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Siemens SINUMERIK 802S Start-Up
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Siemens SINUMERIK 802S Start-Up

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Start-Up 01/2002 Edition
SINUMERIK 802S

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Summary of Contents for Siemens SINUMERIK 802S

  • Page 1 Start-Up 01/2002 Edition SINUMERIK 802S...
  • Page 3 Numerical Control System SINUMERIK 802S Installing the Control System Start–Up Installing the Drives Start–Up Update Valid for Technical Appendix Control Software Version SINUMERIK 802S as from 3 Manual Machine Index 01.2002 Edition...
  • Page 4 Trademarks SIMATICr, SIMATIC HMIr, SIMATIC NETr, SIROTECr, SINUMERIKr and SIMODRIVEr are registered trademarks of Siemens. Third parties using for their own purposes any other names in this document which refer to trademarks might infringe upon the rights of trademark owners.
  • Page 5 The device may only be used for the cases of application, as intended by the Catalog, and only in conjunction with third–party devices and components recommended or approved by Siemens. The proper and safe operation of the product requires transport, storage and installation according to the relevant instructions and qualified operation and maintenance at the prescribed intervals.

  • Page 6: Table Of Contents

    2-15 Installing and removing the SINUMERIK 802S ........
  • Page 7 7-164 Default assignment of special data for the “Manual machine” ......7-165 SINUMERIK 802S 6FC5 597–2AA00–0BP2 (01.02)
  • Page 8 Table of Contents notice SINUMERIK 802S viii 6FC5 597–2AA00–0BP2 (01.02)

  • Page 9: Sinumerik 802S Control System

    SINUMERIK 802S Control System Components of the SINUMERIK 802S What is SINUMERIK? The SINUMERIK 802S is a microprocessor–controlled numerical control system for simple machine tools with stepper motor drives (”S” = stepper). Hardware components It consists of the following hardware components:...
  • Page 10 JOG REF AUTO SBL 7 > < PULSE X2003 X2005 DIAG DC24V X1 AXIS SPINDLE ECUODER RS232 X2004 X2006 DI/O External spindle drive DRIVEs Stepper motors Fig. 1-1 SINUMERIK 802S hardware components (turning variant) SINUMERIK 802S 1-10 6FC5 597–2AA00–0BP2 (01.02)
  • Page 11 – PLC software (Programmable Logic Control), executes the Integrated PLC user program cyclically. – Integrated PLC user program intended to adjust the SINUMERIK 802S to the machine functions (see also Descrip- tion of Functions “Integrated User Program for SINUMERIK 802S”). Toolbox –...
  • Page 12 SINUMERIK 802S Control System Components of the SINUMERIK 802S Warning To avoid data loss, the operator must carry out data saving (see Section 4.1.4). SINUMERIK 802S 1-12 6FC5 597–2AA00–0BP2 (01.02)

  • Page 13: Technical Data

    SINUMERIK 802S Control System Technical data 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 ENC Power dissipation of OP020 Power dissipation of MCP Power dissipation of DI/O16 Start–up current...
  • Page 14 SINUMERIK 802S Control System Technical data Environmental operating conditions Table 1-4 Environmental operating conditions Parameter 0...55 °C Temperature range Permissible relative humidity 5...95 % without condensation Air pressure 700...1,060 hPa The operating conditions comply with IEC 1131-2. Installation in a housing (e.g. cubicle) is absolutely necessary for operation.

  • Page 15: Installing The Control System

    Installing the Control System Installing and removing the SINUMERIK 802S Warning Before performing any installation work, always first make sure that the system is disconnec- ted from the mains! 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 16 Installing the Control System Installing and removing the SINUMERIK 802S Warning Before removing the control components, always first make sure that the system is discon- nected from the mains! SINUMERIK 802S 2-16 6FC5 597–2AA00–0BP2 (01.02)
  • Page 17 Installing the Control System Installing and removing the SINUMERIK 802S Mounting dimensions The dimensions shown below are important for installing the control components: Ñ Ñ SubD Ñ Ñ Ñ Ñ Mounting Holes X2003 X2005 ENCODER1 ENCODER2 DIAG DC24V X1 RS232...

  • Page 18: Interfaces And Cables

    DIAG DC24V X1 RS232 SPINDLE AXIS ENCODER3 X2004 X2006 Fig. 2-2 User interfaces OP020 Rear Rear X1202 X1201 LCD- signal connector X1001 X1002 X1009 Fig. 2-3 Rear of machine control panel and operator panel SINUMERIK 802S 2-18 6FC5 597–2AA00–0BP2 (01.02)

  • Page 19: Start–Up

    DI/O X2003 and X2004 10–pin front connector for connecting digital inputs X2005 and X2006 10–pin front connector for connecting digital outputs LEDs 3 LEDs for fault and status displays Operating elements Start–up switch S1 SINUMERIK 802S 2-19 6FC5 597–2AA00–0BP2 (01.02)
  • Page 20 1...4 Wire (0.14...1.5) Sensor DI/O16 1...16 Wire (0.14...1.5) IN 0..7 IN 8..15 OUT0..7 Wire (0.14...1.5) Actor OUT8..15 1...16 Power Supply Fig. 2-4 SINUMERIK 802S Connection Diagram 1) Ribbon cable (included in scope of supply) SINUMERIK 802S 2-20 6FC5 597–2AA00–0BP2 (01.02)

  • Page 21: Connecting The Individual Components

    2. Fix the sub–D connector in place using the knurled screws. 2.3.1 Connecting the operator panel Connector pin assignment on the ENC side Operator panel interface Connector designation: OP020 Connector type: 25–pin sub–D plug connector SINUMERIK 802S 2-21 6FC5 597–2AA00–0BP2 (01.02)
  • Page 22 Pin assignment of connector X1009 X1009 Signal Type Pin Signal Type P24_OP M_OP OPD0_N OPD0 OPD1_N OPD1 OPD2_N OPD2 OPD3_N OPD3 OPCP1_N OPCP1 OPCP2_N OPCP2 OPS_N OPTXD_N OPTXD OPRXD_N OPRXD OPCTS_N OPCTS P24_OP M_OP SINUMERIK 802S 2-22 6FC5 597–2AA00–0BP2 (01.02)

  • Page 23: Connecting The Feed Drives

    ECU Request to Send P24_OP DC24V M_OP Ground Signal level RS422 / LVDS Signal type Voltage output Voltage input Output Input 2.3.2 Connecting the feed drives Connector pin assignment on the ENC side Feed drive interface SINUMERIK 802S 2-23 6FC5 597–2AA00–0BP2 (01.02)
  • Page 24 Clock pulse, true and negated DIR[1...4], DIR[1...4]_N Direction signal, true and negated EN[1...4], EN[1...4]_N Servo enable, true and negated Ground Signal level RS422 Signal type Signal output Axis assignment X axis Y axis Z axis (reserved) SINUMERIK 802S 2-24 6FC5 597–2AA00–0BP2 (01.02)

  • Page 25: Connecting The Spindle Drive (X3)

    Load resistance "60 Output current Pulse frequency Cable length: max. 50 m (with asymmetric transfer 10 m) 2.3.3 Connecting the spindle drive (X3) Pin assignment of the connector on the ENC side Spindle drive interface SINUMERIK 802S 2-25 6FC5 597–2AA00–0BP2 (01.02)
  • Page 26 SIMODRIVE unit. This signal is used by the ENC when the cyclic control mode is started. Signal parameters The setpoint is output as an analog differential signal. Table 2-6 Electrical parameters of the spindle setpoint signal Parameter Min. Max. Unit Voltage range -10.5 10.5 Output current Relay contact SINUMERIK 802S 2-26 6FC5 597–2AA00–0BP2 (01.02)

  • Page 27: Connecting The Spindle Measuring System (X4)

    Type Signal Type P5_MS P5_MS Signal names A, A_N Track A (true and negated) B, B_N Track B (true and negated) N, N_N Zero mark (true and negated) P5_MS +5.2 V supply Supply ground SINUMERIK 802S 2-27 6FC5 597–2AA00–0BP2 (01.02)
  • Page 28 300 mA Cable lengths The maximum cable length depends on the specification of the encoder supply and on the transmission frequency. When using preassembled cables from SIEMENS, the following va- lues may not be exceeded to ensure interference–free operation: Table 2-9...

  • Page 29: Configuration Of The Rs232 Interface Connection (X8)

    Standby output Standby input Ground Signal level RS232 (+ 12 V) Signal type Input Output Voltage output Cable for WinPCIN Table 2-12 Cable for WinPCIN: Pin assignment of the Sub–D connector 9–Pin Name 25–Pin Shield SINUMERIK 802S 2-29 6FC5 597–2AA00–0BP2 (01.02)

  • Page 30: Connecting Handwheels (X10)

    Track B, true and negated (handwheel 1) A2, A2_N Track A, true and negated (handwheel 2) B2, B2_N Track B, true and negated (handwheel 2) P5_MS 5.2 V supply voltage for handwheels Supply ground Signal level RS422 Signal type SINUMERIK 802S 2-30 6FC5 597–2AA00–0BP2 (01.02)

  • Page 31: Connecting Ncready (X20)

    Table 2-14Pin assignment of connector X20 Name Type NCRDY_1 NCRDY_2 reserved reserved reserved reserved reserved reserved reserved reserved Signal names NCRDY_1...2 NC Ready (NCREADY contacts 1...2) BERO1...BERO4 BERO input for axes 1 ... 4 SINUMERIK 802S 2-31 6FC5 597–2AA00–0BP2 (01.02)
  • Page 32 These inputs are 24 V-P switching. Either switches or non–contact sensors, such as inductive sensors (BEROs), can be connected. When using the BERO as a reference point switch, the following fixed assignment will apply: BERO1 - X axis BERO3 - Z axis SINUMERIK 802S 2-32 6FC5 597–2AA00–0BP2 (01.02)
  • Page 33 Electrical parameters of the NCREADY relay contact Parameter Max. Unit DC switching voltage Switching current Switching power EMERGENCY STOP X20.11 NCREADY X20.12 Machine control voltage Fig. 2-5 The NCREADY contact will switch off the control voltage in case of danger. SINUMERIK 802S 2-33 6FC5 597–2AA00–0BP2 (01.02)

  • Page 34: Connecting The Digital Inputs And Outputs (X2003

    10–pin plug connector Table 2-17 Connector pin assignment X2003 Name Type X2004 Name Type DI10 DI11 DI12 DI13 DI14 DI15 Signal names DI0...15 24 V digital inputs Signal type Voltage input Input (24 V signal) SINUMERIK 802S 2-34 6FC5 597–2AA00–0BP2 (01.02)
  • Page 35 Interface for digital outputs Connector designation: X2005, X2006 Connector type: 10–pin plug connector Table 2-19 Connector pin assignment X2005 Name Type 1P24 1M24 X2006 Name Type 2P24 DO10 DO11 DO12 DO13 DO14 DO15 2M24 SINUMERIK 802S 2-35 6FC5 597–2AA00–0BP2 (01.02)
  • Page 36 3 “1” signal, output current Simultaneity factor 0.5 per 16 outputs “0” signal, leakage current max. 2 Connecting sensors and actuators X2005 X2003 X2004 X2006 Fig. 2-6 Connecting the digital inputs and outputs SINUMERIK 802S 2-36 6FC5 597–2AA00–0BP2 (01.02)

  • Page 37: Enc And Operator Panel Power Supply (X1)

    DC 24 V Ground The contacts 2/4 are connected internally in the device. Operator panel The operator panel does not possess a separate power supply connection. It is powered from the ENC via the signal cables. SINUMERIK 802S 2-37 6FC5 597–2AA00–0BP2 (01.02)

  • Page 38: Grounding

    Shielded signal cable DI/O16 X2003 X2005 ENCODER1 ENCODER2 DIAG DC24V X1 RS232 SPINDLE AXIS ENCODER3 X2004 X2006 to chassis Grounding bar Fig. 2-7 Grounding diagram for MCP/OP020 installation in a cubicle or machine SINUMERIK 802S 2-38 6FC5 597–2AA00–0BP2 (01.02)
  • Page 39 LCD signal- connector Shielded signal cable DI/O16 X2003 X2005 ENCODER1 ENCODER2 DIAG DC24V X1 RS232 ENCODER3 SPINDLE AXIS X2004 X2006 to chassis Grounding bar Fig. 2-8 Grounding diagram for MCP/OP020 installation in a panel SINUMERIK 802S 2-39 6FC5 597–2AA00–0BP2 (01.02)

  • Page 40: Leds And Operating Elements On The Enc Unit

    This LED indicates various diagnosis states. Under normal operating conditions, this LED flashes 1:1. Start–up switch (S1) This rotary switch is intended to assist start–up. Position 0: Normal operation Positions 1-4: Start–up cf. also Section 4.2, Table 4-2 SINUMERIK 802S 2-40 6FC5 597–2AA00–0BP2 (01.02)

  • Page 41: Installing The Stepdrive C Drives

    Do not install devices which are strongly heated during operation beneath the drive modu- les! Removal The drive modules are removed in the reverse order. Warning When removing the drive modules, always first make sure that the system is disconnected from the mains! SINUMERIK 802S 3-41 6FC5 597–2AA00–0BP2 (01.02)
  • Page 42 Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Fig. 3-1 Mounting dimensions SINUMERIK 802S 3-42 6FC5 597–2AA00–0BP2 (01.02)

  • Page 43: Cabling

    Drive of axis 2 yellow white blue orange green gray black brown purple CURR.1 CURR.1 CURR.2 CURR.2 RES. RES. DIR. DIR. SINUMERIK 802S Preassembled cable 6FX6 002-3BA31-1xx +PULS +PULS -PULS -PULS +DIR +DIR -DIR -DIR +ENA +ENA -ENA -ENA +24V +24V 24V GND...
  • Page 44 On the motor side, braid the shield, provided it with a cable shoe and clamp it to the groun- ding screw. Pulse interface To connect the drive pulse interface to the SINUMERIK 802S, use the preassembled ca- ble, order no.6FX6 002-3BA31-1xx0. On the drive side, connect the cable shield to the housing such that an electrical connec- tion is provided via the appropriate strain relief clamp.

  • Page 45: Starting Up The Drive Modules

    DIR signal. Note The DIR 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 3-45 6FC5 597–2AA00–0BP2 (01.02)

  • Page 46: Error Messages And Error Elimination

    Check cable connections – 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 No operating voltage Check cable connections SINUMERIK 802S 3-46 6FC5 597–2AA00–0BP2 (01.02)

  • Page 47: Start-Up

    Installation notes are to be found in Chapter LEERER MERKER. The control system with its components has powered up without errors. Start-up sequence The SINUMERIK 802S can be strated up as follows: 1. Check whether the ENC has powered up. 2. PLC start–up 3.

  • Page 48: Access Levels

    Access levels Protection levels The SINUMERIK 802S provides a protection level concept for enabling data areas. The pro- tection 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. If necessary these passwords can be changed by the appropriate authorized person.

  • Page 49: 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 NEW_CONF (cf) – Activate MD softkey on the operator panel – RESET key on machine control panel (MCP) –...
  • Page 50 Start-Up General If no physical units are applicable to the MD, the field contains a ”-”. SINUMERIK 802S 4-50 6FC5 597–2AA00–0BP2 (01.02)

  • Page 51: Handling Machine Data

    An internal data backup should be carried out if the control system has been switched off for more than 50 hours (at least 10 min/day with controller ON). It is recommended to carry out internal data saving whenever important data changes have been made. SINUMERIK 802S 4-51 6FC5 597–2AA00–0BP2 (01.02)
  • Page 52 2. Files are read in or read out by areas. The following user data can be selected as indivi- dual files: Data – Machine data – Setting data – Tool data – R parameters – Zero offset – Compensation data (LEC) Part programs Standard cycles SINUMERIK 802S 4-52 6FC5 597–2AA00–0BP2 (01.02)

  • Page 53: Turning On And Booting The Control System

    Table 4-2 Start-up switch settings Position Meaning Normal power–up Power–up with default machine data (user data determined by the software version) System software update Power–up with saved data PLC stop Reserve Assigned Assigned SINUMERIK 802S 4-53 6FC5 597–2AA00–0BP2 (01.02)
  • Page 54 Booting with delault machine data (Start–up switch position 1) Result The user memory area not loaded with default data is erased, and the default machine data are loaded from the permanent memory into the user memory. SINUMERIK 802S 4-54 6FC5 597–2AA00–0BP2 (01.02)

  • Page 55: Boot Messages

    DIAG LED (see Fig. 4-1) flashes. Boot errors Boot errors are displayed either on the screen or via the LED (see Fig. 4-1 in the following). The ERR flashes, and the DIAG LED does not flash. DIAG Fig. 4-1 SINUMERIK 802S 4-55 6FC5 597–2AA00–0BP2 (01.02)
  • Page 56 4. Replace the hardware components. ERROR BOOT 5. Inform the hotline if necessary. 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 4-56 6FC5 597–2AA00–0BP2 (01.02)

  • Page 57: Starting Up The Plc

    The PLC is a store–programmable logic controller for simple machines. It has no hardware of its own and is used as a software PLC in the SINUMERIK 802S control system. The task of the PLC is to control machine–related functional sequences.

  • Page 58: Start-Up Modes Of The Plc

    The control system comes with the SAMPLE user program for simple turning machines, which is stored in the permanent memory. 4.3.2 Start–up modes of the PLC The PLC can activate its start–up modes from two places. Table 4-4 Start–up modes SINUMERIK 802S 4-58 6FC5 597–2AA00–0BP2 (01.02)
  • Page 59 Example: Hardware start–up switch position 3 Restart from operator panel => Restart is active from next power–up of the control system The Run mode activates the cyclic mode. SINUMERIK 802S 4-59 6FC5 597–2AA00–0BP2 (01.02)

  • Page 60: Plc Alarms

    SELF–CLEARING: The alarm is cleared because the cause resulting in the alarm has been eliminated or does not exist any longer. Desired alarm responses are defined for each alarm in the PLC. By default, the PLC uses the SHOWALARM response (bit0 – bit5 = 0). SINUMERIK 802S 4-60 6FC5 597–2AA00–0BP2 (01.02)
  • Page 61 Byte 3 : Bit7 => 32nd user alarm ‘’ 700031 ’’ Sub–range 1: User alarm variables The respective bit (sub–range 0) with a 0/1 edge change will activate a new user alarm. Sub– range 1 is intended for additional user information. SINUMERIK 802S 4-61 6FC5 597–2AA00–0BP2 (01.02)
  • Page 62 Each alarm is assigned a configuration byte. The user alarms can be configured by the user in machine data 14516_MN_USER_DATA_PLC_ALARM. Default setting MD 14516: 0 => SHOW ALARM/SELF–CLEARING user alarm Configuration byte structure: Bit0 – bit5 : Alarm responses Bit6 – bit7 : Cancel criterion SINUMERIK 802S 4-62 6FC5 597–2AA00–0BP2 (01.02)
  • Page 63 700003 0 0 ‘’’’ // 4th user alarm, text is assigned by the user 700004 0 0 ‘’’’ // 5th user alarm, text is assigned by the user 700005 0 0 ‘’’’ // 6th user alarm, text is assigned by the user SINUMERIK 802S 4-63 6FC5 597–2AA00–0BP2 (01.02)
  • Page 64 ‘’ ’’ // 32nd user alarm, the text is assi- gned by the user Number Comment line (does The alarm text must be here. not appear in the dia- log window of the Operator Panel) SINUMERIK 802S 4-64 6FC5 597–2AA00–0BP2 (01.02)

  • Page 65: Machine Control Panel (Mcp) Layout

    The machine control panel in the standard version has been configured for simple turning ma- chines (2 axes and one spindle). The user can use the keys 1 – 6 and the associated LEDs (the same applies to keys 1 ... 6) for his own purposes. SINUMERIK 802S 4-65 6FC5 597–2AA00–0BP2 (01.02)

  • Page 66: Plc Programming

    Layout of the machine control panel –Y horizonal turning machine vertical milling machine Fig. 4-4 Examples for the assignment of the axis keyboard 4.3.5 PLC programming The PLC user program is created using the PLC 802 Programming Tool. SINUMERIK 802S 4-66 6FC5 597–2AA00–0BP2 (01.02)
  • Page 67 0000 ... FFFF –32 768 ... + 32 767 DWORD 4 bytes 0000 0000 ... FFFF FFFF –2 147 483 648 ... (Double +2 147 483 647 Word) ... $10 –37 REAL 4 bytes – SINUMERIK 802S 4-67 6FC5 597–2AA00–0BP2 (01.02)
  • Page 68 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 4-68 6FC5 597–2AA00–0BP2 (01.02)
  • Page 69 0 – 6 0 – 126 0 – 15 0 – 31 0 – 58 0 – 3 Double Word 14000000–79999994 0 – 4 0 – 4 0 – 124 0 – 56 0 – 3 SINUMERIK 802S 4-69 6FC5 597–2AA00–0BP2 (01.02)

  • Page 70: Instruction Set

    A detailed description of the instructions is to be found in the help system of the PLC 802 Pro- gramming Tool (Help > Contents and Index, “SIMATIC LAD Instructions”) and in the Docu- mentation “S7–200 Automation System, CPU22x System Manual. SINUMERIK 802S 4-70 6FC5 597–2AA00–0BP2 (01.02)
  • Page 71 ≥ b close And Byte . a t b open > =B Or Byte . Load Byte 3 a ≤ b close And Byte 3 a u b open < =B Or Byte 3 SINUMERIK 802S 4-71 6FC5 597–2AA00–0BP2 (01.02)
  • Page 72 ≥ b close And RWord . a t b open > =R Or RWord . Load RWord 3 a ≤ b close And RWord 3 a u b open < =R Or RWord 3 SINUMERIK 802S 4-72 6FC5 597–2AA00–0BP2 (01.02)
  • Page 73 VW, T, C, IW, QW, MW, AC,Constant, LW Count Down If C = 0, Cnt Down: (CD) Cxxx Value Reset: (R) Cxxx: C0 – 31 Preset: (PV) VW, T, C, IW, QW, MW, AC, Constant, LW SINUMERIK 802S 4-73 6FC5 597–2AA00–0BP2 (01.02)
  • Page 74 If EN = 1, Enable: EN MUL_R VD, ID, QD, MD, AC, Constant, LD Divide b = a x b Out: VD, ID, QD, MD, AC, LD b = b ÷ a Real Numbers SINUMERIK 802S 4-74 6FC5 597–2AA00–0BP2 (01.02)
  • Page 75 VW, T, C, IW, QW, MW, AC, LW Invert DWord If EN = 1, Enable: EN INV_DW VD, ID, QD, MD, AC, Constant, LD a = /a Out: VD, ID, QD, MD, AC, LD SINUMERIK 802S 4-75 6FC5 597–2AA00–0BP2 (01.02)
  • Page 76 Label marker for the Label: WORD: 0–127 jump. Conditional Return If EN = 1, exit the Enable: EN from Subroutine subroutine. Conditional End If EN = 1, END ter- Enable: EN minates the main scan. SINUMERIK 802S 4-76 6FC5 597–2AA00–0BP2 (01.02)

  • Page 77: Programm Organization

    A PLC cycle can be a multiple of the control–internal interpolation cycle (IPO cycle). The ma- chine manufacturer must set the PLC cycle according to his/her own requirements (see ma- chine data “PLC_IPO_TIME_RATIO”). The ratio IPO/ PLC of 1:1 is the fastest possible cyclic processing. SINUMERIK 802S 4-77 6FC5 597–2AA00–0BP2 (01.02)

  • Page 78: Data Organization

    The user program can be analyzed or checked for errors using the following methods: PLC Status menu (PCU) Status list menu (PCU) PLC 802 Programming Tool (see Help menu > Contents and Index, “Debugging” or docu- mentation “S7–200 Automation System”, Section “Testing and Monitoring Your Program”) SINUMERIK 802S 4-78 6FC5 597–2AA00–0BP2 (01.02)

  • Page 79: Plc Applications "Download/Upload/Copy/Compare

    Programming Tool 802 WinPCIN (binary file) PT PLC 802 Download/ Upload/ Compare Permanent 802D memory project PLC user PLC machine texts data Toolbox application WINPCIN Series start–up Fig. 4-5 PLC applications in the control system SINUMERIK 802S 4-79 6FC5 597–2AA00–0BP2 (01.02)

  • Page 80: User Interface

    Tool for his own additional information in the version display (see “View Proper- ties“). User Interface This interface includes all signals between NCK/PLC and HMI/PLC. In addition, the PLC de- codes the auxiliary function commands for straightforward further processing in the user pro- gram. SINUMERIK 802S 4-80 6FC5 597–2AA00–0BP2 (01.02)

  • Page 81: Technology Setting

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

  • Page 82: Commissioning

    Commissioning Commissioning Initializing the control system Turn on the control system. The SINUMERIK 802S 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 83 Auxiliary function value (aux. fct. no. in channel): 0...49 22550 New tool compensation for M function Setting data Default- Number Explanation Value 41110 Jog feedrate 41200 Spindle speed 42000 Start angle 42100 Dry run feedrate 5000 SINUMERIK 802S 4-83 6FC5 597–2AA00–0BP2 (01.02)

  • Page 84: Starting Up The Axes

    Starting up the axes Overview The SINUMERIK 802S 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 at pins 1–3 (PULS1, DIR1 and EN1) Y axis at pins 4–6 (PULS2, DIR2 and EN2) and for the...
  • Page 85 4: Bero with two edges 5: BERO cam Threshold value for velocity monitor- Threshold value for velocity monito- 36200 11500 ing (control parameter set no.): 0...5 ring To solve monitoring problems, set the following machine data: SINUMERIK 802S 4-85 6FC5 597–2AA00–0BP2 (01.02)
  • Page 86 The default setting of the servo gain when controlling stepper motors without measuring sy- stem is K = 2.5 (MD: 32200, limit approx. 2.5). Max. stepper motor frequency The max. permissible stepper motor frequency is 500 kHz. SINUMERIK 802S 4-86 6FC5 597–2AA00–0BP2 (01.02)
  • Page 87 Error case The error “Rotation monitoring“ is signalled (interface signal 390x5000.0) and the monitoring is switched off. The reference point is lost. To re–enable rotation monitoring, rereferencing is required. SINUMERIK 802S 4-87 6FC5 597–2AA00–0BP2 (01.02)
  • Page 88 The bent acceleration characteristic can only be parameterized axis–related. The path traver- sing behavior results from the caluclation using the axes involved. MD 32420 JOG_AND_JERK_ENABLE=0 Prerequisite for action of the bent acceleration characteristic in JOG. SINUMERIK 802S 4-88 6FC5 597–2AA00–0BP2 (01.02)
  • Page 89 : (1 - MA_ACCEL_REDUCTION_FACTOR) @ MA_MAX_AX_ACCEL Service display of the axis drive behavior SINUMERIK 802S provides two possibilities to evaluate the axis drive behavor: Servo Trace To provide axis service, the Servo Trace function is integrated in the Diagnosis menu, which can be used for graphical representation of the axis setpoint speed.
  • Page 90 Using a storage osciiloscope, this feature can be used to display the axis drive behavior when starting up individual axes. To output the analog axis setpoint, with SINUMERIK 802S, the D/A converter of the spindle is used.
  • Page 91 For example, if a load gear is active for an axis, then this transmission ratio (numerator, deno- minator) must also be entered in all of the remaining parameter sets used for thread opera- tions, in addition to the parameter set with index =0. SINUMERIK 802S 4-91 6FC5 597–2AA00–0BP2 (01.02)
  • Page 92 Then the values should be modified sensitively so that the difference path in the compensating chuck approximates to zero. Now, the same values should be displayed for axis and spindle for POSCTRL_GAIN when tapping. SINUMERIK 802S 4-92 6FC5 597–2AA00–0BP2 (01.02)
  • Page 93 With the leadscrew error compensation (LEC), the axis-specific actual position value is correc- ted by the appropriate compensation value. If the compensation values are too large, it is possible that alarm message are output (e.g. contour monitoring, speed setpoint limitation). SINUMERIK 802S 4-93 6FC5 597–2AA00–0BP2 (01.02)

  • Page 94: Starting Up The Spindle

    Starting up the spindle Overview With the SINUMERIK 802S, 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 onwards). For this reason, data have to be entered for the spindle, too; these data are described for axis start-up.
  • Page 95 The standard machine data include spindle adjustment in the 4th machine axis (SP). In the SINUMERIK 802S, the 4th machine axis (SP) is always assigned to the spindle. The spindle setpoint (+10 V analog voltage signal) is output to X3. The spindle measuring system must be connected to X4.
  • Page 96 Feedrate enable for spindle stopped 36000 Exact positioning coarse 0.04 (nur bei SPOS) 36010 Exact positioning fine (nur bei 0.01 SPOS) 36020 Delay exact positioning fine (nur bei SPOS) 36030 Zero-speed tolerance (only SPOS) SINUMERIK 802S 4-96 6FC5 597–2AA00–0BP2 (01.02)
  • Page 97 Spindle machine data are entered depending on the gear stages. Each gear stage is assigned a parameter set. The set of parameters selected corresponding to the current gear stage. 1st gear stage ! set of parameters [1] Example: SINUMERIK 802S 4-97 6FC5 597–2AA00–0BP2 (01.02)
  • Page 98 MD31070 360 @ 1 @ 1000 Internal resolution = = 180 500 @ 4 @ 1 One encoder increment amounts to 180 internal increments. One encoder increment amounts to 0.18 degrees (finest positioning possibility). SINUMERIK 802S 4-98 6FC5 597–2AA00–0BP2 (01.02)
  • Page 99 Acceleration in speed control mode [gear stage no.]: 0...5 31060 Numerator load gearbox (control parameter set no.): 0...5 31050 Denominator load gearbox (control parameter no.): 0...5 Interface signals “Switch gear“ 39032000 bit 3 “Actual gearstage” 38032000 bits 0 through 2 SINUMERIK 802S 4-99 6FC5 597–2AA00–0BP2 (01.02)
  • Page 100 “Switch gear“ 39032000 bit 3 “Reciprocation speed” 38032002 bit 5 “Reciprocation by PLC”38032002 Bit 4 “Setpoint direction CCW“ bit 7 “Setpoint direction CW” 38032002 bit 6 “Reciprocation mode” 39032002 bit 6 “Gear has been switched” 38032000 bit 3 SINUMERIK 802S 4-100 6FC5 597–2AA00–0BP2 (01.02)

  • Page 101: Completing The Start–Up

    These data can be selected from the Services menu by pressing the Data outp./da- ta...softkey. 2. Load all files of the selected technology path from the toolbox diskette into the control sy- stem via the V24 interface. 3. Carry out POWER ON. 4. Reload the saved data. SINUMERIK 802S 4-101 6FC5 597–2AA00–0BP2 (01.02)

  • Page 102: 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. 2. Reading in the series machine start-up file into the SINUMERIK 802S: – Enter the V24 interface settings as described under 1).
  • Page 103 Start-Up Commissioning 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 SINUMERIK 802S 4-103 6FC5 597–2AA00–0BP2 (01.02)
  • Page 104 Start-Up Commissioning SINUMERIK 802S 4-104 6FC5 597–2AA00–0BP2 (01.02)

  • Page 105: Software Update

    ...” appears on the display. 4. Power On ---> control system changes to the update condition. Various patterns appear on the screen. 5. After the patterns on the display of the SINUMERIK 802S have disappeared, start the transfer on the PC/PG. SINUMERIK 802S 5-105 6FC5 597–2AA00–0BP2 (01.02)
  • Page 106 7. Turn the start–up switch to position “1” ---> switch on the control system 8. Booting with default values 9. Prior to next POWER ON ---> start–up switch to 0 position. Note Reload the externally saved user standard data via V24. SINUMERIK 802S 5-106 6FC5 597–2AA00–0BP2 (01.02)

  • Page 107: Updating The System Software Incl. User Data Without Using A Pc/Pg

    2. Carry out POWER ON for slave control system –––> control system changes to the up- date condition. Various patterns appera on the screen. 3. After the patterns on the screen have disappeared, switch on the master control system on the slave control. 3 data blocks are transferred. SINUMERIK 802S 5-107 6FC5 597–2AA00–0BP2 (01.02)

  • Page 108: Update Errors

    Error when erasing the FLASH memory Check diskette Error when writing to the FLASH memory Inconsistent data (incomplete or faulty) SINUMERIK Update without programming the code FLASH 802S completed (no data received, transfer not started) UPDATE NO DATA SINUMERIK 802S 5-108 6FC5 597–2AA00–0BP2 (01.02)

  • Page 109: Technical Appendix

    Foreground language Power On Byte $MM_DISPLA Y_RESOLUTION Decimal Display resolution Power On Byte $MM_USER_CLASS_WRITE_T OA_GEO Decimal User class Write tool geometry Immediately Byte $MM_USER_CLASS_WRITE_T OA_WEAR Decimal User class Write tool wear data Immediately Byte SINUMERIK 802S 6-109 6FC5 597–2AA00–0BP2 (01.02)

  • Page 110: General Machine Data

    Modem baud rate Immediately BYTE $MM_V24_PPI_MODEM_P ARITY Decimal Modem parity Immediately BYTE 6.1.2 General machine data Number MD Name Unit Name, Miscellaneous Activated HW / function Standard value Minimum value Maximum value D type User class SINUMERIK 802S 6-110 6FC5 597–2AA00–0BP2 (01.02)

  • Page 111: Channel-Specific Machine Data

    Standard value Minimum value Maximum value D type User class 20210 CUTCOM_CORNER_LIMIT Degrees Maximum angle for compensation blocks with TRC POWER ON _always 150. DOUBLE 20700 REFP_NC_START_LOCK NC-Start disable without reference point RESET _always BOOLEAN SINUMERIK 802S 6-111 6FC5 597–2AA00–0BP2 (01.02)

  • Page 112: Axis-Specific Machine Data

    POWER ON _always BOOLEAN 30600 FIX_POINT_POS mm, de- Fixed-value positions of axis with G75 (position no.) POWER ON grees _always DOUBLE 31000 ENC_IS_LINEAR Direct measuring system (linear scale) (encoder no.) POWER ON _always BOOLEAN SINUMERIK 802S 6-112 6FC5 597–2AA00–0BP2 (01.02)
  • Page 113 Steps per stepper motor revolution POWER ON 1000 plus DWORD 31500 AXIS_NUMBER_FOR_MONITORING Display setpoint of this axis ollwert for servicing POWER ON DWORD 32000 MAX_AX_VELO mm/min, Maximum axis velocity NEW CONF rev/min _always 10000. plus DOUBLE SINUMERIK 802S 6-113 6FC5 597–2AA00–0BP2 (01.02)
  • Page 114 Axis acceleration NEW CONF rev/s^2 _always DOUBLE 32450 BACKLASH Backlash NEW CONF _always 0.000 DOUBLE 32700 ENC_COMP_ENABLE Interpolatory compensation (encoder no.): 0,1 POWER ON _always BOOLEAN 32900 DYN_MATCH_ENABLE Dynamic response adaptation NEW_CONF BYTE SINUMERIK 802S 6-114 6FC5 597–2AA00–0BP2 (01.02)
  • Page 115 Electr. cam offset of incremental measuring systems with equidistant zero marks RESET _always plus DOUBLE 34100 REFP_SET_POS mm, deg. Reference point value/irrelevant for distance-coded system: 0 ... 3 RESET _always 0., 0., 0., 0. DOUBLE SINUMERIK 802S 6-115 6FC5 597–2AA00–0BP2 (01.02)
  • Page 116 30, 30, 25, 20, 15, 10 DOUBLE 35210 GEAR_STEP_POSCTRL_ACCEL rev/s^2 Acceleration in position control mode (gear stage no.): 1...5 NEW CONF _always 30, 30, 25, 20, 15, 10 DOUBLE 35220 ACCEL_REDUCTION_SPEED_POINT Factor Speed for reduced acceleration RESET _always DOUBLE SINUMERIK 802S 6-116 6FC5 597–2AA00–0BP2 (01.02)
  • Page 117 DOUBLE 36020 POSITIONING_TIME Delay exact positioning fine NEW CONF _always plus DOUBLE 36030 STANDSTILL_POS_TOL mm, deg. Zero-speed tolerance NEW CONF _always plus DOUBLE 36040 STANDSTILL_DELAY_TIME Delay zero-speed monitoring NEW CONF _always plus DOUBLE SINUMERIK 802S 6-117 6FC5 597–2AA00–0BP2 (01.02)
  • Page 118 Duration of the deceleration ramp for error states NEW CONF _always 0.05 plus DOUBLE 36620 SERVO_DISABLE_DELAY_TIME Cutout delay servo enable NEW CONF _always plus DOUBLE 36700 DRIFT_ENABLE Automatic drift compensation NEW CONF _always BOOLEAN SINUMERIK 802S 6-118 6FC5 597–2AA00–0BP2 (01.02)

  • Page 119: Setting Data

    Progr. spindle speed limitation G26 Immediately _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 BOOLEAN SINUMERIK 802S 6-119 6FC5 597–2AA00–0BP2 (01.02)

  • Page 120: Plc User Interface Signals

    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’) SINUMERIK 802S 6-120 6FC5 597–2AA00–0BP2 (01.02)

  • Page 121: Retentive Data Area

    Technical Appendix PLC user interface signals Note 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 =”.

  • Page 122: Nck Signals

    Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 EMER- GENCY 27000000 STOP STOP active 27000001 27000002 Drive ready Ambient tempera- alarm 27000003 ture ture present present alarm SINUMERIK 802S 6-122 6FC5 597–2AA00–0BP2 (01.02)
  • Page 123 Data block Interface NCK –––––> 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 IN SINUMERIK 802S 6-123 6FC5 597–2AA00–0BP2 (01.02)

  • Page 124: Channel Signals

    + Single Block Use the softkey to select Single 31 MD for % weighting Block Type Preselection (SBL1/SBL2) + Rapid traverse override 31 positions (Gray code) with (see ”User Manual” 31 MD for % weighting SINUMERIK 802S 6-124 6FC5 597–2AA00–0BP2 (01.02)
  • Page 125 Axis 3 in WCS 32001008 Traversing keys Rapid Traversing Feed Activate handwheel traverse – override lock stop Axis 3 in WCS 32001009 Machine function continu- 1000 INC 100 INC 10 INC 1 INC 32001010 32001011 SINUMERIK 802S 6-125 6FC5 597–2AA00–0BP2 (01.02)
  • Page 126 Reset active aborted stopped waiting running NCK alarm with alarm 33000004 All axes All axes stop of ma- stop of ma- channel– chining stopped refer- specific present enced present 33000005 33000006 33000007 SINUMERIK 802S 6-126 6FC5 597–2AA00–0BP2 (01.02)
  • Page 127 1 INC 33001006 33001007 Axis 3 in WCS 33001008 Traversing command Handwheel active plus minus Axis 3 in WCS 33001009 Active machine function continu- 1000 INC 100 INC 10 INC 1 INC 33001010 33001011 SINUMERIK 802S 6-127 6FC5 597–2AA00–0BP2 (01.02)
  • Page 128 Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Modify de- coded 25000000 M func- M func- tions 0–99 25000001 Modify T funct. 1 25000002 25000003 SINUMERIK 802S 6-128 6FC5 597–2AA00–0BP2 (01.02)
  • Page 129 Transferred T functions 2500 T functions from NCK 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) SINUMERIK 802S 6-129 6FC5 597–2AA00–0BP2 (01.02)
  • Page 130 Technical Appendix PLC user interface signals 25002004 25002008 25002012 SINUMERIK 802S 6-130 6FC5 597–2AA00–0BP2 (01.02)

  • Page 131: Axis/Spindle Signals

    Servo process reset enable running Speed/ 380x0003 spindle speed limitation Traversing keys Rapid Feed Activate handwheel traverse 380x0004 Travers- stop plus minus override Spindle stop lock Machine function 380x0005 continu- 1000 380x0006 380x0007 SINUMERIK 802S 6-131 6FC5 597–2AA00–0BP2 (01.02)
  • Page 132 Bit 0 Gear is Actual gear stage 38032000 changed (spindle) Spindle feed 38032001 Invert override (spindle) M3/M4 valid Set direction of rotation 38032002 Recipro- Recipro- cating cating (spindle) speed by PLC Spindle override 38032003 (spindle) SINUMERIK 802S 6-132 6FC5 597–2AA00–0BP2 (01.02)
  • Page 133 Speed Axis/spindle 390x0001 Current controller Position stopped controller controller active active active (n < n 390x0002 390x0003 Motion command Handwheel active 390x0004 plus minus Active machine function 390x0005 continu- 1000 390x0006 390x0007 SINUMERIK 802S 6-133 6FC5 597–2AA00–0BP2 (01.02)
  • Page 134 Speed rection 39032001 of rotation within set speed speed limit (spindle) range increased limited exceeded Active spindle mode Tapping 39032002 Control Recipro- Position- without cating compen- sating (spindle) mode mode mode chuck 39032003 (spindle) SINUMERIK 802S 6-134 6FC5 597–2AA00–0BP2 (01.02)

  • Page 135: Signals From/To Mmc

    Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Dry run 17000000 feed (MMC –––> selected selected PLC) Program Feed test override 17000001 for rapid traverse (MMC ––> selected selected PLC) SINUMERIK 802S 6-135 6FC5 597–2AA00–0BP2 (01.02)
  • Page 136 19001001 (MMC –––> PLC) 19001002 (MMC –––> PLC) 19001003 Axis number for handwheel 1 (MMC –––> Machine PLC) axis 19001004 Axis number for handwheel 2 (MMC –––> Machine PLC) axis 19001005 (MMC –––> PLC) SINUMERIK 802S 6-136 6FC5 597–2AA00–0BP2 (01.02)

  • Page 137: Machine Control Panel Signals (Mcp Signals)

    Axis key Axis key Axis key Axis key Axis key Axis key 10000003 ”0” ”0” ”0” ”0” ”0” NC STOP NC RE- START Feed override 10000004 ”0” ”0” ”0” Spindle override 10000005 ”0” ”0” ”0” SINUMERIK 802S 6-137 6FC5 597–2AA00–0BP2 (01.02)

  • Page 138: Plc Machine Data

    Int value (WORD/ 2 bytes) 45000002 Int value (WORD/ 2 bytes) 45000004 Int value (WORD/ 2 bytes) 45000006 Int value (WORD/ 2 bytes) 45000060 Int value (WORD/ 2 bytes) 45000062 Int value (WORD/ 2 bytes) SINUMERIK 802S 6-138 6FC5 597–2AA00–0BP2 (01.02)
  • Page 139 Float value (REAL/ 4 bytes) 45002012 Float value (REAL/ 4 bytes) 45002016 Float value (REAL/ 4 bytes) 45002020 Float value (REAL/ 4 bytes) 45002024 Float value (REAL/ 4 bytes) 45002028 Float value (REAL/ 4 bytes) SINUMERIK 802S 6-139 6FC5 597–2AA00–0BP2 (01.02)

  • Page 140: User Alarm

    700015 700014 700013 700012 700011 700010 700009 700008 Activation of alarm no. 16000002 700023 700022 700021 700020 700019 700018 700017 700016 Activation of alarm no. 16000003 700031 700030 700029 700028 700027 700026 700025 700024 SINUMERIK 802S 6-140 6FC5 597–2AA00–0BP2 (01.02)
  • Page 141 Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Feed Read–in NC start lock disable inhibited 16002000 PLC– NOT– of all axes STOP 16002001 16002002 16002003 SINUMERIK 802S 6-141 6FC5 597–2AA00–0BP2 (01.02)

  • Page 142: Plc User Program For Turning (Upgmturn)

    2 stepper motor axes and a toolholder with 4 to 6 tools. To adapt the program to the particular machine, it can be parameterized via PLC machine data. The SINUMERIK 802S comes with this PLC user program (UPGMTURN) already integrated in the flash memory of the control system.

  • Page 143: Plc Machine Data

    Parameter menu. The PLC machine data for parameterizing the integrated user program are described in the following Tables. During start-up of the SINUMERIK 802S, the PLC machine data must be set according to the machine tool used. The parameters come into effect with the next restart (POWER ON).
  • Page 144 The UPGMTURN sets the Rotation Monitoring interface signal (390x5000.0) (see ”Technical Manual: Rotation Monitoring of Step-Switching Motor with BERO”) Machine configuration: (bit0) key assignment X axis to MCP 0 – tool behind turning center 1 – tool ahead of turning center SINUMERIK 802S 6-144 6FC5 597–2AA00–0BP2 (01.02)

  • Page 145: Input/Output Configuration

    UPGMTURN. Any signals not needed can be mas- ked via PLC machine data. Note When installting the SINUMERIK 802S on your machine, make absolutely sure that the input/ output assignment is carried out as described in the Table. SINUMERIK 802S 6-145 6FC5 597–2AA00–0BP2 (01.02)
  • Page 146 Spindle speed stage2 O1.2 Spindle speed stage3 O1.3 Spindle speed stage4 O1.4 Spindle speed 1 (for display) O1.5 Spindle speed 2 (for display) O1.6 Spindle speed 3 (for display) O1.7 Spindle speed 4 (for display) SINUMERIK 802S 6-146 6FC5 597–2AA00–0BP2 (01.02)
  • Page 147 The effect is the same as with EMERGENCY STOP - all axes and the spindle are stopped. UPGMTURN function keys on the machine control panel Fig. 6-1 Keyboard layout #1: Reduce spindle speed << SINUMERIK 802S 6-147 6FC5 597–2AA00–0BP2 (01.02)
  • Page 148 2. If a 2-stage a.c. motor is used as the spindle drive, only O1.0, O1.1 are used, and O1.2, O1.3 must be masked. O1.4, O1.5, O1.6, O1.7: Display of spindle speed stages (can be masked out if not needed). SINUMERIK 802S 6-148 6FC5 597–2AA00–0BP2 (01.02)

  • Page 149: Description Of The Logics

    Spindle<< - from machine control panel Output signals: Spindle CW (O0.0) Spindle CCW (O0.1) Spindle Brake (O0.2) Spindle speed 1 (O1.0) Spindle speed 2 (O1.1) Spindle speed 3 (O1.2) Spindle speed 4 (O1.3) UPGMTURN control SINUMERIK 802S 6-149 6FC5 597–2AA00–0BP2 (01.02)
  • Page 150 Toolholder CCW is active for the interval set in the PLC MD. In JOG mode Manual Tool Change key Toolholder CW is active as long as the key pressed down is pressed down. SINUMERIK 802S 6-150 6FC5 597–2AA00–0BP2 (01.02)
  • Page 151 (lubrication time set in the PLC-MD interval in PLC MD) In all operating modes when the Manual Lubricant control (O0.6) is active for the lubrication key has been pressed time set in the PLC-MD SINUMERIK 802S 6-151 6FC5 597–2AA00–0BP2 (01.02)
  • Page 152 Pass on program control signals from MMC to channel signals. Save handwheel selection from General Selection/MMC Status Signals as retentive data and recover last selection after Power On. Handwheel logics: Assignment handwheel – axis SINUMERIK 802S 6-152 6FC5 597–2AA00–0BP2 (01.02)

  • Page 153: Upgmturn Program Structure

    Input and Output Control Subroutine 21 (I/O level control) Subroutine 22 ALARM Control Subroutine 23 Handwheel Control Subroutine 25 X axis jog operation for declined turning machine Subroutine 26 X axis jog operation for horizontal turning machine SINUMERIK 802S 6-153 6FC5 597–2AA00–0BP2 (01.02)
  • Page 154 MB17 – MB18 – MB19 – MB20 – MW26 – Buffered brake time MB28 – Spindle speed selection (in AUTO mode) MB29 – Reserved for SHIFT instruction (MW28) MB31 – Buffer for spindle speed selection SINUMERIK 802S 6-154 6FC5 597–2AA00–0BP2 (01.02)
  • Page 155 MD44 – Toolholder position TIMER for the spindle brake time control for the turret reversal time control for the lubricating time control COUNTER C0 – for the 1 min. timer for lubricating interval control SINUMERIK 802S 6-155 6FC5 597–2AA00–0BP2 (01.02)

  • Page 156: Application Note: Unipolar Spindle Control

    Application note: Unipolar spindle control General The spindle speed setpoint of the SINUMERIK 802S is generally output in the range from –10V to +10V (S... M3 or M4). Setpoint output with only positive polarity (0V to +10V) and an additional direction signal as required for unipolar frequency converters can be realized by programming in the NC part program and the PLC user program (two additional M commands for switching the direction signal, and M3 for starting rotation).

  • Page 157: Manual Machine

    Manual Machine This description should be understood as an addition to the “Start–up Guide for the Sinumerik 802S”. Therefore, only the special features of the Sinumerik 802S with regard to the “Manual machine” user interface will be described here. Hardware and software requirements for the installation...

  • Page 158: Loading The Software

    Use the WinPCIN software to start the transfer of the file “manmach.arc” from the Toolbox CD ROM (in some cases, first the file has to be copied to the hard disk, as not every WinPCIN version can access a CD ROM drive). SINUMERIK 802S 7-158 6FC5 597–2AA00–0BP2 (01.02)
  • Page 159 (depending on the amount of data). At the completion of this process, the relevant machine data and – in some cases – also the standard PLC program must be adapted accordingly, depending on the hardware confirgura- tion. SINUMERIK 802S 7-159 6FC5 597–2AA00–0BP2 (01.02)

  • Page 160: Switching The User Interface

    ManMach_3DIO.ptp: designed as described in Section 7.8 (with I/O modules) Switching the user interface From “Manual Machine” to Siemens standard: To switch to the Siemens standard user interface, proceed as follows (always start from the 2nd extension of the basic menu): Press the key to call the password input screenform.

  • Page 161: Additional Machine Data

    Manual Machine Additional machine data In the Siemens standard user interface: Press the key to call the main selection screenform. Press the “Diagnosis” function key. Press the key to extend the function key bar. Press the “Language changeover” function key to switch to the alternative language.

  • Page 162: Operation Without Machine Control Panel (Mcp)

    Pin 5 DI 11 I 1.4 X2004 Pin 6 DI 12 I 1.5 X2004 Pin 7 DI 13 I 1.6 Spindle jogging key X2004 Pin 8 DI 14 I 1.7 X2004 Pin 9 DI 15 SINUMERIK 802S 7-162 6FC5 597–2AA00–0BP2 (01.02)
  • Page 163 Pin 9 DI 15 All inputs marked with a * possess an inverted logics, i.e. their meanings refer to the signal status “LOW”, and with all of the remaining inputs to the signal status “HIGH”. SINUMERIK 802S 7-163 6FC5 597–2AA00–0BP2 (01.02)

  • Page 164: Assignment Of The Digital Outputs:

    O 3.3 X2006 Pin 5 DO 11 O 3.4 X2006 Pin 6 DO 12 O 3.5 X2006 Pin 7 DO 13 O 3.6 X2006 Pin 8 DO 14 O 3.7 X2006 Pin 9 DO 15 SINUMERIK 802S 7-164 6FC5 597–2AA00–0BP2 (01.02)

  • Page 165: Default Assignment Of Special Data For The "Manual Machine"

    MD 12010 $MN_OVR_FACTOR_AX_SPEED[8] MD 12010 $MN_OVR_FACTOR_AX_SPEED[9] MD 12010 $MN_OVR_FACTOR_AX_SPEED[10] 0.95 MD 12010 $MN_OVR_FACTOR_AX_SPEED[11] MD 12010 $MN_OVR_FACTOR_AX_SPEED[12] 1.05 MD 12010 $MN_OVR_FACTOR_AX_SPEED[13] MD 12010 $MN_OVR_FACTOR_AX_SPEED[14] MD 12010 $MN_OVR_FACTOR_AX_SPEED[15] MD 12010 $MN_OVR_FACTOR_AX_SPEED[16] MD 12010 $MN_OVR_FACTOR_AX_SPEED[17] MD 12010 $MN_OVR_FACTOR_AX_SPEED[18] SINUMERIK 802S 7-165 6FC5 597–2AA00–0BP2 (01.02)
  • Page 166 MD 12050 $MN_OVR_FACTOR_RAPID_TRA[9] MD 12050 $MN_OVR_FACTOR_RAPID_TRA[10] 0.95 MD 12050 $MN_OVR_FACTOR_RAPID_TRA[11] MD 12050 $MN_OVR_FACTOR_RAPID_TRA[12] MD 12050 $MN_OVR_FACTOR_RAPID_TRA[13] MD 12050 $MN_OVR_FACTOR_RAPID_TRA[14] MD 12050 $MN_OVR_FACTOR_RAPID_TRA[15] MD 12050 $MN_OVR_FACTOR_RAPID_TRA[16] MD 12050 $MN_OVR_FACTOR_RAPID_TRA[17] MD 12202 $MN_PERMANENT_FEED[0] MD 12202 $MN_PERMANENT_FEED[1] 1000 SINUMERIK 802S 7-166 6FC5 597–2AA00–0BP2 (01.02)
  • Page 167 MD 35040 $MA_SPIND_ACTIVE_AFTER_RESET[AX4] MD 35160 $MA_SPIND_EXTERN_VELO_LIMIT[AX4] Setting data: MD 41110 $SN_JOG_SET_VELO MD 41120 $SN_JOG_REV_SET_VELO MD 41130 $SN_JOG_ROT_AX_SET_VELO MD 41200 $SN_JOG_SPIND_SET_VELO MD 42100 $SC_DRY_RUN_FEED MD 42440 $SC_FRAME_OFFSET_INCR_PROG MD 42442 $SC_TOOL_OFFSET_INCR_PROG MD 43300 $SA_ASSIGN_FEED_PER_REV_SOURCE[AX4] R parameters: R[4] SINUMERIK 802S 7-167 6FC5 597–2AA00–0BP2 (01.02)
  • Page 168 Manual Machine Default assignment of special data for the “Manual machine” notice SINUMERIK 802S 7-168 6FC5 597–2AA00–0BP2 (01.02)
  • Page 169 Servo gain with stepper motors-Controlling without measuring system, 4-86 Grounding, 2-38 Grounding diagram, 2-38 Updating the System Software, 5-105 Installing and Dismantling the SINUMERIK 802C, 2-15 Velocity control, Bent acceleration characteristic, Integrated user program, 6-142 4-88 SINUMERIK 802S Index-169 6FC5 597–2AA00–0BP2 (01.02)
  • Page 170 Index notice SINUMERIK 802S Index-170 6FC5 597–2AA00–0BP2 (01.02)
  • Page 171 Suggestions SIEMENS AG Corrections A&D MC BMS for Publication/Manual: Postfach 3180 SINUMERIK 802S 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.: 6FC5597-2AA00-0BP2...
  • Page 173 SINUMERIK 802S and 802C Document Structure General Documentation: Catalog SINUMERIK 802S SINUMERIK 802C Turning, Milling User Manual: Operation and Programming SINUMERIK 802S SINUMERIK 802S SINUMERIK 802C SINUMERIK 802C Turning Milling User Manual: Diagnostics Guide SINUMERIK 802S SINUMERIK 802C Turning, Milling Technical Manual: Start–Up...
  • Page 174 Siemens AG Automatisierungs- und Antriebstechnik Motion Control Systems © Siemens AG 2002 Postfach 3180, D – 91050 Erlangen Subject to change without prior notice Bundesrepublik Deutschland Order No.: 6FC5597-2AA00-0BP2 Printed in the Federal Republic of Germany www.ad.siemens.de...

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