siemens 802D User Manual

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The Control System 1

Installing the

SINUMERIK 802D SINUMERIK 802D base line

Commissioning Manual

Control System

Commissioning 3

Starting up the Spindle 4

Starting up the PLC 5

Series Machine Start−up Data Backup

Software Update 7

Valid for

Control system Software version

SINUMERIK 802D 2 SINUMERIK 802D base line 1

802D Machine and Setting Data

802D base line Machine and Setting Data

Start−up ISO mode 10

08/2005 Edition

Safety information

This Manual contains information which you should carefully observe to ensure your own personal safety and the prevention of material damage. The notices are highlighted by a warning triangle and, depending on the degree of hazard, represented as shown below:

Danger

indicates that death or severe personal injury will result if proper precautions are not taken.

Warning

indicates that death or severe personal injury can result if proper precautions are not taken.

Caution

with a warning triangle indicates that minor personal injury can result if proper precautions are not taken.

Caution

without a warning triangle means that material damage can occur if the appropriate precautions are not taken.

Attention

indicates that an undesired event or status can occur if the appropriate note is not observed.

If several hazards of different degrees occur, the hazard with the highest degree must always be given preference. If a warning note with a warning triangle warns of personal injury, the same warning note can also contain a warning of material damage.

Qualified personnel

Start−up and operation of the device/equipment/system in question must only be performed using this documentation. The start−up and operation of a device/system must only be performed by qualified personnel. Qualified personnel as referred to in the safety guidelines in this documentation are those who are authorized to start up, ground and label units, systems and circuits in accordance with the relevant safety standards.

Proper use

Please note the following:

Warning

The device must only be used for the applications described in the Catalog and only in combination with the equipment, components and devices of other manufacturers as far as this is recommended or permitted by Siemens. It is assumed that this product be transported, stored and installed as intended and maintained and operated with care to ensure that the product functions correctly and properly.

Trademarks

All designations marked with the copyright notice ® are registered trademarks of Siemens AG. Other names in this publication might be trademarks whose use by a third party for its own purposes may violate the rights of the registered holder.

Disclaimer of liability

Although we have checked the contents of this publication for agreement with the hardware and software described, since differences cannot be totally ruled out. Nonetheless, differences might exist and therefore we cannot guarantee that they are completely identical. The information given in this publication is reviewed at regular intervals and any corrections that might be necessary are made in the subsequent editions.

Siemens AG Automation and Drives Postfach 4848 90437 NÜRNBERG GERMANY

Siemens AG 2005 Subject to change without prior notice.

Preface

SINUMERIK Documentation The SINUMERIK Documentation is organized in 3 levels:

S General Documentation: S User Documentation S Manufacturer/Service Documentation:

For detailed information regarding further publications about SINUMERIK 802D, as well as for publications that apply for all SINUMERIK control systems (e.g. Universal Interface, Measuring Cycles...), please contact your Siemens branch office.

A monthly overview of publications with specification of the available languages can be found on the Internet at:

http://www.siemens.com/motioncontrol

Follow the menu items ”Support”/”Technical Documentation”/”Overview of Publications”. The Internet edition of DOConCD − DOConWEB − can be found at:

http://www.automation.siemens.com/doconweb

Addressees of the documentation

Standard scope

Hotline

The present documentation is aimed at the machine tool manufacturer. This publication provides detailed information required for the machine tool manufacturer to start up the SINUMERIK 802D control system.

The present Instruction Manual describes the functionality of the standard scope. Any amendments made by the machine manufacturer are documented by the machine manufacturer.

Other functions not described in this documentation can possibly also be performed on the control system. However, the customer is not entitled to demand these functions when the new equipment is supplied or servicing is carried out.

If you have any questions, do not hesitate to call our hotline:

A&D Technical Support Tel.: +49 (0) 180 / 5050 − 222 Fax: +49 (0) 180 / 5050 − 223 Internet: http://www.siemens.de/automation/support−request

If you have any questions (suggestions, corrections) regarding the Documentation, please send a fax to the following number or an e−mail to the following address:

Fax: +49 (0) 9131 / 98 − 63315 E−mail: motioncontrol.docu@siemens.com

Fax form: see return fax form at the end of this publication

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition 6FC5 697−2AA00−1BP5

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Preface

Internet address

http://www.siemens.com/motioncontrol

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition

6FC5 697−2AA00−1BP5

1 The SINUMERIK 802D Control System 1-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Components of the SINUMERIK 802D 1-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Technical specifications 1-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Installing the Control System 2-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Installing and removing the SINUMERIK 802D 2-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Interfaces and lines 2-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Connecting the individual components 2-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.1 Connecting the keyboard 2-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.2 Connecting handwheels to the PCU 2-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.3 Terminal configuration of the RS232 interface (COM1) on the PCU 2-30 . . . . . . . . . . . . . . . . . . .

2.3.4 Connecting the I/Os to PP 72/48 2-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.5 Connecting the ADI4 module 2-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 Connecting the SIMODRIVE 611U drive unit 2-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 Connecting the Profibus 2-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6 Grounding 2-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7 Power supply of PCU (X8) and PP 72/48 (X1) 2-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8 Displays on the PCU 2-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9 Displays on the PP 72/48 2-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents

3 Commissioning 3-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 General 3-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.1 Access levels 3-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.2 Structure of machine data (MD) and setting data (SD) 3-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Turning on and booting the control system 3-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Language setting 3-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 Setting the technology 3-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 Entering the machine data 3-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 Setting the Profibus address 3-49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 Starting up the PLC 3-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 Starting up the axes/spindle 3-52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8.1 Setpoint/actual value assignment 3-52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8.2 Default settings for the axis machine data for the feed axes 3-54 . . . . . . . . . . . . . . . . . . . . . . . . .

3.8.3 Connecting a direct measuring system 3-55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8.4 Default settings for the axis machine data for the spindle 3-59 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9 Completing the start−up 3-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 Service display for the axis drive behavior 3-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Starting up the Spindle 4-61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Digital spindle drive with spindle actual−value encoder integrated into the motor 4-63 . . . . . . . .

4.2 Digital spindle drive with spindle actual−value encoder (TTL)

mounted directly on the motor 4-64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Digital spindle drive with the encoder integrated into the motor,

gearbox and external zero mark via BERO 4-65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Digital spindle without external encoder 4-67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition 6FC5 697−2AA00−1BP5

Contents

4.4.1 Parameterization using the Drive Configuration Wizard 4-67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.2 Parameterization using the Expert List 4-67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.3 Adapting the machine data in the control system 4-68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Digital spindle without encoder with external TTL encoder 4-69 . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.1 Parameterization using the Expert List 4-69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.2 Adapting the machine data in the control system 4-70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 Analog spindle (via 611 U(E)) with with spindle actual−value encoder mounted directly on the motor . . . . . .

4-71

4.7 Analog axis/spindle with TTL encoder via ADI4 4-74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 Digital axis/spindle with direct measuring system (TTL) via ADI4 4-76 . . . . . . . . . . . . . . . . . . . . .

5 Starting up the PLC 5-79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Commissioning the PLC 5-80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Start−up modes of the PLC 5-80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 PLC alarms 5-82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.1 General PLC alarms 5-83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.2 User alarms 5-83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 PLC programming 5-85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.1 Command overview 5-87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.2 Explanation of the stack operations 5-89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.3 Program organization 5-96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.4 Data organization 5-96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.5 Interface to the control system 5-96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.6 Testing and monitoring your program 5-97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 PLC applications ”Download/Upload/Copy/Compare” 5-98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 User interface 5-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Series Machine Start−Upand Data Backup 6-101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Series machine start−up 6-101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Data backup 6-104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.1 Internal data backup 6-104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.2 External data backup via V24 6-104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.3 External data backup via NC card 6-105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Formatting an NC card 6-107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 Data backup in case of backlight failure 6-108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Software Update via NC card 7-109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Machine and Setting Data 802D 8-111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 List of machine data 8-112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.1 Display machine data 8-112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.2 General machine data 8-117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.3 Channel−specific machine data 8-120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.4 Axis−specific machine data 8-127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 Setting data 8-137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 Machine and Setting Data 802D base line 9-141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1 List of machine data 9-142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1.1 Display machine data 9-142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1.2 General machine data 9-147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1.3 Channel−specific machine data 9-148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1.4 Axis−specific machine data 9-151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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9.2 Setting data 9-160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Start−Up ISO Mode (with 802D only) 10-163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1 1. Setup 10-163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1.1 Turning variant 10-163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1.2 Milling variant 10-164 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2 Machine data 10-164 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2.1 Decimal point programming 10-164 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2.2 Linear path control at rapid traverse rate G00 10-164 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2.3 Spindle positioning M19 10-165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2.4 Blueprint programming (for the turning technology only) 10-165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2.5 Tool compensation (for the turning technology only) 10-165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.3 Functions 10-166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition 6FC5 697−2AA00−1BP5

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Contents

Platz für Notizen

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SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition

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The SINUMERIK 802D Control System

1.1 Components of the SINUMERIK 802D

Hardware components

S PCU (Panel Control Unit): Component of the control system for max. 4 axes and one

spindle, with graphical display, softkey menu and NC card slot

S KB (keyboard): horizontal or vertical design S MCP: Machine control panel S PP 72/48 (Profibus I/Os): 72 digital inputs, 48 digital outputs S ADI4 (analog drive interface for 4 axes) S Drive module

− SIMODRIVE 611UE closed−loop control module

− PROFIBUS DP option module

Software components

S System software on the permanent flash memory of the PCU

− Boot software starts the system

− Human Machine Interface (HMI) realizes all operator functions

− NCK software (NC Kernel) realizes all NC functions. It controls one ”NC channel ” with up to 5 axes (2 of them can be configured as spindles).

− Programmable Logic Control (PLC) executes the integrated PLC user program cyclically.

S Toolbox

− Setup files for turning and milling

− Configuration file for transformations with turning

− Cycle package for turning and milling

− WINPCIN transfer program for transferring user data and programs between PC and

− Reloadable languages

− Text manager

− PLC user library

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition 6FC5 697−2AA00−1BP5

1-9

The SINUMERIK 802D Control System

1.1 Components of the SINUMERIK 802D

− SimoCom U Parameterization and Commissioning Tool for Drives

− SIMODRIVE 611 UE Firmware

− PLC 802 Programming Tool

Note

Please always observe the readme file supplied with the ”Toolbox”. It provides up−to−date information.

User data

The user data include:

S Machine data S Setting data S Tool data S R parameters S Work offsets S Offset data S Part programs S Standard cycles S PLC user program S PLC alarms

Note

After turning off or in case of power failure, changed user data are stored for at least 50 h. Thereafter, they can be lost if they are not permanently stored by appropriate operator actions (see Section 6.2.1)

1-10

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The SINUMERIK 802D Control System

1.1 Components of the SINUMERIK 802D

PCU

(control system)

KB (operator panel)

Machine control panel (MCP)

JOG Ref Point

[VAR]

Auto Single Block

MDA

Spindle CCW

Spindle CWSpindle CW

Rapid

Reset Cycle STOP

Cycle START

PROCESS FIELD BUS

SIMODRIVE 611UE closed−loop control module

PROFIBUS DP option module

Fig. 1-1 Hardware components of the SINUMERIK 802D

PP 72/48

(input/output module)

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1-11

The SINUMERIK 802D Control System

1.2 Technical specifications

Connected loads

Table 1-1 Connected loads

Weight

Parameters

Supply voltage 20.4 28.8 V Ripple 3.6 Vss 24 V current consumption 1 A * Power dissipation of the PCU including KB

Power dissipation of the MCP Power dissipation of the PP 72/48

Starting current, total 2.6 A

* Basic configuration from PCU, KB, MCP and PP 72/48;

all outputs open

** with nominal load

Table 1-2 Weight

Component

PCU 4.9 kg KB 1.7 kg MCP 1.5 kg PP 72/48 1.2 kg

min. typ. max. Unit

50 <5

Weight

W W W

Dimensions

Table 1-3 Dimensions of the individual components

Component

PCU 310 x 330 x 85 KB, horizontal design 310 x 175 x 32 KB, vertical design 172 x 330 x 32 MCP 170 x 330 x 128

PP 72/48 194 x 325 x 35

Dimensions WxHxD [mm]

1-12

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Ambient conditions during operation

Table 1-4 Ambient conditions during operation

Parameters

Temperature range 0...50 °C Permissible relative humidity 5...95 %, not condensing Air pressure 700...1,060 hPa

The conditions during operation comply with IEC 1131-2. The control system is to be intended for installation in a housing (e.g. cubicle).

Transport and storage conditions

Table 1-5 Transport and storage conditions

Parameter

Temperature range -20...60 °C Permissible relative humidity 5...95 %, not condensing Air pressure 700...1,060 hPa Transport height -1,000...3,000 m Free fall in transport package v 1,200 mm (PP 72/48 v 1,000 mm)

The SINUMERIK 802D Control System

1.2 Technical specifications

Protective quality and degree of protection

Class of protection I to IEC 536. No connection to protective−conductor terminal is required. Protection from foreign matter and penetrating water to IEC 529. S For the PCU : IP 65 (front)

IP 00 (rear)

S For the keyboard : IP 65 (front)

IP 00 (rear)

S For the MCP : IP 54 (front)

IP 00 (rear)

S PP 72/48 IP 00

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The SINUMERIK 802D Control System

1.2 Technical specifications

PP 72/48

Table 1-6 Digital inputs

Parameter

at U

min typ max Unit

15 24 30 V

2 15 mA

−30 0 +5 V

not defi-

15 mA

ned

Signal delay caused by the hardware 0.5 3 ms

A voltage of 24V for controlling the digital inputs is provided at pin 2 of the interfaces X111, X222 and X333.

Max. current on pin 2 I

Table 1-7 Digital outputs (high−side driver)

Parameter

at UH and 100% simultaneity factor 250 mA

out

Signal delay caused by the hardware 0.5 ms Switching rate for the ohmic load 100 Hz Switching rate for the inductive load (free−wheeling

diode required)

at U

(leakage current) 50 400 µA

out

=0.5A

min typ max Unit

Vcc − 3V V

Output open

2 Hz

Switching rate for the lamp load 11 Hz

The 24V voltage for the digital outputs must be connected to all 4 pins 47, 48, 49, 50. Max. 1A may flow per supply pin.

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Installing the Control System

2.1 Installing and removing the SINUMERIK 802D

Warning

Procedure

Before installing the control system, make absolutely sure that the system is disconnected form the mains and deenergized!

The modules contain electrostatic sensitive devices. When handling the modules, make sure that neither p.c.boards, nor components are touched by persons not grounded with ESD protection.

1. Install the PCU, the keyboard (KB) and the machine control panel (MCP).

Attention! The maximum permissible torque for tightening the fastening screws is 1.8 Nm and must not be exceeded.

2. Install the PP 72/48.

3. Installing the drive compound (see SIMODRIVE 611 UE Documentation)

4. Establish the connection between PCU and keyboard, as well as between MCP and PP 72/48.

5. Establish the PROFIBUS connection between PCU, PP 72/48 and SIMODRIVE 611 UE.

Removing the control system

To remove the control system, proceed in the reverse order.

Warning

Mounting dimensions

Before removing the control system, make absolutely sure that the system is disconnected form the mains and deenergized!

Note

When installing the control components, observe the dimensions specified in the diagrams below. These drilling patterns constitute the basis for preparing the mounting holes. The dimensions are binding.

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Installing the Control System

2.1 Installing and removing the SINUMERIK 802D

8.2

90_

ø (X8)4.5

A-A

309.4

302.2

295.6

154.7

13.8

7.2

Required clearance

330

321

Fig. 2-1 PCU mounting dimensions

2-16

161.2

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Installing the Control System

2.1 Installing and removing the SINUMERIK 802D

Panel cutout

0.5

+0.3

302

1) M4

295

281.8

1.6

140.9

+0.3

285

312

286.6

Fig. 2-2 Drilling pattern for the PCU

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152.2

1) M4 rivet−down, insert nut or M4 extruded hole (8x)

2) Drill holes for fixing the position ø 5.2 mm (2x)

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Installing the Control System

2.1 Installing and removing the SINUMERIK 802D

128

68.7

263

330

170

90_

ø (X6)4.5

17.2

Fig. 2-3 Mounting dimensions for the machine control panel (MCP)

9 152.2 159.8

8 154

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Installing the Control System

2.1 Installing and removing the SINUMERIK 802D

>= 2

147 140

6xM4 1)

0 7

301

290

141.2

Fig. 2-4 Drilling pattern for the machine control panel (MCP)

1) M4 rivet−down, insert nut or M4 extruded hole

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Installing the Control System

2.1 Installing and removing the SINUMERIK 802D

86.1

172.2

7.7

330

320

Ground screw M5

Connection socket

Note:

1) This dimension should be added to the height of the connector (15mm),

that is (24+15)=39 mm.

2) Location pins (2xø4.7)

20 290 20

172.2

165

158.8

13.4

7.2 0

330

321

161.2

15 142.2 15

Fig. 2-5 Mounting dimensions for the keyboard (vertical layout for installation alongside the PCU)

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Installing the Control System

2.1 Installing and removing the SINUMERIK 802D

0.5

ø5(2x)

303.5

302.5

295

143.7

M4(6x)

7.5

8.5

0.3

145.7

146

151.9

Fig. 2-6 Drilling pattern for the keyboard (vertical layout for installation alongside the PCU)

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition 6FC5 697−2AA00−1BP5

1) M4 rivet−down, insert nut or M4 extruded hole

2) Drill holes for fixing the position ø5 mm (2x)

3) Observe the cut direction.

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Installing the Control System

2.1 Installing and removing the SINUMERIK 802D

7.2

302.2

309.4

175

7.724

87.5

Connection socket

Ground screw M5

Note:

1) This dimension should be added to the height of the connector (15mm),

that is (24+15) 39 mm.

2) Location pins (2xø4.7)

309.4

295.6

154.7

13.8

14515

175

169

15 279.4 15

Fig. 2-7 Mounting dimensions for the keyboard (horizontal layout for installation beneath the PCU)

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Installing the Control System

2.1 Installing and removing the SINUMERIK 802D

0.5

M4(6x)

ø5(2x)

290

285

283.4

142.5

1.6

158

153

76.5

000

Fig. 2-8 Drilling pattern for the keyboard (horizontal layout for installation beneath the PCU)

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition 6FC5 697−2AA00−1BP5

Location holes ø5 mm

2) Drill holes for fixing the position (2x)

1) M4 rivet−down, insert nut or M4 extruded hole (6x)

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Installing the Control System

2.1 Installing and removing the SINUMERIK 802D

194

325

10.5

306

6.5

10170

Fig. 2-9 Mounting dimensions for the PP 72/48

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2.2 Interfaces and lines

Position of the interfaces, operator controls and displays on the PCU

Installing the Control System

2.2 Interfaces and lines

Fig. 2-10 User interface on the PCU

S 24V DC Power supply connection (X8)

3−pin screw terminal connection for connecting the 24 V load power supply

S Profibus (X4)

B (side view)

24V DC

M5ground terminal

Jumper

9−pin D-Sub socket connector for connecting Profibus

S COM1 RS232 interface (X6)

9−pin D-Sub connector The COM2 port does not have any function.

S Handweels 1 to 3 (X14/X15/X16)

15−pin D-Sub connector for connecting the handwheels

S Keyboard Keyboard connection (X10)

6−pin mini−DIN

S Reset button S Jumper X311 S 4 LEDs for error and status displays (behind the front hatch)

Interface on the keyboard

S Keyboard connection

6−pin mini−DIN

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Installing the Control System

2.2 Interfaces and lines

Position of the interfaces, displays and operator controls on the PP 72/48

OVERTEMP

POWER

X333 X222

Fig. 2-11 User interfaces on the PP 72/48

S X1 Power supply connection (24 V DC)

3−pin screw terminal connection for connecting the 24 V load power supply

S X2 Profibus

9−pin D-Sub socket connector for connecting Profibus

RESET

EXCHANGE

READY

X111

S X111, X222 and X333

50−pin ribbon−cable connector for connecting the digital inputs/outputs

S 4 LEDs on the PP 72/48 for status displays S S1 DIL switches for setting the PROFIBUS address (see Section 3.6)

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Interfaces on the MCP

Installing the Control System

2.2 Interfaces and lines

X1202

X1201

Fig. 2-12 User interfaces on the MCP

S X1201 and X1202

50−pin ribbon−cable connector for connection to PP 72/48

Interconnecting cables

The individual components are connected as shown in the Connection Diagram in Fig. 2-13. For the cable designations and connector types, please refer to the SINUMERIK 802D Catalog.

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Installing the Control System

2.2 Interfaces and lines

Power supply 24 V DC

PCU

Profibus (X4)

COM 1 (X6)

Handwheel1 (X14)

Handwheel 2 (X15)

Handwheel 3 (X16)

Keyboard (X10)

PROCESS FIELD BUS

RS232

Handwheels

CNC keyboard

PP 72/48

X111

SIMODRIVE 611U

Fig. 2-13 Connection Diagram of the SINUMERIK 802D

X222 X333

X111 X222 X333

X423

X1201X1202

Machine I/Os

MCP

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2.3 Connecting the individual components

PinSi

2.3 Connecting the individual components

Note

Always use shielded lines only; make sure that the shield is connected to the metallic or metalized connector housing on the side of the control system.

1. Connect the lines to the components as shown in Fig. 2-13.

2. Lock the D-Sub connector using the fastening screws and install the strain reliefs.

The cable sets offered as accessories provide maximum interference immunity.

2.3.1 Connecting the keyboard

To connect the keyboard to the PCU, use the supplied cable. Insert the angular connector into the keyboard.

2.3.2 Connecting handwheels to the PCU

Installing the Control System

Connector designation: HANDWHEEL1 (X14)

HANDWHEEL2 (X15) HANDWHEEL3 (X16)

Connector type: 15−pin D−Sub socket connector Max. cable length 3 m

Table 2-1 Pin assignment of the socket connectors X14, X15, X16

X14, X15, X16

gna 1 1P5 V 9 1P5 V 2 1 M V 10 N.C. 3 A 11 1 M V 4 A 12 N.C. 5 N.C. 13 N.C. 6 B 14 N.C. 7 B 15 N.C. 8 N.C.

yp.Pin

gna

yp.

Signal names

A A pulse A

Inverted A pulse B B pulse B

Inverted B pulse 1P5 5V power supply 1M Ground

915

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Installing the Control System

2.3 Connecting the individual components

Signal type

V Voltage output

Handwheels

Three electronic handwheels can be connected; these must meet the following requirements:

Transmission technique: 5 V square wave signals (TTL level or RS422) Signals: Track A as true and negated signal (U

Track B as true and negated signal (U

, Ua1)

, Ua2)

Max. output frequency: 500 kHz Phase shift

of the A tracks to B: 90° "30° Power supply: 5 V, max. 250 mA

2.3.3 Terminal configuration of the RS232 interface (COM1) on the PCU

RS232 interface COM1

Connector designation: COM1 (X6) Connector type: 9−pin D−Sub plug connector Max. cable length 15 m

Table 2-2 Pin assignment of the COM1 socket connector (X6)

COM1 (X6)

Pin Name typ. Pin Name typ.

1 DCD I 6 DSR I 2 RXD I 7 RTS O 3 TXD O 8 CTS I 4 DTR O 9 RI I 5 1 M V

2-30

Signal description:

DCD Data Carrier Detect RxD Receive Data V24 TxD Transmit Data V24 RTS Request To Send CTS Clear To Send DTR Data Terminal Ready DSR Data Send Ready RI Ring Indicator 1M Signal Ground

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition

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Signal type

I Input O Output V Voltage output

Cable assignment for the RS232 interface

Fig. 2-14 Cable assignment: Pin assignment of the D−Sub female connectors

Installing the Control System

2.3 Connecting the individual components

2.3.4 Connecting the I/Os to PP 72/48

To connect the machine control panel to the PP 72/48 (X111, X222), use ribbon cable (see Fig. 2-13). Max. cable length: 15 m

Pin assignment of the connectors on the PP 72/48 side

Connector designation: X111, X222, X333 Connector type: 50−pin plug connector

Table 2-3 Pin assignment of the connectors X111, X222, X333

Pin Signal Type Pin Signal Type

1 M GND 2 +24 V Output

3 I m+0.0 Input 4 I m+0.1 Input 5 I m+0.2 Input 6 I m+0.3 Input

7 I m+0.4 Input 8 I m+0.5 Input

9 I m+0.6 Input 10 I m+0.7 Input 11 I m+1.0 Input 12 I m+1.1 Input

13 I m+1.2 Input 14 I m+1.3 Input 15 I m+1.4 Input 16 I m+1.5 Input

17 I m+1.6 Input 18 I m+1.7 Input

19 I m+2.0 Input 20 I m+2.1 Input 21 I m+2.2 Input 22 I m+2.3 Input

23 I m+2.4 Input 24 I m+2.5 Input

(output for I m+0.0 ... I m+2.7)

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Installing the Control System

Input Byte

2.3 Connecting the individual components

Table 2-3 Pin assignment of the connectors X111, X222, X333, cont’d

Pin TypeSignalPinTypeSignal

25 I m+2.6 Input 26 I m+2.7 Input

27 not connected 28 not connected

29 not connected 30 not connected 31 O n+0.0 Output 32 O n+0.1 Output

33 O n+0.2 Output 34 O n+0.3 Output 35 O n+0.4 Output 36 O n+0.5 Output

37 O n+0.6 Output 38 O n+0.7 Output

39 O n+1.0 Output 40 O n+1.1 Output 41 O n+1.2 Output 42 O n+1.3 Output

43 O n+1.4 Output 44 O n+1.5 Output 45 O n+1.6 Output 46 O n+1.7 Output

47 DO-

COM1

49 DO-

COM1

VCC (input for O n+0.0 ... O n+1.7 supply)

48 DO-

COM1

50 DO-

COM1

VCC (input for O n+0.0 ... O n+1.7 supply)

Danger

The 24V power supply for digital outputs (DOCOM1) must be designed as a functional extra−low voltage with safe isolation to EN 60204-1.

Note

The 24V voltage for the digital outputs must be connected to all 4 pins 47, 48, 49, 50. Make sure that the interconnecting cable between the power supply and the supply voltage inputs pins 47 - 50 does not exceed a permissible length of max. 10 m.

The connectors X111, X222 and X333 have the same assignment, but the I/O areas are offset by 3 bytes (inputs) or 2 bytes (outputs) (cf. Table 2-4).

Table 2-4

PP 72/48 1

Profibus address 9

X111 X222 X333 X111 X222 X333

IB 0 3 6 9 12 15

Input Byte

OB 0 2 4 6 8 10

Output Byte

M 0 3 6 9 12 15

n 0 2 4 6 8 10

1 4 7 10 13 16 2 5 8 11 14 17

1 3 5 7 9 11

PP 72/48 2

Profibus address 8

2-32

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2.4 Connecting the SIMODRIVE 611U drive unit

2.3.5 Connecting the ADI4 module

For the relevant data for connecting the ADI4 module, please refer to the documentation ”ADI4 − Analog Drive Interface for 4 Axes”, Product Manual.

For the configuration, please observe the specifications on the Toolbox.

Note

Make sure that your ADI4 module has firmware release 01.02.02.

2.4 Connecting the SIMODRIVE 611U drive unit

For the relevant information regarding the configuration of the interfaces and for connecting the components of the drive unit, please refer to the Documentation ”SIMODRIVE 611UE”.

Installing the Control System

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2-33

Installing the Control System

2.5 Connecting the Profibus

All stations are connected to each other via Profibus. Master is the PCU, and slaves are the SIMODRIVE 611 UE and the PP 72/48.

The baud rate of the clock−synchronous Profibus is fixed to 12 Mbaud and cannot be changed. Converters for optical fiber cable (OLMs, OLPs) or repeaters are not permitted.

Profibusinterface

Socket type: 9−pin D−Sub socket connector Max. cable length: 100 m at 12 Mbaud

Table 2-5 Female connector pin assignment

Signal

Meaning

Pin Signal

1 Shield 6 VP

2 Reserved 7 Reserved 3 RxD/TxD−P

4 CNTR−P

5 DGND

Receive/send data − plus, B line (red)

Control signal for the repeater (direction control)

Data transfer potential (ground to 5V)

8 RxD/TxD−N

9 CNTR−N

Meaning

Supply voltage for the terminators − P, (P5V)

Receive/send data − minus, A line (green)

Repeater control signal (direction control)

Note

Use the recommended Profibus connectors only. They are designed such that the ongoing P branch is disconnected when the terminator is connected.

The PB master = PCU should be connected at the start of the PB line. Make sure that the terminating resistors are only connected at the first and at the last sta-

tions. Line A green Line B red

2-34

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Installing the Control System

2.5 Connecting the Profibus

A1/B1

PCU

A1/B1

A2/B2

PP 72/48

Fig. 2-15 General design of a Profibus line

OFF

A1/B1

A2/B2

A1/B1

611 UE 611 UE

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2-35

Installing the Control System

2.6 Grounding

Ground connections

The following ground connections must be provided:

S PCU S Machine control panel (MCP) S Keyboard (KB)

When establishing the ground connections for PCU, MCP and KB, connect the grounding points to the grounding rail (Fig. 2-16).

Grounding the PP 72/48

Install the PP 72/48 in accordance with EN 60204. If a large−area, permanent metallic connection to the central grounding point is not possible via the backplane, connect the mounting plate to the grounding rail using a line >10 mm

Grounding rail

MCP

to the chassis

PCU

Fig. 2-16 Grounding diagram for installing PCU and MCP

2-36

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2.7 Power supply of PCU (X8) and PP 72/48 (X1)

Screw−terminal block

Connect the 24 V DC load power supply required for the power supply to the screw terminal block X8 or X1.

Features of the load power distribution

Danger

The 24 V DC must be generated as a functional extra−low voltage with safe electrical isolation (to IEC 204-1, Section 6.4, PELV) and be grounded by the user (make a connection from the PELV signal M to the central grounding point of the system).

Table 2-6 Electrical parameters of the load power supply

Installing the Control System

Parameter

Voltage range mean value 20.4 28.8 V Ripple 3.6 Vss

Non−periodic overvoltage 35 V

Rated current consumption 1 A Starting current 2.6 A

Table 2-7 Pin assignment of the screw terminal block X8/X1

Terminal

1 P24 24 V DC 2 M Ground (GND) 3 PE

Signal Description

min. max. Unit Conditions

Duration: 500 ms 50 s recovery time

Note

Make sure that the interconnecting cable between the power supply and the supply voltage connection (screw−terminal block X1) does not exceed a permissible length of max. 10 m.

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Installing the Control System

2.8 Displays on the PCU

Fours LEDs are installed on the front side of the PCU.

Fig. 2-17 Displays on the PCU alongside the PC card slot

ON (green) Power On NC (yellow) Sign−of−life of the NC (flashing) WD (red) Process monitoring PB (yellow) Profibus

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2.9 Displays on the PP 72/48

The status display is realized via 4 LEDs.

POWER (green) Power On READY (red) PP 72/48 is ready; no cyclic data exchange EXCHANGE (green) PP 72/48 is ready; cyclic data exchange is performed OVTEMP (red) Overtemperature display

Installing the Control System

2.9 Displays on the PP 72/48

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Installing the Control System

2.9 Displays on the PP 72/48

This sheet has been left empty for your notes.

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Commissioning

3.1 General

Start−up prerequisites

S You will need the following:

− SINUMERIK 802D User Documentation

− SINUMERIK 802D Description of Functions

− A PC for commissioning and data backup

− Tools installed from the Toolbox CD:

WinPCIN PLC802 Programming Tool SimoCom U Text Manager (is installed using the ”802D Toolbox” menu item)

S The mechanical and electrical installation of the system must be completed. S Starting up the SIMODRIVE 611 UE drive (with the Profibus option module inserted)

Start−up sequence

To commission the SINUMERIK 802D, proceed as follows:

1. Check that the PCU boots.

2. Set the language.

3. Set the required technology.

4. Set the general machine data.

5. Start up the PLC.

6. Set the axis/spindle−specific machine data.

7. Perform a dry run for the axes and for the spindle.

8. Optimize the drive.

9. Complete the commissioning; perform a data backup.

− Match the encoder to the axis / spindle.

− Match the setpoint to the axis / spindle.

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition 6FC5 697−2AA00−1BP5

3-41

Commissioning

3.1 General

3.1.1 Access levels

Protection levels

The SINUMERIK 802D provides a concept of protection levels for enabling data areas. There are the protection levels 0 to 7 whereby 0 is the highest and 7 the lowest level.

The protection levels can be set for certain function areas (e.g. program editor) using the display machine data (USER_CLASS...).

When the control system is delivered, certain default passwords are already set for the protection levels 1 to 3. If necessary, the appropriate authorized person can change these passwords.

Table 3-1 Protection level concept

Protection

level

4 to 7 No password and

Protection levels 1 ... 3

The protection levels 1 to 3 require a password. The passwords can be changed after activation. For example, if the passwords are no longer known, the control system must be reinitialized (booting with default machine data). This will reset all passwords to their defaults according to the software release you have acquired.

The password remains set until it is reset by selecting the Delete password softkey.

POWER ON will not reset the password.

Protection levels 4 ... 7

Protection level 7 is set automatically if no password is set and no protection level interface signal is set. The protection levels 4 to 7 can be set from the PLC user program even without a password by setting the bits in the user interface.

Locked by Area

0 Siemens, reserved

1 Password: SUNRISE (default) Expert mode

2 Password: EVENING (default) Machine manufacturer 3 Password: CUSTOMER (default) Authorized operator, setter

user interface from PLC NCK

Authorized operator, setter or appropriate graduations as desired

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Note for the reader

How to set the access levels is described in the User Manual: ”Operation and Programming”.

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3.1.2 Structure of machine data (MD) and setting data (SD)

Number and identifier

MD and SD are addressed via their numbers or their names (identifiers). The number and the name, as well as the activation type and the unit are displayed on the screen of the control system.

Activation

The activation stages are listed according to their priority. If any data is changed, it comes into effect after:

S POWER ON (po) Turning off / turning on the SINUMERIK 802D S NEW_CONF (cf)

With RESET at the PLC interface (V3000 0000.7)

S RESET (re) With RESET at the PLC interface (V3000 0000.7) or at the end of the pro-

gram M2/M30

Commissioning

3.1 General

S IMMEDIATELY (im) After input of the value

Protection level

For start−up or machine data input, usually, protection level 2 is required.

Unit/system of units

Depending on MD 10240 SCALING_SYSTEM_IS_METRIC, the physical units of the machine data (MD) differ as follows:

If there are machine data with no physical unit assigned, the relevant field remains empty.

Note

The default setting is MD 10240 SCALING_SYSTEM IS METRIC = 1 (metric).

MD 10240 = 1 MD 10240 = 0

mm inch

mm/min inch/min

m/s

mm/rev. inch/rev.

inch/s inch/s

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Commissioning

3.2 Turning on and booting the control system

Procedure

S Check the system visually for:

− correct mechanical design and check that all electrical connections are performed cor-

rectly.

− connected voltages

− connection of shielding and grounding.

S Connect the control system (booting in the normal mode)

Booting the control system in the normal mode

When the control system is turned on, the boot sequence is displayed on the control system with all its individual phases. Once the start screen of the user interface has appeared, the booting sequence is completed.

Booting the control system in the start−up mode

After Power ON and prompting via an appropriate message on the screen, press the SELECT key.

Once the DRAM test is completed, the START UP MENU appears on the display. Use the cursor to select an appropriate power−up/start−up mode and press INPUT to confirm.

The modes specified in the START−UP MENU have the following meanings:

S normal mode

If this option is chosen, the control system will boot with the last machine data setand the previously loaded programs.

S default data (is only displayed if protection level 1 or 2 is set)

If this option is chosen, the control system will boot with default machine data.

S software update

In this case, the control system will not boot at all. The software can only be updated if an NC card with a software update is provided.

S reload saved user data

If this option is chosen, the user data (machine data, programs, etc.) backed up to the flash memory of the control system are accepted as the current data and used for power−up.

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S PLC stop

Select PLC Stop while the control system is booting if PLC Stop can not be triggered via the user interface any more.

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3.3 Language setting

English is set for both the foreground and background languages. You can change the languages by loading new language files from the toolbox using the Text Manager.

The functions provided by the Text Manager are described in its help file.

Sequence

S Establish a V24 connection between the PC and the PCU (COM1). S Turn on the control system and wait until the control system has completed its booting

sequence without errors.

S In the ”System” operating area, set the password for protection level 2. S Preselect the > BIN format from the ”RS232 settings” operating area. S In the ”System” operating area, Data I/O > menu item, position the cursor on the line

”Start−up data PC”.

S Select the Read in softkey.

Commissioning

3.3 Language setting

S Start the Text Manager on your PC. S Use the Text Manager to select the relevant language file for your foreground or back-

ground language and transfer it to the control system.

S Restart the NC. S The desired language is now set.

Note

Make sure that the settings for the interface parameters of the PCU and of the PC are the same.

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Commissioning

3.4 Setting the technology

Note

The SINUMERIK 802D is delivered with default machine data. Load the relevant setup file from the toolbox into the control system, depending on the technology turning or milling.

The following setup files are offered to choose from:

S setup_T.cnf Turning machine with complete cycle package S setup_M.cnf Milling machine with complete cycle pack S setTra_T.cnf Turning machine with complete cycle package and the functions Transmit,

Tracyl, Spindle1, C axis and 2nd spindle technology ’turning’

S trafo_T.ini Machine data with the functions Transmit, Tracyl, Spindle1, C axis and

2nd spindle technology ’turning’

S trafo_M.ini Machine data for the Tracyl function − ”Milling” technology S adi4.ini Machine data for setting up the analog setpoint output via ADI4

The setup file must be loaded during the commissioning after booting of the control system, but prior to the general configuration.

Sequence

Note

The SINUMERIK 802D base line is supplied with default machine data. To set the turning technology, load the following setup file from the toolbox into the control system:

S setup_T.cnf Turning machine with complete cycle package

If you wish to use the analog setpoint output in conjunction with the I/O module ADI4, reload the following ini file:

S adi4.ini Machine data for setting up the analog setpoint output via ADI4

The setup file must be loaded during the commissioning after booting of the control system, but prior to the general configuration.

Note

Please always observe the readme file supplied with the ”Toolbox”. It provides up−to−date information.

S Establish an RS232 connection between the PC and the PCU (COM1). S Turn on the control system and wait until the control system has completed its booting

sequence without errors.

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S In the ”System” operating area, set the password for protection level 2. S Set the binary format.

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Commissioning

3.4 Setting the technology

S In the ”System” operating area, \ Data I/O \ menu item, position the cursor on the line

”Start−up data PC”.

S Select the Read in softkey. S Start your PC with WINPCIN. S Select the Binary format softkey, press RS232 config and set, save and activate the

relevant COM interface of your PC/PG (Save&activate softkey, Back softkey).

S Select the Send data softkey. S Select the setup file (from the toolbox) for turning or milling in the Siemens or ISO mode

(see Readme file in the Toolbox) and transfer it from your PC to the control system via WINPCIN.

S The control system boots automatically during the transmission several times. S The SINUMERIK 802D is now preset to the required technology.

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Commissioning

3.5 Entering the machine data

Overview

The most important machine data of the individual subareas are listed here to assist you. For a detailed description of the machine data and interface signals, please refer to the Descriptions of Functions (cf. cross−references in the tables of Chapter 7 ”Machine Data and Setting Data”).

Note

The default values of the machine data have been chosen such that usually no change is required.

Entering the machine data (MD)

Before you can enter the machine data, the password for protection level 2 must be set. Use the relevant softkey to select the following machine data areas and to change the ma-

chine data if necessary:

S General machine data MD 10000 ... 19999 S Channel machine data MD 20000 ... 29999 S Axis machine data MD 30000 ... 39999 S Display machine data MD 1 ... 999 S Drive machine data Parameters 599 ... 1999

The data you have entered are written to the data memory immediately. An exception is the drive machine data. To save the drive machine data permanently, use either the Save axis softkey, which can be found in the area of the drive machine data with the drives turned on, or the SimoCom U tool. If you forget to save the data, the old data is effective again after the next drive reset. To refresh the display of the drive machine data on the screen after changing, use the Refresh softkey.

The machine data is activated depending on the machine data property ”Activated”, Section

3.1.2.

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3.6 Setting the Profibus address

Certain bus configurations have already been prepared for SINUMERIK 802D. The required configuration can be set via MD 11240: PROFIBUS_SDB_NUMBER. In all cases, the configuration constitutes the maximum configuration. It is not necessary to connect all stations.

Table 3-2

Commissioning

3.6 Setting the Profibus address

MD 11240

3 PP module 1 9 −

PP module 2 8 − Single−axis power section 10 5 Single−axis power section 11 6 Twin−axis power section Drive A

4 PP module 1 9 −

PP module 2 8 − Single−axis power section 10 5 Twin−axis power section Drive A

Twin−axis power section Drive A

5 PP module 1 9 −

PP module 2 8 − Single−axis power section 20 1 Single−axis power section 21 2 Twin−axis power section Drive A

Single−axis power section 10 5

6 PP module 1 9 −

PP module 2 8 − Single−axis power section 20 1 Single−axis power section 21 2 Single−axis power section 22 3 Single−axis power section 10 5

0 PP module 1 9 −

PP module 2 8 −

PB DP station (slave) PB address Drive number

12 1

Drive B

12 1

Drive B

13 3

Drive B

13 3

Drive B

Note

The assignment between PB address and drive number is fixed and cannot be changed.

Set now the MD 11240: PROFIBUS_SDB_NUMBER according to your particular bus configuration.

Parameterize the PB addresses of the PB stations (SIMODRIVE 611 UE and PP module) as specified in the table above.

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Commissioning

3.6 Setting the Profibus address

To parameterize the drive, use the SimoCom U Parameterization and Commissioning Tool. You will need the following documentation: SIMODRIVE 611 UE Description of Functions.

Example 1:

Turning machine with one PP module, one twin−axis power section (X and Z axes) and the spindle as the single−axis power section.

Table 3-3

Example 2:

MD 11240

3 PP module 1 9 −

Single−axis power section 10 5

Twin−axis power section Drive A

PB station (slave) PB address Drive number

Drive B

12 1

Milling machine with two PP modules, two single−axis power sections (X, Z axes), one twin− axis power section (Y, C axis) and one spindle as a single−axis power section.

Table 3-4

MD 11240

5 PP module 1 9 −

PP module 2 8 − Single−axis power section 20 1 Single−axis power section 21 2 Twin−axis power section Drive A

Single−axis power section 10 5

PB station (slave) PB address Drive number

Drive B

13 3

PCU

PP 72/48

3-50

Slave 12 from example 1 has been fully replaced by slaves 20 and 21.

Is master at PROFIBUS; address cannot be changed

Is slave at PROFIBUS; max. two PP modules can be connected. The addresses are set using DIL switch S1 on the PP module.

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Commissioning

3.7 Starting up the PLC

611 UE

PB address 9 (default setting)

(PP module 1) 8

(PP module 2)

DIL switch S1 (PP module) 1 + 4 = ON

2 + 3 + 5 + 6 + 7 + 8 = OFF 4 = ON

1 + 2 + 3 + 5 + 6 + 7 + 8 = OFF

Note

The newly set PB station address is only active after POWER ON.

Is slave at PROFIBUS; the bus address is only set during commissioning using the SimoCom U commissioning tool or directly via the display and the operator terminal.

Note for the reader

SIMODRIVE 611U Description of Functions

3.7 Starting up the PLC

After starting up the Profibus, the prepared PLC user program is ready to run and can be used for further start−up. To load the PLC user program, use the Programming Tool.

For a description, please refer to Section 5.

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Commissioning

3.8 Starting up the axes/spindle

3.8.1 Setpoint/actual value assignment

The axis machine data MD 30130: CTRLOUT_TYPE can be used to switch the setpoint out- put, and MD 30240: ENC_TYPE can be used to switch the actual−value input between simulation and PROFIBUS drive.

Table 3-5

Machine data

MD 30130 Value = 0

Simulation

MD 30240 Value = 0

Simulation

Simulation Normal mode

Value = 1 In this case, the setpoint signals are

output via Profibus. Value = 1 (INCR) or 4 (EnDat)

In this case, the actual values are read in via Profibus.

Note

For simulation, MD 31130 and MD 30240 must be parameterized with ”0”.

To enable the relevant NC axis to assign its setpoint to the appropriate PROFIBUS drive, ensuring that the actual values are returned from this PROFIBUS drive, it is imperative to parameterize the machine data MD 30110: CTRLOUT_MODULE_NR and MD 30220: ENC_MODULE_NR.

Note

With 2−axis power sections, both drives (A and B) each must be assigned to one axis. Otherwise, an error message is issued during power−up (drive alarm 832 ”Profibus not clock−synchronized to master), and the entire power section is not ready for operation.

3-52

A meaningful default setting for these machine data have already been implemented in the default data record for turning and milling.

The following applies for the default data record for turning:

Axis Drive number

MD 30110 MD 30220

X1 1 12 Twin−axis: Drive A

Z1 2 12 Twin−axis: Drive B

SP 5 10 Single−axis

PROFIBUS address Power section

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3.8 Starting up the axes/spindle

The following applies for the default data record for milling:

Commissioning

Axis Drive number MD

30110

MD 30220

X1 1 12 Twin−axis: Drive A

Y1 2 12 Twin−axis: Drive B

Z1 3 13 Twin−axis: Drive A

SP 5 10 Single−axis

A1 4 13 Twin−axis: Drive B

PROFIBUS address Power section

If this default setting does not match your machine configuration, the data must be adapted accordingly.

Note

The machine data MD 31110: CTRLOUT_MODULE_NR and MD 30220: ENC_MODULE_NR must be set such that they have the same drive number because there is a fixed assignment between measuring system and motor.

Example:

The machine you want to start up is a milling machine. The milling machine possesses three axes and one spindle. The X1 and the Y1 axes are controlled by a twin−axis power section, the Z1 axis and the spindle by one single−axis power section each.

S The default data record for a milling machine (setup_m) has been loaded. S The bus configuration has been selected with MD 11240= 3. S Now, adapt the axis machine data MD 30110: CTRLOUT_MODULE_NR and MD 30220:

ENC_MODULE_NR will be adapted as follows (MD 30110 and MD 30240 must only be changed for the Z1 axis).

Axis Drive number

MD 30110 MD 30220

X1 1 12 Twin−axis: Drive A

Y1 2 12 Twin−axis: Drive B

Z1 6 11 Single−axis

SP 5 10 Single−axis

PROFIBUS address Power section

S Set the PB addresses of the drives as specified in the table above (SimoCom U). Due to

the fact that the 5th axis (A1) is not used, MD 20070: AXCONF_MACHAX_USED[4]=0 must be parameterized. This will remove the axis from the configuration of the NC.

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Commissioning

3.8 Starting up the axes/spindle

3.8.2 Default settings for the axis machine data for the feed axes

The following machine data list summarizes all default data or their recommended settings with SIMODRIVE 611 UE PROFIBUS drives connected.611

Once they have been set, the axes are ready to traverse, and only a fine adjustment (reference point approach, software limit switches, position controller optimization, speed feedforward control, lead error compensation,...) must be performed. See: /FB/ SINUMERIK 802D ”Description of Functions”

Note

For feed axes, only parameter set 1 = index [0] is used. Index [1] ... [5] must only be parameterized when using the parameter switching function (see /FB/ Chapter 3), with G331 ”Rigid tapping” or for G33 (see /FB/ Chapter 11).

MD Name Default va-

Unit Remark

lue

31030 LEADSCREW_PITCH 10 mm Leadscrew of the ballscrew

Load gear transmission ratio

31050 31060

32000 MAX_AX_VELO 10000 mm/min Maximum axis velocity

32300 MAX_AX_ACCEL 1 m/s

34200 ENC_REFP_MODE 1 1: Incremental encoder

36200 AX_VELO_LIMIT 11500 mm/min Threshold value for velocity monitoring;

DRIVE_AX_RATIO_DENOM DRIVE_AX_RATIO_NUMERA

1 1

Revolutions of the ballscrew Motor revolutions

Maximum axis acceleration

Motor order no:

1Fx6xxx−xxxxx−xAxx 0: EnDat encoder

Motor order no:

1Fx6xxx−xxxxx−xExx

setting rule: MD 36200 = 1.15 x MD 32000

Example:

Motor with incremental encoder Gear transmission ratio: 1:2

Spindle lead 5 mm Max. axis velocity 12 m/min Max. axis acceleration 1.5 m/s

Machine data settings: MD 31030 = 5

MD 31050 = 1 MD 31060 = 2 MD 32000 = 12000 MD 32300 = 1,5 MD 36200 = 13800

3-54

The axis can now be traversed. The direction of movement can be reversed using MD 32100: AX_MOTION_DIR = 1 or –1 (without influencing the control direction of the position control).

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3.8.3 Connecting a direct measuring system

Prerequisite:

Both rotary and linear measuring systems can be connected to the SINUMERIK 802D. These measuring systems must be signal generators with 1Vss sin/cos track (A, A You can connect either a measuring system with a zero mark (R, R with an EnDat interface. Measuring systems with distance−coded zero marks must not be used!

If a direct measuring system is connected, the 611UE closed−loop control module can only be operated with one axis. The PB address with the appropriate drive number for a single− axis power section must be selected based on Table 3-2. The direct measuring system must be connected to the second encoder interface (X412). switching between the direct measuring system and the motor measuring system via the PLC is not possible.

Realization:

Connect a direct measuring system with Siemens standard cable

Commissioning

3.8 Starting up the axes/spindle

, B, B).

) or a measuring system

− 6FX8002−2CG00−xxxx (incremental encoder)

− 6FX8002−2CH00−xxxx (EnDat encoder)

to the encoder interface X412 of the 611UE closed−loop control module and parameterize the drive for the direct measuring system using SimoCom U.

Special feature:

If a probe is connected when using a direct measuring system, the probe must be connected on the SIMODRIVE 611UE to the –X454 interface, terminal I0.B and parameterized via drive parameter P672 with signal number 80.

Fig. 3-1 Settings for P672

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Commissioning

3.8 Starting up the axes/spindle

Parameterization using the Drive Configuration Wizard in case of identical number of increments

The number of increments of the motor encoder is identical to the number of increments of the direct rotary measuring system.

Fig. 3-2 Display

Adaptations in the Expert list

Fig. 3-3 Values to be entered in the Expert list

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3.8 Starting up the axes/spindle

Change the process data parameterization from encoder 1 to encoder 2.

Fig. 3-4 Process data of encoder 1

Procedure:

S First, set P922 to zero; thereafter, save and press Reset. S Change now P915:6, P916:6 ... P916:10.

Commissioning

Fig. 3-5 Process data of encoder 2

Adapting the machine data in the control system

Table 3-6

Machine Data

30240 ENC_TYPE[0] 1 := Incr. encoder

31020 ENC_RESOL[0] Increments for rot. encoder 34200 ENC_REFP_MODE[0] 1 := Incr. encoder

31000 ENC_IS_LINEAR[0] 0 := Rot. encoder

31010 ENC_GRID_POINT_DIST[0] Graduations on linear scale

31040 ENC_IS_DIRECT[0] 0 := Encoder mounted directly on

Designation Remark

4 := EnDat

0 := EnDat

1 := Linear scale

the motor 1 := Encoder mounted on the load

32110 ENC_FEEDBACK_POL[0] 1 := default

13070 DRIVE_FUNKTION_MASK[X] 8000 (only applies with SW >2.1)

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−1:= Reverse direction of rotation

[X] ...drive number −1

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Commissioning

3.8 Starting up the axes/spindle

Parameterization using the Drive Configuration Wizard with different number of increments

With software version 2.1 and higher, the number of increments of the motor encoder and of the direct measuring system can be different when connecting an external rotary measuring system.

Prerequisite:

NC SW 2.1, 611U SW 05.02.04 Only possible when using a single−axis power section with PB address 20 or 10

Parameterization using the Drive Configuration Wizard

Fig. 3-6 Display

Message frame selection via PROFIBUS parameterization

Fig. 3-7

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Subsequently, save and press Reset.

Adapting the machine data in the control system

Table 3-7

Commissioning

3.8 Starting up the axes/spindle

Machine Data

13060 DRIVE_TELEGRAM_TYP[X]

[X=drive number −1] 30230 ENC_INPUT[0] 2: Encoder 2 actual value (X412) 31020 ENC_RESOL[0] Number of increments for rot.

31040 ENC_IS_DIRECT[0] 0:= Encoder 2 is mounted directly

32110 ENC_FEEDBACK_POL[0] 1:= default

34200 ENC_REF_MODE[0] 1:= Incr. encoder

13070 DRIVE_FUNKTION_MASK[X] 8000 (only applies with SW >2.1)

Designation Remark

103: n_set interface with encoder 1 and encoder 2

encoder

on the motor 1 := Encoder 2 is mounted on the load

−1:= Reverse direction of rotation

0:= EnDat

[X] ...drive number −1

3.8.4 Default settings for the axis machine data for the spindle

With SINUMERIK 802D, the spindle is a subfunction of the entire axis functionality. The machine data of the spindle are therefore to be found amongst the axis machine data (MD 35xxx).

A description of the basic setting for the spindle can be found in Chapter 4.

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Commissioning

3.9 Completing the start−up

After the start−up by the machine manufacturer has been completed, it is recommended to carry out a data backup prior to delivery to the end customer:

1. Performing an internal data backup (at least protection level 3 required):

− Select the Save data softkey.

2. Resetting the access level:

− Select the Delete passw. softkey.

3.10 Service display for the axis drive behavior

Servo Trace

For axis service, the Servo trace function has been implemented in the ”Diagnostic” menu to represent axis signals graphically.

The trace function is selected in the operating area System\Service display\Servo Trace.

Note for the reader

/BH/ SINUMERIK 802D ”Operation and Programming”, Chapter 7

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Starting up the Spindle

With SINUMERIK 802D, the spindle is a subfunction of the entire axis functionality. The machine data of the spindle are therefore to be found amongst the axis machine data (MD 35xxx).

For this reason, data must also be entered for a spindle; this data has already been described in conjunction with the start−up of feed axes.

The following variants are offered for the spindle drive:

S Digital spindle drive with spindle actual−value encoder integrated into the motor S Digital spindle drive with directly mounted spindle actual−value encoder S Digital spindle drive with spindle actual−value encoder integrated into the motor, gearbox

and external zero mark (BERO)

S Digital spindle drive without encoder and without external spindle actual−value encoder S Digital spindle drive without encoder and with external TTL encoder S Analog spindle (via 611 U(E)) with spindle actual−value encodermounted directly on the

motor

Note

For spindles without gear stage switching, only gear stage 1 = index [1] will be used. Index [2] ... [5] must only be parameterized when using the gear stage switching function (see /FB/ Chapter 5).

Table 4-1

30200 NUM_ENCS 1 0: Dig. spindle without speed actual−va-

31050

31060

35100 SPIND_VELO_LIMIT 10000 r.p.m. Maximum spindle speed

35130 GEAR_STEP_MAX_VELO_LI-

DRIVE_AX_RATIO_DENOM[1] DRIVE_AX_RATIO_NU-

MERA[1]

MIT[1]

Name Default va-

lue

500 r.p.m. Max. speed in gear stage 1

Unit Remark

lue encoder (AM mode = operation without encoder)

1: Dig. spindle with speed actual−value encoder integrated into the motor (1PH7 motor)

Load gear transmission ratio

Load revolutions

Motor revolutions

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Starting up the Spindle

35200

36200 AX_VELO_LIMIT[1] 11000 r.p.m. Threshold value for velocity monitoring;

GEAR_STEP_SPEEDCTRL_A CCEL[1]

30 rev./s

Acceleration in the speed controlled mode

setting rule: MD 36200 = 1.1 x MD 35100

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Starting up the Spindle

4.1 Digital spindle drive with spindle actual−value encoder integrated into the motor

For a digital spindle drive (PROFIBUS) with spindle actual−value encoder integrated into the motor, the machine data parameterized in Table 4-1 must be parameterized.

Example

Motor with incremental encoder Gear transmission ratio: 1:2

Max. spindle speed 9,000 r.p.m. Max. spindle acceleration 60 rev./s

Machine data settings: MD 31050 = 1

MD 31060 = 2 MD 35100 = 9000 MD 35130 = 9000 MD 35200 = 60 MD 36200 = 9900

For the spindle, it can be necessary to adapt the following additional machine data.

Table 4-2 Additional machine data

Name Default va-

lue

34000 REFP_CAM_IS_ACTIVE 1 0: without reference point cam

34060 REFP_MAX_MARKER_DIST 20 degrees 720_ = two spindle revolutions

34110 REFP_CYCLE_NR 1 ... 5 0: The spindle is not involved in chan-

35300 SPIND_POSCTRL_VELO 500 r.p.m.

36000 STOP_LIMIT_COARSE 0.04 degrees 0.4

36010 STOP_LIMIT_FINE 0.01 degrees 0.1

36030 STANDSTILL_POS_TOL 0.2 degrees 1

36060 STANDSTILL_VELO_TOL 0.0139 r.p.m. 1 (interface signal ”Axis/spindle stop-

36400 CONTOUR_TOL 1 degrees 3

Unit Recommendation/remark

nel−specific referencing.

ped” V390x 0001.4)

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Starting up the Spindle

4.2 Digital spindle drive with spindle actual−value encoder (TTL) mounted directly on the motor

Procedure

S Parameterize the spindle as specified in Table 4-1. S Connect the TTL encoder to −X472 on the SIMODRIVE 611 UE closed−loop control

module for the spindle.

S Change the message frame type of the spindle to type 104 −>

MD 13060: DRIVE_TELEGRAM_TYPE[4]=104.

S Switch the encoder input of the spindle to the second encoder −>

MD 30230: ENC_INPUT_NR=2.

S Adapt the number of increments of the spindle encoder −>

MD 31020: ENC_RESOL = xxxx.

S Parameterize the resolver gearbox:

MD 31070: DRIVE_RATIO_DENOM (encoder revolutions)

Example

MD 31080: DRIVE_ENC_RATIO_NUMERA (load revolutions) MD 31040: ENC_IS_DIRECT 0: The spindle encoder is mounted on the

motor side. 1: The spindle encoder is mounted on the load side.

S In some cases, the actual value of the position encoder must be inverted (depending on

the mounting direction) −> MD 32110: ENC_FEEDBACK_POL = −1.

S Set the drive parameters (SimoCom U).

P890 − activate the angular encoder/encoder interface= 4 P922 − select the message frame PROFIBUS = 104 Save + PowerOn

Spindle with incremental encoder mounted on the chuck TTL encoder with 2,500 pulses/revolution Resolver gearbox transmission ratio: 1:3

Encoder

Machine data settings: MD 13060[4] = 104

MD 30230 = 2 MD 31020 = 2500 MD 31040 = 1 MD 31070 = 3 MD 31080 = 1 MD 32110 = 1

P890 = 4 P922 = 104

Motor

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Note

If a resolver gearbox with a transmission ratio other than 1:1 is installed, positioning of the spindle can only be realized using a BERO.

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Starting up the Spindle

4.3 Digital spindle drive with the encoder integrated into the motor, gearbox and external zero mark via BERO

Prerequisites

An inductive proximity switch, type Siemens 3RG4050−0AG05, is used. With the approximation, a positive +24V edge is switched.

Parameterization

Fig. 4-1

611 UE (firmware release ≥ 03.01.06): Parameter P660 = 79 611 UE (firmware release ≥ 03.01.06): Parameter P879.13 = 1 Thus, instead of the internal zero mark, the BERO signal connected to terminal I0.A is evaluated.

802D: MD 34200: ENC_REFP_MODE = 7 Thus, a synchronization is only performed if a speed has been defined (MD 34040) using the BERO signal. This is imperative, as a BERO always has certain signal runtimes. This is the only way to guarantee that the synchronization is always performed to the same position.

802D: MD 34040: REFP_VELO_SEARCH_MARKER = 200 r.p.m. The BERO signal is synchronized at this speed.

802D: MD 34060: If necessary, adapt REFP_MAX_MARKER_DIST accordingly. If SPOS is triggered from the standstill, the spindle is first accelerated to the speed entered in MD 34040, thereafter, the BERO edge is synchronized, and, finally, the spindle is positioned. The direction of rotation depends on: MD 35350: SPIND_POSITIONING_DIR (3=CW / 4=CCW). In the CW direction of rotation, the synchronization is performed to the falling edge, and in the CCW direction − to the rising edge.

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Starting up the Spindle

4.3 Digital spindle drive with the encoder integrated into the motor, gearbox and external zero mark via BERO

PLC

To ensure that a resynchronization is performed when switching from the speed−controlled mode to the positioning mode, the interface signal V380x2001.4 ”Resynchronize spindle when positioning” must be linked with V390x0001.5 ”Position controller active”.

Fig. 4-2

Important

switching from the speed−controlled to the positioning mode must only be performed with the spindle rotating and from a defined direction. Otherwise, the spindle is mispositioned! Correct positioning can be guaranteed by programming ACP or ACN.

SPOS = ACP(0) Thus, if first M4 Sxxx was programmed, the spindle will decelerate to the standstill, thereaf-

ter accelerate to the synchronization speed CW, then synchronize and position.

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4.4 Digital spindle without external encoder

It is also possible to configure a motor without encoder (standard motor, non−Siemens mo- tor) as the spindle motor. The KTY of the motor can be evaluated directly at the encoder interface X411 via pins 13 and 15.

4.4.1 Parameterization using the Drive Configuration Wizard

Starting up the Spindle

Fig. 4-3 Display

Fig. 4-4 Display

4.4.2 Parameterization using the Expert List

Table 4-3 Parameters to be entered in the Expert List

Parameters

922 PROFIBUSmessage frame selection 0 Save + Power On Reset 915:6 Process data setpoint assignment 0

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Text Value Remark

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Starting up the Spindle

4.4 Digital spindle without external encoder

Table 4-3 Parameters to be entered in the Expert List, cont’d

Parameters RemarkValueText

916:6 Process data actual value assign-

ment

916:7 Process data actual value assign-

ment

916:8 Process data actual value assign-

ment

916:9 Process data actual value assign-

ment

916:10 Process data actual value assign-

ment Optional 1608 Fixed temperature 0 Save + Power On Reset 1602 Motor overtemperature warning

threshold 1607 Motor temperature shutdown limit 150

0 Save + Power On Reset

120

The temperature evaluation of the KTY connected to terminal X411 is activated and can be used if P1608=0. The evaluation is provided via pins 13 and 25.

For example, if P1608=60 is set, the motor temperature is not evaluated; a temperature of 60_C is used for internal calculation.

Important

It is imperative to observe the order of the parameters listed above; in addition, ”Save + Power On Reset” must be carried out whenever specified.

4.4.3 Adapting the machine data in the control system

Table 4-4

30130 CTRLOUT_TYPE[0] 1 30240 ENC_TYPE[0] 0

If the spindle does not possess an encoder, it will not be possible to display the actual speed. The display on the NC will therefore always remain zero.

With software versions higher than 2.01.05 or with SINUMERIK 802D−bl, the following machine data must be set for the expert password:

MD Designation Value Remark

13070 DRIVE_FUNKTION_MASK[X] 8000 [X] corresponds to the drive num-

Designation Value Remark

ber −1

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Starting up the Spindle

4.5 Digital spindle without encoder with external TTL encoder

It is also possible to configure a motor without encoder (standard motor, non−Siemens mo- tor) as the spindle motor. The external TTL encoder is used to acquire the spindle speed.

This configuration should not be used for positioning. Due to the lack of speed acquisition at the spindle motor, the spindle is always in the toque−controlled operation. This may result in thermal problems and inaccuracies.

Merely the TTL encoder is connected to the 611UE controller module via the angular encoder interface. The KTY of the motor can be evaluated at the encoder interface X411 via pins 13 and 25.

4.5.1 Parameterization using the Expert List

Table 4-5 Parameters to be entered in the Expert List

Parameters

890 Activating the angular encoder/enco-

der interface 922 PROFIBUSmessage frame selection 0 Save + Power On Reset 915:6 Process data setpoint assignment 50017 916:6 Process data act. value assignment 50018 916:7 Process data act. value assignment 50019 916:8 Process data act. value assignment 50019 916:9 Process data act. value assignment 50020 916:10 Process data actual value assign-

ment 1006 Encoder interface mod. code number 99 Save + Power On Reset 1005 Encoder interface mod. code number 2500 Save + Power On Reset Optional 1608 Fixed temperature 0 Save + Power On Reset 1602 Motor overtemperature warning

threshold 1607 Motor temperature shutdown limit 150

Text Value Remark

4 Save + Power On Reset

50020 Save + Power On Reset

120

The temperature evaluation of the KTY connected to terminal X411 is activated and can be used if P1608=0. The evaluation is provided via pins 13 and 25.

For example, if P1608=60 is set, the motor temperature is not evaluated; a temperature of 60_C is used for internal calculation.

Important

It is imperative to observe the order of the parameters listed above; in addition, ”Save + Power On Reset” must be carried out whenever specified.

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Starting up the Spindle

4.5 Digital spindle without encoder with external TTL encoder

4.5.2 Adapting the machine data in the control system

Table 4-6

30130 CTRLOUT_TYPE[0] 1 30240 ENC_TYPE[0] 1 31020 ENC_RESOL[0] 2500 32110 ENC_FEEDBACK_POL[0] −1 1: = default

Designation Value Remark

−1:= Control direction inverted

With software versions higher than 2.01.05 or with SINUMERIK 802D−bl, the following machine data must be set for the expert password:

MD Designation Value Remark

13070 DRIVE_FUNKTION_MASK[X] 8000 [X] corresponds to drive number

”−1”.

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Starting up the Spindle

4.6 Analog spindle (via 611 U(E)) with with spindle actual−value encoder mounted directly on the motor

The analog spindle function uses the analog output of the SIMODRIVE 611 UE closed−loop control module as the setpoint output and die the encoder interface (−X472) as the actual− value input for a TTL encoder. A digital feed axis is used as the transport axis for the setpoint and actual values of the analog spindle.

The servo enable for the analog spindle is output via the digital outputs, and the analog setpoint via terminal 75.A / 15 of the transport axis.

There are three modes:

1. MD 30134: IS_UNIPOLAR_OUTPUT =0 Bipolar spindle + Digital output O0.A −> Servo enable

2. MD 30134: IS_UNIPOLAR_OUTPUT =1 Unipolar spindle 0...+10V

(enable and direction signals)

Digital output O0.A −> Servo enable Digital output O1.A −> Direction of rotation

3. MD 30134: IS_UNIPOLAR_OUTPUT =2 Unipolar spindle 0...+10V

(CW enable, CCW enable)

Digital output O0.A −> CW enable Digital output O1.A −> CCW enable

Important

In case of RESET, a setpoint is output at the analog output of the 611 UE closed−loop con- trol module. It is therefore imperative to connect the servo enable for the analog spindle to terminal O0.A of the transport axis.

Important

Transport axis can only be drive A of the spindle−axis power section with PB address 10 and drive number 5 or drive A of the twin−axis module with PB address 12 and drive number 1 (see also Table 2-3).

10V

When configuring the axes, first define the transfer axis, and then the analog spindle. Example: X, Z, SP, A Only the X or Z axis may be configured as a transfer axis.

Example

The example below will use the first machine axis (X1) as the transport axis. X1 will be drive A on a 611 UE closed−loop control module with PROFIBUS address 12.

In the 802D, the spindle is parameterized as the third machine axis (SP) (standard data record for turning). This spindle is an analog spindle with +/− 10V interface. The maximum speed in 9,000 r.p.m. at 10 V in this example.

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Starting up the Spindle

4.6 Analog spindle (via 611 U(E)) with with spindle actual−value encoder mounted directly on the motor

Only the additional machine data required for starting up an analog spindle will be dealt with in the following. The general machine data for configuring an analog spindle are listed in the table below.

Table 4-7 Settings for the example

Transport axis X1

(machine axis 1)

Connections required between the transport axis X1 and the analog spindle SP

Terminal 75.A to be connected to Terminal 15 to be connected to

Terminal O0.A to be connected to

−X472 to be connected to

NC machine data MD 13060: DRIVE_TELEGRAM_TYPE[0] = 0

([0] corresponds to drive number − 1) MD 13070: DRIVE_FUNCTION_MASK[0] = 8000 (with the 802D,

only valid from software release higher than 2.1.5) ([0] corresponds to drive number − 1)

Drive data If necessary, adapt the monitoring data

P890 Activate angular encoder/encoder interface= 4 P922 Message frame selection PROFIBUS = 104

Save + RESET

e.g. terminal 56 (analog setpoint input) e.g. terminal 14 (analog setpoint input)

e.g. terminal 65 (servo enable) TTL encoder 5V

MD 30110: CTRLOUT_MODULE_NR[0,AX3]=1

(drive number of the transport axis)

MD 30120: CTRLOUT_NR[0,AX3]=2 MD 30130: CTRLOUT_TYPE[0,AX3]=1

MD 30220: ENC_MODULE_NR[0,AX3]=1

(drive number of the transport axis)

MD 30230: ENC_INPUT_NR[0,AX3]=2 MD 30240: ENC_TYPE[0,AX3]=1

MD 31020: ENC_RESOL[0,AX3]=2500

(number of increments of the TTL encoder)

MD 32110: ENC_FEEDBACK_POL[0,AX3]=−1

(if necessary, invert the actual value)

MD 32250: RATED_OUTVAL[0,AX3]=100

MD 32260: RATED_VELO[0,AX3]=9000

(adjust the analog interface) MD 34060: REFP_MAX_MARKER_DIST[0,AX3]=360 MD 35300: SPIND_POSCTRL_VELO=50

(speed at which the position controller becomes active with SPOS)

MD 36000: STOP_LIMIT_COARSE[AX3]=10 MD 36010: STOP_LIMIT_FINE[AX3]=10 MD 36030: STANDSTILL_POS_TOL[AX3]=10 MD 36400: CONTOUR_TOL[AX3]=40

Analog spindle SP

(machine axis 3)

P915[8] Process data setpoint assignment PB = 50103 P915[9] Process data setpoint assignment PB = 50107 P922 Message frame selection PROFIBUS = 0

Save + RESET

Parameterize analog output 75.A/15 to ”DAC1 signal from PROFIBUS PPO”

4-72

Symmetrize analog output: MD 36720 DRIFT_VALUE=0,3891%

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Starting up the Spindle

4.6 Analog spindle (via 611 U(E)) with with spindle actual−value encoder mounted directly on the motor

Table 4-7 Settings for the example, cont’d

Transport axis X1

(machine axis 1)

Parameterize digital outputs O0.A and O1.A to ”Selection via PROFIBUS”

Analog spindle SP

(machine axis 3)

Save + RESET

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Starting up the Spindle

ded)

4.7 Analog axis/spindle with TTL encoder via ADI4

Both rotary and linear 5V TTL square−wave encoders can be connected to SINUMERIK 802D. With this ADI4, up to 4 drives with analog setpoint interface can be connected.

Measuring systems that can be connected

S Incremental TTL encoder (for the number of increments, see Tables 4-9/4-10), difference

transfer using 5 V square wave signals (RS422 standard).

Configuration

With 5 analog axes, 2 ADI4 modules must be used. Depending on the encoder pulse number selected from Table 4-9 or 4-10, either SDB 1_ADI4 or SDB 2_ADI4 must be loaded.

The ADI4 modules have the Profibus addresses 15 and 16 assigned as follows:

Table 4-8 Assignment of the PB addresses

MD 11240

0 PP module 1 9 − (1_ADI4 or 2_ADI4 are loa-

PP module 2 8 − 1st ADI4 drive 1

2nd ADI4 drive 1

PB (slave) PB address Drive number

16 1 Drive 2 Drive 3 Drive 4

15 5 Drive 2 Drive 3 Drive 4

2 3 4

6 7 8

The following tables show the fixed assignment of the axes to the TTL encoders which can be connected.

Table 4-9 SDB: 1_ADI4

PROFIBUS address

Axis 1st axis 2nd axis 3rd axis 4th axis Increments 2500 2500 2500 1024

PROFIBUS address 15

Axis 1st axis 2nd axis 3rd axis 4th axis Increments 1024 18000 9000 2500

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Table 4-10 SDB: 2_ADI4

PROFIBUS address

Axis 1st axis 2nd axis 3rd axis 4th axis Increments 2048 2048 2048 1024

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Table 4-10 SDB: 2_ADI4, cont’d

Starting up the Spindle

4.7 Analog axis/spindle with TTL encoder via ADI4

PROFIBUS address

Axis 1st axis 2nd axis 3rd axis 4th axis Increments 1024 18000 9000 2048

Note for the reader

Toolbox, siemense.txt and ADI4_SDB.pdf

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Starting up the Spindle

4.8 Digital axis/spindle with direct measuring system (TTL) via ADI4

Up to four direct 5V TTL square−wave encoders can be connected to SINUMERIK 802D via max. one ADI4.

Measuring systems that can be connected

S 5V incremental TTL encoder (increments: 4x2,500 or 4x5,000), differential transfer using

5 V square−wave signals (RS422 standard).

Configuration

You can use an ADI4 module with three 611 U modules in 2 different variants. Either of the SDBs DMS1_ADI4 or DMS2_ADI4 can be loaded.

The ADI4 module have the Profibus address 15 and is assigned as follows: S Variant 1: SDB :DMS1_ADI4

PP module 1 PB address 9 PP module 2 PB address 8 Single−axis power section PB address 10 Twin−axis power section PB address 12 Twin−axis power section PB address 13 ADI4: 4 x 2,500 steps/rev. PB address 15

S Variant 2: SDB :DMS2_ADI4

PP module 1 PB address 9 PP module 2 PB address 8 Single−axis power section PB address 10 Twin−axis power section PB address 12 Twin−axis power section PB address 13 ADI4: 4 x 5,000 steps/rev. PB address 15

The table below shows an overview illustrating possible applications and the machine data assignment:

Table 4-11 SDB: DMS1_ADI4

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PROFIBUS address

Axis 1st axis 2nd axis 3rd axis 4th axis Increments 2500 2500 2500 2500 Setpoint:

Drive no. MD 30110 Actual value:

Drive no. MD 30220

1 2 3 4

6 7 8 9

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4.8 Digital axis/spindle with direct measuring system (TTL) via ADI4

Table 4-12 SDB: DMS2_ADI4

Starting up the Spindle

PROFIBUS address

Axis 1st axis 2nd axis 3rd axis 4th axis Increments 5000 5000 5000 5000 Setpoint:

Drive no. MD 30110 Actual value:

Drive no. MD 30220

1 2 3 4

6 7 8 9

The axes are assigned correspondingly as per the particular application.

Note for the reader

Toolbox, siemense.txt and ADI4_SDB for DMS.pdf

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Starting up the Spindle

4.8 Digital axis/spindle with direct measuring system (TTL) via ADI4

This sheet has been left empty for your notes.

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Starting up the PLC

General

The PLC is intended to control machine−related functional sequences. It is realized as a software PLC.

The user program − a PLC cycle − is always executed in the same order of sequence.

S Refresh of the process image (inputs, user interface, timers) S Processing of communication requests (operator panel, PLC 802 programming tool, ver-

sion 3.0 and higher)

S Editing of the user program S Evaluation of alarms S Output of the process image (outputs, user interface)

During the cycle, the PLC executes the user program from the first to the last operation. The user program accesses the hardware inputs/outputs only via the process image and not directly. The PLC refreshes the hardware I/Os at the beginning or end of program execution. Thus, these signals are stable over a whole PLC cycle.

The user program can only be created using the PLC 802 Programming Tool, version 3.1 and higher, with the S7−200 programming language using ladder diagram. Ladder diagram is a graphical programming language for representing electric circuit diagrams.

Important

PLC 802 Library with a description, which can be installed from the toolbox CD is offered as the basis for the PLC user program. The PLC 802 Library constitutes a subroutine library and contains one sample program each for a turning and for a milling machine.

Note

If the stop and reset buttons on the machine control panel are not realized as normally closed contacts, an open circuit cannot be detected.

Monitoring can be performed using software solutions, as shown in the example MCP_802D (SBR 34) from the subroutine library.

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Starting up the PLC

5.1 Commissioning the PLC

By default, the user program of the SINUMERIK 802D only consists of a NOP (”no operation”) instruction and is stored in the permanent memory. The user program addressing the particular requirements of the machine is to be created by the user himself.

5.2 Start−up modes of the PLC

Table 5-1 Start−up modes

Selection Reaction

PCU

Switch−on

(802D)

Normal booting Normal booting User pro-

Booting with default values

Booting with saved data

PLC stop after POWER ON

PCU

Start−up menu

(802D)

NCK start−up *

Booting with default values

Booting with saved data

PT PLC 802

(PC)

PLC stop possible either in Run or in Stop

PLC

program

preselec-

tion

gram ***

User program ***

unchanged Stop unchanged Acceptance of

Program

status

Run unchanged Acceptance of

Run deleted Default PLC

Run saved

Retentive

data

(battery bak-

ked)

data

MD for the PLC in the

user interface

the active PLC MD

Saved PLC MD

the active PLC MD

PLC start−up **

Cold restart Run (after

Stop)

Cold restart and debug mode

Overall reset User pro-

Overall reset and debug mode

* Hardkey System / Softkey Start up switch / NCK ** Hardkey System / Softkey Start up switch / PLC

*** is loaded from the permanent memory into the RAM

User program ***

gram ***

User program ***

Run unchanged Acceptance of

the active PLC MD

Stop unchanged Acceptance of

the active PLC MD

Run deleted Acceptance of

the active PLC MD

Stop deleted Acceptance of

the active PLC MD

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Starting up the PLC

5.2 Start−up modes of the PLC

Thanks to the debug mode (see ”Operation and Programming”, Chapter 7), the PLC remains in PLC Stop after booting of the control system. All start−up modes set via softkey only come into effect when the control system is booted the next time.

The ”Run” mode activates the cyclic operation. The following actions are triggered in the ”Stop” mode:

S All hardware outputs are disabled. S Profibus DP is inactive. S No cyclic operation (the active user program is not executed). S The process image is no longer refreshed (it is frozen). S EMERGENCY STOP active.

Only in the ”Stop” mode can the user load a corrected or new project into the control system. The user program only becomes effective when the control system is booted the next time or if the ”Run” mode is selected.

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Starting up the PLC

5.3 PLC alarms

The control system displays max. 8 PLC alarms (system alarms or user alarms). The PLC manages the alarm information per PLC cycle. It saves / cancels the alarms ac-

cording to their times of occurrence. The first alarm in the list is always the alarm last occurred.

If more than 8 alarms have occurred, the first seven alarms and the newest alarm with the highest cancel priority are displayed.

Alarm response and cancel criteria

In addition, the alarm responses are managed by the PLC. The alarm responses always come into effect, irrespective of the number of active alarms. Depending on the type of the alarm response, the PLC will trigger the required action.

A cancel criterion must be defined for each alarm. The PLC uses the cancel criterion SELF− CLEARING by default (see ”Configuring user alarms”).

Cancel criteria are: S POWERONCLEAR: The alarm is canceled by turning off / turning on the control system

(POWER ON).

S CANCELCLEAR: The alarm is canceled by pressing the Cancel key or the Reset key

(analogously to the NCK alarms). S SELF−CLEARING: The alarm is canceled, since the alarm cause is no longer present. The cancel conditions have the following priority:

S POWERON CLEAR − system alarms ( highest priority ) S CANCEL CLEAR − system alarms S SELF−CLEARING − system alarms S POWERON CLEAR − user alarms S CANCEL CLEAR − user alarms S SELF−CLEARING − user alarm ( lowest priority )

The responses to be triggered by the alarm in question in the PLC are defined for each alarm. The PLC uses the alarm response SHOWALARM by default.

Alarm responses are: S PLC stop: The user program is not executed any more, Profibus DP is inactive, and the

hardware outputs are disabled.

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S EMERGENCY STOP: Once the user program is executed, the PLC transmits the EMER-

GENCY STOP signal to the NCK via the user interface. S Feed disable: Once the user program is executed, the PLC transmits the feed disable

signal to the NCK via the user interface. S Read−in disable: Once the user program is executed, the PLC transmits the read−in dis-

able signal to the NCK via the user interface.

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S NC Start inhibited: Once the user program is executed, the PLC signals the ”NC start

inhibited” signal to the NCK via the user interface.

S SHOWALARM : This alarm has no alarm response.

5.3.1 General PLC alarms

Note for the reader

SINUMERIK 802D Diagnostics Guide

5.3.2 User alarms

The user interface ‘’ 1600xxxx ‘’ provides the subareas (0, 1) for the user to define user

alarms.

Starting up the PLC

5.3 PLC alarms

S Subarea 0: 8 x 8 bits to set the user alarms (0 −>1 edge)

Byte 0 : Bit 0 => 1st user alarm ” 700000 ” Byte 1 : Bit 0 => 9th user alarm ” 700008 ” Byte 7 : Bit 7 => 64th user alarm ” 700063 “

A new user alarm is activated with the relevant bit (subarea 0) via a 0/1 edge.

S Subarea 1: User alarm variables

Subarea 1 is intended for additional user information; it can only be read / written as a double−word.

S Subarea 2: Alarm response

Byte 0 : Bit 0 => NC start inhibited

Bit 1 => Read−in disable Bit 2 => Feed disable for all axes Bit 3 => EMERGENCY STOP Bit 4 => PLC STOP

By using subarea 2, the user can evaluate the active alarm responses; this subarea is read−only.

Self−clearing user alarms must be canceled by the user by resetting the appropriate bit in

subarea 0 (1 −> 0 edge).

Other user alarms are canceled by the PLC after detecting the relevant cancel condition for

the appropriate user alarms. If the bit of the user alarm, however, is still present, the alarm

recurs.

Effect of a user alarm

User alarms have a higher priority than the appropriate signal in the user interface (e.g. NC

start inhibited, read−in disable, feed disable and EMERGENCY STOP).

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Starting up the PLC

5.3 PLC alarms

Configuring user alarms

A configuration byte is provided for each alarm. The user alarms can be configured by the user in the machine data 14516: USER_DATA_PLC_ALARM.

Default setting of MD 14516[0...63]: 0 => SHOWALARM/SELF−CLEARING user alarm Structure of a configuration byte:

S Bit0 − bit5 : Alarm responses S Bit6 − bit7 : Cancel criteria

Alarm responses: Bit0 − bit 5 = 0: Showalarm (default)

Cancel criteria: Bit6 + bit7 = 0: SELF−CLEARING alarm (default)

Bit0 = 1: NC start inhibited Bit1 = 1: Read−in disable Bit2 = 1: Feed disable for all axes Bit3 = 1: EMERGENCY STOP Bit4 = 1: PLC stop Bit5 = reserved

Bit6 = 1 : CANCELCLEAR alarm Bit7 = 1 : POWERONCLEAR alarm

Alarm texts

The alarm response to PLC Stop always has the cancel condition POWER ON.

The user are offered two options of defining his own alarm texts: S via the System hardkey> PLC softkey > Edit PLC txt (cf. ”Operation and Program-

ming”, Chapter 7) S by using the toolbox: Editing and loading the alarm text file using the text manager If no alarm text is assigned by the user, only the alarm number is displayed.

The % character in the alarm text denotes an additional variable. The variable type is the form of representation of the variable.

The following variable types are possible:

S %D integer decimal number S %I integer decimal number S %U decimal number without sign S %O integer octal number S %X integer hexadecimal number S %B binary representation of a 32−bit value

5-84

S %F 4−byte floating point number

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Examples of user alarm texts (Note: The text after the ”//” is a comment and is not dis-

played.)

S 700000 ‘’ ‘’ // only the user alarm number

S 700001 ‘’ Hardware limit switch + of the X axis’’

S 700002 ‘’ %D ‘’ // only a variable as an integer decimal number

S 700003 ‘’ Alarm number with a fixed alarm text and the variable %X ‘’

S 700004 ‘’ %U Alarm number with variable and fixed alarm text ‘’

S 700005 ‘’Axis monitoring active : %U’’

Display: 700005 ‘’Axis monitoring active : 1

or 700005 Axis monitoring active : 3

5.4 PLC programming

The PLC user program is created using the PLC 802 Programming Tool.

Starting up the PLC

5.4 PLC programming

The handling of this tool for an S7−200 is described in the documentation ”SIMATIC S7−200

Automation System Manual”. The PLC 802 Programming Tool constitutes a subset of this

documentation.

Compared to the S7− 200 MicroWin base system, the following is to be observed:

S The user program can only be programmed in ladder diagram.

S Only a subset of the S7−200 programming language is supported.

S The compilation of the user program is performed offline on a PG/PC or automatically

when downloading into the control system.

S The project can be loaded into the control system (download).

S It is also possible to load the project from the control system (upload).

S Indirect data addressing is not possible. Thus, no programming errors will occur during

the runtime.

S The user must manage the data and process information type−specifically.

Example: Information 1 T value Memory size DWord (32−bit) Information 2 Override Memory size Byte (8−bit)

User data Byte 0 DWord (information 1) Byte 4 bytes (information 2)

The user must not access this data together; otherwise, he should have to observe the data access.

S Furthermore, the alignment of the data in the memory model and their types must be ob-

served for all data.

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5.4 PLC programming

Example:

Memory bits MB0.1,MB3.5

Memory bytes MB0,MB1,MB2

Memory word MW0,MW2,MW4

MW3, MW5 ... are not permissible

Memory double wordsMD0,MD4,MD8

MD1,MD2,MD3, MD5 ... are not permissible

Table 5-2 PLC data types permitted in the control system

Data type

BOOL 1 Bit 1 0.1 − BYTE 1 byte 1 00 ... FF 0 ... +255 WORD 2 bytes 2 0000 ... FFFF −32 768 ... + 32 767 DWORD

(Double Word)

REAL 4 bytes 4 − $10

Size Address

alignment

4 bytes 4 0000 0000 ... FFFF FFFF −2 147 483 648 ...

Range for logical operations Range for arithmetical operations

+2 147 483 647

−37

... $10

PLC project

The PLC 802 Programming Tool always manages one project (combinational logic, symbols and comments). All important information of a project can be stored in the control system via a download. The information is transmitted from the control to the PC via upload.

The control system can save max. 6,000 instructions and 1,500 symbols. The PLC memory required is influenced by the following components:

S number of instructions S number and length of the symbol names S number and length of the comments

S7−200 Ladder Diagram

The addresses and operations can be defined using the representation type ”International”. When using the ladder diagram, the user programs his program in networks. Each network corresponds to a certain logic reflecting a certain sequence. The basic elements of a ladder diagram are contacts, coils and boxes. The contacts, in turn, are divided into normally opened and normally closed contacts. Each coil corresponds to a relay. Boxes are used to represent a certain function. A box can be activated using an enable bit.

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5.4.1 Command overview

Table 5-3 Operand identifier

Starting up the PLC

5.4 PLC programming

Operand identifier

Description Area

V Data V1000 0000.0 to V7999 9999.7

T Timers T0 to T15 (100 ms)

T16 to T39 (10 ms)

C Counter C0 to C31

I Image of digital inputs I0.0 to I17.7 Q Image of digital outputs Q0.0 to Q11.7 M Flags M0.0 to M383.7

SM Special bit memory SM0.0 to SM 0.6

(see Table 5-6)

AC ACCU AC0 ... AC3

L Local data L0.0 to L51.7

Table 5-4 Forming the address in the V area (see ”User interface”)

Type identifi-

cation (mo-

dule no.)

(10−79)

Area no.

(channel/

axis no.)

(00−99)

Subarea Offset Addressing

(0−9)

000

(000−999)

symbolic

(8−digit)

Table 5-5 802D Operand Ranges

Access Method

Valid Operand Ranges for

Programming 802D

Bit Access (Byte.Bit) V(1000 0000.0−7900 9999.7)

I(0.0−17.7) Q(0.0−11.7) M(0.0−255.7) SM(0.0−0.7)

− T(0−39) C(0−31)

Byte Access VB(1000 0000−7999 9999)

IB(0−17) QB(0−11 ) MB(0−383) AC(0−3) SMB(0)

−

KB (Constant)

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5.4 PLC programming

Table 5-5 802D Operand Ranges

Word Access VW(1000 0000−7999 9998)

Double Word Access VD(1000 0000−7999 9994)

Access Method Valid Operand Ranges for

Programming 802D

T(0−39) C(0−31) IW(0−16) QW(0−10) MW(0−382) AC(0−3)

−

KW (Constant)

ID(0−14) QD(0−8) MD(0−380) AC(0−3)

−

AC(0−3) KD (Constant)

Table 5-6 Special bit memory SM Bit Definition

SM bits

Description

SM 0.0 Bit memory with defined ONE signal SM 0.1 Initial position : first PLC cycle ‘1’, subsequent cycles ‘0’ SM 0.2 Buffered data lost − only valid in the first PLC cycle

(‘0’ − data o.k., ‘1’ − data lost) SM 0.3 POWER ON: first PLC cycle ‘1’, subsequent cycles ‘0’ SM 0.4 60 s clock (alternating ‘0’ for 30 s, then ‘1’ for 30 s) SM 0.5 1 s clock (alternating ‘0’ for 0.5 s, then ‘1’ for 0.5 s) SM 0.6 PLC cycle clock (alternating one cycle ‘0’, then one cycle’)

The user can only view the statement list (STL) in PT802 under ”View STL”. This type of representation (see Table : Mnemonic) shows the sequential processing.

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5.4.2 Explanation of the stack operations

Table 5-7 INSTRUCTIONS Set

BASIC BOOLEAN INSTRUCTIONS

Instruction Ladder Symbol Valid Operands

Load And Or

normal open n=1 close n=0 open

Starting up the PLC

5.4 PLC programming

n: V, I, Q, M, SM, T, C, L

Load Not And Not Or Not

normal close n=0 close n=1 open

Output prior 0, n=0

prior 1, n=1

Set

(1 Bit)

Reset

(1 Bit)

prior 0, not set prior 1 or ½

prior 0, no reset prior 1 or ½

Instruction Ladder Symbol Valid Operands

Edge Up prior ½ close

(1 PLC cycle)

Edge Down prior ¿ close

(1 PLC cycle)

Logical Not prior 0, later 1

prior 1, later 0

No operation

Bit

n: V, I, Q, M, SM, T, C, L

n: V, I, Q, M,T, C, L

S_Bit: V, I, Q, M,T, C, L n =1

OTHER BOOLEAN INSTRUCTIONS

NOT

NOP

n = 0 ... 255

Instruction Ladder Symbol Valid Operands

Load Byte = And Byte =

a = b close a  b open

Or Byte = Load Byte .

And Byte .

a ≥ b close a t b open

Or Byte . Load Byte 3

And Byte 3

a ≤ b close a u b open

Or Byte 3

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BYTE COMPARES (Unsigned)

==B

> =B

< =B

a: VB, IB, QB, MB, SMB, AC, Constant,

b: VB, IB, QB, MB, SMB, AC, Constant,

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Starting up the PLC

5.4 PLC programming

Instruction Ladder Symbol Valid Operands

Load Word = And Word = Or Word =

a = b close a  b open

WORD COMPARES (Signed)

==I

a: VW, T, C, IW, QW, MW, AC, Constant, LW

b: VW, T, C, IW, QW, MW, AC, Constant,

Load Word . And Word . Or Word .

Load Word 3 And Word 3 Or Word 3

Load DWord = And DWord = Or DWord =

Load DWord . And DWord . Or DWord .

Load DWord 3 And DWord 3 Or DWord 3

Load RWord = And RWord = Or RWord =

a ≥ b close a t b open

a ≤ b close a u b open

> =I

< =I

DOUBLE WORD COMPARES (Signed)

Instruction Ladder Symbol Valid Operands

a = b close a  b open

a ≥ b close a t b open

a ≤ b close a u b open

==D

> =D

< =D

a: VD, ID, QD, MD, AC, Constant, LB b: VD, ID, QD, MD, AC, Constant, LB

REAL WORD COMPARES (Signed)

Instruction Ladder Symbol Valid Operands

a = b close a  b open

= =R

a: VD, ID, QD, MD, AC, Constant, LD b: VD, ID, QD, MD, AC, Constant, LD

Load RWord . And RWord . Or RWord .

Load RWord 3 And RWord 3 Or RWord 3

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a ≥ b close a t b open

a ≤ b close a u b open

> =R

< =R

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Instruction Ladder Symbol Valid Operands

Timer Retentive On Delay

EN=1, Start EN=0, Stop

If T T

bit

Val ue

≥ PT,

Timer On Delay EN=1, Start

EN=0, Stop If T

bit

Val ue

≥ PT,

TIMER

Txxx

TONR

Txxx TON

Starting up the PLC

5.4 PLC programming

Enable: (IN)

S0 Txxx: T0 − T31 Preset: (PT)

VW, T, C, IW, QW, MW, AC,

Constant 100 ms T0 − T15

10 ms T16 − T39 Enable: (IN)

S0 Txxx: T0 − T31 Preset: (PT)

VW, T, C, IW, QW, MW, AC,

Constant 100 ms T0 − T15

10 ms T16 − T39

Timer Of Delay If T

bit

Val ue

< PT,

Txxx TOF

Enable: (IN)

S0 Txxx: T0 − T31 Preset: (PT)

VW, T, C, IW, QW, MW, AC,

Constant 100 ms T0 − T15

10 ms T16 − T39

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5.4 PLC programming

Instruction Ladder Symbol Valid Operands

Count Up CU ½, Value+1

R=1, Reset If C

Count Up/Down CU ½, Value+1

CD ½, Value−1 R=1, Reset If C

Count Down If C

bit

Val ue

≥ PV,

= 0,

COUNTER

Cxxx

CTU

R PV

Cxxx

CTUD CD R PV

Cxxx

CTD LD PV

Cnt Up: (CU)

Reset: (R)

S0 Cxxx: C0 − 31 Preset: (PV)

VW, T, C, IW, QW, MW, AC,

Constant, LW Cnt Up: (CU)

S2 Cnt Dn: (CD)

S1 Reset: (R)

S0 Cxxx: C0 − 31 Preset: (PV)

VW, T, C, IW, QW, MW, AC,

Constant, LW Cnt Down: (CD)

S2 Reset: (R)

S0 Cxxx: C0 − 31 Preset: (PV)

VW, T, C, IW, QW, MW, AC,

Constant, LW

Instruction Ladder Symbol Valid Operands

Word Add Word Subtract

If EN = 1, b = a + b b = b − a

DWord Add DWord Subtract

If EN = 1, b = a + b b = b − a

Multiply If EN = 1,

b = a x b

MATH OPERATIONS

ADD_I

ENO

IN1

OUT

IN2

SUB_DI

ENO

IN1

OUT

IN2

MUL

ENO

IN1

OUT

IN2

Enable: EN In: VW, T, C, IW, QW, MW, AC,

Constant, LW Out: VW, T, C, IW, QW, MW, AC, LW

Enable: EN In: VD, ID, QD, MD, AC, Constant, LD Out: VD, ID, QD, MD, AC, LD

Enable: EN In: VW, T, C, IW, QW, MW, AC,

Constant, LW Out: VD, ID, QD, MD, AC, LD

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Instruction Valid OperandsLadder Symbol

Divide If EN = 1,

b = b ÷ a Out:

16 bit remainder Out+2:

16 bit quotient

EN IN1 IN2

DIV

ENO

OUT

Starting up the PLC

5.4 PLC programming

Enable: EN In: VW, T, C, IW, QW, MW, AC,

Constant, LW

Out: VD, ID, QD, MD, LD

Add Subtract Real Numbers

Multiply Divide Real Numbers

Increment Decrement Byte

Increment Decrement Word

If EN = 1, b = a + b b = b − a

If EN = 1, b = a x b b = b ÷ a

ADD_R EN IN1 IN2

MUL_R EN IN1 IN2

ENO

OUT

ENO

OUT

Enable: EN In: VD, ID, QD, MD, AC, Constant, LD Out: VD, ID, QD, MD, AC, LD

INCREMENT, DECREMENT

Instruction Ladder Symbol Valid Operands

If EN = 1, a = a + 1 a = a − 1

If EN = 1, a = a + 1 a = a − 1 a = /a

INC_W EN

INC_B

ENO

OUT

ENO

OUT

Enable: EN In: VB, IB, QB, MB, AC, Constant LB Out: VB, IB, QB, MB, AC, LB

Enable: EN In: VW, T, C, IW, QW, MW, AC,

Constant, LW

Out: VW, T, C, IW, QW, MW, AC, LW

Increment Decrement.

Byte AND Byte OR Byte XOR

Word AND Word OR Word XOR

If EN = 1, a = a + 1 a = a − 1

INV_DW

ENO

OUT

Enable: EN In: VD, ID, QD, MD, AC, Constant, LD Out: VD, ID, QD, MD, AC, LD

LOGIC OPERATIONS

Instruction Ladder Symbol Valid Operands

If EN = 1, b = a AND b b = a OR b b = a XOR b

WAND_B EN IN1 IN2

WAND_W EN IN1 IN2

ENO

OUT

ENO

OUT

Enable: EN In: VB, IB, QB, MB, AC, Constant, LB Out: VB, IB, QB, MB, AC, LB

Enable: EN In: VW, T, C, IW, QW, MW, AC,

Constant, LW

Out: VW, T, C, IW, QW, MW, AC, LW

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Starting up the PLC

5.4 PLC programming

Instruction Valid OperandsLadder Symbol

DWord AND DWord OR DWord XOR

If EN = 1, b = a AND b b = a OR b b = a XOR b

WXOR_DW EN

ENO

IN1

OUT

IN2

Enable: EN In: VD, ID, QD, MD, AC, Constant, LD Out: VD, ID, QD, MD, AC, LD

Invert Byte If EN = 1,

a = /a

Invert Word If EN = 1,

a = /a

Invert DWord If EN = 1,

a = /a

Instruction Ladder Symbol Valid Operands

Shift Right Shift Left

If EN = 1, a = a SR c bits a = a SL c bits

Shift Right Shift Left

If EN = 1, a = a SR c bits a = a SL c bits

DWord Shift R DWord Shift L

If EN = 1, a = a SR c bits a = a SL c bits

INC_B

INC_W

INV_DW

ENO

OUT

ENO

OUT

ENO

OUT

Enable: EN In: VB, IB, QB, MB, AC, Constant, LB Out: VB, IB, QB, MB, AC, LB

Enable: EN In: VW, T, C, IW, QW, MW, AC,

Out: VW, T, C, IW, QW, MW, AC, LW

Enable: EN In: VD, ID, QD, MD, AC, Constant, LD Out: VD, ID, QD, MD, AC, LD

SHIFT AND ROTATE OPERATIONS

SHL_R EN IN

SHL_W EN IN

ENO

OUT

ENO

OUT

Enable: EN In: VB, IB, QB, MB, AC, Constant, LB Out: VB, IB, QB, MB, AC Count: VB, IB, QB, MB, AC, Constant, LB

Enable: EN In: VW, T, C, IW, QW, MW, AC,

Out: VW, T, C, IW, QW, MW, AC, LW Count: VB, IB, QB, MB, AC, Constant, LB

SHL_DW EN IN N

ENO

OUT

Enable: EN In: VD, ID, QD, MD, AC, Constant, LD Out: VD, ID, QD, MD, AC, LD Count: VB, IB, QB, MB, AC, Constant, LB

Constant, LW

Convert Double Word Integer to a Real

Convert a Real to a Double Word Integer

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CONVERSION OPERATIONS

Instruction Ladder Symbol Valid Operands

If EN = 1, convert the double word integer i to a real number o.

If EN = 1, convert the real number i to a double word integer o.

DI_REAL EN

TRUNC

ENO

OUT

ENO

OUT

Enable: EN In: VD, ID, QD, MD, AC, Constant, LD Out: VD, ID, QD, MD, AC, LD

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PROGRAM CONTROL FUNCTIONS

Instruction Ladder Symbol Valid Operands

Jump to Label If EN = 1, go to label n.

JMP

Starting up the PLC

5.4 PLC programming

Enable: EN Label: WORD: 0−127

Label Label marker for the

jump.

Conditional Return from Subroutine

Return from Subrou-

If EN = 1, exit the subroutine.

Exit subroutine.

tine

Conditional End If EN = 1, END termi-

nates the main scan.

PROGRAM CONTROL FUNCTIONS

Instruction Ladder Symbol Valid Operands

Subroutine If EN ½, go to subrou-

tine n.

MOVE, FILL AND FIND OPERATIONS

Instruction Ladder Symbol Valid Operands

Move Byte If EN = 1,

copy i to o.

LBL

RET

END

SBR EN x1

(x... optional parameters)

MOV_B

ENO

OUT

Label: WORD: 0−127

Enable: EN

Label: Constant : 0−63

Enable: EN In: VB, IB, QB, MB, AC, Constant, LB Out: VB, IB, QB, MB, AC, LB

Move Word If EN = 1,

copy i to o.

Move DWord If EN = 1,

copy i to o.

Move Real If EN = 1,

copy i to o.

Swap Bytes If EN = 1,

exchange MSB and LSB of w.

MOV_W

MOV_DW

MOV_R

SWAP

ENO

OUT

ENO

OUT

ENO

OUT

ENO

Enable: EN In: VW, T, C, IW, QW, MW, AC,

Constant, LW

Out: VW, T, C, IW, QW, MW, AC, LW

Enable: EN In: VD, ID, QD, MD, AC, Constant, LD Out: VD, ID, QD, MD, AC, LD

Enable: EN In: VW, IW, QW, MW, T, C, AC, LW

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Starting up the PLC

5.4 PLC programming

5.4.3 Program organization

Every programmer should structure the user program divided into separate program sections (subroutines). The S7−200 programming language offers the user the possibility to create a structured user program. There are two program types − main program and subroutine. Eight program levels are possible.

A PLC cycle can be a multiple of the control−internal interpolation cycle (IPO cycle). The machine manufacturer must set the PLC cycle according to his particular conditions (see machine data ”PLC_IPO_TIME_RATIO”). An IPO/ PLC ratio of 1:1 has been proven to provide the fastest possible cyclic program execution.

Example: The programmer will write a sequence control in the main program using a cycle defined by himself. This sequence control will organize all cyclic signals in the subroutine (UP0); UP1/UP2 are called every two cycles, and UP3 controls all signals at an interval of three cycles.

5.4.4 Data organization

The data can be divided into three areas:

S non−retentive data S retentive data S machine data for the PLC (all these machine data are active after POWER ON).

Most of the machine data, such as process image, timer and counter are non−retentive data which are deleted each time when the control system is powered up.

The data area 1400 0000 −1400 0127 is reserved for the retentive data. The user can here store all data which are to remain valid after POWER ON.

The user can either load the data in his program with default data using the PLC machine data (see ”User interface”) or parameterize various program sections.

5.4.5 Interface to the control system

This interface can be selected via SYSTEM, softkeys PLC > STEP7−connect. This V24 interface continues to be active even after cold restart or normal booting. The con-

nection (STEP7 connect active) to the control system can be checked in the ”PLC/information” menu of the PLC 802 Programming Tool. If the interface is active, the active PLC mode, for example (Run/Stop) is displayed in this window.

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5.4.6 Testing and monitoring your program

A check or error analysis of the user program is possible as follows:

S PLC status: Display and change of called operands S Status list: Display and change of three freely selectable variable fields S PLC program: Display and monitoring (status) of the entire user program including sym-

bols and comments

S PT PLC 802: Connecting a PG/PC and activating the PT. Connection also possible via

modem

Starting up the PLC

5.4 PLC programming

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Starting up the PLC

5.5 PLC applications ”Download/Upload/Copy/Compare”

The user can save, copy or overwrite the PLC project or the PLC applications in the control system.

This is possible using

S PLC 802 Programming Tool S WINPCIN (binary file) S NC card

PT PLC 802



Toolbox

WINPCIN

Download/ Upload/ Compare

802D



PLC user

alarm

texts



PLC application



Series machine start−up



PLC

project

Permanent memory



PLC

machine data





Series machine start−up

PLC application

NC card

Fig. 5-1 PLC applications in the control system

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Download

Upload

Starting up the PLC

5.5 PLC applications ”Download/Upload/Copy/Compare”

This function writes the transmitted data to the permanent memory (load memory) of the control system.

S Download from the PLC project using the PLC 802

Programming Tool (Step 7 connect on)

S Machine series start−up using the WINPCIN tool (PLC MD, PLC project and user alarm

texts), DataIn or the NC card.

S Reading in PLC applications using the WINPCIN tool or theNC card (PLC project and

user alarm texts) analogously to the series machine start−up DataIn

When the control system is powered up next time, the loaded PLC user program is transferred from the permanent memory to the user memory and is active in the control system from this moment.

The PLC applicationscan be saved from the permanent memory of the control system using the either PLC 802 Programming Tool, WINPCIN or the NC card.

Compare

Version display

S Upload from the PLC project using the PLC 802 Programming Tool (Step 7 connect on)

Reading out the project from the control system and thus reconstructing the current project in the PLC 802 Programming Tool.

S Machine series start−up ”Start−up data” using the WINPCIN tool (PLC MD, PLC project

and user alarm texts), DataIn or the NC card.

S Reading out PLC applications using the WINPCIN tool or theNC card (PLC project and

user alarm texts) analogously to the series machine start−up DataOut

This function compares the project contained in the PLC 802 Programming Tool with the project loaded in the permanent memory (load memory) in the control system.

This function is called using the SYSTEM hardkey, Service Display / Versionsoftkeys.

S Project

The transferred project including the user program which is active in the user memory of the PLC after booting of the control system.

The programmer can use the start of the first comment line in the comment of OB1 in the PLC 802 Programming Tool for his own supplementary information in the version display (see ”View Properties”).

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Starting up the PLC

5.6 User interface

This interface comprises all signals exchanged between NCK/PLC and HMI/PLC. In addition, the PLC decodes all auxiliary function commands for processing in the user program.

Note for the reader

/FB/ Sinumerik 802D Description of Functions, Chapter 20

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siemens 802D User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Contents

The SINUMERIK 802D Control System

1.1 Components of the SINUMERIK 802D

1.2 Technical specifications

Installing the Control System

2.1 Installing and removing the SINUMERIK 802D

2.2 Interfaces and lines

2.3 Connecting the individual components

2.3.1 Connecting the keyboard

2.3.2 Connecting handwheels to the PCU

2.3.3 Terminal configuration of the RS232 interface (COM1) on the PCU

2.3.4 Connecting the I/Os to PP 72/48

2.4 Connecting the SIMODRIVE 611U drive unit

2.3.5 Connecting the ADI4 module

2.5 Connecting the Profibus

2.6 Grounding

2.7 Power supply of PCU (X8) and PP 72/48 (X1)

2.8 Displays on the PCU

2.9 Displays on the PP 72/48

Commissioning

3.1 General

3.1.1 Access levels

3.1.2 Structure of machine data (MD) and setting data (SD)

3.2 Turning on and booting the control system

3.3 Language setting

3.4 Setting the technology

3.5 Entering the machine data

3.6 Setting the Profibus address

3.7 Starting up the PLC

3.8 Starting up the axes/spindle

3.8.1 Setpoint/actual value assignment

3.8.2 Default settings for the axis machine data for the feed axes

3.8.3 Connecting a direct measuring system

3.8.4 Default settings for the axis machine data for the spindle

3.10 Service display for the axis drive behavior

Starting up the Spindle

4.2 Digital spindle drive with spindle actual−value encoder (TTL) mounted directly on the motor

4.4 Digital spindle without external encoder

4.4.1 Parameterization using the Drive Configuration Wizard

4.4.2 Parameterization using the Expert List

4.4.3 Adapting the machine data in the control system

4.5 Digital spindle without encoder with external TTL encoder

4.5.1 Parameterization using the Expert List

4.5.2 Adapting the machine data in the control system

4.7 Analog axis/spindle with TTL encoder via ADI4

4.8 Digital axis/spindle with direct measuring system (TTL) via ADI4

Starting up the PLC

5.1 Commissioning the PLC

5.3 PLC alarms

5.3.1 General PLC alarms

5.3.2 User alarms

5.4 PLC programming

5.4.1 Command overview

5.4.2 Explanation of the stack operations

5.4.3 Program organization

5.4.4 Data organization

5.4.5 Interface to the control system

5.4.6 Testing and monitoring your program

5.5 PLC applications ”Download/Upload/Copy/Compare”

5.6 User interface