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.

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I

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.

II

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.

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Installation and Connection Manual of GSK218MC CNC System

Warning, Notice and Explanation

Statement!

zIn 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!

zBefore 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.

Notice!

zThe 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.

IV

Preface and Precaution

Safety Precautions

■ Transportation and Storage

zDo not pile up the carton over 6 layers.

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

zDo not drag or move the product using the cables connected with the product.

zDo not crash or scratch the panel and display screen.

zAvoid damp, sunshine and raining on the product carton.

■Open carton to inspect

zEnsure that it is your purchased product after opening the carton.

zCheck whether the product is damaged during transporting.

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

zContact our company immediately if the product type is inconsistent with the packing list, lack of accessories or damage in transportation.

■Wiring

zThe person who attends the wiring and check should have the corresponding professional capacity.

zThe 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.

zThe wiring should be correct and firm, otherwise, possibly causing the malfunction in product or unexpectable result.

zThe surge absorb diode connected with the product should be linked based upon the described direction, otherwise, it may damage the product.

zBefore 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

zCut off the power before inspecting and maintaining or changing the components.

zCheck the malfunction when the short-circuit or overloading occurs. The computer can be started after the malfunction is eliminated.

zDo 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.

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Installation and Connection Manual of GSK218MC CNC System

Volume 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 Function Description

Introduce the main function of the GSK218MC series machining center CNC system.

Volume Operation Description

Introduce the operations of the GSK218MC series machining center CNC system

Volume 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

VI

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!

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Installation and Connection Manual of GSK218MC CNC System

VIII

Contents

CONTENTS

VOlUME PROGRAMMING......................................................................................		1H0
CHAPTER ONE THE COMPILATION SCHEDULE OF SEQUENCE PROGRAMMING ...........		3H1
1.1	GSK218MC Series PLC Specification .....................................................................................	3H2
1.2 The Concept of the Sequence Programming .........................................................................		3H
1.3	Distribution Interface (Step one) ...............................................................................................	4H
1.4	Ladder Diagram Programming (Step two)...............................................................................	4H5
1.5	Sequence Programming Debugging (Step 3).........................................................................	4H6
CHAPTER TWO SEQUENCE PROGRAMMING.......................................................................		5H7
2.1	Performance Process of Sequence Programming ................................................................	5H8
2.2	The Performance of the Cycle ..................................................................................................	6H9
2.3	The Priority Sequence of the Performance (the 1st Level, the 2nd level)..........................	6H01
2.4	Sequence Programming Structure ...........................................................................................	7H1
2.5	The Treatment of the Input/output Signal ................................................................................	8H21
2.6	Interlocking.................................................................................................................................	10H3
CHAPTER THREE PLC ADDRESS.........................................................................................		11H4
3.1	Machine → PLC address (X)..................................................................................................	11H5
3.2	PLC → Address of the Machine Tool Side (Y).................................................................	13H6
3.3	PLC →CNC Address (G) ........................................................................................................	14H7
3.4	CNC →PLC Address (F) .........................................................................................................	15H8
3.5	Internal Replay Address (R) ....................................................................................................	15H9
3.6	Nonvolatile Relay Address (K) ................................................................................................	16H02
3.7	Information Display Request Address (A) .............................................................................	16H2
3.8	Counter Timer (C) .....................................................................................................................	17H2
3.9	Counter Preset Value Address (DC) ......................................................................................	17H32
3.10 Timer Address (T) ...................................................................................................................		17H42
3.11 Presetting Value Address of the Timer (DT)........................................................................		17H52
3.12 Data Table Address (D)..........................................................................................................		17H62
3.13 Sign Address (L)......................................................................................................................		17H2
3.14 Subprogram Number (P) .......................................................................................................		17H82
CHAPTER FOUR PLC BASIS CODE......................................................................................		18H92
4.1 RD, RD.NOT, WRT, and WRT.NOT Codes ...........................................................................		18H03
4.2 AND, AND.NOT Codes.............................................................................................................		19H3
4.3 OR, OR.NOT Codes.................................................................................................................		19H23
4.4 OR. STK Code...........................................................................................................................		20H3
4.5 AND. STK Code ........................................................................................................................		20H43
CHAPTER FIVE PLC FUNCTION CODE ................................................................................		22H53
5.1	END1 (End of the 1st Level Sequence Program) .................................................................	22H63
5.2	END2 (The End of the 2nd Sequence Program) ...................................................................	23H7
5.3	CALL (Call Subprogram)..........................................................................................................	23H8
5.4	CALLU (Call Subprogram Without Condition) ......................................................................	23H9
5.5	SP (Subprogram) ......................................................................................................................	24H0
5.6	SPE (End of Subprogram).......................................................................................................	24H1

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5.7 SET (Replacement/Setting) .....................................................................................................		25H4
5.8 RST (Resetting) .........................................................................................................................		25H34
5.9 JMPB (Mark Number Skip) ......................................................................................................		26H4
5.10	LBL (Mark Number).................................................................................................................	26H54
5.11 TMR (Timer) .............................................................................................................................		27H64
5.12 TMRB (Fixed Timer)................................................................................................................		28H74
5.13 TMRC (TIMER)........................................................................................................................		28H4
5.14	CRT (Binary Counter).............................................................................................................	29H4
5.15	DEC (Binary Decoding) ..........................................................................................................	30H5
5.16	COD (Binary System Code Conversion) .............................................................................	31H5
5.17	COM (Concentric Line Control).............................................................................................	33H25
5.18	COME (Concentric Line Control End)..................................................................................	33H5
5.19	ROT (Binary Rotation Control) ..............................................................................................	33H45
5.20	SFT (Register Displacement/Shifting)..................................................................................	35H
5.21	DIFU (Rising Edge Detection)...............................................................................................	36H5
5.22	DIFD (Descending Edge Detection).....................................................................................	37H5
5.23	COMP (The Comparison of the Binary Number)................................................................	38H5
5.24	COIN (Consistency Comparison) .........................................................................................	38H95
5.25	MOVN (Data Transmission)...................................................................................................	39H06
5.26	MOVB (Transmission of 1 Byte)............................................................................................	40H16
5.27	MOVW (Transmission of Two Bytes) ...................................................................................	40H26
5.28	XMOV (Binary Indexed Data Transmission) .......................................................................	41H36
5.29	DSCH (Binary Data Index).....................................................................................................	42H6
5.30 ADD (Binary Addition).............................................................................................................		43H56
5.31	SUB (Binary Subtraction).......................................................................................................	44H6
5.32 ANDF (Bit-by-bit AND)............................................................................................................		45H76
5.34	NOT (Bit-by-bit NOT) ..............................................................................................................	47H86
5.35	EOR (Exclusive OR) ...............................................................................................................	47H96
CHAPTER SIX THE COMPILATION LIMIT OF THE LADDER DIAGRAM ..............................		49H07

VOLUME II FUNCTION EXPLANATION....................................................................		51H7
CHAPTER ONE CONTROLLABLE AXIS ................................................................................		53H27
1.1 The output of the axis movement............................................................................................		53H7
1.2	Servo Ready Signal ..................................................................................................................	54H7
CHAPTER TWO READY FOR OPERATION...........................................................................		55H7
2.1 ESP..............................................................................................................................................		55H67
2.2	CNC Overtravel Signal .............................................................................................................	55H7
2.3 Alarm Signal ...............................................................................................................................		56H87
2.4	Selection of the Operation Method .........................................................................................	56H97
2.5	State Output Signal ................................................................................................................	57H08
CHAPTER THREE MANUAL OPERATION.............................................................................		58H1
3.1	JOG Feed/Incremental Feed ...................................................................................................	58H2
3.2	MPG (Manual Pulse Generator) / Single Step Feed............................................................	59H38
CHAPTER FOUR REFERENCE POSITION RETURN ...........................................................		60H48
4.1	Manual Reference Position Return.........................................................................................	60H58
4.2	Return to the Reference Position Detection Signal..............................................................	61H8
4.3 Area Detection Signal ...............................................................................................................		62H78

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			Contents
CHAPTER FIVE AUTOMATICAL OPERATION .......................................................................			64H8
5.1	Cycle Start/ Feed Hold .............................................................................................................		64H98
5.2	Reset...........................................................................................................................................		65H09
5.3	Program test ..............................................................................................................................		66H19
5.4	Skip Optional Block...................................................................................................................		68H29
CHAPTER SIX FEEDRATE CONTROL...................................................................................			70H39
6.1	Rapid Traverse Rate.................................................................................................................		70H49
6.2	Feedrate Override.....................................................................................................................		71H59
6.3	Override Cancellation...............................................................................................................		71H69
CHAPTER SEVEN		MISCELLANEOUS FUNCTION................................................................	72H9
7.1	M Code Miscellaneous Function.............................................................................................		72H89
7.2	S Code Miscellaneous Function .............................................................................................		72H9
7.3	T Code Miscellaneous Function..............................................................................................		74H01
7.4	Miscellaneous Function Lock ..................................................................................................		76H10
CHAPTER EIGHT		SPINDLE SPEED FUNCTION ...................................................................	78H201
8.1	Spindle Speed Control Method ...............................................................................................		78H301
8.2	Rigid Tapping .............................................................................................................................		80H41
CHAPTER NINE PROGRAMMING CODE ..............................................................................			81H50
9.1	User Macro Program ................................................................................................................		81H60
9.2	Canned Cycle ............................................................................................................................		83H701
CHAPTER TEN DISPLAY/SETTING .......................................................................................			85H01
10.1 Clock Function.........................................................................................................................			85H901
10.2 Display the Operation Record...............................................................................................			85H01
10.3 Help Function ..........................................................................................................................			85H1
CHAPTER ELEVEN		MEASURING..........................................................................................	86H21
11.1 Skip Function ...........................................................................................................................			86H31
CHAPTER TWELVE		PANEL LOCK SETTING.........................................................................	87H41
VOLUME III OPERATION EXPLANATION.................................................................			93H51
CHAPTER ONE PLC INTERFACE DISPLAY ..........................................................................			95H61
1.1	GSK218MC	The Automatic Operation in PLC ON............................................................	95H71
1.2	Programmable Interface Display ............................................................................................		95H81
CHAPTER TWO PLC PROGRAMMING OPERATION..........................................................			103H9
2.2	Basis Code...............................................................................................................................		104H2
2.3	The Operation Explanation of the Ladder Diagram ...........................................................		105H2
2.4	Function Code .........................................................................................................................		107H2
2.5 Command Table ......................................................................................................................			108H32
2.6	Compilation Command...........................................................................................................		109H42
2.7	PLC Operation Steps..............................................................................................................		109H52
CHAPTER THREE		PLC ADDRESS AND PARAMETER SETTING.......................................	111H62
3.1	Nonvolatile/Hold Relay............................................................................................................		111H72
3.2	Timer ..........................................................................................................................................		112H8
3.3	Data List ....................................................................................................................................		113H92
3.4	Counter ......................................................................................................................................		114H03
3.5	M function corresponding to the F address..........................................................................		115H3
CHAPTER FOUR		THE USER EXPLANATION OF THE LADDER DIAGRAM SOFTWARE
EDIT .........................................................................................................................................			117H23

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	4.1 Brief ...........................................................................................................................................		117H3
	4.2 Software Introduction..............................................................................................................		117H43
	4.3 Software Operation .................................................................................................................		119H53
VOLUME INSTALLATION AND CONNCETION.................................................			127H63
CHAPTER ONE		THE SYSTEM CONFIGURATION AND INSTALLATION..............	129H73
1.1	Composition of the System ................................................................................................		129H83
1.2	The System Installation and Connection ............................................................................		129H3
1.3	CNC System Installation Dimension Figure .......................................................................		131H04
1.4	The Additional Panel Figure ...............................................................................................		136H4
CHAPTER TWO		CONNECTION BETWEEN EQUIPMENTS ..................................	137H24
2.1	Connection Diagram of the External System......................................................................		137H4
	2.1.1 The Layout of Interface Position ........................................................................................		137H4
	2.1.2 The Connection Diagram ....................................................................................................		138H54
2.2	Connection between the System and the Drive Unit ..........................................................		139H64
	2.2.1 The System Interface Figure ..............................................................................................		139H74
	2.2.2 The Interface Signal List .....................................................................................................		140H8
	2.2.3 Introduction of Signals.........................................................................................................		140H9
	2.2.4 The Cable Connection Diagram.........................................................................................		142H05
2.3	RS232 Standard Series Interfaces .....................................................................................		144H5
2.4	Connection between MPG and Handhold Unit...................................................................		144H25
	2.4.1 Interface Signal Diagram ....................................................................................................		144H35
	2.4.2 Introduction of Interface Signals ........................................................................................		145H4
2.5	Connection of the Spindle Units .........................................................................................		147H5
	2.5.1 List of the Interface Signals ................................................................................................		147H65
	2.5.3 The Connection Circuit of DAP03 Interfaces ...................................................................		148H75
2.6	The System Power Supply Interface ..................................................................................		149H85
2.7	The Control Interface of the External Power Supply...........................................................		149H5
CHAPTER THREE THE MACHINE CONTROL I/O INTERFACE............................			150H6
3.1	The Interface Signal List.....................................................................................................		150H6
3.2	The Input Interfaces ...........................................................................................................		151H26
	3.2.1 The Circuit Principle of the Input Interface .......................................................................		151H36
	3.2.2 The Interface Definition of the Input Signals ....................................................................		152H46
3.3	The Output Interface ..........................................................................................................		154H6
	3.3.1 The Circuit Principle of the Output Interface....................................................................		154H6
	3.3.2 The Definitions of the Output Signal Interfaces...............................................................		155H76
CHAPTER FOUR		MACHINE DEBUGGING.............................................................	157H86
4.1	Debugging Ready...............................................................................................................		157H96
4.2	System Power-on ...............................................................................................................		158H07
4.3	Emergency Stop and Limit .................................................................................................		158H7
4.4	Changing the Gear Ratio....................................................................................................		161H27
4.5	Backlash Compensation.....................................................................................................		162H37
4.6	Setting the Drive Unit .........................................................................................................		164H7

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Contents

4.7 The Machine Screw Pitch Compensation...........................................................................		165H7
4.8 Mechanical Zero Return (Machine Zero Return) ................................................................		167H6
4.9 Controlling the Input and Output Signals during the Spindle CW and CCW Rotation.........		171H
4.10	The Spindle Automatic Gear Change Control...................................................................	172H8
4.11 The External Cycle Start and Feed Hold...........................................................................		173H9
4.12	The External Editing Lock and the External Operation Panel Lock ..................................	174H08
4.13	Cooling, Lubricating and Chip Removal Control...............................................................	175H8
4.14	Setting the Relative Feedrate ...........................................................................................	176H28
4.15	Setting the Relative Tapping Parameters .........................................................................	178H3
APPENDIX ..................................................................................................................		181H4
APPENDIX ONE THE USAGE GUIDE OF THE LADDER DIAGRAM OF GSK218MC
WITH THE TURRET MAGAZINE ................................................................................		183H5

1.	Points for Attention during Using the Ladder Diagram when GSK218MC with the Turret
Magazine..................................................................................................................................		183H6
2. The Allocation and Definitions of I/O Address and Internal Software Components in CNC PLC
of GSK218MC ..........................................................................................................................		183H7
3. Usage and Maintenance of GSK218MC CNC System with the Turret Magazine......................		212H8

APPENDIX TWO THE USAGE GUIDE OF LADDER DIAGRAM OF GSK218MC WITH

THE DISC MAGAZINE ................................................................................................		221H98
1.	Points for Attention of Using the Disc Magazine:..................................................................	221H09
2. The Allocation and Definition of PMC, I/O Address and the Internal Software Components in
GSK218MC CNC System.........................................................................................................		222H19
3.	Usage and Maintenance of GSK218MC CNC SYSTEM with the Disc Magazine ................	254H91
4.	Note of GSK218MC CNC System with the Disc Magazine Macro Program.........................	262H391
APPENDIX THREE THE ALLOCATED FILE FORMAT OF THE LADDER DIAGRAM
....................................................................................................................................		263H491
1.	M Code M00—Meaning of F Signal in M99..........................................................................	263H591
2.	“%” in a Single Line Meaning Saving M Code Information End ............................................	263H91
3.	X signal X0.0---The Code and Meaning of X6.7 ...................................................................	263H791
4. Y Signal Y0.0—The Code and Meaning of Y5.7...................................................................		263H891
5.	K signal K6.0---The Code and Meaning of K63.7 .................................................................	264H91
6. A signal A0.0---The Code and Meaning of A31.7..................................................................		264H0
7.	End// End Symbol.................................................................................................................	264H10

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XIV

Chapter One The Compilation Schedule of the Sequence Programming

Programming I Volume

VOlUME PROGRAMMING

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Installation and Connection Manual of GSK218MC CNC System

Programming I Volume

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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)	0~511 (byte)
PLC alarm detection	(A)	0~31 (byte)
Nonvolatile memory area	T	0~127 (word)
Timer
Counter	(C)	0~127 (word)
Data base	(D)	0~255 (word)
Nonvolatile relay	(K)	0~63 (byte)
Counter prevalue data register (DC)		0~127 (word)
Timer prevalue data register	(DT)	0~127 (word)
Subprogram	(P)	0~99
Mark	(L)	0~99
Input signal of NC side	(F)	0 63 (byte)
Signal outputs to the NC side	(G)	0 63 (byte)
I/O module	(X)	0~63 (byte)
	(Y)	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

Programming I Volume

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Installation and Connection Manual of GSK218MC CNC System

1.3 Distribution Interface (Step one)

Programming I Volume

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

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.

4

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).

A B

D

A C

E

Fig. 2.1 (a) Circuit illustration

The differences between the relay circuit and PLC programming operation are shown below in the Fig. 2.1 (b) and Fig. 2.1 (c).

A C

B

A

C

Fig. 2.1 (b)

A

C

A C

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.

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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.

2.2 The Performance of the Cycle

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 1st level program performs once each 8ms, which can be treated some fast corresponding and short pulse.

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

may divide the 2nd 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.

6

Chapter Two Sequence Programming

Fig. 2-3-2

When the last partition value of the 2nd level program of the n is performed, the program is then 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 1st level program performs once each 8ms; the 2nd level

program performs once each 8*n ms. If its steps of the 1st level program is increased, and therefore

the steps of the 2nd 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 the 1st level program should be shorter.

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.

A C

B

Task A

A

C

.

.

Task B .

.

Fig. 2-4-1

2) Nesting

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

Main program

Subprogram 1

Subprogram 2

Task A Task A1 Task A11

Task A12

Task B

Task An

Fig. 2-4-2

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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.

Fig. 2-4-3

2.5 The Treatment of the Input/output Signal

The treatment of the input signal:

CNC	CNC—PLC
	Shared register
		The 1st level
		program
	Latched at the
	beginning of the	The 2nd level
	2nd level
	The 2nd	program
	program input
	signal latch
	Machine tool
	input register
8ms

IO terminal

Fig. 2-5-1

The treatment of the output signal:

Fig. 2-5-2

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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 1st level program performs the corresponding treatment using state of these 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 2nd 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 2nd level one.

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

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 2nd level program is the one of the 1st level who is locked. And therefore, the 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.

	A	.			B
		.
		.
			.
			EN.D1
			.
	A	.				It belongs to the 2nd partition
		.			C	of the 2nd level program

Fig. 2-5-3-1

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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 2nd level program, and then the first partition of the 2nd level program is completed.

A turns into 0 to perform the 1st level program when the 2nd 8ms is performed, then B=0. And therefore, the 2nd partition of the 2nd level program is performed; in this case, the state of the A is still latched as the one last time. So, C=1.

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.

10

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.

X 000 . 6

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: Table 3-1

	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
	D	Data register (0 255)	INT16U
	DC	The data register of the counter	INT16U
		preset value
	C	Counter (0 127)	INT16U
	A	PLC alarm detection	INT8U
	T	Timer (0 127)	INT16U
	DT	The data register of the timer preset	INT16U
		value
	K	Keep relay (64 types)	INT8U

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.

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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.

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 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		PLC		Button input			PLC
		address					address
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	Spindle positive override				X27.4
			(218MC-H/-V is N axis +)
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 negative override				X28.4
			(218MC-H/-V is N axis -)
Spindle CW		X22.2	Spindle	blowing	(218MC		X28.7
			integration)
Spindle negative override		X22.3	Spindle orientation				X29.0
(218MC integration)
Spindle	override
cancellation		X22.4	Tool magazine zero return				X29.1
(218MC integration)
Spindle positive override		X22.5	Tool clamping/releasing				X29.2
(218MC integration)
Spindle JOG		X22.6	Tool magazine CW				X29.3
Spindle	override
cancellation (218MC-H/-V		X22.7	Tool magazine CCW				X29.4
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
			Spindle negative override				X31.0
Cycle start		X23.6	(218MC-H/-V is the spindle override
			SOV1)
Feed hold		X23.7	Spindle override cancellation				X31.1

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			Chapter Three	PLC Address
			(218 MC-H/-V is spindle override SOV2)
	User 1	X24.0	Spindle positive override		X31.2
			(218MC-H/-V is spindle override SOV4)
	User 2	X24.1	Feed negative override		X31.3
			(218MC-H/-V is the feed override FOV1)
	User 3	X24.2	Feed override cancellation		X31.4
			(218MC-H/-V is the feed override FOV2)
	User 4	X24.3	Feed positive override		X31.5
			(218MC-H/-V is the feed override FOV4)
	User 5	X24.4	Feed override FOV8		X31.6
			(218MC-H/-V)
	Rapid switch	X24.7	Feed override FOV16		X31.7
			(218MC-H/-V)

3.2PLC → 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

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			PLC		Key-board indicator output			PLC
	output		address					address
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	Y12.3	Tool magazine CCW indicator				Y16.2
indicator
Single	step	key	Y12.4	Tool magazine (tool pivoting) (tool				Y16.3
indicator				infeed) indicator
Manual key indicator			Y12.5	Tool	magazine	(tool	retraction)	Y16.4
				indicator
MPG key indicator			Y12.6	Tool	magazine clamping/releasing			Y16.5
				indicator
DNC key indicator			Y12.7	Tool	magazine	tool	changer	Y16.6

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							indicator
		Spindle CCW indicator				Y13.0	USER3 indicator	Y16.7
		Spindle CW indicator				Y13.1	+X key indicator	Y17.0
		Spindle stop indicator				Y13.2	+Y key indicator	Y17.1
Volume		Y	axis	zero	return	Y13.3	+Z key indicator	Y17.2
		indicator
						Y13.4	+4TH key indicator	Y17.3
		indicator
		Y	axis	zero	return
I
		Z	axis	zero	return	Y13.5	USER1 key indicator	Y17.4
Programming		indicator
		The 4th axis zero return				Y13.6	N axis + key indicator	Y17.5
		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	Y14.4	USER2 key indicator	Y18.4
		indicator
		Machine		tool	lighting	Y14.5	N axis - key indicator	Y18.5
		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		Y15.1	Feed dwell key indicator	Y19.1
		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

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	Operation panel key signal	PLC
		address		address
	Edit mode	G20.0	Feed negative override	G24.2
			(218MC integration)
	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

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			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			IVolume
	Spindle override cancellatio	G22.4	Manual feed axis -Z		G28.2
	Spindle negative override	G22.3	Manual feed axis -Y		G28.1
	(218MC integration)
	(218MC integration)
	Spindle positive override	G22.5	Manual feed axis -4Th		G28.3			Programming
	(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	G24.0	Tool changer		G29.7
	(218MC integration)
	Feed override cancellation	G24.1	Overtravel release		G30.0
	(218MC integration)

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	7	6	5	4	3	2	1	0
	number
	R0

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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