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Siemens SINUMERIK 808D ADVANCED Commissioning Manual

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SINUMERIK
SINUMERIK 808D, SINUMERIK 808D ADVANCED
Commissioning Manual
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The
notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage
have no safety alert symbol. These notices shown below are graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of
injury to persons with a safety alert symbol may also include a warning relating to property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with
the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their
training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products
and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage,
installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any
problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed.
© Siemens AG 2017. All rights reserved
01/2017
1

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   Summary of Contents for Siemens SINUMERIK 808D ADVANCED

  • Page 1 WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems.
  • Page 2: Preface

    Readme file Third-party software - Licensing terms and copyright information My Documentation Manager (MDM) Under the following link you will find information to individually compile your documentation based on the Siemens content: www.siemens.com/mdm Standard scope This manual only describes the functionality of the standard version. Extensions or changes made by the machine tool manufacturer are documented by the machine tool manufacturer.
  • Page 3 The EC Declaration of Conformity for the EMC Directive can be found on the Internet at http://www.siemens.com/automation/service&support. Here, enter the number "67385845" as the search term or contact your local Siemens office. Product maintenance The components are subject to continuous further development within the scope of product maintenance (improvements to robustness, discontinuations of components, etc).
  • Page 4: Table Of Contents

    Residual risks of power drive systems ....................16 Carrying out of repairs ........................... 16 Preparation before commissioning .........................17 Scope of delivery........................... 17 2.1.1 SINUMERIK 808D ADVANCED control system ..................17 2.1.1.1 System overview ........................... 17 2.1.1.2 PPU and MCP ............................18 2.1.1.3...
  • Page 5: Table Of Contents

    Electrical cabinet design ........................78 3.4.1 Correct installation of fans ........................78 3.4.2 Correct installation of cooling units ......................79 Notes on the laying of cables in drag chains ..................79 System connection..............................80 System connection overview ......................... 81 Interfaces on the PPU ........................... 84 4.2.1 Control elements on the PPU ........................
  • Page 6: Table Of Contents

    System startup menu .......................... 142 Synchronizing drive data files between NC and drive (PPU161.3 and PPU160.2 only) ...... 143 Setting the password ........................... 144 Setting the date and time ........................146 Setting the user interface language ....................146 5.5.1 Changing the system language ......................146 5.5.2 Loading system languages .........................
  • Page 7: Table Of Contents

    Probe commissioning .......................... 256 Extended drive commissioning ..........................257 12.1 Configuring the additional axis ......................257 12.1.1 Configuring the additional axis for SINUMERIK 808D ADVANCED control system ......257 12.1.1.1 Configuring an additional feed axis...................... 257 12.1.1.2 Configuring an additional spindle ......................260 12.1.2...
  • Page 8: Table Of Contents

    12.2.1 Setting parameters for the Y axis ......................265 12.2.2 Measuring the tool manually (with the Y axis) ..................266 Other frequently used functions ........................... 270 13.1 Playing a slide show..........................270 13.2 Defining the service planner ........................ 272 13.3 Using the machine manufacturer's startup screen and machine logo ..........
  • Page 9: Table Of Contents

    SIMOTICS M-1PH1 main motors ......................396 15.4 Cables ..............................408 15.4.1 Drive Bus cable for the SINUMERIK 808D ADVANCED ..............408 15.4.2 Cables for the SINAMICS V70 servo system ..................408 15.4.3 Cables for the SINAMICS V60 servo system ..................409 15.5...
  • Page 10: Table Of Contents

    Cutting reserved holes in the MCP ..................... 483 Customizing pre-defined labeling strips for keys of the MCP .............. 484 Diagnostics ............................485 A.8.1 SINUMERIK 808D/SINUMERIK 808D ADVANCED alarms ..............485 A.8.2 SINAMICS V70 faults and alarms ....................... 486 A.8.2.1 General information about faults and alarms ..................486 A.8.2.2...
  • Page 11: Safety Instructions

    A.9.2.2 Operating the HMI via remote control ....................507 A.9.2.3 Saving the remote control screen as a picture ..................508 Safety instructions Fundamental safety instructions 1.1.1 General safety instructions DANGER Danger to life due to live parts and other energy sources Death or serious injury can result when live parts are touched.
  • Page 12 WARNING Danger to life due to electric shock when not grounded For missing or incorrectly implemented protective conductor connection for devices with protection class I, high voltages can be present at open, exposed parts, which when touched, can result in death or severe injury. Ground the device in compliance with the applicable regulations.
  • Page 13 WARNING Danger to life through unexpected movement of machines when using mobile wireless devices or mobile phones Using mobile wireless devices or mobile phones with a transmit power > 1 W closer than approx. 2 m to the components may cause the devices to malfunction, influence the functional safety of machines therefore putting people at risk or causing material damage.
  • Page 14 WARNING Danger to life or malfunctions of the machine as a result of incorrect or changed parameterization As a result of incorrect or changed parameterization, machines can malfunction, which in turn can lead to injuries or death. Protect the parameterization (parameter assignments) against unauthorized access. •...
  • Page 15: Handling Electrostatic Sensitive Devices (esd)

    Note Industrial security Siemens provides products and solutions with industrial security functions that support the secure operation of plants, systems, machines and networks. In order to protect plants, systems, machines and networks against cyber threats, it is necessary to implement – and continuously maintain –...
  • Page 16: Residual Risks Of Power Drive Systems

    1.1.4 Residual risks of power drive systems When assessing the machine- or system-related risk in accordance with the respective local regulations (e.g., EC Machinery Directive), the machine manufacturer or system installer must take into account the following residual risks emanating from the control and drive components of a drive system: 1.
  • Page 17: Scope Of Delivery

    2.1.1.1 System overview The SINUMERIK 808D ADVANCED control system is an economic numerical control system for milling or turning machines. The SINUMERIK 808D ADVANCED controller, coupled with the high performance SINAMICS V70 feed/spindle drive, SIMOTICS S-1FL6 feed motor, and SIMOTICS M-1PH1 main motor, is able to control up to five axes including analog/digital spindles.
  • Page 18: Ppu And Mcp

    2.1.1.2 PPU and MCP Components in the panel processing unit (PPU) package Component Quantity (pieces) Illustration Article number Horizontal Turning 6FC5370-2AT03-0AA0 (English) version 6FC5370-2AT03-0CA0 (Chinese) (PPU161.3) Milling 6FC5370-2AM03-0AA0 (English) 6FC5370-2AM03-0CA0 (Chinese) Vertical Turning 6FC5370-2BT02-0AA0 (English) version 6FC5370-2BT02-0CA0 (Chinese) (PPU160.2) Milling 6FC5370-2BM02-0AA0 (English) 6FC5370-2BM02-0CA0 (Chinese) Drive Bus termi-...
  • Page 19 Components in the machine control panel (MCP) package Component Quantity (piec- Illustration Article number Horizontal MCP, with 6FC5303-0AF35-0AA0 (English) override switches 6FC5303-0AF35-0CA0 (Chinese) Horizontal MCP, with a 6FC5303-0AF35-1CA0 (Chinese) reserved slot for the handwheel Vertical MCP, with an 6FC5303-0AF35-2AA0 (English) override switch for the 6FC5303-0AF35-2CA0 (Chinese) spindle...
  • Page 20: Drives And Motors

    2.1.1.3 Drives and motors SINAMICS V70 feed servo system Components in the SINAMICS V70 feed drive package Component Quantity Illustration Outline dimension Frame Rated output Article number (pieces) (Width × Height × size current (A) Depth, mm) SINAMICS 80 × 180 × 200 6SL3210-5DE12-4UA0 V70 feed 6SL3210-5DE13-5UA0...
  • Page 21 SINAMICS V70 feed drive rating plate Explanation of SINAMICS V70 feed drive article numbers Data position of the article number Article number ● ❑ ❑ ❑ Mains voltage: 3 AC 380 V to 480 V Motor output power 0.4 kW 0.75 kW/1 kW 1.5 kW 1.75 kW...
  • Page 22 Components in the SIMOTICS S-1FL6 motor package Component Illustration Shaft height (mm) Stall torque (Nm) Article number 1FL6042-1AF61-0❑❑1 SIMOTICS S-1FL6 motor 1FL6044-1AF61-0❑❑1 1FL6061-1AC61-0❑❑1 1FL6062-1AC61-0❑❑1 1FL6064-1AC61-0❑❑1 1FL6066-1AC61-0❑❑1 1FL6067-1AC61-0❑❑1 1FL6090-1AC61-0❑❑1 1FL6092-1AC61-0❑❑1 1FL6094-1AC61-0❑❑1 1FL6096-1AC61-0❑❑1 User documentation SIMOTICS S-1FL6 Servo Motors Installation Guide For more information about article numbers, see motor article number explanation described later in this section. SIMOTICS S-1FL6 motor rating plate ①...
  • Page 23 Stall torque 15 Nm, SH90 4 Nm, SH65 1.9 Nm, SH45; 6 Nm, SH65; 22 Nm, SH90 3.5 Nm, SH45; 8 Nm, SH65; 30 Nm, SH90 11 Nm, SH65; 40 Nm, SH90 15 Nm, SH65 High inertia variant Natural cooling Rated speed 2000 rpm 3000 rpm...
  • Page 24 SINAMICS V70 spindle servo system Components in the SINAMICS V70 spindle drive package Component Quantity Illustration Outline dimension Frame Rated output Article number (pieces) (Width × Height × size current (A) Depth, mm) SINAMICS 100 × 180 × 220 10.5 6SL3210-5DE21-1UA0 V70 spindle 140 ×...
  • Page 25 Explanation of SINAMICS V70 spindle drive article numbers Data position of the article number Article number ● ❑ ❑ ❑ Mains voltage: 3 AC 380 V to 480 V Frame size Motor output power 3.7 kW 3.7 kW 7.5 kW 11 kW 15 kW Components in the SIMOTICS M-1PH1 main motor package...
  • Page 26 ⑤ ⑫ ⑲ Encoder type and resolution Rated power Motor operating mode ⑥ ⑬ Maximum current Motor power factor ⑦ ⑭ Rated voltage Weight Explanation of the SIMOTICS M-1PH1 main motor article numbers Data position of the article number Article number ❑...
  • Page 27: Cables And Connectors

    0.25 6FC5548-0BA20-1AA3 0.35 6FC5548-0BA20-1AB0 6FC5548-0BA20-1AD0 6FC5548-0BA20-1AF0 6FC5548-0BA20-1AH0 6FC5548-0BA20-1BA0 6FC5548-0BA20-1BF0 6FC5548-0BA20-1CA0 PPU (analog spindle interface) to Siemens inverter or third-party drive (with analog input) Spindle setpoint cable 6FC5548-0BA05-1AD0 6FC5548-0BA05-1AE0 6FC5548-0BA05-1AF0 6FC5548-0BA05-1AH0 6FC5548-0BA05-1BA0 6FC5548-0BA05-1BF0 6FC5548-0BA05-1CA0 SINAMICS V70 feed drive to 1FL6 motor...
  • Page 28 Component Illustration Article number Length (m) 6FX3002-5CL11-1AD0 MOTION-CONNECT 300 power cable (V70 FSB/FSC to 1FL6) 6FX3002-5CL11-1AF0 6FX3002-5CL11-1AH0 6FX3002-5CL11-1BA0 6FX3002-5CL11-1BF0 6FX3002-5CL11-1CA0 6FX3002-5BL02-1AD0 MOTION-CONNECT 300 brake cable 6FX3002-5BL02-1AF0 6FX3002-5BL02-1AH0 6FX3002-5BL02-1BA0 6FX3002-5BL02-1BF0 6FX3002-5BL02-1CA0 6FX3002-2CT10-1AD0 MOTION-CONNECT 300 incremental encoder cable 6FX3002-2CT10-1AF0 6FX3002-2CT10-1AH0 6FX3002-2CT10-1BA0 6FX3002-2CT10-1BF0 6FX3002-2CT10-1CA0 6FX3002-2DB10-1AD0 MOTION-CONNECT 300 absolute...
  • Page 29: Options

    A 24 VDC power supply is used to supply the 808D ADVANCED and V70 servo drive. Consider the following technical specification requirements when selecting a 24 VDC power supply: ● 24 VDC supplying the SINUMERIK 808D ADVANCED: – Rated input voltage: 24 V –...
  • Page 30 Fuse/Type E combination motor controllers and circuit breakers The fuse/Type E combination motor controller or circuit breaker is used to protect the control system. SINAMICS V70 Standard fuse Type E combination motor controller (for all feed drives and spindle drive FSB) Circuit breakers (for spindle drives FSC and FSD only) Frame size...
  • Page 31 ● Mounting dimensions (mm) ● Connecting Line filters Siemens recommends you to use a filter to protect the system from high frequency noise. The table below lists all filters recommended by Siemens: SINAMICS V70 Recommended filter Drive vari- Frame Rated input...
  • Page 32 SINAMICS V70 Recommended filter Drive vari- Frame Rated input Rated current Wire gauge Degree of Article number size current (A) (AWG) protection Spindle 13.2 13 to 12 IP20 6SL3203-0BE21-2VA0 drive 16.2 11 to 10 IP20 6SL3000-0HE21-0AA0 24.5 10 to 9 IP20 37.3 7 to 6...
  • Page 33 Inside hexagon (M6 screw) SD card An SD card can be used to copy drive parameters or perform a firmware update. Siemens recommends you to use the Siemens SD card (article number: 6SL3054-4AG00-2AA0). You can also select other high quality SD cards with a maximum capacity of 2 GB from manufacturers such as KINGMAX, Kingston or SanDisk, which are not tested by Siemens.
  • Page 34: Spare Parts

    ● Config DATA – Config_DATA contains the configuration data setup. The setup will install the configuration data for the control system to your computer. The configuration data consist of the Siemens examples, and the user documents. 2.1.1.6 Spare parts Connectors for V70 drives...
  • Page 35: Sinumerik 808d Control System

    Replacement fans for 1PH1 motors Motor shaft height Fan components Illustration Article number SH100 1PH1902-0AB00-0AA0 SH132 1PH1902-0AC00-0AA0 For more information about fan replacement, see Section "Replacing the fan for the 1PH1 motor (Page 480)". 2.1.2 SINUMERIK 808D control system 2.1.2.1 System overview The SINUMERIK 808D control system is an economic numerical control system for milling or turning machines.
  • Page 36 Third-party software - Licensing terms and copyright information Components in the MCP package The components in the MCP packages for the SINUMERIK 808D ADVANCED control system and for the SINUMERIK 808D control system are the same. For more information, see Section "PPU and MCP (Page 18)".
  • Page 37 Drive rating plate Explanation of drive article numbers Data position of the article number Article number C ● ❑ ❑ ❑ Mains voltage: 3 AC 220 V to 240 V Multiplier for the output cur- rent × 0.1 × 1 Rated output current 10 A Components in the motor package...
  • Page 38 Motor rating plate Explanation of motor article numbers Data position of the article number Article number ❑ ❑ Stall torque 4.0 Nm 6.0 Nm 7.7 Nm 10.0 Nm Mechanics Plain shaft, without brake Plain shaft, with brake Shaft with key (half-key balancing), without brake Shaft with key (half-key balancing), with brake...
  • Page 39: Cables

    Article number Length (m) PPU to SINAMICS V60 drive Setpoint cable 6FC5548-0BA00-1AD0 6FC5548-0BA00-1AE0 6FC5548-0BA00-1AF0 6FC5548-0BA00-1AH0 6FC5548-0BA00-1BA0 PPU (analog spindle interface) to Siemens inverter or third-party drive (with analog input) Spindle setpoint cable 6FC5548-0BA05-1AD0 6FC5548-0BA05-1AE0 6FC5548-0BA05-1AF0 6FC5548-0BA05-1AH0 6FC5548-0BA05-1BA0 6FC5548-0BA05-1BF0 6FC5548-0BA05-1CA0 SINAMICS V60 drive to 1FL5 motor...
  • Page 40 ● Rated voltage: 24 V (-15% to +20%) Since the excellent quality of a DC power supply is critical to the stable operation of a drive system, Siemens recommends you to select a Siemens 24 VDC stabilized power supply (article number: 6EP1333-3BA00). If there is no Siemens 24 VDC power supply available, you can use a high-quality non-Siemens power supply instead.
  • Page 41: Commissioning Software Tools

    RS232 interface (available on PPU160.2 RS232 interface" in the SINUMERIK only). 808D/SINUMERIK 808D ADVANCED Pro- gramming and Operating Manual (Turning)/( Milling). Supported operating systems The software tools above support the following operating systems: ●...
  • Page 42 2. Read the welcome information and continue with "Next". 3. You can click the "Readme" button to read the indication information then close it and continue with "Next" or you can skip the reading and click "Next" directly. 4. Accept the software license agreement and continue with "Next". Commissioning Manual 01/2017...
  • Page 43: Establishing A Connection With The Software Tools

    5. Select desired languages you want to install. 6. If you have installed an earlier version of a program, un-install the program first, then start the installation again and select the required software from the list. 7. During the installation, various dialog boxes will appear. Acknowledge the dialog boxes and enter and confirm the installation information where necessary.
  • Page 44: Connecting With Plc Programming Tool

    The window below shows three configurable ports which are disabled by default: Select the desired communication port with cursor keys and press either of these keys to enable it. Press this softkey to confirm your settings. WARNING Death, severe personal injury and/or property damage due to improper firewall configuration Improper firewall configuration may cause network security risks, for example, data leakage, virus invasion, and hacker attack.
  • Page 45 Start PLC Programming Tool on your computer, and click the button in the toolbar to open the following dialog box: Double-click the access point symbol, and the following "Set PG/PC Interface" dialog box is displayed. Select "TCP/IP" with the Ethernet card name of your computer and click the "OK" button. Note: You can find the name of your Ethernet card in the local area connection status under Control Panel on your computer.
  • Page 46 Enter the IP address for the control system that displays in the above link setup dialog box in the communication settings dialog box. Double-click this symbol in the communication setting window to establish a connection to the specified IP address. Wait until the information of the connected control system is identified as follows, and then the connection is ready.
  • Page 47 Start PLC Programming Tool on your computer, and click the button in the toolbar to open the following dialog box: Double-click the access point symbol, and the following "Set PG/PC Interface" dialog box is displayed. Select "TCP/IP" with the Ethernet card name of your computer and click the "OK" button. Note: You can find the name of your Ethernet card in the local area connection status under Control Panel on your computer.
  • Page 48 Enter the IP address for the control system in the communication setting window, for exam- ple: Note that the IP address entered here must be the same as that you have set on the PPU. Double-click this symbol in the communication setting window to establish a connection to the specified IP address.
  • Page 49 Start PLC Programming Tool on your computer, and click the button in the toolbar to open the following dialog box: Alternatively, you can call this dialog box by double-clicking the icon in the project tree or choosing from the main screen menu: Double-click the access point symbol.
  • Page 50 Then the following "Set PG/PC Interface" dialog box is displayed. Check the interface being used. For RS232 communication, you must assign the interface "PLC802.PPI.1" to PLC programming tool. Double click the interface "PLC802.PPI.1" or click the "Properties" button, and the following property dialog box is displayed.
  • Page 51: Connecting With Amm

    Open the "Local connection" tab to specify the COM port to which the RS232 (V24) cable is connected. Click this button twice to close the "Set PG/PC Interface" dialog box. Double-click this icon on the right side of the communication setting window. It will take several minutes to search for a valid address.
  • Page 52 Assign the connection parameters. Note that the access level and password must be speci- fied according to those set on the HMI. Note: To avoid unauthorized access of the controller, change the Siemens default pass- words to your own ones. For more information about changing a password, see Section "Setting the password (Page 144)".
  • Page 53 Establishing a network connection Proceed as follows to establish a network connection: Connect the control system with the local network using an Ethernet cable. Select the system data operating area on the PPU. Press this key to view the extended softkeys. Enter the main screen of the service control options through the following softkey opera- tions: →...
  • Page 54: Personal Computer

    HMI. Note: To avoid unauthorized access of the controller, change the Siemens default pass- words to your own ones. For more information about changing a password, see Section "Setting the password (Page 144)".
  • Page 55: Mounting The Ppu And Mcp

    Mounting DANGER Danger to life when live parts are touched Death or serious injury can result when live parts are touched. Only work on electrical devices when you are qualified for this job. • Always observe the country-specific safety rules. •...
  • Page 56 PPU141.2 PPU160.2 Commissioning Manual 01/2017...
  • Page 57 Horizontal MCP (Example: MCP variant with override switches) * not available on the horizontal MCP with a reserved slot for the handwheel Note All horizontal MCP versions have the same outline dimensions. Vertical MCP (Example: MCP variant with an override switch for the spindle) Note All vertical MCP versions have the same outline dimensions.
  • Page 58: Cut-out Dimensions And Mounting Clearance

    3.1.2 Cut-out dimensions and mounting clearance Note Make sure there is enough space around the PPU and the MCP for tightening the screws in the control cabinet. Horizontal PPU and MCP (unit: mm) Note The illustration below uses PPU141.2 and the horizontal MCP with a reserved slot for the handwheel as an example. All horizontal PPU/MCP versions share the same requirements for cut-out dimensions and mounting clearance.
  • Page 59: Mounting The Ppu And Mcp With The Companion Clamps

    Note When mounting a horizontal PPU together with a vertical MCP or vice versa, follow the requirement for the clearance between a vertical PPU and a vertical MCP shown above. 3.1.3 Mounting the PPU and MCP with the companion clamps Use the companion clamps (8 for PPU161.3/PPU141.2, 10 for PPU160.2, 6 for the horizontal MCP, and 8 for the vertical MCP) to fix the PPU and MCP to the cabinet panel.
  • Page 60 See the mounting illustration as follows: The following figures show all mounting positions on the PPU and MCP (unit: mm): Commissioning Manual 01/2017...
  • Page 61: Mounting The Drive

    Mounting the drive Protection against the spread of fire The device may be operated only in closed housings or in control cabinets with protective covers that are closed, and when all of the protective devices are used. The installation of the device in a metal control cabinet or the protection with another equivalent measure must prevent the spread of fire and emissions outside the control cabinet.
  • Page 62: Drill Patterns And Outline Dimensions

    3.2.1.2 Drill patterns and outline dimensions All dimensional data is specified in millimeters. SINAMICS V70 feed drive FSA SINAMICS V70 feed/spindle drive FSB Commissioning Manual 01/2017...
  • Page 63 SINAMICS V70 feed/spindle drive FSC SINAMICS V70 spindle drive FSD Commissioning Manual 01/2017...
  • Page 64 3.2.1.3 Mounting the drive Note EMC instructions The SINAMICS V70 drives have been tested in accordance with the emission requirements of the category of C2 • (residential) environment for FSA/FSB/FSC, and C3 (industrial) environment for FSD. The conducted emissions and radiated emissions are in compliance with the standard of EN 55011 and reached Class A for FSA/FSB/FSC and Class A2 for FSD.
  • Page 65: Mounting The Sinamics V60 Drive

    3.2.2 Mounting the SINAMICS V60 drive 3.2.2.1 Mounting orientation and clearance Mount the drive vertically to the back plate of a shielded cabinet (non-painted) and observe the mounting clearances specified in the illustration below: 3.2.2.2 Drill patterns and outline dimensions 4 A/6 A/7 A versions Commissioning Manual 01/2017...
  • Page 66 Note After the drive installation is complete, make sure that you tighten the screw on the terminal door of the drive. Siemens does not provide the shielded power cable. Please prepare the shielded power cable by yourselves for CE certification.
  • Page 67: Mounting The Motor

    Mounting the motor NOTICE Damage to the motor If the liquid enters the motor, the motor may be damaged. During motor installation or operation, make sure that no liquid (water, oil, etc.) can penetrate into the motor. Besides, when installing the motor horizontally, make sure that the cable outlet faces downward to protect the motor from ingress of oil or water.
  • Page 68 Motor dimensions (unit: mm) Shaft height 45 mm, with the incremental encoder Stall torque 1.9 Nm 154.5 169.5 61.5 3.5 Nm 201.5 216.5 Shaft height 45 mm, with the absolute encoder Stall torque 1.9 Nm 203.5 61.5 3.5 Nm 250.5 Commissioning Manual 01/2017...
  • Page 69 Shaft height 65 mm, with the incremental encoder Stall torque 4 Nm 202.5 69.5 6 Nm 235.5 8 Nm 235.5 11 Nm 268.5 15 Nm 301.5 Shaft height 65 mm, with the absolute encoder Stall torque 4 Nm 205.5 69.5 6 Nm 238.5 8 Nm...
  • Page 70 Shaft height 90 mm, with the incremental encoder Stall torque 15 Nm 189.5 210.5 98.5 22 Nm 211.5 236.5 30 Nm 237.5 262.5 40 Nm 289.5 314.5 Shaft height 90 mm, with the absolute encoder Stall torque 15 Nm 98.5 22 Nm 30 Nm 40 Nm...
  • Page 71 3.3.1.2 Mounting the motor WARNING Personal injury and material damage Some motors, especially the 1FL609❑ are heavy. The excessive weight of the motor should be considered and any necessary assistance required for mounting should be sought. Otherwise, the motor can fall down during mounting. This can result in serious personal injury or material damage. NOTICE Magnetic interference to the absolute encoder due to the magnetic field To avoid magnetic interference to the absolute encoder, keep the servo motor with an absolute encoder at least 15 mm...
  • Page 72: Mounting The Simotics S-1fl5 Motor

    3.3.2 Mounting the SIMOTICS S-1FL5 motor 3.3.2.1 Mounting orientation and outline dimensions Mounting orientation and ingress protection requirements You can mount a motor vertically or horizontally. Make sure that no fluid (water, oil, etc.) can penetrate into the motor while installation or motor operation.
  • Page 73: Mounting The Simotics M-1ph1 Main Motor

    3.3.3 Mounting the SIMOTICS M-1PH1 main motor 3.3.3.1 Mounting orientation and outline dimensions Mounting orientation The SIMOTICS M-1PH1 main motor supports flange mounting and foot mounting as shown below: Mounting method Standard type of construction Rotated type of construction Foot mounting IM B3 IM V5 Flange mounting...
  • Page 74 Motor 1PH1103-1❑D12-❑GA0 1PH1105-1❑F12-❑GA0 1PH1105-1❑D12-❑GA0 Shaft height 100 mm: foot mounting (unit: mm) Motor 1PH1101-1❑F10-❑GA0 1PH1103-1❑F10-❑GA0 1PH1103-1❑D10-❑GA0 1PH1105-1❑F10-❑GA0 1PH1105-1❑D10-❑GA0 Commissioning Manual 01/2017...
  • Page 75 Shaft height 132 mm: flange mounting (unit: mm) Motor 1PH1131-1❑F12-❑GA0 1PH1131-1❑D12-❑GA0 1PH1133-1❑F12-❑GA0 1PH1133-1❑D12-❑GA0 Shaft height 132 mm: foot mounting (unit: mm) Motor 1PH1131-1❑F10-❑GA0 251.8 1PH1131-1❑D10-❑GA0 241.8 1PH1133-1❑F10-❑GA0 301.8 Commissioning Manual 01/2017...
  • Page 76 Motor 1PH1133-1❑D10-❑GA0 301.8 3.3.3.2 Mounting the motor In order to ensure smooth, vibration-free motor operation, a stable foundation design is required, the motor must be precisely aligned, and the components that are to be mounted on the shaft extension must be correctly balanced. The following mounting instructions must be carefully observed: ●...
  • Page 77 Flange mounting Mount the motor through a mounting steel flange. Use four M12 screws with a tightening torque of 84 Nm. Foot mounting Remove the anchor plates with a wrench, fix the motor to the mounting plate with screws, and then reinstall the anchor plates.
  • Page 78: Electrical Cabinet Design

    Electrical cabinet design It may be preferable to always use cooling units as this allows the cabinet to be sealed which is the best option for stopping the entry of contaminants. Within the cabinets it may also be necessary to install fans to ensure the air is circulated and prevent "hot spots"...
  • Page 79: Correct Installation Of Cooling Units

    3.4.2 Correct installation of cooling units The cool air should be directed to the bottom of the drive. The natural convection will draw the air through the drives. The cool air from the cooling unit should not be directed straight onto/into the drives. It should be allowed to mix with the warmer air already in the cabinet, which can minimize the risk of condensation forming.
  • Page 80: System Connection

    Observing minimum bending radius requirements Cables must be able to move without constraint, especially in the bending radii of the chain. • Observe the specified minimum bending radii. • Fixing cables Make sure that cables in the drag chain are unattached and movable. •...
  • Page 81: System Connection Overview

    SINUMERIK 808D ADVANCED control system The following configuration shows a typical example of the SINUMERIK 808D ADVANCED T controller (PPU161.3) with the SINAMICS V70 servo system, controlling two feed axes and one digital spindle. Note that the devices with an asterisk ("*") are not included in the scope of delivery.
  • Page 82 CAUTION Personal injury and damage to property from inadequate protection Inadequate protection may cause minor personal injury or damage to property. Using a copper protective earth conductor with a cross section of 10 mm to connect the PE terminal of V70 to the •...
  • Page 83 For detailed information on cable shield connection, refer to Section "Connecting the drive with the SINUMERIK 808D control system (Page 132)". CAUTION Personal injury and damage to property from inadequate protection Inadequate protection may cause minor personal injury or damage to property. Using a copper protective earth conductor with a cross section of 10 mm to connect the PE terminal of V60 to the •...
  • Page 84: Interfaces On The Ppu

    Note that the PE/PEN busbar in the cabinet must connect to the ground through a grounding cable with a cross section ≥ 10 mm as illustrated below: Interfaces on the PPU 4.2.1 Control elements on the PPU ① ⑧ Status indicators Alarm cancellation key Cancels alarms and messages that are marked with the symbol on this key...
  • Page 85: Status Leds On The Ppu

    ④ ⑪ Horizontal and vertical keys Cursor keys Call the corresponding vertical/horizontal softkeys on the screen ⑤ ⑫ Return key Modifier keys for use in key combinations Returns to the next higher-level menu ⑥ ⑬ Menu extension key Edit control keys Calls the extended menu items ⑦...
  • Page 86: Ppu Interface Overview

    4.2.3 PPU interface overview NOTICE Failing to connect PE terminals to the ground will cause safety problems The PE terminals on the PPU must be connected to the ground; otherwise, it will cause safety problems and unexpected system conditions. Legend Interface Description PPU back...
  • Page 87: Connecting The Ppu

    4.2.4 Connecting the PPU For the SINUMERIK 808D ADVANCED T control system, connecting to the third and fourth drives is optional and depends upon whether you activate the software option "additional axis". For the SINUMERIK ADVANCED M control system, connecting to the fourth drive is optional and depends upon whether you activate the software option "additional axis".
  • Page 88: Digital Input Interfaces - X100, X101, X102

    4.2.5 Digital input interfaces - X100, X101, X102 Pin assignment Type Mini Combicon 10-pin Cable Max. length: 10 m Max. cross-section: 1.5 mm (when using one cable per connection) Inputs Permissible level (including ripple) High level: 20.4 V to 28.8 V Low level: -3 V to +5 V X100 (DIN0) X101 (DIN1)
  • Page 89: Digital Output Interfaces - X200, X201

    4.2.6 Digital output interfaces - X200, X201 Pin assignment Type Mini Combicon 10-pin Cable Max. length: 10 m Max. cross-section: 1.5 mm (when using one cable per connection) Outputs Rated digital output current: 250 mA X200 (DOUT0) X201 (DOUT1) Remarks +24 V +24 V +24 V input (20.4 V to...
  • Page 90: Fast Input/output - X21

    4.2.7 Fast input/output - X21 Pin assignment Type Mini Combicon 10-pin Cable Shielded cable Max. length: 10 m Max. cross-section: 1.5 mm (when use one cable per connection) Inputs Permissible level (including ripple) High level: 20.4 V to 28.8 V Low level: -3 V to +5 V Illustration Signal...
  • Page 91: Distributed I/o - X301, X302

    NC readiness is in the form of a relay contact (NO). It must be integrated into an EMERGENCY STOP circuit. The connection diagram is shown as follows: When the NC is not ready, the contact is open; otherwise, the contact is closed. Connection cables End sleeves are necessary if you use two cables per connection.
  • Page 92 Signal Comment Signal Comment I4.5 Digital input Q3.2 Digital output I4.6 Digital input Q3.3 Digital output I4.7 Digital input Q3.4 Digital output I5.0 Digital input Q3.5 Digital output I5.1 Digital input Q3.6 Digital output I5.2 Digital input Q3.7 Digital output I5.3 Digital input +24 V...
  • Page 93 Connecting DANGER The 24 V power supply must be protective extra-low voltage in accordance with EN60204-1, Section 6.4, PELV (with M ground). CAUTION Be sure not to connect the pin 2 of X301/302 to ground; otherwise, the CNC controller of the power supply could be damaged! Note The 24 V output of X301/302 pin 2 comes from pins 47 to 50.
  • Page 94 Digital outputs The diagram below shows you how to connect the connector pins of the digital outputs at interface X301 (example). You can connect connector X302 in the same way. To supply the digital outputs, you must connect an external 24 VDC power supply (X301, X302: pins 47, 48, 49, 50). You must also connect the reference ground of the external power supply to X301, X302: Pin 1 (M).
  • Page 95: Handwheel Inputs - X10

    4.2.9 Handwheel inputs - X10 Pin assignment Type Mini Combicon 10-pin Cable Less than 3 m Illustration Signal Comment Track A, handwheel 1 Negative Track A, handwheel 1 Track B, handwheel 1 Negative Track B, handwheel 1 +5 V +5 V power output Ground Track A, handwheel 2 Negative Track A, handwheel 2...
  • Page 96: Drive Bus Interface - X126 (ppu161.3 And Ppu160.2 Only)

    4.2.10 Drive Bus interface - X126 (PPU161.3 and PPU160.2 only) Pin assignment Type IEEE 1394, 6-pin, female Cable Type: Drive Bus cable Max. length: 20 m Illustration Signal Comment PB_N Negative RxD/TxD of Drive Bus +5 V Positive RxD/TxD of Drive Bus NULL Not connected PB_RTS...
  • Page 97: Pulse Drive Interfaces - X51, X52, X53 (ppu141.2 Only)

    Filter A line filter (rated current: 16 A, degree of protection: IP20) is required so that the system can pass the CE certification (radiated emission test or conducted emission test). The article number of Siemens recommended filter is 6SN1111-0AA01- 1BA1.
  • Page 98 X52 (the Y axis) and X53 (the Z axis) in the same way. If necessary, you can also serially connect an emergency stop switch between the 65 enable signal and the 24 V signal. The connected motors are Siemens 1FL5 servo motors. Commissioning Manual...
  • Page 99: Analog Spindle Interface - X54, Spindle Encoder Interface - X60

    4.2.12 Analog spindle interface - X54, spindle encoder interface - X60 Interface X54 is for connecting the PPU to the inverter or servo spindle drive. Interface X60 is for connecting the PPU to the spindle encoder. Pin assignment - X54 Type Sub-D, 9-pin, female Cable...
  • Page 100 Connecting Connecting the inverter or servo spindle drive (unipolar) 10 V analog voltage 0 V signal Use twisted pair cables for signals A/A_N, B/B_N, Z/Z_N, and +5 V/M. See the following table for the enable status of pin 8 and pin 9 when the spindle rotates clockwise or counter-clockwise respectively for unipolar 1 and unipolar 2.
  • Page 101: Ethernet Interface - X130

    Connecting the inverter or servo spindle drive (bipolar) +/- 10 V analog voltage 0 V signal Use twisted pair cables for signals A/A_N, B/B_N, Z/Z_N, and +5 V/M. 4.2.13 Ethernet interface - X130 Pin assignment Type 8-pin RJ45 socket Cable Type: Ethernet cable Illustration Signal...
  • Page 102: Power Supply Interface - X1

    4.2.14 Power supply interface - X1 The PPU uses a 24 VDC power supply. You can connect the 24 VDC power supply via interface X1. For more information about the 24 VDC power supply, see Section "External 24 VDC power supply (Page 29)". Pin assignment Type Combicon 4-pin...
  • Page 103: Usb Interface - X30

    Illustration Signal name Signal type Comment Note Use only shielded twisted pair cables; You must connect the cable shield to the metal or metalized connector casing of the control system. 4.2.16 USB interface - X30 There is a USB interface on the back of the PPU. This USB interface is used for connecting with the MCP. Pin assignment Type USB socket, type A Combicon 4-pin...
  • Page 104: Usb Interface On The Front Cover Of The Ppu

    Maintenance door ② System CF card ③ Slot for the CF card Note The system CF card is accessible only by the Siemens service personnel. Do not touch or remove the system CF card under any conditions. Commissioning Manual 01/2017...
  • Page 105: Interfaces On The Mcp

    Interfaces on the MCP 4.3.1 Control elements on the MCP Horizontal MCP ● Variant with override switches ● Variant with a reserved slot for the handwheel Vertical MCP Variant with an override switch for the spindle Variant with a reserved slot for the handwheel •...
  • Page 106: Mcp Interface Overview

    ① ⑨ Reserved hole for emergency stop button Spindle control keys ② ⑩ Tool number display Keys for program start, stop, and reset Displays the number of the currently active tool ③ ⑪ Operating mode selection area Pre-defined labeling strips for keys of the MCP ④...
  • Page 107: Interfaces On The Sinamics V70 Servo System

    Interfaces on the SINAMICS V70 servo system The SINAMICS V70 servo system, consisting of the SINAMICS V70 servo drive and SIMOTICS servo motor, is an economical closed-loop servo drive solution for machine tool applications. It is designed for use with the SINUMERIK 808D ADVANCED controller.
  • Page 108: Interface Overview

    4.4.2 Interface overview 4.4.2.1 SINAMICS V70 feed servo system SINAMICS V70 FSA (with detachable terminal blocks) Commissioning Manual 01/2017...
  • Page 109 SINAMICS V70 FSB/FSC (with screw terminals) Note For more information about the connection of the X10 and X11, see Section "Drive Bus interface - X126 (PPU161.3 and PPU160.2 only) (Page 96)". SIMOTICS S-1FL6 motor Commissioning Manual 01/2017...
  • Page 110: Sinamics V70 Spindle Servo System

    4.4.2.2 SINAMICS V70 spindle servo system SINAMICS V70 FSB/FSC (with screw terminals) Commissioning Manual 01/2017...
  • Page 111 SINAMICS V70 FSD * The protective covers are available for the PE, line supply, motor power, external braking resistor, and DC link terminals. Before connecting these terminals, remove the plastic covers first with a slot/cross head screw driver. Note For more information about the connection of the X10 and X11, see Section "Drive Bus interface - X126 (PPU161.3 and PPU160.2 only) (Page 96)".
  • Page 112: Main Circuit Interfaces

    4.4.3 Main circuit interfaces Main circuit interfaces (drive side) Type Illustration Signal Description Line supply FSA: FSB/FSC: FSD: Line phase L1 For connecting to the 3 phase input interface 380 VAC to 480 VAC power Line phase L2 supply Line phase L3 PE (protective earth, for FSD only) V70 feed drive: for con-...
  • Page 113 Main circuit interface (motor side) Type Illustration Signal Description Power connector 1FL6 motor: 1PH1 motor: 1: U Phase U 2: V Phase V 3: W Phase W 4: PE Protective earth Wiring Main circuit wiring for SINAMICS V70 FSA/FSB/FSC A short-circuit stick is available only for the SINAMICS V70 feed drive. Commissioning Manual 01/2017...
  • Page 114: Connecting The 24 V Power Supply/sto - X6

    You can install a Type E combination motor controller or circuit breaker to protect the system. For more information about the article numbers of Siemens recommended filters and Type E combination motor controllers/circuit breakers, see Sections "Line filters (Page 31)" and "Fuse/Type E combination motor controllers and circuit breakers (Page 30)".
  • Page 115 For more information about the 24 VDC power supply, see Section "External 24 VDC power supply (Page 29)". Wiring WARNING Material damages and personal injuries by the drop of a hanging axis When the servo system is used as a hanging axis, the axis will drop if the positive and negative poles of the 24 V power supply are connected inversely.
  • Page 116 If you use the STO function with the SINUMERIK 808D ADVANCED control system, perform the wiring as illustrated below: STO function In conjunction with a machine function or in the event of a fault, the "Safe Torque Off" (STO) function is used to safely disconnect the torque-generating energy feed to the motor.
  • Page 117: Connecting The Holding Brake - X7 (feed Drive Only)

    Low level High level Unsafe Alarm occurs and servo motor coasts down. For more information about the STO function, see the SINUMERIK 808D/SINUMERIK 808D ADVANCED Function Manual. 4.4.5 Connecting the holding brake - X7 (feed drive only) Holding brake (drive side)
  • Page 118: Connecting The Encoder - X9

    4.4.6 Connecting the encoder - X9 The SINAMICS V70 drive supports the following types of encoders: V70 feed drive Incremental encoder, TTL 2500 ppr Absolute encoder, 20-bit + 12-bit multi-turn V70 spindle drive Incremental encoder, TTL 2500 ppr NOTICE Cable shielding The encoder cable must be shielded to meet the EMC requirements.
  • Page 119 10-pin connector for the incremental encoder, used for the 1PH1 motor: Illustration Pin No. Incremental encoder Signal Description Incremental encoder: P_Supply Power supply 5 V Power supply 0 V Phase A+ Phase A- Phase B+ Phase B- Phase R+ Phase R- Shielding Grounding n.c.
  • Page 120 SINAMICS V70 spindle servo system Grounding the shielded encoder cable To ensure better EMC complicance, you are recommended to strip the encoder cable and connect the cable shield to earth to enhance the grounding effect: Commissioning Manual 01/2017...
  • Page 121: Connecting An External Braking Resistor

    4.4.7 Connecting an external braking resistor The SINAMICS V70 feed drive has been designed with an internal braking resistor to absorb regenerative energy from the motor. When the internal braking resistor cannot meet the braking requirements, you can connect an external braking resistor.
  • Page 122 Status indicators Description 7-segment LED display description RDY/JOG Continuously lit Drive ready Depends on current menu operation Continuously lit Drive error Alarm code Continuously lit Continuously lit Initialization Displays "8.8.8.8.8.8." Flashing at 1 Hz JOG mode Displays "J-Run" 4.5.2 Main circuit interfaces Main circuit interfaces - drive side Interface Signal name...
  • Page 123: Setpoint Interface - X5

    4.5.5 Setpoint interface - X5 Interface Signal Description I/O type Remark name +PULS Pulse input setpoint + Use the differential drive mode here to transmit the pulse data correctly. -PULS Pulse input setpoint - +DIR Direction of motor setpoint -DIR Direction of motor setpoint +ENA Pulse enable +...
  • Page 124: Connecting The Encoder - X7

    4.5.7 Connecting the encoder - X7 Interface Signal name Description Incremental encoder A phase signal Incremental encoder B phase signal Incremental encoder Z phase signal Incremental encoder U phase signal Incremental encoder V phase signal Incremental encoder W phase signal Not connected (reserved) 5/6/17/18...
  • Page 125: Signal Sequence Example

    4.5.8 Signal sequence example Power-on sequence Power-off sequence Commissioning Manual 01/2017...
  • Page 126: Connecting The Sinamics V70 Servo System

    Connecting the SINAMICS V70 servo system 4.6.1 Connecting the drive to motor CAUTION Risk of injury due to improper cable connection When connecting cables to the drive interfaces with detachable connectors, fixing the cables directly to the connectors which have not been fitted onto the drive may result in finger injury. First fit the connectors onto the drive, and then fix the cables to the connectors.
  • Page 127 An external braking resistor can be used to absorb excess regenerative energy in the DC link when the capacity of the internal braking resistor is insufficient. Note that no internal braking resistor is available in the V70 spindle drive, and you must select an external braking resistor as specified in Section "Braking resistors (Page 30)".
  • Page 128 WARNING Personal injury and damage to property from improper connections Improper connections have high risks of electrical shock and short circuit, which will jeopardize personal safety and equipment. The drive must be directly connected with the motor. It is not permissible to connect a capacitor, inductor or •...
  • Page 129 DANGER Death or severe personal injury from electrical shock The earth leakage current for the drive can be greater than AC 3.5 mA, which may cause death or severe personal injury due to electrical shock. A fixed earth connection is required to eliminate the dangerous leakage current. In addition, the minimum size of the protective earth conductor shall comply with the local safety regulations for high leakage current equipment.
  • Page 130: Connecting The Terminal Boxes Of The 1ph1 Motor

    4.6.2 Connecting the terminal boxes of the 1PH1 motor CAUTION Use of appropriate connecting cables To reduce the risk of cable overheating and even overburning, appropriate cables are necessary for connecting the terminal box. Carefully observe the current which the motor draws for your particular application. Adequately dimension the connecting cables according to IEC 60204-1 or IEC 60364-5-52.
  • Page 131 Loosen the screws on the top of both the motor terminal box and the fan terminal box to remove the terminal box covers. Remove the three screw plugs on one side of the two terminal boxes. Loosen the cable gland pre-assembled on the encoder cable. Pass the encoder cable through the first threaded hole in the motor terminal box housing.
  • Page 132: Connecting The Sinamics V60 Servo System

    Replace the covers of the terminal boxes, and then tighten the screws respectively for the motor terminal box (4 x M5: max. 4.7 Nm) and the fan terminal box (4 x M4: max. 2.4 Nm). NOTICE Damage to the motor After you finish connecting the terminal boxes and start the motor, make sure the fan rotates in the correct direction as indicated by the arrows marked on the fan;...
  • Page 133 WARNING Personal injury and damage to property from improper connections Improper connections have high risks of electrical shock and short circuit, which will jeopardize personal safety and equipment. The drive must be directly connected with the motor. It is not permissible to connect a capacitor, inductor or •...
  • Page 134: Connecting The Drive With The Simatic Plc

    4.7.2 Connecting the drive with the SIMATIC PLC Drive Cable Connection between the SIMATIC PLC and the SINAMICS V60 drive Commissioning Manual 01/2017...
  • Page 135: Switching On The Drive

    Note When using the drive together with the SIMATIC PLC, you are recommended to use a standard 24 V DC power supply for the SIMATIC PLC and use a Siemens cable (6ES7298-2DS23-0XA0) to connect the two ones. Note It is recommended to use signal 65 from X6 interface for emergency stop. Therefore, this signal is not used for the communication between the SIMATIC PLC and the SINAMICS V60 drive.
  • Page 136: Switching On The Sinamics V70 Drive

    – = 2: Motor holding brake always open – = 3: Motor holding brake under sequence control by the SINUMERIK 808D ADVANCED Note For a motor with an absolute encoder, the operating principle of the holding brake is configured automatically.
  • Page 137 NOTICE Shortening the service life of motor brake The motor brake is used for holding the load in position only. Frequent emergency stops with the motor brake can shorten its service life. Unless absolutely necessary, do not apply the motor brake as an emergency stop or deceleration mechanism. 5.
  • Page 138: Configuring Drive Bus Addresses

    7. Run the connected motor with the Jog function and check the Jog speed or Jog torque. Note When you run a servo motor with an incremental encoder in JOG mode, the servo motor makes a short buzzing sound indicating that it is identifying the magnetic pole position of the rotor. 4.8.1.2 Configuring Drive Bus addresses To configure the Drive Bus addresses on the SINAMICS V70 drive, set parameter p0918 (default = 10) with the drive BOP...
  • Page 139: Switching On The Sinamics V60 Drive

    Note Do not switch on the 24 VDC power supply for the SINUMERIK 808D ADVANCED before you finish setting the Drive Bus addresses for all connected drives. After setting a proper address, you must save the parameter and then restart the drive to apply your setting.
  • Page 140 4. Set the Jog speed P46 with a value between 0 and the rated speed of the connected motor. If you want to use the default Jog speed (200 rpm), skip this step. 5. Go to "Func" main menu, and select "Store" to save the parameter settings into the memory. 6.
  • Page 141: Switching On The Control System

    Switching on the control system Preparation before switch-on Make sure the following before switching on the control system: ● You have finished the mechanical installation of the whole system based on the information included in Chapter "Mounting (Page 55)". ● You have completed the wiring of the whole system according to the information included in Chapter "System connection (Page 80)"...
  • Page 142: Initial System Setup

    Initial system setup System startup menu The control system carries out a normal startup by default after power-on. When necessary, you can press this key on the PPU once the message "Press the SELECT key to enter set-up menu" appears while the system boots to select other startup options via the following menu: ①...
  • Page 143: Synchronizing Drive Data Files Between Nc And Drive (ppu161.3 And Ppu160.2 Only)

    Synchronizing drive data files between NC and drive (PPU161.3 and PPU160.2 only) Note This function is available on the PPU161.3 and PPU160.2 only. The NC always compares its data backup with the drive data upon every startup. ● If no data backup files can be found, the NC creates a new backup file automatically with the following message displaying on the screen: ●...
  • Page 144: Setting The Password

    The control system delivered from Siemens is set by default to the lowest protection level 7 (without password). If the password is no longer known, you must reinitialize the control system with the default machine/drive data. All passwords are then reset to default passwords for this software release.
  • Page 145 The following password operations are also available in this operating area: Changes the default password of the control system Note To avoid unauthorized access to the controller, you must change the Siemens default passwords to your own ones. Deletes the current password Note Clear the password before the machine is delivered;...
  • Page 146: Setting The Date And Time

    Setting the date and time By default, the system date and time remain the factory settings. You can proceed through the following operating sequence to change the date and time as required. Operating sequence Select the system data operating area. Open the date and time setting window through the following softkey operations: →...
  • Page 147: Loading System Languages

    5.5.2 Loading system languages You can load a new system language or update an existing language on the control system. Siemens will provide each language in the form of an archive file. The file name format is as follows: 808_lang_<LANG>_04070400yyy.arc Where, <LANG>...
  • Page 148: Activating The Optional Functions

    Press this softkey to confirm the archive information, and then the following message appears: Press this softkey to confirm and start loading the archive. The control system restarts to com- plete restoring the system language archive. Power off/on the control system to activate the loaded language. Then you can find the new system language and select it through the following operations: →...
  • Page 149 Note: The last option (see below) in this window indicates the variant information and the licensing status of your control system, for example: In case of any problems with the licensing status of your control system, contact Siemens service personnel.
  • Page 150: Plc Programming Conventions

    Press this softkey to restart the NCK, so that the licensed options are activated. Note To use the CNC lock function, further activation operations are required after the CNC lock option is activated. For more information, see Section "CNC lock function (Page 289)". Commissioning the PLC PLC programming conventions Program organization...
  • Page 151: Operation Symbols Of Plc Programming Languages

    Operation symbols of PLC programming languages Operand identifier Address identifier Description Range Data DB1000 to DB7999 DB9900 to DB9906 Timers T0 to T15 (100 ms) T16 to T63 (10 ms) Counters C0 to C63 Image of digital inputs I0.0 to I8.7 Image of digital outputs Q0.0 to Q5.7 Bit memory...
  • Page 152 Structure of the DB-range address Access Example Description DB3801.DBX1000.7 Bit 7 of the byte with offset 0 in subrange 1 for axis 2, user range 38 Byte DB3801.DBB0 Byte with offset 0 in subrange 0 for axis, user range 38 Word DB4500.DBW2 Work with offset 2 in subrange 0, range 0, user range 45...
  • Page 153 Special bit memory SM bit definition (read-only) Inputs (I) and outputs (Q) Form ● Bit: I0.0, I4.6; Q2.1, Q1.7 ● Byte: IB4, IB12; QB3, QB7 ● Word: IW2, IW4; QW0, QW6 ● Double word: ID2, ID8; QD0, QD4 Accumulators (AC) A maximum of four accumulators are available: ●...
  • Page 154 Flag registers (M) Form ● Bit: M0.1, M124.5 ● Byte: MB21, MB12 ● Word: MW22, MW106 ● Double word: MD4, MD28 Counters (C) Form Condition of counter: C3 and C25 - represent the comparison result of the counter and preset value Type ●...
  • Page 155 DINT/DWORD/REAL Note All of the empty fields in the user interface are reserved for Siemens and may neither be written to nor be evaluated. Fields designated with "0" always have the value "logical 0". If there is no data format information, you can read or write to all the specified data formats.
  • Page 156: Plc Sample Applications

    PLC sample applications 6.4.1 PLC sample application (turning) This sample application is applicable to machines with the following configurations: ● Two axes: axes X and Z, with a hardware limit switch respectively in the positive and negative directions of each axis ●...
  • Page 157 Signal Description Remark I4.2 Handheld unit: axis Z selected Valid at a high level I4.3 Handheld unit: fourth axis selected Reserved I4.4 Handheld unit: increment X1 Valid at a high level I4.5 Handheld unit: increment X10 Valid at a high level I4.6 Handheld unit: increment X100 Valid at a high level...
  • Page 158: Plc Sample Application (milling)

    Call Conditions Subroutine Name Description Each scan (SM0.0) PI_SERVICE (SBR46) ASUP (Asynchronous Subroutine Pro- gram) Each scan (SM0.0) ServPlan (SBR48) Maintenance plan example: first task Each scan (SM0.0) Turret1_HED_T (SBR51) HALL effect device turret control Each scan (SM0.0) Tail_stock_T (SBR55) Tailstock control Each scan (SM0.0) Lock_unlock_T (SBR56)
  • Page 159 Signal Description Remark I3.2 Reserved I3.3 Reserved I3.4 Reserved I3.5 Reserved I3.6 Reserved I3.7 Reserved I4.0 Handheld unit: axis X selected Valid at a high level I4.1 Handheld unit: axis Y selected Valid at a high level I4.2 Handheld unit: axis Z selected Valid at a high level I4.3 Handheld unit: fourth axis selected...
  • Page 160: Plc Machine Data

    Call Conditions Subroutine Name Description Each scan (SM0.0) MCP_NCK (SBR37) Transferring MCP and HMI signals to the NCK interface Each scan (SM0.0) HANDWHL (SBR39) Selecting a hand wheel through the interface signal DB1900.DBB1xxx Each scan (SM0.0) AXIS_CTL (SBR40) Coordinate enabling control, hardware limit, etc.
  • Page 161 MD14512 PLC interface ad- Function dress Machine data - 14512[18] Bit 2 DB4500.DBX1018.2 Automatic lubrication at power-on Bit 4 DB4500.DBX1018.4 External signal for spindle stop Bit 5 DB4500.DBX1018.5 Fixed spindle direction Bit 6 DB4500.DBX1018.6 The hardware limit is independent from a PLC program Bit 7 DB4500.DBX1018.7 Each feed axis has a hardware limit switch (activated when Bit 6 = 0) 14512[19] Bit 1 DB4500.DBX1019.1 Function of spindle braking Bit 2 DB4500.DBX1019.2 Password clearing by power-on (0: delete the password;...
  • Page 162: Plc Subroutine Library

    USER_DATA_FLOAT MD14514 PLC interface Unit Range Function address Machine data - Float 14514[0] DB4500.DBD2000 - -3.40e38 to 3.40e38 Tool magazine: spindle poisoning angle 14514[1] DB4500.DBD2004 - -3.40e38 to 3.40e38 Tool magazine: preparation position of Z axis for tool change 14514[2] DB4500.DBD2008 - -3.40e38 to 3.40e38 Tool magazine: tool change position of Z axis...
  • Page 163 Constant definition Constant input Symbol Address Constant "1" SM0.0 Constant "2" ZERO M251.0 Zero output definition Data type Symbol Address NULL_b M255.7 byte NULL_B M255 word NULL_W M254 double-word NULL_DW M252 Structure of symbol tables All the addresses in the PLC subroutine library are programmed with symbols. All the signals of interfaces are named by symbols and arranged in different symbol tables.
  • Page 164 Structure of subroutines PLC sample subroutines offer PLC functions for the machine tool. Subroutine No. Name Description 0 to 19 Reserved AUX_MCP Auxiliary function AUX_LAMP Working lamp control, called in the subroutine "AUX_MCP" AUX_SAFE_DOOR Safety door control, called in the subroutine "AUX_MCP" for a milling application AUX_CHIP Chip conveyor control, called in the subroutine "AUX_MCP"...
  • Page 165: Conventions For The Symbols Used In The Subroutines

    Turning and milling functions PLC sample subroutines for turning functions: For turning only SBR 51 Turret1_HED_T HED turret control SBR 52 Turret2_BIN_T Bi-direction turret (binary coded) SBR 53 Turret3_CODE_T Bi-direction turret (coded by turret supplier) SBR 55 Tail_stock_T Tailstock control SBR 56 Lock_unlock_T Chuck control...
  • Page 166: Subroutine 20 - Aux_mcp (machine Auxiliary Functions)

    6.6.3 Subroutine 20 - AUX_MCP (machine auxiliary functions) Purpose Subroutine 20 is used to call the Auxiliary function Subroutines AUX_LAMP, AUX_CHIP, and AUX_SAFETY_DOOR. Local variable definition None Relevant PLC machine data None Example for calling subroutine 20 6.6.4 Subroutine 21 - AUX_LAMP (working lamp) Purpose Subroutine 21 is used to control working lamp and can be called in AUX_MCP.
  • Page 167: Subroutine 22 - Aux_safe_door (safety Door)

    6.6.5 Subroutine 22 - AUX_SAFE_DOOR (safety door) Purpose Subroutine 22 is used to control the safety door and can be called in AUX_MCP. If you open the safety door, that means you activate the spindle speed limiting function, with the speed limit being specified in MD35160.
  • Page 168: Subroutine 23 - Aux_chip (chip Conveyor)

    6.6.6 Subroutine 23 - AUX_CHIP (chip conveyor) Purpose Subroutine 23 is used to control the chip conveyor and can be called in AUX_MCP. At first-time pressing of the "Chip Forward" key the output "ChipFwd" is high; at second-time pressing of the "Chip Forward" key the output "ChipFwd" becomes low.
  • Page 169: Subroutine 24 - Aux_3color_lamp

    6.6.7 Subroutine 24 - AUX_3Color_LAMP Purpose Subroutine 24 is used to control the three-color lamp function and can be called in AUX_MCP. Local variable definition Inputs Variable Type Description nodef BYTE Reserved Outputs Variable Type Description BOOL Alarm lamp: red Yellow BOOL Alarm lamp: yellow...
  • Page 170: Subroutine 32 - Plc_ini (plc Initialization)

    6.6.9 Subroutine 32 - PLC_INI (PLC initialization) Purpose Subroutine 32 is executed at the first PLC cycle (SM0.1). This subroutine sets NCK interface signals according to the machine settings defined by PLC machine data. In this subroutine, the following interface signals are set: ●...
  • Page 171: Subroutine 37 - Mcp_nck (mcp And Hmi Signal Processing)

    Local variable definition Inputs Variable Type Description nodef BYTE Reserved E_KEY BOOL Emergency stop key (NC) HWL_ON BOOL Any one of the hardware limit switches is active (NO) SpStop BOOL Spindle stopped (NO) NO: Normally Open NC: Normally Closed This input can come from signal OVlmt of subroutine 40, and triggers emergency stop when the hardware limit appears. Before the drive system disables the control enable signal, the PLC detects the spindle stop signal from NCK to ensure that the spindle has stopped.
  • Page 172 Variable Type Description ConHw_Key BOOL Define the Contour Handwheel at the MCP key SimConHw_Key BOOL Define the simulation contour handwheel at the MCP key NegDir- BOOL Define the negative direction for simulation contour handwheel at the MCP key SimConHw_Key INCvar_Key BOOL Define the INCvar at the MCP key When the Auxiliary Function Lock function is active, all the outputs caused by auxiliary functions (like T, M, or S code)
  • Page 173: Subroutine 38 - Mcp_tool_nr (display Tool Number On The Mcp)

    6.6.12 Subroutine 38 - MCP_Tool_Nr (display tool number on the MCP) Purpose Subroutine 38 is used to display active tool number (< 100) with the 7-segment LED on the MCP, and should be called in subroutine MCP_NCK. For a tool number ≥ 100, it displays "FF". Local variable definition None Assigned global variables...
  • Page 174: Subroutine 40 - Axis_ctl (controlling The Spindle And Axes)

    6.6.14 Subroutine 40 - AXIS_CTL (controlling the spindle and axes) Purpose Subroutine 40 is used to control the drive pulse enable (DB380x.DBX4001.7) and controller enable (DB380x.DBX2.1), monitoring the hardware limits and the reference cam signals, and controlling the enable signal for the spindle according to a spindle command (for example, SPINDLE CW, SPINDLE CCW, M03, M04, SPOS, etc.).
  • Page 175 Note When using the hardware solution, you must take below information into consideration: You must assign the axes one by one; for example, X axis, Z axis, spindle or X axis, Y axis, Z axis, spindle. You must not • assign the axes like X axis, Y axis, spindle, Z axis.
  • Page 176: Subroutine 41 - Mini_hhu (handwheel On Hand-held Unit)

    Example for calling subroutine 40 6.6.15 Subroutine 41 - MINI_HHU (handwheel on hand-held unit) Purpose Subroutine 41 is used to support the customer's handheld units. With a handheld unit, you can assign the handwheels to X axis, Y axis and Z axis, and select incremental override X1, X10, X100 at the same time. You can then use the handwheels to control the movements of your machine.
  • Page 177: Subroutine 42 - Spindle (spindle Control)

    Relevant PLC machine data Value Description 14512 [17].3 Choose to use a hand-held unit Choose to use a handwheel 14512 [21].1 Set I0.0 to I2.7/Q0.0 to Q1.7 as the standard I/O wiring in the default PLC Set I6.0 to I8.7/Q4.0 to Q5.7 as the standard I/O wiring in the default PLC Example for calling subroutine 41 6.6.16 Subroutine 42 - SPINDLE (spindle control)
  • Page 178: Subroutine 43 - Meas_jog (measurement In Jog Mode)

    Assigned global variables SP_B_CMD BOOL Spindle braking command TIMER Spindle braking timer Relevant PLC machine data Type Description 14510 [13] BOOL Spindle braking duration (unit: 0.1 s) 14512 [19].1 BOOL Selection of spindle braking function (1: enabled; 0: forbidden) Example for calling subroutine 42 6.6.17 Subroutine 43 - MEAS_JOG (measurement in JOG mode) Purpose...
  • Page 179: Subroutine 44 - Cooling (cooling Control)

    Relevant PLC machine data None Example for calling subroutine 43 6.6.18 Subroutine 44 - COOLING (cooling control) Purpose Subroutine 44 is used to start/stop cooling using the buttons on the MCP in JOG mode, or to start (using the auxiliary function M07/M08 in the part program) or to stop (using the M09 in the part program) cooling in AUTO/MDA mode.
  • Page 180: Subroutine 45 - Lubricat (control Of Lubricate)

    Example for calling subroutine 44 6.6.19 Subroutine 45 - LUBRICAT (control of lubricate) Purpose Subroutine 45 is used to control the lubrication according to specific time interval and duration (independent of the distance that the axis has travelled). Meanwhile, a manual button is available to start the lubrication, and you can configure that the lubrication starts automatically each time that the machine is powered up.
  • Page 181: Subroutine 46 - Pi_service

    Example for calling subroutine 45 6.6.20 Subroutine 46 - PI_SERVICE Purpose Subroutine 46 is for realizing functions like ASUP (Asynchronous Subroutine Program) and deleting a password. ● ASUP function The ASUP function means the execution of PLCASUP1.SPF or PLCASUP2.SPF called by the PLC. The two ASUPs cannot be simultaneously executed, and the PLCASUP1.SPF has a higher priority over the PLCASUP2.SPF.
  • Page 182 Local variable definition Inputs Name Type Description nodef BYTE Reserved ASUP1_trigger BOOL Start ASUP1 (rise edge) ASUP2_trigger BOOL Start ASUP2 (rise edge) Outputs Name Type Description ASUP1Run BOOL Indicates whether ASUP1 is running ASUP2Run BOOL Indicates whether ASUP2 is running Err1 BOOL ASUP1 error...
  • Page 183: Subroutine 47 - Plc_select_pp (plc Selects A Subroutine)

    47 you can assign DB1700.DBB1000 to the "Program index" to select the corresponding part program. Local variable definition Inputs Name Type Description PP_num BOOL Part program number, 1-100: user; 101-200: OEM; 201-255: Siemens Outputs Name Type Description Finish BOOL PLC selects a part program successfully...
  • Page 184: Subroutine 49 - Gearchg1_auto (automatic Spindle Gear Change)

    Outputs Name Type Description HintMsg0 BOOL Hint message for 1st service plan Alarm0 BOOL Alarm message for 1st service plan Assigned global variables ServPlan_msg0 BOOL Notification message of the first service plan ServPlan_alm0 BOOL Alarm message for 1st service plan Relevant PLC machine data None Example for calling subroutine 48...
  • Page 185: Subroutine 50 - Gearchg2_virtual (virtual Spindle Gear Change)

    Assigned global variables HGom BOOL M248.0 Signal indication of high gear stage output LGom BOOL M248.1 Signal indication of low gear stage output HGcmd BOOL M248.2 High gear level command LGcmd BOOL M248.3 Low gear level command SPhold BOOL M248.4 Spindle stops and ready for oscillation Dstill BOOL...
  • Page 186: Subroutine 51 - Turret1_hed_t (turret With Hall Effect Device Position Sensor)

    Relevant PLC machine data None Example for calling subroutine 50 6.6.25 Subroutine 51 - Turret1_HED_T (turret with Hall effect device position sensor) Purpose Subroutine 51 is used to control the turret with a Hall effect device positioning sensor, and the turret motor is controlled by the PLC.
  • Page 187 Timing diagram Local variable definition Inputs Name Type Description Tmax WORD Number of tool on the turret, only 4, 6 are permitted C_time WORD Turret clamping delay time (unit: 0.1 s) M_time WORD Monitor time for searching for a tool (unit: 0.1s) T_polar BOOL Tool position signal: NC/NO...
  • Page 188: Subroutine 52 - Turret2_bin_t (turret With Binary Coding Function)

    T_CLAMP Clamping timer for turret 1 Relevant PLC machine data Unit Description 14510 [20] Max. tool number (4 or 6) 14510 [21] 0.1 s Turret clamping time 14510 [22] 0.1 s Monitoring time for tool searching 14512 [17].0 Activating the turret function of a turning machine 14512 [21].1 Switch of the I/O interface (0: set I0.0 to I2.7/Q0.0 to Q1.7 as the standard I/O wiring in the default PLC;...
  • Page 189 Name Type Description Tm_Chg WORD Tool change monitor time (unit: 0.1s) BOOL T code A BOOL T code B BOOL T code C BOOL T code D Parity BOOL Parity bit Strobe BOOL Tool on position signal OVload BOOL Turret motor overload (NC) P_Indx BOOL Turret pre-indexing sensor...
  • Page 190: Subroutine 53 - Turret3_code_t (tool Change Control For Turret With Coding Function)

    Example for calling subroutine 52 6.6.27 Subroutine 53 - Turret3_CODE_T (tool change control for turret with coding function) Purpose Subroutine 53 is used to control the turret with coded tool positions and function of adjacent tool change. The difference between the subroutine 52 and the subroutine 53 is that the subroutine 52 uses binary tool position codes while the subroutine 53 uses tool position codes made according to a specific common turret.
  • Page 191 Tool position Tool position code A Tool position code B Tool position code C Tool position code D Outputs Name Type Description T_UNCLAMP BOOL Turret release T_CLAMP BOOL Turret clamping T_CW BOOL Turret CW rotation T_CCW BOOL Turret CCW rotation T_LED BOOL Status display during the tool change...
  • Page 192: Subroutine 54 - Turret2_3_tooldir (tool Change Direction)

    6.6.28 Subroutine 54 - Turret2_3_ToolDir (tool change direction) Purpose Subroutine 54 is used to find out the direction of searching for an adjacent tool and the pre-indexing position (this is, the previous position of the desired tool in the direction of an adjacent tool). To find out the direction, you need to know the max. tool number of the turret and the programmed tool number.
  • Page 193: Subroutine 55 - Tail_stock_t (tailstock Control Program For Turning Machines)

    6.6.29 Subroutine 55 - Tail_stock_T (Tailstock control program for turning machines) Purpose Subroutine 55 is used to control forward or backward movement of the tailstock on a turning machine. In JOG mode, press the "Tailstock" key to move the tailstock forward or backward. Pressing "Tailstock" moves the tailstock forward, and one more pressing moves the tailstock backward.
  • Page 194: Subroutine 56 - Lock_unlock_t (clamping Control For Turning Machine)

    6.6.30 Subroutine 56 - Lock_unlock_T (clamping control for turning machine) Purpose Subroutine 56 is used to control the clamping or release for the chuck for a turning machine. In JOG mode, press the "External/Inside clamping" key to select either external clamping or inside clamping, and press "Clamp"...
  • Page 195: Subroutine 58 (mm_main)

    To use subroutine 58, you must have licensed the optional Manual Machine Plus function for the SINUMERIK 808D (Turning) or SINUMERIK 808D ADVANCED T (Turning). The subroutines 46, 58 and 59 must be used together. This subroutine is used to control the manual machine function after the manual machine interface is activated.
  • Page 196 Assigned global variables Byte Signal Byte 7 Byte 6 Byte 5 Byte 4 Byte 3 Byte 2 Byte 1 Byte 0 MB170 HMI<->MM Request MM HMI MM HMI for MM enabled started startup MB171 HMI<->MM MB172 HMI<->MM MB173 HMI<->MM MB174 HMI<->MM Cone angle Cone Cone...
  • Page 197: Subroutine 59 (mm_mcp_808d)

    To use subroutine 59, you must have licensed the optional Manual Machine Plus function for the SINUMERIK 808D (Turning) or SINUMERIK 808D ADVANCED T (Turning). The subroutines 46, 58 and 59 must be used together. Normally, the spindle will be stopped after you press the NC reset key. However, when a manual machine is started, you do not want to stop the spindle after pressing the NC reset key.
  • Page 198: Subroutine 60 - Disk_mgz_m (disk-style Tool Magazine Used For Milling)

    Assigned global variables None Relevant PLC machine data Unit Range Description MD14512[19].7 1: to enable the manual machine function 0: to disable the manual machine function Example for calling subroutine 59 6.6.33 Subroutine 60 - Disk_MGZ_M (disk-style tool magazine used for milling) Purpose You can use subroutine 60 to control the disk-style tool magazine on a milling machine.
  • Page 199 Name Type Description nodef BYTE Reserved MgzCnt BOOL Magazine counter MgzRef_k BOOL Set current tool no. to 1 in magazine via this key MgzCW_k BOOL Magazine CW rotate key MgzCCW_k BOOL Magazine CCW rotate key MgzSp_k BOOL Magazine enter spindle position key MgzOrg_k BOOL Magazine original position key...
  • Page 200: Subroutine 62 - Trg_key_or

    Example for calling subroutine 60 6.6.34 Subroutine 62 - Trg_key_OR Purpose Subroutine 62 is used for the override control via trigger user keys in the following MCP variants: ● Vertical MCP with a reserved slot for the handwheel: for spindle override control only ●...
  • Page 201 Name Type Description F_100_Key BOOL Feedrate override 100% key RapidOvr_1 BOOL Rapid override 1% RapidOvr_25 BOOL Rapid override 25% RapidOvr_50 BOOL Rapid override 50% RapidOvr_100 BOOL Rapid override 100% Noder1 BYTE Reserved Outputs Name Type Description LED1_S BOOL Lights, spindle override < 100%; flashing, 50% LED2_S BOOL Lights, spindle override 100%...
  • Page 202 Example for calling subroutine 62 Subroutine 62 for milling application Set the following PLC machine data for different MCP variants: MCP variants PLC machine data setting Description 14512 [20].0 Vertical MCP with a reserved slot for Spindle override controlled by trigger user keys the handwheel Horizontal/vertical MCP with two Spindle override and feedrate override controlled by...
  • Page 203 Outputs Name Type Description LED1_S BOOL Lights, spindle override < 100%; flashing, 50% LED2_S BOOL Lights, spindle override 100% LED3_S BOOL Lights, spindle override 105-115%; flashing, 120% Assigned global variables SP_OV_Switch BYTE MB202 Spindle override switch buffer USB_MCP_SP_OV BYTE MB209 USB MCP signal: spindle override Relevant PLC machine data Unit...
  • Page 204: Subroutine 63 - Toggles

    6.6.35 Subroutine 63 - TOGGLES Purpose Two types of switches are provided in subroutine 63, more specifically, a hold switch for switching a circuit on (press) and off (press again), and a delay switch for switching on a circuit and automatically switching it off after a certain time period. A total of six hold switches and two delay switches are available in this subroutine, with the delay duration being configurable.
  • Page 205: Plc Programming Tool

    PLC Programming Tool 6.7.1 Overview of PLC Programming Tool In order to edit the PLC program, use PLC Programming Tool V3.2.4 or higher. By using PLC Programming Tool, you can perform the following operations: ● Creating the PLC program ● Editing the PLC program ●...
  • Page 206: Renaming The Default Program

    6.7.2 Renaming the default program PLC Programming Tool contains a default PLC program. You can give this program a new name by performing the following operations: Start the software by double-clicking the icon on your desktop. Click the button in the toolbar or select from the main window menu as follows to select and open the default PLC program from the Toolbox: Select the following menu command to save this file under a new name to a desired folder so that the default program will not be overwritten:...
  • Page 207: Changing The Display Language

    6.7.3 Changing the display language You can select the languages to be installed when installing the software. Then you can change the display language as desired in PLC Programming Tool. Perform the following steps to change the display language. Choose from the main menu as follows: In the appeared dialog box, select the desired display language, and then click this button to confirm.
  • Page 208: Selecting A Target System

    6.7.4 Selecting a target system In PLC Programming Tool, you can select the PLC type as preset. In the instruction tree, the instructions that cannot be used for the target system are marked with a red × (for example, After the PLC type is preset, an error check of the program takes place when the program is written. Operating sequence Start PLC Programming Tool on your PC.
  • Page 209: Downloading/uploading/comparing Plc Applications

    Note that the compatibility mode must not be activated to use the CNC lock function of the control system. Click this button to confirm and close the dialog box. 6.7.5 Downloading/uploading/comparing PLC applications You can save, copy, or overwrite a PLC project on the control system by using the following: ●...
  • Page 210 Select from the main screen menu as follows or click the toolbar button to start the download: Click this button on the download dialog box to proceed directly. You can also select the following checkbox for data blocks to include the actual values of the data blocks, and then click this button.
  • Page 211 Note If you have chosen to download when the PLC is in the stop mode, you can place the PLC at the run mode again with PLC Programming Tool (click the button To download a PLC project with a USB memory stick or the network drive, proceed as follows: Open the desired PLC project in PLC Programming Tool.
  • Page 212 Uploading a PLC project from the control system You can back up a PLC project from the permanent memory of the control system using PLC Programming Tool, a USB memory stick, or the network drive. To upload a PLC project using PLC Programming Tool, proceed as follows: Establish the communication between the control system and PLC Programming Tool.
  • Page 213 Click this button and you can view the upload results. To upload a PLC project using a USB memory stick or the network drive, proceed as follows: To upload the PLC project via USB, insert the USB memory stick into the USB interface •...
  • Page 214 Select from the main screen menu of PLC Programming Tool as follows or click the toolbar button to create a new and empty PLC project: Import the .pte file from the USB memory stick or the network drive by selecting from the main screen menu as follows: Click this button or double-click the .pte file in the following dialog box.
  • Page 215 After successfully importing the PLC project, you can view the import results. Comparing the PLC projects You can compare the project opened in PLC Programming Tool with that stored on the control system by proceeding through the following steps: Select from the main screen menu as follows: You can also select the checkbox for data blocks to include the actual values of the data blocks.
  • Page 216 Click this button and the comparing begins. Wait for a few seconds, and then you can view the compare results. Version display The transferred PLC application will be active in the working memory of the control after the system is started up. Then you can view the detailed information about the currently active PLC application in the version display through the following softkey operations: →...
  • Page 217: Compiling And Monitoring Programs

    6.7.6 Compiling and monitoring programs Compiling PLC programs You can check for syntax errors after editing or modifying a PLC project using the compile function of PLC Programming Tool. Proceed through the following steps to compile the PLC programs: Open an existing or a new PLC project in PLC Programming Tool, and save it after editing. Start compiling by clicking the toolbar button or choosing from the main screen menu as follows:...
  • Page 218: Plc Alarms

    The blue color in the program editing window indicates the online connection status. PLC alarms Diagnosing of the machine is important. Complete diagnosis of the external electrics can help users understand the cause and location of breakdown immediately. User alarms in the PLC subroutines System provides users with 128 PLC user alarms.
  • Page 219 Alarm No. Interface Address Alarm Description From SBR 700010 DB1600.DBX1.2 Handheld unit active SBR41: MINI_HHU 700011 DB1600.DBX1.3 Tool clamping timeout SBR53: Turret3_CODE_T 700012 DB1600.DBX1.4 Spindle being braked SBR42: SPINDLE 700013 DB1600.DBX1.5 Operation not allowed: chuck unclamped SBR56: Lock_unlock_T 700014 DB1600.DBX1.6 Gear stage change timeout SBR49: GearChg1_Auto 700015...
  • Page 220: Alarm Cancel/reset And Reaction

    6.8.1 Alarm cancel/reset and reaction Conditions of alarm cancel/reset After the cancel of an alarm, you need to press one of the following two keys to clear the alarm finally. Then the alarm displayed will disappear by itself. Alarm reaction There are the following two ways for alarm reaction.
  • Page 221 Select the HMI data folder and press this key to open it. Move the cursor to the folder highlighted as follows and press this key to open it. Press this softkey to copy the PLC alarm text file in the desired language. Press this softkey to enter the USB storage directory.
  • Page 222 Connect the USB stick with your computer, find the PLC alarm text file copied from the NC, and open it with the WordPad. Edit the alarm text as desired and then save and close the file. Insert the USB stick into the USB interface on the front panel of the PPU. Enter the USB storage directory through the following operations: →...
  • Page 223: Plc Diagnostics

    Confirm your entry with this softkey or the following key: PLC diagnostics A PLC user program consists to a large degree of logical operations to realize safety functions and to support process sequences. These logical operations include the linking of various contacts and relays. As a rule, the failure of a single contact or relay results in a failure of the whole system/installation.
  • Page 224 Two windows are available for you to view the program. You can use this softkey to select the main program or a specific subroutine that you desire to dis- play. Displaying the PLC properties You can use this softkey to check the following PLC properties: Operating status •...
  • Page 225 The following softkey operations are possible in this window: Use these softkeys to increase or decrease the bit of the operand. Pressing this softkey deletes all the entered operands. You can press this softkey to change the status of the PLC interface or I/O signals by entering "0" (low) or "1"...
  • Page 226: Handwheel Assignment

    Displaying cross references All operands used in the PLC project are displayed in the list of cross references. This list indicates in which networks an input, output, flag etc. is used. You can press this softkey to display the list of cross references. The operands are displayed ac- cording to the absolute address by default, for example: The following softkey operations are possible in this window: Press this softkey to switch between the absolute and symbolic representation of the components.
  • Page 227: Commissioning The Prototype Machine

    Commissioning the prototype machine Overview on commissioning and operation wizards The control system has two commissioning wizards and one operation wizard. ● The commissioning wizards require a manufacturer access level. They are designed to help you commission the basic machine tool functions on the prototype machine and series machines. ●...
  • Page 228 Commissioning status You can check the commissioning status via the status symbols from the main screens of the commissioning wizards. Status symbol Meaning Completed task Current task Partially completed task group Uncompleted task Commissioning diagram The diagram below shows the general commissioning procedure for the NC. ①...
  • Page 229: Commissioning The Plc

    Commissioning the PLC 7.2.1 Setting PLC related parameters Use either of the following softkeys on the main screen of prototype commissioning wizard to enter the window for setting the PLC related parameters: Softkey functions ① ③ Activates the parameter changes. Note that the con- Cancels the last change to the parameter trol system restarts to accept the new values.
  • Page 230: Downloading And Commissioning Plc Programs

    7.2.2 Downloading and commissioning PLC programs Note If you use the default PLC programs, you can skip this step and move to the next step. To realize your own PLC functions, you can upload the default PLC program to your computer and edit it. With PLC Programming Tool installed on your computer, you can download customized PLC programs into the permanent memory of the control system.
  • Page 231: Checking I/o Address Assignment

    7.2.3 Checking I/O address assignment You must check the I/O address assignment in this step to ensure correct wiring. Softkey functions ① ④ Selects the digital inputs Shows the I/O addresses of the last byte ② ⑤ Selects the digital outputs Returns to the previous step ③...
  • Page 232: Configuring The Drives (ppu161.3 And Ppu160.2 Only)

    You can also use these two softkeys to import/export the PLC user alarm texts from/to the following directories: After you finish editing the alarm texts, press this softkey to move on to the next step. Note You can edit the alarm text either in English or in simplified Chinese. Editing in Chinese is only possible when the system language is simplified Chinese.
  • Page 233 Configuring the feed axes Note This procedure is required only for a feed axis driven by a motor with an incremental encoder. If the selected axis is configured with a motor with an absolute encoder, the motor ID is identified automatically. Select a feed axis using the cursor keys in the drive list window.
  • Page 234 Press this softkey to confirm your settings and go to the motor configuration window. Use the cursor keys to select the right motor ID according to the motor rating plate. Press this softkey to confirm your selection and return to the drive list window. ●...
  • Page 235: Setting Basic Parameters

    Setting basic parameters 7.4.1 Setting feed axis parameters You can set the axis-specific machine data for each feed axis under this commissioning step. Softkey functions ① ⑤ Selects the next axis Cancels the last change to the parameter ② ⑥ Selects the previous axis Returns to the last step ③...
  • Page 236: Commissioning The Referencing Function

    7.4.2 Commissioning the referencing function Principles for referencing ● Zero mark is away from the reference cam (MD34050: REFP_SEARCH_MARKER_REVERS = 0) ● Zero mark is above the reference point (MD34050: REFP_SEARCH_MARKER_REVERS = 1) Velocity for searching for the reference cam (MD34020: REFP_VELO_SEARCH_CAM) Velocity for searching for the zero mark (MD34040: REFP_VELO_SEARCH_MARKER) Position velocity (MD34070: REFP_VELO_POS) Shift of the reference point (MD34080: REFP_MOVE_DIST + MD34090: REFP_MOVE_DIST_CORR)
  • Page 237 ② ⑥ Selects the previous axis Returns to the last step ③ ⑦ Activates the modified values Proceeds to the next step ④ Resets the value of the selected parameter to default Approaching the reference point To approach the reference point, you must follow the instructions on the screen: ●...
  • Page 238: Setting Spindle Parameters

    Name Unit Range Description 34093[0] REFP_CAM_MARKER_DIST Distance between the reference cam and the first zero mark 34100[0] REFP_SET_POS Reference point position for incremental system 34200[0] ENC_REFP_MODE 0 to 8 Referencing mode 34210[0] ENC_REFP_STATE 0 to 3 Adjustment status of the absolute encoder 34220[0] ENC_ABS_TURNS_MODULO 1 to 100000...
  • Page 239: Creating Series Archives

    Name Unit Range Description 32100 AX_MOTION_DIR -1 to 1 Traversing direction (not control direction) -1: Direction reversal • 0, 1: No direction reversal • 32110[0] ENC_FEEDBACK_POL -1 to 1 Sign actual value (control direction) 35010 GEAR_STEP_CHANGE_ENABLE - Parameterize gear stage change 35100 SPIND_VELO_LIMIT Maximum spindle speed...
  • Page 240: Setting Compensation Data

    Press this softkey to open the window for saving the archive file. You must select a directory in this window. The default name of the data archive is "arc_product.arc". You can use your desired name for it. The file name extension ".arc" must be entered. Note that you can press this key on the PPU to toggle between the file name input field and the directory selection area.
  • Page 241: Setting Backlash Compensation Data

    ③ ⑦ Activates the modified values Proceeds to the next step ④ Resets the value of the selected parameter to default Setting parameters Name Unit Range Description 36100 POS_LIMIT_MINUS - software limit switch 36110 POS_LIMIT_PLUS + software limit switch 7.6.2 Setting backlash compensation data In the case of axes/spindle with indirect measuring systems, mechanical backlash results in corruption of the traverse path, causing an axis, for example, to travel too much or too little by the amount of the backlash when the direction of movement...
  • Page 242: Setting Leadscrew Error Compensation Data

    Note: This softkey is active only if the optional bidirectional leadscrew error compensation has been activated with the license key. For more information about this software option, refer to the SINUMERIK 808D/SINUMERIK 808D ADVANCED Function Manual. Use these softkeys to select an axis.
  • Page 243: Tuning Drive Performance (ppu161.3 And Ppu160.2 Only)

    The tuning process is sophisticated and generally performed by experienced engineers. The SINUMERIK 808D ADVANCED control system is integrated with the advanced function of auto drive tuning, which provides facilities to tune the drive performance for the feed axes or the digital spindle by automatically modifying the control loop parameters.
  • Page 244 Operating sequence Switch to "JOG" mode. Note that the drive tuning can be performed in "JOG" mode only. You can select all axes (including the spindle) or an individual axis/spindle for tuning. Press this softkey to enter the window for selecting the tuning options. Use this key to select a desired tuning objective.
  • Page 245 Use the axis traversing keys to move the axis/axes to be tuned to safe positions. Press this softkey and the drive tuning starts automatically. Press this key on the MCP to start the measurement when the following message appears during the tuning process: After the drive tuning finishes successfully, the tuning results appear on the screen in the form of a parameter list, for example: You can check the tuning results of other tuned axis/axes (if any) with these softkeys.
  • Page 246: Creating Prototype Machine Commissioning Archives

    Parameter adjustment after drive tuning To ensure correct machining results of all interpolating axes, it is necessary to adjust the following axis-specific parameters after the drive tuning: ● Position controller gain – For the feed axes, set MD32200[0] to the minimum gain value of all interpolating axes. –...
  • Page 247 To create a start-up archive for the prototype machine, proceed as follows: Specify the properties of the archive as required: Press this softkey to open the window for saving the archive file. You must select a directory in this window. The default name of the data archive is "arc_startup.arc". You can use your desired name for it.
  • Page 248: Commissioning The Turret/magazine

    Commissioning the turret/magazine PLC subroutines for tool change The following PLC subroutines are provided for the turret/magazine control on a turning or milling machine. Subroutine Name Description See also SBR 51 Turret1_HED_T HED turret control for turning ma- Subroutine 51 - Turret1_HED_T (turret with Hall chine effect device position sensor) (Page 186) SBR 52...
  • Page 249: Series Machine Commissioning

    G153 G01 Z0 F2000 ;G153 suppresses work offset including base frame, non-modal MSG("Start to change tool *** New tool number: T"<<$P_TOOLP) GOTOF _END _NO: MSG("No action *** Reason: programmed tool num- ber=spindle tool number") _END: ;>>> End of the standard cycle <<< Calling a tool change cycle with "T"...
  • Page 250: Setting Software Limit Switch Data

    Press this softkey to open the dialog for loading the series archive. Enter the backup directory and select the desired archive file. Press this softkey to confirm your selection, and the archive information displays on the screen. Check the archive information and press this softkey to start loading the series commission- ing archive.
  • Page 251: Network Functions

    Network functions 10.1 Network configuration Ethernet connections You can establish a network connection between the control system and a computer via the Ethernet interface X130. The following Ethernet connections are possible: ● Direct connection: connecting the control system directly to a computer ●...
  • Page 252: Configuring The Network Drive

    Note: make sure this vertical softkey is not selected. Configure the network as required in the following window: You can configure the DHCP with this key. Note: if you select "No" for DHCP, you must enter the IP address (which must belong to the same network as that of your PC) and subnet mask manually.
  • Page 253 Move the cursor to the following input fields: ① : Enter the user name of your Windows account ② : Enter the logon password (case sensitive) of your Windows account ③ : Enter the IP address of the server and the share name of the shared directory on your computer.
  • Page 254: Configuring The Firewall

    10.3 Configuring the firewall Configuring the firewall Secure access and communication is achieved through the security function of the integrated firewall. You can open the window for firewall configuration through the following operations: → → → → Configurable ports are listed in the following window: The ports are disabled by default and can be enabled when necessary.
  • Page 255: Measurement Functions

    Measurement functions 11.1 Fast inputs and outputs The fast input/output interface (X21) provides 3 digital inputs and 1 digital output: Illustration Signal Variable Description $A_IN[1] Fast input with address DB2900.DBX0.0, for connection to probe 1 $A_IN[2] Fast input with address DB2900.DBX0.1, for connection to probe 2 $A_IN[3] Fast input with address DB2900.DBX0.2...
  • Page 256: Probe Commissioning

    11.2 Probe commissioning The first probe is connected to pin 4 (DI1) and the second probe to pin 5 (DI2) of interface X21. For the probe, use an external voltage (24 V) whose reference potential should be connected to X21 pin 10 Setting machine data The following machine data should be checked and adjusted if necessary: ●...
  • Page 257: Extended Drive Commissioning

    Configuring the additional axis for SINUMERIK 808D ADVANCED control system The SINUMERIK 808D ADVANCED control system with PPU161.3/PPU160.2 supports up to two additional axes for the turning variant and one for the milling variant. You can configure an additional axis as a feed axis or a spindle. Before the configuration, you must first activate the option for additional axis (Page 148).
  • Page 258 Prerequisite: The Drive Bus address is properly set (p0918) via the drive BOP. The following steps are also applicable to configuring the standard axes/spindle, if necessary. Select the system data operating area. Press this horizontal softkey to open the window for drive configuration. Press this softkey and the control system starts to identify the drives and motors connected.
  • Page 259 Tuning the drive performance The control system provides facilities to tune the drive performance for the additional axis by automatically modifying the control loop parameters. The tuning is performed based on frequency response measurements of the dynamic response of the machine. Note that an axis must be referenced first before the drive tuning. The following steps are also applicable to tuning the standard feed axes, if necessary.
  • Page 260: Configuring An Additional Spindle

    After the drive tuning finishes successfully, the tuning results appear on the screen in the form of a parameter list. You can check the tuning results of the additional axis with these softkeys. Press this softkey to save the tuning results and write the modified parameters into the drives.
  • Page 261 Press this key to return to the higher-level menu. Open the basic machine data window. Use this softkey or the cursor keys to search for "14512 USER_DATA_HEX[20]". Select "Bit2" and "Bit3" by using this key and the cursor keys. Press this softkey to confirm your input. Press this softkey to activate the value changes.
  • Page 262 Use this softkey or the cursor keys to search for the following machine data and assign the desired values: 30130[0] = 1 • 32260 = the rated motor speed • 35000 = 2 • Press this softkey to activate the value changes. Note that the control system restarts to ac- cept the new values and the additional spindle can be used in the system.
  • Page 263 Select the system data operating area. Open the axis machine data window through the following softkey operations: → → Use these softkeys to switch to the data set for the additional spindle (MSP2). Default the machine data 30110[0] and 30220[0] for MSP2 with this softkey. Use this softkey or the cursor keys to search for the following machine data and assign the desired values: If you use an external spindle encoder for the additional spindle:...
  • Page 264: Configuring The Additional Axis For Sinumerik 808d Control System

    12.1.2 Configuring the additional axis for SINUMERIK 808D control system The SINUMERIK 808D control system with PPU141.2 supports one additional axis for the turning variant only. Before the configuration, you must first activate the option for additional axis (Page 148). To use the additional axis function after activating it, you must enable the additional axis by setting the signals DB380x.DBX2.1 (drive enable) and DB380x.DBX4001.7 (pulse enable) to "1".
  • Page 265: Configuring The Y Axis On A Turning Machine

    12.2 Configuring the Y axis on a turning machine Prerequisites: ● The Drive Bus address of the corresponding drive is properly set (p0918 = 12). For more information, see Section "Configuring Drive Bus addresses (Page 138)". ● At least one additional axis is activated. For more information, see Section "Activating the optional functions (Page 148)". 12.2.1 Setting parameters for the Y axis Proceed as follows to set the parameters for the Y axis:...
  • Page 266: Measuring The Tool Manually (with The Y Axis)

    Use these softkeys to switch to the data set for axis MY1. Use this softkey or the cursor keys to search for the drive parameter p29000. Enter the motor ID of the motor connected to axis MY1. You can find the motor ID on the motor rating plate. Press this softkey to activate the value changes.
  • Page 267 Move the cursor to the input field for Length X with the cursor keys and then press this soft- key. Enter the distance measured in Step 9 in the input field (for example, 48). If you desire to use the relative coordinate, press this softkey. Press this softkey to confirm your input.
  • Page 268 Select the offset operating area. Press the alphabetic key <Y> or proceed through the following method to open the window for measuring the tool in the Y direction: Move the cursor to the input field for Length Y with the cursor keys and then press this soft- key.
  • Page 269 Move the cursor to the input field for Length Z with the cursor keys and then press this soft- key. Enter the distance between the tool tip and the workpiece edge in the input field, for exam- ple, "0". (This value is the thickness of a setting block if it is used.) If you desire to use the relative coordinate, press this softkey.
  • Page 270: Playing A Slide Show

    13.1 Playing a slide show The control system has the function of playing a slide show. By default, the slide show of Siemens product information is provided. You can press this key combination on the PPU to play a slide show and press the key combination again to exit the slide show.
  • Page 271 Move the cursor to the folder highlighted as follows: Press this key to open this folder. Paste the copied folder(s) containing the slides with this softkey. Now you can press this key combination to play your own slide show. Note You can set the time interval of the slide show with MD9001 TIME_BTWEEN_SLIDES.
  • Page 272: Defining The Service Planner

    13.2 Defining the service planner With the service planning function, you can set up maintenance tasks that have to be performed at certain intervals (for example, top up oil, change coolant). An alarm appears as a reminder when the interval expires. A list is displayed of all the maintenance tasks that have been set up together with the time remaining until the end of the specified maintenance interval.
  • Page 273: Using The Machine Manufacturer's Startup Screen And Machine Logo

    13.3 Using the machine manufacturer's startup screen and machine logo Using the machine manufacturer startup screen The control system uses the Siemens startup screen as follows by default. If necessary, you can use your own startup screen. Commissioning Manual 01/2017...
  • Page 274 Proceed as follows to use your own startup screen: Prepare the image for the startup screen in BMP format. To achieve the best display effect, the recommended image size is 750*450 pixels for PPU161.3 and 600*360 pixels for PPU160.2/PPU141.2. Name the image "startup.bmp" and save it on a USB memory stick. Insert the USB stick into the USB interface on the front panel of the PPU.
  • Page 275 Using the machine manufacturer machine logo The default machine logo is displayed in the machining operating area as follows. If necessary, you can use your own machine logo. Proceed as follows to use your own machine logo: Prepare the image of your own machine logo in BMP format. To achieve the best display effect, the recommended image size is 153*24 pixels for PPU161.3 and 122*19 pixels for PPU160.2/PPU141.2.
  • Page 276 Press these two keys to restart the HMI. Then you can see your own machine logo in the machining operating area. Note To restore the default display of "SIEMENS" logo, delete the customized bitmap file (mtbico.bmp) from the control system. Commissioning Manual 01/2017...
  • Page 277: Creating User Cycles

    Here "xxx" refers to the cycle number. It must not exceed four digits.. Note The name of a user cycle must not be same with that of a standard Siemens cycle. It is recommend to use a cycle number with the range of 100 to 800.
  • Page 278 SBLON G90 G0 X=VAR1 Z=STAP+2 G1 Z=ENDP G91 X=MID G0 G91 X=VRT Z=VRT G90 G0 Z=STAP+2 SBLOF VAR1=VAR1-2*MID R104=R104+1 IF R104<=R103 GOTOB LL2 IF R104>R103 GOTOF ROUGHING2 ROUGHING2: SBLON G90 G0 X=DIAF+UX G1 Z=ENDP G0 G91X=VRT Z=VRT G90 G0 X=DIA+2 Z=STAP+2 IF MACH==2 GOTOF FINISHING SBLOF...
  • Page 279: Creating The User Cycle Alarm File

    13.4.2 Creating the user cycle alarm file The user cycle alarm file is required to display alarm numbers and alarm messages for user cycles. Naming rule alc_<LANG>.txt Here "<LANG>" refers to the language denotation, for example, eng. For more information, see Section "Loading system languages (Page 147)". Text definition rules When defining the texts, you must follow the rule below: <AlarmNumber>...
  • Page 280: Creating The User Cycle Softkey Index File

    Example 83000 "User%nCycles" // 2*9 ⇒ two lines, each line with nine-character space 83001 "CYCLE100" // 9 ⇒ one line with nine-character space 83020 "DIA short description" // 21 ⇒ one line with 21-character space 13.4.5 Creating the user cycle softkey index file The user cycle softkey index file (cov.com) file is required to define the softkeys for the user cycle.
  • Page 281: Transferring The Desired Files To The Control System

    Description of the parameters Entry Default value Value is missing in the cycle if no entry is made. Separator Short parameter text $ + the identifier (the short description of the selected parameter, which will display in the upper left corner of the parameter screen;...
  • Page 282 Transferring the bitmap file Press this softkey to switch to the USB storage directory. Select the desired bitmap file(s) (for example, cn1.bmp, cn2.bmp...) and then press this softkey to copy the file(s). Note that you can use the following key to select multiple files: Press this softkey to open the window of system data.
  • Page 283 Paste the user cycle alarm file with this softkey. Press this softkey when a message appears prompting you to restart the HMI. The new data will be active after the HMI restarts successfully. Transferring the cov.com file and sc.com file Select the system data operating area.
  • Page 284: Calling The Created User Cycle

    Find the folder for storing the extended user text file through the following operations, and press this key to open it: → → Press this softkey to paste the extended user text file. Press this softkey when a message appears prompting you to restart the HMI. The new data will be active after the HMI restarts successfully.
  • Page 285 Press this softkey to open the lower-level menu for calling user cycles, for example: Press this softkey to open the window for CYCLE100, for example: Set the parameters as desired, and press this softkey to confirm and return to the program editing screen.
  • Page 286: Using The Machine Manufacturer's Machine Data Descriptions

    13.5 Using the machine manufacturer's machine data descriptions If necessary, you can use your own descriptions for the PLC machine data 14510, 14512, 14514, 14516, and 17400. Proceed as follows to edit the machine data description: Select the system data operating area. Press this softkey, and the window of basic NC data opens by default.
  • Page 287: Using The Machine Manufacturer's R Variable Names

    13.6 Using the machine manufacturer's R variable names If necessary, you can define the names of the R variables as desired. Proceed as follows to define your own R variable names: Select the offset operating area. Press this softkey to open the list of R variables. Press this softkey to activate the name display of all R variables.
  • Page 288: Pi Service Functions

    13.7 PI service functions The following PI service functions are supported on the control system: ● ASUP function ● Deleting a password PLC interface address DB1200 PI service [r/w] PLC → NCK interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2...
  • Page 289: Cnc Lock Function

    The company that created the CNC lock function (machine manufacturer or dealer) must retain the license certificate for this option. This certificate can be used as legitimation for Siemens should the PIN be forgotten. The owner of the certificate (CoL) can have the machine unlocked.
  • Page 290 Supplementary conditions NOTICE Circumvention of the CNC lock function due to improper operations Any of the following operations allow circumvention of the CNC lock function: Using an unlocked PLC project • Using the default PLC project • Reimplementing the PLC project of the machine tool •...
  • Page 291: Creating The Activation File

    Enter the data required in the dialog box, for example: ① The software version 4.7 SP4 must be selected for the SINUMERIK 808D/SINUMERIK 808D ADVANCED control system. ② The serial number of the CF card can be found on the PPU HMI through the following operations: →...
  • Page 292: Importing The Activation File

    13.8.3 Importing the activation file The activation file must be transferred to the control system either directly via an Ethernet connection or alternatively via a storage medium, e.g. USB flash drive. The end-user or higher access level is required for the import. The control system must be in the reset state for the import.
  • Page 293: Extending The Cnc Lock Function

    Note If an error occurs when importing the activation file, an error-specific alarm will be issued. The state of the CNC lock function remains unchanged. Note We recommend that the machine manufacturer creates a complete commissioning archive over all control system components after commissioning the machine and activating the CNC lock function.
  • Page 294: Deactivating The Cnc Lock Function

    Importing the activation file The new activation file must be imported into the control system to extend the CNC lock function. The machine manufacturer can import the new activation file directly or send the file to the end user who transfers the file to the control system. For more information about how to import the activation file, see Section "Importing the activation file (Page 292)".
  • Page 295 Enter the data required in the dialog box, for example: Note: The serial numbers of the CF card and the PPU as well as the OEM PIN must match the values used when the CNC lock function was activated initially. For more information, see Section "Creating the activation file (Page 291)".
  • Page 296: Oem Pin Forgotten

    Unlocking the machine To allow the machine manufacturer or dealer to operate the machine, the technician must contact the Siemens Hotline and provide the following information: ● License certificate (CoL) for the option of the CNC lock function ●...
  • Page 297 Enter the data required in the dialog box, for example: Click this button to save the data in the form of .ucls file. Clicking this button allows you to reimport the unencrypted data stored in the project file. Faulty settings of date If a date earlier than the actual date is set for activated CNC lock function, alarm 8065 is issued after NC restart and then NC start is disabled.
  • Page 298: Scope Of Functions

    Scope of functions The "Generate user dialogs" function offers an open structure and enables the user to develop customer-specific and application-specific user interfaces in the SINUMERIK 808D/SINUMERIK 808D ADVANCED. The control system offers an XML-based script language for generating user dialogs.
  • Page 299: Fundamentals Of Configuration

    Note The following section is not intended as a comprehensive description of XML (Extensible Markup Language). Please refer to the relevant specialist literature for additional information. 14.2 Fundamentals of configuration Configuration files The defining data for new user interfaces are stored in configuration files. These files are automatically interpreted and the result displayed on the screen.
  • Page 300: Configuration Files (easyxlanguage Scripts)

    14.3 Configuration files (EasyXLanguage scripts) The following files in the relevant manufacturer's folder on the control are needed to configure user dialogs: File type Name of the file Meaning Script file "xmldial.xml" This script file uses XML tags to control how the configured softkey menus and dialog forms will appear in the user- defined operating area on the HMI.
  • Page 301: Structure Of Configuration File

    Note When a script file "xmldial.xml" is available in the folder above, you can call the start menu in the user-defined operating area. After the initial copying process, reset the control system through the following operations: → → → Example of a user dialog on the HMI The configured softkey menus are displayed when the user-defined operating area is called.
  • Page 302: Language Dependency

    14.5 Language dependency Language-dependent texts are used for: ● Softkey labels ● Headers ● Help texts ● Any other texts 14.6 Creating language-dependent texts Structure of text file The XML files with the language-dependent texts must be created in UTF8 format: Example oem_aggregate_eng.ts <?xml version="1.0"...
  • Page 303: Instruction/identifier Description

    </INIT> </FORM> </DialogGui> Instructions The language offers the following instructions for executing conditional instructions and loop controls: ● For loop ● While loop ● Do while loop ● Conditional processing ● Switch and case instructions ● Operator controls in a dialog form ●...
  • Page 304 Tag identifier Meaning CREATE_CYCLE_EVENT If the parser starts to process the tag CREATE_CYCLE, initially, the message <CREATE_CYCLE_EVENT> is sent to the active form. This message can be used for preparing the cycle parameters, before the parser generates the NC operation from the parameter list and the generation rule.
  • Page 305 Tag identifier Meaning DATA The tag enables the NC, PLC, GUD and drive data to be directly written to. The Addressing components (Page 352) section contains details on address formation. Attribute: name • Variable address Tag value: All alphanumeric terms are approved as tag values. If a value is to be written from a local variable directly, the $ replacement operator preceding the name of the local variable should be used.
  • Page 306 Tag identifier Meaning DO_WHILE Do while loop Instructions WHILE (Test) Syntax: <DO_WHILE> Instructions … <CONDITION>…</CONDITION> </DO_WHILE> The Do while loop comprises a block of instructions and a condition. The code in the instruction block is executed first, then the condition is applied. If the condition is true, the function executes the code section again.
  • Page 307 Tag identifier Meaning For loop for (initialization; test; continuation) instruction(s) Syntax: <FOR> <INIT>…</INIT> <CONDITION>…</CONDITION> <INCREMENT>…</INCREMENT> Instructions … </FOR> The For loop is executed as follows: 1. Evaluation of the expression initialization (INIT). 2. Evaluation of the expression test (CONDITION) as a Boolean expression. If the value is false, the For loop is exited.
  • Page 308 Tag identifier Meaning FORM The tag contains the description of a user dialog. The relevant tags are described in the section on generating menus and dialog forms. Syntax: <FORM name="<dialog name>" color="#ff0000"> Attributes: color • Background color of the dialog form (color coding, see Section "Color coding (Page 323)") –...
  • Page 309 Tag identifier Meaning FORM Continued You can define how the images in a form will be displayed on the screen with a resolution of 800x600 pixels, that is, adapt the image size to the screen, by setting bit 1 of MD1113. Precondition: This function is applicable only when the script file is copied to the control system with a screen resolution of 800x600 pixels.
  • Page 310 Tag identifier Meaning INCLUDE The instruction includes an XML description. (see also DYNAMIC_INCLUDE in this table) Attribute: • Contains the path name. Syntax: <?INCLUDE src="<Path name>" ?> The instruction creates a local variable under the specified name. Fields: Using the attribute dim (dimension) single or two-dimensional fields can be created. The field index addresses the individual field elements.
  • Page 311 Tag identifier Meaning LET Continued Example: One-dimensional field: <let name="array" dim="10"></let> Two-dimensional field: <let name="list_string" dim="10,3" type="string"></let> Pre-assignment: A variable can be initialized with a value. <LET name = "VAR1" type = "INT"> 10 </LET> If values comprising NC or PLC variables are saved in a local variable, the assignment operation automatically adapts the format to that of the variables which have been loaded.
  • Page 312 Tag identifier Meaning LET Continued Variable type struct: This variable type contains a composition of variables that can be addressed using the structure name. A structure can contain all variable types and structures. Within the structure, a variable is declared with the "element" tag. The attributes of the tags and the initialization correspond to the attributes and initialization of the let instruc- tion.
  • Page 313 Tag identifier Meaning MSGBOX The instruction opens a message box whose return value can be used for branching. Syntax: <MSGBOX text="<Message>" caption="<caption>" retvalue="<variable name>" type="<button type>" /> Attributes: text • Text retvalue • Name of the variables to which the return value is copied: 1 –...
  • Page 314 Tag identifier Meaning The tag executes the specified operations. The operations listed in Section "Operators (Page 324)" can be executed. For the purpose of accessing the NC, PLC, and drive data, the complete variable name should be placed in quotation marks. Section "Addressing components (Page 352) " de- scribes how addresses are formed.
  • Page 315 Tag identifier Meaning OPERATION Operation Instructions can be moved within an equation. Move left "<<" operator The << function moves bits to the left. You can specify the value and the number of move increments directly or with a variable. If the limit of the data format is reached, the bits will be moved beyond the limit without an error message being issued.
  • Page 316 Tag identifier Meaning PRINT The tag outputs a text in the dialog line or copies the text to the variable specified. If the text contains formatting identifiers, the variable values are inserted at the appropri- ate places. Syntax: <PRINT name="Variable name " text="text %Formatting "> Variable, … </PRINT>...
  • Page 317 Tag identifier Meaning PROGRESS_BAR The tag opens or closes a progress bar. The bar is displayed below the application win- dow. Syntax: <PROGRESS_BAR type="<true/false>"> value </ PROGRESS_BAR> Attributes: type = "TRUE" - opens the progress bar • type = "FALSE" - closes the progress bar •...
  • Page 318 Tag identifier Meaning SHOW_CONTROL The visibility of a control can be controlled using the tag. Syntax: <SHOW_CONTROL name="<name>" type="<type>" /> Attributes: name • Name of the control type = "TRUE" - control becomes visible • type = "FALSE" - control becomes invisible (hidden) •...
  • Page 319 Tag identifier Meaning TYPE_CAST The tag converts the data type of a local variable. Syntax: <type_cast name="variable name" type=" new type" /> Attributes: name • Variable name type • The new data type is assigned to the variable. convert • The new data type is assigned to the variable.
  • Page 320 Tag identifier Meaning TYPEDEF Continued Some predefined functions expect variables of structure type RECT, POINT, or SIZE as the call parameter. These structures are defined in the file struct_def.xml. RECT: <typedef name="StructRect" type="struct" > <element name="left" type="int">0</element> <element name="top" type="int">0</element> <element name="right"...
  • Page 321 Tag identifier Meaning XML_PARSER The “XML_PARSER” tag can be used to parse XML files. The parser interprets an XML file and calls defined call-back functions. Each call-back function belongs to a predefined event. The programmer can process the XML data within this function.
  • Page 322 Tag identifier Meaning XML_PARSER Continued The parser also supplies variables so that the call-back functions can access the event data. startElementHandler: Function parameters tag_name - tag name - number of attributes found System variables $xmlAttribute String array that contains the 0-num attribute name range. $xmlValue String array that contains the 0-num attribute value range.
  • Page 323: System Variables

    14.7.3 System variables The system variables can be used in the EasyXLanguage scripts for the data exchange between a script parser and a program flow. The table below provides the automatically created system variables that can be used in the relevant tags. System variable Description Tags where valid...
  • Page 324: Operators

    14.7.6 Operators The operation instruction processes the following operators: Operator Meaning Assignment Equal to <, &lt; Less than >, &gt; Greater than <=, &lt;= Less than or equal to >=, &gt;= Greater than or equal to OR operation in bits Logic OR operation &, &amp;...
  • Page 325 Tag identifier Meaning FORM This tag contains the description of a user dialog. Attributes: color • Background color of the dialog box (for color coding, see Section "Color coding (Page 323)") name • Identifier of the form type • cycle -attribute specifies a cycle form xpos •...
  • Page 326 Tag identifier Meaning FORM continued FORM continued Syntax: <FORM name = "<dialog name>" color = "#ff0000"> Example: <FORM name = "R-Parameter"> <INIT> <DATA_ACCESS type = "true" /> <CAPTION>R - Parameter</CAPTION> <CONTROL name = "edit1" xpos = "322" ypos = "34" refvar = "nck/Channel/Parameter/R[1]"...
  • Page 327 Tag identifier Meaning KEY_EVENT Dialog message The tag KEY_EVENT can be integrated in the form to evaluate keyboard events. The sys- tem sends the MF2 keyboard code to the active form if the tag is available in a form. If the variable $actionresult is not set to zero, the system then subsequently processes the key- board event.
  • Page 328 Tag identifier Meaning MESSAGE Dialog message If the Send_message operation is executed in the script, then the parser processes the tag message. Values P1 and P2 are provided in the variables $message_par1 and $mes- sage_par2 (see the "SEND_MESSAGE" tag). Syntax: <MESSAGE>...
  • Page 329 Tag identifier Meaning SEND_MESSAGE The tag sends a message with two parameters to the active form, which is processed in the tag message (see also MESSAGE). Syntax: <SEND_MESSAGE>p1, p2</SEND_MESSAGE> Example: <LET name="user_selection" /> <SOFTKEY POSITION="3"> <CAPTION>Set%nParameter</CAPTION> <SEND_MESSAGE>1, 10</SEND_MESSAGE> </SOFTKEY> … …...
  • Page 330 Tag identifier Meaning CAPTION The tag contains the title of the dialog box. This tag should be used within the INIT tag. Syntax: <CAPTION>Titel</CAPTION> Example: <CAPTION>my first dialogue</CAPTION> CLOSE Dialog box message This tag is executed before the dialog box is closed. CLOSE_FORM The tag closes the active dialog.
  • Page 331 Tag identifier Meaning CONTROL The tag is used to generate control elements. Syntax: <CONTROL name = "<control name>" xpos = "<X position>" ypos = "<Y position>" refvar = "<NC variable>" hotlink = "true" format = "<for- mat>" /> Attributes: name •...
  • Page 332 Tag identifier Meaning fieldtype CONTROL Continued • – graphicbox The field type generates a 2D broken line graphic control. Using the tag <ITEM> a graphical element can be inserted into the control. Parameters width and height specify the width and height of the box. After the control has been created, additional elements can be inserted using the functions addItem, insertItem, or loadItem.
  • Page 333 Tag identifier Meaning CONTROL continued Attributes: font • The attribute defines the font size used. – – – – – – color_bk • The attribute sets the background color of the control. color_fg • The attribute sets the foreground color of the control. Color coding (see Section "Color coding (Page 323)") display_format •...
  • Page 334 Tag identifier Meaning CONTROL continued Example: <CONTROL name = "button1" xpos = "10" ypos = "10" fieldtype = " com- bobox "> <ITEM>text1</ITEM> <ITEM>text2</ITEM> <ITEM>text3</ITEM> <ITEM>text4</ITEM> </CONTROL> If any integer value is to be assigned to an expression, the attribute value = "value" should be added to the tag.
  • Page 335 Tag identifier Meaning CONTROL Continued Changing the control after creation A control tag changes the properties of an existing control after it has been created. The tag must be specified with the name of the control to be changed and the new properties. It can be executed only within a form tag.
  • Page 336 Tag identifier Meaning CONTROL Continued The following properties can be changed in an operation statement. For this purpose, the control name and property have to be specified. The property has to be separated by a point from the control name. xpos •...
  • Page 337 Tag identifier Meaning DATA_ACCESS The tag controls the behavior of the dialog forms when user inputs are being saved. The behavior should be defined within the INIT tag. If the tag is not used, inputs are buffered in each case. Exception: Controls for which the hotlink attribute is set to true are always written to and read directly.
  • Page 338 Tag identifier Meaning MENU The tag defines a menu containing the softkey description and the dialog to be opened. Attribute: name • Menu name Syntax: <MENU name = "<menu name>"> … <open_form …> … <SOFTKEY …> </SOFTKEY> </MENU> NAVIGATION This tag defines the menu to be called. It can be used within a softkey block, a menu block, and in a form.
  • Page 339 Tag identifier Meaning OPEN_FORM The tag opens the dialog form given under the name. Attribute: name • Name of the dialog form Syntax: <OPEN_FORM name = "<form name>" /> Example: <menu name = "main"> <open_form name = "main_form" /> <softkey POSITION="1"> <caption>main form</caption>...
  • Page 340 Tag identifier Meaning PROPERTY This tag can be used to define additional properties for an operator control. Attributes: max = "<maximum value>" • min = "<minimum value>" • default = "<pre-assignment>" • factor = "conversion factor" • color_bk = "<background color coding>" •...
  • Page 341 Tag identifier Meaning SOFTKEY The tag defines the properties and responses of a softkey. Attributes: position • Number of the softkey. 1-8 horizontal softkeys, 9-16 vertical softkeys The following attributes become effective from: type • Defines the property of the softkey. user_controled - The script defines how the softkey is displayed toggle_softkey - The softkey is displayed alternating between pressed and not pressed refvar...
  • Page 342 Tag identifier Meaning SOFTKEY continued Syntax: Standard softkey: <state type="<softkey state>" /> <softkey position = "<1>"> … … </softkey> Script-controlled softkey: <softkey position = "<1>" type="<user_defined>" > <state type="<softkey state>" /> … … </softkey> Toggle softkey: <softkey position = "<1>" type="<toggle_softkey>" refvar="<variable name>"...
  • Page 343 Tag identifier Meaning SOFTKEY continued Example: <let name="curr_softkey_state" type="string">PRESSED</let> </softkey> <softkey POSITION="3" type="toggle_softkey" refvar="curr_softkey_state"> <caption>Toggle%nSK</caption> … </softkey> SOFTKEY_OK The tag defines the response of the softkey "OK". The following additional actions can be defined within the softkey block: navigation • update_controls •...
  • Page 344 Tag identifier Meaning SOFTKEY_BACK The tag defines the response of the softkey "Back". The following additional actions can be defined within the softkey block: navigation • update_controls • function • Syntax: <SOFTKEY_BACK> … … </SOFTKEY_BACK> SOFTKEY_ACCEPT The tag defines the response of the softkey "Accept". The following additional actions can be defined within the softkey block: navigation •...
  • Page 345 Tag identifier Meaning The tag is used to display an image in the specified position. The BMP and PNG image formats are supported. Syntax: <IMG xpos = "<X position>" ypos = "<Y position>" name = "<name>" /> <IMG … xrot="angle X axis" yrot=" angle Y axis " zrot=" angle Z axis "...
  • Page 346 Tag identifier Meaning The tag draws a rectangle at the specified position, colored as indicated. Syntax: <BOX xpos = "<X position>" ypos = "<Y position>" width = "<X exten- sion>" height = "<Y extension>" color = "<Color code>" /> Attributes: xpos •...
  • Page 347 Tag identifier Meaning FUNCTION_BODY Function body The tag contains the function body of a subfunction. The function body needs to be pro- grammed within the DialogGui tag. Attributes: name = "Name of the function body" • parameter = "Parameter list" (optional) •...
  • Page 348 Tag identifier Meaning FUNCTION_BODY contin- Example: <function_body name = "test" parameter = "c1,c2,c3" return = "true"> <LET name = "tmp">0</LET> <OP> tmp = c1+c2+c3 </OP> <OP> $return = tmp </OP> </function_body> … … … <LET name = "my_var"> 4 </LET> <function name = "test"...
  • Page 349: Generating User Menus

    Tag identifier Meaning UPDATE_CONTROLS The tag runs a comparison between the operator controls and the reference variables. Attribute: type • The attribute defines the direction of the data comparison. = TRUE – data is read from the reference variables and copied to the operator controls. = FALSE –...
  • Page 350 Tag identifier Description NC_INSTRUCTION This tag is used to define the NC instruction to be generated. All listed cycle parameters are automatically created as string variables of the FORM and are available to the FORM. Precondition: The FORMattribute type is set to the value CYCLE. Attribute: refvar •...
  • Page 351 Tag identifier Description CREATE_CYCLE The tag generates an NC block, whose syntax is defined by the value of the NC_INSTRUCTION tag. Before generating the NC instruction, the parser calls the CYCLE_CREATE_EVENT tag of the FORM. This tag can be used to calculate the cycle parameters.
  • Page 352: Substitution Characters

    14.8.2 Substitution characters The system offers the option of defining control properties (attribute values) for the runtime. In order to use this function, the desired property must be set in a local variable and the variable name must be transferred to the tag as an attribute value preceded by the character $.
  • Page 353: Addressing Nc Variables

    Address x: Valid S7-200 address identifier Bit addressing: b – Bit number Examples: <data name = "plc/mb170">1</data> <data name = "i0.1"> 1 </data> <op> "m19.2" = 1 </op> 14.9.2 Addressing NC variables Addressing the NC variables starts with the path section nck. This section is followed by the data address;...
  • Page 354: Addressing Machine And Setting Data

    Example: <LET name="r0002_content"></LET> <LET name="p1460_content"></LET> <!— Reading of value r0002 on the CU of drive with address 11 -> <op> r0002_content = "drive/cu/r2[do1]" </op> <!— Reading of value r0002 on the CU of drive with address 15 -> <op> r0002_content = "drive/cu/r0002[do5]" </op> <!—...
  • Page 355: Addressing The User Data

    Addressing starts with the path section gud, followed by the specification of the area CHANNEL. This address section is followed by the specification of the GUD areas: GUD areas Assignment sgud Siemens GUD mgud Machine manufacturer GUD ugud User GUD Then enter the GUD name.
  • Page 356 Function name Description ncfunc.cap.write The function writes a value into the specified variable. If the write operation was error-free, then the return variable contains the value zero. Contrary to the operation instruction, in the event of a fault, this func- tion does not interrupt the processing of the script operations.
  • Page 357 Function name Description ncfunc.pi_service Jobs can be transferred to the NCK using the program invocation (PI) service. If the service has been executed error-free, the function returns the value 1 in the return variable. Manipulation of the tool list _N_CREATO - Create tool _N_DELETO - Delete tool _N_CREACE - Create tool cutting edge _N_DELECE - Delete tool cutting edge...
  • Page 358 Function name Description ncfunc.pi_service Continued Arguments: _N_CREATO • var1 - Tool number _N_DELETO • var1 - Tool number _N_CREACE • var1 - Tool number var2 - Cutting edge number _N_DELECE • var1 - Tool number var2 - Cutting edge number _N_SETUFR •...
  • Page 359 Function name Description ncfunc.chan_pi_service The function executes a PI service in a channel-related manner. The channel number is passed after the PI service name. This is followed by all other call parameters. Parameters: channel - Channel number Syntax: <function name="ncfunc.chan_pi_service" re- turn="error">...
  • Page 360 Function name Description ncfunc.password This function sets or deletes a password level. Set password: • The password should be specified for the required password lev- el as parameter. Delete password: • A blank string deletes the password level. Syntax: <function name="ncfunc.password">password </function>...
  • Page 361 Function name Description control.localtime The function copies the local time in a field with 7 array elements. The name of the variable is expected as call parameter. The following is stored in an array element: Index 0 - year • Index 1 - month •...
  • Page 362 Function name Description string.icmp Two strings are compared from a lexicographical perspective (the comparison is not case-sensitive). The function gives a return value of zero if the strings are the same, a value less than zero if the first string is smaller than the second string or a value greater than zero if the second string is smaller then the first string.
  • Page 363 Function name Description string.right The function extracts the last nCount character from string 1 and copies this to the return variable. Parameter: str1 - string nCount - number of characters Syntax: <function name="string.right" return="<result string>"> str1, nCount </function> Example: <let name="str1" type="string">A brown bear hunts a brown dog.</let>...
  • Page 364 Function name Description string.length The function gives the number of characters in a string. Parameter: str1 - string Syntax: <function name="string.length" return="<int var>"> str1 </function> Example: <let name="length">0</let> <let name="str1" type="string">A brown bear hunts a brown dog.</let> <function name="string.length" return="length"> str1 </function>...
  • Page 365 Function name Description string.remove The function removes all the substrings found. Parameter: string - string variable remove string - substring to be deleted Syntax: <function name="string.remove"> string, remove string </function> Example: <let name="index">0</let> <let name="str1" type="string">A brown bear hunts a brown dog.
  • Page 366 Function name Description string.delete The function deletes the defined number of characters starting from the start position specified. Parameter: string - string variable start index - start index (zero based) nCount - number of characters to be deleted Syntax: <function name="string.delete"> string, start index , nCount </function>...
  • Page 367 Function name Description string.reversefind The function searches the transferred string for the last match with the substring. If the substring is found, the function provides the index to the first character (starting with zero) or, failing this, -1. Parameter: string - string variable find string - string to be found startindex –...
  • Page 368 Function name Description string.trimright The function trims the closing characters from a string. Parameter: str1 - string variable Syntax: <function name="string.trimright" > str1 </function> Example: <let name="str1" type="string"> test trim right </let> <function name="string.trimright" > str1 </function> Result: str1 = "test trim right" The function calculates the sine of the value transferred in degrees.
  • Page 369 Function name Description The function calculates the tangent of the value transferred in de- grees. Parameter: double - angle Syntax: <function name="tan" return="<double val>"> double </function> Example: <let name= "tan_val" type="double"></let> <function name="tan" return="tan_val"> 20.0 </function> arcsin The function calculates the arcsine of the value transferred in de- grees.
  • Page 370 Function name Description arctan The function calculates the arctan of the value transferred in de- grees. Parameter: double - arctan of y/x Syntax: <function name="arctan" return="<double val>"> dou- ble </function> Example: <let name= "arctan_val" type="double"></let> <function name="arctan" return="arctan_val"> 20.0 </function> File processing doc.readfromfile The function reads the contents of the specified file into a string vari-...
  • Page 371 Function name Description doc.writetofile The function writes the contents of a string variable to the file speci- fied. Parameter: progname - file name str1 - string Syntax: <function name="doc.writetofile" > progname, str1 </function> Example: <let name = "my_var" type="string" > file content </let>...
  • Page 372 Function name Description doc.loadscript The function copies a dialog description embedded in a part program into the specified local variable. The call parameters to be specified are the program name, the dialog name, and a variable for storing the main menu name. If the name of the dialog description was found in the part program, the return vari- able contains this description.
  • Page 373 Function name Description doc.exist If the file exists, the function returns the value 1. Parameter: progname - file name Note: The file name is case-sensitive for a file on the CF card. Syntax: <function name="doc.exist" return="<int_var>" > progname </function> Example: <let name ="exist">0</let>...
  • Page 374 Function name Description ncfunc.bitset The function is used to manipulate individual bits of the specified variables. The bits can either be set or reset. Syntax: <function name="ncfunc.bitset" refvar="address" value="set/reset" > bit0, bit1, … bit9 </function> Attributes: refvar - specifies the name of the variable, in which the bit combina- tion should be written value –...
  • Page 375 Function name Description control.additem The function inserts a new element at the end of the list. Note: The function is only available for the control types "listbox" and "graphicbox". Syntax: <function name="control.additem"> control name, item </function> Attribute: name – function name Values: control name –...
  • Page 376 Function name Description control.insertitem The function inserts a new element at the specified position. Note: The function is only available for the control types "listbox" and "graphicbox". Syntax: <function name="control.insertitem"> control name, index, item, itemdata </function> Attribute: name – function name Values: control name –...
  • Page 377 Function name Description control.loaditem The function inserts a list of expressions into the control. The function is only available for the control types "listbox" and "graphicbox". Syntax: <function name="control.loaditem"> control name, list </function> Attribute: name – function name Values: control name – control name list- string variable Structure of the list: The list contains a number of expressions, which must be separated...
  • Page 378 Function name Description control.empty The function deletes the contents of the specified list box or graphic box controls. Syntax: <function name="control.empty"> control name, </function> Attribute: name – function name Values: control name – control name Example: <function name="control.empty">_T"listbox1"</function> control.getfocus The function supplies the name of the control, which has the input focus.
  • Page 379 Function name Description control.getcurssel For a list box, the function supplies the cursor index. The control name should be transferred as text expression of the function. Syntax: <function name="control.getcurssel" retvar="var"> control name </function> Example: <let name>="index"></let> <function name="control.getcurssel" ">_T"listbox1"</function> control.setcurssel For a list box, the function sets the cursor to the appropriate line.
  • Page 380 Function name Description control.getitemdata For a list box, the function copies the user-specific allocated value of an element to the specified variable. For an edit control, the function copies the user-specific allocated value (item_data) to the specified variable. An integer variable should be specified as reference variable. The control name should be transferred as text expression of the function.
  • Page 381 Function name Description hmi.get_caption_heigt The function returns the title bar height in pixels. Syntax: <function name="hmi.get_caption_heigt" re- turn="<return var>" /> Attributes: return - integer variable This function returns the absolute value of the specified number. Syntax: <function name="abs" return="var"> value </function>...
  • Page 382 Function name Description The function calculates the logarithm of the specified value. Syntax: <function name="log" return="var"> value </function> log10 The function calculates the common (decadic) logarithm of the speci- fied value. Syntax: <function name="log10" return="var"> value </function> The function calculates the value "a ".
  • Page 383: Technical Data

    Technical data 15.1 SINUMERIK 808D/SINUMERIK 808D ADVANCED Horizontal PPU Vertical PPU Horizontal MCP Vertical MCP (161.3/141.2) (160.2) Design data Dimensions (W × H × D, mm) 420 × 200 × 95 265 × 330 × 104 420 × 120 × 58 265 ×...
  • Page 384: Servo Drives

    Horizontal PPU Vertical PPU Horizontal MCP Vertical MCP (161.3/141.2) (160.2) Vibration resistance (in operation) 10 Hz to 58 Hz: 0.35 mm 58 Hz to 200 Hz: 1g Shock resistance (in operation) 10 g peak value, 6 ms duration 6 shocks in each of the 3 axes vertical to each other Certification CE, KC , and EAC...
  • Page 385 Frame size Overload capability 300% Control system Servo control Braking resistor Built-in Protective functions Earthing fault protection, output short-cut protection, overvolt- age/undervoltage protection t detection, IGBT overtemperature protec- tion Cooling method Self-cooled Fan-cooled Environmental Surround- Operation 0 °C to 45 °C: without power derating conditions ing air 45 °C to 55 °C: with power derating...
  • Page 386: Sinamics V70 Spindle Drives

    Frame size Vibration Operation Operational area II 10 Hz to 58 Hz: 0.075 mm deflection 58 Hz to 200 Hz: 1g vibration Transport & 5 Hz to 9 Hz: 7.5 mm deflection storage 9 Hz to 200 Hz: 2 g vibration Vibration class: 2M3 transportation Certification Outline dimensions (W ×...
  • Page 387 Frame size Overload capability Note: The overload capability is 150% by default. It can be set up to 200% via p0640, but the corresponding overload duration might be reduced under the circumstances. Control system Servo control Braking resistor External Protective functions Earthing fault protection, output short-cut protection, overvolt- age/undervoltage protection t detection, IGBT overtempera-...
  • Page 388: Sinamics V60 Servo Drives

    Frame size Shock Operation Operational area: II Ambient classification: 3M2 Peak acceleration: 5 g + 15 g Duration: 30 ms + 11 ms Quantity of shocks: 3 Summed shocks: 18 Cycle time: 1 s Transport & Covered by vibration test storage Vibration Operation...
  • Page 389 Order No. : 6SL3210- 5CC14-0UA0 5CC16-0UA0 5CC17-0UA0 5CC21-0UA0 Overload capability Applicable load inertia ≤ 5 times of motor inertia Control performance Control mode 1. Position control (Input mode: pulse + direction signals) 2. JOG mode Input pulse frequency ≤ 333 kHz Drive input 1.
  • Page 390: Servo Motors

    15.3 Servo motors 15.3.1 SIMOTICS S-1FL6 feed motors General technical data Parameter Description Type of motor Permanent-magnet synchronous motor Cooling Self-cooled Operating temperature 0 °C to 40 °C (without power derating) Storage temperature -15 °C to +65 °C Relative humidity ≤...
  • Page 391 Order No. 1FL60... Stall torque (Nm) Rated torque (Nm) 1.27 2.39 3.58 4.78 7.16 8.36 9.55 11.9 16.7 23.9 33.4 Maximum torque 10.7 14.3 21.5 25.1 28.7 35.7 50.0 70.0 90.0 (Nm) Rated speed (rpm) 3000 2000 2000 Maximum speed 4000 3000 3000...
  • Page 392 Torque-speed characteristics Commissioning Manual 01/2017...
  • Page 393 Note Continuous operating area is a series of states when a motor can operate continuously and safely. The effective torque • must be located in this area. Short-term operating area is a series of states when a motor can operate in a short duration if its effective torque is •...
  • Page 394: Simotics S-1fl5 Servo Motors

    Do not break the cable during your installation work or machine moves. No force should be applied to the cables. Note The motor can only be connected with Siemens SINAMICS V60 drives and relevantly designed cables, and vice versa. NOTICE Motor damage caused by direct connection with a 3-phase power supply Direct connection of the motor with a 3-phase power supply will cause damages to the motor.
  • Page 395 DANGER Danger of electric shock Voltage on motor terminals can reach 300 V while the rotor is rotating. Do shut down the motor before any electrical work. Only a qualified person is allowed to do mounting and wiring work of the motor. No hot plugs.
  • Page 396: Simotics M-1ph1 Main Motors

    15.3.3 SIMOTICS M-1PH1 main motors General technical data Parameter Description Type of motor Asynchronous motor Cooling method Fan-cooled Operating temperature -15 °C to 40 °C (without power derating) Storage temperature -20 °C to 65 °C Relative humidity (storage) ≤ 95% Relative humidity (operating) ≤...
  • Page 397 Order No. 1PH110... 1-1❑F 3-1❑F 5-1❑F 3-1❑D 5-1❑D Rated frequency 53.3 Hz 53 Hz 52.6 Hz 36.9 Hz 36.4 Hz Rated voltage (phase/phase) 326 V 290 V 327 V 269 V 265 V Motor maximum voltage 355 V Rated current 10.3 A 16.9 A 19.6 A...
  • Page 398 NOTICE Damage to the motors For surrounding air temperatures > 55 °C, please contact your local Siemens office. The standard motors are not suitable for use in corrosive atmospheres, atmospheres with a high salt content, or in outdoor applications; otherwise, the motors may be damaged.
  • Page 399 1PH1103-1❑F❑: s6-25% s6-25% s6-25% [rpm] [kW] [Nm] [Hz] [rpm] [rpm] [kW] [Nm] 1500 16.9 5500 10000 8.25 52.5 33.8 Commissioning Manual 01/2017...
  • Page 400 1PH1105-1❑F❑: s6-25% s6-25% s6-25% [rpm] [kW] [Nm] [Hz] [rpm] [rpm] [kW] [Nm] 1500 19.6 52.6 4300 10000 11.25 39.2 Commissioning Manual 01/2017...
  • Page 401 1PH1103-1❑D❑: s6-25% s6-25% s6-25% [rpm] [kW] [Nm] [Hz] [rpm] [rpm] [kW] [Nm] 1000 12.9 36.9 4600 6000 5.55 52.5 25.8 Commissioning Manual 01/2017...
  • Page 402 1PH1105-1❑D❑: s6-25% s6-25% s6-25% [rpm] [kW] [Nm] [Hz] [rpm] [rpm] [kW] [Nm] 1000 18.8 36.4 4600 6000 8.25 79.5 37.6 Commissioning Manual 01/2017...
  • Page 403 Torque-speed/power-speed characteristics - SH132 1PH1131-1❑F❑: s6-25% s6-25% s6-25% [rpm] [kW] [Nm] [Hz] [rpm] [rpm] [kW] [Nm] 1500 28.8 51.5 5000 8000 16.5 57.6 Commissioning Manual 01/2017...
  • Page 404 1PH1133-1❑F❑: s6-25% s6-25% s6-25% [rpm] [kW] [Nm] [Hz] [rpm] [rpm] [kW] [Nm] 1500 95.5 36.7 50.8 4000 8000 22.5 73.4 Commissioning Manual 01/2017...
  • Page 405 1PH1131-1❑D❑: s6-25% s6-25% s6-25% [rpm] [kW] [Nm] [Hz] [rpm] [rpm] [kW] [Nm] 1000 71.6 26.6 35.2 5000 6000 11.25 53.2 Commissioning Manual 01/2017...
  • Page 406 1PH1133-1❑D❑: s6-25% s6-25% s6-25% [rpm] [kW] [Nm] [Hz] [rpm] [rpm] [kW] [Nm] 1000 28.3 3000 6000 16.5 56.6 Permissible radial and axial forces - SH100 Commissioning Manual 01/2017...
  • Page 407 Permissible radial and axial forces - SH132 Commissioning Manual 01/2017...
  • Page 408 15.4 Cables 15.4.1 Drive Bus cable for the SINUMERIK 808D ADVANCED Parameter Drive Bus cable Jacket material Degree of protection IP20 Number of cores Operation voltage 100 V Operation temperature, static -40 °C to 80 °C Shielding Minimum bending radius, static...
  • Page 409: Cables For The Sinamics V60 Servo System

    Parameter MOTION-CONNECT 500 power MOTION-CONNECT 300 encoder cable cable Operation temperature -20 °C to 80 °C -30 °C to 60 °C Shielding Yes (coverage ≥ 80%) Minimum bending radius, static 5 × outer diameter Minimum bending radius, dynamic 180 mm, 210 mm, 360 mm, 20 ×...
  • Page 410: Transformers For The Sinamics V60 Servo System

    15.5 Transformers for the SINAMICS V60 servo system CAUTION Use of an appropriate isolating transformer To reduce the risk of electric shock as well as interference from power supply and electromagnetic field, an isolating transformer is necessary for the 3 AC 380 V mains system. You may select an appropriate transformer with reference to the table below (determine the right transformer power based on desired motor combinations).
  • Page 411: Address Of Ce-authorized Manufacturer

    Note: You can further press this softkey in the current help screen to show a complete list of all SINUMERIK 808D/SINUMERIK 808D ADVANCED machine data. In addition, you can also use the following softkey to search for a specific MD by number in this list: Pressing this softkey exits the help system.
  • Page 412 Machine data list Name Default Range Type Unit Activating 11300 JOG_INC_MO BOOL DE_LEVELTRI GGRD INC and REF in JOG mode 14510 * USER_DATA_I -62,768 to DWORD NT[0] ... [31] 32,767 User data (INT) 14512 * USER_DATA_ 0 to 0x0FF BYTE HEX[0] ...
  • Page 413 Name Default Range Type Unit Activating 31020 ENC_RESOL[0 10,000 DWORD Encoder lines per revolution 31030 LEADSCREW_ 10.000000 ≥ 0 DOUBLE PITCH Pitch of leadscrew 31040 ENC_IS_DIRE FALSE, FALSE - BYTE Direct measuring system (no compilation to load position) 31050 DRIVE_AX_RA 1 to DWORD TIO_DENOM[0]...
  • Page 414 Name Default Range Type Unit Activating Feed axis: 32300 MAX_AX_ACC • ≥ 0.001 DOUBLE mm/s , rev/s EL[0] ... [4] Spindle: • – [0]...[2]: – [3]...[4]: 2.778 Maximum axis acceleration 32450 Backlash[0] DOUBLE Backlash 32700 ENC_COMP_E BOOL NABLE[0] Encoder/spindle error compensation 34000 REFP_CAM_IS BOOL...
  • Page 415 Name Default Range Type Unit Activating 34093 REFP_CAM_M DOUBLE ARKER_DIST[0 Reference cam/reference mark distance 34100 REFP_SET_PO DOUBLE mm, degrees S[0] ... [3] Reference point for incremental system 34200 ENC_REFP_M 0 to 8 BYTE ODE[0] Referencing mode 34210 ENC_REFP_ST 0 to 3 BYTE ATE[0] Adjustment status of the absolute encoder...
  • Page 416: Sinamics V70 Parameters

    16.2 SINAMICS V70 parameters This section lists only the parameters displayed on the drive BOP and those frequently used for drive commissioning. For more parameters of the servo drive, see SINUMERIK 808D ADVANCED HMI through the following operations: → →...
  • Page 417 Data type Type Description 16-bit integer 32-bit integer 16 bits without sign 32 bits without sign Uint16 16-bit unsigned integer Uint32 32-bit unsigned integer Float 32-bit floating point number Calling help information for V70 parameters You can call the help information for the V70 drive parameters on the PPU by proceeding through the following steps: Select the system data operating area.
  • Page 418: V70 Parameters On Bop

    16.2.1 V70 parameters on BOP The table below lists the parameters displayed on the drive BOP only. Par. No. Name Factory Unit Data type Effective Can be setting changed r0020 Speed setpoint smoothed Float Description: Displays the currently smoothed speed setpoint at the input of the speed controller or U/f characteristic (after the interpolator).
  • Page 419 Par. No. Name Factory Unit Data type Effective Can be setting changed Description: Displays the temperatures in the servo drive. [0] = Inverter, maximum value • [1] = Depletion layer maximum value • [2] = Rectifier maximum value • [3] = Air intake •...
  • Page 420 Par. No. Name Factory Unit Data type Effective Can be setting changed r0079[0...1] Torque setpoint total Float Description: Displays the torque setpoint at the output of the speed controller (before clock cycle interpola- tion). [0]: Unsmoothed • [1]: Smoothed • r0632 Motor temperature model, °C...
  • Page 421 Par. No. Name Factory Unit Data type Effective Can be setting changed p1216 Motor holding brake, open- 10000 Float T, U ing time Description: Sets the time to open the motor holding brake. After controlling the holding brake (opens), the speed/velocity setpoint remains at zero for this time. After this, the speed/velocity setpoint is enabled.
  • Page 422 Par. No. Name Factory Unit Data type Effective Can be setting changed Description: Setting for activating/de-activating the speed setpoint filter. If only one filter is required, filter 1 should be activated and filter 2 de-activated, to avoid excessive pro- cessing time. Dependency: The individual speed setpoint filters are parameterized as of p1415.
  • Page 423 Par. No. Name Factory Unit Data type Effective Can be setting changed Description: Sets the integration time of the speed controller before the adaptation speed range. This value corresponds to the basic setting of the integral time of the speed controller without adaptation. p1520 Torque limit upper/motoring 2000000...
  • Page 424 Par. No. Name Factory Unit Data type Effective Can be setting changed r2114[0...1] System runtime total Description: Displays the total system runtime for the drive unit. The time comprises r2114[0] (milliseconds) and r2114[1] (days). After r2114[0] has reached a value of 86.400.000 ms (24 hours) this value is reset and r2114[1] is incre- mented.
  • Page 425: Drive Basic List On Hmi

    16.2.2 Drive basic list on HMI The drive basic list on HMI contains the most frequently used drive parameters for commissioning. You can also view them through the following operations: → → Par. No. Name Factory Unit Data type Effective Can be setting changed...
  • Page 426 Par. No. Name Factory Unit Data type Effective Can be setting changed Description: Setting to change the direction of rotation. If the parameter is changed, it reverses the direction of rotation of the motor and the encoder actual value without changing the setpoint. Dependency: F07434 Caution: Changing the direction using p1820 or p1821 is not recognized by the "Safe Direction without encoder".
  • Page 427: Sinamics V60 Parameters

    16.3 SINAMICS V60 parameters Editable parameters Par. No. Name Range Default Increment Unit Effective Parameter write protection 0 - 1 Immediately 0: Sets all parameters other than P01 as read-only parameters. 1: Sets all parameters to be both readable and writable. P01 automatically resets to 0 after power-on.
  • Page 428 Par. No. Name Range Default Increment Unit Effective Maximum following error 20-999 100 pulses Immediately This parameter specifies the maximum possible following error. When the actual following error is larger than the setpoint, the drive sends an over-position alarm (A43) Input pulse multiplier 1, 2, 4, 5, Power On...
  • Page 429 This parameter defines the time period when the motor ramps up from 0 rpm to 2,000 rpm or ramps down from 2, 000 rpm to 0 rpm in JOG mode. Reserved for Siemens internal use only Note For parameters with an asterisk (*), the values in brackets are the second default values. For details, see Section "Function menu".
  • Page 430 Data Name Data Unit Data Display example format group Digital output signal Bits in hex Firmware version Decimal HW, FW Power Board rated cur- Integer rent Parameter version num- Decimal The type of these display data is all decimal format. The display value for these display data respectively varies as the case may require.
  • Page 431: Signals From/to The Mcp

    PLC user interface 17.1 Signals from/to the MCP Horizontal MCP with override switches The figure below takes the horizontal MCP variant with override switches as an example. The vertical MCP variants share the same PLC interface addresses for the corresponding keys. Note that labels K13, K15, K19, and K21 are not included in the pre-inserted labeling strips for keys of the MCP.
  • Page 432 Axis trav- Key 13 CYCLE CYCLE RESET SPINDLE SPINDLE SPINDLE ersing key START STOP RIGHT STOP LEFT (↑x) Key 21 Axis trav- Key 19 Axis trav- RAPID Axis trav- Key 15 ersing key ersing key ersing key (↓x) (→z) (←z) 7 SEG LED1 7 SEG LED2 To ensure the correct display of the active tool number, make sure that you set Bit 4 and Bit 5 to 1.
  • Page 433: Reading/writing Nc Data

    Axis trav- Spindle CYCLE CYCLE RESET SPINDLE SPINDLE SPINDLE ersing key override START STOP RIGHT STOP LEFT (↑x) key (-) PROGRAM Axis trav- Spindle Axis trav- RAPID Axis trav- Spindle TEST ersing key override ersing key ersing key override (↓x) key (+) (→z) (←z)
  • Page 434: Pi Service

    3004 Reading: data from NCK variable x (data type of the variables: 1 to 4 bytes) 0: no error; 3: illegal access to object; 5: invalid address; 10: object does not exist 17.3 PI Service 17.3.1 PI service: Job DB1200 PI service [r/w] PLC →...
  • Page 435: User Alarms

    User data User data 17.5 User Alarms 17.5.1 User alarms: Activating DB1600 Activating alarm [r/w] PLC -> HMI interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Activation of alarm no. 700007 700006 700005...
  • Page 436: Active Alarm Response

    17.5.3 Active alarm response DB1600 Active alarm response [r] PLC -> HMI interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 2000 Acknowledge Acknowledge PLC STOP EMERGENCY Feedrate Read-in NC start POWER ON with STOP...
  • Page 437: Program Selection From Plc (retentive Area)

    17.6.2 Program selection from PLC (retentive area) DB1700 Program selection [r/w] PLC -> HMI interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 1000 Program selection from the PLC: Program number 1001 Command job from the PLC: Command 1002...
  • Page 438: Signals To Maintenance Planners

    1011 Hour: Tens digit, BCD Hour: Units digit, BCD 1012 Minute: Tens digit, BCD Minute: Units digit, BCD 1013 Second: Tens digit, BCD Second: Units digit, BCD 1014 Millisecond: Hundreds digit, BCD Millisecond: Tens digit, BCD 1015 Millisecond: Units digit, BCD Weekday, BCD {1, 2, ...
  • Page 439: Signals From Operator Panel (retentive Area)

    3002 Alarm 24 Alarm 23 Alarm 22 Alarm 21 Alarm 20 Alarm 19 Alarm 18 Alarm 17 3003 Alarm 32 Alarm 31 Alarm 30 Alarm 29 Alarm 28 Alarm 27 Alarm 26 Alarm 25 17.6.8 Signals from operator panel (retentive area) DB1900 Signals from operator panel [r/w] HMI ->...
  • Page 440: Auxiliary Functions Transfer From Nc Channel

    5004 ... T-number for tool measurement in JOG (DINT) 5007 5008 ... 5011 5012 ... 5015 5016 ... 5019 17.7 Auxiliary functions transfer from NC channel 17.7.1 Overview DB2500 Auxiliary functions from NCK channel [r] NCK -> PLC interface Byte Bit 7 Bit 6 Bit 5...
  • Page 441: Decoded M Signals (m0 To M99)

    17.7.2 Decoded M signals (M0 to M99) Note The signals are output for the duration of a PLC cycle. DB2500 M functions from NCK channel [r] 1) 2) NCK -> PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1...
  • Page 442: Transferred S Functions

    3036 Extended address M function 5 (byte) 17.7.5 Transferred S functions DB2500 S functions from NCK channel [r] NCK -> PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 4000 S function 1 (REAL) (DINT) 4004 Extended address S function 1 (byte)
  • Page 443: General Signals From Nck

    Refer to mode signals 17.8.2 General signals from NCK DB2700 General signals from NCK [r/w] NCK -> PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 EMERGEN CY OFF active Inch meas- Probe actuated uring sys-...
  • Page 444: Signals From Fast Inputs And Outputs

    Value from PLC for digital NCK outputs Output 8 Output 7 Output 6 Output 5 Output 4 Output 3 Output 2 Hardware output Setting mask for NCK outputs Output 8 Output 7 Output 6 Output 5 Output 4 Output 3 Output 2 Hardware output...
  • Page 445: Channel Signals

    17.9 Channel signals 17.9.1 Signals to NC channel Control signals to NC channel DB3200 Signals to NCK channel [r/w] PLC -> NCK interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Activate Activate Activate...
  • Page 446 Program branches (GOTOS) control Select single-block type selection using the softkey. 31 positions (Gray code) Controls signals to axes in Work DB3200 Signals to NCK channel [r/w] PLC -> NCK interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1...
  • Page 447: Signals From Nc Channel

    1011 Invert handwheel direction The handwheel number is represented according to the $MD_HANDWH_VDI_REPRESENTATION machine data in a bit-coded (=0) or binary-coded (=1) manner. Machine function: the machine function is only entered if the "INC inputs in the operating-mode signal range active" signal (DB2600.DBX1.0) is not set.
  • Page 448 Area 8 Area 7 Area 6 Area 5 Area 4 Area 3 Area 2 Area 1 Channel-specific protection zone violated Area 10 Area 9 Status signals, axes in Work DB3300 Signals from NCK channel [r] NCK → PLC interface Byte Bit 7 Bit 6 Bit 5...
  • Page 449 Additional status signals from NC channel DB3300 Signals from NCK channel [r] NCK → PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 4000 G00 active 4001 Travel Workpiece External request, setpoint language...
  • Page 450: Axis/spindle Signals

    Asynchronous subroutines (ASUPs): Result DB3400 ASUP: Result [r] NCK → PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 1000 INT1 ASUP exe- Interrupt ASUP is ASUP end- cution not no.
  • Page 451 Axis/spindle Veloci- Activate fixed feedrate Enable enable ty/spindle approach to Feed 4 Feed 3 Feed 2 Feed 1 program speed limit- fixed stop test Traversing keys Rapid trav- Traverse Feedrate Activate handwheel erse over- key disable stop/spindle Plus Minus ride stop Machine function Continuous...
  • Page 452 2003 Spindle override Signals to drive DB3800 ... Signals to axis/spindle [r/w] 3803 PLC -> NCK interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 4000 Holding brake 4001 Pulse ena- Integrator disable speed con-...
  • Page 453: Signals From Axis/spindle

    17.10.3 Signals from axis/spindle General signals from axis/spindle DB3900 ... Signals from axis/spindle [r] 3903 NCK -> PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Position reached Referenced Encoder limit freq. ex- Spindle/no ceeded axis...
  • Page 454 Signals from spindle DB3900 ... Signals from spindle [r] 3903 NCK -> PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 2000 Change Setpoint gear stage gear stage 2001 Actual Speed Spindle in Overlay...
  • Page 455 5006 5007 Synchro- nism over- ride is factored in 5008 Active special axis (grinding) Axis 6 Axis 5 Axis 4 Axis 3 Axis 2 Axis 1 17.11 PLC machine data 17.11.1 INT values (MD 14510 USER_DATA_INT) DB4500 Signals from NCK [r16] NCK ->...
  • Page 456: User Alarm: Configuring (md 14516 User_data_plc_alarm)

    17.11.4 User alarm: Configuring (MD 14516 USER_DATA_PLC_ALARM) DB4500 Signals from NCK [r8] NCK -> PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 3000 Alarm response/cancel criteria, alarm 700000 3001 Alarm response/cancel criteria, alarm 700001 3002 Alarm response/cancel criteria, alarm 700002...
  • Page 457: Axis Actual Values And Distance-to-go

    Note The programming engineer (NCK and PLC) is responsible for organizing (structuring) this memory area. Every storage position in the memory can be addressed provided that the limit is selected according to the appropriate data format (i.e. a 'DWORD' for a 4byte limit, a WORD for a 2byte limit, etc.). The memory area is always accessed with the information about the data type and the position offset within the memory area.
  • Page 458: User Interface For Ctrl Energy

    Number of warnings to be output 2 Reserved_1 2 Reserved_2 2 Interval 32 [h] Number of warnings to be output 32 Reserved_1 32 Reserved_2 32 17.15 User interface for ctrl energy Energy saving profile DB9906 Ctrl energy Byte Bit 7 Bit 6 Bit 5 Bit 4...
  • Page 459: A.1 Operation And Display

    State conditions (HMI -> PLC) Machine control panel State conditions (HMI -> PLC) NC channel 1 in reset State conditions (HMI -> PLC) PLC user Master signal computer signal State conditions (HMI -> PLC) Activation time T1 State conditions (HMI -> PLC) Activation time T2 Appendix Operation and display...
  • Page 460 You can use the BOP for following operations: ● Standalone commissioning ● Diagnosis ● Parameter access ● Parameter settings ● SD card operation ● Drive restart Button functions Button Description Remarks Exits from current menu M button • Switches between operating modes in the top level menu •...
  • Page 461 BOP display Display Example Description Remarks 8.8.8.8.8.8. Drive is in startup state Takes 20 s to 30 s ------ Drive is busy In the case of a task being executed Fxxxxx Fault code In the case of a single fault F.xxxxx.
  • Page 462 Display Example Description Remarks P.ara Editable parameter group The dot means that at least one parameter has been changed without saving Data Read-only parameter group Func Function group See Section "Auxiliary functions (Page 466)". Addr Set Drive Bus address See Section "Setting Drive Bus address (Page 467)".
  • Page 463: A.1.1.2 Parameter Structure

    A.1.1.2 Parameter structure You can navigate through the parameter structure by pressing the keys as shown in the sequences below. Commissioning Manual 01/2017...
  • Page 464: A.1.1.3 Actual Status Display

    A.1.1.3 Actual status display You can monitor the following drive states by using the operating panel after power-on: ● Servo off ● Actual speed ● Torque ● Voltage If the servo enable signal is available, actual drive speed is displayed by default; otherwise, "S OFF" (servo off) is displayed. With p29002, you define which of the following drive operating status data is to be displayed on the BOP.
  • Page 465 If you change a parameter value with method 1, proceed as follows: To change a parameter value digit by digit, proceed as follows: Note You cannot change parameters p1414 and p1656 with the SHIFT button. Commissioning Manual 01/2017...
  • Page 466: A.1.1.5 Auxiliary Functions

    Viewing parameters If a parameter has no index, view its value as follows: If a parameter has indices, view its value as follows: A.1.1.5 Auxiliary functions Seven BOP functions in total are available: ① ⑤ Set Drive Bus address Copy parameter set from drive to an SD card ②...
  • Page 467 Setting Drive Bus address When connecting the SINAMICS V70 to the SINUMERIK 808D ADVANCED, you must set the Drive Bus address with the BOP. Five addresses in total are available: ● 11: X axis ● 12: Y axis (or additional axis for the turning variant of the control system) ●...
  • Page 468 Saving parameter set in drive (RAM to ROM) This function is used for saving a parameter set from drive RAM to drive ROM. To use this function, proceed as follows: Note Plugging or unplugging the SD card will cause saving failure. Do not plug or unplug the SD card during saving;...
  • Page 469 For more information, see Section "Transferring data (drive to SD card) (Page 468)". Note Before performing the firmware update, Siemens recommends you to disable the communication between the drive and the control system by removing the Drive Bus cable from the drive; otherwise, after the firmware update you may need to power off/on the control system to clear possible alarms.
  • Page 470 After updating the firmware, you must restore the drive data through any of the following methods: Restoring the drive data via the control system • For more information about restoring a startup archive, see the SINUMERIK 808D/SINUMERIK 808D ADVANCED Operating and Programming manuals. Restoring the drive data via the SD card •...
  • Page 471: A.1.2 Operating The Sinamics V60 Basic Operator Panel (bop)

    A.1.2 Operating the SINAMICS V60 Basic Operator Panel (BOP) A.1.2.1 BOP overview Button functions Button Description Function Exits from current menu Mode selection • button Switches between operating modes in the top level menu • Go to next lower-level menu item or back to higher-level item Enter button •...
  • Page 472 BOP display Display Example Description Preconditions for display of normal status No error code appears 8.8.8.8.8.8 Initializes the drive (drive self- • testing at power-on) and stay for No power supply (24 VDC) fault • about one second during the pro- cess No power supply (24 VDC) fault Precharges the drive (waiting for...
  • Page 473: A.1.2.3 Function Menu

    A.1.2.3 Function menu Display and settings ① If the current drive operating status supports the JOG function, "J-Run" is displayed; otherwise, "Forbid" is displayed. ② Keeping the UP button pressed can make the motor run counter-clockwise. Keeping the DOWN button pressed can make the motor run clockwise.
  • Page 474 Note Current display status Accessibility to JOG mode or the mode of saving user parameters depends on the current display status of the drive: When the drive is in "S-4" (waiting for pulse enable) state, access to JOG mode is possible; alternatively, when the drive •...
  • Page 475: A.1.2.4 Parameter Setting Menu

    A.1.2.4 Parameter setting menu Display and settings ① "P01" is displayed by default at first power-on only. • The last parameter you changed before power-off is displayed by default at the next power-on. • To change parameter settings, change the default setting of P01 first. •...
  • Page 476: A.1.2.5 Data Display Menu

    BOP display Display Example Description Preconditions for display of normal status Parameter number xxxx.x/xxxx.xx Parameter value Para. At least one parameter is changed without saving Pxx. This parameter is changed without saving A.1.2.5 Data display menu Display and settings Note For detailed description of display data, see Section "SINAMICS V60 parameters (Page 427)".
  • Page 477: A.2 Replacing The Fan For The V70 Drive

    Replacing the fan for the V70 drive Proceed as illustrated below to remove the fan from the drive. To re-assemble the fan, proceed in reverse order. When re- assembling the fan, make sure that the arrow symbol ("A" in the illustration) on the fan points to the drive rather than the fan housing.
  • Page 478 Replacing the fan for V70 FSC Commissioning Manual 01/2017...
  • Page 479 Replacing the fan for V70 FSD Commissioning Manual 01/2017...
  • Page 480: A.3 Replacing The Fan For The 1ph1 Motor

    Replacing the fan for the 1PH1 motor Proceed through the steps as illustrated below to remove the fan from the motor. To reassemble the fan, proceed in reverse order. Assembling the power cable for the 1PH1 motor For more information about selecting a proper power cable for the 1PH1 motor, see Section "Cables and connectors (Page 27)".
  • Page 481 Assembling procedure Motor side 1. Strip the specified length (see below) of the outer sheath at the end of the cable. 4 x 2.5 mm power cable: 125 mm all other power cables: 135 mm 2. Cut off the exposed braided shield in its entirety. 3.
  • Page 482 Drive side 1. Strip the specified length (see below) of the outer sheath at the end of the cable. 4 x 2.5 mm /4 x 4 mm power cable: 100 mm 4 x 10 mm /4 x 16 mm power cable: 110 mm 2.
  • Page 483: A.5 Assembling The Line Supply Terminal For The Drive

    Assembling the line supply terminal for the drive Drive variant Assembling procedure Illustration SINAMICS V70 1. Strip the specified length (see illustra- tion) of the insulation at the end of the wire. 2. Insert the stripped end into the pin- type terminal.
  • Page 484: A.7 Customizing Pre-defined Labeling Strips For Keys Of The Mcp

    To cut a reserved hole, proceed as follows: Customizing pre-defined labeling strips for keys of the MCP Note The horizontal MCP with a reserved slot for the handwheel is designed for turning machines only. The customization of the pre-defined labeling strips for keys is not supported by this MCP variant. Replacing the MCP strips The MCP strips of the turning version are already pre-assembled into the MCP.
  • Page 485: A.8 Diagnostics

    (...\examples\SINUMERIK_808D_ADVANCED\MCP). Siemens also provides you with a template file for printing customized strips. Key positions in the template accord with real key layout on the MCP. You can copy symbols from the symbol library and paste them to the key positions where you want to use customized symbols.
  • Page 486: A.8.2 Sinamics V70 Faults And Alarms

    Note: You can further press this softkey in the current help screen to show a complete list of all SINUMERIK 808D/SINUMERIK 808D ADVANCED alarms. In addition, you can also use the following softkey to search for a specific alarm by number in this list: Pressing this softkey exits the help system.
  • Page 487: A.8.2.2 List Of Faults And Alarms

    Acknowledgement Description IMMEDIATELY Faults disappear immediately after the fault causes have been eliminated. NOTE: These faults can also be acknowledged by a POWER ON operation. • If this action has not eliminated the fault cause, the fault will continue to be displayed after •...
  • Page 488 Fault Cause Remedy Carry out a POWER ON (power off/on) for F1002: Internal software An internal software error has occurred. • all components. error Upgrade firmware to the latest version. • Reaction: OFF2 Contact the Hotline. • Acknowledgement: IMMEDIATELY Carry out a POWER ON (power off/on) for F1003: Acknowledgement A memory area was accessed that does •...
  • Page 489 Fault Cause Remedy Physically check the bus (cables, connect- F1912: Clock cycle synchro- The maximum permissible number of • ors, terminating resistor, shielding, etc.). nous operation sign-of-life errors in the controller sign-of-life (clock failure synchronous operation) has been exceed- Correct the interconnection of the controller •...
  • Page 490 Fault Cause Remedy If the encoder mounting was changed, re- F7412: Commutation angle An incorrect commutation angle was de- • adjust the encoder. incorrect (motor model) tected that can result in a positive coupling in the speed controller. Replace the defective motor encoder. •...
  • Page 491 Fault Cause Remedy F7452: Following error too The difference between the position set- Check the causes and resolve. high point position actual value (following error dynamic model) is greater than the toler- Reaction: OFF1 ance. Acknowledgement: The drive torque or accelerating capac- •...
  • Page 492 Fault Cause Remedy F7995: Pole position identifi- The pole position identification routine was Contact the Hotline. cation not successful unsuccessful. Reaction: OFF2 Acknowledgement: IMMEDIATELY Check the motor data - if required, carry out F30001: Power unit: Over- The power unit has detected an overcur- •...
  • Page 493 Fault Cause Remedy Check the main circuit fuses. F30011: Line phase failure At the power unit, the DC link voltage • in main circuit ripple has exceeded the permissible limit Check whether a single-phase load is dis- • value. torting the line voltages. Reaction: OFF2 Possible causes: Check the motor feeder cables.
  • Page 494 Fault Cause Remedy Check the 24 V power supply. F30050: 24 V supply over- The voltage monitor signals an overvolt- • voltage age fault on the module. Replace the module if necessary. • Reaction: OFF2 Acknowledgement: POWER F30071: No new actual The number of actual value telegrams Replace the module if necessary.
  • Page 495 Fault Cause Remedy Check the encoder cable and shielding F31110: Serial communica- Serial communication protocol transfer • connection. tions error error between the encoder and evaluation module. Replace the motor. • Reaction: ENCODER Acknowledgement: PULSE INHIBIT Check the encoder cable connection, and F31111: Encoder 1: Abso- The absolute encoder fault word supplies •...
  • Page 496 Fault Cause Remedy Commissioning of the servo motor has F52984: Incremental encod- • Configure the motor ID by setting the parame- failed. er motor not configured ter p29000. An incremental encoder motor is con- • Reaction: OFF1 nected but not commissioned. Acknowledgement: IMMEDIATELY Motor ID is downloaded wrong during...
  • Page 497 A5000: Drive heat sink over- The alarm threshold for overtemperature Check the following: temperature at the inverter heat sink has been reached. Is the surrounding air temperature within • the defined limit values? If the temperature of the heat sink in- creases by an additional 5 K, then fault Have the load conditions and the load duty •...
  • Page 498 A30031: Hardware current Hardware current limit for phase U re- Check the motor data. As an alternative, run a limiting in phase U sponded. The pulsing in this phase is motor data identification. inhibited for one pulse period. Check the motor circuit configuration (star- •...
  • Page 499: A.8.3 Sinamics V60 Faults And Alarms

    A.8.3 SINAMICS V60 faults and alarms A.8.3.1 Overview Alarm code Description Unable to identify the power board Parameter validation error (CRC error, encoder type or parameter header invalid) Unable to write data to memory Control voltage is lower than 3.5 V. IGBT is detected overcurrent.
  • Page 500 Alarm Background Possible Cause Remedy code IGBT module is broken Replace the drive with a new This alarm may occur • • when the DC link is There is a short-circuit between U, V or W • connected and PE Check the wiring •...
  • Page 501 Alarm Background Possible Cause Remedy code value is greater than There is shaft move when the drive is in "S-2", When P38 = 1, check whether the 1000 pulses when the "S-3", or "S-4" state motor shaft moves more than 1000 drive is in "S-2", "S-3", pulses when the drive is in "S-2", or "S-4"...
  • Page 502: A.8.3.3 Errors During Drive Self-test

    Alarm Background Possible Cause Remedy code The 65 enable signal is lost when the motor is Check the 65 enable terminal running NOTICE Result Alarms with alarm code < A41 result in free stop, while alarms with alarm code ≥ A41 result in emergency stop. NOTICE Cancelling an alarm Alarms with alarm code <...
  • Page 503: A.9 Amm Communication Tool

    AMM communication tool With the communication tool Access MyMachine (AMM), you can establish an Ethernet connection and realize data transfer between the control system and a computer. This tool is available in the Toolbox and is supported by Windows Vista/Win 7. Ethernet connections The following Ethernet connections are possible between the control system and the AMM tool on the computer: ●...
  • Page 504 Transferring a file to the control system The file transfer between the control system and a computer is possible by means of simple copy and paste/drag and drop operations. Proceed as follows to transfer a program file from a computer to the control system: Open the main screen of the AMM tool on your computer.
  • Page 505: A.9.2 Remote Control

    A.9.2 Remote control A.9.2.1 Configuring the remote control With the remote control function you can perform the following operations: ● Operating the HMI remotely from a computer ● Generating screenshots of the HMI and saving them onto a computer Note To use the remote control function of AMM, make sure you enable the communication ports 22 and 5900 on the HMI.
  • Page 506 ② Use the following key to select the automatic response for the control system after the above dialog box disappears with no softkey operations. Press this softkey to save the settings. Starting/stopping remote control Proceed through the following steps to start/stop the remote control of the HMI: Start the AMM tool and establish an Ethernet connection to the control system (see section "Connecting with AMM (Page 51)").
  • Page 507 A.9.2.2 Operating the HMI via remote control If the remote control has been started, you can use your mouse to operate the HMI by clicking on the softkeys displayed in the monitoring window. You can perform the return operation by clicking the icon in the screen when possible.
  • Page 508 Click this button to save the picture. Trademarks All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

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Sinumerik 808d

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