gsk GSK218MC Connection Manual

This user manual describes all proceedings concerning the

operations of this CNC system in detail as much as possible. However, it is

impractical to give particular descriptions for all unnecessary or unallowable

system operations due to the manual text limit, product specific applications

and other causes. Therefore, the proceedings not indicated herein should

be considered impractical or unallowable.

This user manual is the property of GSK CNC Equipment Co., Ltd. All

rights are reserved. It is against the law for any organization or individual

to publish or reprint this manual without the express written permission of

GSK and the latter reserves the right to ascertain their legal liability.

- -

Installation and Connection Manual of GSK218MC CNC System

Preface

Your Excellency,

It’s our pleasure for your patronage and purchase of this GSK218MC Series Machining Center CNC System made by GSK CNC Equipment Co., Ltd.

This manual is the part of the “Installation and Connection”, which

is introduced the installation and connection and the PLC

programming method of the machining center CNC of the

GSK218MC.

In order to guarantee the product is operated with a safe, normal and

effective situation, it is necessary to carefully read this manual before installing

and using this product.

Chinese version of all technical documents in Chinese and English languages is regarded as final.

Preface and Precaution

Security Precaution

Accident may occur by improper connection and operation ！This

system only can be operated by authorized and qualified personnel.

Please carefully read this manual before using！

Especially prompt: The power installed on/inside the main cabinet

is a special one offering by our company CNC system.

Never attempt to use for other purposes by this power.

Otherwise, huge hazard may occur.

III

Installation and Connection Manual of GSK218MC CNC System

Warning, Notice and Explanation

Statement!

z In this manual we have tried as much as possible to describe all

various matters. However, we cannot describe all the matters which

must not be done, or which cannot be done, because there are so

many possibilities. Therefore, matters which are not especially

described as possible in this manual should be regarded as

“impossible”.

Warning!

z Before installing, programming and operating the machine, thoroughly

read this manual and user manual issued by the machine

manufacturer, and rigidly operate the machine based upon the

requirement of this manual, otherwise, possibly causing damage to

the workpiece and/or machine itself, or injury to the user.

z The product functions and technical indexes (such as accuracy,

velocity) described in this manual are only for this machine, which

installs the CNC system of this product. The actual function

configuration and technical capacity are determined by the machine

manufacturer, and the function configurations of the CNC machine

and technical indexes are subjected on the manual issued by the

machine builder.

All specifications and designs are subject to change without notice.

Notice!

Preface and Precaution

Safety Precautions

■ Transportation and Storage

z Do not pile up the carton over 6 layers.

z Do not climb, stand on the carton, and as well not place the heave objects on it.

z Do not drag or move the product using the cables connected with the product.

z Do not crash or scratch the panel and display screen.

z Avoid damp, sunshine and raining on the product carton.

■ Open carton to inspect

z Ensure that it is your purchased product after opening the carton.

z Check whether the product is damaged during transporting.

z Confirm whether each part is prepared or damaged based upon the packing list.

z Contact our company immediately if the product type is inconsistent with the

packing list, lack of accessories or damage in transportation.

■ Wiring

z The person who attends the wiring and check should have the corresponding

professional capacity.

z The product should be reliably grounded, and its resistance should be less than

0.1Ω and can not be used the neutral conductor (zero cable) to replace the

ground wire.

z The wiring should be correct and firm, otherwise, possibly causing the

malfunction in product or unexpectable result.

z The surge absorb diode connected with the product should be linked based upon

the described direction, otherwise, it may damage the product.

z Before Inserting/pulling out the plug or opening the main cabinet of the product, it

is important to cut off the product’s power.

■ Inspection and maintenance

z Cut off the power before inspecting and maintaining or changing the

components.

z Check the malfunction when the short-circuit or overloading occurs. The

computer can be started after the malfunction is eliminated.

z Do not power ON/OFF frequently for the product, if you want to turn on the

power again after power off, its interval time is 1min. at least.

Installation and Connection Manual of GSK218MC CNC System

Volume Ⅰ Programming Description

Introduce the technical specification, product type series and parameter

configuration, command code and program format of 218MC series machining center CNC system.

Volume Ⅱ Function Description

Introduce the main function of the GSK218MC series machining center CNC

system.

Volume Ⅲ Operation Description

Introduce the operations of the GSK218MC series machining center CNC

system

Volume Ⅳ Installation and Connection

Introduce the installation, connection and setting methods of the GSK218MC

series machining center CNC system.

Appendix

Introduce the use explanations of the GSK218MC series machining center CNC

system and the appendix

Preface and Precaution

Security Responsibility

Security responsibility of the manufacturer

——Manufacturer should take responsibility for the design and structure danger of the

motor and the accessories which have been eliminated and/or controlled.

——Manufacturer should take responsibility for the security of the motor and

accessories.

——Manufacturer should take responsibility for the offered information and

suggestions for the user.

Security responsibility of the users

——User should know and understand about the contents of security operations by

learning and training the security operations of the motor.

——User should take responsibility for the security and danger because of increasing,

changing or modifying the original motor or accessory by themselves.

——User should take responsibility for the danger without following the operations,

maintenances, installations and storages described in the manual.

This manual is stored by the last user.

Sincerely thanks for your friendly supporting of GSK’s

products!

VII

Installation and Connection Manual of GSK218MC CNC System

VIII

Contents

CONTENTS

VOlUME Ⅰ PROGRAMMING......................................................................................0H1

CHAPTER ONE THE COMPILATION SCHEDULE OF SEQUENCE PROGRAMMING ...........

1.1 GSK218MC Series PLC Specification .....................................................................................

1.2 The Concept of the Sequence Programming ......................................................................... 3H3

1.3 Distribution Interface (Step one) ...............................................................................................

1.4 Ladder Diagram Programming (Step two)............................................................................... 5H4

1.5 Sequence Programming Debugging (Step 3)......................................................................... 6H4

CHAPTER TWO SEQUENCE PROGRAMMING.......................................................................

2.1 Performance Process of Sequence Programming ................................................................

2.2 The Performance of the Cycle ..................................................................................................

2.3 The Priority Sequence of the Performance (the 1st Level, the 2nd level).......................... 10H6

2.4 Sequence Programming Structure ...........................................................................................

2.5 The Treatment of the Input/output Signal ................................................................................ 12H8

2.6 Interlocking.................................................................................................................................

CHAPTER THREE PLC ADDRESS.........................................................................................

3.1 Machine → PLC address (X)..................................................................................................

3.2 PLC → Address of the Machine Tool Side (Y) .................................................................

3.3 PLC →CNC Address (G) ........................................................................................................

3.4 CNC →PLC Address (F) .........................................................................................................

3.5 Internal Replay Address (R) ....................................................................................................

3.6 Nonvolatile Relay Address (K) ................................................................................................

3.7 Information Display Request Address (A) ............................................................................. 21H16

3.8 Counter Timer (C) ..................................................................................................................... 22H17

3.9 Counter Preset Value Address (DC) ......................................................................................

3.10 Timer Address (T) ................................................................................................................... 24H17

3.11 Presetting Value Address of the Timer (DT)........................................................................

3.12 Data Table Address (D) ..........................................................................................................

3.13 Sign Address (L)......................................................................................................................

3.14 Subprogram Number (P) .......................................................................................................

CHAPTER FOUR PLC BASIS CODE......................................................................................

4.1 RD, RD.NOT, WRT, and WRT.NOT Codes...........................................................................

4.2 AND, AND.NOT Codes............................................................................................................. 31H19

4.3 OR, OR.NOT Codes.................................................................................................................

4.4 OR. STK Code........................................................................................................................... 33H20

4.5 AND. STK Code ........................................................................................................................ 34H20

CHAPTER FIVE PLC FUNCTION CODE ................................................................................

5.1 END1 (End of the 1

5.2 END2 (The End of the 2

Level Sequence Program) ................................................................. 36H22

Sequence Program) ................................................................... 37H23

5.3 CALL (Call Subprogram)..........................................................................................................

5.4 CALLU (Call Subprogram Without Condition) ......................................................................

5.5 SP (Subprogram) ......................................................................................................................

5.6 SPE (End of Subprogram).......................................................................................................

1H3

2H3

4H4

7H5

8H5 9H6

11H7

13H10 14H11 15H11

16H13 17H14 18H15 19H15

20H16

23H17

25H17 26H17 27H17 28H17

29H18

30H18

32H19

35H22

38H23 39H23 40H24 41H24

Installation and Connection Manual of GSK218MC CNC System

5.7 SET (Replacement/Setting) .....................................................................................................42H25

5.8 RST (Resetting) .........................................................................................................................43H25

5.9 JMPB (Mark Number Skip) ......................................................................................................44H26

5.10 LBL (Mark Number).................................................................................................................

45H26

5.11 TMR (Timer) .............................................................................................................................46H27

5.12 TMRB (Fixed Timer)................................................................................................................47H28

5.13 TMRC (TIMER)........................................................................................................................

48H28

5.14 CRT (Binary Counter).............................................................................................................49H29

5.15 DEC (Binary Decoding) ..........................................................................................................50H30

5.16 COD (Binary System Code Conversion) .............................................................................51H31

5.17 COM (Concentric Line Control).............................................................................................

52H33

5.18 COME (Concentric Line Control End)..................................................................................53H33

5.19 ROT (Binary Rotation Control) ..............................................................................................54H33

5.20 SFT (Register Displacement/Shifting)..................................................................................

55H35

5.21 DIFU (Rising Edge Detection)...............................................................................................56H36

5.22 DIFD (Descending Edge Detection) .....................................................................................57H37

5.23 COMP (The Comparison of the Binary Number)................................................................

58H38

5.24 COIN (Consistency Comparison) ......................................................................................... 59H38

5.25 MOVN (Data Transmission)...................................................................................................60H39

5.26 MOVB (Transmission of 1 Byte)............................................................................................

61H40

5.27 MOVW (Transmission of Two Bytes) ...................................................................................62H40

5.28 XMOV (Binary Indexed Data Transmission) .......................................................................63H41

5.29 DSCH (Binary Data Index).....................................................................................................

64H42

5.30 ADD (Binary Addition).............................................................................................................65H43

5.31 SUB (Binary Subtraction).......................................................................................................66H44

5.32 ANDF (Bit-by-bit AND)............................................................................................................67H45

5.34 NOT (Bit-by-bit NOT)..............................................................................................................

68H47

5.35 EOR (Exclusive OR) ...............................................................................................................69H47

CHAPTER SIX THE COMPILATION LIMIT OF THE LADDER DIAGRAM ..............................

70H49

VOLUME II FUNCTION EXPLANATION.................................................................... 71H51

CHAPTER ONE CONTROLLABLE AXIS ................................................................................

1.1 The output of the axis movement............................................................................................

1.2 Servo Ready Signal ..................................................................................................................

CHAPTER TWO READY FOR OPERATION...........................................................................

2.1 ESP..............................................................................................................................................

2.2 CNC Overtravel Signal .............................................................................................................

2.3 Alarm Signal ...............................................................................................................................

2.4 Selection of the Operation Method .........................................................................................79H56

2.5 State Output Signal ................................................................................................................80H57

CHAPTER THREE MANUAL OPERATION.............................................................................

3.1 JOG Feed/Incremental Feed ...................................................................................................

3.2 MPG (Manual Pulse Generator) / Single Step Feed............................................................

CHAPTER FOUR REFERENCE POSITION RETURN ...........................................................

4.1 Manual Reference Position Return.........................................................................................

4.2 Return to the Reference Position Detection Signal..............................................................

4.3 Area Detection Signal ...............................................................................................................87H62

72H53

73H53 74H54

75H55

76H55 77H55 78H56

81H58

82H58 83H59

84H60

85H60 86H61

Contents

CHAPTER FIVE AUTOMATICAL OPERATION .......................................................................88H64

5.1 Cycle Start/ Feed Hold .............................................................................................................

5.2 Reset...........................................................................................................................................

5.3 Program test .............................................................................................................................. 91H66

5.4 Skip Optional Block................................................................................................................... 92H68

CHAPTER SIX FEEDRATE CONTROL...................................................................................

6.1 Rapid Traverse Rate.................................................................................................................

6.2 Feedrate Override..................................................................................................................... 95H71

6.3 Override Cancellation...............................................................................................................

CHAPTER SEVEN MISCELLANEOUS FUNCTION................................................................

7.1 M Code Miscellaneous Function.............................................................................................

7.2 S Code Miscellaneous Function .............................................................................................

7.3 T Code Miscellaneous Function.............................................................................................. 100H74

7.4 Miscellaneous Function Lock .................................................................................................. 101H76

CHAPTER EIGHT SPINDLE SPEED FUNCTION...................................................................

8.1 Spindle Speed Control Method ...............................................................................................

8.2 Rigid Tapping .............................................................................................................................

CHAPTER NINE PROGRAMMING CODE ..............................................................................

9.1 User Macro Program ................................................................................................................

9.2 Canned Cycle ............................................................................................................................

CHAPTER TEN DISPLAY/SETTING .......................................................................................

10.1 Clock Function.........................................................................................................................

10.2 Display the Operation Record............................................................................................... 110H85

10.3 Help Function .......................................................................................................................... 111H85

CHAPTER ELEVEN MEASURING ..........................................................................................

11.1 Skip Function ...........................................................................................................................

CHAPTER TWELVE PANEL LOCK SETTING.........................................................................

89H64 90H65

93H70

94H70

96H71

97H72

98H72 99H72

102H78

103H78 104H80

105H81

106H81 107H83

108H85

109H85

112H86

113H86

114H87

VOLUME III OPERATION EXPLANATION.................................................................115H93

CHAPTER ONE PLC INTERFACE DISPLAY ..........................................................................

1.1 GSK218MC The Automatic Operation in PLC ON............................................................

1.2 Programmable Interface Display ............................................................................................ 118H95

CHAPTER TWO PLC PROGRAMMING OPERATION ..........................................................

2.2 Basis Code...............................................................................................................................

2.3 The Operation Explanation of the Ladder Diagram ...........................................................

2.4 Function Code .........................................................................................................................

2.5 Command Table ...................................................................................................................... 123H108

2.6 Compilation Command........................................................................................................... 124H109

2.7 PLC Operation Steps..............................................................................................................

CHAPTER THREE PLC ADDRESS AND PARAMETER SETTING.......................................

3.1 Nonvolatile/Hold Relay............................................................................................................

3.2 Timer ............................................................................................................................... ...........128H112

3.3 Data List ....................................................................................................................................129H113

3.4 Counter ......................................................................................................................................130H114

3.5 M function corresponding to the F address..........................................................................

CHAPTER FOUR THE USER EXPLANATION OF THE LADDER DIAGRAM SOFTWARE

EDIT .........................................................................................................................................

116H95

117H95

119H103

120H104 121H105 122H107

125H109 126H111

127H111

131H115

132H117

Installation and Connection Manual of GSK218MC CNC System

4.1 Brief ............................................................................................................................... ............ 133H117

4.2 Software Introduction.............................................................................................................. 134H117

4.3 Software Operation ................................................................................................................. 135H119

VOLUME Ⅳ INSTALLATION AND CONNCETION................................................. 136H127

CHAPTER ONE THE SYSTEM CONFIGURATION AND INSTALLATION.............. 137H129

1.1 Composition of the System ................................................................................................

1.2 The System Installation and Connection ............................................................................139H129

1.3 CNC System Installation Dimension Figure .......................................................................

1.4 The Additional Panel Figure ...............................................................................................

138H129

140H131 141H136

CHAPTER TWO CONNECTION BETWEEN EQUIPMENTS .................................. 142H137

2.1 Connection Diagram of the External System......................................................................143H137

2.1.1 The Layout of Interface Position ........................................................................................

2.1.2 The Connection Diagram ....................................................................................................

2.2 Connection between the System and the Drive Unit ..........................................................

2.2.1 The System Interface Figure ..............................................................................................

2.2.2 The Interface Signal List .....................................................................................................148H140

2.2.3 Introduction of Signals.........................................................................................................149H140

2.2.4 The Cable Connection Diagram.........................................................................................

2.3 RS232 Standard Series Interfaces .....................................................................................

2.4 Connection between MPG and Handhold Unit...................................................................

2.4.1 Interface Signal Diagram ....................................................................................................

2.4.2 Introduction of Interface Signals ........................................................................................154H145

2.5 Connection of the Spindle Units .........................................................................................

2.5.1 List of the Interface Signals ................................................................................................

2.5.3 The Connection Circuit of DAP03 Interfaces ................................................................... 157H148

2.6 The System Power Supply Interface ..................................................................................

2.7 The Control Interface of the External Power Supply...........................................................

144H137 145H138

146H139

147H139

150H142 151H144 152H144

153H144

155H147

156H147

158H149 159H149

CHAPTER THREE THE MACHINE CONTROL I/O INTERFACE ............................ 160H150

3.1 The Interface Signal List.....................................................................................................

3.2 The Input Interfaces ...........................................................................................................

3.2.1 The Circuit Principle of the Input Interface .......................................................................

3.2.2 The Interface Definition of the Input Signals....................................................................

3.3 The Output Interface ..........................................................................................................

3.3.1 The Circuit Principle of the Output Interface....................................................................

3.3.2 The Definitions of the Output Signal Interfaces...............................................................167H155

161H150 162H151

163H151

164H152 165H154

166H154

CHAPTER FOUR MACHINE DEBUGGING............................................................. 168H157

4.1 Debugging Ready...............................................................................................................

4.2 System Power-on ...............................................................................................................

4.3 Emergency Stop and Limit .................................................................................................

4.4 Changing the Gear Ratio....................................................................................................

4.5 Backlash Compensation.....................................................................................................173H162

4.6 Setting the Drive Unit .........................................................................................................

XII

169H157 170H158 171H158 172H161

174H164

Contents

4.7 The Machine Screw Pitch Compensation...........................................................................175H165

4.8 Mechanical Zero Return (Machine Zero Return) ................................................................

176H167

4.9 Controlling the Input and Output Signals during the Spindle CW and CCW Rotation.........177H171

4.10 The Spindle Automatic Gear Change Control ...................................................................

178H172

4.11 The External Cycle Start and Feed Hold...........................................................................179H173

4.12 The External Editing Lock and the External Operation Panel Lock ..................................

180H174

4.13 Cooling, Lubricating and Chip Removal Control...............................................................181H175

4.14 Setting the Relative Feedrate ...........................................................................................

182H176

4.15 Setting the Relative Tapping Parameters .........................................................................183H178

APPENDIX ..................................................................................................................184H181

APPENDIX ONE THE USAGE GUIDE OF THE LADDER DIAGRAM OF GSK218MC

WITH THE TURRET MAGAZINE ................................................................................

185H183

1. Points for Attention during Using the Ladder Diagram when GSK218MC with the Turret

Magazine..................................................................................................................................186H183

2. The Allocation and Definitions of I/O Address and Internal Software Components in CNC PLC

of GSK218MC ..........................................................................................................................

3. Usage and Maintenance of GSK218MC CNC System with the Turret Magazine......................

187H183 188H212

APPENDIX TWO THE USAGE GUIDE OF LADDER DIAGRAM OF GSK218MC WITH

THE DISC MAGAZINE ................................................................................................189H221

1. Points for Attention of Using the Disc Magazine: ..................................................................190H221

2. The Allocation and Definition of PMC, I/O Address and the Internal Software Components in

GSK218MC CNC System.........................................................................................................

3. Usage and Maintenance of GSK218MC CNC SYSTEM with the Disc Magazine ................

191H222 192H254

4. Note of GSK218MC CNC System with the Disc Magazine Macro Program.........................193H262

APPENDIX THREE THE ALLOCATED FILE FORMAT OF THE LADDER DIAGRAM

....................................................................................................................................194H263

1. M Code M00—Meaning of F Signal in M99..........................................................................

2. “%” in a Single Line Meaning Saving M Code Information End ............................................196H263

3. X signal X0.0---The Code and Meaning of X6.7 ...................................................................

4. Y Signal Y0.0—The Code and Meaning of Y5.7...................................................................198H263

5. K signal K6.0---The Code and Meaning of K63.7 .................................................................

6. A signal A0.0---The Code and Meaning of A31.7..................................................................200H264

7. End// End Symbol.................................................................................................................201H264

195H263

197H263

199H264

XIII

Installation and Connection Manual of GSK218MC CNC System

XIV

Chapter One The Compilation Schedule of the Sequence Programming

Volume I Programming

VOlUME Ⅰ PROGRAMMING

Installation and Connection Manual of GSK218MC CNC System

Volume I Programming

VolumI Programming

Chapter One The Compilation Schedule of the Sequence Programming

CHAPTER ONE THE COMPILATION SCHEDULE OF SEQUENCE

PROGRAMMING

1.1 GSK218MC Series PLC Specification

GSK218MC series PLC specification is shown below:

Table 1-1-1

Specification GSK218MC Series PLC

Programming language Ladder

Program level 2

The 1st level program execution cycle 8ms

Basis code average treatment time 5μs

Programming capacity 4700 steps

Code Basis code + function code Internal relay (R)

PLC alarm detection (A) Nonvolatile memory area

Timer （T） Counter (C)

Data base (D) Nonvolatile relay (K) Counter prevalue data register (DC) Timer prevalue data register (DT) Subprogram (P) Mark (L) Input signal of NC side (F) Signal outputs to the NC side (G)

Volume I Programming

0~511 (byte)

0~31 (byte)

0~127 (word) 0~127 (word) 0~255 (word)

0~63 (byte) 0~127 (word) 0~127 (word)

0~99 0~99

0～63 (byte) 0～63 (byte)

I/O module (X)

(Y)

0~63 (byte)

0~47 (byte)

1.2 The Concept of the Sequence Programming

The programming is performed a logic control to the machine tool and its relative equipments, which is called sequence programming.

After the programming is converted into some kind of format, CPU can be performed the code and calculation treatment for it, and its fruits can be memorized to RAM. CPU can be rapidly read each code stored in the memory, which can be performed the programming according to the calculation operation.

The compiling of the sequence programming starts with developing of the ladder diagram

Installation and Connection Manual of GSK218MC CNC System

1.3 Distribution Interface (Step one)

The interface can be distributed after confirming the controlled object and calculating the points of the

Volume I Programming

corresponding input/output signal.

Refer to the Chapter Four Input/output interface signal table in the part of the Installation and Connection when distributing the interface.

VolumI Programming

1.4 Ladder Diagram Programming (Step two)

The control operation required by the machine tool can be expressed by the ladder diagram with the on-line compiling of the GSK218MC. The functions, such as the timer and counter, can not be expressed by relay symbols, which can be indicated by the specified function code symbols.

The compiled ladder diagram should be stored and converted into the corresponding PLC codes before operating, namely, the so-called instruction list.

1.5 Sequence Programming Debugging (Step 3)

The sequence programming can be debugged using the following methods:

1) Debugging with emulator The machine tool can be replaced by an emulator (it composes of the lights and switches). The input signal state of the machine tool can be expressed by the ON or OFF of the switches; and the output signal state can be indicated by the ON or OFF of the light.

2) Debugging with actual operation Debug on the actual machine tool. It is better to prepare the precautions before debugging, due to an unexpected behavior may occur.

Chapter Two Sequence Programming

CHAPTER TWO SEQUENCE PROGRAMMING

The operating principle is different with the common relay, because the PLC sequence controlling is carried out by compiling the on-line diagram. And therefore, it is better to thoroughly understand the sequence controlling principle when designing the PLC sequence programming.

2.1 Performance Process of Sequence Programming

In the general relay controlling circuits, each of them can be simultaneously operated. When the relay A is operated in the following figure, the replay D and E can be operated (when the contactor A and B are closed) at the same. Each replay in the PLC sequence control is operated in turn. The relay D is operated before relay A, and then the relay E operates (refer to the following figure). Namely, each relay is operated based upon the sequence of the ladder diagram (compiling sequence).

Fig. 2.1 (a) Circuit illustration

Volume I Programming

The differences between the relay circuit and PLC programming operation are shown below in the Fig.

2.1 (b) and Fig. 2.1 (c).

Fig. 2.1 (b)

Fig. 2.1 (c)

(1) Relay circuit Both Fig. 2.1 (b) and Fig. 2.1 (c) are shared a same operation. B and C are switched on after A is turned on. B is cut off after C is ON.

Installation and Connection Manual of GSK218MC CNC System

(2) PLC program A same relay is shared a same circuit, refer to the Fig. 2.1 (b); B and C are switched on after A is turned on. B is cut off after one cycle of the PLC program is performed. In the Fig. 2.1 (c), C is ON instead of B, after C is turned on.

Volume I Programming

2.2 The Performance of the Cycle

VolumI Programming

PLC performs from the beginning to the end of the ladder diagram. It performs again from the beginning of the ladder diagram after this diagram is performed, which is called cycle performance.

The performance time from the beginning to the end of the ladder diagram is abbreviated as a period of a cycle treatment. The shorter of the treatment period is, the stronger of the response capacity of the signal is.

2.3 The Priority Sequence of the Performance (the 1st Level, the 2nd

level)

GSK218MC PLC program are composed of two parts: the 1st level program and the 2nd level program, which are inconsistent with the performance period.

The 1

level program performs once each 8ms, which can be treated some fast corresponding and

short pulse.

The 2

may divide the 2

program performs once each 8*nms. N is the partition value of the 2nd level program. PLC

level program into N parts when the 2nd level program is executed. It is performed

one part for each 8ms.

Fig. 2-3-1

PLC in the GSK218MC is separately performed in the PLC-AVR SCM. The 1ms of each 8ms is the communication time for reading the PLC data from the CNC. The 5ms is that the PLC gains the system control signal (F. X), and uploads the control result data (G, Y parameter) external port I/O. PLC is always performed the ladder diagram calculation other than the interruption of the response exchange data.

Chapter Two Sequence Programming

Fig. 2-3-2

When the last partition value of the 2 executed from the beginning of the program. In this case, when the partition value is n, the performance time of one cycle is 8*n ms. The 1

program performs once each 8*n ms. If its steps of the 1

the steps of the 2

level program within 8ms should be reduced correspondingly; the partition value

may be increased, and the treatment time of the overall program will be longer. So, the compiling of

level program should be shorter.

the 1

level program of the n is performed, the program is then

level program performs once each 8ms; the 2nd level

level program is increased, and therefore

Volume I Programming

2.4 Sequence Programming Structure

The ladder diagram is compiled with sequence in the traditional PLC. It owns the following advantages in the ladder diagram language allowing the structured programming:

1. The program is easy to comprehend and compile.

2. It is more convenient to find the faults during the programming.

3. It is easy to find some reasons when the operation malfunction occurs.

The methods of the main structure programming are shown below:

1) Sub-program The subprogram is regarded as a treatment unit based on the ladder diagram.

Task A

Task B

. . . .

Fig. 2-4-1

2) Nesting

One subprogram can be performed the task by calling another one.

Main program

Task A

Task B

Subprogram 1 Subprogram 2

Task A1

Task An

Task A11

Task A12

Fig. 2-4-2

Installation and Connection Manual of GSK218MC CNC System

3) Conditional branch The main program is performed circularly, and checks whether its conditions are suitable. The corresponding subprograms are performed under these conditions, vice versa.

Volume I Programming

VolumI Programming

Fig. 2-4-3

2.5 The Treatment of the Input/output Signal

The treatment of the input signal:

CNC

CNC—PLC

Shared register

Latched at the beginning of the

level

The 2

program input

signal latch

Machine tool input register

8ms

IO terminal

Fig. 2-5-1

The 1stlevel program

The 2ndlevel program

The treatment of the output signal:

Fig. 2-5-2

Chapter Two Sequence Programming

2.5.1 Input Signal Treatment

(1) NC input register The NC input signals from the NC are memorized into the NC input register, which are transferred to

PLC each 8ms. The 1 signals.

(2) Machine tool input register The machine tool input register is scanned and memorized its input signal from the machine each 8ms. The 1st level program is also performed the corresponding treatment by using this signals directly.

(3) The 2

level program input register

The 2nd level program input signal register is also called the 2nd level program synchronic input signal register. Wherein, the stored input signal is treated by the 2nd level program. This signal state in the register is synchronic with the 2

The signals both in the NC and machine tool input register can be locked to the 2 input latch, as long as the 2nd level program performs. The signal state in this latch keeps invariable during the performance of the 2

level program performs the corresponding treatment using state of these

level one.

level program

level program.

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2.5.2 The Treatment of the Output Signal

(1) NC output register The output signal transfers to the NC output register from the PLC each 8ms. (2) Machine tool output register The signal memorized in the machine tool output register conveys to the machine tool each 8ms.

Note: The signal states, such as the NC input register, NC output register, machine input register and machine output

register, which can be displayed by the self-diagnosis function. The diagnosis number is the address number in the sequence programming.

2.5.3 The Distinguish of the Signal State Between the 1st Level and the

2nd Level Program

As for the same input signal, their states may different between the 1st and 2nd level programming, that is the reason that different registers are used between two levels programming. Namely, the input

signal used with the 2 signal in the 2nd level program is later than the 1st level one. At the worst case, one 2nd level program performance cycle can be lagged. It is better to remember this point when programming the ladder diagram.

level program is the one of the 1st level who is locked. And therefore, the

. . . .

END1

. . . .

It belongs to the 2nd partition of the 2

level program

Fig. 2-5-3-1

Installation and Connection Manual of GSK218MC CNC System

A=1 performs the 1st level program when the 1st 8ms is performed, then B=1. And therefore, the 2nd

level program is performed, the A=1 is latched to the 2

level program, and then the first partition of

the 2nd level program is completed.

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A turns into 0 to perform the 1

therefore, the 2

partition of the 2nd level program is performed; in this case, the state of the A is still

level program when the 2nd 8ms is performed, then B=0. And

latched as the one last time. So, C=1.

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In this way, the state both B and C are different.

2.6 Interlocking

In the sequence control, the interlocking is very important from the safety issue.

It is necessary to use the interlocking in the sequence control programming. Simultaneously, the hard interlocking is used in the relay control circuit of the strong electric cabinet of the machine tool sides. This is the reason that the interlocking is disabled when the hardware of the performance sequence programming malfunctions, even if the interlocking is logically used in the sequence program (software). And therefore, the interlocking can be ensured the safety for the user, and prevent the machine tool from damaging in the strong electric cabinet of the machine sides.

Chapter Three PLC Address

CHAPTER THREE PLC ADDRESS

Address distinguishes signal. Different address is separately corresponding to the I/O signal at the side of the machine tool, the I/O signal at the side of the CNC, the internal relay, the counter, the timer, the keep relay and the data list. Each address is composed of the address number and bit number, and its number is as shown below:

Address number rules: Address number consists of address type, address number and bit number.

Type Address number Bit number Address type: X, Y, R, F, G, K, A, D, C and T Address number: Decimal number means one byte. Bit number: Octonary number system, 0～7 are separately indicated the bytes (0～7 bits) in the front

of the address number.

The address type of the GSK218MC PLC is shown below:

Address Address explanation Length

X Machine →PLC (64 bytes) INT8U Y PLC → machine tool (48 bytes) INT8U F CNC → PLC (64 bytes) INT8U G PLC → CNC (64 bytes) INT8U R Intermediate relay (512 bytes) INT8U

C A PLC alarm detection INT8U T

K Keep relay (64 types) INT8U

Data register (0～255) The data register of the counter

preset value Counter (0～127)

Timer (0～127) The data register of the timer preset

value

X 000 . 6

Table 3-1

INT16U

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INT8U data type is 8-bit character type without symbol, INT16U data type is 16-bit integral type without symbol.

3.1 Machine → PLC address (X)

The X address of the GSK218MC PLC composes of two types:

1. The X address is assorted with the three I/O input terminals, namely, XS40, XS41 and XS42.

2. The X address is assorted with the input button on the MDI panel of the system.

3.1.1 X Address on the I/O Input

The addresses (48 addresses) are defined as INT8U from X0 to X5, which are distributed on the three I/O input terminals, for example, XS40, XS41 and XS42.

Installation and Connection Manual of GSK218MC CNC System

Users can define the signal significance of the X address of the I/O ports based upon the actual cases, which can be connected the machine tool and compiled the corresponding ladder diagram. Refer to the appendix one (GSK218MC CNC system PLC I/O address) and the configuration and definition of the internal software components for the initial definition of the input address.

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3.1.2 X Address on the MDI Panel

There are 11 types from the addresses X20 ~ X30 of which these addresses are corresponding with the button input on the MDI panel one by one. User can not modify its signal definition. The buttons

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on the MDI panel should be firstly responded by CNC, and then conveys the X signal to PLC.

The corresponding relationships are shown below:

Table 3-1-2-1

Button input

Edit X20.0 Rapid Fo X25.0 Auto X20.1 Rapid 25% X25.1 MDI X20.2 Rapid 50% X25.2 Zero return X20.3 Rapid 100% X25.3 Single step X20.4 Increment step 0.001 X26.0 Manual X20.5 Increment step 0.01 X26.1 MPG X20.6 Increment step 0.1 X26.2 DNC X20.7 Increment step 1 X26.3 Skip X21.0 Manual feed shaft +X X27.0 Single step X21.1 Manual feed shaft +Y X27.1 Dry run X21.2 Manual feed shaft +Z X27.2 M.S.T Lock X21.3 Manual feed shaft +Nth X27.3

Machine tool lock X21.4

Selection stop X21.5 Manual feed shaft -X X28.0 Program restart X21.6 Manual feed shaft -Y X28.1 Working light X21.7 Manual feed shaft -Z X28.2 Spindle CCW X22.0 Manual feed shaft -Nth X28.3

Spindle stop X22.1

Spindle CW X22.2

Spindle negative override (218MC integration) Spindle override cancellation (218MC integration) Spindle positive override (218MC integration) Spindle JOG X22.6 Tool magazine CW X29.3 Spindle override cancellation (218MC-H/-V is the channel selection) Lubrication X23.0 Tool pivoting (tool infeed) X29.5 Cooling X23.1 Tool back (tool retracting) X29.6 Chip-removal X23.2 Tool changer X29.7 ESP X23.5 Overtravel release X30.0

Cycle start X23.6

Feed hold X23.7 Spindle override cancellation X31.1

PLC

address

Spindle positive override (218MC-H/-V is N axis +)

Spindle negative override (218MC-H/-V is N axis -)

Spindle blowing (218MC 一 integration)

X22.3 Spindle orientation X29.0

X22.4 Tool magazine zero return X29.1

X22.5 Tool clamping/releasing X29.2

X22.7 Tool magazine CCW X29.4

Spindle negative override (218MC-H/-V is the spindle override SOV1)

Button input

PLC

address

X27.4

X28.4

X28.7

X31.0

Chapter Three PLC Address

(218 MC-H/-V is spindle override SOV2)

User 1 X24.0

User 2 X24.1

User 3 X24.2

User 4 X24.3

User 5 X24.4

Rapid switch X24.7

Spindle positive override (218MC-H/-V is spindle override SOV4) Feed negative override (218MC-H/-V is the feed override FOV1) Feed override cancellation (218MC-H/-V is the feed override FOV2) Feed positive override (218MC-H/-V is the feed override FOV4) Feed override FOV8 (218MC-H/-V) Feed override FOV16 (218MC-H/-V)

X31.2

X31.3

X31.4

X31.5

X31.6

X31.7

3.2 PLC → Address of the Machine Tool Side (Y)

The Y address of the GSK218MC PLC composes of two types:

1. The Y address is assorted with the three I/O input terminals, namely, XS43, XS44 and XS45.

2. The Y address is assorted with the indicator on the MDI panel of the system.

3.2.1 Y Address on the I/O Output Port

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The addresses (48 addresses) are defined as INT8U from Y0 to Y5, which are distributed on the three I/O input terminals, for example, XS43, XS44 and XS45.

Users can define the signal significance of the Y address of the I/O ports based upon the actual cases, which can be connected the machine tool and compiled the corresponding ladder diagram. Refer to the appendix one (GSK218MC CNC system PLC I/O address) and the configuration and definition of the internal software components for the initial definition of the input address.

3.2.2 Y Address on the MDI Panel

There are 8 types from the addresses Y12 ~ Y19 of which these addresses are corresponding with the button input on the MDI panel one by one. User can not modify its signal definition. PLC system reports to the CNC system keyboard module after calculating, and it is used for displaying the indicator signal.

The corresponding relationships of each prompt light:

Table 3-2-2-1

Key-board indicator

output

Edit key indicator Y12.0 Spindle orientation indicator Y15.7 Auto key indicator Y12.1 Tool magazine zero return indicator Y16.0 MDI key indicator Y12.2 Tool magazine CW indicator Y16.1 Zero return key indicator Single step key indicator Manual key indicator

MPG key indicator

DNC key indicator Y12.7 Tool magazine tool changer Y16.6

PLC

address

Y12.3 Tool magazine CCW indicator Y16.2

Y12.4

Y12.5

Y12.6

Key-board indicator output

Tool magazine (tool pivoting) (tool infeed) indicator Tool magazine (tool retraction) indicator Tool magazine clamping/releasing indicator

PLC

address

Y16.3

Y16.4

Y16.5

Installation and Connection Manual of GSK218MC CNC System

Spindle CCW indicator Y13.0 USER3 indicator Y16.7 Spindle CW indicator Y13.1 +X key indicator Y17.0

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Spindle stop indicator Y13.2 +Y key indicator Y17.1 Y axis zero return indicator Y axis zero return indicator Z axis zero return indicator The 4th axis zero return indicator DEF indicator Y13.7 (218MC integration) Y17.7 Skip indicator Y14.0 -X key indicator Y18.0 Single-step indicator Y14.1 -Y key indicator Y18.1 Dry run indicator Y14.2 -Z key indicator Y18.2 M.S.T lock indicator Y14.3 -4TH key indicator Y18.3 Machine tool lock indicator Machine tool lighting indicator Lubrication indicator Y14.6 Tunnel selection key indicator Y18.6 Cooling indicator Y14.7 JOG key indicator Y18.7 Chip-removal indicator Y15.0 Overtravel end key indicator Y19.0 The indicator of feed override cancellation key Rapid switch indicator Y15.2 Cycle start key indicator Y19.2

0.001/F0 key indicator Y15.3 Tool magazine zero point indicator Y19.3

0.01/25% key indicator Y15.4 Selection stop indicator Y19.4

0.1/50% key indicator Y15.5 Program re-start indicator Y19.5 1/100% key indicator Y15.6

indicator

Y13.3 +Z key indicator Y17.2

Y13.4 +4TH key indicator Y17.3

Y13.5 USER1 key indicator Y17.4

Y13.6 N axis + key indicator Y17.5

Y14.4 USER2 key indicator Y18.4

Y14.5 N axis - key indicator Y18.5

Y15.1 Feed dwell key indicator Y19.1

3.3 PLC →CNC Address (G)

The addresses from G0 to G63, its definition type: INT8U, totally 64 bytes. The operation panel key signal is shown below:

Table 3-3-1

Operation panel key signal PLC

address

Edit mode G20.0

Auto mode G20.1 Rapid switch G24.7 MDI mode G20.2 Rapid Fo G25.0 Zero return mode G20.3 Rapid 25% G25.1 Single step mode G20.4 Rapid 50% G25.2 Manual mode G20.5 Rapid 100% G25.3 MPG mode G20.6 Increment step length 0.001 G26.0 DNC mode G20.7 Increment step length 0.01 G261 Skip G21.0 Increment step length 0.1 G26.2 Single block G21.1 Increment length 1 G26.3 Dry run G21.2 MPG step length 0.001 G26.4 M.S.T lock G21.3 MPG step length 0.01 G26.5 Machine lock G21.4 MPG step length 0.1 G26.6

Operation panel key signal

Feed negative override (218MC integration)

PLC

address

G24.2

Chapter Three PLC Address

Selection stop G21.5 Manual feed axis + X G27.0 Program re-start G21.6 Manual feed axis +Y G27.1 Spindle CCW (positive) G22.0 Manual feed axis +Z G27.2 Spindle stop G22.1 Manual feed axis +4Th G27.3 Spindle CW (negative) G22.2 Manual feed axis –X G28.0 Spindle negative override (218MC integration) Spindle override cancellati (218MC integration) Spindle positive override (218MC integration) Spindle JOG G22.6 Spindle orientation G29.0 Tunnel selection signal G22.7 Tool magazine zero return G29.1 Lubrication G23.0 Tool clamping/release G29.2 Cooling G23.1 Tool magazine positive G29.3 Chip removal G23.2 Tool magazine negative G29.4 Cycle start G23.6 Tool pivoting (Tool infeed) G29.5 Feed hold G23.7 Tool return (tool retraction ) G29.6 Feed positive override (218MC integration) Feed override cancellation (218MC integration)

G22.3 Manual feed axis -Y G28.1

G22.4 Manual feed axis -Z G28.2

G22.5 Manual feed axis -4

G28.3

G24.0 Tool changer G29.7

G24.1 Overtravel release G30.0

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The signal of G63 bytes are used inside the system, the G63.0, G63.1 and G63.2 are the answer signal inside the system separately performed by M, S and T.

3.4 CNC →PLC Address (F)

The addresses from F0 to F63 are defined as: INT9U, totally 64 bytes. Refer to the Chapter Two Function for details.

3.5 Internal Replay Address (R)

The address area is reset when the system is turned on. R510 and R511 are used by the system. Its definition type is: INT8U, totally 512 bytes.

Address

number

012

R511

Fig. 3-5-1

System program administration area

R510 The signal of R510.0 address is set to 1 when PLC starts and restarts, which is used the signal set by the initial user. The R510.0 is reset to 0 after the ladder diagram is performed once.

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