP SPEEDCTRL ACCEL 0 5 E 30 0 30 0 25 0 20 0 Ec GEAR STEP POSCTRL ACCELJO 5 NN 30 0 30 0 25 0 20 0 35300 JSPIND POSCTRL VELO 5 S1 Faways J0 Dome E 35310 SPIND_POSIT_DELAY_TIME O 5 5 S1 De 35350 SPIND POSITIONING DIR 5 S1 erecto der when postonng TRES m awas Se 35400 SPIND_OSCILL_DES_VELO 5 S1 aways 500 oo omo ale cl y
83. The S7 200 programming language offers the user the possibility to create a structured user program There are two program types main program and subrou tine 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 particular conditions see machine data PLC IPO TIME RATIO An IPO PLC ratio of 1 1 has been proven to pro vide the fastest possible cyclic program execution Example The programmer will write a sequence control in the main program using a cycle defined by himself This sequence control will organize all cyclic signals in the subroutine UPO UP1 UP2 are called every two cycles and UP3 controls all signals at an interval of three cycles Data organization The data can be divided into three areas e non retentive data e retentive data e machine data for the PLC all these machine data are active after POWER ON Most of the machine data such as process image timer and counter are non retentive data which are deleted each time when the control system is powered up The data area 1400 0000 1400 0127 is reserved for the retentive data The user can here store all data which are to remain valid after POWER ON The user can either load the data in his program with default data using the PLC machine data see User interface or parameterize various program sections Interface to the
84. UD PG Baud rate 300 600 1200 2400 4800 9600 19200 38400 3 3 pec do Cf E sd MINO CE ET TAS IE ato ares L Jo 289 CTM_SIMULATION_TIME_NEW_POS 10 K1 a je fio o 420 iwreeerR 290 CTM POS COORDINATE SYSTEM 10 K1 fof 291 CTM CROSS AX DIAMETER ON 10 K1 37 lo a Jo RER 292 CTM Got DIAMETER ON 10 K1 a7 tc e qm ENE Es 5 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 9 143 Machine and Setting Data 802D base line 9 1 List of machine data User oriented G group for position display immediately beco po hm INTEGER User oriented G group for position display immediately User oriented G group for position display immediately lo ls di voo INTEGER p ll User oriented G group for position display 3 7 je ja mo INTEGER User oriented G group for position display immediately o jJ 000 INTEGER RR User oriented G group for position display external language immediately ml 100 INTEGER ESA User oriented G group for position display external language immediately User oriented G group for position display external language immediately je di 100 INTEGER gt User oriented G group for position display external language 3 7 je ja m0 INTEGER gt gt gt User oriented G group for position display external language immediately ase cum POS COORDINATE SYSTEM rees a7 p fe E IM
85. W CONF 100000000 DOUBLE 36120 JPOS LIMIT MINUS2 36130 POS LIMIT PLUS2 2nd software limit switch plus NEW CONF 100000000 DOUBLE 36200 JAX VELO LIMIT O 5 Velocity monitoring threshold value NEW CONF 11500 11500 11500 mm min 31 944 31 944 31 944 DOUBLE 31 944 r p m 36300 ENC FREQ LIMITIO Encoder limit frequency POWER ON 2 2 300000 DOUBLE 86302 ENC FREQ LIMIT LOWI0 Encoder limit frequency resynchronization NEW CONF aways see jo 100 DOUBLE SINUMERIK 802D 802D H Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 8 135 Machine and Setting Data 802D 8 1 List of machine data 36400 CONTOUR TOL 2 A3 mas he Te Iv geag S 36500 JENC CHANGE TOL 16 K3 Position actual value switching tolerance NEW CONF 36600 BRAKE MODE CHOICE 2 A3 smear wena foo mas p o fo po EE 36610 AX EMERGENCY STOP TIME 2 A3 fs Tmeorbakingrampincassofemm _ weon ee aways Jos Jop La Jong 86620 SERVO DISABLE DELAY TIME 1 N2 e oioutdesyonmoierense econ ap aways Jo foo La Jong 36710 DRIFT LIMIT E Drift limit value for automatic drift compensation NEW CONF aways io jo spo EEN 36720 DRIFT VALUEIOI 5 S1 mas oo Jese ge soog 37000 FIXED STOP MODE 17 F1 Tide Taveringtothesstop TE TC Fct Travel to fi 37002 FIXED STOP CONTROL 17 F1 E Sequence contolfortaveliohesstop Poweron Fct Tra
86. am a PLC cycle is always executed in the same order of sequence e Refresh of the process image inputs user interface timers e Processing of communication requests operator panel PLC 802 programming tool ver sion 3 0 and higher e Editing of the user program e Evaluation of alarms e Output of the process image outputs user interface During the cycle the PLC executes the user program from the first to the last operation The user program accesses the hardware inputs outputs only via the process image and not di rectly The PLC refreshes the hardware I Os at the beginning or end of program execution Thus these signals are stable over a whole PLC cycle The user program can only be created using the PLC 802 Programming Tool version 3 1 and higher with the S7 200 programming language using ladder diagram Ladder diagram is a graphical programming language for representing electric circuit diagrams Important PLC 802 Library with a description which can be installed from the toolbox CD is offered as the basis for the PLC user program The PLC 802 Library constitutes a subroutine library and contains one sample program each for a turning and for a milling machine Note If the stop and reset buttons on the machine control panel are not realized as normally clo sed contacts an open circuit cannot be detected Monitoring can be performed using software solutions as shown in the example MCP 802D SBR 34 from the
87. art up Sequence with NC card Important Make sure that a flash file system max 2 MB possible is formatted on the NC card see Section 6 3 Never insert or remove the NC card when the PCU is connected to the mains Do not insert or remove the NC card with the control system turned on otherwise the NC card can be damaged 1 Creating a series machine start up file on the NC card Before booting the control system make sure that the NC card flash card from Sie mens is inserted The control system requires the password for protection level 2 gt Select the Start up data NC Card line from the Data I O menu and use the Read out softkey to read out the series machine start up file 2 Reading in the series start up file from the NC card into the SINUMERIK 802D Before booting the control system make sure that the NC card flash card from Sie mens is inserted The control system requires the password for protection level 2 gt Select the Start up data NC Card line from the Data I O menu and use the Read in softkey to read in the series machine start up file SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 6 103 Series Machine Start Upand Data Backup 6 2 6 2 6 2 1 Data backup Data backup Internal data backup The data of the limited buffered memory must be saved via a backup copy to the permanent memory of the control system This bac
88. ax Unit Uy 15 24 30 V lin at Uu 2 15 mA UL 30 0 5 V lin at UL not defi 15 mA ned Signal delay caused by the hardware 0 5 3 ms A voltage of 24V for controlling the digital inputs is provided at pin 2 of the interfaces X111 X222 and X333 Max current on pin 2 lou 0 5A Table 1 7 Digital outputs high side driver Parameter min typ max Unit UH Voc 3V Voc V lout at Uy and 100 simultaneity factor 250 mA UL Output open lout at UL leakage current 50 400 LA Signal delay caused by the hardware 0 5 ms Switching rate for the ohmic load 100 Hz Switching rate for the inductive load free wheeling 2 Hz diode required Switching rate for the lamp load 11 Hz The 24V voltage for the digital outputs must be connected to all 4 pins 47 48 49 50 Max 1A may flow per supply pin SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 1 14 6FC5 697 2AA00 1BP5 Installing the Control System 2 2 1 Installing and removing the SINUMERIK 802D T Warning Before installing the control system make absolutely sure that the system is disconnected form the mains and deenergized The modules contain electrostatic sensitive devices When handling the modules make sure that neither p c boards nor components are touched by persons not grounded with ESD protection Procedure 1 Install the PCU the keyboard KB and the machine control panel MCP Attention The maximum p
89. axis spindle with TTL encoder via ADI4 aaa aa 4 74 4 8 Digital axis spindle with direct measuring system TTL via ADIA 4 76 5 Starting up the PEC 3 T EE RD 5 79 5 1 Commissioning the PLC K e gR a aR K R R RR ee RR RE Re ossis I dd ee ee ee ee 5 80 5 2 Start up modes of the PLC n 5 80 5 3 PEG alarms mes EE ren EK 5 82 5 3 1 General PLC alarms usi hio EER is ee ee one bh asa er ee a 5 83 5 3 2 RTE EEN 5 83 5 4 PEG programming 3 causas o indo O Ee Rd EN T EO E 5 85 5 4 1 Command overview anne eed eU sepe ewe etes ern oad 5 87 5 4 2 Explanation of the stack operations 5 89 5 4 3 Program organization aa 5 96 5 4 4 Data organization semi e Br sh 5 96 5 4 5 Interface to the control system 5 96 5 4 6 Testing and monitoring your program 5 97 5 5 PLC applications Download Upload Copy Compare L nanne 5 98 5 6 User interface EE GE GE en ER dd ae 5 100 6 Series Machine Start Upand Data Backup ex x x sk e e RR RR RR RR RR RR RR RR AR RR ee 6 101 6 1 Series machine start up 6 101 6 2 Data backup EE ssa ED E We Ald a ie niet 6 104 6 2 1 Internal data backup a ENE uc pi Ra en nl ein 6 104 6 2 2 External data backup via V 4 n 6 104 6 2 3 External data backup via NC card 6 105 6 3 Formatting an NC card aa 6 107 6 4 Data backup in case of backlight failure 6 108 Software Update via NC card aa aa ana aaa nn nene RR ke eee nun 7 109 Machine and Setting Da
90. booting in the normal mode Booting the control system in the normal mode When the control system is turned on the boot sequence is displayed on the control system with all its individual phases Once the start screen of the user interface has appeared the booting sequence is completed Booting the control system in the start up mode After Power ON and prompting via an appropriate message on the screen press the SELECT key Once the DRAM test is completed the START UP MENU appears on the display Use the cursor to select an appropriate power up start up mode and press INPUT to confirm The modes specified in the START UP MENU have the following meanings 3 44 normal mode If this option is chosen the control system will boot with the last machine data setand the previously loaded programs default data is only displayed if protection level 1 or 2 is set If this option is chosen the control system will boot with default machine data software update In this case the control system will not boot at all The software can only be updated if an NC card with a software update is provided reload saved user data If this option is chosen the user data machine data programs etc backed up to the flash memory of the control system are accepted as the current data and used for pow er up PLC stop Select PLC Stop while the control system is booting if PLC Stop can not be triggered via the user interface any more SI
91. bus line SINUMERIK 802D 802D H Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 2 35 Installing the Control System 2 6 Grounding 2 6 Grounding Ground connections The following ground connections must be provided e PCU e Machine control panel MCP e Keyboard KB When establishing the ground connections for PCU MCP and KB connect the grounding points to the grounding rail Fig 2 16 Grounding the PP 72 48 Install the PP 72 48 in accordance with EN 60204 If a large area permanent metallic con nection to the central grounding point is not possible via the backplane connect the mount ing plate to the grounding rail using a line gt 10 mm 9 ale 9 ea eo SCUOHDE SE AODEEEFIDOD ms A im main min nine mobeopDondo B arrin DESH gt OODODTOBER SODDOBEDDE ES a tB oo ole je lol SOI ss PE S S da Pap DO T pasa lt gt o HE Ik Geer gt 20000 gjeo a lo to the chassis
92. ce mark RESET SET Ber c 84050 REFP SEARCH MARKER REVERSEI0 8 R1 e roemeens T 1 O f e mas bo o tolo o 34060 REFP MAX MARKER DISTIO 8 R1 ao les m Tome 1 34070 REFP VELO POS 8 R1 GC Reference point approach velocity RESET 1 000 0 mm min ow o 0 always 2 77 rp m MER 34080 REFP MOVE DIST 0 8 R1 mw lae II ame 34090 REFP MOVE DIST CORR 0 8 R1 wa Jo IE ewe o TT 34092 REFP CAM SHIFTIOJ 8 R1 aways foo JI Jm oque 34093 REFP CAM MARKER DIST 8 R1 Distance Reference cam reference mark POWER ON 0 0 0 0 LE ee 34100 REFP SET POSIO 3 8 R1 aways fo JI Jm pos LI 34110 REFP CYCLE NR 8 R1 Onterotsseswnenretsen ng mese was Je Ja 1 1m 6 34200 ENC REFP MODE 0 8 R1 ES TIT Teomeron se aak S ls E 34210 ENC_REFP_STATEIO 8 R1 Fra eoderagjustng sas Times ae as po o Qe El tre o 34220 JENC ABS TURNS MODULO 6 R2 vto range otro art ener romeo ae aways Jam wwe wo j SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 9 155 Machine and Setting Data 802D base line 9 1 List of machine data 35000 SPIND ASSIGN TO MACHAX 5 S1 TF Assignment pide machinesr pon mon ze ways Jo o o fome TI E po I Gear stage change possible POWER ON aways o lo JS wor E PET GEAR_STEP_CHANGE_POSITION 0 5 A SPIND_DEFAUL
93. control system This interface can be selected via SYSTEM softkeys PLC gt STEP7 connect This V24 interface continues to be active even after cold restart or normal booting The con nection STEP7 connect active to the control system can be checked in the PLC informa tion menu of the PLC 802 Programming Tool If the interface is active the active PLC mode for example Run Stop is displayed in this window SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Starting up the PLC 5 4 PLC programming 5 4 6 Testing and monitoring your program A check or error analysis of the user program is possible as follows PLC status Display and change of called operands Status list Display and change of three freely selectable variable fields PLC program Display and monitoring status of the entire user program including sym bols and comments PT PLC 802 Connecting a PG PC and activating the PT Connection also possible via modem SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 5 97 Starting up the PLC 5 5 PLC applications Download Upload Copy Compare 5 5 PLC applications Download Upload Copy Compare The user can save copy or overwrite the PLC project or the PLC applications in the control system This is possible using e PLC 802 Programming Tool e WINPCIN binary file e NC card PT PLC 802 Download gt Upload Compare Permanent PL
94. d into the motor gearbox and external zero mark via BERO 4 3 Digital spindle drive with the encoder integrated into the motor gearbox and external zero mark via BERO Prerequisites An inductive proximity switch type Siemens 3RG4050 0AGOS is used With the approximation a positive 24V edge is switched QV 24V braun blau schwarz BERO 5RG4050 0A605 KI 10 A Fig 4 1 Parameterization 611 UE firmware release gt 03 01 06 Parameter P660 79 611 UE firmware release gt 03 01 06 Parameter P879 13 1 Thus instead of the internal zero mark the BERO signal connected to terminal 10 A is evalu ated 802D MD 34200 ENC REFP MODE 7 Thus a synchronization is only performed if a speed has been defined MD 34040 using the BERO signal This is imperative as a BERO always has certain signal runtimes This is the only way to guarantee that the synchronization is always performed to the same position 802D MD 34040 REFP VELO SEARCH MARKER 200 r p m The BERO signal is synchronized at this speed 802D MD 34060 If necessary adapt REFP MAX MARKER DIST accordingly If SPOS is triggered from the standstill the spindle is first accelerated to the speed entered in MD 34040 thereafter the BERO edge is synchronized and finally the spindle is posi tioned The direction of rotation depends on MD 35350 SPIND POSITIONING DIR 32CW 4 CCW In
95. date was successful the following message is displayed on the screen SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 7 109 Software Update via NC card SINUMERIK 802D UPDATE O K VERSION 802D SW XX XX XX 6 Perform a POVVER ON for the control system turn off and back on again the CNC 7 The update is completed and the user data can be reloaded after setting the password Note If necessary load a language as described in Section 3 3 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 7 110 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D H Boolean value 1 TRUE or O FALSE as an INTEGER value 128 127 as a hexadecimal value 00 FF as a character as per ASCII character set e g a Sequence of characters max 16 Data type BOOLEAN BYTE 8 bit value STRING WORD 16 bit value UNSIGNED WORD INTEGER DWORD UNSIGNED WORD DOUBLE as an INTEGER value 32768 32767 as a hexadecimal value 0000 FFFF 16 bit value as an INTEGER value 0 65535 as a hexadecimal value 0000 FFFF 16 bit value here defined locally INTEGER value 32768 32767 32 bit value as an INTEGER value 2147483648 2147483647 as a hexadecimal value 0000 0000 FFFF 32 bit value as an INTEGER value 0 4294967295 as a hexadecimal value 0000 0000 FFFF FFFF 64 bit value floating point value 4 19 10907 1 67 1030
96. diately INTEGER 370 TOOL REF PROBE AXIS1 decimal Absolute position of probe X immediately 999999 999 999999 999 DOUBLE 371 TOOL REF PROBE AXIS2 decimal Absolute position of probe Y immediately 999999 999 999999 999 DOUBLE 372 TOOL_REF_PROBE_AXIS3 decimal Absolute position of probe Z immediately 999999 999 999999 999 DOUBLE 373 MEAS_SAVE_POS_LENGTH2 decimal Activate tool gauging select Save Pos softkey for all values immediately Byte 374 TOOL WEAR LIMIT VALUE decimal Limit value for wear control during input immediately DOUBLE 375 USER CLASS READ CUS DIR decimal Protection level for Read user cycles immediately 0 Byte 376 USER_CLASS_WRITE_CUS_DIR decimal Protection level for Write user cycles immediately 0 Byte SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 8 116 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D 8 1 List of machine data 377 USER CLASS WRITE TO MON DAT decimal Protection level for Tool monitoring immediately 0 Byte 378 USER CLASS LADDER VIEW decimal Protection level for Select user ladder view immediately 0 Byte 379 SPINDLE DISP MODE 0 Standard mode display of spindle speed decimal 1 Constant cutting rate display with G96 set immediately 2 Mixed display 0 Byte 8 1 2 General machine data Cross ref to the relevant MD id
97. dition 6FC5 697 2AA00 1BP5 2 25 Installing the Control System 2 2 Interfaces and lines Position of the interfaces displays and operator controls on the PP 72 48 CO E OVERTEMP 4 O EXCHANGE H POWER READY x2 R x2 De S1 4 5 E E xi SH x ER x333 4 L x222 4 L x111 4 L Le 6 b id e b zd LEE E Oh D S Fig 2 11 User interfaces on the PP 72 48 e XI Power supply connection 24 V DC 3 pin screw terminal connection for connecting the 24 V load power supply X2 Profibus 9 pin D Sub socket connector for connecting Profibus e X111 X222 and X333 50 pin ribbon cable connector for connecting the digital inputs outputs e 4LEDs on the PP 72 48 for status displays e Si DIL switches for setting the PROFIBUS address see Section 3 6 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 2 26 6FC5 697 2AA00 1BP5 Installing the Control System 2 2 Interfaces and lines Interfaces on the MCP Fig 2 12 User interfaces on the MCP e X1201 and X1202 50 pin ribbon cable connector for connection to PP 72 48 Interconnecting cables The individual components are connected as shown i
98. e and Setting Data 802D 8 1 List of machine data 30320 DISPLAY IS MODULO 6 R2 EE Display modulo 360 degrees for rotary axis POWER ON aways jo qm qm BOOLEAN KH 80350 SIMU AX VDI OUTPUT 3 G2 fake srt tor aaa ie romeo ae bo E Isa 30600 FIX POINT POS 0 a aways oo mote 31000 ENC IS LINEAR 3 G2 Drac measures aa owen ee aways Jo JJ Boon 31010 ENC GRID POINT DIST 3 G2 aways Jon In JI ooe j 31020 ENC RESOL 0 3 G2 REES aways Log Jr JI Jooo 31030 LEADSCREW PITCH 3 G2 was lo Eos BEE 31040 ENC IS DIRECTIOI 3 G2 CS Encoder mounted directly on the machine POWER ON aways jo qm o qm BOOLEAN gt x 1 Encoders installed at the attached gearbox POWER ON aways jo qm e BOOLEAN EEE 31050 DRIVE AX RATIO DENOMIO 5 3 G2 Ces leen always Ji In 247000 JoworD 81060 DRIVE AX RATIO NUMERAI0 5 3 62 Ei gero meros rom ron a aways Di Lamm 2147000000 bworm Denominator of attached gearbox POWER ON aways Ji tf 2447000000 DWORD c7 j Numerator of attached gearbox POWER ON 2147000000 2147000000 DWORD DO 31070 DRIVE ENC RATIO DENOM O 3 G2 TMessrmggearordenammair feeweres 2 E H Imewmm foworn SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 8 128 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D 8 1 List of
99. e assignment aaa 3 52 3 8 2 Default settings for the axis machine data for the feed axes 3 54 3 8 3 Connecting a direct measuring system 3 55 3 8 4 Default settings for the axis machine data for the spindle ana rennen 3 59 3 9 Completing the start up susaeusaaeua nauan ranean annarra a aeaaaee 3 60 3 10 Service display for the axis drive behavior aa 3 60 4 Starting up the Spindle 4 61 4 1 Digital spindle drive with spindle actual value encoder integrated into the motor 4 63 4 2 Digital spindle drive with spindle actual value encoder TTL mounted directly on the motor 4 64 4 3 Digital spindle drive with the encoder integrated into the motor gearbox and external zero mark via BERO aaa 4 65 4 4 Digital spindle without external encoder 4 67 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 V Contents 4 4 1 Parameterization using the Drive Configuration Wizard ann ea 4 67 4 4 2 Parameterization using the Expert List aaa 4 67 4 4 3 Adapting the machine data in the control system 00 cee eese 4 68 4 5 Digital spindle without encoder with external TTL encoder aaa aaa een 4 69 4 5 1 Parameterization using the Expert List aaa 4 69 4 5 2 Adapting the machine data in the control system aaa 4 70 4 6 Analog spindle via 611 U E with with spindle actual value encoder mounted directly on the motor 4 71 4 7 Analog
100. e basic elements of a ladder diagram are contacts coils and boxes The contacts in turn are divided into normally opened and normally closed contacts Each coil corresponds to a relay Boxes are used to represent a certain function A box can be activated using an enable bit SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 5 86 6FC5 697 2AA00 1BP5 Starting up the PLC Command overview 5 4 PLC programming Table 5 3 Operand identifier Operand identifier Description Area V Data V1000 0000 0 to V7999 9999 7 T Timers TO to T15 100 ms T16 to T39 10 ms C Counter CO to C31 I Image of digital inputs 10 0 to 117 7 Q Image of digital outputs Q0 0 to Q11 7 M Flags MO O to M383 7 SM Special bit memory SMO 0 to SM 0 6 see Table 5 6 AC ACCU ACO AC3 L Local data LO O to L51 7 Table 5 4 Forming the address in the V area see User interface Type identifi Area no Subarea Offset Addressing cation mo channel dule no axis no 00 00 0 000 symbolic 10 79 00 99 0 9 000 999 8 digit Table 5 5 802D Operand Ranges Access Method Bit Access Byte Bit Valid Operand Ranges for Programming 802D V 1000 0000 0 7900 9999 7 1 0 0 17 7 Q 0 0 11 7 M 0 0 255 7 SM 0 0 0 7 T 0 39 C 0 31 Byte Access VB 1000 0000 7999 9999 IB 0 17 QB 0 11 MB 0 383 AC 0 3 SMB 0 KB Constant SINUMERIK 802D 802D bl Start up
101. e relevant setup file from the toolbox into the control system depending on the technology turning or milling The follovving setup files are offered to choose from e setup T cnf Turning machine with complete cycle package setup M cnf Milling machine with complete cycle pack setTra T cnf Turning machine with complete cycle package and the functions Transmit Tracyl Spindle1 C axis and 2nd spindle technology turning e trafo Tini Machine data vvith the functions Transmit Tracyl Spindle1 C axis and 2nd spindle technology turning e trafo Mim Machine data for the Tracyl function Milling technology e adi4 ini Machine data for setting up the analog setpoint output via ADI4 The setup file must be loaded during the commissioning after booting of the control system but prior to the general configuration Note The SINUMERIK 802D base line is supplied with default machine data To set the turning technology load the following setup file from the toolbox into the control system e setup T cnf Turning machine with complete cycle package If you wish to use the analog setpoint output in conjunction with the I O module ADI4 reload the following ini file e adi4 ini Machine data for setting up the analog setpoint output via ADI4 The setup file must be loaded during the commissioning after booting of the control system but prior to the general configuration Note Please always observe the readme file supplied with t
102. ed Cancel criteria Bit6 bit7 0 SELF CLEARING alarm default Bit6 1 CANCELCLEAR alarm Bit7 21 POWERONCLEAR alarm The alarm response to PLC Stop always has the cancel condition POWER ON The user are offered two options of defining his own alarm texts e via the System hardkey gt PLC softkey gt Edit PLC txt cf Operation and Program ming Chapter 7 e by using the toolbox Editing and loading the alarm text file using the text manager If no alarm text is assigned by the user only the alarm number is displayed The character in the alarm text denotes an additional variable The variable type is the form of representation of the variable The following variable types are possible e D integer decimal number e l integer decimal number e U decimal number without sign e 0 integer octal number e X integer hexadecimal number e B binary representation of a 32 bit value e F 4 byte floating point number SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Starting up the PLC 5 4 PLC programming Examples of user alarm texts Note The text after the is a comment and is not dis played 700000 only the user alarm number 700001 Hardware limit switch of the X axis 700002 96D only a variable as an integer decimal number 700003 Alarm number with a fixed alarm text and the variable X 700004 U Alarm number with variable and fixed alarm text
103. emove the NC card with the control system turned on otherwise the NC card can be damaged SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 6 105 Series Machine Start Upand Data Backup 6 2 Data backup Variants of data backup on the NC card e Start up data e Reading out the PLC application e Display machine data e PLC useralarm texts e Part programs NC NC card not with the 802D base line e Part programs NC card gt NC not with the 802D base line e HMI start up files start up data with the languages loaded Performing the external data backup In the Data VO menu use the Read in Read out softkeys to activate the process SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6 106 6FC5 697 2AA00 1BP5 Series Machine Start Upand Data Backup 6 3 Formatting an NC card 6 3 Formatting an NC card An appropriate menu item for formatting the NC card has been implemented in the Start menu By selecting Format NC card an inserted NC card can be deleted and subse quently a 1 5 MB file system can be formatted thereon Note This menu item is only displayed if protection level 0 3 is set Sequence NC card inserted turn on the control system After the DRAM check press the Select key In the Start menu SWITCH ON MENUE select the Format NC card menu item At completion of the initialization answer the question Do you really want N Y
104. entifier chapter in the Description of Functions Read write pro gt CT CI e a o OE sae mme ETT o F sme t Dmm avez sae 10074 PLC IPO TIME RATIO Ta Ra owm ae aways jo co wor 1615 DISPLAY MODE POSITION ES mas Je TJ E 10200 INT INCR PER MM 3 G2 ERES Computational resolution for linear positions POWER ON 1000000000 DOUBLE DO 10210 JINTINCR PER DEG 3 G2 E Computational resolution for angular positions POWER ON 1000000000 DOUBLE ESTA 10240 SCALING SYSTEM IS METRIC 3 G2 E wmewsesmem _ CT CN ze amy 00 poten 1 10713 M NO FCT STOPRE r 0 Max permissible M function number 1 M function with preprocessing stop POWER ON E so o 9 L SINUMERIK 802D 802D H Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 8 117 Machine and Setting Data 802D 8 1 List of machine data 10714 M NO FCT EOP ei es Tij M function active for spindle after reset POWER ON 2 2 Laways fu Dorr EEE 10715 M NO FCT_CYCLE O FETA Minamoto yasane JFoWERoN a aways fr la d oe 1 10716 M NO FCT CYCLE NAME Era l Name of subroutine for the M function to be replaced POWER ON 2 2 aways JH rina p a 10717 T NO FCT CYCLE NAME STET Name of subroutine for the T function to be replaced POWER ON 2 2 aways STRING 10718 M_NO_FCT_CYCLE_PAR ee Winconrepacorentby parameters romeo awas a CS ort 10719 T NO FCT CYCLE MODE
105. er up of the CNC 3 44 normal mode 3 44 start up mode 3 44 Profibus address 3 49 Program organization 5 100 Protection levels 3 42 Protective quality 1 13 S S7 200 Ladder Diagram 5 90 Series start up file 6 105 Servo Trace 3 62 Setpoint actual value assignment 3 52 Setting data of the 802D base line 9 164 Setting the technology 3 46 Software update 7 113 Spindle drive 4 65 analog 4 75 TTL encoder via ADI4 4 78 with spindle actual value encoder mounted directly on the motor 4 75 digital 4 65 direct measuring system TTL via ADI4 4 80 encoder integrated into motor gearbox and external zero mark 4 68 spindle actual value encoder TTL mounted directly on the motor TTL 4 66 spindle actual value encoder integrated into the mo tor 4 65 without encoder with external TTL encoder 4 73 without external encoder 4 70 Index 170 Stack operations 5 93 BASIC BOOLEAN INSTRUCTIONS 5 93 BYTE COMPARES 5 93 CONVERSION OPERATIONS 5 98 COUNTER 5 96 DOUBLE WORD COMPARES 5 94 INCREMENT DECREMENT 5 97 LOGIC OPERATIONS 5 97 MATH OPERATIONS 5 96 MOVE FILL AND FIND OPERATIONS 5 99 OTHER BOOLEAN INSTRUCTIONS 5 93 PROGRAM CONTROL FUNCTIONS 5 99 REAL WORD COMPARES 5 94 SHIFT AND ROTATE OPERATIONS 5 98 TIMER 5 95 WORD COMPARES 5 94 Start up Axes spindle 3 52 completing 3 62 PLC 5 83 Series machine start up 6 105 functionality 6 105 prerequisites 6 105 Series start up sequence
106. ermissible torque for tightening the fastening screws is 1 8 Nm and must not be exceeded 2 Install the PP 72 48 3 Installing the drive compound see SIMODRIVE 611 UE Documentation 4 Establish the connection between PCU and keyboard as well as between MCP and PP 72 48 5 Establish the PROFIBUS connection between PCU PP 72 48 and SIMODRIVE 611 UE Removing the control system To remove the control system proceed in the reverse order T Warning Before removing the control system make absolutely sure that the system is disconnected form the mains and deenergized Mounting dimensions Note When installing the control components observe the dimensions specified in the diagrams below These drilling patterns constitute the basis for preparing the mounting holes The di mensions are binding SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 2 15 Installing the Control System 2 1 Installing and removing the SINUMERIK 802D 8 2 l lt 8X 57 5 lt A
107. eturn from Subrou Instruction If EN 1 go to label n Label marker for the jump routine HEN 1 END termi nates the main scan If EN 1 exit the sub Exit subroutine Ladder Symbol Label Label N Enable RET Enable eno 4 Enable Valid Operands EN WORD 0 127 WORD 0 127 EN PROGRAM CONTROL FUNCTIONS Instruction Ladder Symbol Valid Operands LSB of w Subroutine If EN 7 go to subrou Label Constant 0 63 o F x optional parameters MOVE FILL AND FIND OPERATIONS Instruction Ladder Symbol Valid Operands Move Byte If EN 1 Enable EN copy ito o In VB IB QB MB AC Constant LB Out VB IB QB MB AC LB Move Word If EN 1 Enable EN copy i to o In VW T C IW QW MW AC Constant LW Out VW T C IW QW MW AC LW Move DWord If EN 1 Enable EN copy i to o VD ID QD MD AC Constant LD VD ID QD MD AC LD Move Real If EN 1 EN copy i to o VD ID QD MD AC Constant LD VD ID QD MD AC LD Swap Bytes HEN 1 SWAP Enable EN exchange MSB and EN ENO In VW IW QW MW T C AC LW SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 5 95 Starting up the PLC 5 4 5 4 3 5 4 4 5 4 5 5 96 PLC programming Program organization Every programmer should structure the user program divided into separate program sec tions subroutines
108. he Toolbox It provides up to date information e Establish an RS232 connection between the PC and the PCU COMI e Turn on the control system and wait until the control system has completed its booting sequence without errors e In the System operating area set the password for protection level 2 e Get the binary format SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Commissioning 3 4 Setting the technology In the System operating area Data I O menu item position the cursor on the line Start up data PC Select the Read in softkey Start your PC with WINPCIN Select the Binary format softkey press RS232 config and set save and activate the relevant COM interface of your PC PG Save amp activate softkey Back softkey Select the Send data softkey Select the setup file from the toolbox for turning or milling in the Siemens or ISO mode see Readme file in the Toolbox and transfer it from your PC to the control system via WINPCIN The control system boots automatically during the transmission several times The SINUMERIK 802D is now preset to the required technology SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 3 47 Commissioning 3 5 Entering the machine data 3 5 Entering the machine data Overview The most important machine data of the individual subareas are listed here to assist you For a detailed descriptio
109. hine data 9 1 List of machine data 9 1 1 Display machine data Cross refe rence to the relevant sec MD identifier tion chapter in the Des cription of Functions Read write pro Default value Data type 202 FIRST LANGUAGE p o fo Tor Eme II 20 DISPLAY RESOLUTION Kee je Bo RE EE lm 2 DISPLAY RESOLUTION INCH LE s p 14 1 1 dE I 205 DISPLAY RESOLUTION SPINDLE ERES o po Jo ls sere o Protection level for reading tool offsets general jo TE Ee EE px 208 USER CLASS WRITE TOA GEO sees je 1 To o m E 1 1 9 USER CLASS WRITE TOA WEAR a COMINO COMINO COMAS CAMINOS Ci RIAS IEA 210 USER CLASS WRITE ZOA IESSEN joo fo hr EA 22 USER CLASS WRITE SEA ees 218 USER CLASS READ PROGRAM EE p 1 lote to SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 9 142 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D base line 9 1 List of machine data 24 USER CLASS WRITE PROGRAM aa He 1 zs USER GLASS SELECT PROGRAM E E a e E EE EE 218 USER CLASS WRITE RPA ri Protection level for Write R parameters 3 3 je job TE SA 2419 USER CLASS SET V24 RES E po le tlm k e USER CLASS DIR ACCESS EE E je Je Je p e SSS e USER GLASS PLC ACCESS E E je Je e AAA S 223 TJUSER CLASS WRITE PWA E Protection level for protected working area 2 3 po jr ley L 247 V24 PG PC BA
110. ional M functions for conditional stop POWER ON mam bo Etr e 22400 S VALUES ACTIVE AFTER RESET 5 S1 tata even ater OO fown e aways lo JJ Boon 22550 TOOL CHANGE MODE 14 W1 Newtoolcompensaton winT orMfuneion omenon ze us ll le E FRAME SUPPRESS MODE Positions with frame suppression POWER ON 0x0 0 DWORD 27860 PROCESSTIMER_MODE 10 K1 mas los Je lee lere 27880 PART COUNTER 10 K1 ez o IO 7 27882 PART COUNTER MCODEJO 2 10 K1 wengiece counting win user defnea Meommerds ROwERON am ma aa lo le e o 1 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 9 150 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D base line 9 1 List of machine data 9 1 4 Axis specific machine data Cross refe rence to the relevant sec MD identifier tion chapter in the Des cription of Functions Read write pro Default value Data type 30110 CTRLOUT MODULE NRIO 3 G2 Seboine dre ne rose no TEC e mm po Ee AAA 30120 CTRLOUT NRI0 3 G2 Semono CT TIAS e aways oo fe 30130 CTRLOUT TYPEIO 3 G2 E i moe OOOO CT Jo Ek III II 30134 IS UNIPOLAR OUTPUTIOI 5 S1 E swememtsupom Jeowenen 22 ma fo EE E Ne 30220 ENC MODULE NRIOI 3 G2 lee 7 am awas Moo fe 30230 ENC INPUT NR 0 3 G2 FEE Act value No of input on module measuring circuit board POWER ON mo ENC PE
111. is not executed any more Profibus DP is inactive and the hardware outputs are disabled e EMERGENCY STOP Once the user program is executed the PLC transmits the EMER GENCY STOP signal to the NCK via the user interface e Feed disable Once the user program is executed the PLC transmits the feed disable signal to the NCK via the user interface e Read in disable Once the user program is executed the PLC transmits the read in dis able signal to the NCK via the user interface SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Starting up the PLC 5 3 PLC alarms e NC Start inhibited Once the user program is executed the PLC signals the NC start inhibited signal to the NCK via the user interface e SHOWALARM This alarm has no alarm response 5 3 1 General PLC alarms EH Note for the reader SINUMERIK 802D Diagnostics Guide 5 3 2 User alarms The user interface 1600xxxx provides the subareas 0 1 for the user to define user alarms e Subarea O 8x8 bits to set the user alarms 0 gt 1 edge Byte 0 BitO gt 1st user alarm 700000 Byte 1 BitO gt 9th user alarm 700008 Byte 7 Bit7 gt 64th user alarm 700063 A new user alarm is activated with the relevant bit subarea 0 via a 0 1 edge e Subarea 1 User alarm variables Subarea 1 is intended for additional user information it can only be read written as a double word e Subarea2 Alarm response
112. issioning 3 7 Starting up the PLC PB address DIL switch S1 PP module 9 default setting 1 4 0N PP module 1 2 3 5 6 7 8 OFF 8 4 ON PP module 2 1 2 3 5 6 7 8 0OFF Note The newly set PB station address is only active after POWER ON 611 UE Is slave at PROFIBUS the bus address is only set during commissioning using the Simo Com U commissioning tool or directly via the display and the operator terminal E Note for the reader SIMODRIVE 611U Description of Functions 3 7 Starting up the PLC After starting up the Profibus the prepared PLC user program is ready to run and can be used for further start up To load the PLC user program use the Programming Tool For a description please refer to Section 5 SINUMERIK 802D 802D H Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 3 51 Commissioning 3 8 Starting up the axes spindle 3 8 Starting up the axes spindle 3 8 1 Setpoint actual value assignment 3 52 The axis machine data MD 30130 CTRLOUT TYPE can be used to switch the setpoint out put and MD 30240 ENC TYPE can be used to switch the actual value input between sim ulation and PROFIBUS drive Table 3 5 Machine data Simulation Normal mode MD 30130 Value O Value 1 Simulation In this case the setpoint signals are output via Profibus MD 30240 Value O Value 1 INCR or 4 EnDat Simulation In this case the actual values are read in
113. kup is performed internally and required whenever the control system has been switched off for more than 50 hours with control system ON min 10 min day Recommendation After changing important data it is recommended to carry out a data backup immediately Note During the data backup an image of the limited buffered memory is produced and stored in the permanent memory A backup of selected data e g only machine data and no work piece programs is not possible Performing an internal data backup In the System operating area or in the Program Manager select the Save data softkey at least protection level 3 required Loading internally backed up data 6 2 2 6 104 e Bootthe control system in the start up mode Reload saved user data e n case of data loss of the buffered memory the data saved in the permanent memory are automatically reloaded into the memory with POWER ON Note Message 4062 Data backup copy has been loaded is displayed on the screen External data backup via V24 Important Never connect or disconnect the V24 cable when the PCU is connected to the mains In addition to an internal data backup the user data of the control system can also be saved externally To do so a PC with V24 interface and the WINPCIN tool included in the toolbox are required An external data backup should be performed if major data changes have been made or al ways at the end of the start up
114. l data backup 6 108 6 109 in case of backlight failure 6 112 internal data backup 6 108 Data organization 5 100 Data types 8 115 9 145 Degree of protection 1 13 Digital axis 4 80 Displays PCU 2 38 PP 72 48 2 39 Drive interfacejassignment 2 30 E Entering machine data 3 48 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 G Grounding 2 36 H Handwheels electronic 2 30 Installing the Control System 2 15 Interfaces 2 25 keyboard 2 25 MCP 2 27 PP 72 48 2 26 Interfaces and lines 2 25 ISO mode 10 167 functions 10 171 machine data 10 168 programming 10 167 Milling variant 10 168 Turning variant 10 167 L Language setting 3 45 Machine data of the 802D axis specific 8 131 channel specific 8 124 display 8 116 9 146 general 8 121 Machine data of the 802D base line axis specific 9 155 general 9 151 Machine data of the 802D baseline channel specific 9 152 Machine data setting data activation 3 43 structure 3 43 Measuring system direct connecting 3 55 Parameterization 3 56 3 59 Mounting dimensions 2 15 keyboard horizontal layout 2 22 vertical layout 2 20 MCP 2 18 PCU 2 16 PP 72 48 2 24 Index 169 Index N NC card formatting 6 111 P PLC alarms 5 86 PLC application 5 102 PLC command overvievv 5 91 PLC programming 5 89 PLC project 5 90 PLC user interface 5 104 Power supply of PCU and PP 72 48 2 37 Pow
115. lo Poro 42950 TOOL LENGTH TYPE Bol Se of the geom length compensationcomponents independent of immediately Letrave fo oR fp 42990 MAX_BLOCKS_IN_IPOBUFFER fa nunterofbccisiniheIPObufer O Times e awas ua LL ort REESEN EECHER wa 9 Ie E HS Spindle speed when starting the spindle via VDI interface signals immediately aways joo lm l LEE E ox 48202 sPIND CONSTCUT S IEEE Specify constant cutting rate for master spindle aways foo Jr Jr DOUBLE y 48210 SPIND MIN VELO G25 5 S1 ms Jo rs lL eme 43220 SPIND MAX VELO G26 5 S1 1000 0 DOUBLE 43230 SPIND_MAX_VELO_LIMS 5 S1 was mo le E oe HS SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 8 139 Machine and Setting Data 802D 8 2 Setting data 43240r p m M19 SPOS ees Sg aways Ing 00000000 10000000 0 DOUBLE y 48250 mio SPOSMODE BE ER Spindle position approach mode for positioning spindle using M19 amas Jo Qe poe E Ci a5 EXTERN REF POSITION G30 3 ER EECHER External NC progr language e RE SE Es 43400 WORKAREA PLUS ENABLE 2 A3 Working are mio aciveinthe postive arecion Desen m was po Je v fo o il 48410 WORKAREA MINUS ENABLE 2 A3 Jena aca Inv sve n me neoane arenon meae am aways Jo qe BOOLEAN TN 48420 WORKAREA LIMIT PLUS 2 A3 100000000 DOUBLE 0 43430 WORKAREA LIMIT MINUS 2 A3
116. machine data 31080 DRIVE ENC RATIO NUMERAIO 3 G2 wemwngsemtermeao OOOO Tromemon ae ws Do posso oom ESSA Trace specification for die axial Vdi signals POWER ON Ek Po To fee fo sw WEES ee mm eme mm mo mum p Fe 1 mio oe vezo rario mum p Fo de o 32020 soe vero Tt sme wxwonoppa MET ERP Traversing direction not control direction POWER ON DWORD 32110 ENC FEEDBACK POL O 3 G2 Sn aus vals konroldrecien _ JroMERON e e ho po o 32200 POSCTRL GAIN O 5 3 G2 mm mm aways ho ico ToouBe emo JPOSGTALINTESR Time 0 ewep Tom w fome sm POSCTRLINTEGA ENABLE TT mm o O E a 32300 JMAX AX ACCEL 4 B2 mm s 2 p m 2 32420 JOG AND POS JERK ENABLE 4 B2 L re or iron C 1 ma boo 9 Elfo to SINUMERIK 802D 802D H Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 8 129 Machine and Setting Data 802D 8 1 List of machine data 32430 JOG AND POS MAX JERK 4 B2 Mud Ep ee Jor e qme o 4 B2 12 B1 dd Maximum axial jerk when traveling along the path NEW CONF 1 000 dia D PATH_TRANS_JERK_LIM 12 B1 s Max axial jerk in path motion mm s s s deg s s s NEW CONF 1 000 un 3 BACKLASH 0 16 K3 aways Jon Jm t pot LI Fnetoncompensatenadapstenzee _ _ T ax CO p o p lom 32520 JFRICT COMP CONST MAX FE Maximum f
117. mas foo Jon Jr poe LI 4130 JOG ROT AX SET VELO 9 H1 aways oo oo JI Jop j 41200 JJOG SPIND SET VELO 9 H1 mas Jo IF ser 42000 THREAD START ANGLE 10 K1 Starting angle for thread immediately 42010 THREAD RAMP DISPI0 1 10 K1 aways ao Ji Logg T DOUBLE o O 42100 DRY RUN FEED 10 K1 aways sooo TT pos 0 42110 DEFAULT FEED 11 V1 mas fo ium 1 eg DEFAULT SCALE FACTOR P EEE TT mmedmay _ mas o E we SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 9 160 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D base line 9 2 Setting data em DEFAULT ROT FACTOR R BE EECH r External NC progr language le jd o PRERE NEN 470 SNGLEBLOCK2 STOPRE EE 42440 FRAME OFFSET INCR PROG ze EECHER ws po IE fon SSS Traversing of tool offsets with incr Programming 42480 STOP CUTCOM STOPRE Es always mote 1 42490 CUTCOM Gan STOPRE ERES Retraction behavior of TRC with preprocessing stop aways Jul e BOOLEAN gt 42750 ABSBLOCK_ENABLE ix D msewekdshyemds Tammy ap awas Ji JJ BOEN y 42940 TOOL LENGTH CONST 14 W1 E CS Change of tool length compensation when changing the plane aways fo wor 42950 JTOOL LENGTH TYPE 14 W1 Assignment of the tool length compensation independently of the tool type aways fof wor DES 42990 MAX BLOCKS IN IPOBUFFER PP mbar Ranga
118. mod code number 99 Save Power On Reset 1005 Encoder interface mod code number 2500 Save Power On Reset Optional 1608 Fixed temperature 0 Save Power On Reset 1602 Motor overtemperature warning 120 threshold 1607 Motor temperature shutdown limit 150 The temperature evaluation of the KTY connected to terminal X411 is activated and can be used if P1608 0 The evaluation is provided via pins 13 and 25 For example if P1608 60 is set the motor temperature is not evaluated a temperature of 60 C is used for internal calculation Important It is imperative to observe the order of the parameters listed above in addition Save Power On Reset must be carried out whenever specified SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 4 69 Starting up the Spindle 4 5 Digital spindle without encoder with external TTL encoder 4 5 2 Adapting the machine data in the control system Table 4 6 MD Designation Value Remark 30130 CTRLOUT_TYPE O 1 30240 ENC TYPEJOJ 1 31020 ENC RESOL 0 2500 32110 ENC FEEDBACK POLO 1 1 default 1 Control direction inverted With software versions higher than 2 01 05 or with SINUMERIK 802D bl the following ma chine data must be set for the expert password MD 13070 Designation DRIVE FUNKTION MASKIX Value 8000 Remark X corresponds to drive number 1 4 70 SINUMERIK
119. mounted on the load 32110 ENC FEEDBACK POLO 1 default 1 Reverse direction of rotation 13070 DRIVE FUNKTION MASKIX 8000 only applies with SW gt 2 1 X drive number 1 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 3 57 Commissioning 3 8 Starting up the axes spindle Parameterization using the Drive Configuration Wizard with different number of increments With software version 2 1 and higher the number of increments of the motor encoder and of the direct measuring system can be different when connecting an external rotary measuring system Prerequisite NC SW2 1 611U SW 05 02 04 Only possible when using a single axis power section with PB address 20 or 10 Parameterization using the Drive Configuration Wizard direktes MeBsystem Geber x Geberdaten x Welches direkte Me system verwenden Sie Daten eingeben X Jinkrementel Sin Cos m Rotatorisches Me system Geberstrichzahl 2500 an Me an Me Fig 3 6 Display Message frame selection via PROFIBUS parameterization Reglerfreigabe KI 65 fehlt F hrung von taktsynchronem PROFIBUS az Optionsmodultyp 4 PROFIBUS Teilnehmeradresse 7 Antrieb A Name Konfiguration erwarteter Optionsmodultyp 4 Telegramm Auswahl 103 Mechanik B sale Empfangene Daten PZD Gesendete Daten PZD egrenzungen Digitale Eing nge 1 S
120. n DM Derse ora futesh DWGweehmg of Jee DEER DM Seriennummer nana Il Jee DM Geberstrichzahi 2048 Power On 3 56 Values to be entered in the Expert list SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Commissioning 3 8 Starting up the axes spindle Change the process data parameterization from encoder 1 to encoder 2 922 Telegramm Auswahl PROFIBUS 102 Power On sss sss 5167 EEE 5163 916 10 PZD Istwertzuordnung PROFIBUS 50012 sofort Fig 3 4 Process data of encoder 1 Procedure e First set P922 to zero thereafter save and press Reset e Change now P915 6 P916 6 P916 10 Telegramm Auswahl PROFIBUS Doo q ewe PZD Sollwertzuordnung PROFIBUS 50013 Jsofot FZD Istwertzuordnung PROFIBUS 500014 sofort FZDstwenzuordnung PROFIBUS some set L E set FZDiswemweengPRORBUS Sol ew FzDiswewweengPR rBus Sun fo Fig 3 5 Process data of encoder 2 Adapting the machine data in the control system Table 3 6 Machine Data Designation Remark 30240 ENC TYPE O 1 Incr encoder 4 EnDat 31020 ENC RESOL 0 Increments for rot encoder 34200 ENC REFP MODE 0 1 Incr encoder 0 EnDat 31000 ENC IS LINEAR O O Rot encoder 1 Linear scale 31010 ENC GRID POINT DIST O0 Graduations on linear scale 31040 ENC IS DIRECT O O Encoder mounted directly on the motor 1 Encoder
121. n of the machine data and interface signals please refer to the De scriptions of Functions cf cross references in the tables of Chapter 7 Machine Data and Setting Data Note The default values of the machine data have been chosen such that usually no change is required Entering the machine data MD 3 48 Before you can enter the machine data the password for protection level 2 must be set Use the relevant softkey to select the following machine data areas and to change the ma chine data if necessary e General machine data MD 10000 19999 e Channel machine data MD 20000 29999 e Axis machine data MD 30000 39999 e Display machine data MD 1 999 e Drive machine data Parameters 599 1999 The data you have entered are written to the data memory immediately An exception is the drive machine data To save the drive machine data permanently use either the Save axis softkey which can be found in the area of the drive machine data with the drives turned on or the SimoCom U tool If you forget to save the data the old data is effective again after the next drive reset To refresh the display of the drive machine data on the screen after chang ing use the Refresh softkey The machine data is activated depending on the machine data property Activated Section 3 1 2 SINUMERIK 802D 802D bl Start up IBN 08705 Edition 6FC5 697 2AA00 1BP5 Commissioning 3 6 Setting the Profibus address 3
122. n the Connection Diagram in Fig 2 13 For the cable designations and connector types please refer to the SINUMERIK 802D Cata log SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 2 27 Installing the Control System 2 2 Interfaces and lines Power supply 24 V DC X8 Profibus X4 COM 1 X6 Handwheel1 X14 Handwheel 3 X16 Ca Handyvheel 2 X15 Handwheels KB Keyboard X10 CNC keyboard PP 72 48 X1202 X1201 Machine I Os SIMODRIVE 611U Fig 2 13 Connection Diagram of the SINUMERIK 802D SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 2 28 6FC5 697 2AA00 1BP5 Installing the Control System 2 3 Connecting the individual components 2 3 Connecting the individual components Note Always use shielded lines only make sure that the shield is connected to the metallic or metalized connector housing on the side of the control system 1 Connect the lines to the components as shown in Fig 2 13 2 Lock the D Sub connector using the fastening screws and install the strain reliefs The cable sets offered as accessories provide maximum interference immunity 2 3 1 Connecting the keyboard To connect the keyboard to the PCU use the supplied cable Insert the angular connector into the keyboard 2 3 2 Connecting handwheels to the PCU Connector designation Connector type H
123. nctions Turning Variant Milling Variant A B C G54 Select 1st work offset G55 Select 2nd work offset 56 Select 3rd work offset 57 Select 4th work offset 58 Select 5th work offset G59 Select 6th work offset 6 7 0 G Tapping 5 6 6 Continuous path control mode 7 7 7 G70 70 72 G71 71 73 G72 72 74 Finishing cycle N Rough turning cycle for the longitudinal axis Rough turning cycle for the transverse axis G Deep hole drilling cycle with chip breaking G73 73 75 Contour repetition Tapping cycle LH tread G74 74 76 G75 75 77 Deep hole drilling and plunge cutting in longitudinal axis ERR Deep hole drilling and plunge cutting in transverse axis Z G Fine drilling cycle G76 76 76 G90 77 20 G92 78 21 G94 79 24 Multiple thread cutting cycle Outer inner diameter single longitudinal turning cycle Single face turning cycle a Single thread cutting cycle Q o s G80 Cycle OFF Drilling cycle counterboring Drilling cycle countersinking Deep hole drilling cycle with stock removal End face deep hole drilling Tapping cycle RH thread 9 00 BR CO v Front face tapping Q oo a 8 8 Front face drilling 8 G Drilling cycle retraction with GO as Side face deep hole drilling Reverse countersinking 8 o co q Q co ole 3 4 3 4 6 4 5 6 Side face drilling 9 G Drilling cycle retraction with machining feedrate G 90 90 Absol
124. ng does not match your machine configuration the data must be adapted accordingly Note The machine data MD 31110 CTRLOUT MODULE NR and MD 30220 ENC MODULE NR must be set such that they have the same drive number because there is a fixed assignment between measuring system and motor Example The machine you want to start up is a milling machine The milling machine possesses three axes and one spindle The X1 and the Y1 axes are controlled by a twin axis power section the Z1 axis and the spindle by one single axis power section each e The default data record for a milling machine setup m has been loaded e The bus configuration has been selected with MD 11240 3 e Now adapt the axis machine data MD 30110 CTRLOUT MODULE NR and MD 30220 ENC MODULE NR will be adapted as follows MD 30110 and MD 30240 must only be changed for the Z1 axis Axis Drive number PROFIBUS address Power section MD 30110 MD 30220 x1 1 12 Twin axis Drive A Y1 2 12 Twin axis Drive B Z1 6 11 Single axis SP 5 10 Single axis e Setthe PB addresses of the drives as specified in the table above SimoCom U Due to the fact that the 5th axis A1 is not used MD 20070 AXCONF MACHAX USED 4 0 must be parameterized This will remove the axis from the configuration of the NC SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 3 53 Commissioning 3 8 Starting up the axes spindle 3
125. of 27860 PROCESSTIMER_MODE 10 K1 HEX a mas ov le leer fame 1 S 27880 PART COUNTER 10 K1 x E 27882 PART COUNTER MCODEJO 2 10 K1 REENEN aas aa lo o EC E MM ABSBLOCK Block display with absolute values 0 Deactivate 1 Activate POWERON DWORD 28402 MM_ABSBLOCK_BUFFER_CONF Dimension size of upload buffer POWER ON always 0 0 DWORD SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 8 126 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D 8 1 List of machine data 8 1 4 Axis specific machine data Cross ref to the relevant MD identifier chapter in the Description of Functions A 4 Ge Read write pro Default value Data type 30110 CTRLOUT MODULE NRIO 3 G2 seemwemmeuem O Teoveson ae mas po EE lm II 30120 CTRLOUT NRI0 3 G2 Seton Ouputiomeaie CT TAS e me fm Ce mE 3 80130 CTRLOUT TYPEIO 3 G2 emoe OOOO o Jo aways Jo Jo Ji de LI IS UNIPOLAR OUTPUTIOI 3020 NUM ENES Number of encoders POWER ON 2 2 awas Jo si TE ENC MODULE NR 0 H E A ENC INPUT NR O Act value No of input on module measuring circuit board POWER ON 2 2 BYTE ENC TYPE 0 Actual value Encoder type POWER ON OTE IS_ROT_AX Rotary axis spindle POWER ON ROT_IS_MODULO Modulo conversion for rotary axis spindle POWER ON 2 2 oom BOOLEAN SINUMERIK 802D 802D H Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 8 127 Machin
126. riction compensation value NEW CONF aw Jo Jos que vr Minimum friction compensation value NEW CONF je preiomeompensaionmecondann econ 32630 FFW ACTIVATION MODE 16 K3 rectora cool can be scvates nom me progam _ RESET zz po HE feto 32640 STIFFNESS CONTROL ENABLE ei i leen not 810D CCU1 32542 STIFENESS CONTROL CONFIG BERE ot oreynamiestitess cnm romeo mmuswe o s 1 Ime ERRA Dyn stiffness control Delay POWER ON Profibus adapter 0 0015 DOUBLE EE SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 8 130 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D 8 1 List of machine data 32700 ENC COMP ENABLE 0 16 K3 Enenderendenoreompensaten Jee 22 wa fo fe Iv how J 32810 EGUIV SPEEDCTRL TIMEJo 5 Seeerei Jr 0 003 0 003 0 003 33080 LUBRICATION DIST Distance to be traversed f lubrication pulse PLC signal NEW CONF 100000000 DOUBLE fe A 34000 REFP CAM IS ACTIVE 8 R1 E asiswihreerenoepoimem Il ws ho TE fossem o TT 34010 REFP CAM DIR IS MINUS 8 R1 Reference point approach in the negative direction RESET aways lo lm qm BOOLEAN ERENS 34020 JREFP VELO SEARCH CAM mm min d rpm Cam travel velocity RESET EEG 5 000 0 mm min always 13 88 r p m ERE er E 34030 REFP MAX CAM DIST 8 R1 10000 0 DOUBLE je Sol 34040 REFP VELO SEARCH MARKER 0 8 R1
127. rol system at a machine of the same type to the samecondition as after a commissioning or e to bring a new control system to the initial state in case of servicing after hardware re placement with lowest possible expenditure Series start up file The series machine start up file contains the following data e Machine data e R parameters e PLC user alarm texts e Display machine data e PLC user program e Part programs e Cycles e Setting data e Work offsets e Tool offsets e Leadscrew error compensation data e SIMODRIVE 611UE drive machine data This data is only transferred with the drive con nected Prerequisites The prerequisite for the series start up is a PC with V24 interface for data transfer from to the control system or an NC card In the PC the WINPCIN tool must be used SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 6 101 Series Machine Start Upand Data Backup 6 1 Series machine start up Sequence with PC 6 102 1 Create a series machine start up archive in the PC data transfer from the control sys temto the PC Establish a V24 cable connection between the PC COM port and the SINUMERIK 802D COMI Use the WINPCIN tool to make the following settings in the RS232 Config menu the settings not printed in bold correspond to the default setting when starting WINPCIN Com Port Number of the PC COM to SINUMERIK 802D Baud rate 19200 Parity none Data bits 8
128. see FB Chapter 5 Table 4 1 MD Name Default va Unit Remark lue 30200 NUM ENCS 1 O Dig spindle without speed actual va lue encoder AM mode operation wi thout encoder 1 Dig spindle with speed actual value encoder integrated into the motor 1PH7 motor Load gear transmission ratio 31050 DRIVE AX RATIO DENOM 1 1 Load revolutions DRIVE AX RATIO NU 31060 MERA 1 1 Motor revolutions 35100 SPIND_VELO_LIMIT 10000 r p m Maximum spindle speed 35130 GEAR STEP MAX VELO LI 500 r p m Max speed in gear stage 1 MIT 1 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 4 61 Starting up the Spindle 4 62 35200 GEAR STEP SPEEDCTRL A 30 rev s2 Acceleration in the speed controlled CCEL 1 mode 36200 AX_VELO_LIMIT 1 11000 r p m Threshold value for velocity monitoring setting rule MD 36200 1 1 x MD 35100 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Starting up the Spindle 4 1 Digital spindle drive with spindle actual value encoder integrated into the motor 4 1 Digital spindle drive with spindle actual value encoder integrated into the motor Example For a digital spindle drive PROFIBUS with spindle actual value encoder integrated into the motor the machine data parameterized in Table 4 1 must be parameterized Motor with incremental encoder Gear transmission ratio
129. smission ratio 1 2 Spindle lead 5 mm Max axis velocity 12 m min Max axis acceleration 1 5 m s2 Machine data settings MD 31030 5 MD 31050 1 MD 31060 2 MD 32000 12000 MD 32300 1 5 MD 36200 13800 The axis can now be traversed The direction of movement can be reversed using MD 32100 AX MOTION DIR 1 or 1 without influencing the control direction of the position control SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 3 54 6FC5 697 2AA00 1BP5 Commissioning 3 8 Starting up the axes spindle 3 8 3 Connecting a direct measuring system Prerequisite Both rotary and linear measuring systems can be connected to the SINUMERIK 802D These measuring systems must be signal generators with 1Vss sin cos track A A B B You can connect either a measuring system with a zero mark R R or a measuring system with an EnDat interface Measuring systems with distance coded zero marks must not be used If a direct measuring system is connected the 611UE closed loop control module can only be operated with one axis The PB address with the appropriate drive number for a single axis power section must be selected based on Table 3 2 The direct measuring system must be connected to the second encoder interface X412 switching between the direct measur ing system and the motor measuring system via the PLC is not possible Realization Connect a direct measuring system with Siemens standard cable 6FX8002 2C
130. software limit switch minus NEW CONF 100000000 DOUBLE sd 36130 POS LIMIT PLUS2 2 A3 2nd software limit switch plus NEW CONF 100000000 DOUBLE y SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 9 158 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D base line 9 1 List of machine data 36200 AX VELO LIMITIO 5 Velocity monitoring threshold value NEW CONF 11500 11500 11500 mm min always 31 944 31 944 31 944 DOUBLE 31 944 r p m ENC ZERO MONITORINGI0 Zero mark monitoring NEW CONF p oe CARO BOD 36400 CONTOUR TOL Contour monitoring tolerance band NEW CONF DOUBLE ES ENC CHANGE TOL 16 K3 Position actual value switching tolerance NEW CONF 2 2 36600 BRAKE MODE CHOICE 36610 AX EMERGENCY STOP TIME E Tmeofbraingrampmoaseofemm econ 36710 DRIFT LIMIT n O O Drift limit value for automatic drift compensation NEW CONF aways io jo so BLE 36720 DRIFT VALUEJOJ 38000 MM ENC COMP MAX POINTS O0 16 K3 memedaeponsrenoderpndecompemaion povemon o mas le Jo Te E 1 1 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 9 159 Machine and Setting Data 802D base line 9 2 Setting data 9 2 Setting data Cross refe rence to the relevant sec SD identifier tion chapter in the Des cription of Functions Read write pro 41010 JOG VAR INCR SIZE 9 H1 aways do JJ LE amo JJoG SET VELO 9 H1 a
131. splay external language immediately Ot voo INTEGER sso Jem POS COORDINATE SYSTEM E 7 p 1 1 E EEE EEE Explanation Both the position and the size of the representation are handed over during initialization The position of the coordinate system can be influenced by the parameter Axis direction in the header of the file The follovving positions are possible Position X Z 0 to the top to the right 1 to the top to the left 2 downwards to the right 3 downwards to the left 4 to the right upwards 5 to the left upwards 6 to the right downwards 7 to the left downwards The positions of the elements must be specified in position 4 mathematic coordinate system The simulation will then automatically convert the representation to the relevant system Activate the 802blueprint programming immediately 3 7 Of TE xj SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 8 114 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D 8 1 List of machine data 332 TOOL LIST PLACE NO EE o fof integer EEE RE E Ummdmey 35 gt EE E EI A Baud rate for modem connection immediately Os Js gt Too aas V24 PPL MODEM PARITY Es je bo je E IR to 1 GR VER PL MODEM STOPBIT Es PRE of e ie EE A za vaa_PPI_MODEM_DATABITS Es Dot EE rm lo Color settings title bar focus window foreground po pb ques EE oc HM COL TITLE FOCUS BACK e e fe JE o
132. stalling and removing the SINUMERIK 802D EJ 05 2 7 290 285 283 4 142 5 1 M4 rivet down insert nut or M4 extruded hole 6x Location holes 95 mm 2 Drill holes for fixing the position 2x Fig 2 8 Drilling pattern for the keyboard horizontal layout for installation beneath the PCU SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 2 23 Installing the Control System 2 1 Installing and removing the SINUMERIK 802D CS ver s sel Y 209 i 7 D O a pa I SEMENSIAIBICIDIE A J 7 0L O OLL g se E D HHH Us er S Fig 2 9 Mounting dimensions for the PP 72 48 2 24 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Installing the Control System 2 2 Interfaces and lines 2 2 Interfaces and lines Position of the interfaces operator controls and displays on the PCU
133. t up IBN 08 05 Edition 6 108 6FC5 697 2AA00 1BP5 Software Update via NC card 1 General Sequence AN A change in the system software can be necessary for either of the following reasons e Anew system software is to be installed new software release e After replacing the hardware if a system software other than that delivered is to be installed Note An external data backup of the user data must always be performed via V 24 see Section 6 1 or NC card see Section 6 2 Prerequisite The control system is turned off 1 Insert the supplied NC card with the system software and the flash file system Caution Never insert or remove the NC card when the PCU is connected to the mains Do not insert or remove the NC card with the control system turned on otherwise the NC card can be damaged Attention Software release 02 xx xx can only be loaded on a hardware with 32MB user memory This hardware configuration can be identified via the order number MLFB 6FC5610 0BA10 0BA1 2 Turning on the control system 3 as per display on the screen DRAM CHECK You can press SELECT Key to get START UP MENU after DRAM Check Press the SELECT key 4 Upon completion of the DRAM test the selection menu appears Use the cursor to select Software update and press INPUT to confirm 5 The update is performed The progress of the update is displayed via appropriate mes sages on the screen If the up
134. ta 802D ssseeesseeeeeee nn nnn 8 111 8 1 List of machine data EE EE ER ER ada a heed I NAME RES 8 112 8 1 1 Display machine data 8 112 8 1 2 General machine data 8 117 8 1 3 Channel specific machine data 8 120 8 1 4 Axis specific machine data 8 127 8 2 Selling data EE 8 137 Machine and Setting Data 802D base ne 9 141 9 1 List of machine data ee ER deeg tar ete antes reden olen 9 142 9 1 1 Display machine data ui EERS ho A RIA PA ee a 9 142 9 1 2 General machine data 9 147 9 1 3 Channel specific machine data 9 148 9 1 4 Axis specific machine data 9 151 I SINUMERIK 802D 802D H Start up IBN 08 05 Edition vi 6FC5 697 2AA00 1BP5 Contents 9 2 Setling daltd as sus ti ANT IL MUS DU dab e rA ed utate 9 160 10 Start Up ISO Mode with 802D only 10 163 10 1 EIE EER th te a Ra wih td E AE Esc aee 10 163 10 1 1 Turning variant i adi kt eee aegis daa D ok BEEN EE eens E ke 10 163 10 1 2 Milling Variant home ie a a dr a 10 164 10 2 Machine data ssa Sa SERE ar a ee ne erlag 10 164 10 2 1 Decimal point programming EE EE EE IH 10 164 10 2 2 Linear path control at rapid traverse rate GOO aa 10 164 10 2 3 Spindle positioning Mig III nenn 10 165 10 2 4 Blueprint programming for the turning technology oh 10 165 10 2 5 Tool compensation for the turning technology only 10 165 10 3 FUNCHONS su A Dann EE el ee 10 166 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 69
135. tandard motor non Siemens mo tor as the spindle motor The KTY of the motor can be evaluated directly at the encoder in terface X411 via pins 13 and 15 4 4 1 Parameterization using the Drive Configuration VVizard Motorauswahl Motor Daten eingeben el Motortyp EN Asynchronmotor Daten eingeben Suche nach Motordaten xj Nummer Text 1103 Motornennstrom 1119 1129 Induktivit t der Vorschaltdrossel Cosinus Phi Leistungsfaktor Wert 0 00 0 000 0 800 Einheit A eff mH a 1130 1132 Ersatzsch Motornennleistung Motornennspannung valtbilddaten bere 0 00 380 0 kw Fig 4 3 Display lt Zur ck Abbrechen Hilfe Me system Geber E xi Welches Motorme system verwenden Sie Fig 4 4 Display 4 4 2 Parameterization using the Expert List Table 4 3 Parameters to be entered in the Expert List lt Zur ck Abbrechen Hilfe Parameters 922 Text PROFIBUSmessage frame selection 0 Value Remark Save Power On Reset 915 6 Process data setpoint assignment 0 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 4 67 Starting up the Spindle 4 4 Digital spindle without external encoder Table 4 3 Parameters to be entered in the Expert List cont d Parameters Text Value Remark 916 6 Process data ac
136. teuerwort 1 STW1 1 Digitale Ausg nge Analoge Ausg nge 2 Drehzahlsollwert B NSOLL B zl 2 Drehzahlistwert B NIST B M n 3 Drehzahlsollwert B NSOLL B zl 3 Drehzahlistwert B NIST B m Verfahrsatze 4 Steuerwort 2 STw2 v 4 Zustandswort 2 Z5w2 m PROFIBUS Parametri 5 Momentenreduzierung MomRed 5 Meldungswort Meldw mm Spindelpositionieren Filtereinstellungen Stromsc Filtereinstellungen Drehza B Geber 1 Steuerwort 81 ST GE 6 Geber 1 Zustandswort G1 ZSw Motordatenoptimierung 7 Geber 2 Steuerwort 62 STW zl 7 Geber 1 Lageistwert 1 IG XIST1 p 8 kein Signal NIL b 8 Geber 1 Lageistwert 1 81 XIST1 9 kein Signal NIL pe 9 Geber 1 Lageistwert 2 81 XIST2 pe 10 kein Signal NIL cl 10 Geber 1 Lageistwert 2 G1 KIST2 y 11 len Sanai ej 11 Geber 2 Zustandswort 82 ZSwW E 12 kein Signal NIL el 12 Geber 2 Lageistwert 1 82 KISTI s 13 kein Signal NIL el 13 Geber 2 Lageistwert 1 82 KISTI 14 kein Signal NIL cl 14 Geber 2 Lageistwert 2 G2_XIST2 y 15 kein Signal NIL el 15 Geber 2 Lageistwert 2 82 KIST2 v SS E SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 3 58 6FC5 697 2AA00 1BP5 Commissioning 3 8 Starting up the axes spindle Subsequently save and press Reset Adapting the machine data in the control system Table 3 7 Machine Data Designation Remark 13060 DRIVE TELEGRAM
137. the Diagnostic menu to represent axis signals graphically The trace function is selected in the operating area System Service display Servo Trace Note for the reader Di BH SINUMERIK 802D Operation and Programming Chapter 7 SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 3 60 6FC5 697 2AA00 1BP5 Starting up the Spindle 4 With SINUMERIK 802D the spindle is a subfunction of the entire axis functionality The machine data of the spindle are therefore to be found amongst the axis machine data MD 35xxx For this reason data must also be entered for a spindle this data has already been de scribed in conjunction with the start up of feed axes The following variants are offered for the spindle drive Digital spindle drive with spindle actual value encoder integrated into the motor Digital spindle drive with directly mounted spindle actual value encoder Digital spindle drive with spindle actual value encoder integrated into the motor gearbox and external zero mark BERO Digital spindle drive without encoder and without external spindle actual value encoder Digital spindle drive without encoder and with external TTL encoder Analog spindle via 611 U E with spindle actual value encodermounted directly on the motor Note For spindles without gear stage switching only gear stage 1 index 1 will be used Index 2 5 must only be parameterized when using the gear stage switching function
138. the CW direction of rotation the synchronization is performed to the falling edge and in the CCW direction to the rising edge SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 4 65 Starting up the Spindle 4 3 Digital spindle drive with the encoder integrated into the motor gearbox and external zero mark via BERO PLC To ensure that a resynchronization is performed when switching from the speed controlled mode to the positioning mode the interface signal V380x2001 4 Resynchronize spindle when positioning must be linked with V390x0001 5 Position controller active Network 1 EOY BERO neusync beim Wechsel von Drehzahl auf Positionierbetrieb V33030001 5 V38032001 4 i Fig 4 2 Important switching from the speed controlled to the positioning mode must only be performed with the spindle rotating and from a defined direction Otherwise the spindle is mispositioned Correct positioning can be guaranteed by programming ACP or ACN SPOS ACP 0 Thus if first M4 Sxxx was programmed the spindle will decelerate to the standstill thereaf ter accelerate to the synchronization speed CW then synchronize and position SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 4 66 6FC5 697 2AA00 1BP5 Starting up the Spindle 4 4 Digital spindle without external encoder 4 4 Digital spindle without external encoder It is also possible to configure a motor without encoder s
139. the spindle to type 104 gt MD 13060 DRIVE TELEGRAM TYPE 4 104 e Switch the encoder input of the spindle to the second encoder gt MD 30230 ENC INPUT NR 2 e Adapt the number of increments of the spindle encoder gt MD 31020 ENC_RESOL xxxx e Parameterize the resolver gearbox MD 31070 DRIVE RATIO DENOM encoder revolutions MD 31080 DRIVE ENC RATIO NUMERA load revolutions MD 31040 ENC IS DIRECT O The spindle encoder is mounted on the motor side 1 The spindle encoder is mounted on the load side e n some cases the actual value of the position encoder must be inverted depending on the mounting direction gt MD 32110 ENC FEEDBACK POL 1 e Set the drive parameters SimoCom U P890 activate the angular encoder encoder interface 4 P922 select the message frame PROFIBUS 104 Save PowerOn Example Spindle with incremental encoder mounted on the chuck TTL encoder with 2 500 pulses revolution Resolver gearbox transmission ratio 1 3 Machine data settings MD 13060 4 104 MD 30230 2 MD 31020 2500 MD 31040 1 MD 31070 8 MD 31080 1 MD 32110 1 P890 4 P922 104 Note If a resolver gearbox with a transmission ratio other than 1 1 is installed positioning of the spindle can only be realized using a BERO SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 4 64 6FC5 697 2AA00 1BP5 Starting up the Spindle 4 3 Digital spindle drive with the encoder integrate
140. to the relevant MD identifier chapter in the Description of Functions Read write pro 20050 JAXCONF GEOAX ASSIGN TABIO 12 aomen gemennas _ _ _ pown e 20070 AXCONFMACHAXUSEDU U Ee CETTATTTCTTTTT TH mms CE EE gasse H Dm 2 8 45 fe CA CI A SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 8 120 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D 8 1 List of machine data E E Iren ze am o EE same BE Ek jen A EE E 20090 SPIND DEF MASTER SPIND Initial setting for master spindle in channel POWER ON BYTE 20094 SPIND_RIGID_TAPPING_M_NR M function for switching to controlled axis mode Siemens mode POWER ON was Jo TE Pr owon 20095 JEXTERN RIGID TAPPING M NR p M function for switching to controlled axis mode External mode POWER ON mas Jo TE TO owon 20108 PROG EVENT MASK EEvent controlled program calls POWER ON aways lo lo To DWORD 20140 TRAFO RESET VALUE 18 M1 E Tansomsiondaiarecortsesceddungpower u ResetTPend RESET 22 Fct Trans 20156 EXTERN GCODE RESET MODE n O 30 External NC Ge lb o Je 20204 WAB CLEARANCE TOLERANCE aways jo oo ps DOUBE TOOL MANAGEMENT MASK Activation of the tool management in various configurations POWER ON ms m Toe pwom TOOL TIME MONITOR MASK ana fm or TOOL_PARAMETER_DEF_MASK Definition of the tool parameters POWER ON aways Jg foot o
141. tomerir O EE External NC 22999 EXTERN PARALLEL GEOAX r0 7 PESE gt Jassonmentofparaichenneigemenyscs _ Poweron External NC progr language 0 0 po jw ais RENE 24020 FRAME SUPPRESS MODE Positions with frame suppression POWER ON always 0x0 0 DWORD 24100 TRAFO TYPE 1 18 M1 DeWoorawomaen tie sr L Fct Trans 24110 TRAFO AXES IN 1 0 max number of axes per channel 1 18 M1 E Assassignmentterwanstomaten T HT Fct Trans 1 i 2 Po EN Ea 24120 JTRAFO GEOAX ASSIGN TAB 1 0 2 me EE Fet Trans 2850 TRAFO INCLUDES TOOL E Tooihandingwihzeve etwanstomalon wewcowr Fet Trans 24200 TRAFO TYPE 2 18 M1 Daron orransomaton2inthe shanna one ae Fet Trans 2420 TRAFO AXES IN 2 0 max number of axes per channel 1 18 M1 Aasgmentrwansomaina L 7 HT Fet Trans i ii 2 o Jj o O O ids poor 24220 TRAFO GEOAX ASSIGN TAB 2 n 0 2 18 M1 assgnmentotnegsamenyasstiechamelaxsfortanstmaton NEWCONE 22 Fct Trans 249 TRAFO INCLUDES TOOL 2 een EIERE CECR Fet Trans 24800 TRACYL ROT AX OFFSET 1 18 M1 Fct Peripheral SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 8 124 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D 8 1 List of machine data 24805 TRACYL ROT AX FRAME 1 Fct Peripheral 24810 TRACYL ROT SIGN IS PLUS 1 TEENA Dee Fet SE 24820 TRACYL BASE TOOL 1
142. tual value assign 0 ment 916 7 Process data actual value assign 0 ment 916 8 Process data actual value assign 0 ment 916 9 Process data actual value assign 0 ment 916 10 Process data actual value assign 0 Save Power On Reset ment Optional 1608 Fixed temperature 0 Save Power On Reset 1602 Motor overtemperature warning 120 threshold 1607 Motor temperature shutdown limit 150 The temperature evaluation of the KTY connected to terminal X411 is activated and can be used if P1608 0 The evaluation is provided via pins 13 and 25 For example if P1608 60 is set the motor temperature is not evaluated a temperature of 60 C is used for internal calculation Important It is imperative to observe the order of the parameters listed above in addition Save Power On Reset must be carried out whenever specified 4 4 3 Adapting the machine data in the control system Table 4 4 MD Designation Value Remark 30130 CTRLOUT TYPEIO 1 30240 ENC TYPEJOJ 0 If the spindle does not possess an encoder it will not be possible to display the actual speed The display on the NC will therefore always remain zero With software versions higher than 2 01 05 or with SINUMERIK 802D bl the following ma chine data must be set for the expert password MD Designation Value Remark 13070 DRIVE FUNKTION MASKIX 8000 X corresponds to the drive num ber 1 SINUMERIK 802D 802D bl Start up
143. ute programming G 91 91 Incremental programming SINUMERIK 802D 802D bi Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 10 167 Start Up ISO Mode with 802D only 10 3 Functions G50 92 92 PRESET preset actual value memory G98 94 94 Feedrate in mm min inch min Turning Variant Milling Variant A B C G99 95 95 Feedrate in mm rev inch rev G 98 98 Return to starting point with fixed cycles G 99 99 Return to point R with fixed cycles G290 G290 Deselect ISO 66025 programming G291 G291 Select ISO 66025 programming E Note for the reader For further information please refer to the Manufacturer Service Documentation ISO Dialect for SINUMERIK order no 6FC5297 6AE10 0BP0 Note However only the functions described in the present documentation are supported SINUMERIK 802D 802D D Start up IBN 08 05 Edition 10 168 6FC5 697 2AA00 1BP5 Index Index Numbers 802D setting data 8 141 A Access levels 3 42 ADIA 4 78 4 80 Ambient conditions 1 13 Analog axis 4 78 Axis machine data for the feed axes default settings 3 54 3 61 B BERO 4 68 C Cables for WinPCIN connector pin assignment 2 31 Commissioning 3 41 Components hardware 1 9 software 1 9 Connecting the individual components 2 29 ADI4 module 2 33 drive unit 2 33 handwheels 2 29 Keyboard 2 29 PP 72 48 2 31 Profibus 2 34 Connection Diagram 2 28 D Data backup 6 108 externa
144. vel to fi 37010 FIXED_STOP_TORQUE_DEF Ee Fct Travel to fi 37012 FIXED STOP TORQUE RAMP TIME 17 F1 je Pine regres rean te changes torque tin ween Fct Travel to fi 37020 FIXED STOP WINDOW DEF 17 F1 mm degrees Fed siop campina torque entorngwndow TH Fct Travel to fi 37030 FIXED_STOP_THRESHOLD 17 F1 mmdegees _ Mreshosformagstopdeeeion fewe O O Fct Travel to fi SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 8 136 6FC5 697 2AA00 1BP5 Machine and Setting Data 802D 8 2 Setting data 37040 FIXED STOP BY SENSOR E Fnenstondsiectonwasensor _ _ _ TRoveron Fct Travel to fi 37050 FIXED_STOP_ALARM_MASK ERES E Ewongssemersssams T Fct Travel to fi 37060 FIXED STOP ACKN MASK 17 F1 Observing PLC acknowledgments for traversing to fixed stop 0 Do not wait 1 Wait 3 Analog drives POWER ON Fct Travel to fi 37610 PROFIBUS CTRL CONFIG k Prehsusconcbitcomguaien OOO Tromeson e LProfibus adapter Jo lo la fe JI j 37620 PROFIBUS TORQUE RED RESOL ee aways to Jon ioo Jong TN 38000 MM ENC COMP MAX POINTS O0 16 K3 memes points tar encoderspinae compensation povemon o was s p e o ES 8 2 Setting data Cross ref to the relevant SD identifier chapter in the Description of Functions Read write pro 41010 JOG_VAR_INCR_SIZE 9 H1 aways do JJ powe 4110 JJoG SET VELO 9 H1 ws jo lee
145. via Profibus Note For simulation MD 31130 and MD 30240 must be parameterized with 0 To enable the relevant NC axis to assign its setpoint to the appropriate PROFIBUS drive ensuring that the actual values are returned from this PROFIBUS drive it is imperative to parameterize the machine data MD 30110 CTRLOUT MODULE NR and MD 30220 ENC MODULE NR Note With 2 axis power sections both drives A and B each must be assigned to one axis Otherwise an error message is issued during power up drive alarm 832 Profibus not clock synchronized to master and the entire power section is not ready for operation A meaningful default setting for these machine data have already been implemented in the default data record for turning and milling The following applies for the default data record for turning Axis Drive number PROFIBUS address Power section MD 30110 MD 30220 x1 1 12 Twin axis Drive A Zi 2 12 Twin axis Drive B SP 5 10 Single axis SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 Commissioning 3 8 Starting up the axes spindle The following applies for the default data record for milling Axis Drive number MD PROFIBUS address Power section 30110 MD 30220 x1 1 12 Twin axis Drive A Y1 2 12 Twin axis Drive B Z1 3 13 Twin axis Drive A SP 5 10 Single axis A1 4 13 Twin axis Drive B If this default setti
146. warning note with a warning triangle warns of personal injury the same warning note can also contain a warning of material damage Qualified personnel Start up and operation of the device equipment system in question must only be performed using this docu mentation The start up and operation of a device system must only be performed by qualified personnel Qualified personnel as referred to in the safety guidelines in this documentation are those who are authori zed to start up ground and label units systems and circuits in accordance with the relevant safety stan dards Proper use ZN Please note the following Warning The device must only be used for the applications described in the Catalog and only in combination with the equipment components and devices of other manufacturers as far as this is recommended or permitted by Siemens It is assumed that this product be transported stored and installed as intended and maintained and operated with care to ensure that the product functions correctly and properly Trademarks All designations marked with the copyright notice are registered trademarks of Siemens AG Other names in this publication might be trademarks whose use by a third party for its own purposes may violate the rights of the registered holder Disclaimer of liability Although we have checked the contents of this publication for agreement with the hardware and software described since differences cannot
147. word SUNRISE default Expert mode 2 Password EVENING default Machine manufacturer 3 Password CUSTOMER default Authorized operator setter 4to7 No password and Authorized operator setter or appropriate gra user interface from PLC NCK duations as desired Protection levels 1 3 The protection levels 1 to 3 require a password The passwords can be changed after ac tivation For example if the passwords are no longer known the control system must be re initialized booting with default machine data This will reset all passwords to their defaults according to the software release you have acquired The password remains set until it is reset by selecting the Delete password softkey POWER ON will not reset the password Protection levels 4 7 Protection level 7 is set automatically if no password is set and no protection level interface signal is set The protection levels 4 to 7 can be set from the PLC user program even vvith out a password by setting the bits in the user interface E Note for the reader How to set the access levels is described in the User Manual Operation and Programming SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 3 42 6FC5 697 2AA00 1BP5 Commissioning 3 1 General 3 1 2 Structure of machine data MD and setting data SD Number and identifier MD and SD are addressed via their numbers or their names identifiers The number and the name as well as the
148. worw TOOL CORR MODE G43G44 External NC progr language Po Po e PUE SINUMERIK 802D 802D bl Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 8 121 Machine and Setting Data 802D 8 1 List of machine data 20384 TOOL CORR MULTIPLE AXES us zou Tollngth compensation in several anes simutensousy RESET as External NC 20500 CONST VELO MIN TIME mimm ls Minimum time with constant velocity POWER ON ae aways lo oo jo poe ass EXACT POS MODE ES Exact stop conditions with G00 and G01 NEW CONF Exact stop condition with the G00 gt GO1transition NEW CONF 20700 REFP NC START LOCK 8 R1 E tr dis vot veren poi E m mas CO CAS CAS deem EEE 20730 GO LINEAR MODE mU E meseenmhwwrwmos Teonenon ae awas 1 fo 5 t Boon 20732 EXTERN GO LINEAR MODE HERE E Interpolation behavior with Goo POWER ON always To Cd BOOLEAN a gt 2 20734 EXTERN_FUNCTION_MASK I GET sr External NC 21000 CIRCLE ERROR CONST 10 K1 aways loot CET 21010 CIRCLE ERROR FACTOR seen Factor for circle end point monitoring POWER ON 21020 WORKAREA WITH TOOL RADIUS 2 A3 Tooirduswnwoningarenimiaien es aa was po E eo bow 1 22000 JAUXFU ASSIGN GROUP O 63 13 H2 Fry trono H ae always errire oo 64 ET 22010 AUXFU_ASSIGN_TYPE O 63 13 H2 O nO CT e aways eses e semwe SINUMERIK 802D 802D bl Start up
149. xis spindle with TTL encoder via ADI4 PROFIBUS address 15 Axis 1st axis 2nd axis 3rd axis 4th axis Increments 1024 18000 9000 2048 Note for the reader Toolbox siemense txt and ADI4_SDB pdf SINUMERIK 802D 802D H Start up IBN 08 05 Edition 6FC5 697 2AA00 1BP5 4 75 Starting up the Spindle 4 8 Digital axis spindle with direct measuring system TTL via ADI4 4 8 Digital axis spindle with direct measuring system TTL via ADI4 Up to four direct 5V TTL square wave encoders can be connected to SINUMERIK 802D via max one ADI4 Measuring systems that can be connected Configuration 4 76 e 5V incremental TTL encoder increments 4x2 500 or 4x5 000 differential transfer using 5 V square wave signals RS422 standard You can use an ADI4 module with three 611 U modules in 2 different variants Either of the SDBs DMS1_ADI4 or DMS2 ADI4 can be loaded The ADI4 module have the Profibus address 15 and is assigned as follows e Variant 1 PP module 1 PP module 2 Single axis power section Twin axis power section Twin axis power section ADI4 4 x 2 500 steps rev e Variant 2 PP module 1 PP module 2 Single axis power section Twin axis power section Twin axis power section ADIA 4 x 5 000 steps rev SDB DMS1 ADI4 PB address 9 PB address 8 PB address 10 PB address 12 PB address 13 PB address 15 SDB DMS2 ADI4 PB address 9 PB address 8 PB address 10 PB address

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