siemens 808D User Manual

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PLC Subroutines Manual

SINUMERIK

SINUMERIK 808D PLC Subroutines Manual

Operating Instructions

_________________

Preface

_________________

Overview

__________________

PLC Programming Tool

Descriptions of the PLC

_________________

subroutines

Use of user alarms in the

_________________

PLC subroutines

_________________

PLC sample applications

Valid for: SINUMERIK 808D Turning (software version: V4.4.2) SINUMERIK 808D Milling (software version: V4.4.2)

Target group: OEM engineers

12/2012

6FC5397-2EP10-0BA0

Page 2

Legal information Warning notice system

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.

DANGER

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

WARNING

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

CAUTION

indicates that minor personal injury can result if proper precautions are not taken.

NOTICE indicates that property damage can result if proper precautions are not taken.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

Qualified Personnel

The product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.

Proper use of Siemens products

Note the following:

WARNING

Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks

All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of Liability

We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AG

Industry Sector Postfach 48 48 90026 NÜRNBERG GERMANY

Order number: 6FC5397-2EP10-0BA0 Ⓟ 12/2012 Technical data subject to change

Page 3

Preface

SINUMERIK 808D documentation

The SINUMERIK 808D documentation consists of the following components:

● Operating Instructions

– Mechanical Installation Manual

– Electrical Installation Manual

– PLC Subroutines Manual

– Function Manual

– Parameter Manual

● Diagnostics Manual

● Commissioning Manual

● Programming and Operating Manual (Turning)

● Programming and Operating Manual (Milling)

● Manual Machine Plus (Turning)

● Online Help for Programming and Operating (Turning)

● Online Help for Programming and Operating (Milling)

● Online Help for Manual Machine Plus (Turning)

My Documentation Manager (MDM)

Under the following link you will find information to individually compile your documentation based on the Siemens content:

www.siemens.com/mdm

Target group

This manual is intended for use by the OEM engineers who have basic CNC and PLC knowledge.

Benefits

This manual enables the intended target group to get detailed information about the PLC subroutines and how to use them.

PLC Subroutines Manual Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0

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Preface

Technical support

Hotline: +86 400-810-4288 Service and Support

 China:

www.siemens.com.cn/808D

 Worldwide:

http://support.automation.siemens.com

EC Declaration of Conformity

The EC Declaration of Conformity for the EMC Directive can be found on the Internet at http://support.automation.siemens.com

Here, enter the number 15257461 as the search term or contact your local Siemens office.

Licensing provisions

The SINUMERIK 808D software is protected by national and international copyright laws and agreements. Unauthorized reproduction and distribution of this software or parts thereof is liable to prosecution. It will be prosecuted both according to criminal and civil law and may result in severe penalties or claims for compensation.

In the SINUMERIK 808D, open source software is used. The licensing provisions for this software are included on the Toolbox DVD and are to be observed accordingly.

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Page 5

Preface ...................................................................................................................................................... 3

1 Ove

2 P

3 Des

rview.................................................................................................................................................... 7

LC Programming Tool ........................................................................................................................... 11

2.1 Ins

2.2 PLC ins

2.3 Data management

2.4 Program organiz

2.5 Tes

2.6 Es

2.7 PLC appli

criptions of the PLC subroutines........................................................................................................ 31

3.1 PLC mac

3.2 Conv

3.3 Subroutine 20 - AUX_M

3.4 Subroutine 21 - AUX_LAMP (work

3.5 Subroutine 22 - AUX_

3.6 Subroutine 23 - AUX_CHI

3.7 Subroutine 31 - PLC_

talling the 808D Toolbox .........................................................................................................11

tructions...........................................................................................................................12

.......................................................................................................................13

ation...................................................................................................................13

ting and monitoring your program..........................................................................................14

tablishing a connection with the RS232 interface....................................................................17

cation Download/Upload/Copy/Compare.....................................................................22

hine data .......................................................................................................................31

entions for the symbols used in the subroutines .................................................................32

CP (machine auxiliary functions) ...........................................................34

ing lamp)................................................................................35

SAFE_DOOR (safe door)..........................................................................35

P (chip remover) .................................................................................36

ini_USR_ini (user initialization)..................................................................37

3.8 Subroutine 32 - PLC_

3.9 Subroutine 33 - EMG_

3.10

3.11

3.12

3.13 S

3.14 S

3.15 S

3.16 S

3.17 S

3.18 S

3.19

3.20

PLC Subroutines Manual Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0

Subroutine 37 - MCP_NCK (MCP and HMI signal processing)...................................................39

Subroutine 38 - MCP_Tool_Nr (display tool number on the MCP)..............................................40

Subroutine 39 - HANDWHL (selecting a handwheel according to HMI interface signals) ..........41

ubroutine 40 - AXIS_CTL (controlling the spindle and axes) ....................................................42

ubroutine 41 - MINI_HHU (handwheel hand-held unit) .............................................................45

ubroutine 42 - SPINDLE (spindle control) .................................................................................47

ubroutine 43 - MEAS_JOG (measurement in the JOG mode)..................................................48

ubroutine 44 - COOLING (cooling control)................................................................................49

ubroutine 45 - LUBRICAT (control of lubricate).........................................................................51

Subroutine 46 - PI_SERVICE (Asynchronous Subroutine Program)...........................................52

Subroutine 47 - PLC_Select_PP (PLC selects a subroutine) ......................................................54

INI (PLC initialization)................................................................................37

STOP........................................................................................................38

Page 6

Table of contents

3.21 Subroutine 48 - ServPlan (service plan) ..................................................................................... 55

3.22 Subroutine 49 - GearChg1_Auto (automatic spindle gear change)............................................ 56

3.23

3.24

3.25

3.26

3.27

3.28

3.29

Subroutine 50 - GearChg2_Virtual (virtual spindle gear change)............................................... 57

Subroutine 51 - Turret1_HED_T (turret with Hall effect device position sensor) ........................ 58

Subroutine 52 - TURRET2_BIN_T (turret with binary coding function) ...................................... 61

Subroutine 53 - Turret3_CODE_T (tool change control for turret with coding function) ............. 63

Subroutine 54 - Turret2_3_ToolDir (tool change direction)......................................................... 65

Subroutine 55 - Tail_stock_T (Tailstcok control program for turning machines)......................... 67

Subroutine 56 - Lock_unlock_T (clamping control for turning machines)................................... 68

3.30 Subroutine 58 (MM_

3.31 S

3.32

3.33 S

3.34 S

4 Use

5 P

LC sample applications ......................................................................................................................... 79

ubroutine 59 (MM_MCP_808D) ................................................................................................ 72

Subroutine 60 - Disk_MGZ_M (disk-style tool magazine for milling) .......................................... 73

ubroutines 34 to 36, 57, 61 and 62........................................................................................... 75

ubroutine 63 - TOGGLES ......................................................................................................... 75

of user alarms in the PLC subroutines.............................................................................................. 77

5.1 PLC sample

5.2 PLC sample

ndex........................................................................................................................................................ 85

MAIN).......................................................................................................... 69

application (turning)................................................................................................ 79

application (milling)................................................................................................. 82

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Page 7

Overview

The PLC subroutines consist of three project files:

● default_turning.ptp (sample application for turning machines)

● default_milling.ptp (sample application for milling machines)

● default_ManMachPlus_T.ptp (sample application for Manual Machine Plus)

With the sample applications, you can get a good understanding about how to create or call a PLC subroutine. You can realize most machine functions by re-organizing the PLC subroutines or modifying some must networks.

System resource distribution

WARNING

Make sure that you perform a complete machine test to all subroutines used in your main program, in order to verify that all the subroutines called by the main program function as you desire. Failure to observe may cause personal injury or property damage.

The system resources can be distributed into three parts:

● PLC system – Inputs

I0.0 to I2.7 (24 inputs of the SINUMERIK 808D) I3.0 to I8.7 (distributed 48 inputs)

– Outputs

Q0.0 to Q1.7 (16 inputs of the SINUMERIK 808D) Q2.0 to Q5.7 (distributed 32 outputs)

– Memory

M0.0 to M255.7 (256 bytes)

– Non-volatile memory

DB1400.DBX0.0 to DB1400.DBX127.7 (128 bytes)

– PLC user alarms:

DB1600.DBX0.0 to DB1600.DBX15.7 (128 user alarms)

– Timer

T0 to T15 (100ms timer) T16 to T63 (10ms timer)

– Counter

C0 to C63 (64 counters)

● NCK – PLC machine data: MD14510, MD14512, MD 14514 – MD14510 machine data INT: DB4500.DBW0 to DB4500.DBW62 (32 words) – MD14512 machine data hex: DB4500.DBB1000 to EDB4500.DBB1031 (32 bytes) – MD14514 machine data real: DB4500.DBD2000 to DB4500.DBD2028 (8 Dword)

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Overview

● PLC Programming Tool – Symbol table: SYM1 to SYM32 (32 symbol tables) – Subroutine: SBR0 to SBR63 (64 subroutines)

Structure of the symbol tables

The PLC subroutine library has been designed with symbol addressing method, which helps you easily understand the PLC programs. All the addresses in the subroutine library use symbols for programming. All the interface signals are named with symbols and assigned to different symbol tables.

Symbol table Table name Descriptions 1 IO_1 Module I/O are defined by the manufacturer 2 IO_2 Distributed I/O are defined by the manufacturer 3, 5, 7, 13 Reserved for the manufacturer 6 MANMACH JOG function 14 ASUP ASUP function 15 PLC_sel_PP PLC selects part programs 16 IS_MCP Signals from/to the MCP 17 IS_HMI Signals from/to the HMI 18 IS_AUX Auxiliary functions from the NCK 19 IS_NCK Signals from/to the NCK 20 IS_CHA Signals from/to the channel 21 IS_AX1 Signals to/from axis 1 22 IS_AX2 Signals to/from axis 2 23 IS_AX3 Signals to/from axis 3 24 IS_AX4 Signals to/from axis 4 27 MD_PLC PLC machine data 28 ALARM User alarms 29 NV_MEM Non-volatile memory 30 SPC_MEM Special memory bit 31 SBR_MEM Global memory used in the sample applications and subroutines 32 RESVD1 Reserved for the sample applications and subroutines

Structure of the subroutines

Subroutine No. Name Description 0 to 19 - Reserved for the manufacturer 20 AUX_MCP Auxiliary function 21 AUX_LAMP Lamp control, called in the subroutine "AUX_MCP". 22 AUX_SAFE_DOOR

23 AUX_CHIP

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Safe door control, called in the subroutine "AUX_MCP" of a milling application.

Chip remover control, called in the subroutine "AUX_MCP" of a milling application.

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Overview

Subroutine No. Name Description 31 PLC_ini_USR_INI

32 PLC_INI PLC initialization 33 EMG_STOP Emergency Stop 37 MCP_NCK

38 MCP_Tool_Nr Display tool numbers via the LED of the MCP 39 HANDWHL Handwheel selection via HMI 40 AXIS_CTL Control of feed axis enable and spindle enable 41 MINI_HHU Handwheel hand held unit 42 SPINDLE Spindle function 43 MEAS_JOG Tool measurement in the JOG mode 44 COOLING

45 LUBRICATE Lubrication control (interval and time) 46 PI_SERVICE ASUP (Asynchronous Subroutine Program) 47 PLC_Select_PP PLC selects a subroutine. 48 ServPlan Service plan 49 Gear_Chg1_Auto Automatic gear change of the spindle 50 Gear_Chg2_Virtual Dummy gear change of the spindle 51 Turret1_HED_T

52 Turret2_BIN_T

53 Turret3_CODE_T

54 Turret2_3_ToolDir

55 Tail_stock_T Tail stock control for the turning machine 56 Lock_unlock_T Clamp or release control for the turning machine 58 MM_MAIN Manual machine 59 MM_MCP_808D Spindle signal processing for the manual machine 60 Disk_MGZ_M Disk tool magazine for a milling machine 61, 62 Reserved for the subroutine 63 TOGGLE Six key-operated switches: K1 to K6

Reserved for the initialization by the manufacturer (this subroutine is automatically called by subroutine 32)

Signals from the MCP and the HMI are sent to NCK interfaces

Coolant control (Manual Machine key and M code: M07, M08, M09)

Turret control of the turning machine (turret type: Hall element transistor, 4/6 position)

Turret control of the turning machine (turret type: position detection with encodings)

Hydraulic turret control of the turning machine (turret type: position detection with encodings)

Evaluate tool direction and calculate tool position (called by Turret2_BIN_T, Turret3_CODE_T)

Two delay switches: K7, K8

MCP interface description

Input/output DB number Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0 Input (MCP ->

PPU), DB1000

PLC Subroutines Manual Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0

DB1000.DBB0 M01 Program

test

DB1000.DBB1 Key 16 Key 15 Key 14 Key 13 Key 12 Key 11 Key 10 ROV

MDA Single

block

AUTO REF.

POINT

JOG Hand-

wheel

Page 10

Overview

Input/output DB number Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0

DB1000.DBB2 100

(INC)

DB1000.DBB3 Key 32 Key 31 Cycle

DB1000.DBB4 Key 39 Key 38 Key 37 Key 36 RAPID Key 34 Key 33 DB1000.DBB5 DB1000.DBB6 DB1000.DBB7 DB1000.DBB8 Feed override value (in Gray code) DB1000.DBB9 Spindle override value (in Gray code) DB1000.DBB10

Output (PPU > MCP), DB1100

DB1100.DBB0 LED 8 LED 7 LED 6 LED 5 LED 4 LED 3 LED 2 LED 1 DB1100.DBB1 LED

DB1100.DBB2 LED

24 DB1100.DBB3 LED 30 LED 29 LED 28 LED 27 LED 26 LED 25 DB1100.DBB4 DB1100.DBB5 DB1100.DBB6 DB1100.DBB7 DB1100.DBB8 7 SEG LED 1 DB1100.DBB9 7SEG LED 2 DB1100.DBB10 DB1100.DBB11 DB1100.DBB12 DP 2 2) DP 1 1)

The decimal point of the 7 SEG LED 1.

The decimal point of the 7 SEG LED 2.

Note

10 (INC) 1 (INC) Key 21 Key 20 Key 19 Key 18 Key 17

start

Cycle Stop

RESET Spindle

right

Spindle Stop

Spindle left

LED 15 LED 14 LED 13 LED 12 LED 11 LED 10 LED 9

LED 23 LED 22 LED 21 LED 20 LED 19 LED 18 LED 17

Interfaces where nothing has been entered are reserved for the next version.

You can understand the relationship between the PLC interface addresses and the SINUMERIK 808D MCP from the illustration below:

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PLC Programming Tool

2.1 Installing the 808D Toolbox

You must install the 808D Toolbox on your PC/PG. The 808D Toolbox contains the following software tools or information:

● Config Data 808D

– System software update

– Examples (EasyXLanguage, symbols for MCP customized keys, template for MCP

strips, PLC subroutine library)

● PLC Programming Tool

The tool for creating PLC user programs

● Windows setup software for toolbox

● User documentation

● License information and conditions about Open Source Software (Readme_OSS)

● SinuComPCIN

Installing the 808D toolbox

The toolbox installation folder is shown below:

To start the installation, double-click the Setup.exe file. In the setup dialog, select one or multiple options that you desire to install.

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PLC Programming Tool

2.2 PLC instructions

Various instructions are available in the PLC Programming Tool. You can view them in the instruction branch on the instruction tree:

You can right-click over an instruction or directly press the F1 key to view its help information. For example:

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PLC Programming Tool

2.3 Data management

The data can be broken down into three areas:

● non-retentive data

● retentive data

● machine data for the PLC (this machine data is all active at POWER ON)

Most data, such as the process image, timers, and counters are non-retentive and are cleared each time the control system is restarted.

For the retentive data, there is a data range of 1400 0000 -1400 0127. This location can be used to save all the data which is to remain valid after POWER OFF/ON.

With the aid of the PLC-MD (see user interface), you can pre-assign your program with data or parameterize various parts of the program.

2.4 Program organization

When programming the PLC, you must structure your program into finished program parts (subroutines). The programming language for S7-200 offers you the capability to set up your user program in a structured manner.

There are two types of programs:

● The main program

● The subroutine.

Eight levels of programming are possible.

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PLC Programming Tool

2.5 Testing and monitoring your program

You can check or perform an error analysis of the user program in two methods:

● The HMI of the SINUMERIK 808D

● The PLC Programming Tool

Testing and monitoring a PLC program with the HMI

There are three ways for program testing and monitoring in the "SYSTEM" operating area:

● "PLC" > "PLC status"

You can input an operand to view its status.

Use the softkey "Operand +" or "Operand -" to increase/decrease the bit of the operand. Use the "Change" softkey to change the value of the operand and the "Delete all" softkey to delete all the input operands.

● "PLC" > "Status list"

You can view the status of a PLC signal.

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PLC Programming Tool

2.5 Testing and monitoring your program

By default, three signal status lists (inputs, flags and outputs) are displayed in three columns. You can change column sequence or assign a new signal status list (variables) with the "Edit pad" softkey:

You can also change the status of a PLC signal with the "Change" softkey.

● "PLC" > "PLC program"

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PLC Programming Tool

2.5 Testing and monitoring your program

You can view the status of the main program or use the "Program block" softkey to view the status of a subroutine:

Two windows are available for you to view the program.

Testing and monitoring a PLC program with the PLC Programming Tool

You can also view the status of your PLC program with the PLC Programming Tool:

1. Establish the communication between the SINUMERIK 808D and the PLC Programming Tool.

For detailed information about the establishment of the communication between the SINUMERIK 808D and the PLC Programming Tool, refer to section "Establishing a conn

ection with the RS232 interface (Page 17)"

2. Use the menu can also first click the status chart symbol status.

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16 Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0

command "Debug > Chart status" to view the status of a PLC signal. You

and then click the symbol to view the

Page 17

PLC Programming Tool

2.6 Establishing a connection with the RS232 interface

You can establish a communication between the control system and the PC/PG (PLC Programming Tool) via the RS232 port.

Activating the connection to the control system

You can activate the connection with the HMI: "SYSTEM" operating area > "PLC" > "STEP 7 connect" > "Connect. ON":

Use the <SELECT> key to select a communication baud rate. The SINUMERIK 808D supports the following baud rates:

● 9.6 kbps

● 19.2 kbps

● 38.4 kbps

● 57.6 kbps

PLC Subroutines Manual Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0

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PLC Programming Tool

2.6 Establishing a connection with the RS232 interface

● 115.2 kbps.

The active or inactive state is retained even after a power-on (except when starting with the default data). An active connection is displayed by a symbol in the status bar:

Communication settings in the PLC Programming Tool

To setup the PPI parameters in the PLC Programming Tool, proceed as follows:

1. Display the "Communication Links" dialog with menu command "View > Communications", or click communication button communication symbol

in the View column, or click the

in the operations tree:

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PLC Programming Tool

2.6 Establishing a connection with the RS232 interface

2. Double click on the "Access point" symbol in the "Communication" window on the right

side:

The "Set PG/PC Interface" dialog is displayed as follows:

3. Check the PG/PC interface being used. For RS232 communication, you must assign the

interface "PLC802(PPI)" to the PLC programming tool.

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PLC Programming Tool

2.6 Establishing a connection with the RS232 interface

4. Double click the interface "PLC802(PPI)" or right-click the "Properties" button, and the property dialog is displayed. Set the baud rate for the transmission rate, which the PLC Programming Tool will use to communicate:

NOTE: The baud rate you select must be in accordance with what you have set on the controller side.

5. Open the "Local connection" tab to specify the COM port to which the RS232 (V24) cable is connected:

6. Click "OK" twice to exit the "Set PG/PC Interface" dialog box.

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PLC Programming Tool

2.6 Establishing a connection with the RS232 interface

7. On the right of the "Communications Setup" dialog box, click the blue text "Double-Click

to Refresh". It will take several minutes to search for a valid address:

8. Wait until the icon "808D-PPU14x, Address 2" displays as below, and then the

connection is ready:

Note

You must activate the connection on the control via the HMI ("SYSTEM" operating area > "PLC" > "STEP 7 connect" > "Connect. ON").

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PLC Programming Tool

2.7 PLC application Download/Upload/Copy/Compare

You can save, copy or over-write the PLC project or the PLC applications in the control system.

This is possible using:

● the PLC Programming Tool

● a USB stick

A PLC project contains the PLC user program, including all of the important information (symbols, comments, ...).

You can upload / download the PLC project to the control system with the PLC Programming Tool. With the PLC Programming Tool, you can also import and export it in ".pte" format.

You can also read the PLC project in ".pte" format from / to the USB stick directly on the control system.

3/& 3URJUDPPLQJ 7RRO

Download

3/&DSSOLFDWLRQSWH

56FDEOH

'RZQORDG 8SORDG &RPSDUH

86%VWLFN

3/&DSSOLFDWLRQSWH

6,180(5,.

'

Figure 2-1 PLC applications on the control system

You can write the transferred data into the permanent memory (load memory) of the control system with the PLC Programming Tool or an USB stick.

To download a PLC application with the PLC Programming Tool, proceed as follows:

1. Establish the communication between the CNC controller and the PLC Programming Tool with an RS232 cable.

For information about how to establish a communication between the CNC controller and the PLC Programming Tool, refer to section "Establishing a connection with the RS232 interface (Page 17)".

2. Use the menu

command "File > Download..." or click the download button

to start the

download, and a download dialog pops up:

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PLC Programming Tool

2.7 PLC application Download/Upload/Copy/Compare

3. Click "OK" to proceed directly. You can also select the checkbox "Data Blocks (only

actual values)" to include the actual values of the data blocks, and then click "OK":

4. Either select to download the PLC application when the PLC is in the RUN mode (the

"Download in RUN mode" button) or in the STOP mode (the "Place the PLC in STOP mode" button):

It is recommended to download when the PLC is in the STOP mode. Downloading when the PLC is in the RUN mode can cause machine damages or even human injuries.

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PLC Programming Tool

2.7 PLC application Download/Upload/Copy/Compare

5. The download starts and it will take several seconds to do it.

6. The download finishes when the message below appears, Click "OK" to end your operations:

Note

If you have chosen to download when the PLC is in the STOP mode, you can place the PLC at RUN mode again with the PLC Programming Tool (click button

)

To download an OEM PLC application with an USB stick, perform as follows:

1. Export the PLC application created with the PLC Programming Tool to a USB stick using the menu command "File > Export...".

2. Insert the USB stick into the USB interface at the front of the PPU.

3. Open the USB stick via the HMI: "SYSTEM" operating area > "Sys. data" > "USB":

4. Select the .pte file and press the "Copy" softkey.

5. Press the "808D data" softkey, and enter the "NCK/PLC data" folder by pressing the <INPUT> key.

6. Press the "Paste" softkey.

7. A warning note appears warning you that the original .pte file will be overwritten. Press "OK" to continue.

8. Download has been completed when the progress bar disappears.

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PLC Programming Tool

2.7 PLC application Download/Upload/Copy/Compare

Upload

You can backup a PLC application from the permanent memory of the control system using the PLC Programming Tool or an USB stick.

To upload a PLC application using the PLC Programming Tool, proceed as follows:

1. Create a new and empty PLC application using the PLC Programming Tool:

2. Establish the communication between the CNC controller and the PLC Programming Tool

with an RS232 cable.

For information about how to establish a communication between the CNC controller and the PLC Programming Tool, refer to section "Establishing a connection with the RS232 interface (Pa

ge 17)".

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PLC Programming Tool

2.7 PLC application Download/Upload/Copy/Compare

3. Use the menu command "File > Upload..." or click the upload button to start the upload, and the upload dialog pops up:

4. Click the "OK" button.

5. An information dialog appears saying "Uploading will replace the contents of the selected project components and unsaved changes will be lost. Do you wish to continue?":

6. Click "Yes" and the upload will start.

7. The upload has been completed when the message below appears:

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PLC Programming Tool

2.7 PLC application Download/Upload/Copy/Compare

8. Click "OK" and you can view the upload result:

To upload a PLC application using an USB stick, proceed as follows:

1. Insert the USB stick into the USB interface at the front of the PPU.

2. Locate the PLC application (.pte file): "SYSTEM" operating area > "Sys. data" > "808D

data" > "NCK/PLC data" > "OEM PLC application (*.pte)":

3. Press the "Copy" softkey.

4. Press the "USB" softkey and paste the .pte file into the USB stick with the "Paste"

softkey.

5. Unplug the USB stick and plug it into the PC/PG.

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PLC Programming Tool

2.7 PLC application Download/Upload/Copy/Compare

6. Create an empty PLC application with the PLC Programming Tool:

7. Import the .pte file from the USB stick using the menu command "File > Import...":

8. Click "Open" button or double-click on the .pte file.

9. It will take several seconds to import the .pte file.

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PLC Programming Tool

2.7 PLC application Download/Upload/Copy/Compare

10. After successfully importing the PLC application, you can view the imported result:

Compare

You can compare the project in the PLC Programming Tool with the project on the control system by using the menu command "PLC > Compare...":

Press the "Begin" button and the comparing begins. Wait for a few seconds, then you can view the compare results:

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PLC Programming Tool

2.7 PLC application Download/Upload/Copy/Compare

Version display

Call up via the "SYSTEM" operating area > "Serv. displ." > "Version"

● PLC application The transferred project that is active in the working memory of the PLC after the control system has started up.

In the PLC Programming Tool in the comments of the OB1 properties, programmers can use the beginning of the first line of comments to add their own additional information in the version display.

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Descriptions of the PLC subroutines

3.1 PLC machine data

Table 3- 1 USER_DATA_INT

No. Unit Description 14510 [12] - Layout of the traverse keys 14510 [13] 0.1s Time for spindle braking 14510 [20] - The maximum number of tool bits 14510 [21] 0.1s Turret clamping time 14510 [22] 0.1s Monitoring time for searching a tool 14510 [24] 1 min Lubricating intervals 14510 [25] 0.01s Lubricating duration

Table 3- 2 USER_DATA_HEX

No. Descriptions 14512 [16] Bit 1: function of chip remover (milling)

Bit 2: function of safe door (milling) Bit 3: when the function of safe door is active, it can be triggered by M01/M02

(milling). Bit 4: control of X axis rotation monitoring Bit 5: control of Y axis rotation monitoring Bit 6: control of Z axis rotation monitoring Bit 7: handwheel assignment with the MCP / HMI

14512 [17] Bit 0: turret (turning); tool magazine (milling)

Bit 1: clamping function (turning) Bit 2: tail stock function (turning) Bit 3: selection between handwheel and hand-held unit (0: handwheel; 1: hand-held

unit)

14512 [18] Special configurations for a machine

Bit 2: automatic lubrication after first power-on (factory setting) Bit 4: signal that external spindle stops Bit 5: spindle positioning direction Bit 6: the hardware limit is independent from a PLC program Bit 7: each feed axis has a hardware limit switch (activated when Bit 6 = 0)

14512 [19] Bit 1: function of spindle braking

Bit 2: password clearing by power-on (0: delete the password; 1: do not delete the password)

Bit 7: manual machine function (this function become active if you have installed licensed turning machine system and called it with a PLC subroutine)

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Descriptions of the PLC subroutines

3.2 Conventions for the symbols used in the subroutines

The symbols used in the subroutines follow the conventions listed below:

● Leading characters designate the destinations of interface signals

– P_: to PLC interface – H_: to HMI interface – N_: to NCK interface – M_: to MCP interface

● Subsequent characters are for areas

– N_: NCK – C_: Channel – 1_: Axes – M_: MCP

Other short forms of the symbols – HWL: Hardware Limit – HW: Handwheel – RT: Rapid Traverse – TK: Traverse key – ACT: Active – SEL: Selected

● A symbol consists of a maximum of 11 upper case characters and numbers (including the leading character). Except for underlines, you cannot use any other special symbols like =, +, -, [ ], etc.

Symbol tables 1 to 2

The symbol tables 1 to 2 are for the manufacturer-defined SINUMERIK 808D I/O. Here you can define input/output tables for your machines.

Symbol tables 3 to 5, 7 to 13

These ten symbol tables are reserved for the subroutines.

Note Important!

If the colour of a symbol is displayed in red, this indicates that the naming does not follow the rules of the PLC Programming Tool. In this case, you must check:

 whether the name uses special symbols like =, +, -, [ ], etc..  whether the leading character is a number.

If there is a red wave under a symbol name or address, it indicates that you have used the same symbol name or address for another symbol (there is also a red wave under its name or address). In this case, you must check the repeated name or address and change it.

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Descriptions of the PLC subroutines

3.2 Conventions for the symbols used in the subroutines

Symbol table 6: MANMACH

This symbol table is for the function of a manual machine.

Symbol table 14: ASUP

This symbol table is for the ASUP function. It defines the start, operating results and other properties of the ASUP function.

Symbol table 15: PLC_sle_PP

This symbol table is for the PLC to select part programs. It defines the interface signals for the PLC to select part programs.

Symbol table 16: IS_MCP

This symbol table is for the manufacturer-defined MCP interface signals. With this symbol table you can define the MCP signal tables for your machines.

Within the PLC subroutine library and all the subroutines, all the MCP-related signals are defined in this symbol table.

An MCP signal is transferred to the interface area via a subroutine. For the SINUMERIK 808D MCP, you can use subroutine 37 to transfer the MCP input/output signals to the interface area. For your own MCP, you just need to create a subroutine to realize the transfer, and the other subroutines are still available.

Symbol table 17: IS_HMI

The symbol table 17 defines interface signals to/from the HMI.

Symbol table 18: IS_AUX

The symbol table 18 defines the interface signals from the NCK channel, including the auxiliary functions, D functions, H function, etc.

Symbol table 19: IS_NCK

The symbol table 19 defines the interface signals to/from the NCK.

Symbol table 20: IS_CHA

The symbol table 20 defines the interface signals to/from the channel.

Symbol table 21, 22, 23, 24, 25: IS_AX1, IS_AX2, IS_AX3, IS_AX4, IS_AX5

These five symbol tables define the interface signals to/from the axes.

Symbol table 26: IS_AX_P1

The symbol table 26 defines the interface signals to/from the PLC axis.

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Descriptions of the PLC subroutines

3.3 Subroutine 20 - AUX_MCP (machine auxiliary functions)

Symbol table 27: MD_PLC

The symbol table 27 defines the PLC machine data from the NCK.

Symbol table 28: ALARM

The symbol table 28 defines each bit of a PLC user alarm (V1600 000x).

Symbol table 29: NV_MEM

The symbol table 29 defines all the user data (128 byte, retentive) used in the standard subroutines.

Symbol table 30: SPC_MEM

The symbol table 30 defines the seven special memories of the SINUMERIK 808D (SM0.0 to SM0.6).

Symbol table 31: SBR_MEM

The symbol table 31 defines the memories used in the standard subroutines. These memories can be used as the global variables.

Symbol table 32: reserved for the subroutines

The symbol table 32 is a reserved symbol table.

3.3 Subroutine 20 - AUX_MCP (machine auxiliary functions)

Purpose

Subroutine 20 is used to control machine auxiliary functions like lamps, safe door (milling) and chip remover (milling).

Local variable definition

None

Relevant PLC machine data

None

Example for calling subroutine 20

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Descriptions of the PLC subroutines

3.4 Subroutine 21 - AUX_LAMP (working lamp)

Purpose

Subroutine 21 is used to control working lamp and can be called in AUX_MCP. One-time pressing of the "LAMP" key activates the working lamp while double pressing de-activates the working lamp.

Local variable definition

None

Relevant PLC machine data

None

Example for calling subroutine 20

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3.5 Subroutine 22 - AUX_SAFE_DOOR (safe door)

Purpose

Subroutine 22 is used to control safe door and can be called in AUX_MCP.

Local variable definition

None

Relevant PLC machine data

No. Description 14512 [16].2 Selection of safe door function (0: do not use; 1: use) 14512 [16].3 Safe door function is activated by M01/M02 (0: deactivate; 1: activate)

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Descriptions of the PLC subroutines

3.6 Subroutine 23 - AUX_CHIP (chip remover)

Example for calling subroutine 22

3.6 Subroutine 23 - AUX_CHIP (chip remover)

Purpose

Subroutine 23 is used to control chip remover and can be called in AUX_MCP. At first-time pressing of the "Chip Forward" key the output "ChipFwd" is high; at second-time pressing of the "Chip Forward" key the output "ChipFwd" becomes low. When the output "ChipFwd" is low, the output "ChipRev" becomes high at pressing "Chip Reverse" key and becomes low at releasing the "Chip Reverse" key.

Local variable definition

None

Relevant PLC machine data

No. Description 14512 [16].1 Selection of chip remover function (0: do not use; 1: use)

Example for calling subroutine 23

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Descriptions of the PLC subroutines

3.7 Subroutine 31 - PLC_ini_USR_ini (user initialization)

Purpose

Subroutine 31 is used for user initialization and can be called in subroutine PLC_INI. Since the subroutine PLC_INI can be called only during the first PLC cycle, the subroutine PLC_ini_USER_ini can be called also only during the first PLC cycle.

Local variable definition

None

Relevant PLC machine data

None

Example for calling subroutine 31

3.8 Subroutine 32 - PLC_INI (PLC initialization)

Purpose

Subroutine 32 is executed at the first PLC cycle (SM0.1). This subroutine set NCK interface signals according to the machine settings defined by PLC machine data. In this subroutine, the following interface signals are set:

● DB3200.DBX6.7: feed override of the NCK channel becomes active

● DB380x.DBX1.5: measurement system 1 of the axes is active

● DB380x.DBX1.7: feed override of the axes is active

● DB1700.DBX1.3: active ROV

At the end of this subroutine, subroutine 31 (PLC_ini_USR_ini) is automatically called. You can program the initialization of customer PLC project in the subroutine 31.

Local variable definition

None

Relevant PLC machine data

None

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Descriptions of the PLC subroutines

3.9 Subroutine 33 - EMG_STOP

Example for calling subroutine 32

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3.9 Subroutine 33 - EMG_STOP

Purpose

NOTICE

Do check whether this subroutine complies with relevant safety requirements or not.

Subroutine 33 handles the Emergency Stop. Pressing down the Emergency Stop button produces an emergency stop alarm and disables the 65 enable signal for SINAMICS V60. If you want to clear the emergency stop alarm, you must first release the Emergency Stop button and then press the RESET key on the MCP.

This subroutine can activate the alarm below:

Alarm 700016: DRIVE NOT READY

Local variable definition

Table 3- 3 Inputs

Variable Type Description DELAY WORD Power on/off sequence delay (unit: 10ms) E_KEY BOOL Emergency Stop key (NC) Drv_RDY BOOL Drive Ready: signal for SINAMICS V60 ready HWL_ON BOOL Triggered by the hardware limit switch of any axis (NO) 1) SpStop BOOL External spindle stop (NO) 2) Drv_ALM BOOL Drive alarm: signal for SINAMICS V60 alarm NO: Normal Open NC: Normal Close

This input can come from signal OVlmt of subroutine 40, and triggers the emergency stop when

the hardware limit appears.

Before the drive system disables the 65 enable signal, the PLC detects the spindle stop signal

from NCK to ensure that the spindle has stopped.

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Descriptions of the PLC subroutines

3.10 Subroutine 37 - MCP_NCK (MCP and HMI signal processing)

Table 3- 4 Outputs

Variable Type Description Drv1_En65 BOOL 65 enable signal of the first SINAMICS V60 Drv2_En65 BOOL 65 enable signal of the second SINAMICS V60 Drv3_En65 BOOL 65 enable signal of the third SINAMICS V60

One timer is used in this subroutine:

D_PON T26 Power-on delay

Relevant PLC machine data

No. Value Description

1 Spindle has an external stop signal 14512 [18].4 0 Spindle has no external stop signal

Example for calling subroutine 33

3.10 Subroutine 37 - MCP_NCK (MCP and HMI signal processing)

Purpose

Subroutine 37 is used to transfer the interface signals from the MCP and HMI to the NCK interfaces, and thus to activate the specific operating mode and control sequences. It has the following main functions:

● Selecting specific operating mode

● Selecting override

● Transferring signals from the HMI to NCK interfaces (for instance, program control,

handwheel, etc.)

● Controlling the axis traversing signal according to the PLC machine data

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Descriptions of the PLC subroutines

3.11 Subroutine 38 - MCP_Tool_Nr (display tool number on the MCP)

Local variable definition

None

Assigned global variables

None

Example for calling subroutine 37

3.11 Subroutine 38 - MCP_Tool_Nr (display tool number on the MCP)

Purpose

Subroutine 38 is used to display active tool number (< 100) with the 7-segment LED on the MCP. For a tool number ≥ 100, it displays "FF".

Local variable definition

None

Assigned global variables

None

Relevant PLC machine data

None

Example for calling subroutine 38

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Descriptions of the PLC subroutines

3.12 Subroutine 39 - HANDWHL (selecting a handwheel according to HMI interface signals)

Purpose

Subroutine 39 is used to select one of the two handwheels to control an axis (X, Y or Z) in the machine coordinate system or the workpiece coordinate system according to the HMI signals. With the HANDWHEEL key and axis selection key on the MCP, you can assign the handwheel 1 in the workpiece coordinate system to any axis.

Local variable definition

Assigned global variable

Note

You cannot use subroutine 39 together with subroutine 41 - MINI_HHU.

None

Relevant PLC machine data

No. Value Description

Example for calling subroutine 39

1 Handwheel assignment with the HMI 14512 [16].7 0 Handwheel assignment with the MCP

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Descriptions of the PLC subroutines

3.13 Subroutine 40 - AXIS_CTL (controlling the spindle and axes)

Purpose

Subroutine 40 is used to control the drive pulse enable (DB380xDBX4001.7) and controller enable (DB380xDBX2.1), monitoring the hardware limits and the reference cam signals, and controlling the enable signal for the spindle according to a spindle command (for example, SPINDLE CW, SPINDLE CCW, Mo3, M04, SPOS, etc.). The motor brake is automatically controlled by the SINAMICS V60 drives.

This subroutine provides two ways to realize the hardware limit control:

● PLC solution (MD14512 [18] bit 6 = 0)

Each feed axis has one (MD14512 [18] bit 7 = 1) or two (MD14512 [18] bit 7 = 0) hardware limit switches. This subroutine activates the NCK hardware limit function via the NCK interface DB380xDBX1000.0 or DB380xDBX1000.1 according to the configurations of the hardware limit switches, and thus makes the NCK produce a feed stop signal to an over-distance axis.

Furthermore, you can also connect the output OVlmt of this subroutine with the input HWL_ON of subroutine 33 to activate the Emergency Stop automatically once the hardware limit of any axis has been reached.

● Hardware solution (MD14512 [18] bit 6 = 1)

This solution is independent of the PLC and thus is much safer:

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The connection between the terminal 65 of the SINAMICS V60 and the +24 V signal is cut off automatically at any of the hardware limits or an EMERGENCY STOP.

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Descriptions of the PLC subroutines

3.13 Subroutine 40 - AXIS_CTL (controlling the spindle and axes)

Encoding the hardware limit switches

E_Key _1LMTp _2LMTp _3LMTp Direction 0 1 1 1 - EMERGENCY

0 0 1 1 DB3900.DBX4.7 1st + over limit 0 0 1 1 DB3900.DBX4.6 1st - over limit 0 0 0 1 DB3901.DBX4.7 2nd + over limit 0 0 0 1 DB3901.DBX4.6 2nd - over limit 0 0 0 0 DB3902.DBX4.7 3rd + over limit 0 0 0 0 DB3902.DBX4.6 3rd - over limit

Result

STOP active

In the hardware solution above, the feed stop signals for all axes (for example, disconnect the terminal 65 of the SINAMICS V60 via a relay) can be activated via the hardware limit switches when any of the hardware limits is reached or an EMERGENCY STOP happens. You can check the information of the PLC diagnostics from the encoding of the hardware limit switches shown in the table above, and identify the cause (Emergency Stop button or a hardware limit switch of an axis) of the EMERGENCY STOP signal.

Note

When using the hardware solution, you must take below information into consideration:  You must assign the axes one by one; for example, X axis, Z axis, spindle or X axis, Y

axis, Z axis, spindle. You must not assign the axes like X axis, Y axis, spindle, Z axis.

 You must set constant "1" (i.e. SM0.0) to the input signals of the hardware limits for

undefined axes; otherwise, the hardware limits of the undefined axes can be activated.

Local variable definition

Table 3- 5 Inputs

Name Type Description NODEF WORD Reserved word DrvEn_65 BOOL Drive enable signal from AXIS_CTL (SBR40) Drv1_RDY BOOL Ready signal of the 1st drive, reserved 1) Drv2_RDY BOOL Ready signal of the 2nd drive, reserved 1) Drv3_RDY BOOL Ready signal of the 3rd drive, reserved 1) OPTM BOOL Brake release switch (NO), used for drive optimization, reserved _1LMTp BOOL 1st axis hardware limit switch + (NC) 2) _1LMTn BOOL 1st axis hardware limit switch - (NC) _1REF BOOL 1st axis reference cam (NO) _2LMTp BOOL 2nd axis hardware limit switch + (NC) 2) _2LMTn BOOL 2nd axis hardware limit switch - (NC) _2REF BOOL 2nd axis reference cam (NO) _3LMTp BOOL 3rd axis hardware limit switch + (NC) 2) _3LMTn BOOL 3rd axis hardware limit switch - (NC)

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Descriptions of the PLC subroutines

3.13 Subroutine 40 - AXIS_CTL (controlling the spindle and axes)

Name Type Description _3REF BOOL 3rd axis reference cam (NO) _4REF BOOL Reserved

The PLC does not need to process the drive ready signals and alarm signals received from the

SINAMICS V60 because the SINUMERIK 808D has already processed these signals.

The hardware limit + is used for the input if there is only one hardware limit switch or when the

hardware solution is used.

Table 3- 6 Outputs

Name Type Description _1BRK BOOL 1st brake release output (high active, reserved) 1) _2BRK BOOL 2nd brake release output (high active, reserved) 1) _3BRK BOOL 3rd brake release output (high active, reserved) 1) OVlmt BOOL Over-distance output (active at any hardware limit, high active )

Motor brakes are controlled by the SINAMICS V60 drives themselves.

Assigned global variables

SP_CMD M138.1 Spindle start command (CW or CCW)

Relevant PLC machine data

No. Value Description

1 Overtravel employs the hardware solution 14512 [18].6 0 Overtravel employs the PLC solution 1 Each axis has only one hardware limit switch 14512 [18].7 0 Each axis direction has an hardware limit switch

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Descriptions of the PLC subroutines

3.14 Subroutine 41 - MINI_HHU (handwheel hand-held unit)

Example for calling subroutine 40

3.14 Subroutine 41 - MINI_HHU (handwheel hand-held unit)

Purpose

Subroutine 41 is used to support the customer's handheld units. With a handheld unit, you can assign the handwheels to X axis, Y axis and Z axis, and select incremental override X1, X10, X100 at the same time. You can then use the handwheels to control the movements of your machine.

Local variable definition

None

Assigned global variables

None

Relevant PLC machine data

None

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Descriptions of the PLC subroutines

3.14 Subroutine 41 - MINI_HHU (handwheel hand-held unit)

Example for calling subroutine 41

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Descriptions of the PLC subroutines

3.15 Subroutine 42 - SPINDLE (spindle control)

Purpose

Subroutine 42 is used for spindle control, including the spindle braking function. When the braking function is activated, in the JOG mode press the "SPINDLE LEFT" key or "SPINDLE RIGHT" key and then press the "SPINDLE STOP" key, after that, the spindle brakes. In the AUTO mode, the spindle brakes when it changes rotating direction or coasts down. When the spindle brakes, corresponding output becomes active; meanwhile, the spindle does not accept rotary command until braking completes.

Local variable definition

Table 3- 7 Inputs

Name Type Description DELAY WORD Spindle braking duration (unit: 0.1s) DrvEn BOOL Drive enable SP_EN BOOL Spindle action condition (1: allowed; 0: not allowed) IsBrake BOOL Spindle braking function (1: enabled; 0: forbidden)

Table 3- 8 Outputs

Name Type Description SP_brake BOOL Spindle braking output SP_LED BOOL Spindle running state

Assigned global variables

SP_B_CMD BOOL Spindle braking command T11 TIMER Spindle braking timer

Relevant PLC machine data

No. Type Description 14510 [13] BOOL Spindle braking duration (unit: 0.1s) 14510 [19].1 BOOL Selection of spindle braking function (1: enabled; 0:

forbidden)

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Descriptions of the PLC subroutines

3.16 Subroutine 43 - MEAS_JOG (measurement in the JOG mode)

Example for calling subroutine 42

3.16 Subroutine 43 - MEAS_JOG (measurement in the JOG mode)

Purpose

Subroutine 43 is used to process the information from the measuring probe and to realize the "measuring in the JOG mode" function. You can use this subroutine to calibrate the probe and measure a tool.

The precondition for calling this subroutine is to call subroutine MCP_NCK (SBR38) in the main program. The "measuring in the JOG mode" function is automatically deactivated if you have changed the operating mode when the function becomes active.

Local variable definition

Table 3- 9 Inputs

Name Type Description Meas_Enable BOOL Activating the function of "measuring in JOG mode" DB1400.DBD64 DWORD Valid tool number DB1400.DBD64

Assigned global variables

MEAS_OPAUT M240.0 Measuring in the AUTO mode CHL_HMI M240.2 From HMI signals: mode changes during measurement NO_KEY M240.3 No JOG key available for the axes FDI_MEASJOG M240.5 Meas_JOG forbidden for feed ON_MEASJOG M240.6 Meas_JOG activated PROBE_ON M240.7 Probe signal released JOG_MEASJOG M241.0 Operating mode manually output to Meas_JOG AUT_MEASJOG M241.1 Operating mode manually output to Meas_JOG CHL_MEASJOG M241.2 Operating mode change forbidden to Meas_JOG KEY_MEASJOG M241.3 JOG key Meas_JOG

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Descriptions of the PLC subroutines

3.17 Subroutine 44 - COOLING (cooling control)

RES_MEASJOG M241.4 Reset Meas_JOG ESC_MEASJOG M241.5 Interrupt Meas_JOG DRY_MEASJOG M241.6 Dry run Meas_JOG SBL_MEASJOG M241.7 Single block Meas_JOG

Relevant PLC machine data

None

Example for calling subroutine 43

3.17 Subroutine 44 - COOLING (cooling control)

Purpose

Subroutine 44 is used to start/stop cooling using the buttons on the MCP in the JOG mode, or to start (using the auxiliary function M07/M08 in the part program) or to stop (using the M09 in the part program) cooling in the AUTO/MDA mode. Cooling is forbidden in case of EMERGENCY STOP, cooling motor overload, program test or under the simulation mode.

This subroutine can activate the following alarms:

● Alarm 700018: motor overload for the cooling pump

● Alarm 700019: low coolant level

Local variable definition

Table 3- 10 Inputs

Name Type Description C_key BOOL Manual operating key (triggering signal) OVload BOOL Cooling motor overload (NC) C_low BOOL Low coolant level

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Descriptions of the PLC subroutines

3.17 Subroutine 44 - COOLING (cooling control)

Table 3- 11 Outputs

Name Type Description C_out BOOL Coolant output C_LED BOOL Coolant status display

Assigned global variables

COOLon MB150.0 Coolant on/off status

Relevant PLC machine data

None

Example for calling subroutine 44

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Descriptions of the PLC subroutines

3.18 Subroutine 45 - LUBRICAT (control of lubricate)

Purpose

Subroutine 45 is used to control the lubrication according to specific time interval and duration (independent of the distance that the axis has travelled). Meanwhile, a manual button is available to start the lubrication, and you can configure that the lubrication starts automatically each time that the machine is powered up. Normally, lubricating starts automatically and cyclically according to specified time interval Lintv, and operates for a specific time Ltime at each cycle. Lubrication stops in case of an Emergency Stop, lubrication motor overload, low lubricant level.

This subroutine can activate following alarms:

● Alarm 700020: lubrication motor overload

● Alarm 700021: low lubricant level

Local variable definition

Table 3- 12 Inputs

Name Type Description Lintv WORD Lubricating time interval (unit: 1 min) Ltime WORD Lubricating time duration of each cycle (unit: 0.01 s, max. 327.67 s) L_key BOOL Manual lubricating key (triggering signal) L1st BOOL Mode selection: the lubrication starts at the first PLC scan Ovload BOOL Lubricating motor overload L_low BOOL Low lubricate level

Table 3- 13 Outputs

Name Type Description L_out BOOL Lubrication output L_LED BOOL Indicant for lubricate output

Assigned global variables

L_interval C24 Timer for the lubricating time intervals (unit: min) L_time T27 Timer for very lubricating time duration (unit:

0.01s, max. 327.67 s)

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Descriptions of the PLC subroutines

3.19 Subroutine 46 - PI_SERVICE (Asynchronous Subroutine Program)

Relevant PLC machine data

No. Unit Range Description 14510 [24] Min. - Lubricating time interval 14510 [25] 0.01 s 100 to 2,000 Lubricating time duration

Example for calling subroutine 45

3.19 Subroutine 46 - PI_SERVICE (Asynchronous Subroutine Program)

Purpose

Subroutine 46 is for realizing functions like ASUP (Asynchronous Subroutine Program), deleting a password and reading current tool number. ASUP function means the execution of PLCASUP1.SPF or PLCASUP2.SPF called by the PLC. SINUMERIK 808D provides two ASUPs for the PLC. The two ASUPs can not be simultaneously executed, and the PLCASUP1.SPF has a higher priority over the PLCASUP2.SPF.

In a program, firstly you can initialize the ASUP1 and ASUP2 by setting "PI index" (DB1200.DBB4001) and "NCK read/write start" (DB1200.DBX4000.0), and then use a rising edge to trigger "ASUP1 start" (DB3400.DBX0.0) and "ASUP2 start" (DB3400.DBX1.0).

Table 3- 14 Relevant machine data

No. Name 10702 IGNORE_SINGLEBLOCK_MASK 11602 ASUP_START_MASK 11604 ASUP_START_PRIO_LEVEL 20116 IGNORE_INHIBIT_ASUP

Note Important!

The SINUMERIK 808D provides two user ASUPs. In the sample application, ASUP1 is used for manual tool change and ASUP2 is used for the MANUAL MACHINE of the workpiece on a turning machine with the Manual Machine Plus function.

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Descriptions of the PLC subroutines

3.19 Subroutine 46 - PI_SERVICE (Asynchronous Subroutine Program)

Local variable definition

Table 3- 15 Inputs

Name Type Description ASUP1_trigger BOOL Calling the ASUP1, rising edge active ASUP2_trigger BOOL Calling the ASUP1, rising edge active

Table 3- 16 Outputs

Name Type Description ASUP1Run BOOL Running state of the ASUP1 ASUP2Run BOOL Running state of the ASUP2 Err1 BOOL ASUP1 execution error Err2 BOOL ASUP2 execution error

Occupied global variables

IniASUP1 M229.0 Mark of ASUP1 initialization IniASUP2 M229.1 Mark of ASUP2 initialization

Relevant PLC machine data

None

Example for calling subroutine 46

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Descriptions of the PLC subroutines

3.20 Subroutine 47 - PLC_Select_PP (PLC selects a subroutine)

Purpose

Subroutine 47 is used to select a part program.

You firstly need to create a PLC program-calling table, and assign a program index to each part program in this table. In subroutine 47 you can assign DB1700.DBB1000 to the "Program index" to select the corresponding part program.

Local variable definition

Table 3- 17 Inputs

Name Type Description PP_num BOOL The index for a part program

Table 3- 18 Outputs

Name Type Description Finish BOOL Part program selection finished Error BOOL Part program selection error

Assigned global variables

SelPP_FinOm BOOL M239.6 Indicates that a part program has been selected SelPP_ErrOm BOOL M239.7 Indicates that an error occurs when selecting a part program

Relevant PLC machine data

None

Example for calling subroutine 47

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Descriptions of the PLC subroutines

3.21 Subroutine 48 - ServPlan (service plan)

Purpose

To use subroutine 48, you must have created a service plan on the SINUMERIK 808D. When the pre-alarm time arrives, the machine outputs a notification message. When the final alarm time arrives, the machine outputs an alarm message.

Local variable definition

Note

To perform a service plan on the PLC, you need to download DB9903(SP_INI) and DB9904(SP_ACT).

Table 3- 19 Inputs

Name Type Description Deact0 BOOL Freezing a service plan AckMsg0 BOOL Confirming the notification message of a service plan

Table 3- 20 Outputs

Name Type Description HintMsg0 BOOL Notification message Alarm0 BOOL Alarm message

Assigned global variables

ServPlan_msg0 BOOL Notification message of the first service plan ServPlan_alm0 BOOL Alarm message of the first service plan

Relevant PLC machine data

None

Example for calling subroutine 48

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Descriptions of the PLC subroutines

3.22 Subroutine 49 - GearChg1_Auto (automatic spindle gear change)

Purpose

Subroutine 49 is used to automatically change the gear for the analog spindle with 2-level gear detection signals.

During a gear change, the spindle oscillates and the PLC outputs the gear change signal. When the PLC detects that the desired gear level has been reached, the gear change has been completed.

You cannot use this subroutine together with subroutine 50.

Local variable definition

Table 3- 21 Inputs

Name Type Description D_CHG WORD Gear change delay time (unit: 0.01 s) D_MON WORD Gear change monitoring time (unit: 0.01 s) D_S0 WORD Spindle stop delay time (unit: 0.01 s) T_GC WORD Monitor time for whole gear change process, must > D_CHG + D_MON

+ D_S0 (unit: 0.01 s) S_hold BOOL Signal of zero spindle velocity (NO) S_alarm BOOL Spindle alarm (NO) LGi BOOL Low detection switch (NO) HGi BOOL High detection switch (NO)

Table 3- 22 Outputs

Name Type Description LGo BOOL Low gear output HGo BOOL High gear output LG_LED BOOL Status display for the low gear HG_LED BOOL Status display for the high gear

Assigned global variables

HGom BOOL M248.0 Signal indication of high gear stage output LGom BOOL M248.1 Signal indication of low gear stage output HGcmd BOOL M248.2 High gear level command LGcmd BOOL M248.3 Low gear level command SPhold BOOL M248.4 Spindle stops and ready for oscillation Dstill BOOL M248.5 Signal for spindle stop Dchg BOOL M248.6 Spindle gear change delay Dmon BOOL M248.7 Monitoring for the gear change

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Descriptions of the PLC subroutines

3.23 Subroutine 50 - GearChg2_Virtual (virtual spindle gear change)

Req_SP_G_ CHG

Req_Low_G BOOL M244.1 Request to change to the low gear stage Req_Hign_G BOOL M244.2 Request to change to the high gear stage D_S0 TIMER T13 Spindle stop delay Td_GearChg TIMER T24 Gear change delay Tm_GearChg TIMER T25 Delay for monitoring the gear change

BOOL M244.0 Request for spindle gear change

Relevant PLC machine data

None

Example for calling subroutine 49

3.23 Subroutine 50 - GearChg2_Virtual (virtual spindle gear change)

Purpose

Using subroutine 50, you can requests the system to switch to the corresponding gear after changing the gear manually. The corresponding gear is set when M41-M45 are executed.

This subroutine must not be used together with GearChg1_Auto (SBR 49).

Local variable definition

Inputs

None

Table 3- 23 Outputs

Name Type Description HL_gear BOOL Output of the high/low gear

0: gear-level low gear; 1: gear-level high gear)

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Descriptions of the PLC subroutines

3.24 Subroutine 51 - Turret1_HED_T (turret with Hall effect device position sensor)

Assigned global variables

None

Relevant PLC machine data

None

Example for calling subroutine 50

3.24 Subroutine 51 - Turret1_HED_T (turret with Hall effect device position sensor)

Purpose

Subroutine 51 is used to control the turret with a Hall effect device positioning sensor, and the turret motor is controlled by the PLC.

The turret rotates clockwise to search for a tool, and rotates counter-clockwise after positioning the desired tool to clamp it (the turret CCW rotation time can be adjusted). An alarm occurs if the turret fails to position the desired tool after the duration expires. The subroutine verifies the time that the turret rotates CCW, and sets a limit of maximum 3 seconds for this rotation time to prevent the turret motor from being broken.

In the AUTO and MDA modes, the T function starts a tool change operation. In the JOG mode, a short strike on the MCP key changes a turret position.

During a tool change, the NC interface signals "Read-in disable" (DB3200.DBX6.1) and "Feedhold" (DB3200.DBX6.0) are set; this means that the part program can only continue to run after the tool change.

The turret positioning is prohibited in the case of an Emergency Stop, turret motor overload or program test/simulation.

The timing diagram for positioning a tool in the turret using the Hall effect device positioning sensor is shown as follows:

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Descriptions of the PLC subroutines

3.24 Subroutine 51 - Turret1_HED_T (turret with Hall effect device position sensor)

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This subroutine can activate the following alarms:

● Alarm 700022: Turret motor overload

● Alarm 700023: Programmed tool number higher than the max. tool number of the turret

● Alarm 700024: Wrong setting of the max. tool number for the turret

● Alarm 700025: No turret positioning signals available

● Alarm 700026: Tool positioning time out

Local variable definition

Table 3- 24 Inputs

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Name Type Description Tmax WORD Max. tool number of the turret C_time WORD CCW clamping time (unit: 0.1 s) M_time WORD Monitoring time for the tool change T_polar BOOL Polar selection for the tool change

0: tool position low active

1: tool position high active T_key BOOL Manual tool change key (triggering signal ) T_01 to T_06 BOOL Tool position sensor (low active) OVload BOOL Turret motor overload (NC)

Table 3- 25 Outputs

Name Type Description T_cw BOOL Turret positioning T_ccw BOOL Turret clamping T_LED BOOL Status display during the tool change ERR1 BOOL No turret positioning signals available ERR2 BOOL Programmed tool out of turret range ERR3 BOOL Tool positioning time out ERR4 BOOL Turret motor overload ERR5 BOOL Wrong setting of the max. tool for the turret ERR6 BOOL Reserved

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Descriptions of the PLC subroutines

3.24 Subroutine 51 - Turret1_HED_T (turret with Hall effect device position sensor)

Assigned global variables

T_cw_m M156.0 Position marking for turret CW rotation T_ccw_m M156.1 Position marking for turret CCW rotation CcwDelay M156.2 Turret CCW rotation delay K_active M156.3 Manual key active Tpos_C M156.4 Turret position changed Tp_eq_Tc M156.5 Programmed tool number equal to the current tool

number Tp_eq_0 M156.6 Programmed tool number equal to zero T_P_INDX MD160 Monitoring the tool change buffer zone in the JOG

mode T_CHL M168.4 Operating mode locked Tm1_FindT T15 Monitoring timer for tool searching T_CLAMP T13 Clamping timer for turret 1

Relevant PLC machine data

No. Unit Description 14510 [20] - Max. tool number (4 or 6) 14510 [21] 0.1 s Turret clamping time 14510 [22] 0.1 s Monitoring time for tool searching 14512[17].0 - Activating the turret function of a turning machine

Example for calling subroutine 51

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Descriptions of the PLC subroutines

3.25 Subroutine 52 - TURRET2_BIN_T (turret with binary coding function)

3.25 Subroutine 52 - TURRET2_BIN_T (turret with binary coding

Purpose

function)

Subroutine 52 is used to control the turret with encoder positioning signals and function of dual-direction adjacent tool change. Contact the turret vendor for the working theory and the timing diagram of a tool change.

During a tool change, the NC interface signals "Read-in disable" (DB3200.DBX6.1) and "Feedhold" (DB3200.DBX6.0) are set, so the part program can continue running only after the tool change action.

The turret position action is forbidden in case of an emergency stop, turret motor overload or program test/simulation.

This subroutine can activate the following alarms:

● Alarm 700022: Turret motor overload

● Alarm 700023: Programmed tool number higher than the max. tool number of the turret

● Alarm 700024: Wrong setting of the max. tool number for the turret

● Alarm 700026: Not able to find expected tool in monitor time

● Alarm 700011: Not able to lock tool in expected time

Local variable definition

Table 3- 26 Inputs

Name Type Description Tmax WORD Max. tool number of the turret Tm_Lck WORD Turret clamping time (unit: 0.1 s) Tm_Chg WORD Tool change monitoring T_1 BOOL Tool code A x 1 T_2 BOOL Tool code B x 2 T_3 BOOL Tool code C x 4 T_4 BOOL Tool code D x 8 Parity BOOL Position parity Strobe BOOL Position strobe OVload BOOL Turret motor overload (NC) P_Indx BOOL Turret pre-indexing sensor T_key BOOL Manual tool change key (triggering signal )

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Descriptions of the PLC subroutines

3.25 Subroutine 52 - TURRET2_BIN_T (turret with binary coding function)

Table 3- 27 Outputs

Name Type Description T_cw BOOL Turret CW rotation output T_ccw BOOL Turret CCW rotation output Magent BOOL Turret clamping output T_LED BOOL Status display during the tool change ERR1 BOOL Turret motor overload ERR2 BOOL Programmed tool out of turret range ERR3 BOOL Wrong setting of the max. tool for the turret ERR4 BOOL Not able to find pre-index signal in expected time ERR5 BOOL Not able to lock in expected time

Assigned global variables

T_CURRENT VD14000064 Current tool (retentive data) T_cw_m M156.0 Position marking for turret CW rotation T_ccw_m M156.1 Position marking for turret CCW rotation T_P_INDX MD160 Monitoring the tool change buffer zone in the JOG mode T_DES M164 Desired tool number T_DIR M168.0 Direction of adjacent tool change T_POS M168.1 Turret tool positioning finished T_LOCK M168.2 Turret clamping command T_MAG M168.3 Turret magnetic clamping

Relevant PLC machine data

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Descriptions of the PLC subroutines

3.26 Subroutine 53 - Turret3_CODE_T (tool change control for turret with coding function)

Example for calling subroutine 52

3.26 Subroutine 53 - Turret3_CODE_T (tool change control for turret with coding function)

Purpose

Subroutine 53 is used to control the turret with coded tool positions and function of adjacent tool change. The difference between the subroutine 52 and the subroutine 53 is that the subroutine 52 uses binary tool position codes while the subroutine 53 uses tool position codes made according to a specific common turret.

During a tool change, the NC interface signal "Feedhold" (DB3200.DBX6.0) is set; this means that the part program can only continue to run only after the tool change.

The turret positioning is prohibited in the case of an Emergency Stop, turret motor overload or program test/simulation.

Local variable definition

Table 3- 28 Inputs

Name Type Description M_time WORD Monitoring time for the tool change T_key BOOL Manual tool change key (NO ) A to D BOOL Tool position code signals Strobe BOOL Position strobe Lock_i BOOL Position clamping OVload BOOL Turret motor overload (NC)

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Descriptions of the PLC subroutines

3.26 Subroutine 53 - Turret3_CODE_T (tool change control for turret with coding function)

Tool position Tool position code A Tool position code B Tool position code C Tool position code

D 1 0 1 0 0 2 0 0 0 1 3 1 0 0 0 4 0 0 1 0 5 1 1 1 0 6 1 0 1 1 7 1 1 0 1 8 0 1 1 1

Table 3- 29 Outputs

Name Type Description T_UNCLAMP BOOL Turret release T_CLAMP BOOL Turret clamping T_CW BOOL Turret CW rotation T_CCW BOOL Turret CCW rotation T_LED BOOL Status display during the tool change

Assigned global variables

Tpos_C BOOL M156.4 Tool searching finished T_cwm BOOL M235.6 Mark for turret CW rotation T_ccwm BOOL M235.7 Mark for turret CCW rotation TK_act BOOL M236.4 Mark for manual tool change Tc_ne_0 BOOL M237.0 Current tool number is not 0 T_dir BOOL M237.1 Direction for searching for an adjacent tool

Relevant PLC machine data

No. Unit Description 14510 [22] 0.1 s Monitoring time for searching for a tool

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Descriptions of the PLC subroutines

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3.27 Subroutine 54 - Turret2_3_ToolDir (tool change direction)

Example for calling subroutine 53

3.27 Subroutine 54 - Turret2_3_ToolDir (tool change direction)

Purpose

Subroutine 54 is used to find out the direction of searching for an adjacent tool and the preindexing position (this is, the previous position of the desired tool in the direction of an adjacent tool). To find out the direction, you need to know the max. tool number of the turret and the programmed tool number.

You can use this subroutine to control the turret to search for an adjacent tool on a turning machine or a machine centre. The turret tool position ranges from 2 to 64.

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Descriptions of the PLC subroutines

3.27 Subroutine 54 - Turret2_3_ToolDir (tool change direction)

Local variable definition

Table 3- 30 Inputs

Name Type Description Tmax DWORD The max. turret tool position number Pnum DWORD Programmed tool number Tcurr DWORD Current position of the turret

Table 3- 31 Outputs

Name Type Description P_INDXo DWORD Pre-indexing position: the previous tool position of the desired tool in

the direction of an adjacent tool.

DIR BOOL Tool change direction:

1: CW; 0: CCW

Assigned global variables

None

Relevant PLC machine data

None

Example for calling subroutine 54

This subroutine is called by subroutine 52 and subroutine 53.

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Descriptions of the PLC subroutines

3.28 Subroutine 55 - Tail_stock_T (Tailstcok control program for turning machines)

Purpose

Subroutine 55 is used to control forward or backward movement of the tail stock on a turning machine.

In the JOG mode, press the "Tailstock" key to move the tailstock forward or backward. Pressing "Tailstock" moves the tailstock forward, and one more pressing moves the tailstock backward.

In the AUTO mode, you can use M20 or M21 to control the forward or backward movement of the tailstock.

Local variable definition

Table 3- 32 Inputs

Name Type Description TailCtrl_K BOOL Tailstock SP_status BOOL Spindle status

Table 3- 33 Outputs

Name Type Description TailAdv_O BOOL Output to move the tailstock forward TailRet_O BOOL Output to move the tailstock backward

Assigned global variables

SP_RUNm BOOL M236.0 Indicate that the spindle is running TailAdv_m BOOL M229.2 Indicates that the tailstock is moving forward TailRet_m BOOL M229.3 Indicates tailstock is moving backward

Relevant PLC machine data

None

Example for calling subroutine 55

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Descriptions of the PLC subroutines

3.29 Subroutine 56 - Lock_unlock_T (clamping control for turning machines)

Purpose

Subroutine 56 is used to control the clamping or release for the chuck for a turning machine.

In the JOG mode, press the "External/Inside clamping" key to select either external clamping or inside clamping, and press "Clamp" or "Unclamp" key to clamp or release the chuck. Furthermore, you can also use the "Foot switch" to clamp or release the chuck. Pressing the "Foot switch" for once release the chuck, and one more pressing clamps the chuck.

In the AUTO mode, you can execute M10/M11 to control the clamping or release of the chuck.

Local variable definition

Note

The chuck status should be kept when clamping outputs are zero.

Table 3- 34 Inputs

Name Type Description Delay WORD Clamping delay time LckRel_k BOOL Lock / release toggle signal ExtIn_k BOOL External/inside clamping key S_velo BOOL Spindle velocity signals

Foot_switch BOOL Foot switch signal

0: spindle velocity is 0 1: spindle is running

Table 3- 35 Outputs

Name Type Description Lck1_O BOOL Clamping output 1 Lck2_O BOOL Clamping output 2 Lck_LED BOOL Clamping state ExtIn_LED BOOL External/inside clamping state:

0: external clamping 1: inside clamping

Err1 BOOL No chuck operation during the running of the spindle

Assigned global variables

ChuckLcked BOOL M229.4 Chuck clamped ChuckLckLED BOOL M239.2 Chuck at released state ExtInLED_Om BOOL M239.5 External/inside clamping state TR_Status BOOL M237.6 Chuck release command

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Descriptions of the PLC subroutines

3.30 Subroutine 58 (MM_MAIN)

Relevant PLC machine data

None

Example for calling subroutine 56

3.30 Subroutine 58 (MM_MAIN)

Purpose

To use subroutine 58, you must have licensed the optional manual machine plus function for the SINUMERIK 808D turning machine. The subroutines 46, 58 and 59 must be used together. This subroutine is used to control the manual machine function after the manual machine interface is activated.

Local variable definition

Table 3- 36 Inputs

Name Type Description TK_X_P BOOL Forward on axis X TK_X_M BOOL Backward on axis X TK_Z_P BOOL Forward on axis Z TK_Z_M BOOL Backward on axis Z RAPID BOOL Rapid feed SP_CW BOOL Clockwise rotation of the spindle SP_CCW BOOL Counter-clockwise rotation of the spindle SP_STOP BOOL Spindle stop NC_START BOOL NC start NC_STOP BOOL NC stop AUTO_ENABLE BOOL AUTO mode allowed MDA_ENABLE BOOL MDA mode allowed ROV BOOL Rapid rate

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Descriptions of the PLC subroutines

3.30 Subroutine 58 (MM_MAIN)

Table 3- 37 Outputs

Name Type Description AL_03 BOOL Not approaching the reference point on axis X AL_04 BOOL Not approaching the reference point on axis Z AL_09 BOOL Incorrect start in the spindle direction AL_11 BOOL JOG program timeout AL_12 BOOL Spindle rate not 100% AL_13 BOOL Spindle not being started AL_14 BOOL Feed rate 0% AL_16 BOOL Spindle direction change in a thread not allowed

Assigned global variables

Byte Signal Byte 7 Byte 6 Byte 5 Byte 4 Byte 3 Byte 2 Byte 1 Byte 0

MB1 70

MB1 71

MB1 72

MB1 73

MB1 74

MB1 75

MB1 76

MB1 77

MB1 78

MB1 79

MB1 80

HMI<->MM Request

for MM HMI startup

HMI<->MM

HMI<->MM Cone

angle 270°360°

HMI<->MM Directio

HMI<->MM Working

HMI<->MM

Recuttin

Cone angle 270°

step enabled

Cone angle 180°270°

Groove enabled

Cone angle 180°

Thread chaining enabled

Cone angle 90°180°

Drilling enabled

Cone angle 90°

n key enabled

Arc enabled

g cancele d

MM HMI enabled

Cone angle 0°-90°

Spindle

Cutting enabled

Recuttin g perform ed

MM HMI started

Cone angle 0°

rotated

Thread enabled

Recut the thread or not?

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Descriptions of the PLC subroutines

3.30 Subroutine 58 (MM_MAIN)

Relevant PLC machine data

No. Unit Range Description MD14512[19].7 - - 1: to enable the manual machine function

0: to disable the manual machine function

Example for calling subroutine 58

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Descriptions of the PLC subroutines

3.31 Subroutine 59 (MM_MCP_808D)

Purpose

To use subroutine 59, you must have licensed the optional manual machine plus function for the SINUMERIK 808D turning machine. The subroutines 46, 58 and 59 must be used together. Normally, the spindle will be stopped after you press the NC reset key. However, when a manual machine is started, you do not want to stop the spindle after pressing the NC reset key. In this case, call subroutine 59 (MM_MCP_808D) after executing subroutine 37 (MCP_NCK). Then you do not need to rewrite subroutine 37 (MCP_NCK).

Local variable definition

Table 3- 38 Inputs

Name Type Description SP_STOP_K BOOL Spindle stop

Outputs

None

Assigned global variables

None

Relevant PLC machine data

No. Unit Range Description MD14512[19].7 - - 1: to enable the manual machine function

Example for calling subroutine 59

0: to disable the manual machine function

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Descriptions of the PLC subroutines

3.32 Subroutine 60 - Disk_MGZ_M (disk-style tool magazine for milling)

Purpose

You can use subroutine 60 to control the disk-style tool magazine on a milling machine.

In the reference point mode, initialize the tool magazine by pressing the "Original position of the tool magazine" key.

In the manual mode, you can rotate the tool magazine clockwise or counter-clockwise, and enable the tool magazine to reach the spindle or tool change position respectively through the "Clockwise rotation of the magazine", "Counter-clockwise rotation of the magazine", "Tool magazine reaching the spindle", and "Tool magazine reaching the tool change position" keys.

In the auto mode, you need to execute M06 to call the tool change subroutine when compiling a part program. Subroutine 60 and the tool change subroutine must be used together during the tool change process. Three operations are involved in the tool change control, that is, tool return, tool retrieval, and tool change.

1. The tool return operation is to return the tool on the spindle back to the tool magazine disk when compiling T0 and a tool is located on the spindle.

2. The tool retrieval operation is to get the desired tool from the tool magazine disk and install it on the spindle when compiling Tx (x ≠ 0) and no tool is on the spindle.

3. The tool change operation is to first return the tool on the spindle back to the tool magazine disk and then get the desired tool from the tool magazine disk when compiling Tx (x ≠ 0; x ≠ number of the tool on the spindle).

For details, please refer to the tool change subroutine.

The following machine data is involved in this subroutine:

MD10715: M_NO_FCT_CYCLE[0]

MD10716: M_NO_FCT_CYCLE_NAME[0]

MD22550: TOOL_CHANGE_MODE

MD22560: TOOL_CHANGE_M_CODE

Local variable definition

Table 3- 39 Inputs

Name Type Description MgzCnt BOOL Tool magazine count MgzRef_k BOOL Tool magazine reset, with the current tool number set

MgzCW_k BOOL Tool magazine forward MgzCCW_k BOOL Tool magazine backward MgzSp_k BOOL Spindle position key for the tool magazine MgzOrg_k BOOL Original position key for the tool magazine

to 1

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Descriptions of the PLC subroutines

3.32 Subroutine 60 - Disk_MGZ_M (disk-style tool magazine for milling)

Name Type Description MgzSp_pos BOOL Tool magazine has reached the spindle position MgzOrg_pos BOOL Tool magazine has reached the original position T_rel_pos BOOL Release position fort he tool magazine T_lck_pos BOOL Clamping position for the tool magazine T_rel_k BOOL Tool release key for the spindle T_rel_EnK BOOL Enabling key for the tool release of the spindle

Table 3- 40 Outputs

Name Type Description MgzCW_o BOOL Clockwise rotation of the tool magazine MgzCCW_o BOOL Counter-clockwise rotation of the tool magazine MgzSp_o BOOL The spindle position for the tool magazine MgzOrg_o BOOL The original position for the tool magazine SpRelT_o BOOL Releasing a tool RelT_En_o BOOL Enabling releasing a tool MgzSp_LED BOOL Magazine reaches spindle position MgzOrg_LED BOOL Magazine reaches original position

Assigned global variables

MgzCW_cmd BOOL M230.0 Command for clockwise rotation of the tool magazine MgzCCW_cmd BOOL M230.1 Command for counter-clockwise rotation of the tool

Mgz_rot_CMD BOOL DB4900.DBB24 Tool change command from the tool change subroutine

Relevant PLC machine data

None

magazine

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Descriptions of the PLC subroutines

3.33 Subroutines 34 to 36, 57, 61 and 62

Example for calling subroutine 60

3.33 Subroutines 34 to 36, 57, 61 and 62

Explanation

Subroutines 34 to 36, 57, 61 and 62 are reserved for users.

3.34 Subroutine 63 - TOGGLES

Purpose

Two types of switches are provided in subroutine 63, more specifically, a hold switch for switching a circuit on (press) and off (press again), and a delay switch for switching on a circuit and automatically switching it off after a certain time period. A total of six hold switches and two delay switches are available in this subroutine, with the delay duration being configurable. The key inputs or outputs of the subroutine can be connected with any physical inputs or outputs. The inputs and outputs of all idle switches are respectively "ZERO" and "NULL_b" (M255.7).

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Descriptions of the PLC subroutines

3.34 Subroutine 63 - TOGGLES

Local variable definition

Table 3- 41 Inputs

Name Type Description Delay7 WORD Delay duration of switch 7 (unit: 10 ms) Delay8 WORD Delay duration of switch 8 (unit: 10 ms) Ki_1…Ki_6 BOOL Input of hold switch 1...input of hold switch 6 Ki_7…Ki_8 BOOL Inputs of delay switches 7 and 8

Table 3- 42 Outputs

Name Type Description Ko_1…Ko_8 BOOL Output of switch 1...output of switch 8

Assigned global variables

K1st1 … K8st1 MB245 State 1 of the hold switch K1st2 … K8st2 MB246 State 2 of the hold switch K1on … K8on MB247 "On" state of the hold switch

Relevant PLC machine data

None

Example for calling subroutine 63

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Use of user alarms in the PLC subroutines

Some user alarms are activated in a subroutine. In the case that such an alarm is generated, you can search the following list for the subroutine wherein the alarm is activated.

Alarm No. Interface Address Alarm Description From SBR 700010 DB1600.DBX1.2 HHU is active SBR41: MINI_HHU 700011 DB1600.DBX1.3 Not able to lock tool in expected time 700012 DB1600.DBX1.4 Spindle in braking progress SBR42: SPINDLE 700013 DB1600.DBX1.5 Operation while chuck is not locked SBR56:

700014 DB1600.DBX1.6 Gear-change time out 700015 DB1600.DBX1.7 Gear level position error 700016 DB1600.DBX2.0 Drives not ready SBR33: EMG_STOP 700017 DB1600.DBX2.1 Operate chuck when spindle or part

program is running 700018 DB1600.DBX2.2 Cooling motor overload 700019 DB1600.DBX2.3 Coolant liquid position in low level 700020 DB1600.DBX2.4 Lubrication motor overload 700021 DB1600.DBX2.5 Lubricant liquid position in low level 700022 DB1600.DBX2.6 Turret motor overload 700023 DB1600.DBX2.7 Programmed tool number > max. turret

on turret number 700024 DB1600.DBX3.0 Max. tool number setting error 700025 DB1600.DBX3.1 No position signals from turret 700026 DB1600.DBX3.2 Not able to find expected tool in monitor

time 700027 DB1600.DBX3.3 Approach reference point again after

rotation monitoring 700028 DB1600.DBX3.4 Tool is not locked SBR53:

700029 DB1600.DBX3.5 Reminding information for 1st service

plan 700030 DB1600.DBX3.6 Alarm for 1st service plan 700031 DB1600.DBX3.7 Magazine not in spindle position or

original position 700032 DB1600.DBX4.0 Magazine in spindle position and

original position 700033 DB1600.DBX4.1 Magazine turn key when magazine or

spindle not ready 700034 DB1600.DBX4.2 Block search, tool in spindle <>

programmed tool

Lock_unlock_T SBR49:

GearChg1_Auto

SBR56: Lock_unlock_T

SBR44: COOLING

SBR45: LUBRICAT

SBR51: Turret1_HED_T

SBR52: Turret2_BIN_T

SBR53: Turret3_CODE_T

SBR40: AXIS_CTL

Turret3_CODE_T SBR48: ServPlan

SBR60: Disk_MGZ_M

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Use of user alarms in the PLC subroutines

Alarm No. Interface Address Alarm Description From SBR

700035 DB1600.DBX4.3 Spindle not reach tool-release pos. in

time 700036 DB1600.DBX4.4 Spindle not reach tool-lock pos. in time SBR60: Disk_MGZ_M 700049 DB1600.DBX6.1 Reference point X-axis not reached SBR58: MM_MAIN 700050 DB1600.DBX6.2 Reference point Z-axis not reached SBR58: MM_MAIN 700051 DB1600.DBX6.3 Wrong spindle direction started SBR58: MM_MAIN 700052 DB1600.DBX6.4 Watchdog timer JOG-program SBR58: MM_MAIN 700053 DB1600.DBX6.5 Spindle override not 100% SBR58: MM_MAIN 700054 DB1600.DBX6.6 Spindle is not started SBR58: MM_MAIN 700055 DB1600.DBX6.7 Feed override = 0% SBR58: MM_MAIN 700056 DB1600.DBX7.0 Change of spindle direction not

possible in thread 700059 DB1600.DBX7.3 Safe door not closed, NC start not

possible 700060 DB1600.DBX7.4 Channel not in reset, change PRT not

possible

SBR60: Disk_MGZ_M

SBR58: MM_MAIN

SBR22: AUX_SAFE_DOOR

SBR37: MCP_NCK

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PLC sample applications

5.1 PLC sample application (turning)

This sample application is applicable to machines with the following configurations:

● Two axes: axes X and Z, with a hardware limit switch respectively in the positive and negative directions of each axis

● An analog spindle: SP

● HALL effect device turret with six-working stations

● PLC-controlled timely and quantitatively lubrication system

● PLC-controlled cooling system

Table 5- 1 Assignment of inputs and outputs

Signal Description Remark

I0.0 Emergency Stop button Normally closed I0.1 Limit switch in the "+" direction of axis X Normally closed I0.2 Limit switch in the "-" direction of axis X Normally closed I0.3 I0.4 I0.5 Limit switch in the "+" direction of axis Z Normally closed I0.6 Limit switch in the "-" direction of axis Z Normally closed I0.7 Reference point switch of axis X Normally open I1.0 I1.1 Reference switch of axis Z Normally open I1.2 Tool path detecting signal T1 Valid at a low level I1.3 Tool path detecting signal T2 Valid at a low level I1.4 Tool path detecting signal T3 Valid at a low level I1.5 Tool path detecting signal T4 Valid at a low level I1.6 Tool path detecting signal T5 Valid at a low level I1.7 Tool path detecting signal T6 Valid at a low level I2.0 Turret motor overload Normally closed I2.1 Reserved for other types of turrets Reserved I2.2 I2.3 Chuck foot switch Normally open I2.4 Coolant level too low Normally closed I2.5 Cooling pump motor overload Normally closed I2.6 Lubricant level to low Normally closed I2.7 Lubrication pump motor overload Normally closed I3.0 Reserved

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PLC sample applications

5.1 PLC sample application (turning)

Signal Description Remark

I3.1 Reserved I3.2 Reserved I3.3 Reserved I3.4 Reserved I3.5 Reserved I3.6 Reserved I3.7 Reserved I4.0 Handheld unit: axis X selected Valid at a high level I4.1 Handheld unit: axis Y selected Valid at a high level I4.2 Handheld unit: axis Z selected Valid at a high level I4.3 Handheld unit: fourth axis selected Reserved I4.4 Handheld unit: increment X1 Valid at a high level I4.5 Handheld unit: increment X10 Valid at a high level I4.6 Handheld unit: increment X100 Valid at a high level

I4.7 Handheld unit: enabled Valid at a high level Q0.0 Working lamp Q0.1 Q0.2 Tailstock forward Q0.3 Tailstock backward Q0.4 Cooling pump Q0.5 Lubrication pump Q0.6 Chuck output 1 Q0.7 Chuck output 2 Q1.0 Turret motor rotating clockwise Q1.1 Turret motor rotating counter-clockwise Q1.2 Reserved for other types of turrets Q1.3 Reserved for other types of turrets Q1.4 Gear shift: low gear level (SBR49: GearChg1_Auto) / Gear

level status (SBR50: GearChg2_Virtual) Q1.5 Gear shift: high gear level (SBR49: GearChg1_Auto) Q1.6 Q1.7 Handheld unit valid

Table 5- 2 Definition of user-defined keys on the MCP

User-defined key 1 Working lamp User-defined key 2 Manual cooling User-defined key 3 Manual tool change User-defined key 4 Manual chuck clamping and unclamping User-defined key 5 Chuck clamping internally/externally User-defined key 6 Tailstock

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PLC sample applications

5.1 PLC sample application (turning)

Structure of the sample application (OB1)

Call Conditions Subroutine Name Description Each scan (SM0.0) AUX_MCP (SBR20) Auxiliary function First scan (SM0.1) PLC_INI (SBR32) PLC initialization Each scan (SM0.0) EMG_STOP (SBR33) Emergency Stop control Each scan (SM0.0) MCP_NCK (SBR37) Transferring MCP and HMI

signals to the NCK interface

Each scan (SM0.0) HANDWHL (SBR39) Selecting a hand wheel through

the interface signal DB1900.DBB1xxx

Each scan (SM0.0) AXIS_CTL (SBR40) Coordinate enabling control,

hardware limit, etc. Each scan (SM0.0) SPINDLE (SBR42) Spindle control Each scan (SM0.0) COOLING (SBR44) Cooling control Each scan (SM0.0) TURRET1 (SBR46) HALL effect device turret control Each scan (SM0.0) ServPlan (SBR48) Maintenance plan example: first

task

Setting relevant PLC machine data

Machine data Corresponding function 14510[12] JOG key layout 14510[20] The maximum number of tool positions 14510[21] Time for locking a turret (in 0.1s) 14510[22] The monitoring time for searching a tool (in 0.1s) 14510[24] Lubrication interval (in 1min) 14510[25] Lubrication duration (in 0.01s) 14512[16]

14512[17]

14512[18]

Bit 4 Control of X axis rotation monitoring Bit 5 Control of Y axis rotation monitoring Bit 6 Control of Z axis rotation monitoring Bit 7 Handwheel assignment with the MCP / HMI Bit 0 Turret function Bit 1 Clamping function Bit 2 Tailstock function Bit 3 Selection between handwheel and hand-held unit (0: handwheel; 1: hand-

Bit 2 One time automatic lubrication after the power-on Bit 4 Stop signal for an external spindle Bit 5 Fixing the direction of a spindle Bit 6 Hardware limit is independent of the PLC application Bit 7 One hardware limit triggered per axis (enabled when bit 6=0)

held unit)

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PLC sample applications

5.2 PLC sample application (milling)

Machine data Corresponding function 14512[19]

Bit 1 Function of spindle braking Bit 2 Password clearing by power-on (0: delete the password; 1: do not delete

the password)

Bit 7 MM+ (Manual Machine Plus) function (enabled when the MM+ has been

licensed and corresponding PLC subroutine has been called)

5.2 PLC sample application (milling)

This sample application is applicable to machines with the following configurations:

● Three axes: axes X, Y and Z, with a hardware limit switch respectively in the positive and negative directions of each axis

● An analog spindle: SP (the fourth axis)

● PLC-controlled timely and quantitatively lubrication system

● PLC-controlled cooling system

Table 5- 3 Assignment of inputs and outputs

Signal Description Remark

I0.0 Emergency Stop button Normally closed I0.1 Limit switch in the "+" direction of axis X Normally closed I0.2 Limit switch in the "-" direction of axis X Normally closed I0.3 Limit switch in the "+" direction of axis Y I0.4 Limit switch in the "-" direction of axis Y I0.5 Limit switch in the "+" direction of axis Z Normally closed I0.6 Limit switch in the "-" direction of axis Z Normally closed I0.7 Reference point switch of axis X Normally open I1.0 Reference point switch of axis Y I1.1 Reference point switch of axis Z Normally open I1.2 Disk-style tool magazine: tool magazine count Valid at a low level I1.3 Disk-style tool magazine: tool magazine at the spindle

position

I1.4 Disk-style tool magazine: tool magazine at the original

position I1.5 Disk-style tool magazine: tool at the release position Valid at a low level I1.6 Disk-style tool magazine: tool at the clamping position Valid at a low level I1.7 Valid at a low level I2.0 Normally closed I2.1 Reserved I2.2 I2.3 Normally open I2.4 Coolant level too low Normally closed I2.5 Cooling pump motor overload Normally closed I2.6 Lubricant level too low Normally closed

Valid at a low level

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PLC sample applications

5.2 PLC sample application (milling)

Signal Description Remark

I2.7 Lubrication pump motor overload Normally closed I3.0 Reserved I3.1 Reserved I3.2 Reserved I3.3 Reserved I3.4 Reserved I3.5 Reserved I3.6 Reserved I3.7 Reserved I4.0 Handheld unit: axis X selected Valid at a high level I4.1 Handheld unit: axis Y selected Valid at a high level I4.2 Handheld unit: axis Z selected Valid at a high level I4.3 Handheld unit: fourth axis selected Reserved I4.4 Handheld unit: increment X1 Valid at a high level I4.5 Handheld unit: increment X10 Valid at a high level I4.6 Handheld unit: increment X100 Valid at a high level

I4.7 Handheld unit: enabled Valid at a high level Q0.0 Working lamp Q0.1 Q0.2 Chip forward Q0.3 Chip backward Q0.4 Cooling pump Q0.5 Lubrication pump Q0.6 Safety door open Q0.7 Q1.0 Magazine rotating clockwise Q1.1 Magazine rotating counter-clockwise Q1.2 Magazine approaching spindle position Q1.3 Magazine approaching original position Q1.4 Tool release from the spindle Q1.5 Q1.6 Q1.7 Handheld unit valid

Table 5- 4 Definition of user-defined keys on the MCP

User-defined key 1 Working lamp User-defined key 2 Manual cooling User-defined key 3 Safe door User-defined key 4 Manual clockwise rotation of the tool magazine User-defined key 5 Manual reset of the tool magazine User-defined key 6 Manual counter-clockwise rotation of the tool magazine User-defined key 7 Removing chip forward User-defined key 8 Removing chip backward

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PLC sample applications

5.2 PLC sample application (milling)

Structure of the sample application (OB1)

signals to the NCK interface

Each scan (SM0.0) HANDWHL (SBR39) Selecting a hand wheel through

the interface signal DB1900.DBB1xxx

Each scan (SM0.0) AXIS_CTL (SBR40) Coordinate enabling control,

hardware limit, etc. Each scan (SM0.0) SPINDLE (SBR42) Spindle control Each scan (SM0.0) COOLING (SBR44) Cooling control Each scan (SM0.0) LUBRICAT (SBR45) Lubrication control

Setting relevant PLC machine data

Machine data Corresponding function 14510[12] JOG key layout 14510[20] The maximum number of tool positions 14510[24] Lubrication interval (in 1min) 14510[25] Lubrication duration (in 0.01s) 14512[16]

14512[18]

14512[19]

Bit 1 Function of chip remover Bit 2 Function of safe door Bit 3 When the function of safe door is active, it can be triggered by M01/M02 Bit 4 Control of X axis rotation monitoring Bit 5 Control of Y axis rotation monitoring Bit 6 Control of Z axis rotation monitoring Bit 7 Handwheel assignment with the MCP / HMI Bit 0 Tool magazine function 14512[17] Bit 3 Selection between handwheel and hand-held unit (0: handwheel; 1: hand-

held unit) Bit 2 One time automatic lubrication after the power-on Bit 4 Stop signal for an external spindle Bit 5 Fixing the direction of a spindle Bit 6 Hardware limit is independent of the PLC application Bit 7 One hardware limit triggered per axis (enabled when bit 6=0) Bit 1 Function of spindle braking Bit 2 Password clearing by power-on (0: delete the password; 1: do not delete the

password) Bit 7 MM+ (Manual Machine Plus) function (enabled when the MM+ has been

licensed and corresponding PLC subroutine has been called)

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Index

Data management, 13

MCP interface description, 9

Overview, 7

Program organization, 13

Structure of the subroutines, 8 Structure of the symbol tables, 8 Subrou Subrou Subrou Subrou Subrou Subrou Subrou Subrou Subrou Subrou Subrou Subrou Subrou Subrou Subrou Subrou Subrou Subrou Subrou Subrou Subrou Subrou Subrou Subrou

tine 20, 34 tine 21, 35 tine 22, 35 tine 23, 36 tine 31, 37 tine 32, 37 tine 33, 38 tine 37, 39 tine 38, 40 tine 39, 41 tine 40, 42 tine 41, 45 tine 42, 47 tine 43, 48 tine 44, 49 tine 45, 51 tine 46, 58 tine 47, 54, 61 tine 48, 55 tine 48, 63 tine 49, 56, 65 tine 50, 57 tine 51, 52 tine 53, 67

tine 56, 68

Subro Subrou Subrou Subrou Subrou Symbols u System r

tine 58, 69 tine 59, 72 tine 60, 73 tine 63, 75

sed in the subroutines, 32

esource distribution, 7

User alarms, 77

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Index

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