Siemens SINUMERIK 802S Technical Manual
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Siemens SINUMERIK 802S Technical Manual

Siemens SINUMERIK 802S Technical Manual

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SINUMERIK 802S base line

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  • Page 1 Start-Up 08/2003 Edition sinumerik SINUMERIK 802S base line...
  • Page 3 SINUMERIK 802S base line SINUMERIK 802S base line Control System Start-Up  Installing the control system Installing the STEPDRIVE Technical Manual  Start-Up  Software Update Technical Appendix   Valid as from Control system Software version SINUMERIK 802S base line...
  • Page 4 Other names in this publication might be trademarks whose use by a third party for his own purposes may violate the registered holder. Copyright Siemens AG 2003. All right reserved Exclusion of liability The reproduction, transmission or use of this document or its con- We have checked that the contents of this document correspond to tents is not permitted without express written authority.
  • Page 5 Siemens. This product must be transported, stored and installed as intended, and maintained and operated with care to ensure that it functions correctly and...

  • Page 7: Table Of Contents

    SINUMERIK 802S base line Control System Components of the SINUMERIK 802S base line Technical data Installing the Control System Installing and Dismantling the SINUMERIK 802S base line Interfaces and cables Connecting the individual components 2.3.1 Connecting the feed drives and the spindle (X7) 2.3.2...
  • Page 8 Function 6-40 6.3.2 Input/output configuration 6-43 6.3.3 Definition of user keys 6-44 6.3.4 PLC machine data 6-46 6.3.5 SAMPLE program structure 6-50 6.3.6 User alarm 6-52 6.3.7 Start-Up of SAMPLE program 6-53 Unipolar spindle 6-55 SINUMERIK 802S base line Start-Up...

  • Page 9: Sinumerik 802S Base Line Control System

    The SINUMERIK 802S base line is a microprocessor-controlled numerical control system for economic machine tools with stepper motor drives. Hardware components The SINUMERIK 802S base line is a compact CNC unit. It consists of the following areas (see figure 1-1): MCP Area...
  • Page 10  PLC software (Programmable Logic Control) executes the integrated PLC user program cyclically.  Integrated PLC user program intended to adjust the SINUMERIK 802S base line to the machine functions (see also Description of Functions “Integrated User Program for SINUMERIK 802S base line”).

  • Page 11: Technical Data

    SINUMERIK 802S base line Control System Technical data Connected load Table 1–1 Connected load Parameter Min. Typ. Max. Unit Supply voltage 20.4 28.8 Ripple Current consumption from 24 V Power dissipation of CNC Start-up current Weight Table 1–2 Weight Component...
  • Page 12 SINUMERIK 802S base line Control System SINUMERIK 802S base line Start-Up...

  • Page 13: Installing The Control System

    Installing the Control System Installing and Dismantling the SINUMERIK 802S base line Warning Do not install when the equipment is under power! The modules contain electrostatically sensitive devices. It must be ensured that persons without ESD protection never touch printed circuit boards or components when handling operator and machine control panels.
  • Page 14 Installing the Control System Mounting dimensions The dimensions shown below are important for installing the control system: Fig. 2-1 Mounting dimensions for 802S base line SINUMERIK 802S base line Start-Up...
  • Page 15 Installing the Control System 1) Thread plugging M4 or ø5 hole (8x) Fig. 2-2 Mounting dimensions for 802S base line SINUMERIK 802S base line Start-Up...

  • Page 16: Interfaces And Cables

    50-pin sub-D socket connector for connecting the power sections for a maximum of four analog drives including spindle X10 handwheel interface (MPG) 10-pin front connector for connecting the handwheels X20 digital inputs (DI) 10-pin front connector for connecting BERO proximity switches SINUMERIK 802S base line Start-Up...
  • Page 17 X200 and X201 10-pin front connector for connecting digital outputs Operating elements Start-up switch S3 Fuse Fuse F1, externally designed to allow users for convenient replacement. S2 and D15 These elements are provided only for debugging internally. SINUMERIK 802S base line Start-Up...
  • Page 18 +DQGZKHHO %(52  ZLUH PP %(52 6LJQDO  ZLUH PP        /RDG  ZLUH PP  3 3 9'& 9'& Fig. 2-4 Connection Diagram for SINUMERIK 802S base line SINUMERIK 802S base line Start-Up...

  • Page 19: Connecting The Individual Components

    DIR1_N PULS2_N O PULS2 DIR2_N DIR2 PULS3 ENABLE3 PULS3_N DIR3 ENABLE3_N O DIR3_N PULS4_N O ENABLE4 PULS4 DIR4_N ENABLE4_N O DIR4 n.c. n.c. n.c. n.c. n.c. n.c. n.c. n.c. n.c. n.c. n.c. n.c. SE4.1 SE4.2 SINUMERIK 802S base line Start-Up...
  • Page 20 Cable Drive Side Core Color Signal Name black 1st axis brown orange yellow green White/grey 2nd axis Brown/black Blue Violet Grey White white/black 3rd axis white/brown brown/red brown/orange White/red White/orange White/yellow Spindle White/green White/blue White/violet SINUMERIK 802S base line Start-Up...
  • Page 21 Table 2–3 Electrical parameters of the signal outputs for step-switching drives Parameter Unit Voltage range –10.5 10.5 Output current –3 Relay contact Table 2–4 Electrical parameters of the relay contacts Parameter Max. Unit Switching voltage Switching current Switching power Cable length: max. 35 m SINUMERIK 802S base line Start-Up...
  • Page 22 Track B as true and negated signal (U Zero signal N as true and negated signal (U Max. output frequency: 1.5 MHz Phase offset between tracks A and B: 90º ± 30º Current consumption: max. 300 mA SINUMERIK 802S base line 2-10 Start-Up...

  • Page 23: Configuration Of The Rs232 Interface Connection (X2)

    To provide fault-free operation, make sure that the following values are not exceeded when using preassembled interconnecting cables from SIEMENS: Table 2–6 Maximum cable lengths depending on the encoder power supply Max. Cable...
  • Page 24 D S R D T R R T S C T S R T S C T S C T S R T S C T S R T S Fig. 2-5 Communication connector RS232(X2) SINUMERIK 802S base line 2-12 Start-Up...

  • Page 25: Connecting Handwheels (X10)

    Track A as true and negated signal (U Track B as true and negated signal (U Max. output frequency: 500 kHz Phase offset between 90  ± 30 tracks A and B: Supply: 5 V, max. 250 mA SINUMERIK 802S base line 2-13 Start-Up...

  • Page 26: Connecting Bero And Nc-Ready (X20)

    6…15 “0” signal, voltage range -3…5 Or input open Signal delay 0Æ1 Signal delay 1Æ0 NC–READY output Readiness in the form of a relay contact (NO); must be integrated into the EMERGENCY STOP circuit. SINUMERIK 802S base line 2-14 Start-Up...
  • Page 27 R elay N C _R D Y 1P 5 Fig. 2-5 The NCREADY is an internal relay of NC. It will open when NC is not ready, and close after NC is ready for operation. SINUMERIK 802S base line 2-15 Start-Up...

  • Page 28: Connecting The Digital Inputs (X100 ... X105)

    Table 2–14 Connector pin assignment X100 Name Type n.c. X100 X101 Name Type n.c. X101 DI10 DI11 DI12 DI13 DI14 DI15 X102 Name Type n.c. X102 DI16 DI17 DI18 DI19 DI20 DI21 DI22 DI23 SINUMERIK 802S base line 2-16 Start-Up...
  • Page 29 Parameter Value Unit Note “1” signal, voltage range 15...30 “1” signal, current consumption 2...15 “0” signal, voltage range –3...5 or input open Signal delay 0 Æ 1 0.5...3 Signal delay 1 Æ 0 0.5...3 SINUMERIK 802S base line 2-17 Start-Up...

  • Page 30: Connecting The Digital Outputs (X200 ,X201)

    Digital output 1 / Unipolar Spindle CCW Direction, Max. current 500mA. 1P24, M Power supply for the digital outputs 0...7 2P24, M Power supply for the digital outputs 8...15 Signal type Voltage input Output (24 V signal) SINUMERIK 802S base line 2-18 Start-Up...
  • Page 31 Table 2–17 Electrical parameters of the digital outputs Parameter Value Unit Note “1” signal, nominal voltage Voltage drop max. 3 “1” signal, output current Simultaneity factor 0.5 per 16 outputs “0” signal, leakage current max. 2 SINUMERIK 802S base line 2-19 Start-Up...

  • Page 32: Power Supply For Cnc (X1)

    Ripple Non-periodic overvoltage 500 ms cont. 50 s recovery Rated current consumption Starting current Pin assignment on the CNC side Table 2–19 Pin assignment of screw terminal block X1 Terminal Ground DC 24 V SINUMERIK 802S base line 2-20 Start-Up...

  • Page 33: Leds And Other Elements On Cnc

    This LED indicates an error condition of the CNC. POK (green) Power OK The power supply is ready. DIA (yellow) Diagnostics This LED indicates various diagnosis states. Under normal operating conditions, this LED flashes 1:1. SINUMERIK 802S base line 2-21 Start-Up...
  • Page 34 They are provided only for debugging internally. Grounding Screw In order to ensure the system functions correctly and safely, the CNC must be grounded through the grounding screw on the rear side of CNC. SINUMERIK 802S base line 2-22 Start-Up...

  • Page 35: Installing The Stepdrive

    Do not install devices which are strongly heated during operation beneath the drive modules! Dismantling The drive modules are dismantled in the reverse order. Warning When removing the drive modules, always first make sure that the system is disconnected from the mains! SINUMERIK 802S base line Start-Up...
  • Page 36 Installing the STEPDRIVE Mounting Dimensions Washer, lock washer Fig.3-1 Mounting dimensions SINUMERIK 802S base line Start-Up...

  • Page 37: Cabling

    Installing the STEPDRIVE Cabling Cable overview Connect the STEPDRIVE C/C+ drive modules, the BYG stepper motors and the SINUMERIK 802S base line control system as shown in Fig. 3–2: D rive o f axis 1 D rive o f axis 2 yellow...
  • Page 38 Pulse interface To connect the drive pulse interface to the SINUMERIK 802S base line, use the preassembled cable, order no.6FX2 002–3AD02–1xx0. On the drive side, connect the cable shield to the housing such that an electrical connection is provided via the appropriate strain relief clamp.

  • Page 39: Starting Up The Drive Modules

    DIR signal. Notice The DIP switch can be used to adapt the direction of rotation to the mechanics of the machine. Never actuate the switch when the drive is powered! SINUMERIK 802S base line Start-Up...
  • Page 40 Check cable connections Overvoltage or undervoltage Short-circuit between the motor phases Short-circuit between motor phase and ground is lit Overtemperature in the drive Drive defective; replace No LED is lit No operating voltage Check cable connections SINUMERIK 802S base line Start-Up...

  • Page 41: General

    For installation refer to the installation notes provided in the section 2. The control system with its components has powered up without errors. Start–up sequence The SINUMERIK 802S base line can be strated up as follows: Check whether the ENC has powered up. PLC start-up Technology setting Set general machine data.

  • Page 42: Access Levels

    4.1.1 Access levels Protection levels The SINUMERIK 802S base line provides a protection level concept for enabling data areas. The protection levels range from 0 to 7 whereby 0 is the highest and 7 the lowest level. The control system comes with default passwords for protection levels 2 and 3.

  • Page 43: Structure Of Machine Data (Md) And Setting Data (Sd)

    Activation The activation levels are listed according to their priority. Any data changes come into effect after: POWER ON (po) switching on/off the SINUMERIK 802S base line NEW_CONF (cf)  Activate MD softkey on the operator panel  RESET key on the operator panel  Modifications at the block limits are possible while the program is running.

  • Page 44: Handling Of Machine Data

    Use the ETC key to extend the menu in the Diagnosis/Start–up menu and press the Save data softkey. Loading data from an internal data backup: Boot the control system using the start–up switch, position 3 SINUMERIK 802S base line Start-Up...
  • Page 45 Use the Services/Data outp. menu to transfer the following user data as individual files to an external PC via the V24 interface. Loading data from an external data backup into the control system: Press the Start data inp. softkey in the Services menu. SINUMERIK 802S base line Start-Up...

  • Page 46: Turning On And Booting The Control System

    When the control system is turned on for the first time, an initial state of the control system is established automatically. All memory areas are initialized and are loaded with previously stored default data. The PLC area of retentive bit memories is explicitly erased. SINUMERIK 802S base line Start-Up...
  • Page 47 Booting with saved data (Start–up switch position 3) Result The user data backed–up on the permanent memory are loaded into the user memory. Contrast control See User’s Guide “Operation and Programming” SINUMERIK 802S base line Start-Up...

  • Page 48: Boot Messages

    Carry out a software update. DRAM Replace the hardware components. ERROR BOOT ERROR NO BOOT2 ERROR NO SYSTEM ERROR LOAD NC NO SYSTEM–LOADER ERROR LOAD NC CHECKSUM–ERROR ERROR LOAD NC DECOMPRESS–ERROR ERROR LOAD NC INTERNAL–ERROR 1 SINUMERIK 802S base line Start-Up...

  • Page 49: Starting Up The Plc

    PLC in detail. 4.3.1 Commissioning of the PLC The SINUMERIK 802S base line comes to the user with a simulation program included. The SAMPLE user program is stored in the permanent memory. This sample program and the documentation are included in the SINUMERIK 802SC base line Toolbox component “PLC802SC base line Library”.
  • Page 50 Reference Point is not supported. Standard user program The control system comes with an universal program, the customer can choose the technology mode (Turning or Milling) with PLC user machine data. SINUMERIK 802S base line 4-10 Start-Up...

  • Page 51: Start-Up Modes Of The Plc

    Example: Hardware start-up switch position 3 Restart from operator panel Ö Restart is active from next power-up of the control system The Run mode activates the cyclic mode. SINUMERIK 802S base line 4-11 Start-Up...

  • Page 52: Plc Alarms

    ( OUTDS ). EMERGENCY STOP: The PLC provides the EMERGENCY STOP signal to the CNC in the user interface after the user program has been executed. SINUMERIK 802S base line 4-12 Start-Up...
  • Page 53 “1600xxxx” in sub-range 0 (1 -> 0 edge). The remaining user alarms are cleared by the PLC after detecting the respective cancel condition. If the alarm is still present, the alarm occurs again. SINUMERIK 802S base line 4-13 Start-Up...
  • Page 54 The user has two possibilities to define his own alarms. using the “Edit PLC txt” softkey (See “Operation, Programming”, Chapter using the “Text Manager” in Toolbox CD The procedure is described in the Toolbox readme file. SINUMERIK 802S base line 4-14 Start-Up...
  • Page 55 % I ... Integer decimal number %U ... Unsigned decimal number %O ... Integer octal number %X ... Integer hexadecimal number %B ... Binary representation of 32-bit value % F... 4 byte floating point number SINUMERIK 802S base line 4-15 Start-Up...
  • Page 56 700004 “ %U Alarm number with variable and fixed alarm text ” 700005 “ Rotation monitoring of axis active : %U ” Operator panel display: 700005 Rotation monitoring of axis active : 1 700005 Rotation monitoring of axis active : 3 SINUMERIK 802S base line 4-16 Start-Up...

  • Page 57: Machine Control Panel Area Layout

    It is also possible for the user to customize keys K1…K12. The method in details is explained in Toolbox. Key assignment Layout when delivered K1…K39 Æ keys 1…39 Available as accessory: Emergency Stop Switch (see user interface) Fig. 4-3 Layout of machine control panel area SINUMERIK 802S base line 4-17 Start-Up...

  • Page 58: Plc Programming

    Furthermore, the data direction in the memory model (alignment) and the data type must be observed for all data. Example: Flag bit MB0.1,MB3.5 Flag byte MB0,MB1,MB2 Flag word MW0,MW2,MW4 MW3, MW5 ... are not permissible Flag double-word MD0,MD4,MD8 MD1,MD2,MD3, MD5 ... are not permissible SINUMERIK 802S base line 4-18 Start-Up...
  • Page 59 C0 to C31 Map of digital inputs I0.0 to I7.7 Map of digital outputs Q0.0 to Q7.7 Flags M0.0 to M127.7 Special flags SM0.0 to SM 0.6 (see Table 4-10) ACCU AC0 ... AC3 SINUMERIK 802S base line 4-19 Start-Up...
  • Page 60 (00-79) (00-99) (0-9) (000-999) (8-digit) Table 4–9 802S base line ranges of operands Accessed by: Memory Type SINUMERIK 802S base line Bit (Byte.bit) 14000000.0-79999999.7 0.0 - 7.7 0.0 - 7.7 0.0 - 127.7 0.0 – 0.6 0 – 15 0 - 31 0.0 - 59.7...

  • Page 61: Instruction Set

    EFORVH VB, IB, QB, MB, Load Byte a < b open SMB, AC, Constant, And Byte > =B Or Byte a EFORVH Load Byte a > b open And Byte < =B Or Byte SINUMERIK 802S base line 4-21 Start-Up...
  • Page 62 VD, ID, QD, MD, a EFORVH AC, Constant, LD Load RWord a < b open And RWord > =R Or RWord a EFORVH Load RWord a > b open And RWord < =R Or RWord SINUMERIK 802S base line 4-22 Start-Up...
  • Page 63 VW, T, C, IW, QW, MW, AC, Constant, LW Count Down If C = 0, Cnt Down: (CD) Value Cxxx Reset: Cxxx: C0 - 31 Preset: (PV) VW, T, C, IW, QW, MW, AC, Constant, LW SINUMERIK 802S base line 4-23 Start-Up...
  • Page 64 MW, AC, LW Increment If EN = 1, Enable: INC_DW Decrement. a = a + 1 VD, ID, QD, MD, a = a - 1 AC, Constant, LD Out: VD, ID, QD, MD, AC, LD SINUMERIK 802S base line 4-24 Start-Up...
  • Page 65 = a SR c bits VD, ID, QD, MD, AC, SHL_DW a = a SL c bits Constant, LD Out: VD, ID, QD, MD, AC, Count: VB, IB, QB, MB, AC, Constant, LB SINUMERIK 802S base line 4-25 Start-Up...
  • Page 66 If EN = 1, exit the Enable: Return from subroutine. Subroutine Conditional End If EN = 1, END Enable: terminates the main scan. If EN ↑, go to Subroutine Label: Constant : 0-63 subroutine n. (x... optional parameters) SINUMERIK 802S base line 4-26 Start-Up...

  • Page 67: Program Organization

    The sequence control defines all cyclic signals in the subroutine (UP0); UP1/UP2 is called every two cycles, and UP 3 controls all signals in steps of three cycles. SINUMERIK 802S base line 4-27 Start-Up...

  • Page 68: Data Organization

    The user program can be analyzed or checked for errors using the following methods: PLC Status menu (OP) Status list menu (OP) PLC 802 Programming Tool (see Help menu > Contents and Index, “Debugging” or documentation “S7-200 Automation System”, Section “Testing and Monitoring Your Program”) SINUMERIK 802S base line 4-28 Start-Up...

  • Page 69: Plc Applications "Download/Upload/Copy/Compare

    (load memory) of the control system. Download the PLC project using the PLC 802 Programming Tool (Step 7 connect on) Series start-up using the WinPCIN tool (PLC MD, PLC project and user alarm texts) Data In SINUMERIK 802S base line 4-29 Start-Up...
  • Page 70 The programmer can use the first comment line in the program title of the PLC 802 Programming Tool for his own additional information in the version display (see “View Properties“). SINUMERIK 802S base line 4-30 Start-Up...

  • Page 71: User Interface

    Technology Setting Overview The SINUMERIK 802S base line is supplied with the default machine data as a control system for turning machines (2 axes, 1 spindle). If you wish to set another technology (e.g. milling), the relevant machine data file must be loaded from the tool box into the control system.

  • Page 72: Commissioning

    Start-Up Commissioning Initializing the control system Turn on the control system. The SINUMERIK 802S base line will load the standard machine data automatically. 4.7.1 Entering the general machine data Overview To make your work easier, the most important machine data of the individual subranges are listed.
  • Page 73 Auxiliary function value (aux. fct. no. in channel): 0...49 22550 New tool compensation for M function Setting data Number Explanation DefaultValue 41110 Jog feedrate 41200 Spindle speed 42000 Start angle 42100 Dry run feedrate 5000 SINUMERIK 802S base line 4-33 Start-Up...

  • Page 74: Starting Up The Axes

    4.7.2 Starting up the axes Overview The SINUMERIK 802S base line has up to three stepper motor feedrate axes (X, Y and Z). The stepper motor drive signals are output at connector X7 for the: X axis (SW1, BS1, RF1.1, RF1.2) Y axis (SW2, BS2, RF2.2, RF2.2)
  • Page 75 1: Zero pulse (on encoder track) 2: BERO 3: Distance–coded reference marks 4: Bero with two edges 5: BERO cam 36200 Threshold value for velocity 11500 Threshold value monitoring (control parameter velocity monitoring set no.): 0...5 SINUMERIK 802S base line 4-35 Start-Up...
  • Page 76 The “Servo enable” signal provided via the NC will not be used to turn off the drive (“Drive Enable” is always active). This pertains to the following signals: SINUMERIK 802S base line 4-36 Start-Up...
  • Page 77 The error “Rotation monitoring” will also always occur if the stepper motor has been controlled incorrectly even if the speed monitoring is not enabled. If deemed necessary, the user must take appropriate measures to ensure that the stepper motor is shut down reliably. SINUMERIK 802S base line 4-37 Start-Up...
  • Page 78 MD 32420 JOG_AND_JERK_ENABLE=0 Prerequisite for action of the bent acceleration characteristic in JOG. Parameterization of the axis characteristic The axial course of the acceleration characteristic must be parameterized using the following machine data: SINUMERIK 802S base line 4-38 Start-Up...
  • Page 79 To output the analog axis setpoint, with SINUMERIK 802S base line, the D/A converter of the spindle is used. SINUMERIK 802S base line...
  • Page 80 The gear stage is dependent on the spindle speed with M40 or is set directly via M41...M45 (see also Section 4.5.3 “Start-up of the spindle”). Number Description Default Value 32900 Dynamic response adaptation 32910 Time constant of dynamic adaption (control parameter set no): 0...5 SINUMERIK 802S base line 4-40 Start-Up...
  • Page 81 POSCTRL_GAIN is displayed on the service display. MD 32900 DYN_MATCH_ENABLE must be set to = 1. Example: service display for Z axis with POSCTRL_GAIN : 2.437 in 1,000/min Exact calculation: 0.0954s MD 32910 DYN_MATCH_TIME[1] = 2.437 1000 SINUMERIK 802S base line 4-41 Start-Up...
  • Page 82 Activation The LEC is only activated in all operating modes if the following requirements are met: The number of compensation intermediate points must be defined. They are only active after Power ON (MD: MM_ENC_MAX_POINTS). SINUMERIK 802S base line 4-42 Start-Up...
  • Page 83 _N_COMPLETE_EEC by means of the editor (e.g. in the WINPCIN/OUT program). Then re-read the edited file into the control system. Approach the reference point in the axes and set MD: ENC_COMP_ ENABLE (0)=1. The LEC is thus activated. SINUMERIK 802S base line 4-43 Start-Up...

  • Page 84: Starting Up The Spindle

    Starting up the spindle Overview With the SINUMERIK 802S base line, the spindle is a subfunction of the entire axis functionality. The machine data of the spindle are therefore to be found under the axis machine data (from MD35000). For this reason, data have to be entered for the spindle, too;...
  • Page 85 Feedrate enable for spindle stopped 36000 Exact positioning coarse 0.04 (only SPOS) 36010 Exact positioning fine 0.01 (only SPOS) 36020 Delay exact positioning fine (only SPOS) 36030 Zero–speed tolerance (only SPOS) 36040 Delay zero–speed monitoring (only SPOS) SINUMERIK 802S base line 4-45 Start-Up...
  • Page 86 Machine data for setpoint and actual values Setpoints: MD 30130 CTRLOUT_TYPE [AX4] = 1 Actual values: MD 30200 NUM_ENCS[AX4] = 0 Spindle without encoder MD 30200 NUM_ENCS[AX4] = 1 Spindle with encoder MD 30240 ENC_TYPE[AX4] = 2 Type of encoder SINUMERIK 802S base line 4-46 Start-Up...
  • Page 87 MD 31060 Internal resolution = ----------------- x ------------- x ------------ x 1000pulses/deg = 17.5781 4 x 2048 One encoder increment corresponds to 17.5781 internal increments. One encoder increment corresponds to 0.0175781 degrees (minimum positioning step). SINUMERIK 802S base line 4-47 Start-Up...
  • Page 88 (MD 30130=0) and with drive (MD 30130=1). Reciprocation mode for gear change The reciprocation mode of the spindle is intended to facilitate the gear change. For reciprocation mode, the following axis MD and interface signals are relevant: SINUMERIK 802S base line 4-48 Start-Up...

  • Page 89: Completing The Start-Up

    To this aim, set access level 7 (final customer); otherwise, access level 2 will also be saved.  Press the softkey Delete passw.  The access level will be reset. Carry out internal data saving.  Press the softkey Save data. SINUMERIK 802S base line 4-49 Start-Up...

  • Page 90: Cycle Start-Up

    These data can be selected in the Services menu by pressing the Data outp./data...softkey. Load all files of the selected technology path from the toolbox diskette into the control system via the V24 interface. Carry out POWER ON. Reload the recovered data. SINUMERIK 802S base line 4-50 Start-Up...

  • Page 91: Series Machine Start-Up

    Select the Start–up data line from the Services menu and press Start data outp. to output the series machine start–up file. Reading in the series machine start–up file into the SINUMERIK 802S base line: Enter the V24 interface settings as described under 1).
  • Page 92 Start-Up Series machine start–up file The series machine start–up file contains: machine data R parameters display and alarm text files display machine data PLC user program main programs subroutines cycles Leadscrew error compensation data SINUMERIK 802S base line 4-52 Start-Up...

  • Page 93: Software Update

    After hardware replacement, if software versions other than the supplied are to be loaded. Preconditions To change the system software of the SINUMERIK 802S base line, you will need the following: Update software (Toolbox) A PG/PC with V24 interface (COM1 or COM2) and an appropriate cable.

  • Page 94: Update Errors

    Error when writing to the FLASH PC/PG memory Check Inconsistent data (incomplete or Toolbox faulty) SINUMERIK Update without programming the code 802S base FLASH completed (no data received, line transfer not started) UPDATE NO DATA SINUMERIK 802S base line Start-Up...

  • Page 95: Technical Appendix

    SIGNED DWORD Integer values (from –2147483650 to 2147483649) WORD Hex values (from 0000 to FFFF) DWORD Hex values (from 00000000 to FFFFFFFF) Real values (from ±8.43 x 10 to ±3.37 x 10 –37 FLOAT DWORD SINUMERIK 802S base line Start-Up...

  • Page 96: Display Machine Data

    User class Set V24 Immediately Byte $MM_USER_CLASS_DIR_ACCESS Decimal User class access directory Immediately Byte V24_PG_PC_BAUD PG: Baud rate (300, 600, 1200, 2400, 4800, 9600, Immediately 19200, 38400) Byte $MM_USER_CLASS_PLC_ACCESS Decimal User class access PLC project Immediately Byte SINUMERIK 802S base line Start-Up...
  • Page 97 POWER ON BYTE $MM_V24_PPI_MODEM_ACTIVE Decimal Modem active Immediately BYTE $MM_V24_PPI_MODEM_BAUD Decimal Modem baud rate Immediately BYTE $MM_V24_PPI_MODEM_PARITY Decimal Modem parity Immediately BYTE $MM_STARTUP_PICTURE_TIME Decimal Average time of start up picture visibility in POWER ON second BYTE SINUMERIK 802S base line Start-Up...

  • Page 98: General Machine Data

    – Handwheel POWER ON _always BYTE 14510 USER_DATA_INT [n] User data (INT) 0 ... 31 POWER ON _always – – DWORD 14512 USER_DATA_HEX [n] User data (Hex) 0 ... 31 POWER ON – 0xFF BYTE SINUMERIK 802S base line Start-Up...

  • Page 99: Channel-Specific Machine Data

    _always – – STRING 22030 AUXFU_ASSIGN_VALUE – Auxiliary function value (aux. fct. no. in channel): 0...49 POWER ON _always – – DWORD 22550 TOOL_CHANGE_MODE – New tool compensation for M function POWER ON _always BYTE SINUMERIK 802S base line Start-Up...

  • Page 100: Axis-Specific Machine Data

    Fixed–value positions of axis with G75 (position no.) POWER ON degrees _always – – DOUBLE 31000 ENC_IS_LINEAR – Direct measuring system (linear scale) (encoder no.) POWER ON _always B O O LE A N 2/7 SINUMERIK 802S base line Start-Up...
  • Page 101 – Steps for monitoring rotation POWER ON 2000 10000000 DWORD 31110 BERO_EDGE_TOL – Step tolerance for monitoring rotation POWER ON 10000000 DWORD 31350 FREQ_STEP_LIMIT – Stepping rate at maximum velocity NEW CONF 250000 4000000 DOUBLE SINUMERIK 802S base line Start-Up...
  • Page 102 NEW CONF _always (2,5; 2,5; 2,5; 1), ... plus DOUBLE 32250 RATED_OUTVAL Ratedoutput voltage (setprint brauch):0 NEW CONF _always DOUBLE 32260 RATED_VELO rev/min Rated motor speed (setpoint branch): 0 NEW CONF _always 3000 plus DOUBLE SINUMERIK 802S base line Start-Up...
  • Page 103 34000 REFP_CAM_IS_ACTIVE – Axis with reference point cam RESET _always B O O LE A N 2/7 34010 REFP_CAM_DIR_IS_MINUS – Approach reference point in minus direction RESET _always B O O LE A N 2/7 SINUMERIK 802S base line Start-Up...
  • Page 104 – DOUBLE 34090 REFP_MOVE_DIST_CORR Reference point offset/absolute offset distance–coded POWER ON deg. _always – – DOUBLE 34092 REFP_CAM_SHIFT Electr. cam offset of incremental measuring systems with RESET deg. equidistant zero marks _always plus DOUBLE SINUMERIK 802S base line 6-10 Start-Up...
  • Page 105 Maximum speed of gear stage (gear stage no.): 0...5 NEW CONF _always 500, 500, 1000, 2000, plus DOUBLE 4000, 8000 35140 GEAR_STEP_MIN_VELO_LIMIT rev/min Minimum speed of gearsetp (gear stage no.): 0...5 NEW CONF _always 5, 5,10, 20, 40, 80 plus DOUBLE SINUMERIK 802S base line 6-11 Start-Up...
  • Page 106 _always plus DOUBLE 35350 SPIND_POSITIONING_DIR – Direction of rotation when positioning RESET _always BYTE 35400 SPIND_OSCILL_DES_VELO rev/min Reciprocation speed NEW CONF _always plus DOUBLE 35410 SPIND_OSCILL_ACCEL rev/s^2 Acceleration during reciprocating NEW CONF _always DOUBLE SINUMERIK 802S base line 6-12 Start-Up...
  • Page 107 NEW CONF _always plus DOUBLE 36030 STANDSTILL_POS_TOL Zero–speed tolerance NEW CONF deg. _always plus DOUBLE 36040 STANDSTILL_DELAY_TIME Delay zero–speed monitoring NEW CONF _always plus DOUBLE 36050 CLAMP_POS_TOL Clamping tolerance NEW CONF deg. _always plus DOUBLE SINUMERIK 802S base line 6-13 Start-Up...
  • Page 108 NEW CONF Zero mark monitoring off, encoder HW monitoring on 1–99, >100: Number of recognized zero mark errors during monitoring 100: Zero mark monitoring off, encoder HW monitoring off _always 0, 0 plus DWORD SINUMERIK 802S base line 6-14 Start-Up...
  • Page 109 Drift limit value for automatic drift compensation NEW CONF _always 1.000 plus DOUBLE 36720 DRIFT_VALUE Drift basic value NEW CONF _always DOUBLE 38000 MM_ENC_COMP_MAX_POINTS – Number intermediate points interpolatory POWER ON compensation (SRAM) _always 0, 0 5000 DWORD SINUMERIK 802S base line 6-15 Start-Up...

  • Page 110: Setting Data

    _always 1000 plus DOUBLE 43230 SPIND_MAX_VELO_LIMS rev/min Spindle speed limitation with G96 Immediately _always plus DOUBLE 52011 STOP_CUTCOM_STORE Alarm response for TRC and feedforward stop Immediately – B O O LE A N 4/4 SINUMERIK 802S base line 6-16 Start-Up...

  • Page 111: Plc User Interface Signals

    PLC cycle clock (alternating one cycle ‘0’, then one cycle ‘1’) Notice All empty user interface fields in the following tables are Reserved for SIEMENS and may neither be written, nor evaluated by the user! All fields with a “0” contain the value “logic =”. Variable access rights...

  • Page 112: Retentive Data Area

    Interface CNC -----> PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 User Data 14000000 User Data 14000001 User Data 14000002 User Data 14000062 User Data 14000063 SINUMERIK 802S base line 6-18 Start-Up...

  • Page 113: Cnc Signals

    Interface CNC -----> PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 EMER- 27000000 GENCY STOP active 27000001 27000002 Drive ready Ambient 27000003 Tempera- alarm ture present alarm SINUMERIK 802S base line 6-19 Start-Up...
  • Page 114 Mode signals from CNC [r] Data block Interface CNC -----> PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Active mode 31000000 READY AUTOM. Active machine function 31000001 TEACH SINUMERIK 802S base line 6-20 Start-Up...

  • Page 115: Channel Signals

    + Feed override 31 positions (Gray code) with 31 MD for % weighting + Rapid traverse override 31 positions (Gray code) with 31 MD for % weighting + Single Block Use the softkey to select Single Block Type Preselection (SBL1/SBL2) see “User Manual” SINUMERIK 802S base line 6-21 Start-Up...
  • Page 116 Axis 3 in WCS 32001008 Traversing keys Rapid Travers- Feed Activate handwheel traverse ing key override lock stop Axis 3 in WCS 32001009 Machine function Continu- 1000 INC 100 INC 10 INC 1 INC 32001010 32001011 SINUMERIK 802S base line 6-22 Start-Up...
  • Page 117 33000002 Channel state Program state 33000003 Interrupt- Interrupt- Reset active aborted stopped waiting running 33000004 alarm alarm All axes All axes with channel- stopped Referenc- stop specific machin- present present 33000005 33000006 33000007 SINUMERIK 802S base line 6-23 Start-Up...
  • Page 118 1 INC 33001006 33001007 Axis 3 in WCS 33001008 Traversing Handwheel active command plus minus Axis 3 in WCS 33001009 Active machine function Continu- 1000 INC 100 INC 10 INC 1 INC 33001010 33001011 SINUMERIK 802S base line 6-24 Start-Up...
  • Page 119 Auxiliary functions from CNC channel [r] Data block Interface PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Modify 25000000 decoded functions 0-99 25000001 Modify T funct. 1 25000002 25000003 SINUMERIK 802S base line 6-25 Start-Up...
  • Page 120 25001012 25001013 25001014 25001015 Notes: + Static M functions must be generated by the PLC user from the dynamic M functions. + Dynamic M functions are decoded by the basic program (M00 to M99). SINUMERIK 802S base line 6-26 Start-Up...
  • Page 121 T functions from CNC channel [r] Data block Interface PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 25002000 T function 1 (DINT) 25002004 25002008 25002012 SINUMERIK 802S base line 6-27 Start-Up...

  • Page 122: Axis/Spindle Signals

    Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Delay 2nd software limit switch Hardware limit switch 380x1000 Ref.-point (axis) approach plus minus plus minus 380x1001 (axis) 380x1002 (axis) 380x1003 (axis) SINUMERIK 802S base line 6-28 Start-Up...
  • Page 123 Signals to axis/spindle [r/w] Data block Interface PLC -----> CNC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Rotation 380x5000 monitoring (stepper motor) 380x5001 (stepper motor) 380x5002 380x5003 SINUMERIK 802S base line 6-29 Start-Up...
  • Page 124 Data block Interface CNC -----> PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 390x1000 (axis) 390x1001 (axis) 390x1002 Lubrica- (axis) tion pulse 390x1003 (axis) SINUMERIK 802S base line 6-30 Start-Up...
  • Page 125 Data block Interface CNC -----> PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Rotation 390x5000 monitoring (Stepper error motor) 390x5001 (Stepper motor) 390x5002 390x5003 SINUMERIK 802S base line 6-31 Start-Up...
  • Page 126 Interface CNC -----> PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 570x0000 Axis Axis actual values actual values 570x0004 Axis Axis distances to go distances to go SINUMERIK 802S base line 6-32 Start-Up...

  • Page 127: Signals From/To Mmc

    Signals from MMC [r] Data block Interface MMC -----> PLC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 18000000 Machine function 18000001 TEACH 18000002 18000003 SINUMERIK 802S base line 6-33 Start-Up...
  • Page 128 Signals to operator panel [r/w] Data block Interface PLC -----> MMC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 19005000 key lock 19005001 19005002 19005003 SINUMERIK 802S base line 6-34 Start-Up...

  • Page 129: Machine Control Panel Signals (Mcp Signals)

    User- defined defined defined defined defined defined defined defined LED16 LED15 LED14 LED13 LED12 LED11 LED10 LED9 11000001 Spindle Feed Spindle Feed User- User- User- User- override override override override defined defined defined defined SINUMERIK 802S base line 6-35 Start-Up...

  • Page 130: Plc Machine Data

    Signals from CNC [r] Data block Interface CNC -----> PLC Byte 45001000 Hex value (BYTE) 45001001 Hex value (BYTE) 45001002 Hex value (BYTE) 45001003 Hex value (BYTE) 45001030 Hex value (BYTE) 45001031 Hex value (BYTE) SINUMERIK 802S base line 6-36 Start-Up...
  • Page 131 Alarm reaction / clear criterion of alarm 700000 45003001 Alarm reaction / clear criterion of alarm 700001 45003002 Alarm reaction / clear criterion of alarm 700002 45003031 Alarm reaction / clear criterion of alarm 700031 SINUMERIK 802S base line 6-37 Start-Up...

  • Page 132: User Alarm

    Interface PLC -----> MMC Byte 16001000 Variable for alarm 700000 16001004 Variable for alarm 700001 Variable for alarm 700002 16001008 16001116 Variable for alarm 700029 16001120 Variable for alarm 700030 16001124 Variable for alarm 700031 SINUMERIK 802S base line 6-38 Start-Up...
  • Page 133 Data block Interface PLC -----> MMC Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 570x0000 Axis actual value (REAL) 570x0004 Axis distance to go (REAL) SINUMERIK 802S base line 6-39 Start-Up...

  • Page 134: Plc User Program For Turning (Sample)

    NC parameters and drives. SINUMERIK 802S/C base line is pre-loaded “SAMPLE” – integrated PLC application program, this application applies to SINUMERIK 802S base line or SINUMERIK 802C base line turning or milling technology. The functions of PLC application can be configured through the setting of PLC machine data.
  • Page 135 Turret control for turning machine Suitable for 4 or 6 position Hall Effect Device sensor turret; Turret clamping time monitoring (time can be specified by PLC MD) Turret sensors monitoring During turret activate “read-in disable” and “Feedhold” SINUMERIK 802S base line 6-41 Start-Up...
  • Page 136 Combined keys activated by PLC MD to release motor brake during drive optimization (only for 611U drive with SimoCom U) Combined keys: Æ & Release brake; Æ & motor braking An alarm to warn that motor brake is released during drive optimization SINUMERIK 802S base line 6-42 Start-Up...

  • Page 137: Input/Output Configuration

    Q1.3 Motor brake release Motor brake release Q1.4 Spindle brake Spindle brake Q1.5 Supply infeed: T48 Supply infeed: T48 Q1.6 Supply infeed: T63 Supply infeed: T63 Q1.7 Supply infeed: T64 Supply infeed: T64 SINUMERIK 802S base line 6-43 Start-Up...

  • Page 138: Definition Of User Keys

    If an input is a Normal Close, it should be specified via PLC MD as negative logic. Spindle enable signals come from P17(SE4.1) and P50(SE4.2) (Internal relay) of X7. 6.3.3 Definition of user keys User keys Fig. 6-1 User keys on MCP area SINUMERIK 802S base line 6-44 Start-Up...
  • Page 139 Lubricating LED6 Cooling Cooling LED7 User defined User defined LED8 User defined User defined LED9 User defined User defined LED10 User defined User defined LED11 User defined User defined LED12 User defined User defined SINUMERIK 802S base line 6-45 Start-Up...

  • Page 140: Plc Machine Data

    Technical Appendix 6.3.4 PLC machine data Definition of MD14512 The function of all 48 inputs and 16 outputs of the SINUMERIK 802S base line basic variant can be set by means of the following parameters: MD14512 USER_DATA_HEX Machine data PLC machine data - Hex...
  • Page 141 Standard speed. The steps are: 50%,55%,60%,65%,70%,75%,80%,85%,90%,95%,1 00%,105%,110%,115%,120%. Two times fast than standard. The steps are: 50%,60%,70%,80%,90%,100%,110%,120%. About three times fast than standard. The steps are: 50%,60%,70%,85%,100%,110%,120%. About four times fast than standard. The steps are: 50%,60%,80%,100%,120%. SINUMERIK 802S base line 6-47 Start-Up...
  • Page 142 Bit 6/5/4=1 Z/Y/X has only one limit switch (in case Bit 7=0) Bit 7=0 Hardware limit using PLC solution (default) (Bit 6/5/4 is effective) Bit 7=1 Hardware limit using hardware solution (Emergency Stop Chain) SINUMERIK 802S base line 6-48 Start-Up...
  • Page 143 Definition: Z axis + traverse key position 14510[30] Unit: - Range: between 22 ~ 30, but not 26 Definition: Z axis – traverse key position 14510[31] Unit: - Range: between 22 ~ 30, but not 26 SINUMERIK 802S base line 6-49 Start-Up...

  • Page 144: Sample Program Structure

    Therefore in SAMPLE M100.0 is a buffered input for I0.0, and M101.2 is for I1.2; M102.3 is for Q0.3 and M103.4 is for Q1.4, and so on. All subroutines in LIBRARY are inputs/output independent. SINUMERIK 802S base line 6-50 Start-Up...
  • Page 145 “1” to inform FILTER. In case you compose your own application using the building blocks provided in SUBR_LIBRARY, please take care of definition of each input of the subroutine – NO or NC. SINUMERIK 802S base line 6-51 Start-Up...

  • Page 146: User Alarm

    TOOL NOT FOUND, MONITORING TIME UP 700025 V16000003.1 NO POSITION SIGNALS FROM TURRET 700026 V16000003.2 MOTOR BRAKE RELEASED FOR DRIVE OPTIMIZATION 700027 V16000003.3 APPROACH REF. POINT AGAIN AFTER ROT. MONITORING 700028 V16000003.4 700029 V16000003.5 700030 V16000003.6 700031 V16000003.7 SINUMERIK 802S base line 6-52 Start-Up...

  • Page 147: Start-Up Of Sample Program

    Bit 2=1 Unclamping control Bit 1=1 Auto lubrication active Bit 0=1 Cooling active Define system parameter: MD14512 [16] / [17] / [18] After setting, the parameter will be active when the next power on of the system. SINUMERIK 802S base line 6-53 Start-Up...
  • Page 148 The result is you can not release emergency stop. It is possible for you either to connect a high signal to I1.7 or simply specify MD14512[16].bit0=1, so that you can quit from emergency stop. SINUMERIK 802S base line 6-54 Start-Up...

  • Page 149: Unipolar Spindle

    The binary outputs used for the unipolar spindle must not be used by the PLC. This must be guaranteed by the user, as they are not any monitoring functions in the control system. Not observing this fact will result in undesired reactions of the control system. SINUMERIK 802S base line 6-55 Start-Up...
  • Page 150 Technical Appendix SINUMERIK 802S base line 6-56 Start-Up...
  • Page 151 Suggestions SIEMENS AG Corrections A&D MC BMS for Publication/Manual: Postfach 3180 SINUMERIK 802S base line D–91050 Erlangen (Tel. +49 180 / 5050 – 222 [Hotline] Fax +49 9131 / 98 – 2176 [Documentation] Mailto: motioncontrol.docu@erlf.siemens.de) Manufacturer Documentation Start-Up From Order No.: 6FC5597–4AA01–0BP0...
  • Page 154 Siemens AG Automatisierungs- und Antriebstechnik Motion Control Systems © Siemens AG 2003 Postfach 3180, D – 91050 Erlangen Subject to change without prior notice Germany Order No.: 6F5597-4AA01-0BP0 www.ad.siemens.de Printed in the Federal Republic of Germany...

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