4 sinumerik 808d commissioning manual 5 - …...the sinumerik 808d is an economic cnc solution for...

Commissioning Manual

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SINUMERIK

SINUMERIK 808D Commissioning Manual

Commissioning Manual

Valid for the following control systems: SINUMERIK 808D Turning (software version: V4.4.2) SINUMERIK 808D Milling (software version: V4.4.2) Target group: Electrical engineers, calibration engineers and testing

01/2015 6FC5397-4EP10-0BA0

Delivery check 1

Mounting 2

Connecting 3

Switching on and preparing for commissioning

4

Commissioning diagram 5

Default PLC applications 6

Commissioning the prototype 7

Series production 8

Other frequently used functions

9

Appendix A

Siemens AG Industry Sector Postfach 48 48 90026 NÜRNBERG GERMANY

Order number: 6FC5397-4EP10-0BA0 Ⓟ 02/2015 Subject to change

Copyright © Siemens AG 2012. All rights reserved

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.

Commissioning Manual Commissioning Manual, 01/2015, 6FC5397-4EP10-0BA0 3

Table of contents

1 Delivery check ........................................................................................................................................... 7

2 Mounting .................................................................................................................................................. 13

2.1 Mounting the controller ........................................................................................................... 13

2.2 Mounting the drive .................................................................................................................. 15

2.3 Mounting the motor ................................................................................................................. 18

3 Connecting .............................................................................................................................................. 19

3.1 Interface overview ................................................................................................................... 19

3.2 Connecting the battery ............................................................................................................ 21

3.3 Connecting according to the default PLC program ................................................................. 22

3.4 Connection Overview .............................................................................................................. 27

4 Switching on and preparing for commissioning ........................................................................................ 29

4.1 Switching on controller ............................................................................................................ 29

4.2 PPU keyboard function ........................................................................................................... 30

4.3 MCP mode changeover .......................................................................................................... 31

4.4 Status LEDs ............................................................................................................................ 32

4.5 Password ................................................................................................................................ 33 4.5.1 Access levels .......................................................................................................................... 33 4.5.2 Setting a password ................................................................................................................. 35

4.6 Setting the date and time ........................................................................................................ 36

4.7 Introduction to the onboard assistants .................................................................................... 37

5 Commissioning diagram .......................................................................................................................... 39

6 Default PLC applications ......................................................................................................................... 41

6.1 Turning .................................................................................................................................... 41

6.2 Milling ...................................................................................................................................... 45

6.3 PLC user alarms ..................................................................................................................... 48 6.3.1 General information ................................................................................................................ 48 6.3.2 Alarm properties ...................................................................................................................... 48 6.3.3 Activating the PLC user alarms .............................................................................................. 50 6.3.4 Editing a PLC user alarm text ................................................................................................. 52

7 Commissioning the prototype .................................................................................................................. 57

7.1 Commissioning the controller ................................................................................................. 57 7.1.1 Entering machine data ............................................................................................................ 57 7.1.2 Setting the axis-relevant parameters ...................................................................................... 58 7.1.2.1 Enabling the position control ................................................................................................... 58

Table of contents

Commissioning Manual 4 Commissioning Manual, 01/2015, 6FC5397-4EP10-0BA0

7.1.2.2 Setting the leadscrew pitch, deceleration ratio, and motor rotation direction ........................ 58 7.1.2.3 Setting the axis speed and acceleration ................................................................................ 59 7.1.2.4 Setting the position-loop gain ................................................................................................. 59 7.1.3 Setting the spindle-relevant parameters ................................................................................ 60 7.1.4 Approaching the reference point ............................................................................................ 62 7.1.5 Compensation parameter settings ......................................................................................... 64 7.1.5.1 Setting the software limit switches ......................................................................................... 64 7.1.5.2 Setting backlash compensation ............................................................................................. 64 7.1.5.3 Making leadscrew error compensation .................................................................................. 65 7.1.5.4 Setting protection levels ......................................................................................................... 68

7.2 Data backup ........................................................................................................................... 70 7.2.1 Creating a series archive ....................................................................................................... 70 7.2.2 Creating a start-up archive for the prototype ......................................................................... 71 7.2.3 Restoring the control system with the start-up archive file .................................................... 73

8 Series production ..................................................................................................................................... 75

8.1 Uploading the series archive for series commissioning ......................................................... 75

8.2 Data settings for individual machine ...................................................................................... 77 8.2.1 Setting the software limit switches ......................................................................................... 77 8.2.2 Setting the backlash ............................................................................................................... 77 8.2.3 Making leadscrew error compensation .................................................................................. 77

8.3 Data backup ........................................................................................................................... 77 8.3.1 Overview ................................................................................................................................ 77 8.3.2 Creating an original status archive......................................................................................... 78 8.3.3 Creating the start-up archive .................................................................................................. 78 8.3.4 Restoring the control system ................................................................................................. 79

9 Other frequently used functions ............................................................................................................... 81

9.1 Playing a slide show .............................................................................................................. 81

9.2 Defining the service planner .................................................................................................. 83

9.3 Using the OEM startup screen and the OEM machine logo .................................................. 86

A Appendix .................................................................................................................................................. 89

A.1 Cutting reserved holes ........................................................................................................... 89

A.2 Inserting, printing or cutting the MCP strips ........................................................................... 90

A.3 Basic knowledge about NC programming ............................................................................. 91

A.4 Selection of the transformers ................................................................................................. 92

A.5 Parameter list ......................................................................................................................... 93 A.5.1 Basic machine data ................................................................................................................ 93 A.5.2 SINAMICS V60 parameters ................................................................................................... 97

A.6 Diagnostics ............................................................................................................................. 99 A.6.1 SINUMERIK 808D alarms ...................................................................................................... 99 A.6.2 SINAMICS alarms .................................................................................................................. 99 A.6.2.1 Overview of alarms ................................................................................................................ 99 A.6.2.2 Alarm list .............................................................................................................................. 100 A.6.2.3 Errors during drive self-test .................................................................................................. 103 A.6.2.4 Other faults ........................................................................................................................... 104

Table of contents


A.6.2.5 Display data list ..................................................................................................................... 104

A.7 PLC user interfaces .............................................................................................................. 106 A.7.1 Addressing ranges ................................................................................................................ 106 A.7.2 MCP ...................................................................................................................................... 108 A.7.2.1 Signals from MCP ................................................................................................................. 108 A.7.2.2 Signals to MCP ..................................................................................................................... 108 A.7.2.3 Reading/writing NC data: Job ............................................................................................... 109 A.7.2.4 Reading/writing NC data: Result ........................................................................................... 109 A.7.2.5 PI service: Job ...................................................................................................................... 109 A.7.2.6 PI service: Result .................................................................................................................. 110 A.7.3 Retentative data area ........................................................................................................... 110 A.7.4 User Alarms .......................................................................................................................... 110 A.7.4.1 User alarms: Activating ......................................................................................................... 110 A.7.4.2 Variables for user alarms ...................................................................................................... 110 A.7.4.3 Active alarm response .......................................................................................................... 111 A.7.4.4 Acknowledgement of alarms ................................................................................................. 111 A.7.5 Axis/spindle signals ............................................................................................................... 111 A.7.5.1 Transferred M and S functions, axis specific ........................................................................ 111 A.7.5.2 Signals to axis/spindle .......................................................................................................... 111 A.7.5.3 Signals from axis/spindle ...................................................................................................... 113 A.7.6 PLC machine data ................................................................................................................ 116 A.7.6.1 INT values (MD 14510 USER_DATA_INT) .......................................................................... 116 A.7.6.2 HEX values (MD 14512 USER_DATA_HEX) ....................................................................... 116 A.7.6.3 FLOAT values (MD 14514 USER_DATA_FLOAT) ............................................................... 116 A.7.6.4 User alarm: Configuring (MD 14516 USER_DATA_PLC_ALARM) ...................................... 116 A.7.7 Signals from/to HMI .............................................................................................................. 117 A.7.7.1 Program control signals from the HMI (retentive area) (also refer to signals at channel

DB3200) ................................................................................................................................ 117 A.7.7.2 Program selection from PLC (retentive area) ....................................................................... 117 A.7.7.3 Checkback signal: Program selection from HMI (retentive area) ......................................... 117 A.7.7.4 Signals from HMI .................................................................................................................. 118 A.7.7.5 Signals from PLC .................................................................................................................. 118 A.7.7.6 Signals to maintenance planners .......................................................................................... 118 A.7.7.7 Signals from maintenance planners ..................................................................................... 119 A.7.7.8 Signals from operator panel (retentive area) ........................................................................ 119 A.7.7.9 General selection/status signals from HMI (retentive area).................................................. 119 A.7.7.10 General selection/status signals to HMI (retentive area) ...................................................... 120 A.7.8 Auxiliary functions transfer from NC channel ....................................................................... 120 A.7.8.1 Overview ............................................................................................................................... 120 A.7.8.2 Decoded M signals (M0 to M99) ........................................................................................... 121 A.7.8.3 Transferred T functions ......................................................................................................... 121 A.7.8.4 Transferred M functions ........................................................................................................ 121 A.7.8.5 Transferred S functions ........................................................................................................ 122 A.7.8.6 Transferred D functions ........................................................................................................ 122 A.7.8.7 Transferred H functions ........................................................................................................ 122 A.7.9 NCK signals .......................................................................................................................... 122 A.7.9.1 General signals to NCK ........................................................................................................ 122 A.7.9.2 General signals from NCK .................................................................................................... 123 A.7.9.3 Signals at fast inputs and outputs ......................................................................................... 123 A.7.9.4 Signals from fast inputs and outputs ..................................................................................... 124 A.7.10 Channel signals .................................................................................................................... 125 A.7.10.1 Signals to NC channel .......................................................................................................... 125

Table of contents


A.7.10.2 Signals from NC channel ..................................................................................................... 127 A.7.11 Signals, synchronized actions .............................................................................................. 130 A.7.11.1 Signals, synchronized actions to channel ............................................................................ 130 A.7.11.2 Signals, synchronized actions from channel ........................................................................ 130 A.7.11.3 Reading and writing PLC variables ...................................................................................... 131 A.7.12 Axis actual values and distance-to-go ................................................................................. 131 A.7.13 Maintenance scheduler: User interface ............................................................................... 132 A.7.13.1 Initial (start) data .................................................................................................................. 132 A.7.13.2 Actual data ........................................................................................................................... 132 A.7.14 User interface for Ctrl-Energy .............................................................................................. 133

Index ...................................................................................................................................................... 135


Delivery check 1

System overview

The SINUMERIK 808D is an economic CNC solution for milling and turning machines in the global market. For the turning variant, it is designed to control three axes, including two feed axes via two pulse drive interfaces (with SINAMICS V60) and one spindle via one analog spindle interface. For the milling variant, it is designed to control four axes, including three feed axes via three pulse drive interfaces (with SINAMICS V60) and one spindle via one analog spindle interface.

Delivery check


The following diagram shows a system configuration example for the SINUMERIK 808D control system:

11) 12)

5)

2)

6)

3)

4)

7) 8)

9)

10)

13)

1)

Note:The following devices in this diagram are not standard system components:- PC- USB- Handwheel- +24VDC power supply- Inverter or servo spindle drive- Spindle motor- Spindle encoder

Figure 1-1 SINUMERIK 808D control system overview (taking a milling machine for an example)

11), 12), 13): For detailed information on cable shield connection, refer to Section "Connecting according to the default PLC program (Page 22)".

Delivery check


NOTICE Using a copper protective earth conductor with a cross section of 10 mm2 to connect the PE terminal of V60 to the protective earth. For the NC and 24 VDC power supply, there are no special requirements of the cross section of the copper protective earth conductor. For the inverter or servo spindle drive, it is recommended to refer to the relevant specifications to confirm the cross section of the copper protective earth conductor.

Note For a turning machine, you need two sets of setpoint cable + SINAMICS V60 drive + power cable + brake cable (if necessary) + encoder cable + 1FL5 servomotor.

Legend Name Order number 1) PPU141.1, turning 6FC5370-1AT00-0AA0 (English)

6FC5370-1AT00-0CA0 (Chinese) PPU141.1, milling 6FC5370-1AM00-0AA0 (English)

6FC5370-1AM00-0CA0 (Chinese) 2) MCP 6FC5303-0AF35-0AA0 (English)

6FC5303-0AF35-0CA0 (Chinese) 3) Setpoint cable (PPU141.1 to CPM60.1) 6FC5548-0BA00-1AF0 (5 m)

6FC5548-0BA00-1AH0 (7 m) 6FC5548-0BA00-1BA0 (10 m)

4) SINAMICS V60 Controlled Power Module (CPM60.1)

6SL3210-5CC14-0UA0 (4 A) 6SL3210-5CC16-0UA0 (6 A) 6SL3210-5CC17-0UA0 (7 A) 6SL3210-5CC21-0UA0 (10 A)

5) 1FL5 Motor 1FL5060-0AC21-0AA0 (4 Nm, with key, without brake) 1FL5060-0AC21-0AG0 (4 Nm, without key, without brake) 1FL5062-0AC21-0AA0 (6 Nm, with key, without brake) 1FL5062-0AC21-0AG0 (6 Nm, without key, without brake) 1FL5064-0AC21-0AA0 (7.7 Nm, with key, without brake) 1FL5064-0AC21-0AG0 (7.7 Nm, without key, without brake) 1FL5066-0AC21-0AA0 (10 Nm, with key, without brake) 1FL5066-0AC21-0AG0 (10 Nm, without key, without brake) 1FL5060-0AC21-0AB0 (4 Nm, with key, with brake) 1FL5060-0AC21-0AH0 (4 Nm, without key, with brake) 1FL5062-0AC21-0AB0 (6 Nm, with key, with brake) 1FL5062-0AC21-0AH0 (6 Nm, without key, with brake) 1FL5064-0AC21-0AB0 (7.7 Nm, with key, with brake) 1FL5064-0AC21-0AH0 (7.7 Nm, without key, with brake) 1FL5066-0AC21-0AB0 (10 Nm, with key, with brake) 1FL5066-0AC21-0AH0 (10 Nm, without key, with brake)

6) Setpoint cable (PPU141.1 to inverter or servo spindle drive)

6FC5548-0BA05-1AD0 (3 m) 6FC5548-0BA05-1AF0 (5 m) 6FC5548-0BA05-1AH0 (7 m) 6FC5548-0BA05-1BA0 (10 m) 6FC5548-0BA05-1CA0 (20 m)

Delivery check


Legend Name Order number 7) Power cable (unshielded) 6FX6002-5LE00-1AD0 (3 m)

6FX6002-5LE00-1AF0 (5 m) 6FX6002-5LE00-1AH0 (7 m) 6FX6002-5LE00-1BA0 (10 m)

8) Brake cable (unshielded) 6FX6002-2BR00-1AD0 (3 m) 6FX6002-2BR00-1AF0 (5 m) 6FX6002-2BR00-1AH0 (7 m) 6FX6002-2BR00-1BA0 (10 m)

9) Encoder cable (shielded) 6FX6002-2LE00-1AD0 (3 m) 6FX6002-2LE00-1AF0 (5 m) 6FX6002-2LE00-1AH0 (7 m) 6FX6002-2LE00-1BA0 (10 m)

10) Inverter or servo spindle drive From Siemens or a third-party manufacturer

Check list Table 1- 1 PPU package Component Quantity (pieces) Panel Processing Unit (PPU) 1 Mounting clamps with screws 8 Connectors • I/O connectors: 7

• 24 V power input connector: 1

Table 1- 2 MCP package Component Quantity (pieces) Machine Control Panel (MCP) 1 MCP connection cable (for connecting the MCP to the PPU, max. 50 cm) 1 Mounting clamps with screws 6 Pre-printed MCP strip, Milling 1 set of 6 pieces Blank strip paper, A4 size 1 Product Information for MCP 1

Table 1- 3 CNC accessories Component Quantity (pieces) Setpoint cable to SINAMICS V60 (for feed axis) 2 (turning) or 3 (milling) Setpoint cable to Siemens inverter or third-party drive (for spindle) 1

Note Emergency stop button is not included in our scope of delivery. You can, if necessary, con-tact your local Siemens salesperson for it.

Table 1- 4 SINAMICS V60 package Component Quantity (pieces) SINAMICS V60 1 Getting Started 1 Cable clamps 2

Table 1- 5 1FL5 motor package Component Quantity (pieces) 1FL5 motor 1 Data sheet for 1FL5 motor 1

Delivery check


Table 1- 6 Cables individually packaged Component Quantity (pieces) Power cable (unshielded) 1 Brake cable (unshielded) 1 Encoder cable (shielded) 1

Cabinet grounding guide

Figure 1-2 Cabinet grounding

Delivery check


Note that the PE/PEN busbar in the cabinet must connect to the ground through a grounding cable with a cross section ≥ 10 mm2 as illustrated below.

Figure 1-3 Busbar grounding


Mounting 2 2.1 Mounting the controller

Cut-out dimensions

Figure 2-1 Cut-out dimensions (in mm)

Note

Make sure there is enough space around the PPU and the MCP for tightening the screws in the control cabinet.

Mounting 2.1 Mounting the controller


Mounting dimensions

Figure 2-2 Mounting dimensions for PPU (in mm)

Figure 2-3 Mounting dimensions for MCP (in mm)

Mounting 2.2 Mounting the drive


Mounting clearance (in mm) To ensure easy maintenance purpose, you must provide sufficient clearance (recommended distance: 80 mm) between the maintenance door and the cabinet wall for replacing the battery and CF card:

① Cabinet panel ② Maintenance door

2.2 Mounting the drive

Cut-outs and mounting dimensions

Figure 2-4 4/6/7 A version (in mm)



Figure 2-5 10 A version (in mm)

Mounting method With 4xM5 preassembled screws, the drive can be mounted vertically onto the inner panel of the cabinet. The maximum screw torque must be 2.0 Nm.

Minimum mounting clearance To ensure adequate cooling, as a minimum, maintain the specified clearance between drives, one drive and another device/inner panel of the cabinet.

Figure 2-6 Drive mounting clearance (in mm)

Using the cable clamps supplied If the CE marking requirements for cables are mandatory, the line supply cable and the power cable used must all be shielded cables. In this case, you can use the cable clamps as a ground connection between the cable shield and a common ground point. Clamps can also be helpful in better fixing cables (the unshielded power cable and the line supply cable) in place.



The illustration below shows you how to use the clamps to fix both cables and to make a shield connection with the cable.

Power cable (shielded) Figure 2-7 Cable fixing with two cable clamps

CAUTION

Make sure that the clamp for fixing the shielded power cable has a good contact with the cable shield.

Note

Siemens does not provide the shielded power cable. Please prepare the shielded power cable by yourselves for CE certification.

After the installation, it is recommended that the terminal screws should be checked to ensure that they are tight.

Reference For further information about the drive mounting, refer to SINAMICS V60 Getting Started.

Mounting 2.3 Mounting the motor


2.3 Mounting the motor

Mounting dimensions (mm)

Motor type A (in mm) B (in mm) 4 Nm 163 (205) 80 6 Nm 181 (223) 90 7.7 Nm 195 (237) 112 10 Nm 219 (261) 136

Note

Value in brackets is the length of a motor with a built-in brake unit.

Motors with plain shaft have the same dimensions.

Reference For further information about the motor, refer to 1FL5 Motor Technical Data.


Connecting 3 3.1 Interface overview

Interface overview on the Panel Processing Unit (PPU)

NOTICE

The + 24 V and M signals of X200 must be connected; otherwise, the communication between the PPU and the drives does not function as it should.

Figure 3-1 Interface layout

Connecting 3.2 Connecting the battery


Legend Interface Comment Rear

① X100, X101, X102 Digital inputs

② X200, X201 Digital outputs

③ X21 FAST I/O

④ X301, X302 Distributed I/O

⑤ X10 Hand-wheel inputs

⑥ X60 Spindle encoder interface

⑦ X54 Analog spindle interface

⑧ X2 RS232 interface

⑨ X51, X52, X53 Pulse drive interfaces

⑩ X30 USB interface, for connection with the MCP

⑪ X1 Power supply interface, +24V DC power supply

⑫ - Battery interface

⑬ - Slot for the System CompactFlash Card (CF card)

Front

⑭ - USB interface

Interface overview on the Machine Control Panel (MCP)

Figure 3-2 Interface layout

Legend Interface Comment Rear

① X10 USB interface, for connection with the PPU

Connecting 3.2 Connecting the battery


3.2 Connecting the battery A battery has been pre-assembled on the back cover of the PPU.

The battery is not connected when delivered. You must plug the battery connector into the battery interface by yourself before switching the controller on. You can access it after removing the maintenance door:

① Maintenance door ③ Battery interface

② Battery ④ Battery connector

Note

When connecting the battery, ensure that the groove is at the upper side; otherwise, the alarm "NCK battery alarm" will be output after you switch on the controller, and you could lose your data after an unexpected power failure if you do not insert the battery connector correctly.

Note Battery

Life time: 3 years

Replacement: do not replace the battery when the controller is switched off; otherwise, your data can be lost.

Order number: 6FC5247-0AA18-0AA0.

Connecting 3.3 Connecting according to the default PLC program


3.3 Connecting according to the default PLC program The SINUMERIK 808D has integrated with a default PLC application. If you perform the commissioning work with the default PLC application, perform wiring as follows.

Connecting the digital inputs and outputs

Figure 3-3 Connecting the digital inputs and outputs (Milling)



Figure 3-4 Connecting the digital inputs and outputs (Turning)



Connecting the distributed I/O

Figure 3-5 Connecting the distributed I/O

Connecting the SINAMICS V60 (take X51: axis X for an example)

1)

Figure 3-6 Connecting the SINAMICS V60 (X51: axis X)

1) If necessary, you can also serially connect an emergency stop switch between the 65 enable signal and the 24V signal.



Note Filter

A line filter (rated current: 16 A, protection level: IP20) is required so that the system can pass the CE certification (radiated emission test or conducted emission test). The order number of Siemens recommended filter is 6SN1111-0AA01-1BA1.

Note Circuit breaker

You can install a mains linear breaker (rated current: 15 A for 7 A or 10 A version of the drive and 10 A for 4 A or 6 A version of the drive; rated voltage: 250 VAC) to protect the system.

Connecting the inverter or the servo spindle drive

PPU

Figure 3-7 Connecting the inverter or the servo spindle drive (unipolar)

1) 10 V analog voltage

2) 0 V signal

3) Use twisted pair cables for signals A/A_N, B/B_N, Z/Z_N, and +5 V/M.



PPU

Figure 3-8 Connecting the inverter or the servo spindle drive (bipolar)

1) +/- 10 V analog voltage

2) 0 V signal

3) Use twisted pair cables for signals A/A_N, B/B_N, Z/Z_N, and +5 V/M.

Note

Cables for connecting X21 must be shielded ones.

Connecting the handwheel

Figure 3-9 Connecting the handwheel

Connecting 3.4 Connection Overview


3.4 Connection Overview

Connecting 3.4 Connection Overview


Note

For the turning variant, connection to X52 is optional and depends upon whether you use the software option "additional axis". If you desire to configure the control system to control a rotary axis or an additional linear axis, connect X52 to a SINAMICS V60 which connects to a servo motor.


Switching on and preparing for commissioning 4 DANGER

Carrying out of repairs

Anywhere in the automation equipment where faults might cause physical injury or major material damage, in other words, where faults could be dangerous, additional external pre-cautions must be taken, or facilities must be provided, that guarantee or enforce a safe operational state, even when there is a fault (e.g. using an independent limit value switch, mechanical locking mechanisms, EMERGENCY STOP/EMERGENCY OFF devices).

4.1 Switching on controller

Before switching on Make sure that: ● You have finished the mechanical installation of the whole system based on the

information included in the chapter "Mounting (Page 13)" or the Mechanical Installation Manual.

● You have completed the wirings of the whole system according to the information included in the chapter "Connecting (Page 19)" (if you use the default PLC program) or the Electrical Installation Manual.

Switching on Do as follows: 1. Power on the mains supply. 2. When the NC enters the main screen, check the NC normal status according to the status

LEDs on the PPU. POK: green RDY: green TEMP: unlit For detailed information about the status LEDs, refer to the section "Status LEDs (Page 32)".

3. Check the drive normal status: – "S-run" is displayed. – LED "RDY/JOG": green – LED "ERR": dark For detailed information about the SINAMICS V60 drives, refer to the SINAMICS V60 Getting Started.

Switching on and preparing for commissioning 4.2 PPU keyboard function


4.2 PPU keyboard function

Legend Name Description

① Return key Returns to higher level menu ② Horizontal softkeys Call corresponding menu functions ③ Extension key Reserved. No function ④ Vertical softkeys Call corresponding menu functions

⑤ Operating area keys

Opens the "MACHINE" operating area

Opens the "PROGRAM" operating area

Opens the "OFFSET" operating area

Opens the "PROGRAM MANAGER" operating area

• Opens the "ALARM" operating area • Combines with the <SHIFT> key to open the

"SYSTEM" area

Opens the "CUSTOM" operating area

Switching on and preparing for commissioning 4.3 MCP mode changeover


4.3 MCP mode changeover Use the machine control panel (MCP) to make changeover between the JOG mode, the Ref Point mode, the AUTO mode and the MDA mode.

The MCP key layout is shown below:

Legend Name Description

① Mode navigation keys

Enters the Ref. Point mode for reference point approach

Enters the JOG mode (manual operation)

Enters the AUTO mode (automatic operation)

Enters the MDA mode (manual program input and auto-matic execution)

② Incremental feed keys

Axis traverses at the increment of 1



③ Axis traversing keys Move an axis (X, Y, Z)

④ RESET key • Resets NC programs • Cancels alarms

Switching on and preparing for commissioning 4.4 Status LEDs


4.4 Status LEDs

LEDs on the PPU The following LEDs are installed on the SINUMERIK 808D PPU.

The individual LEDs and their functions are described in the table below.

Table 4- 1 Status and error displays

LED Color Significance POK Green Power supply is OK. RDY Green Ready for operation TEMP Yellow Temperature exceeds the limit

For more information, refer to error description in the SINUMERIK 808D Diagnostics Manual.

LEDs on the SINAMICS V60 drives

Figure 4-1 SINAMICS V60 status LEDs

Switching on and preparing for commissioning 4.5 Password


Table 4- 2 Description of the LED status

Status LED 1 Status LED 2 Description 7-segment LED display description RDY/JOG ERR

Green LED Red LED Dark Dark No 24 V DC Input/Drive Defect Dark Dark Flashing at 1 Hz Drive not ready Current status Green Dark Drive ready Depends on the current menu opera-

tion Dark Red Drvie error Alarm code Green Red Initialization Display "8.8.8.8.8.8." Flashing at 1 Hz Dark JOG mode Display "J-run"

4.5 Password

4.5.1 Access levels

Purpose Access levels/passwords are necessary to prevent system data damages caused by unexpected mistake operations.

Cases You must set a password for an access level under following cases:

● Data restoring

● Software update

● Password has been deleted

● A higher or lower access level is required

Access levels The SINUMERIK 808D provides a concept of access levels for enabling data areas. You can view such information from the table below:

Table 4- 3 Access level

Access level Default password Target group Manufacturer SUNRISE OEMs Customer CUSTOMER End users No password - -



With the access level "Manufacturer", you can perform the following operations:

● Inputting or modifying all the machine data

● Commissioning work

With the access level "Customer", you can perform the following operations:

● Inputting or modifying part of the machine data

● Programming

● Setting offsets

● Measuring tools

For the function areas listed below, the input and modification of data depends on the protection level you have set:

● Tool offsets

● Work offsets

● Setting data

● RS232 settings

● Program creation / program correction

You can set the protection levels for these function areas via the display machine data (USER_CLASS...): "SYSTEM" operating area > "Mach. data" > "Expert list" > "Display MD".

Note

For detailed information about the display machine data, refer to the Parameter Manual.

Note

For detailed information about how to set the access levels, refer to Programming and Operating Manual.

Access levels: Manufacturer, Customer Both access levels require a password.

You can change the password only after being activated with the access level "Manufacturer".

If you forget your password, you can carry out an NC start-up: "SYSTEM" operating area > "Start-up" > "NC" > "Power-up with default data". This will reset all passwords to their defaults according to the software release you have acquired.

Note

Before performing a start-up with default data, you must backup your data; otherwise, you will lose your data. For detailed information about how to do data backup, refer to section "Data backup (Page 77)".



Access level: No password If you have deleted your password or do not set a password, you only have the access right of viewing above-mentioned function areas.

Note

The system has no password by default.

4.5.2 Setting a password The control system is delivered without a password. You must input the password of "SUNRISE" to perform the commissioning work.

Perform the following steps to input the password:

1. In the "SYSTEM" operating area (key combination: + ), press the vertical softkey "Set password". The message text at the bottom of the screen shows "No pass-word set":

2. Enter "SUNRISE" and press the "Accept" softkey.

3. The message text now shows "Access level: Manufacturer", which indicates that you have successfully set the password.

Note

You can change the default password to you by using the "Change password" softkey.

You can also delete the current password to protect your settings by pressing the "Delete password" softkey.

After the series production, you must press the "Delete password" softkey to exit the "Manufacturer" access level.

Switching on and preparing for commissioning 4.6 Setting the date and time


4.6 Setting the date and time At delivery, the system date and time remain at the factory settings, and thus you must manually modify the date and time. Proceed as follows to set the date and time:

1. Press + to enter the "SYSTEM" operating area, then press the softkey "Date time".

2. Input your date and time.

3. Press the "OK" softkey to confirm your settings.

Switching on and preparing for commissioning 4.7 Introduction to the onboard assistants


4.7 Introduction to the onboard assistants The SINUMERIK 808D system software has three onboard assistants:

● Startup assistant (requires "Manufacturer" access level)

This on-board assistant is designed to help you commission the prototype. With this assistant, you can complete basic machine tool functions.

● Series assistant (requires "Manufacturer" access level)

This on-board assistant is designed to help you correctly finish the series machine commissioning.

● Operation assistant (requires "Customer" access level)

This onboard assistant is designed to help you learn about the basic operations of the machining process.

Where can I find the assistants? Press the <MENU FUNCTION> key on the PPU to call the assistants:

Switching on and preparing for commissioning 4.7 Introduction to the onboard assistants


How can I use the assistants?

Status indicators:

Completed task

Current task

Partially completed task group

Uncompleted task

Press one of the three softkeys to access the corre-sponding assistant

Press to start the assistant

Press to return to the main screen of the onboard as-sistants

Press any operating area key (CUSTOM excluded) to exit the main screen of the onboard assistants and enter the corresponding operating area

Press to enter the current task or a task that is prior to the current task Note: This softkey becomes active when you move the cursor key to a valid task.


Commissioning diagram 5

You can commission the SINUMERIK 808D in two ways:

● Alternative 1: with the onboard assistants

● Alternative 2: without the onboard assistants

When commissioning with the onboard assistants, just follow the assistants step by step.

In this manual, only the second way is described. To do the commissioning work without the onboard assistants, proceed as follows:

Commissioning diagram



Default PLC applications 6 6.1 Turning

Overview of the PLC 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". 31 PLC_ini_USR_INI Reserved for the initialization by the manufacturer (this subroutine is automati-

cally called by subroutine 32) 32 PLC_INI PLC initialization 33 EMG_STOP Emergency Stop 37 MCP_NCK Signals from the MCP and the HMI are sent to NCK interfaces 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 Coolant control (Manual Machine key and M code: M07, M08, M09) 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 Turret control of the turning machine (turret type: Hall element transistor, 4/6

position) 52 Turret2_BIN_T Turret control of the turning machine (turret type: position detection with codings) 53 Turret3_CODE_T Hydraulic turret control of the turning machine (turret type: position detection with

codings) 54 Turret2_3_ToolDir Evaluate tool direction and calculate tool position (called by Turret2_BIN_T,

Turret3_CODE_T) 55 Tail_stock_T Tail stock control 56 Lock_unlock_T Clamp or release control 58 MM_MAIN Manual machine 59 MM_MCP_808D Spindle signal processing for the manual machine 61, 62 Reserved for the subroutine 63 TOGGLE Six key-operated switches: K1 to K6

Two delay switches: k7, K8

Default PLC applications 6.1 Turning


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

Structure of the sample application (OB1)

Call Conditions Subroutine Name Description 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) 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

PLC user alarms

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: Lock_unlock_T 700014 DB1600.DBX1.6 Gear-change time out SBR49: GearChg1_Auto 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 SBR56: Lock_unlock_T

700018 DB1600.DBX2.2 Cooling motor overload SBR44: COOLING 700019 DB1600.DBX2.3 Coolant liquid position in low level 700020 DB1600.DBX2.4 Lubrication motor overload SBR45: LUBRICAT 700021 DB1600.DBX2.5 Lubricant liquid position in low level 700022 DB1600.DBX2.6 Turret motor overload SBR51: Turret1_HED_T

SBR52: Turret2_BIN_T SBR53: Turret3_CODE_T

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



Alarm No. Interface Address Alarm Description From SBR 700027 DB1600.DBX3.3 Approach reference point again after rotation

monitoring SBR40: AXIS_CTL

700028 DB1600.DBX3.4 Tool is not locked SBR53: Turret3_CODE_T 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 SBR58: MM_MAIN

700059 DB1600.DBX7.3 Safe door not closed, NC start not possible SBR22: AUX_SAFE_DOOR

700060 DB1600.DBX7.4 Channel not in reset, change PRT not possible SBR37: MCP_NCK

Relevant machine data MD14510 Machine data - Integer

Unit Range Function

14510[12] * 0 to 1 JOG key layout 14510[20] - 2 to 64 The maximum number of tool positions 14510[21] 0.1s 5 to 30 Time for locking a turret 14510[22] 0.1s 30 to 300 The monitoring time for searching a tool 14510[24] 1 min 5 to 300 Lubrication interval 14510[25] 0.01s 100 to 2,000 Lubrication duration



MD14512 Machine data - Hex

Function

Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

14512[16] Handwheel assignment with the MCP

Control of Z axis rotation monitoring

Control of X axis rotation monitoring

14512[17] Selection between handwheel and hand-held unit (0: hand-wheel; 1: hand-held unit)

Tail stock function

Clamp-ing function

14512[18] Each feed axis has a hardware limit switch (activated when Bit 6 = 0)

The hardware limit is inde-pendent of a PLC program

Spindle positioning direction

Signal that ex-ternal spindle stops

Automatic lubrication after the first power-on (factory setting)

14512[19] Manual ma-chine function (this function becomes active if you install licensed turning machine sys-tem and call it with a PLC subroutine)

Password clearing by power-on (0: delete the pass-word; 1: do not delete the pass-word)

Func-tion of spindle braking

Default PLC applications 6.2 Milling


6.2 Milling

Overview of the PLC 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 Safe door control, called in the subroutine "AUX_MCP" of a milling application. 23 AUX_CHIP Chip remover control, called in the subroutine "AUX_MCP" of a milling applica-

tion. 31 PLC_ini_USR_INI Reserved for the initialization by the manufacturer (this subroutine is automatical-

ly called by subroutine 32) 32 PLC_INI PLC initialization 33 EMG_STOP Emergency Stop 37 MCP_NCK Signals from the MCP and the HMI are sent to NCK interfaces 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 Coolant control (Manual Machine key and M code: M07, M08, M09) 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 58 MM_MAIN Manual machine 59 MM_MCP_808D Spindle signal processing for the manual machine 61, 62 Reserved for the subroutine 63 TOGGLE Six key-operated switches: K1 to K6

Two delay switches: K7, K8

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



Structure of the sample application (OB1)

Call Conditions Subroutine Name Description 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 V1900 1xxx Each scan (SM0.0) AXIS_CTL (SBR40) Coordinate enabling control, hardware limit, etc. Each scan (SM0.0) COOLING (SBR44) Cooling control Each scan (SM0.0) LUBRICATE (SBR45) Lubrication control

PLC user alarms

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 700014 DB1600.DBX1.6 Gear-change time out SBR49: GearChg1_Auto 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 SBR56: Lock_unlock_T

700018 DB1600.DBX2.2 Cooling motor overload SBR44: COOLING 700019 DB1600.DBX2.3 Coolant liquid position in low level 700027 DB1600.DBX3.3 Approach reference point again after rotation

monitoring SBR40: AXIS_CTL

700029 DB1600.DBX3.5 Reminding information for 1st service plan SBR48:ServPlan 700030 DB1600.DBX3.6 Alarm for 1st service plan 700031 DB1600.DBX3.7 Magazine not in spindle position or original

position SBR60: Disk_MGZ_M

700032 DB1600.DBX4.0 Magazine in spindle position and original posi-tion

SBR60: Disk_MGZ_M

700033 DB1600.DBX4.1 Magazine turn key when magazine or spindle not ready

SBR60: Disk_MGZ_M

700034 DB1600.DBX4.2 Block search, tool in spindle <> programmed tool

SBR60: Disk_MGZ_M

700035 DB1600.DBX4.3 Spindle not reach tool-release pos. in time SBR60: Disk_MGZ_M 700036 DB1600.DBX4.4 Spindle not reach tool-lock pos. in time SBR60: Disk_MGZ_M 700059 DB1600.DBX7.3 Safe door not closed, NC start not possible SBR22:

AUX_SAFE_DOOR 700060 DB1600.DBX7.4 Channel not in reset, change PRT not possible SBR37: MCP_NCK



Relevant machine data MD14510 Machine data - Integer

Unit Range Function

14510[12] * 0 to 1 JOG key layout 14510[20] - 2 to 64 The maximum number of tool positions 14510[24] 1 min 5 to 300 Lubrication interval 14510[25] 0.01s 100 to 2,000 Lubrication duration

MD14512 Machine data - Hex

Function

Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

14512[16] Handwheel assignment with the MCP

Control of Z axis rotation monitoring

Control of Y axis rotation monitoring

Control of X axis rotation monitoring

When the function of safe door is active, it can be triggered by M01/M02

Function of safe door

Function of chip re-mover

14512[17] Selection between handwheel and hand-held unit (0: handwheel; 1: hand-held unit)

Tool maga-zine

14512[18] Each feed axis has a hardware limit switch (activated when Bit 6 = 0)

The hardware limit is independ-ent from a PLC pro-gram

Spindle position-ing direc-tion

Signal that ex-ternal spindle stops

Automatic lubrication after the first power-on (factory setting)

14512[19] Manual ma-chine function (this function becomes active if you install licensed turning machine sys-tem and call it with a PLC subroutine)

Password clearing by power-on (0: delete the password; 1: do not de-lete the password)

Function of spindle braking

Default PLC applications 6.3 PLC user alarms


6.3 PLC user alarms

6.3.1 General information PLC user alarms can be used as one of the most effective diagnosis methods.

The SINUMERIK 808D control system provides 128 PLC user alarms (700xxx). Each alarm corresponds with an alarm variable that is relevant to an alarm text, and each alarm corresponds with a machine data MD14516 used to configure alarm properties.

6.3.2 Alarm properties

Alarm responses You can configure the response of the control system after a user alarm is output:

● PLC STOP: When the user alarm is output, PLC detection stops, interface signal "NC RDY" is disabled and all outputs are disabled.

● EMERGENCY STOP: The user alarm automatically activates interface signal "EMER STOP".

● Feed disabled for all axes: The user alarm automatically activates interface signal "Feed disable".

● Read-in disabled: The user alarm automatically activates interface signal "Read-in disable".

● NC Start disabled: The user alarm automatically activates interface signal "NC Start disable".

● Only display: No response occurs when the user alarm is output. Only alarm number and alarm text are displayed.

Cancelling methods You can configure a cancelling method for a PLC user alarm. There are totally three cancelling methods available:

● POWER ON: cancel the user alarm by re-powering on the control system after clearing the conditions for the alarm.

● <ALARM CANCEL> key on the PPU or <RESET> key on the MCP: cancel the user alarm by pressing the <ALARM CANCEL> key or the <RESET> key after clearing the conditions for the alarm.

● Auto-cancelling: the user alarm disappears automatically after clearing the conditions for the alarm.



Configuring the properties Each user alarm has a corresponding 8-bit parameter called "USER_DATA_PLC_ALARM": MD14516[0] to MD14516[127]. You can configure a cancelling method and a response for each user alarm based on your actual situation. The parameter structure is shown as follows:

Note

• If both bit 7 and bit 6 are "0", the user alarm is an "auto-cancelling" alarm. • If bits 5 to 0 are all "0", the user alarm is a "display-only" alarm. • You can directly use the alarm response in a PLC application.

PLC user alarms list with corresponding interface addresses and MD14516 No. Alarm description Interface address MD14516

700000 - DB1600.DBX0.0 MD14516[0] ... - ... ... 700010 HHU is active DB1600.DBX1.2 MD14516[10] 700011 Not able to lock tool in expected time DB1600.DBX1.3 MD14516[11] 700012 Spindle in braking progress DB1600.DBX1.4 MD14516[12] 700013 Operation while chuck is not locked DB1600.DBX1.5 MD14516[13] 700014 Gear-change time out DB1600.DBX1.6 MD14516[14] 700015 Gear level position error DB1600.DBX1.7 MD14516[15] 700016 Drives not ready DB1600.DBX2.0 MD14516[16] 700017 Operate chuck when spindle or part program is running DB1600.DBX2.1 MD14516[17] 700018 Cooling motor overload DB1600.DBX2.2 MD14516[18] 700019 Coolant liquid position in low level DB1600.DBX2.3 MD14516[19] 700020 Lubrication motor overload DB1600.DBX2.4 MD14516[20] 700021 Lubricant liquid position in low level DB1600.DBX2.5 MD14516[21] 700022 Turret motor overload DB1600.DBX2.6 MD14516[22] 700023 Programmed tool number > max. turret on turret number DB1600.DBX2.7 MD14516[23] 700024 Max. tool number setting error DB1600.DBX3.0 MD14516[24] 700025 No position signals from turret DB1600.DBX3.1 MD14516[25] 700026 Not able to find expected tool in monitor time DB1600.DBX3.2 MD14516[26] 700027 Approach reference point again after rotation monitoring DB1600.DBX3.3 MD14516[27]



No. Alarm description Interface address MD14516 700028 Tool is not locked DB1600.DBX3.4 MD14516[28] 700029 Reminding information for 1st service plan DB1600.DBX3.5 MD14516[29] 700030 Alarm for 1st service plan DB1600.DBX3.6 MD14516[30] 700031 Magazine not in spindle position or original position DB1600.DBX3.7 MD14516[31] 700032 Magazine in spindle position and original position DB1600.DBX4.0 MD14516[32] 700033 Magazine turn key when magazine or spindle not ready DB1600.DBX4.1 MD14516[33] 700034 Block search, tool in spindle <> programmed tool DB1600.DBX4.2 MD14516[34] 700035 Spindle not reach tool-release position in time DB1600.DBX4.3 MD14516[35] 700036 Spindle not reach tool-lock position in time DB1600.DBX4.4 MD14516[36] 700037 - DB1600.DBX4.5 MD14516[37] ... - ... ... 700048 - DB1600.DBX6.0 MD14516[48] 700049 Reference point X-axis not reached DB1600.DBX6.1 MD14516[49] 700050 Reference point Z-axis not reached DB1600.DBX6.2 MD14516[50] 700051 Wrong spindle direction started DB1600.DBX6.3 MD14516[51] 700052 Watchdog timer JOG-program DB1600.DBX6.4 MD14516[52] 700053 Spindle override not 100% DB1600.DBX6.5 MD14516[53] 700054 Spindle is not started DB1600.DBX6.6 MD14516[54] 700055 Feed override = 0% DB1600.DBX6.7 MD14516[55] 700056 Change of spindle direction not possible in thread DB1600.DBX7.0 MD14516[56] 700057 - DB1600.DBX7.1 MD14516[57] 700059 Safe door not closed, NC start not possible DB1600.DBX7.3 MD14516[59] 700060 Channel not in reset, change PRT not possible DB1600.DBX7.4 MD14516[60] ... - ... ... 700127 - DB1600.DBX15.7 MD14516[127]

6.3.3 Activating the PLC user alarms The control system provides totally 128 PLC user alarms. Each user alarm has a corresponding NCK address. Setting "1" for an address activates its corresponding alarm, while resetting "0" for this address clears the alarm. Each user alarm also corresponds to a 64-bit alarm variable DB1600.DBD1000 to DB1600.DBD1508. Value of a variable can be inserted into the displayed alarm text according to the data type defined by the alarm text. Available data types for the alarm variables are shown as follows: ● %d: decimal ● %x: hex ● %b: binary ● %o: octal ● %u: unassigned integral ● %f: floating

You can insert a variable into your alarm text to display variable information. For example, 700009 "Signal of cooling start is active but the contactor KM %d does not absorb."



PLC user alarms list with corresponding interface addresses and variables

No. Alarm description Interface address Variable 700000 - DB1600.DBX0.0 DB1600.DBD1000 ... - ... 700009 - DB1600.DBX1.1 DB1600.DBD1036 700010 HHU is active DB1600.DBX1.2 DB1600.DBD1040 700011 Not able to lock tool in expected time DB1600.DBX1.3 DB1600.DBD1044 700012 Spindle in braking progress DB1600.DBX1.4 DB1600.DBD1048 700013 Operation while chuck is not locked DB1600.DBX1.5 DB1600.DBD1052 700014 Gear-change time out DB1600.DBX1.6 DB1600.DBD1056 700015 Gear level position error DB1600.DBX1.7 DB1600.DBD1060 700016 Drives not ready DB1600.DBX2.0 DB1600.DBD1064 700017 Operate chuck when spindle or part program is running DB1600.DBX2.1 DB1600.DBD1068 700018 Cooling motor overload DB1600.DBX2.2 DB1600.DBD1072 700019 Coolant liquid position in low level DB1600.DBX2.3 DB1600.DBD1076 700020 Lubrication motor overload DB1600.DBX2.4 DB1600.DBD1080 700021 Lubricant liquid position in low level DB1600.DBX2.5 DB1600.DBD1084 700022 Turret motor overload DB1600.DBX2.6 DB1600.DBD1088 700023 Programmed tool number > max. turret on turret number DB1600.DBX2.7 DB1600.DBD1092 700024 Max. tool number setting error DB1600.DBX3.0 DB1600.DBD1096 700025 No position signals from turret DB1600.DBX3.1 DB1600.DBD1100 700026 Not able to find expected tool in monitor time DB1600.DBX3.2 DB1600.DBD1104 700027 Approach reference point again after rotation monitoring DB1600.DBX3.3 DB1600.DBD1108 700028 Tool is not locked DB1600.DBX3.4 DB1600.DBD1112 700029 Reminding information for 1st service plan DB1600.DBX3.5 DB1600.DBD1116 700030 Alarm for 1st service plan DB1600.DBX3.6 DB1600.DBD1120 700031 Magazine not in spindle position or original position DB1600.DBX3.7 DB1600.DBD1124 700032 Magazine in spindle position and original position DB1600.DBX4.0 DB1600.DBD1128 700033 Magazine turn key when magazine or spindle not ready DB1600.DBX4.1 DB1600.DBD1132 700034 Block search, tool in spindle <> programmed tool DB1600.DBX4.2 DB1600.DBD1136 700035 Spindle not reach tool-release position in time DB1600.DBX4.3 DB1600.DBD1400 700036 Spindle not reach tool-lock position in time DB1600.DBX4.4 DB1600.DBD1144 700037 - DB1600.DBX4.5 DB1600.DBD1148 ... - ... ... 700048 - DB1600.DBX6.0 DB1600.DBD1192 700049 Reference point X-axis not reached DB1600.DBX6.1 DB1600.DBD1196 700050 Reference point Z-axis not reached DB1600.DBX6.2 DB1600.DBD1200 700051 Wrong spindle direction started DB1600.DBX6.3 DB1600.DBD1204 700052 Watchdog timer JOG-program DB1600.DBX6.4 DB1600.DBD1208 700053 Spindle override not 100% DB1600.DBX6.5 DB1600.DBD1212 700054 Spindle is not started DB1600.DBX6.6 DB1600.DBD1216 700055 Feed override = 0% DB1600.DBX6.7 DB1600.DBD1220



No. Alarm description Interface address Variable 700056 Change of spindle direction not possible in thread DB1600.DBX7.0 DB1600.DBD1224 700057 - DB1600.DBX7.1 DB1600.DBD1228 700059 Safe door not closed, NC start not possible DB1600.DBX7.3 DB1600.DBD1236 700060 Channel not in reset, change PRT not possible DB1600.DBX7.4 DB1600.DBD1240 ... - ... 700127 - DB1600.DBX15.7 DB1600.DBD1508

Note

For more information about NC-PLC interfaces, refer to the SINUMERIK 808D Parameter Manual.

6.3.4 Editing a PLC user alarm text For the SINUMERIK 808D control system, you have two methods to edit a PLC user alarm text:

● the HMI

● a USB stick

Editing a PLC user alarm with the HMI To edit a PLC user alarm text with the HMI, proceed as follows:

1. In the "SYSTEM" operating area (press key combination: + ), press the "PLC" softkey.

2. Press the "Edit PLC alarm text" softkey.

3. Use the up/down arrow key to locate your target alarm text:



4. Press the "Edit text" softkey, and input the text you want to define:

5. Press the "OK" softkey to confirm your entry.

Note

You can create the alarm text either in English or in simplified Chinese.

Note

If you want to create an alarm text in Chinese, you must first change the system language to simplified Chinese ("SYSTEM" operating area > "Change language"), and then call the simplified Chinese with the key combination ALT + S when typing in your text.

Editing a PLC user alarm with a USB stick To edit a PLC user alarm text with a USB stick, proceed as follows:

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

2. In the "SYSTEM" operating area (press key combination: : + ), press softkeys "Sys. data" > "808D data", and enter the folder "HMI data" using the <INPUT> key.



3. Select the file "PLC alarm texts (alcu....txt)", press the <INPUT> key and select a file for a specific language. Press the "Copy" vertical softkey:

4. Press the "USB" horizontal softkey and press the "Paste" vertical softkey.

5. Remove the USB stick and insert it into the PC USB interface.

6. Find the downloaded PLC alarm text file.

By default, the alrm text file in English is named "alcu_eng":

7. Open the alarm text file with Wordpad, and you can view the PLC alarm text list.

8. Find the alarm text you want to edit and type in your own text.

In this example, text for PLC alarm 700048 is changed to "For test":

9. After editing the necessary alarm text, close it by saving.

10. Remove the USB stick from your PC and insert it into the USB interface at the front of the PPU again.



11. In the "SYSTEM" operating area, press the "USB" softkey. Locate the modified PLC alarm text and press the "Copy" vertical softkey:

12. Press the "808D data" horizontal softkey, enter directory "HMI data" > "PLC alarm texts

(alcu....txt)" by pressing the <INPUT> key twice. 13. Press the "Paste" vertical softkey to replace existing PLC alarm text file.

The HMI will restart to apply the change to the PLC alarm text file (alcu....txt). 14. After the HMI restart, return to the "SYSTEM" operating area, and press softkeys "PLC" >

"Edit PLC alarm text". Now you can view the results of what you have edited:


Commissioning the prototype 7 7.1 Commissioning the controller

7.1.1 Entering machine data

Note

Make sure that the current access level is "Manufacturer".

The most important machine data of the individual subareas are listed here to assist you. You can find a detailed description of the machine data and interface signals in the Parameter Manual with cross-references to the section on function description.

Entering the machine data (MD) Use the relevant softkeys to select the following machine data areas and to change the machine data if necessary:

● Basic list ("SYSTEM" operating areas -> "Mach. data" -> "Basic list")

– Basic machine data

● Expert list ("SYSTEM" operating areas -> "Mach. data" -> "Expert list")

– General machine data

– Axis machine data

– Channel machine data

– Display machine data

Activating conditions The control system has defined four activating conditions. Each machine has a corresponding activating condition:

● PO: Power On (activate by powering on)

● RE: Reset (activate by pressing the "RESET" key)

● CF: Config (activate by pressing the "Activate" vertical softkey)

● IM: Immediate (activated immediately after your change)

Note

The activating condition for a machine data is shown at the end of the data line in the parameter lists. For information about basic machine data, refer to the section "Basic machine data (Page 93)"; for information about all the machine data, refer to the SINUMERIK 808D Parameter Manual.

Commissioning the prototype 7.1 Commissioning the controller


7.1.2 Setting the axis-relevant parameters

7.1.2.1 Enabling the position control By default, each axis is a simulation axis. This means that the control system neither produces an instruction that is output to the drive, nor reads position signals from the motor. You can enable the position control of this axis by setting the machine data shown in the table below so that the axis goes into the operating state: No. Name Unit Set Value Description 30130 CTRLOUT_TYPE - 2 Control setpoint output type 30240 ENC_TYPE - 3 Encoder feedback type

7.1.2.2 Setting the leadscrew pitch, deceleration ratio, and motor rotation direction The actual moving distance depends on the parameter settings of the drive system. The parameters are shown in the table below: No. Name Unit Default Value Description 31030 LEADSCREW_PITCH mm 10 Leadingscrew pitch 31050 DRIVE_AX_RATIO_DEN

UM [0 to 5] - 1 Number of gearbox teeth at the drive end

(denominator of the deceleration ratio) 31060 DRIVE_AX_RATIO_NOM

ERA [0 to 5] - 1 Number of gearbox teeth at the leading

screw end (numerator of the deceleration ratio)

Note

For the spindle, index [0] means that both the denominator and the numerator are inactive, index [1] means the deceleration ratio of the first gearbox, index [2] that of the second gearbox, and the rest may be deducted in the same way.

For the feed axes, you must set the deceleration ratio at index [0].

For the deceleration ratio of a turning machine, you must enter a same value from the index [0] to [5] both for the denominator and the numerator; otherwise, the alarm 26050 will occur during the machining of screw threads.

If the motion direction of this axis does not correspond with the motion direction defined by the machine, you can modify it by setting the machine data shown in the table below: No. Name Unit Set Value Description 32100 AX_MOTION_DIR - 1 Motor runs clockwise (factory setting)

-1 Motor runs counter-clockwise



7.1.2.3 Setting the axis speed and acceleration You can configure the axis velocity and the acceleration by setting parameters shown in the table below: No. Name Unit Value Description 32000 MAX_AX_VELO mm/min * Maximum axis velocity 32010 JOG_VELO_RAPID mm/min * JOG rapid velocity 32020 JOG_VELO mm/min * JOG velocity 36200 AX_VELO_LIMIT mm/min * Axis velocity limit

Note

The value of MD36200 should be 10% higher than that of MD 32000; otherwise, alarm 025030 occurs.

No. Name Unit Value Description 32300 MAX_AX_ACCEL m/s2 * Maximum acceleration (standard value: 1

m/s2)

7.1.2.4 Setting the position-loop gain You can configure the position loop gain by setting the parameters shown in the following table: No. Name Unit Value Description 32200 POSCTRL_GAIN - * Position controller gain or servo gain factor (standard

value: 1)

Note

The position-loop gain influences the position following error, so when setting this parameter, you must make adjustments with reference to the actual position precision of the axes.



7.1.3 Setting the spindle-relevant parameters The SINUMERIK 808D control system controls one analog spindle, and you can commission the spindle by setting the parameters listed below:

Table 7- 1 Enabling the position control

No. Name Unit Value Description 30130 CTRLOUT_TYPE - 1 Control setpoint output type 30240 ENC_TYPE - 2 Encoder feedback type

Setting the machine spindle outputs as unipolar/bipolar setpoint output

Table 7- 2 Setting the machine spindle outputs as unipolar/bipolar setpoint output

No. Name Unit Value Description 30134 IS_UNIPOLAR_OUTPUT[0] - 0 Setpoint output is bipolar.

- 1 Setpoint output is unipolar. 2 Setpoint output is unipolar; signals from

pin 8 and pin 9 of the X21 (FAST I/O) are used.

Note

When MD30134 = 1: X21-8 = Servo enable; X21-9 = Spindle CCW.

When MD30134 = 2: X21-8 = Servo enable, spindle CW; X21-9 = Servo enable, spindle CCW.

For details, refer to information about connecting the inverter or servo spindle drive in the section "Connecting according to the default PLC program (Page 22)".

If the spindle has no encoder feedback: No. Name Unit Value Description 30200 NUM_ENCS - 0 Spindle without encoder 30350 SIMU_AX_VDI_OUTPUT - 1 Axis signals output for simulation axes 31040 ENC_IS_DIRECT - 0 Direct measuring system (no compilation

to load position)

Table 7- 3 Spindle machine data

No. Name Unit Value Description 31020 ENC_RESOL IPR 2048 Encoder pulses/steps per revolution

(encoder No.) 32000 MAX_AX_VELO mm/min * Maximum axis velocity 32260 RATED_VELO RPM 1900 Rated motor speed 36200 AX_VELO_LIMIT[0] to [5] RPM 575 Threshold value for velocity monitoring



Note

The value of MD36200 should be 10% higher than that of MD 32000; otherwise, alarm 025030 occurs.

Fill in weighted machine data No. Name Unit Value Description 36300 ENC_FREQ_LIMIT Hz 300,000 Encoder limit frequency = Motor rated

velocity/60 x Encoder resolution

Table 7- 4 For spindle with selective gearbox

No. Name Unit Value Description 35010 GEAR_STEP_CHANGE_ENA

BLE - 0 Gear change active. Spindle has several

steps 35110 GEAR_STEP_MAX_VELO[0]

to [5] - * Maximum speed for gear stage change

(gear stage number): 0 to 5 35130 GEAR_STEP_MAX_VELO_LI

MIT[0] to [5] - * Maximum speed of gear stage (gear

stage number): 0 to 5 36200 AX_VELO_LIMIT[0] to [5] - * Threshold value for velocity monitoring

(control parameter set number): 0 to 5 31050 DRIVE_AX_RATIO_DENUM[0]

to [5] - * Denominator load gearbox (control pa-

rameter number): 0 to 5 31060 DRIVE_AX_RATIO_NUMERA[

0] to [5] - * Numerator load gearbox (control param-

eter set): 0 to 5

Note

A maximum of 5 spindle gear stages can be available. Assigning the same parameters to the index [0] and [1] can activate gear changes (1 to 5) just by setting the corresponding interface signals via the PLC application.



7.1.4 Approaching the reference point

Principles for approaching the reference point ● Zero mark is away from the reference cam (MD: REFP_SEARCH_MARKER_REVERS =

0)

Vc Velocity for searching the reference cam (MD34020: REFP_VELO_SEARCH_CAM) VM Velocity for searching the zero mark (MD34040: REFP_VELO_SEARCH_MARKER) Vp Position velocity (MD34070: REFP_VELO_POS) Rv Shift of the reference point (MD34080: REFP_MOVE_DIST + MD34090:

REFP_MOVE_DIST_CORR) Rk Set position of the reference point (MD34100: REFP_SET_POS [0])

● Zero mark is above the reference point

Vc Velocity for searching for the reference cam (MD34020: REFP_VELO_SEARCH_CAM) VM Velocity for searching for the zero mark (MD34040: REFP_VELO_SEARCH_MARKER) Vp Position velocity (MD34070: REFP_VELO_POS) Rv Shift of the reference point (MD34080: REFP_MOVE_DIST + MD34090:

REFP_MOVE_DIST_CORR) Rk Set position of the reference point (MD34100: REFP_SET_POS [0])



Relevant parameters No. Name Unit Value Description 34010 REFP_CAM_DIR_IS_MINUS - 0, 1 Direction for approaching the reference point:

• 0: + • 1: -

34020 REFP_VELO_SEARCH_CAM mm/min * Velocity for searching for the reference cam 34040 REFP_VELO_SEARCH_MARKER mm/min * Velocity for searching for the zero mark 34050 REFP_SEARCH_MARKER_REVERSE - 0, 1 Direction for searching for the zero mark:

• 0: + • 1: -

34060 REFP_MAX_MARKER_DIST mm * Checking the maximum distance from the refer-ence cam

34070 REFP_VELO_POS mm/min * Positioning velocity for approaching the refer-ence point

34080 REFP_MOVE_DIST mm * Reference point distance (with marker) 34090 REFP_MOVE_DIST_CORR mm * Correction of reference point distance 34092 REFP_CAM_SHIFT mm * Shift of the reference cam 34093 REFP_CAM_MARKER_DIST mm * Distance between the reference cam and the

first zero mark 34100 REFP_SET_POS mm * Reference point position for incremental system 34200 ENC_REFP_MODE - 2 Referencing mode

Note

You must set the length of the reference cam based on the velocity set by MD34020. An axis can stop above the cam after it approaches the cam at the velocity set by MD34020 and then decelerates to "0".

Approaching the reference point To approach the reference point, you can proceed as follows:

1. Press the REF. POINT key on the MCP to enter the "Reference point" mode;

2. Keep the direction key pressed for the axis approaching the reference point until the symbol is displayed on the screen.

Figure 7-1 Example (turning)



You can also approach the reference point in the trigger mode: once you press the direction key for the reference point, it will return to the reference point automatically. To do this, you must install a reference cam in the way shown in the figure below so that the axis cannot stop between the reference cam and hardware limit switch before it arrives at the reference point.

If you have defined positions of the reference cam and the hardware limit switch as shown in the above figure, you can approach the reference point in the trigger mode by setting MD11300: No. Name Unit Value Description 11300 JOG_INC_MODE_LEVELTRIGGRD - 0 The trigger mode for returning to the

reference point.

Note

To modify this parameter, the access level "Manufacturer" is required.

7.1.5 Compensation parameter settings

7.1.5.1 Setting the software limit switches You can set the software limit switches by configuring the parameters described in the following table: No. Name Unit Value Description 36100 POS_LIMIT_MINUS mm * - software limit switch 36110 POS_LIMIT_PLUS mm * + software limit switch

7.1.5.2 Setting backlash compensation You can set the backlash compensation by configuring the parameter shown in the table below: No. Name Unit Value Description 32450 Backlash mm * Backlash compensation is active after reference

point approach.



7.1.5.3 Making leadscrew error compensation No. Name Unit Fixed value Description 38000 MM_ENC_COMP_MAX_POINTS - 125 The max. number of intermediate

points for interpolation compensa-tion

Compensation theory

Structure of the compensation arrays $AA_ENC_COMP [0, 0, AX3] = 0.0 Error value at the lowest point $AA_ENC_COMP [0, 1, AX3] = 0.0 Error value at the position of the lowest point + 1 $AA_ENC_COMP [0, 2, AX3] = 0.0 Error value at the position of the lowest point + 2 $AA_ENC_COMP [0, 3, AX3] = 0.0 Error value at the position of the lowest point + 3 ... ... $AA_ENC_COMP [0, 123, AX3] = 0.0 Error value at the position of the lowest point + 123 $AA_ENC_COMP [0, 124, AX3] = 0.0 Error value at the position of the lowest point + 124 $AA_ENC_COMP_STEP [0, AX3] = 0.0 Measurement distance (in mm) $AA_ENC_COMP_MIN [0, AX3] = 0.0 The lowest point (absolute) $AA_ENC_COMP_MAX [0, AX3] = 0.0 The highest point (absolute) $AA_ENC_COMP_IS_MODULO [0, AX3] = 0.0 (for the turning axis)



Compensation methods You can make the compensation as follows with a USB stick:

Method 1:

1. Plug your USB stick into the USB interface at the front of the PPU.

2. Find the compensation file ("SYSTEM" operating area > "Sys. data" > "808D data" > "NCK/PLC data" >: Leadscrew error compensation).

3. Copy it with the "Copy" softkey.

4. Press the "USB" softkey and paste the compensation file into the USB stick by pressing the "Paste" softkey.

5. Unplug the USB stick from the PPU, and insert it into a USB port of your PC.

6. Open the compensation file with the WordPad in the USB stick (default name: complete.eec).

7. Move the axis to be compensated based on the pre-set minimum position, maximum position and measurement distance.

8. Measure each error with a laser interferometer.

9. Record the error values into the compensation file, and delete the check code (for the compensation point).

For example:

10. Re-insert the USB stick into the USB interface at the front PPU. Copy the modified

compensation file from the USB stick and paste it under the original directory ("SYSTEM" operating area > "Sys data" > "808D data" > "NCK/PLC data": Leadscrew error compensation) to replace the old compensation file.

11. Wait for a few seconds: replacing the old compensation file can cause a PLC restart.

12. Set MD32700 = 1 ("SYSTEM" operating area > "Mach. data"> "Basic list").

13. The compensation values are effective after returning to the reference point.

14. Move the axes in JOG mode, and you can view the actual compensation value under "SYSTEM" operating area > "Serv. displ."> "Service axes": Abs. compens. value meas. system 1.



Method 2:

1. Follow steps 1 to 4 in method 1.

2. Press the <PROGRAM MANAGER> key.

3. Copy the compensation file from the USB to NC

4. Press the extension softkey ">>" and change the compensation file to a program file with the "Rename" softkey.

For example, press the "Rename" softkey >change "COMPLETE.EEC" to "COMPLETE.MPF":

5. Press the <INPUT> key to open the program file:

6. Measure each error with a laser interferometer.



7. Record the measurement values in the COMPLETE.MPF for the corresponding axis, and delete the check code (for the compensation point).

For example:

8. Press the "Execute" softkey. The SINUMERIK 808D enters the AUTO mode.

9. Press the <CYCLE START> key to execute COMPLETE.MPF. And the recorded compensation values will be saved into the SINUMERIK 808D.

10. Set MD32700 = 1 ("SYSTEM" operating area > "Mach. data" > "Basic list").

11. Restart the NC ("SYSTEM" operating area > "Start-up" > NC: Standard power-up).

12. The compensation values are effective after returning to the reference point.

13. Move the axes in JOG mode, and then you can view the actual compensation value under "SYSTEM" operating area > " Serv. displ." > "Service axes": Abs. compens. value meas. system 1.

7.1.5.4 Setting protection levels The SINUMERIK 808D control system has defined protection levels for user data. You can set protection levels for the following user data:

● Tool offsets

● Zero offsets

● Setting data

● R parameters

● Part programs

● RS232 settings

● PLC projects

● Protected work areas

Commissioning the prototype 7.2 Data backup


You can set the read/write protection for these user data by setting the following display machine data ("SYSTEM" operating area > "Mach. data" > "Expert list" > "Display MD"): No. Name Value Description 207 USER_CLASS_READ_TOA 3 to 7 Protection level: read, for tool offsets 208 USER_CLASS_WRITE_TOA_GEO 3 to 7 Protection level: write, for tool geome-

try 209 USER_CLASS_WRITE_TOA_WEAR 3 to 7 Protection level: write, for tool wear

data 210 USER_CLASS_WRITE_ZOA 3 to 7 Protection level: write, for zero offsets 212 USER_CLASS_WRITE_SEA 3 to 7 Protection level: write, for setting data 213 USER_CLASS_READ_PROGRAM 3 to 7 Protection level: read, for part pro-

grams 214 USER_CLASS_WRITE_PROGRAM 3 to 7 Protection level: write, for part pro-

grams 215 USER_CLASS_SELECT_PROGRAM 3 to 7 Protection level: select, for part pro-

grams 218 USER_CLASS_WRITE_PRA 3 to 7 Protection level: write, for R parame-

ters 219 USER_CLASS_SET_V24 3 to 7 Protection level: set, for RS232 set-

tings 221 USER_CLASS_DIR_ACCESS 3 to 7 Protection level: directory access 222 USER_CLASS_PLC_ACCESS 3 to 7 Protection level: PLC project access 223 USER_CLASS_WRITE_PWA 3 to 7 Protection level: protected work area

access

User data with protection level 3 can be read or written with access level "Customer" or higher.

User data with protection level 4 can be read or written only when the PLC address DB2600.DBX0.7 is set to "1".



User data with protection level 7 can be read or written without any password or PLC interface signal.

For detailed information about the PLC user interface, refer to the section "PLC user interfaces (Page 106)".



7.2 Data backup

7.2.1 Creating a series archive After commissioning the prototype, you must create a series archive for series production.

The series archive file includes the following data:

● Machine and setting data

● PLC data (for example, PLC program and PLC alarm texts)

● User cycles and part programs

● Tool and work offset data

● R variables

● HMI data (for example, OEM Online Help and OEM Manual)

You can back up the production archive in two ways:

● Internal: on the CNC controller

● External: on a USB stick

To create a series archive, proceed as follows:

1. In the "SYSTEM" operating area (key combination: + ), press the "Archv." softkey.

2. Select the option of "Create series start-up archive" and press the "OK" softkey:

You must select a back-up path from the list to store the production archive file:

– OEM files: folder on the CNC controller for storing OEM files

– User files: folder on the CNC controller for storing end-user files

– USB: USB stick

The default name of the data archive is "arc_product.arc". You can use your favourite name for it.



3. Press the <INPUT> key to enter selected directory and press the "OK" softkey to proceed:

In the "Archive information" box that follows, you can enter the following information:

– Archive creator

– Archive version

– Comment

4. Press the "OK" softkey to create the data archive.

Note

Do not remove the USB stick during the data back-up.

7.2.2 Creating a start-up archive for the prototype After commissioning the prototype, you must also create a start-up archive for the data backup of the prototype itself.

The start-up archive file includes the following data:


● Compensation data




● R variables


You can also back up the start-up archive in two ways:

● Internal: on the CNC controller

● External: on an USB stick



To create a start-up archive, proceed as follows:


2. Select the option "Create start-up archive":

Press the "OK" softkey and the following window opens:

The default name of the data archive is "arc_startup.arc". You can use your own name for it.

3. Select the target directory and press the <INPUT> key to enter the directory and press

the "OK" softkey to proceed:

In the "Archive information" box that follows, you can enter the information below:

– Archive creator

– Archive version

– Comment


Note

Do not remove the USB stick during the data back-up.



7.2.3 Restoring the control system with the start-up archive file You can, if necessary, restore the system of the prototype machine by uploading the start-up archive file.

To upload the start-up archive, perform the following operations:

1. In the "SYSTEM" operating area, press the "Archv." softkey.

2. Select the option "Restore start-up archive":

Press the "OK" softkey:

3. Find the backed-up path and press the <INPUT> key to enter the directory. Select the

backed-up data archive and press the "OK" softkey:

4. Check the archive information and press the "OK" softkey to proceed if the selected data

archive is correct:



5. Press "OK" to confirm the warning information:

6. Now the upload starts:

It will take you several minutes to complete the upload.

7. The CNC controller restarts after successfully uploading the start-up archive.

Note

Since the system restoring can delete the password, you must input your password again when the CNC controller restarts.


Series production 8 8.1 Uploading the series archive for series commissioning

You can use the production archive to do series commissioning for series production. The series archive is created during the commissioning of the prototype. For details about the creating of the production archive, refer to the section "Creating a series archive (Page 70)".

You must upload the production archive to the CNC controllers for series commissioning. To upload the production archive, proceed as follows:

1. In the "SYSTEM" operating area, press the "Archv." softkey.

2. Select the option "Restore start-up archive":

Press the "OK" softkey:

3. Find the back-up path and press the <INPUT> key to enter the directory. Select the

backed-up data archive and press the "OK" softkey:

Series production 8.1 Uploading the series archive for series commissioning


4. Check the archive information and press the "OK" softkey to proceed if the selected data archive is correct:

5. Press "OK" to confirm the warning information:

6. Now the upload begins:

It will take you several minutes to complete the upload.

7. The CNC controller restarts after successfully uploading the production archive.

Note

Successfully uploading the data archive can delete the password. You must set the password again in the "SYSTEM" operating area.

Series production 8.2 Data settings for individual machine


8.2 Data settings for individual machine

8.2.1 Setting the software limit switches Refer to the section "Setting the software limit switches (Page 64)".

8.2.2 Setting the backlash Refer to the section "Setting backlash compensation (Page 64)".

8.2.3 Making leadscrew error compensation Refer to the section "Making leadscrew error compensation (Page 65)".

8.3 Data backup

8.3.1 Overview After the series production, you can do the data backup of individual machine for delivery in two ways:

● Creating an original status archive: data backup only on the CNC controller

● Creating a start-up archive: data backup either on the CNC controller or on an external USB stick

The original status archive and the start-up archive contain exactly the same data:


● Compensation data




● R-parameter


Series production 8.3 Data backup


8.3.2 Creating an original status archive To create an original status archive, proceed as follows:


2. Select the option of "Create start-up archive in the default directory" and press the "OK" softkey:

1. In the "Archive information" box that follows, you can enter the information below:

– Archive creator

– Archive version

– Comment


8.3.3 Creating the start-up archive When creating the start-up archive for the series production, follow exactly the same procedures used to create the start-up archive for the prototype. Refer to the section "Creating a start-up archive for the prototype (Page 71)" for details.



8.3.4 Restoring the control system You can, if necessary, restore the control system either with the original status archive or with the start-up archive.

Restore the control system with the original status archive Proceed as follows to restore the CNC controller with the original status archive:


2. Select the option "Restore start-up archive from the default directory", and press the "OK" softkey:

Note: The option "Restore start-up archive from the default directory" is displayed only when you have created the original status archive.

3. Check the archive information and press the "OK" softkey to proceed; otherwise, press

the "Cancel" softkey to cancel the restore operation.



4. Press the "OK" softkey to confirm the warning information and the system restoring begins:

5. Wait until the CNC controller restarts and the control system has been successfully

restored.

Note

Since the system restoring can delete the password, you must input your password again when the CNC controllers restarts.

Restore the control system with the start-up archive When restoring the control system with a start-up archive, you can follow exactly the same procedures used to restore the prototype machine. For details, refer to the section "Restoring the control system with the start-up archive file (Page 73)".


Other frequently used functions 9 9.1 Playing a slide show

The SINUMERIK 808D has a function of playing a slide show. You can create a slide show to display your product information.

Playing a slide show You can press the key combination <CTRL> + <D> on the PPU to show a slide show and press the key combination again to exit the slide show.

Creating a slide show By default, the slide show of Siemens product information is provided. You can create the desired slide show as follows:

1. Prepare your own slides and save them in the respective language folders on a USB stick. Name each folder according to the following convention.

Chinese: folder name = "chs";

English: folder name = "eng";

Portuguese: folder name = "ptb";

Russian: folder name = "rus".

The SINUMERIK 808D supports two kinds of image formats:

– *.png

– *.bmp

Image size is recommended to be 640*480 pixels for the best display effect.

Name each slide according to the following syntax:

– slide%u.png or

– slide%u.bmp

Here "%u" is the number sequence starting with "1". For example, slide1.png, slide2.png, slide3.png ...

If your slides include both PNG-format images and BMP-format images, then number them separately. During the slide show, the PNG-format images will have a higher priority over the BMP-format images.


Other frequently used functions 9.1 Playing a slide show


3. In the "SYSTEM" operating area, press softkey "Sys. data" > "USB". Select all the language folders for slide show by using the <Mark all> softkey or you can select the desired language folder by moving the cursor up and down, and then press the "Copy" softkey:

4. Press the "808D data" softkey. Enter directory "HMI data" > "OEM slideshow (*.bmp;

*.png)" by pressing the <INPUT> key twice.Press the "Paste" softkey:

5. Press the key combination <CTRL> + <D>, and now you can view the slideshow you

have created.

Note

Using MD9001 TIME_BTWEEN_SLIDES ("SYSTEM" operating area >"Mach. Data" > "Expert list" > "Display MD") you can set the time between slides.

Press the key combination <CTRL> + <D> again to exit the slide show.

Other frequently used functions 9.2 Defining the service planner


9.2 Defining the service planner The SINUMERIK 808D has the service planning function. With this function, you can specify the service timer and define your own service information. This section shows you how to define the OEM service planner.

Creating a new service task To create a new service task, perform the following steps:

+ 1. Enter the desired operating area.

2. Enter the main screen of service planning.

3. Create a new task. Enter values in the respective fields.

4. Confirm the above input to complete creating the new task.



Viewing the service task To edit the created service task, proceed as follows:


2. Enter the main screen of HMI data.

3. Enter the folder related to HMI data.

4. Navigate to the last folder.

5. Press this key to open the folder.

6. Copy the desired service planner text.

7. Press this softkey to enter the screen form of user cycle.



8. Press this softkey to paste the copied text into the screen form of user

cycle.

9. Press this softkey to view the service task.

Editing the service task


2. Enter the main screen of service planning.

3. Press this softkey to enter the screen form of task change.

4. Change the task description in the following box as desired.

4. Confirm the above input to complete changing the task.

Other frequently used functions 9.3 Using the OEM startup screen and the OEM machine logo


9.3 Using the OEM startup screen and the OEM machine logo The SINUMERIK 808D uses the SIEMENS start-up screen and machine logo by default. If necessary, you can use you own start-up screen and machine logo.

Using the OEM startup screen The default start-up screen is shown below:

To change it to your own start-up screen, proceed as follows:

1. Prepare the image of the start-up screen and save it on a USB stick.

The SINUMERIK 808D supports a start-up screen in the BMP format and with a maximum size of 640*480 pixels (W*H).

Name the image as "startup.bmp".


3. Press softkeys "Sys. data" > "USB" in the "SYSTEM" operating area. Find the start-up screen file and copy it with the "Copy" softkey.

4. Press the "808D data" softkey. Press the <INPUT> key to enter "HMI data" > "Custom-ized bitmaps".

The default start-up screen and machine logo are placed under the "Customized bitmaps" folder:

– OEM machine logo (mtbico.bmp)

– OEM start-up splash screen (startup.bmp)

Press the "Paste" softkey to replace the default startup screen with your own start-up screen.



5. Press Ctrl + R to restart the HMI. You can view your own start-up screen in the process of control system start-up.

Note

To restore the default start-up screen, delete the customized bitmap file (startup.bmp) from the control system.

Using the OEM machine logo Machine logo can be displayed in the "Machine" operating area. The default machine logo is displayed as follows:



To use your own machine logo, proceed as follows:

1. Prepare your own machine logo and save it on a USB stick.

The SINUMERIK 808D supports the OEM machine logo in the BMP format with a maximum size of 124*19 pixels (W*H).

Name the image as "mtbico.bmp".

Note that a machine logo with the size of 124*19 pixels can make the best effect.


3. Press softkeys "Sys. data" > "USB" in the "SYSTEM" operating area. Find the machine logo and copy it with the "Copy" softkey:

4. Press the "808D data" softkey. Press the <INPUT> key to enter "HMI data" > "Customized bitmaps".

The default startup screen and machine logo are placed under the "Customized bitmaps" folder:

– OEM machine logo (mtbico.bmp)

– OEM start-up splash screen (startup.bmp)

Press the "Paste" softkey to replace the default machine with your own machine logo.

5. Press Ctrl + R to restart the HMI. You can view your own machine logo in the "Machine" operating area.

Note

To restore the default "SIEMENS" logo display, delete the customized bitmap file (mtbico.bmp) from the control system.


Appendix A A.1 Cutting reserved holes

On the MCP, three reserved holes with a standard diameter of 16 mm are available for you to install necessary devices according to your own needs:

Figure A-1 Reserved holes

To cut a reserved hole, proceed as follows:

Figure A-2 Cutting reserved holes

Appendix A.2 Inserting, printing or cutting the MCP strips


A.2 Inserting, printing or cutting the MCP strips

Inserting the MCP strips The MCP strips for the SINUMERIK 808D (Turning) are already pre-assembled into the MCP. If you are using the control system of Milling version, you need to take these pre-assembled strips out firstly, and then insert the MCP strips for the Milling version into the MCP by yourself.

To insert the MCP strips, follow the order shown as follows with reference to the marks (M1 to M6, T1 to T6) on the strips:

Printing customized MCP strips Siemens provides you a symbol library for customized MCP keys. You can print customized strips with the A4-size blank paper included in the delivered MCP package. You can find the symbol library in the Toolbox (...\04040000\examples\MCP).

Siemens also provides you with a template file for printing customized strips. Key positions in the template accord with real key layout on the MCP. You can copy symbols from the symbol library and paste them to the key positions that you want to use customized symbols. You can find the template file in the Toolbox (...\04040000\examples\MCP).

Cutting customized MCP strips The delivered A4-size paper has been pre-cut with boundaries. You just need to tear them off after printing customized symbols.

Appendix A.3 Basic knowledge about NC programming


A.3 Basic knowledge about NC programming

Theory Table A- 1 Basic NC commands

Commands Descriptions M3 Spindle rotates CW M4 Spindle rotates CCW Tn Activate or change to a new tool.

n = tool number G00 When G00 is active in the program, the axis traverses at the maximum axis speed in

a straight line. G01 When G01 is active in the program, the axis traverses at the programmed feedrate in

a straight line, according to the feedrate type defined by G94 (F as the feedrate in mm/min) / G95 (F as the feedrate in rev/min of the spindle).

G02 CW circular interpolation G03 CCW circular interpolation Nn Block number - subblock

n = an integer at the range of 0 to 99,999,999

Programming under the MDA mode (example) PPU:

+ MCP:

Figure A-3 NC programming (example)

Appendix A.4 Selection of the transformers


References Programming and Operating Manual (Turning) Programming and Operating Manual (Milling)

A.4 Selection of the transformers You can select the appropriate transformers according to the desired motor combinations.

Recommended transformer type 380 V/220 V SG series 3AC isolating servo transformer Supply voltage 3 AC 380 / 220 V

50/60 Hz Connection group Y/Y-12 Impedance voltage (Uk%) 4 No-load current (%) For a transformer =< 1.0 kVA, the no-load current < 18%;

For a transformer > 1.0 kVA, the no-load current < 14%. Power selection according to possible motor combinations

4 Nm ⇔ 1.0 kVA 4 Nm + 4 Nm + 10 Nm ⇔ 2.0 kVA 6 Nm ⇔ 1.5 kVA 4 Nm + 6 Nm + 6 Nm ⇔ 2.0 kVA 7.7 Nm ⇔ 2.0 kVA 4 Nm + 6 Nm + 7.7 Nm ⇔ 2.0 kVA 10 Nm ⇔ 2.0 kVA 4 Nm + 6 Nm + 10 Nm ⇔ 2.0 kVA 4 Nm + 4 Nm ⇔ 1.5 kVA 4 Nm + 7.7 Nm + 7.7 Nm ⇔ 2.0 kVA 4 Nm + 6 Nm ⇔ 1.5 kVA 4 Nm + 7.7 Nm + 10 Nm ⇔ 2.5 kVA 4 Nm + 7.7 Nm ⇔ 1.5 kVA 4 Nm + 10 Nm + 10 Nm ⇔ 2.5 kVA 4 Nm + 10 Nm ⇔ 2.0 kVA 6 Nm + 6 Nm + 6 Nm ⇔ 2.0 kVA 6 Nm + 6 Nm ⇔ 1.5 kVA 6 Nm + 6 Nm + 7.7 Nm ⇔ 2.0 kVA 6 Nm + 7.7 Nm ⇔ 2.0 kVA 6 Nm + 6 Nm + 10 Nm ⇔ 2.5 kVA 6 Nm + 10 Nm ⇔ 2.0 kVA 6 Nm + 7.7 Nm + 7.7 Nm ⇔ 2.5 kVA 7.7 Nm + 7.7 Nm ⇔ 2.0 kVA 6 Nm + 7.7 Nm + 10 Nm ⇔ 2.5 kVA 7.7 Nm + 10 Nm ⇔ 2.5 kVA 6 Nm + 10 Nm + 10 Nm ⇔ 3.0 kVA 10 Nm + 10 Nm ⇔ 3.0 kVA 7.7 Nm + 7.7 Nm + 7.7 Nm ⇔ 2.5 kVA 4 Nm + 4 Nm + 4 Nm ⇔ 1.5 kVA 7.7 Nm + 7.7 Nm + 10 Nm ⇔ 3.0 kVA 4 Nm + 4 Nm + 6 Nm ⇔ 1.5 kVA 7.7 Nm + 10 Nm + 10 Nm ⇔ 3.0 kVA 4 Nm + 4 Nm + 7.7 Nm ⇔ 2.0 kVA 10 Nm + 10 Nm + 10 Nm ⇔ 3.5 kVA

CAUTION

To reduce the risk of electric shock, interference from power supply and electromagnetic field, an isolating transformer is necessary for the 3AC 380V mains system.

Appendix A.5 Parameter list


A.5 Parameter list

A.5.1 Basic machine data

No. Name Default Range Type Unit Activating 11300 JOG_INC_MODE_LEVELTRIGGRD 1 - BOOL - PO

INC and REF in JOG mode 14510 * USER_DATA_INT[0] ... [31] 0 -62,768 to

32,767 DWORD - PO

User data (INT) 14512 * USER_DATA_HEX[0] ... [31] 0H 0 to 0x0FF BYTE - PO

User data (HEX) 14514 * USER_DATA_FLOAT[0] ... [7] 0.000000 -3.4e+038 to

3.4e+038 DOUBLE - PO

User data (float) 20700 REFP_NC_START_LOCK 1 - BOOL - RE

NC start disable without reference point 30350 SIMU_AX_VDI_OUTPUT FALSE - BOOL - PO

Axis signals output for simulation axes 30600 FIX_POINT_POS[0] ... [3] 0.000000 - DOUBLE mm, de-

grees PO

Fixed-value positions of axis with G75 30130 CTRLOUT_TYPE 0 0 to 3 BYTE - PO

Output type of setpoint 30134 IS_UNIPOLAR_OUTPUT[0] 0 0 to 1 - - PO

Setpoint output is unipolar 30200 NUM_ENCS 1 0 to 1 BYTE - PO

Number of encoders 30240 ENC_TYPE 0 0 to 5 BYTE - PO

Encoder type of actual value sensing (actual position value) 31020 ENC_RESOL[0] 10,000 DWORD - PO

Encoder lines per revolution 31030 LEADSCREW_PITCH 10.000000 ≥ 0 DOUBLE mm PO

Pitch of leadscrew 31040 ENC_IS_DIRECT FALSE,

FALSE - BYTE - PO

Direct measuring system (no compilation to load position) 31050 DRIVE_AX_RATIO_DENOM[0] ... [5] 1 1 to

2,147,000,000 DWORD - PO

Denominator load gearbox



No. Name Default Range Type Unit Activating 31060 DRIVE_AX_RATIO_NUMERA[0] ...

[5] 1 1 to

2,147,000,000 DWORD - PO

Numerator load gearbox 31400 STEP_RESOL[0] 10,000 100 to 100,000 DWORD - PO

Steps per stepper motor revolution 32000 MAX_AX_VELO 10,000

(mm/min) 27.77 (rpm)

- DOUBLE

mm/min, rpm CF

Maximum axis velocity 32010 JOG_VELO_RAPID 10,000


- DOUBLE mm/min, rpm

RE

Rapid traverse in JOG mode 32020 JOG_VELO 20,000

(mm/min) 5.55 (rpm)


RE

Jog axis velocity 32060 POS_AX_VELO 10,000



RE

Initial setting for positioning axis velocity 32100 AX_MOTION_DIR 1 -1 to 1 DWORD - PO

Traversing direction (not control direction) 32110 ENC_FEEDBACK_POL[0] 1 -1 to 1 DWORD - PO

Sign actual value (control direction) 32200 POSCTRL_GAIN[0] ... [5] 1.000000 0.000000 to

2000.000000 DOUBLE User de-

fined CF

Servo gain factor 32260 RATED_VELO[0] 1,900.0 - DOUBLE rpm CF

Rated motor speed 32300 MAX_AX_ACCEL[0] ... [4] [0]...[2]: 2.0

[3]...[4]: 1.0 ≥ 0.001 DOUBLE mm/s2,

rev/s2 CF

Maximum axis acceleration 32450 Backlash[0] 0.0 - DOUBLE mm CF

Backlash 32700 ENC_COMP_ENABLE[0] 0 - BOOL - CF

Encoder/spindle error compensation 34000 REFP_CAM_IS_ACTIVE 1 - BOOL - RE

Axis with reference point cam 34010 REFP_CAM_DIR_IS_MINUS 0 - BOOL - RE

Approach reference point in minus direction



No. Name Default Range Type Unit Activating 34020 REFP_VELO_SEARCH_CAM 5,000.0



RE

Reference point approach velocity 34040 REFP_VELO_SEARCH_MARKER[0] 300.0



RE

Creep velocity 34050 REFP_SEARCH_MARKER_REVER

SE[0] 0 - BOOL - RE

Direction reversal to reference cam 34060 REFP_MAX_MARKER_DIST[]0[ 20.0 - DOUBLE mm, de-

grees RE

Maximum distance to reference mark 34070 REFP_VELO_POS 10,000.00



RE

Reference point positioning velocity 34080 REFP_MOVE_DIST[0] -2.0 - DOUBLE mm, de-

grees RE

Reference point distance 34090 REFP_MOVE_DIST_CORR[0] 0.0 - DOUBLE mm, de-

grees RE

Reference point offset/absolute offset 34092 REFP_CAM_SHIFT 0.000000 - DOUBLE mm RE

Electronic cam offset for incremental measuring system 34093 REFP_CAM_MARKER_DIST 1.054500 - DOUBLE mm PO

Reference cam/reference mark distance 34100 REFP_SET_POS[0] ... [3] 0.0 - DOUBLE mm, de-

grees RE

Reference point for incremental system 34200 ENC_REFP_MODE 1 0 to 8 BYTE - PO

Referencing mode 35010 GEAR_STEP_CHANGE_ENABLE 0 - BOOL - RE

Parameterize gear stage change 35100 * SPIND_VELO_LIMIT 10,000.0 - DOUBLE rpm PO

Maximum spindle speed 35110 GEAR_STEP_MAX_VELO[0] ... [5] [0]...[1]: 500

[2]: 1,000 [3]: 2,000 [4]: 4,000 [5]: 8,000

- DOUBLE rpm CF

Maximum speed for gear stage change



No. Name Default Range Type Unit Activating 35120 GEAR_STEP_MIN_VELO[0] ... [5] [0]...[1]: 50

[2]: 400 [3]: 800 [4]: 1,500 [5]: 3,000

- DOUBLE rpm CF

Minimum speed for gear stage change 35130 GEAR_STEP_MAX_VELO_LIMIT[0]

... [5] [0]...[1]: 500 [2]: 1,000 [3]: 2,000 [4]: 4,000 [5]: 8,000

- DOUBLE rpm CF

Maximum speed for gear stage 35140 GEAR_STEP_MIN_VELO_LIMIT[0] ...

[5] [0]...[1]: 5 [2]: 10 [3]: 20 [4]: 40 [5]: 80

- DOUBLE rpm CF

Minimum speed for gear stage 36100 POS_LIMIT_MINUS -100,000,000 - DOUBLE mm, de-

grees RE

1st software limit switch minus Access level: Manufacturer

36110 POS_LIMIT_PLUS 100,000,000 - DOUBLE mm, de-grees

RE

1st software limit switch plus 36120 POS_LIMIT_MINUS2 -100,000,000 - DOUBLE mm, de-

grees RE

2nd software limit switch minus 36130 POS_LIMIT_PLUS2 100,000,000 - DOUBLE mm, de-

grees RE

2nd software limit switch plus 36200 AX_VELO_LIMIT[0] ... [5] 11,500

(mm/min) 31,944 (rpm)


CF

Threshold value for velocity monitoring 38000 MM_ENC_COMP_MAX_POINTS 125 - DWORD - PO

Number of intermediate for interpolar compensation (SRAM) The machine data followed by an asterisk (*) have the access level of "Customer", while those without an asterisk have the

access level of "Manufacturer".



A.5.2 SINAMICS V60 parameters

Par. No. Name Range Default Increment Unit Effective P01 Parameter write protection 0 - 1 0 1 - Immediately

0: Sets all parameters other than P01 as read-only parameters. 1: Sets all parameters to be both readable and writable. P01 automatically resets to 0 after power-on!

P05 Internal enable 0-1 0 1 - Immediately 0: JOG mode can be enabled externally. 1: JOG mode can be enabled internally. P05 automatically resets to 0 after power-on!

P16 Maximum motor current 0-100 100 1 % Power On Specifies the maximum motor current (2 x rated motor current) of your choice.

P20 Speed loop proportional gain 0.01-5.00 Depends on drive version

0.01 Nm*s/rad Immediately

Factory defaults: 4 Nm: 0.81; 6 Nm: 1.19; 7.7 Nm: 1.50; 10 Nm: 2.10 Note: Default value varies with software version. This parameter specifies the proportional gain (Kp, proportional component) of speed control loop. The bigger the value, the higher the gain and rigidity. The setting depends on specific drive and load. General-ly, the bigger the load inertia, the bigger the value is to set. However, if there is no oscillation occurring in the system, you can set the value as big as possible.

P21 Speed loop integral time constant

0.1-300.0 Depends on drive version

0.1 ms Immediately

Factory defaults: 4 Nm: 17.7; 6 Nm: 17.7; 7.7 Nm: 17.7; 10 Nm: 18.0 Note: Default value varies with software version. This parameter specifies the integral action time (Tn, integral component) of speed control loop. The smaller the value, the higher the gain and rigidity. The setting depends on specific drive and load.

P26 Maximum motor speed 0-2,200 2,200 20 rpm Power On Sets the maximum possible motor speed.

P30 Position loop proportional gain

0.1-3.2 3.0 0.1 1,000/min Immediately

1. This parameter specifies the proportional gain of position loop. 2. The bigger the value, the higher both the gain and rigidity, and at the same pulse command frequency the

smaller the position hysteresis. However, excessively high value setting may cause system oscillation or overshooting.

3. The setting depends on specific drive and load.

P31 Position loop feedforward gain

0-100 85 1 % Immediately



Par. No. Name Range Default Increment Unit Effective 1. This parameter specifies the feedforward gain of position loop. 2. Setting the value to 100 % means position hysteresis is always 0 at any pulse command frequency. 3. Increasing the feedforward gain of position loop improves the high-speed response characteristics of the

control system, but meanwhile causes the system's position loop unstable and liable to oscillation. 4. Unless very high response characteristics are necessary, set the feedforward gain of position loop to 0.

P34 Maximum following error 20-999 500 1 100 pulses Immediately This parameter specifies the maximum possible following error. When the actual following error is larger than the setpoint, the drive sends an over-position alarm (A43)

P36 Input pulse multiplier 1, 2, 4, 5, 8, 10, 16, 20, 100, 1,000

1 - - Power On

This parameter specifies the input pulse multiplier. For example, when P36 = 100, input frequency = 1 kHz, output frequency = 1 kHz x 100 = 100 kHz. Note: Pulse frequency setpoint = Actual pulse frequency x input pulse multiplier; This parameter is applicable only when the software version is V01.06 or later; When P36 = 100 or 1,000, speed stability will decrease with higher multiplication factor.

P41 Brake open delay 20-2,000 100 10 ms Power On The setpoint transfer after drive enable is delayed by this time. Drive can be enabled under the following conditions: A: When the following three conditions are all met: 1. Terminal 65 (external enable) has been enabled; 2. The drive has received an enable signal from NC; 3. No alarm is detected by the drive. B: When the following two conditions are both met: 1. Terminal 65 (control enable) has been activated; 2. Motor operates in "JOG-RUN" mode (enabled from function menu ) C: When the following two conditions are both met: 1. P05 = 1 (The JOG mode can be enabled internally); 2. Motor operates in "JOG-RUN" mode (enabled from function menu )

P42 Brake close time while motor operation

20-2,000 100 10 ms Power On

When motor speed exceeds 30 rpm, the drive generates an alarm. If, within the specified brake close time (P42), the actual motor speed remains bigger than brake close speed setpoint (P43), brake is closed after the specified brake close time (P42) expires.

P43 Brake close speed while motor operation

0-2,000 100 20 r/min Power on

When motor speed exceeds 30 rpm, the drive generates an alarm. If, within the specified brake close time (P42), the actual motor speed becomes smaller than the P43 setpoint, brake is closed when the actual speed reaches the speed setpoint.

P44 Drive enable time after the brake close

20-2,000 600 10 ms Power on

When motor speed is lower than 30 rpm, the drive remains enabled within the time period set by P44 after brake close.

Appendix A.6 Diagnostics


Par. No. Name Range Default Increment Unit Effective P46 JOG speed 0-2,000 200 10 rpm Immediately

This parameter specifies the motor speed in JOG mode. P47 Ramp-up/-down time con-

stant 0.0 – 10.0

4.0 0.1 s Power on

This parameter defines the time period when the motor ramps up from 0 rpm to 2,000 rpm or ramps down from 2, 000 rpm to 0 rpm.

P99 Reserved for Siemens internal use only

A.6 Diagnostics

A.6.1 SINUMERIK 808D alarms Some alarms may occur during the commissioning work. In the "ALARM" operating area, you can press the <HELP> key to call the help information for an alarm. For details about it, refer to the Diagnostics Manual.

A.6.2 SINAMICS alarms

A.6.2.1 Overview of alarms Table A- 2 Overview of alarms

Alarm code Alarm name Description A01 Power board ID number

error Unable to identify the power board

A02 Parameter error Parameter validation error (CRC error, encoder type or parameter header invalid)

A03 Memory-write failure Unable to write data to memory A04 Control voltage error Control voltage is lower than 3.5 V. A05 IGBT overcurrent IGBT is detected overcurrent. A06 lnternal chip overcurrent Internal chip is detected overcurrent. A07 Grounding short circuit Grouding short circuit occurs during drive initialization A08 Endoder UVW sginals error Signals from encoder phases U, V, W are detected all the same (all high or all

low) A09 Encoder TTL signals error TTL pulse error A14 Internal error Software failure A21 DC link overvoltage DC link voltage is higher than 405 V A22 IT protection IGBT current exceeds the upper limit for 300 ms A23 DC link undervoltage DC link voltage is lower than 200 V A41 Overspeed Actual motor speed is higher than 2200 rpm A42 IGBT overtemperature IGBT becomes overheating A43 Over-position Position offset is out of limit A44 I2T protection Motor load exceeds nominal motor torque A45 Emergency stop Enable signal from Terminal 65 is lost during normal drive operation



A.6.2.2 Alarm list Alarm code

Background Possible Cause Remedy Result Acknowledgement

A01 Power board is broken Replace the drive with a new one

Free stop Power on

A02 The memory is damaged due to unexpected power-off during data saving

Restore default parame-ters

Free stop Power on

A03 Memory is damaged Replace the drive with a new one

Free stop Power on

A04 The 24 V DC supply is abnormal

Check the 24 V DC sup-ply

Free stop Power on

The drive is defective Replace the drive with a new one

A05 This alarm may occur when the DC link is con-nected

1. There is a short-circuit between terminals U, V, W and PE on the drive

2. bad grounding 3. motor insulation is

broken 4. the drive is broken

1. check the wiring 2. make a correct

grounding 3. replace the motor

with a new one 4. replace the drive with

a new one

Free stop Power on

This alarm may occur when the motor is running


1. There is a short-circuit between terminals U, V, W and PE on the drive

2. bad grounding 3. motor insulation is

broken the drive is broken

1. check the wiring or whether the connec-tion to U, V or W is broken

2. make a correct grounding

3. replace the motor with a new one

4. replace the drive with a new one

Free stop Power on



1. IGBT module is broken 2. There is a short-circuit

between U, V or W and PE

1. replace the drive with a new one

2. Check the wiring

Free stop Power on


A08 1. UVW signals of the encoder are bad

2. bad cable 3. bad cable shielding 4. bad wiring of the

shielded ground cable 5. there is a failure in the

interface circuit of the encoder

1. replace the encoder with a new one

2. check the interface circuit of the encoder

Free stop Power on



Alarm code


A09 1. connection failure of encoder ABZ

2. bad cable 3. bad cable shielding 4. bad wiring of the

shielded grounded ca-ble

5. there is a failure in the interface circuit of the encoder

1. check the wiring of encoder cable

2. check the interface circuit of the encoder

Free stop Power on

A14 There is failure at the inter-nal software

Reset by power-on Free stop Power on

A short-circuit occurs to the encoder

Check the wiring of en-coder

A21 This alarm may occur when the 24 V DC supply is connected

There is a failure at the circuit board

Replace the drive with a new one

Free stop Press Enter key on the operator panel or terminal RST of X6 interface

This alarm may occur when the DC link is con-nected

1. the mains supply volt-age is too high

2. the waveform of mains supply voltage is ab-normal

Check the power supply


1. disconnection of the internal brake resistor

2. the internal brake resis-tor is broken


Brake loop has no enough space

1. lower the start-stop frequency

2. reduce the limit value of current

3. reduce load inertia 4. use another drive

and motor with higher frequencies

A22 The motor is mechanically blocked

Check the mechanical load


Overload 1. lighten the load 2. use another drive

and motor with higher frequencies

A23 1. circuit board fails 2. fuse of the power is

burnt out 3. rectifier is broken





Alarm code


1. low supply voltage 2. insufficient supply pow-

er capacity 3. transient power failure

Check the power supply


Circuit board fails Replace the drive with a new one

Emergency stop (the motor will stop with the maximum energy or torque)

Press Enter key on the operator panel or terminal RST of X6 interface

The encoder fails Replace the motor with a new one


The encoder fails Replace the drive with a new one

The encoder cable is badly connected

Replace the motor with a new one

This alarm may occur when the motor starts running

1. terminals U, V and W on the motor are wrongly connected

2. the encoder is wrongly wired

Check the wiring

A42 Ambient temperature is too high

Check the ambient tem-perature



The drive is overloaded Check the drive load Circuit board fails Replace the drive with a

new one


Circuit board fails Replace the drive with a new one



The motor does not rotate or reversely rotate if the command pulse is input after DC-link and mains line are connected

1. terminals U, V and W on the motor is wrongly connected

2. encoder cable is wrong-ly connected

Check the wiring

Encoder fails Replace the motor with a new one


The permitted maximum position difference is too small

Set a wider value range for the detection of posi-tion over-tolerance (P34)

The position loop gain is too small

Give more gains

No enough torque Check the limit value of current Reduce the load Use a drive and motor with higher frequencies

Low speed Check the maximum speed limitation (refer to parameter P26)



Alarm code


Command pulse frequency is too high

1. Lower the frequency 2. Check whether P36

has the right value


The circuit board fails Replace the drive with a new one



This alarm may occur when the DC link is con-nected

The rated torque is ex-ceeded

1. check the load 2. lower the start/stop

frequency 3. use drive and motor

with more power

The brake is not open Check whether the brake is open or not

The motor is not stable 1. modify the gain value 2. lessen load inertia

The encoder is wrongly wired

Check the wiring

A45 The 65 enable signal is lost when the motor is running

Check the 65 enable terminal



Note

Alarms with alarm code < A21 can be cancelled by power-on, while alarms with alarm code ≥ A21 can be cancelled by RST terminal.

A.6.2.3 Errors during drive self-test The drive module always conducts a self-test at every power-on. If any error occurs during this period, the drive screen form will show one of the following error codes:

Drive display Description Cause Remedy

Error 1 RAM damaged Replace the drive

Error 2 Flash damaged Replace the drive

Error 3 Program copy error Replace the drive



A.6.2.4 Other faults 1. Motor speed incorrect

– Description: The actual motor position is always wrong, and the motor speed is not right, either.

– Cause: The pulse signal from the NC to drive is incorrect. – Remedy: Check the pulse signal line connection

2. Brake not open – Description: The brake is not open when the drive is in "S-Run" state. – Cause: A short circuit has occurred in the brake cable. – Remedy: Check brake cable connection

A.6.2.5 Display data list

Data No. Name Data format Unit Data group D10 1) Torque setpoint Decimal

(See table below) Nm Current

D11 1) Actual value of the torque Nm D12 1) Actual value of the phase cur-

rent A

D20 Motor speed setpoint Integer

RPM Speed D21 Actual motor speed RPM D30 Position revolution setpoint Motor revolutions Position D31 Position angle setpoint Increments (10000/r) D32 Actual position revolutions Motor revolutions D33 Actual position angle Increments (10000/r) D34 Position deviation angle Increments (10000/r) D50 1) Digital input signal Bit (See table below) Bits in hex I/O D51 1) Digital output signal Bits in hex D80 1) Firmware version (See table below) HW, FW D81 Power Board rated current Integer D82 1) Parameter version number (See table below) 1) The data type of D10, D11, D12, D80, D82 is in all decimal format. The display value for D50 and D51 respectively

varies as the case requires.



Figure A-4 Special data displays (D10, D11, D12, D80, D82)

Appendix A.7 PLC user interfaces


A.7 PLC user interfaces

A.7.1 Addressing ranges

Table A- 3 Operand identifier

Address identifier Description Range DB 1) Data DB1000 to DB7999

DB9900 to DB9906 T Times T0 to T15 (100 ms)

T16 to T63 (10 ms) C Counters C0 to C63 I Image of digital inputs I0.0 to I8.7 Q Image of digital outputs Q0.0 to Q5.7 M Bit memory M0.0 to M255.7 SM Special bit memory SM0.0 to SM0.6 (see table below - Special

Marker SM Bit Definition) AC ACCU AC0 to AC3 1) When programming with the PLC Programming Tool, you can switch the DBs to V Bits with the

key combination of Ctrl + B.

Structure of the DB-range address

Access Example Description VB format -> DB format (example) Bit DB3801.DBX1000.7 Bit 7 of the byte with offset 0 in

subrange 1 for axis 2, user range 38 V3801 1000.7-->DB3801.DBX1000.7

Byte DB3801.DBB0 Byte with offset 0 in subrange 0 for axis, user range 38

VB3801 0000-->DB3801.DBB0

Word DB4500.DBW2 Work with offset 2 in subrange 0, range 0, user range 45

VW3801 0002-->DB3801.DBW2

Double Word DB2500.DBD3004 Double word with offset 4 in subrange 3, range 0, user range 25

VD2500 4000-->DB2500.DBD4000



Note

The permitted offset for an address is dependent on the access: • Bit or byte access: any offset.

Byte-size variables are placed one next to another seamlessly in a DB. • Word access: the offset must be divisible by 2.

Word-size variables (2 bytes) are always saved on straight offsets. • Double word access: the offset must be divisible by 4.

Double word-size variables (4 bytes) are always saved on offsets that are divisible by 4.

Table A- 4 Special Marker SM Bit Definition

SM bits Description SM 0.0 Bit memory with defined ONE signal SM 0.1 Initial setting: first PLC cycle '1', subsequent cycles '0' SM 0.2 buffered data lost - only valid in first PLC cycle

('0' data ok, '1' data lost) SM 0.3 POWER ON: first PLC cycle '1', subsequent cycles '0' SM 0.4 60 s clock (alternating '0' for 30 s, then '1' for 30 s) SM 0.5 1 s clock (alternating '0' for 0.5 s, then '1' for 0.5 s) SM 0.6 PLC cycle clock (alternating one cycle '0', then one cycle'1')

Special bit memory SM bit definition (read-only)

Table A- 5 Variable access rights

[r] You can "read only" designated area [r/w] You can "read and write" designated area

Table A- 6 Data format information

1 BIT 8 BYTE 16 INT/WORD 32 DINT/DWORD/REAL

Note

All the empty fields in the user interface are "reserved for Siemens" and may neither be written to nor evaluated.

Fields designated with "0" always have the value "logical 0".

If there is no data format information, you can read or write to all the specified data formats.



A.7.2 MCP

A.7.2.1 Signals from MCP

DB1000 From the MCP [r] Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 MCP DBB0 M01 PROGRAM

TEST MDA SINGLE

BLOCK AUTO REF.

POINT JOG Hand-wheel

MCP DBB1 Key 16 Key 15 Key 14 Key 13 Key 12 Key 11 Key 10 ROV MCP DBB2 100 (INC) 10 (INC) 1 (INC) Key 21 Key 20 Key 19 Key 18 Key 17 MCP DBB3 Key 32 Key 31 CYCLE

START CYCLE STOP

RESET SPINDLE RIGHT

SPINDLE STOP

SPINDLE LEFT

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

A.7.2.2 Signals to MCP

DB1100 To MCP [r/w] Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 DBB0 MCP

LED 8 LED 7 LED 6 LED 5 LED 4 LED 3 LED 2 LED 1 ... ... DBB7 MCP

LED 30 LED 29 LED 28 LED 27 LED 26 LED 25 DBB8 7 SEG LED1

... ... DBB11 7 SEG LED4

MCP DBB12 DP 2 DP 1



A.7.2.3 Reading/writing NC data: Job

DB1200

Reading / writing NC data [r/w] PLC -> NCK interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Write varia-

ble Start

1 Number of variables DB1200 ... 1207

Reading / writing NC data [r/w] PLC -> NCK interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 1000 Variable index 1001 Area number 1002 Column index for the NCK variable x (WORD) 1003 LIne index for the NCK variable x (WORD) 1008 Writing: data to NCK variable x (data type of the variables: 1 to 4 bytes)

A.7.2.4 Reading/writing NC data: Result

DB1200 Reading / writing NC data [r] PLC -> NCK interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 2000 Error in job Job com-

pleted

DB1200 ... 1207

Reading / writing NC data [r] PLC -> NCK interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 3000 Error has

occurred Valid varia-

ble 3001 Access result 1) 3004 Reading: data from NCK variable x (data type of the variables: 1 to 4 bytes) 1) 0: no error; 3: illegal access to object; 5: invalid address; 10: object does not exist

A.7.2.5 PI service: Job

DB1200 PI service [r/w] PLC -> NCK interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 4000 Start 4001 PI index 4004 PI parameter 1 4006 PI parameter 2 ... ... 4022 PI parameter 10



A.7.2.6 PI service: Result DB1200 Reading / writing NC data [r]

PLC -> NCK interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 5000 Error in job Job com-

pleted 5001 5002

A.7.3 Retentative data area DB1400 Retentative data [r/w] Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 User data 0 ... 127

A.7.4 User Alarms

A.7.4.1 User alarms: Activating

DB1600 Activating alarm [r/w] PLC -> HMI interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Activation of alarm no.

700007 700006 700005 700004 700003 700002 700001 700000 ... ... 15 Activation of alarm no.

700127 700126 700125 700124 700123 700122 700121 700120

A.7.4.2 Variables for user alarms

DB1600 Variables for user alarms [r32/w32] PLC -> HMI interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 DBD1000 Variable for alarm 700000 DBD1004 Variable for alarm 700001 … … DBD1508 Variable for alarm 700127



A.7.4.3 Active alarm response

DB1600 Active alarm response [r] PLC -> HMI interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 2000 Acknowledge

POWER ON Acknowledge

with DB1600DBX3

000.0

PLC STOP EMERGENCY STOP

Feedrate disable all

axes

Read-in disable

NC start disable

A.7.4.4 Acknowledgement of alarms

DB1600 Alarm acknowledgement [r/w] PLC -> HMI interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 3000 Ack

A.7.5 Axis/spindle signals

A.7.5.1 Transferred M and S functions, axis specific

DB3700 … 3703 M, S functions [r] NCK -> PLC interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 M function for spindle (DINT) 4 S function for spindle (REAL)

A.7.5.2 Signals to axis/spindle

Common signals to axis/spindle DB3800 ... 3803

Signals to axis/spindle [r/w] PLC -> NCK interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Feedrate override

H G F E D C B A 1 Override

active Position

measuring system 2

Position measuring system 1

Follow up mode

Axis spindle disable

2 Reference point value Clamping in progress

Distance-to-

go/spindle reset

Controller enable

4 3 2 1

3 Axis/spindle enable

program test

Veloci-ty/spindle

speed limit-ing

Activate fixed feedrate Enable approach to fixed stop

Feed 4 Feed 3 Feed 2 Feed 1



4 Traversing keys Rapid trav-erse over-

ride

Traverse key disable

Feedrate stop/spindle

stop

Activate handwheel Plus Minus 2 1

5 Machine function 1) Continuous

traversing Var. INC 1000 INC 1000 INC 100 INC 10 INC 1 INC

7 Contour-handwheel direction of

rotation inverted

9 Parameter set, servo C B A

1) The machine function is only entered if the signal "INC inputs in the operating-mode signal range active" (DB2600.DBX1.0) is set.

Signals to axis DB3800 ... 3803

Signals to axis [r/w] PLC -> NCK interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 1000 Delay Ref.

pt. ap-proach

Module limit enabled

Software limit switch Hardware limit switch Plus Minus Plus Minus

1002 Activate program

test

Suppress program

test

Signals to spindle DB3800 ... 3803

Signals to axis [r/w] PLC -> NCK interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 2000 Delete S

value No speed monitoring

for gear change

Resynchronize spindle Gear changed

Actual gear stage 2 1 C B A

2001 Invert M3/M4

Resynchro-nize during positioning

Feedrate override for

spindle valid

2002 Setpoint direction of rota-tion

Oscillation speed

Oscillation controlled by PLC

Counter-clockwise

Clockwise

2003 Spindle override H G F E D C B A



Signals to drive DB3800 ... 3803


Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 4000 Holding

brake

4001 Pulse ena-ble

Integrator disable

speed con-troller

Motor se-lected

Signals to technology functions DB3800 ... 3803


Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 5000 Torque

equalization controller

on

5003 5005 5006 (spin-dle)

Spindle positioning

Automatic gear stage

change

Setpoint direction of rota-tion

Spindle stop

Counter-clockwise

Clockwise

A.7.5.3 Signals from axis/spindle

General signals from axis/spindle DB3900 ... 3903

Signals from axis/spindle [r] NCK -> PLC interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Position reached Referenced Encoder limit freq. ex-

ceeded Spindle/no

axis With exact/ stop, fine

With exact stop,

coarse

Synchro-nized 2

Synchro-nized 1

2 1

1 Current controller

active

Speed controller

active

Position controller

active

Axis/spindle stationary (n < nmm)

Follow up mode ac-

tive

Axis ready for opera-

tion

Traversing requests

2 Force fixed stop limited

Fixed stop reached

Activate travel to

fixed stop

Measure-ment active

Handwheel override active



3 AxStop active

4 Travel command Travel request Handwheel active (bit/binary coded) Plus Minus Plus Minus 2 1

5 Active machine function Continuous Var. INC 10000 INC 1000 INC 100 INC 10 INC 1 INC

7 Contour-handwheel direction of

rotation inverted

9 Parameter set, servo C B A

11 PLC axis, permanent-ly assigned

POS_RESTO RED 2 RED 1

Signals from axis DB3900 ... 3903

Signals from axis [r] NCK -> PLC interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 1000 Module limit

enabled active

1001 1002 Rotary axis

in position Indexing axis in

position

Positioning axis

Path axis Lubrication pulse

1003

Signals from spindle DB3900 ... 3903

Signals from spindle [r] NCK -> PLC interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 2000 Change

gear stage Setpoint gear stage

C B A 2001 Actual

direction of rotation,

clockwise

Speed monitoring

Spindle in setpoint range

Overlay range limit

violated

Setpoint Speed limit exceeded Increased Limited

2002 Active spindle mode Rigid tap-ping

GWPS active

Const. cutting velocity active

Control mode

Oscillation mode

Positioning mode

2003 Spindle in position reach

Tool with dynamic limiting



Signals from drive DB3900 ... 3903


Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 4000 Holding

brake opened

RLI active

4001 Pulse ena-bled

Speed controller integrator disabled

Drive ready

4002 nact = nset nact < nx nact < nmin Md < Mdx Ramp-up completed

4003 Generator operation, minimum

speed fall-en below

VDClink < alarm

threshold

Signals from technology functions DB3900 ... 3903


Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 5000 5002 Accelera-

tion warn-ing

threshold reached

Velocity warning

threshold reached

Superim-posed mo-

tion

Actual value cou-

pling

Synchronous operation Coarse Fine

5003 Max. accel-eration

reached

Max. veloci-ty reached

Synchroni-zation in progress

Axis is accelerat-

ing

Synchro-nism over-ride travel

5007 Synchro-nism over-

ride is factored in

5008 (grinding)

Active special axis Axis 6 Axis 5 Axis 4 Axis 3 Axis 2 Axis 1



A.7.6 PLC machine data

A.7.6.1 INT values (MD 14510 USER_DATA_INT)

DB4500 Signals from NCK [r16] NCK -> PLC interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 ... 62

Int value (WORD/2 byte)

A.7.6.2 HEX values (MD 14512 USER_DATA_HEX)



Hex value (BYTE)

A.7.6.3 FLOAT values (MD 14514 USER_DATA_FLOAT)



Float value (REAL/4 byte)

A.7.6.4 User alarm: Configuring (MD 14516 USER_DATA_PLC_ALARM)



Alarm response/cancel criteria, alarm 700000 ...

Alarm response/cancel criteria, alarm 700247

Note

You can refer to the Diagnostics Manual for the information about how to configure the user alarms.



A.7.7 Signals from/to HMI

A.7.7.1 Program control signals from the HMI (retentive area) (also refer to signals at channel DB3200)

DB1700 Signals, HMI [r/w] HMI -> PLC interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Dry run

feedrate selected

M01 se-lected

DRF se-lected

1 Program test select-ed

Feedrate override selected for rapid trav-erse

2 Skip block selected

3 Measur-ment in JOG active

Calculation of meas-urement value not finished

7 Reset NC stop NC start

A.7.7.2 Program selection from PLC (retentive area)

DB1700 Program selection [r/w] PLC -> HMI interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 1000 Program selection from the PLC: Program number 1001 Command job from the PLC: Command 1002 1003

A.7.7.3 Checkback signal: Program selection from HMI (retentive area)

DB1700 Program selection [r] HMI -> PLC interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 2000 Error pro-

gram selec-tion

Program selected

2001 Error com-mand exe-cution

Execute command

2002 2003



A.7.7.4 Signals from HMI

DB1800 Signals from HMI [r] HMI -> PLC interface (signals are only present for PLC cycle)

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Reset Start

measure-ment in JOG

JOG Mode MDI AUTOMATIC

1 Current machine function REF

A.7.7.5 Signals from PLC

DB1800 Signals from PLC [r] Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 1000 Commis-

sioning archive has been read in

Boot with saved data

Boot with default values

1004 PLC cycle in μs [DINT] 1008 Year: Tens digit, BCD Year: Units digit, BCD 1009 Month: Tens digit, BCD Month: Units digit, BCD 1010 Day: Tens digit, BCD Day: Units digit, BCD 1011 Hour: Tens digit, BCD Hour: Units digit, BCD 1012 Minute: Tens digit, BCD Minute: Units digit, BCD 1013 Second: Tens digit, BCD Second: Units digit, BCD 1014 Millisecond: Hundreds digit, BCD Millisecond: Tens digit, BCD 1015 Millisecond: Units digit, BCD Weekday, BCD {1, 2, ... 7} (1 = Sunday)

A.7.7.6 Signals to maintenance planners

DB1800 Deactivation [r/w] Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 2000 Deactiva-

tion 8 Deactiva-tion 7

Deactiva-tion 6

Deactiva-tion 5

Deactiva-tion 4

Deactiva-tion 3

Deactiva-tion 2

Deactiva-tion 1

... ... 2003 Deactiva-

tion 32 Deactiva-tion 31

Deactiva-tion 30

Deactiva-tion 29

Deactiva-tion 28

Deactiva-tion 27

Deactiva-tion 26

Deactiva-tion 25

DB1800 Deactivation [r/w] Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 4000 Acknowl-

edgement 8 Acknowl-edgement 7

Acknowl-edgement 6

Acknowl-edgement 5

Acknowl-edgement 4

Acknowl-edgement 3

Acknowl-edgement 2

Acknowl-edgement 1



... ... 4003 Acknowl-

edgement 32

Acknowl-edgement 31

Acknowl-edgement 30

Acknowl-edgement 29

Acknowl-edgement 28

Acknowl-edgement 27

Acknowl-edgement 26

Acknowl-edgement 25

DB1800 Deactivation [r/w] Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 5000 Acknowl-

edgement 8 Acknowl-edgement 7

Acknowl-edgement 6

Acknowl-edgement 5

Acknowl-edgement 4

Acknowl-edgement 3

Acknowl-edgement 2

Acknowl-edgement 1

... ... 5003 Acknowl-

edgement 32

Acknowl-edgement 31

Acknowl-edgement 30

Acknowl-edgement 29

Acknowl-edgement 28

Acknowl-edgement 27

Acknowl-edgement 26

Acknowl-edgement 25

A.7.7.7 Signals from maintenance planners

DB1800 Warnings/Alarms [r] Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 3000 Alarm 8 Alarm 7 Alarm 6 Alarm 5 Alarm 4 Alarm 3 Alarm 2 Alarm 1 ... ... 3003 Alarm 32 Alarm 31 Alarm 30 Alarm 29 Alarm 28 Alarm 27 Alarm 26 Alarm 25

A.7.7.8 Signals from operator panel (retentive area)

DB1900 Signals from operator panel [r/w] HMI -> PLC interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Switch over

Ma-chine/Workpiece

Simulation active

A.7.7.9 General selection/status signals from HMI (retentive area)

DB1900 Signals from HMI [r] HMI -> PLC interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 1003 Axis number for handwheel 1

Machine axis

Handwheel selected

Contour handwheel

C B A

1004 Axis number for handwheel 2 Machine axis

Handwheel selected

Contour handwheel

C B A



A.7.7.10 General selection/status signals to HMI (retentive area) DB1900 Signals to HMI [r/w]

PLC -> HMI interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 5000 OP key

block

5002 Enable measure-ment in JOG

5004 ... 5007

T-number for tool measurement in JOG (DINT)

5008 ... 5011

5012 ... 5015

5016 ... 5019

A.7.8 Auxiliary functions transfer from NC channel

A.7.8.1 Overview DB2500 Auxiliary functions from the NCK channel [r]

NCK -> PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 4 M fct. 5

change M fct. 4 change

M fct. 3 change

M fct. 2 change

M fct. 1 change

6 S fct. 1 change

8 T fct. 1 change

10 D fct. 1 change

12 H fct. 3 change

H fct. 2 change

H fct. 1 change



A.7.8.2 Decoded M signals (M0 to M99)

Note

The signals are output for the duration of a PLC cycle.

DB2500 M functions from NCK channel [r] 1) 2) NCK -> PLC interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 1000 Dynamic M functions

M7 M6 M5 M4 M3 M2 M1 M0 … ...

1012 Dynamic M functions

M99 M98 M97 M96 1) As the PLC user, you must generate basic functions yourself from the dynamic M functions.

2) The basic program decodes dynamic M functions (M0 to M99).

A.7.8.3 Transferred T functions DB2500 T functions from NCK channel [r]

NCK -> PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 2000 T function 1 (DINT)

A.7.8.4 Transferred M functions DB2500 M functions from NCK channel [r]

NCK -> PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 3000 M function 1 (DINT) 3004 Extended address M function 1 (byte) 3008 M function 2 (DINT) 3012 Extended address M function 2 (byte) 3016 M function 3 (DINT) 3020 Extended address M function 3 (byte) 3024 M function 4 (DINT) 3028 Extended address M function 4 (byte) 3032 M function 5 (DINT) 3036 Extended address M function 5 (byte)



A.7.8.5 Transferred S functions

DB2500 S functions from NCK channel [r] NCK -> PLC interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 4000 S function 1 (REAL) (DINT) 4004 Extended address S function 1 (byte) 4008 S function 2 (REAL) 4012 Extended address S function 2 (byte)

A.7.8.6 Transferred D functions

DB2500 D functions from NCK channel [r] NCK -> PLC interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 5000 D function 1 (DINT)

A.7.8.7 Transferred H functions

DB2500 H functions from NCK channel [r] NCK -> PLC interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 6000 H function 1 (REAL) (DINT) 6004 Extended address H function 1 (byte) 6008 H function 2 (REAL) 6012 Extended address H function 2 (byte) 6016 H function 3 (REAL) 6020 Extended address H function 3 (byte)

A.7.9 NCK signals

A.7.9.1 General signals to NCK

DB2600 General signals to NCK [r/w] PLC -> NCK interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Protection level

Keyswitch position 0 to 3 Acknowled

ge EMERGENCY STOP

Acknowledge

EMERGENCY STOP

Braking along the contour in

case of EMERGENCY STOP

4 5 6 7

1 Request axis dis-tances to

go

Request axis actual

values

INC inputs in mode signal

range ac-tive 1)

1) Refer to mode signals



A.7.9.2 General signals from NCK

DB2700 General signals from NCK [r/w] NCK -> PLC interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 EMERGEN

CY OFF active

1 Inch meas-uring sys-tem

Probe actuated Probe 2 Probe 1

2 NC ready Drive ready Drives in cyclic oper-

ation

3 Air temper-ature alarm

NCK alarm is active

12 Change counter for motion, handwheel 1 13 Modification counter for motion, handwheel 2 15 Change counter , inch/metric measuring system

A.7.9.3 Signals at fast inputs and outputs

DB2800 Signals at fast inputs and outputs [r/w] PLC -> NCK interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Block digital NCK inputs

Input 3 Input 2 Input 1 1 Value from PLC for NCK inputs

Input 3 Input 2 Input 1 4 Block digital NCK outputs

Output 1 5 Overwrite mask for digital NCK outputs

Output 1 6 Value from PLC for digital NCK outputs

Output 1 7 Setting mask for NCK outputs

Output 1

DB2800 Signals at fast inputs and outputs [r/w] PLC -> NCK interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 1000 Block external digital NCK inputs

1001 Value from PLC for external digit NCK inputs

1008 Block external digital NCK outputs



1009 Overwrite mask for external digital NCK outputs

1010 Value from PLC for external digital NCK outputs

1011 Setting mask for external NCK outputs

A.7.9.4 Signals from fast inputs and outputs DB2900 Signals from fast inputs and outputs [r]

PLC -> NCK interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Actual value for digital NCK inputs

Input 3 Input 2 Input 1 4 Setpoint for digital NCK outputs

Output 1

DB2900 Signals from fast inputs and outputs [r]

NCK -> PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 1000 Actual value for external digital NCK inputs

Input 3 Input 2 Input 1 1004 NCK setpoint for external digital NCK outputs

Output 1

DB3000 Mode signals to NCK [r/w]

PLC -> NCK interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Reset Mode

change block

Mode JOG MDI AUTO

1 Single block Machine function Type A Type B REF TEACH IN

2 Machine function 1) Continuous


3



1) To use the machine function signals in DB3000.DBB2, you must set the "INC inputs in the operating-mode signal range active" signal (DB2600.DBX1.0) to "1".

DB3100 Mode signals from NCK [r]

NCK -> PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Reset 808

READY Mode

JOG MDI AUTO 1 Active machine function

REF TEACH IN 2 Machine function

Continuous traversing

active

Var. INC active

10000 INC active

1000 INC active

100 INC active

10 INC active

1 INC ac-tive

A.7.10 Channel signals

A.7.10.1 Signals to NC channel

Control signals to NC channel DB3200 Signals to NCK channel [r/w]

PLC -> NCK interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Activate

test run feedrate

Activate M01

Activate single block

1)

Activate DRF

Activate traverse forwards

Activate traverse

backwards

1 Activate program

test

Enable protection

zones

Activate referencing

2 Activate skip block 7 6 5 4 3 2 1 0

4 Feedrate offset 2) H G F E D C B A

5 Rapid traverse override H G F E D C B A

6 Feedrate override active 3)

Rapid trav-erse over-ride active

Path veloci-ty limiting

Program level abort

Delete number of subroutine

cycles

Delete distance -

to-go

Read-in disable

Federate disable

7 Suppress start lock

NC stop axes plus spindle

NC stop NC stop at block limit

NC start NC start disable

8 Activate machine-related protection zone Area 8 Area 7 Area 6 Area 5 Area 4 Area 3 Area 2 Area 1



9 Activate machine-related protection zone Area 10 Area 9

10 Activate channel-specific protection zone Area 5 Area 5 Area 5 Area 5 Area 5 Area 5 Area 5 Area 5

11 Activate channel-specific protection zone Area 10 Area 9

13 Do not block tool

Deactivate workpiece

counter

Activate fixed feedrate Feed 4 Feed 3 Feed 2 Feed 1

14 No tool change

commands

JOG circle Activate associated

M01

Negative direction for simulation

contour handwheel

Simulation contour

handwheel ON

Activate contour handwheel (bit/binary coded)

Handwheel 1

Handwheel 2

15 Activate skip block 9

Activate skip block 8

Invert con-tour hand-

wheel direction

16 Program branches (GOTOS)

control 1) Select the single-block type using the softkey.

2) 31 positions (Gray code)

Controls signals to axes in Work DB3200 Signals to NCK channel [r/w]

PLC -> NCK interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 1000 Axis 1 in Work

Traversing keys Rapid trav-erse over-

ride

Traversing key dis-

tance disa-ble

Feedrate stop

Activate handwheel (bit/binary coded) 1) Plus Minus 2 1

1001 Axis 1 in Work Machine function 2)


Var. INC 10000 INC 1000 INC 100 INC 10 INC 1 INC

1003 Handwheel

direction of rotation inverted

1004 Axis 2 in Work Traversing keys Rapid trav-

erse over-ride

Traversing key disable

Feedrate stop

Activate handwheel (bit/binary coded) Plus Minus 2 1



1005 Axis 2 in Work Machine function



1007 Invert con-

tour hand-wheel

direction 1008 Axis 3 in Work

Traversing keys Rapid trav-erse over-

ride

Traversing key disable

Feedrate stop

Activate handwheel (bit/binary coded) Plus Minus 2 1




1011 Invert con-tour hand-

wheel direction

1) The handwheel number is represented according to the $MD_HANDWH_VDI_REPRESENTATION machine data in a bit-coded (=0) or binary-coded (=1) manner.

2) Machine function: the machine function is only entered if the "INC inputs in the operating-mode signal range active" signal (DB2600DBX1.0) is not set.

A.7.10.2 Signals from NC channel

Status signals from NC channel DB3300 Signals from NCK channel [r]

NCK -> PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Last action

block active M0/M1 active

Approach block active

Action block active

Forwards traverse active

Backwards traverse active

Execution from exter-nal active

1 Program test active

M2/M30 active

Block search active

Handwheel override active

Rev. feder-ate active

Referenc-ing active

3 Channel status Program status Reset Interrupted Active Aborted Interrupted Stopped Waiting Running

4 NCK alarm with pro-cessing

stop pre-sent

Channel specific

NCK alarm is active

Channel operational

All axes Stop re-quest

Start re-quest Stationary Referenced



5 Contuour handwheel active (bit/binary coded)

7 Invert con-

tuour handwheel direction

Protection zone not

guranteed

8 Machine-related protection zone preactivated Area 8 Area 7 Area 6 Area 5 Area 4 Area 3 Area 2 Area 1

9 Machine-related protection zone preactivated Area 10 Area 9

10 Channel-specific protection zone preactivated Area 8 Area 7 Area 6 Area 5 Area 4 Area 3 Area 2 Area 1

11 Channel-specific protection zone preactivated Area 10 Area 9

12 Machine-related protection zone violated Area 8 Area 7 Area 6 Area 5 Area 4 Area 3 Area 2 Area 1

13 Machine-related protection zone violated Area 10 Area 9

14 Channel-specific protection zone violated Area 8 Area 7 Area 6 Area 5 Area 4 Area 3 Area 2 Area 1

15 Channel-specific protection zone violated Area 10 Area 9

Status signals, axes in Work DB3300 Signals from NCK channel [r]

NCK -> PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 1000 Axis 1 in Work

Travel command Travel request Handwheel active (bit/binary coded) 1) Plus Minus Plus Minus 2 1

1001 Axis 1 in Work Machine function 2)



1003 Contour

handwheel direction of

rotation inverted

1004 Axis 2 in Work Traversing command Travel request Handwheel active (bit/binary coded)

Plus Minus Plus Minus 2 1






1007 Contour

handwheel direction of

rotation inverted

1008 Axis 3 in Work Traversing command Travel request Handwheel active (bit/binary coded)

Plus Minus Plus Minus 2 1 1009 Axis 3 in Work

Machine function Continuous


1011 Contour handwheel direction of

rotation inverted

Other status signals from NC channel DB3300 Signals from NCK channel [r]

NCK -> PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 4000 G00 active 4001 Travel

request, drive test present

Workpiece setpoint reached

External language mode ac-

tive 4002 Dry run

feedrate Active

Associated M01/M00

Active

STOP_DELAYED

ASUP is stopped

4003 No tool change

command active

DELAY FST

SUPPRESS

DELAY FST

4004 ProgEvent display Start after

block search

Boot Operator panel Reset

Part pro-gram End

Part pro-gram

Start from RESET

4005 Jog circle Active

Stop condi-tion

StopByColl Danger



4006 Dormant ASUP Active

ASUP ac-tive

4008 Active the transformation number

4009 ... 4011

Reserved

G functions from NCK channel DB3500 G functions from NCK channel [r]

NCK -> PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 ... 63

Active the G function of group 1 (8 bit int) ...

Active the G function of group 64 (8 bit int)

A.7.11 Signals, synchronized actions

A.7.11.1 Signals, synchronized actions to channel

DB4600 Signals, synchronized actions to channel [r/w] PLC -> HMI interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Deactivate the synchronized action with ID...

ID8 ID7 ID6 ID5 ID4 ID3 ID2 ID1 1 Deactivate the synchronized action with ID...

ID16 ID15 ID14 ID13 ID12 ID11 ID10 ID9 2 Deactivate the synchronized action with ID...

ID24 ID23 ID22 ID21 ID20 ID19 ID18 ID17

A.7.11.2 Signals, synchronized actions from channel

DB4700 Signals, synchronized actions from channel [r] NCK -> PLC interface

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Synchronized action with ID...can be blocked from the PLC

ID8 ID7 ID6 ID5 ID4 ID3 ID2 ID1 1 Synchronized action with ID...can be blocked from the PLC

ID16 ID15 ID14 ID13 ID12 ID11 ID10 ID9 2 Synchronized action with ID...can be blocked from the PLC

ID24 ID23 ID22 ID21 ID20 ID19 ID18 ID17



A.7.11.3 Reading and writing PLC variables DB4900 PLC variables [r/w]

PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 … 4095

Offset [0] …

Offset [4095]

Note

The programming engineer (NCK and PLC) is responsible for organizing (structuring) this memory area. Every storage position in the memory can be addressed provided that the limit is selected according to the appropriate data format (i.e. a 'DWORD' for a 4-byte limit, a WORD for a 2-byte limit, etc.). The memory area is always accessed with the information about the data type and the position offset within the memory area.

A.7.12 Axis actual values and distance-to-go DB5700 ... 5704


Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Axis actual value (REAL) 4 Axis distance-to-go (REAL)

Note

The axis actual values and distances-to-go can be separately requested: • DB2600.DBX0001.1 Request axis actual values • DB2600.DBX0001.2 Request axis distances-to-go

If the particular request is set, then the NCK supplies these values for all axes.



A.7.13 Maintenance scheduler: User interface

A.7.13.1 Initial (start) data DB9903 Initial data table [r16] Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Interval 1 [h] 2 Time of the first warning 1 [h] 4 Number of warnings to be output 1 6 Reserved 1 8 Interval 2 [h] 10 Time of first warning 2 [h] 11 Number of warnings to be output 2 14 Reserved 2 ... ... 248 Interval 32 [h] 250 Time of first warning 32 [h] 252 Number of warnings to be output 32 254 Reserved 32

A.7.13.2 Actual data DB9904 Actual data table [r16] Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Interval 1 [h] 2 Number of warnings to be output 1 4 Reserved_1 1 6 Reserved_2 1 8 Interval 2 [h] 10 Number of warnings to be output 2 11 Reserved_1 2 14 Reserved_2 2 ... ... 248 Interval 32 [h] 250 Number of warnings to be output 32 252 Reserved_1 32 254 Reserved_2 32



A.7.14 User interface for Ctrl-Energy

Table A- 7 Energy saving profile

DB9906 Ctrl energy Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Control signals

Set time to pre-warning

limit

Immeadi-ately acti-vate the energy saving profile

1 Control signals (HMI -> PLC) Immeadi-

ately acti-vate the energy saving profile

2 Signals to check/test the energy-saving profile PLC user

signal Master

computer signal

3 Reserved

4 Status signal Activation

time T1 expired

Energy saving

profile ac-tive

5 Reversed

6 Actual value: actual value T1

8 Actual value: actual value T2

10 Effectiveness, profile Disable

energy saving profile

Energy saving

profile con-figured

11 State conditions (HMI -> PLC) Screen

change Data trans-

fer Operator

panel 12 State conditions (HMI -> PLC)

Machine control panel



13 State conditions (HMI -> PLC) NC channel

1 in reset 14 15 State conditions (HMI -> PLC)

PLC user signal

Master computer

signal 16 State conditions (HMI -> PLC)

Activation time T1

18 State conditions (HMI -> PLC) Activation time T2


Index

A Access levels, 33 Active alarm reponse, 111 Actual data, 132 Alarm acknowledgement, 111 approaching the reference point, 62 Axis actual values and distance-to-go, 131 axis velocity and the acceleration, 59

C CNC

Accessories, 10 MCP package, 10 PPU package, 10

Compensation methods, 66 Cutting customized MCP strips, 90

D D functions from NCK channel, 122 Decoded M signals, 121 Display data list for the SINAMICS V60, 104 Drive and motor

1FL5 motor package, 10 Cables, 11 SINAMICS V60 package, 10

E Enabling the position control, 58 Entering the machine data (MD), 57

Activating conditions, 57 External data backup in a data archive, 70, 72, 78

F FLOAT values, 116

G General selection/status signals from HMI, 119 General selection/status signals to HMI, 120

General signals from NCK, 123 General signals to NCK, 122

H H functions from NCK channel, 122 HEX values, 116

I Initial data, 132 Inserting the MCP strips, 90 INT values, 116 Interface

battery interface, 21 Interface overview on the Machine Control Panel (MCP), 20 Interface overview on the Panel Processing Unit (PPU), 19

M M functions from NCK channel, 121 Matching the parameters of the drive system, 58 Mounting

Cutout dimensions, 13 Cut-outs and mounting dimensions for the drives, 15 Minimum mounting clearance for the drives, 16 Mounting dimensions, 14 Mounting dimensions for the motors, 18 Mounting method for the drives, 16 Using the cable clamps supplied for the drives, 16

Mounting clearance, 15

O onboard assistants, 37 Operand identifier, 106 Other faults for the SINAMICS V60, 104 Overview of alarms, 99

Index


P PI service: Job, PI service: Result, position-loop gain, 59 Printing customized MCP strips, 90 Program control from the HMI (retentive area), 117 Program selection via lists, 117

R Reading / writing NC data: Job, Reading / writing NC data: Result, Reading and writing PLC variables, 131 Retentative data, 110

S S functions from NCK channel, 122 Signals at fast inputs and outputs, 123 Signals from fast inputs and outputs, 124 Signals from maintenance planners, 119 Signals from MCP, 108 Signals from NC channel, 127 Signals from operator panel, 119 Signals from PLC, 118 Signals from the HMI, 118 Signals to axis/spindle, 111 Signals to maintenance planners, 118 Signals to MCP, 108 Signals to NC channel, 125 Signals, synchronized actions from channel, 130 Signals, synchronized actions to channel, 130 SINAMICS parameters, 97 SINAMICS V60 alarms, 100 SINAMICS V60 errors during self-test, 103 Singlas from axis/spindle, 113 software limit, 64 Special bit memory SM bit definition (read-only), 107 Structure of the DB-range address, 106 System overview, 7

T T functions from NCK channel, 121 Transferred M and S functions, axis specific, 111

U User alarm: Configuring, User alarms: Activating,

User interface for ctrl energy, 133

V Variables for user alarms, 110

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