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Siemens SINUMERIK 808D Commissioning Manual
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Siemens SINUMERIK 808D Commissioning Manual

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See also: Programming and Operating Manual , Diagnostic Manual
Commissioning Manual
SINUMERIK
SINUMERIK 808D
Commissioning Manual
Commissioning Manual
Valid for the following control systems:
SINUMERIK 808D Turning (software version: V4.4.2)
SINUMERIK 808D Milling (software version: V4.4.2)
Target group:
Electrical engineers, calibration engineers and testing
01/2015
6FC5397-4EP10-0BA0
___________________
Delivery check
___________________
Mounting
___________________
Connecting
___________________
Switching on and preparing
for commissioning
___________________
Commissioning diagram
___________________
Default PLC applications
___________________
Commissioning the prototype
___________________
Series production
___________________
Other frequently used
functions
___________________
Appendix
1
2
3
4
5
6
7
8
9
A

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Summary of Contents for Siemens SINUMERIK 808D

  • Page 1 Commissioning the prototype ___________________ Series production ___________________ Other frequently used functions ___________________ Appendix Valid for the following control systems: SINUMERIK 808D Turning (software version: V4.4.2) SINUMERIK 808D Milling (software version: V4.4.2) Target group: Electrical engineers, calibration engineers and testing 01/2015 6FC5397-4EP10-0BA0...
  • Page 2 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.

  • Page 3: Table Of Contents

    Table of contents Delivery check ............................7 Mounting ..............................13 Mounting the controller ......................13 Mounting the drive ........................15 Mounting the motor ......................... 18 Connecting .............................. 19 Interface overview ........................19 Connecting the battery ......................21 Connecting according to the default PLC program ..............22 Connection Overview ......................
  • Page 4 Parameter list ......................... 93 A.5.1 Basic machine data ........................ 93 A.5.2 SINAMICS V60 parameters ....................97 Diagnostics ..........................99 A.6.1 SINUMERIK 808D alarms ...................... 99 A.6.2 SINAMICS alarms ........................99 A.6.2.1 Overview of alarms ........................ 99 A.6.2.2 Alarm list ..........................100 A.6.2.3...
  • Page 5 Table of contents A.6.2.5 Display data list ........................104 PLC user interfaces ......................106 A.7.1 Addressing ranges ........................ 106 A.7.2 MCP ............................108 A.7.2.1 Signals from MCP ......................... 108 A.7.2.2 Signals to MCP ........................108 A.7.2.3 Reading/writing NC data: Job ....................109 A.7.2.4 Reading/writing NC data: Result ...................
  • Page 6 Table of contents A.7.10.2 Signals from NC channel ..................... 127 A.7.11 Signals, synchronized actions ....................130 A.7.11.1 Signals, synchronized actions to channel ................130 A.7.11.2 Signals, synchronized actions from channel ................ 130 A.7.11.3 Reading and writing PLC variables ..................131 A.7.12 Axis actual values and distance-to-go .................

  • Page 7: Delivery Check

    Delivery check System overview The SINUMERIK 808D is an economic CNC solution for milling and turning machines in the global market. For the turning variant, it is designed to control three axes, including two feed axes via two pulse drive interfaces (with SINAMICS V60) and one spindle via one analog spindle interface.
  • Page 8 Delivery check The following diagram shows a system configuration example for the SINUMERIK 808D control system: Note: The following devices in this diagram are not standard system components: - PC - USB - Handwheel - +24VDC power supply - Inverter or servo spindle drive...
  • Page 9 Delivery check NOTICE Using a copper protective earth conductor with a cross section of 10 mm to connect the PE terminal of V60 to the protective earth. For the NC and 24 VDC power supply, there are no special requirements of the cross section of the copper protective earth conductor. For the inverter or servo spindle drive, it is recommended to refer to the relevant specifications to confirm the cross section of the copper protective earth conductor.
  • Page 10 Setpoint cable to SINAMICS V60 (for feed axis) 2 (turning) or 3 (milling) Setpoint cable to Siemens inverter or third-party drive (for spindle) 1 Note Emergency stop button is not included in our scope of delivery. You can, if necessary, con- tact your local Siemens salesperson for it.
  • Page 11 Delivery check Table 1- 6 Cables individually packaged Component Quantity (pieces) Power cable (unshielded) Brake cable (unshielded) Encoder cable (shielded) Cabinet grounding guide Figure 1-2 Cabinet grounding Commissioning Manual Commissioning Manual, 01/2015, 6FC5397-4EP10-0BA0...
  • Page 12 Delivery check Note that the PE/PEN busbar in the cabinet must connect to the ground through a grounding cable with a cross section ≥ 10 mm as illustrated below. Figure 1-3 Busbar grounding Commissioning Manual Commissioning Manual, 01/2015, 6FC5397-4EP10-0BA0...

  • Page 13: Mounting

    Mounting Mounting the controller Cut-out dimensions Figure 2-1 Cut-out dimensions (in mm) Note Make sure there is enough space around the PPU and the MCP for tightening the screws in the control cabinet. Commissioning Manual Commissioning Manual, 01/2015, 6FC5397-4EP10-0BA0...
  • Page 14 Mounting 2.1 Mounting the controller Mounting dimensions Figure 2-2 Mounting dimensions for PPU (in mm) Figure 2-3 Mounting dimensions for MCP (in mm) Commissioning Manual Commissioning Manual, 01/2015, 6FC5397-4EP10-0BA0...

  • Page 15: Mounting The Drive

    Mounting 2.2 Mounting the drive Mounting clearance (in mm) To ensure easy maintenance purpose, you must provide sufficient clearance (recommended distance: 80 mm) between the maintenance door and the cabinet wall for replacing the battery and CF card: ① ② Cabinet panel Maintenance door Mounting the drive...
  • Page 16 Mounting 2.2 Mounting the drive Figure 2-5 10 A version (in mm) Mounting method With 4xM5 preassembled screws, the drive can be mounted vertically onto the inner panel of the cabinet. The maximum screw torque must be 2.0 Nm. Minimum mounting clearance To ensure adequate cooling, as a minimum, maintain the specified clearance between drives, one drive and another device/inner panel of the cabinet.
  • Page 17 Make sure that the clamp for fixing the shielded power cable has a good contact with the cable shield. Note Siemens does not provide the shielded power cable. Please prepare the shielded power cable by yourselves for CE certification. After the installation, it is recommended that the terminal screws should be checked to ensure that they are tight.

  • Page 18: Mounting The Motor

    Mounting 2.3 Mounting the motor Mounting the motor Mounting dimensions (mm) Motor type A (in mm) B (in mm) 4 Nm 163 (205) 6 Nm 181 (223) 7.7 Nm 195 (237) 10 Nm 219 (261) Note Value in brackets is the length of a motor with a built-in brake unit. Motors with plain shaft have the same dimensions.

  • Page 19: Connecting

    Connecting Interface overview Interface overview on the Panel Processing Unit (PPU) NOTICE The + 24 V and M signals of X200 must be connected; otherwise, the communication between the PPU and the drives does not function as it should. Figure 3-1 Interface layout Commissioning Manual Commissioning Manual, 01/2015, 6FC5397-4EP10-0BA0...
  • Page 20 Connecting 3.2 Connecting the battery Legend Interface Comment Rear ① X100, X101, X102 Digital inputs ② X200, X201 Digital outputs ③ FAST I/O ④ X301, X302 Distributed I/O ⑤ Hand-wheel inputs ⑥ Spindle encoder interface ⑦ Analog spindle interface ⑧ RS232 interface ⑨...

  • Page 21: Connecting The Battery

    Connecting 3.2 Connecting the battery Connecting the battery A battery has been pre-assembled on the back cover of the PPU. The battery is not connected when delivered. You must plug the battery connector into the battery interface by yourself before switching the controller on. You can access it after removing the maintenance door: ①...

  • Page 22: Connecting According To The Default Plc Program

    3.3 Connecting according to the default PLC program Connecting according to the default PLC program The SINUMERIK 808D has integrated with a default PLC application. If you perform the commissioning work with the default PLC application, perform wiring as follows.
  • Page 23 Connecting 3.3 Connecting according to the default PLC program Figure 3-4 Connecting the digital inputs and outputs (Turning) Commissioning Manual Commissioning Manual, 01/2015, 6FC5397-4EP10-0BA0...
  • Page 24 Connecting 3.3 Connecting according to the default PLC program Connecting the distributed I/O Figure 3-5 Connecting the distributed I/O Connecting the SINAMICS V60 (take X51: axis X for an example) Figure 3-6 Connecting the SINAMICS V60 (X51: axis X) 1) If necessary, you can also serially connect an emergency stop switch between the 65 enable signal and the 24V signal. Commissioning Manual Commissioning Manual, 01/2015, 6FC5397-4EP10-0BA0...
  • Page 25 A line filter (rated current: 16 A, protection level: IP20) is required so that the system can pass the CE certification (radiated emission test or conducted emission test). The order number of Siemens recommended filter is 6SN1111-0AA01-1BA1. Note Circuit breaker You can install a mains linear breaker (rated current: 15 A for 7 A or 10 A version of the drive and 10 A for 4 A or 6 A version of the drive;...
  • Page 26 Connecting 3.3 Connecting according to the default PLC program Figure 3-8 Connecting the inverter or the servo spindle drive (bipolar) 1) +/- 10 V analog voltage 2) 0 V signal 3) Use twisted pair cables for signals A/A_N, B/B_N, Z/Z_N, and +5 V/M. Note Cables for connecting X21 must be shielded ones.

  • Page 27: Connection Overview

    Connecting 3.4 Connection Overview Connection Overview Commissioning Manual Commissioning Manual, 01/2015, 6FC5397-4EP10-0BA0...
  • Page 28 Connecting 3.4 Connection Overview Note For the turning variant, connection to X52 is optional and depends upon whether you use the software option "additional axis". If you desire to configure the control system to control a rotary axis or an additional linear axis, connect X52 to a SINAMICS V60 which connects to a servo motor.

  • Page 29: Switching On And Preparing For Commissioning

    Switching on and preparing for commissioning DANGER Carrying out of repairs Anywhere in the automation equipment where faults might cause physical injury or major material damage, in other words, where faults could be dangerous, additional external pre- cautions must be taken, or facilities must be provided, that guarantee or enforce a safe operational state, even when there is a fault (e.g.

  • Page 30: Ppu Keyboard Function

    Switching on and preparing for commissioning 4.2 PPU keyboard function PPU keyboard function Legend Name Description ① Return key Returns to higher level menu ② Horizontal softkeys Call corresponding menu functions ③ Extension key Reserved. No function ④ Vertical softkeys Call corresponding menu functions ⑤...

  • Page 31: Mcp Mode Changeover

    Switching on and preparing for commissioning 4.3 MCP mode changeover MCP mode changeover Use the machine control panel (MCP) to make changeover between the JOG mode, the Ref Point mode, the AUTO mode and the MDA mode. The MCP key layout is shown below: Legend Name Description...

  • Page 32: Status Leds

    Switching on and preparing for commissioning 4.4 Status LEDs Status LEDs LEDs on the PPU The following LEDs are installed on the SINUMERIK 808D PPU. The individual LEDs and their functions are described in the table below. Table 4- 1 Status and error displays...

  • Page 33: Password

    ● Password has been deleted ● A higher or lower access level is required Access levels The SINUMERIK 808D provides a concept of access levels for enabling data areas. You can view such information from the table below: Table 4- 3...
  • Page 34 Switching on and preparing for commissioning 4.5 Password With the access level "Manufacturer", you can perform the following operations: ● Inputting or modifying all the machine data ● Commissioning work With the access level "Customer", you can perform the following operations: ●...

  • Page 35: Setting A Password

    Switching on and preparing for commissioning 4.5 Password Access level: No password If you have deleted your password or do not set a password, you only have the access right of viewing above-mentioned function areas. Note The system has no password by default. 4.5.2 Setting a password The control system is delivered without a password.

  • Page 36: Setting The Date And Time

    Switching on and preparing for commissioning 4.6 Setting the date and time Setting the date and time At delivery, the system date and time remain at the factory settings, and thus you must manually modify the date and time. Proceed as follows to set the date and time: 1.

  • Page 37: Introduction To The Onboard Assistants

    4.7 Introduction to the onboard assistants Introduction to the onboard assistants The SINUMERIK 808D system software has three onboard assistants: ● Startup assistant (requires "Manufacturer" access level) This on-board assistant is designed to help you commission the prototype. With this assistant, you can complete basic machine tool functions.
  • Page 38 Switching on and preparing for commissioning 4.7 Introduction to the onboard assistants How can I use the assistants? Status indicators: Completed task Current task Partially completed task group Uncompleted task Press one of the three softkeys to access the corre- sponding assistant Press to start the assistant Press to return to the main screen of the onboard as-...

  • Page 39: Commissioning Diagram

    Commissioning diagram You can commission the SINUMERIK 808D in two ways: ● Alternative 1: with the onboard assistants ● Alternative 2: without the onboard assistants When commissioning with the onboard assistants, just follow the assistants step by step. In this manual, only the second way is described. To do the commissioning work without the...
  • Page 40 Commissioning diagram Commissioning Manual Commissioning Manual, 01/2015, 6FC5397-4EP10-0BA0...

  • Page 41: Default Plc Applications

    Default PLC applications Turning Overview of the PLC subroutines Subroutine No. Name Description 0 to 19 Reserved for the manufacturer AUX_MCP Auxiliary function AUX_LAMP Lamp control, called in the subroutine "AUX_MCP". PLC_ini_USR_INI Reserved for the initialization by the manufacturer (this subroutine is automati- cally called by subroutine 32) PLC_INI PLC initialization...
  • Page 42 Default PLC applications 6.1 Turning Definition of user-defined keys on the MCP User-defined key 1 Working lamp User-defined key 2 Manual cooling User-defined key 3 Manual tool change User-defined key 4 Manual chuck clamping and unclamping User-defined key 5 Chuck clamping internally/externally User-defined key 6 Tailstock Structure of the sample application (OB1)
  • Page 43 Default PLC applications 6.1 Turning Alarm No. Interface Address Alarm Description From SBR 700027 DB1600.DBX3.3 Approach reference point again after rotation SBR40: AXIS_CTL monitoring 700028 DB1600.DBX3.4 Tool is not locked SBR53: Turret3_CODE_T 700049 DB1600.DBX6.1 Reference point X-axis not reached SBR58: MM_MAIN 700050 DB1600.DBX6.2 Reference point Z-axis not reached...
  • Page 44 Default PLC applications 6.1 Turning MD14512 Function Machine data Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 - Hex 14512[16] Handwheel Control of Z Control of assignment with axis rotation X axis the MCP monitoring rotation...

  • Page 45: Milling

    Default PLC applications 6.2 Milling Milling Overview of the PLC subroutines Subroutine No. Name Description 0 to 19 Reserved for the manufacturer AUX_MCP Auxiliary function AUX_LAMP Lamp control, called in the subroutine "AUX_MCP". AUX_SAFE_DOOR Safe door control, called in the subroutine "AUX_MCP" of a milling application. AUX_CHIP Chip remover control, called in the subroutine "AUX_MCP"...
  • Page 46 Default PLC applications 6.2 Milling Structure of the sample application (OB1) Call Conditions Subroutine Name Description First scan (SM0.1) PLC_INI (SBR32) PLC initialization Each scan (SM0.0) EMG_STOP (SBR33) Emergency Stop control Each scan (SM0.0) MCP_NCK (SBR37) Transferring MCP and HMI signals to the NCK interface Each scan (SM0.0) HANDWHL (SBR39) Selecting a hand wheel through the interface signal V1900 1xxx...
  • Page 47 Default PLC applications 6.2 Milling Relevant machine data MD14510 Unit Range Function Machine data - Integer 14510[12] 0 to 1 JOG key layout 14510[20] 2 to 64 The maximum number of tool positions 14510[24] 1 min 5 to 300 Lubrication interval 14510[25] 0.01s 100 to 2,000...

  • Page 48: Plc User Alarms

    PLC user alarms can be used as one of the most effective diagnosis methods. The SINUMERIK 808D control system provides 128 PLC user alarms (700xxx). Each alarm corresponds with an alarm variable that is relevant to an alarm text, and each alarm corresponds with a machine data MD14516 used to configure alarm properties.
  • Page 49 Default PLC applications 6.3 PLC user alarms Configuring the properties Each user alarm has a corresponding 8-bit parameter called "USER_DATA_PLC_ALARM": MD14516[0] to MD14516[127]. You can configure a cancelling method and a response for each user alarm based on your actual situation. The parameter structure is shown as follows: Note •...

  • Page 50: Activating The Plc User Alarms

    Default PLC applications 6.3 PLC user alarms Alarm description Interface address MD14516 700028 Tool is not locked DB1600.DBX3.4 MD14516[28] 700029 Reminding information for 1st service plan DB1600.DBX3.5 MD14516[29] 700030 Alarm for 1st service plan DB1600.DBX3.6 MD14516[30] 700031 Magazine not in spindle position or original position DB1600.DBX3.7 MD14516[31] 700032...
  • Page 51 Default PLC applications 6.3 PLC user alarms PLC user alarms list with corresponding interface addresses and variables Alarm description Interface address Variable 700000 DB1600.DBX0.0 DB1600.DBD1000 700009 DB1600.DBX1.1 DB1600.DBD1036 700010 HHU is active DB1600.DBX1.2 DB1600.DBD1040 700011 Not able to lock tool in expected time DB1600.DBX1.3 DB1600.DBD1044 700012...

  • Page 52: Editing A Plc User Alarm Text

    For more information about NC-PLC interfaces, refer to the Manual 6.3.4 Editing a PLC user alarm text For the SINUMERIK 808D control system, you have two methods to edit a PLC user alarm text: ● the HMI ● a USB stick...
  • Page 53 Default PLC applications 6.3 PLC user alarms 4. Press the "Edit text" softkey, and input the text you want to define: 5. Press the "OK" softkey to confirm your entry. Note You can create the alarm text either in English or in simplified Chinese. Note If you want to create an alarm text in Chinese, you must first change the system language to simplified Chinese ("SYSTEM"...
  • Page 54 Default PLC applications 6.3 PLC user alarms 3. Select the file "PLC alarm texts (alcu..txt)", press the <INPUT> key and select a file for a specific language. Press the "Copy" vertical softkey: 4. Press the "USB" horizontal softkey and press the "Paste" vertical softkey. 5.
  • Page 55 Default PLC applications 6.3 PLC user alarms 11. In the "SYSTEM" operating area, press the "USB" softkey. Locate the modified PLC alarm text and press the "Copy" vertical softkey: 12. Press the "808D data" horizontal softkey, enter directory "HMI data" > "PLC alarm texts (alcu..txt)"...
  • Page 56 Default PLC applications 6.3 PLC user alarms Commissioning Manual Commissioning Manual, 01/2015, 6FC5397-4EP10-0BA0...

  • Page 57: Commissioning The Prototype

    The activating condition for a machine data is shown at the end of the data line in the parameter lists. For information about basic machine data, refer to the section "Basic machine data (Page 93)"; for information about all the machine data, refer to the SINUMERIK 808D Parameter Manual Commissioning Manual Commissioning Manual, 01/2015, 6FC5397-4EP10-0BA0...

  • Page 58: Setting The Axis-Relevant Parameters

    Commissioning the prototype 7.1 Commissioning the controller 7.1.2 Setting the axis-relevant parameters 7.1.2.1 Enabling the position control By default, each axis is a simulation axis. This means that the control system neither produces an instruction that is output to the drive, nor reads position signals from the motor. You can enable the position control of this axis by setting the machine data shown in the table below so that the axis goes into the operating state: Name...

  • Page 59: Setting The Axis Speed And Acceleration

    Commissioning the prototype 7.1 Commissioning the controller 7.1.2.3 Setting the axis speed and acceleration You can configure the axis velocity and the acceleration by setting parameters shown in the table below: Name Unit Value Description 32000 MAX_AX_VELO mm/min Maximum axis velocity 32010 JOG_VELO_RAPID mm/min JOG rapid velocity...

  • Page 60: Setting The Spindle-Relevant Parameters

    Commissioning the prototype 7.1 Commissioning the controller 7.1.3 Setting the spindle-relevant parameters The SINUMERIK 808D control system controls one analog spindle, and you can commission the spindle by setting the parameters listed below: Table 7- 1 Enabling the position control...
  • Page 61 Commissioning the prototype 7.1 Commissioning the controller Note The value of MD36200 should be 10% higher than that of MD 32000; otherwise, alarm 025030 occurs. Fill in weighted machine data Name Unit Value Description 36300 ENC_FREQ_LIMIT 300,000 Encoder limit frequency = Motor rated velocity/60 x Encoder resolution Table 7- 4 For spindle with selective gearbox...

  • Page 62: Approaching The Reference Point

    Commissioning the prototype 7.1 Commissioning the controller 7.1.4 Approaching the reference point Principles for approaching the reference point ● Zero mark is away from the reference cam (MD: REFP_SEARCH_MARKER_REVERS = Velocity for searching the reference cam (MD34020: REFP_VELO_SEARCH_CAM) Velocity for searching 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 63 Commissioning the prototype 7.1 Commissioning the controller Relevant parameters Name Unit Value Description 34010 REFP_CAM_DIR_IS_MINUS 0, 1 Direction for approaching the reference point: 0: + • 1: - • 34020 REFP_VELO_SEARCH_CAM mm/min Velocity for searching for the reference cam 34040 REFP_VELO_SEARCH_MARKER mm/min Velocity for searching for the zero mark...

  • Page 64: Compensation Parameter Settings

    Commissioning the prototype 7.1 Commissioning the controller You can also approach the reference point in the trigger mode: once you press the direction key for the reference point, it will return to the reference point automatically. To do this, you must install a reference cam in the way shown in the figure below so that the axis cannot stop between the reference cam and hardware limit switch before it arrives at the reference point.

  • Page 65: Making Leadscrew Error Compensation

    Commissioning the prototype 7.1 Commissioning the controller 7.1.5.3 Making leadscrew error compensation Name Unit Fixed value Description 38000 MM_ENC_COMP_MAX_POINTS The max. number of intermediate points for interpolation compensa- tion Compensation theory Structure of the compensation arrays $AA_ENC_COMP [0, 0, AX3] = 0.0 Error value at the lowest point $AA_ENC_COMP [0, 1, AX3] = 0.0 Error value at the position of the lowest point + 1...
  • Page 66 Commissioning the prototype 7.1 Commissioning the controller Compensation methods You can make the compensation as follows with a USB stick: Method 1: 1. Plug your USB stick into the USB interface at the front of the PPU. 2. Find the compensation file ("SYSTEM" operating area > "Sys. data" > "808D data" > "NCK/PLC data"...
  • Page 67 Commissioning the prototype 7.1 Commissioning the controller Method 2: 1. Follow steps 1 to 4 in method 1. 2. Press the <PROGRAM MANAGER> key. 3. Copy the compensation file from the USB to NC 4. Press the extension softkey ">>" and change the compensation file to a program file with the "Rename"...

  • Page 68: Setting Protection Levels

    "SYSTEM" operating area > " Serv. displ." > "Service axes": Abs. compens. value meas. system 1. 7.1.5.4 Setting protection levels The SINUMERIK 808D control system has defined protection levels for user data. You can set protection levels for the following user data: ● Tool offsets ● Zero offsets ●...
  • Page 69 Commissioning the prototype 7.2 Data backup You can set the read/write protection for these user data by setting the following display machine data ("SYSTEM" operating area > "Mach. data" > "Expert list" > "Display MD"): Name Value Description USER_CLASS_READ_TOA 3 to 7 Protection level: read, for tool offsets USER_CLASS_WRITE_TOA_GEO 3 to 7...

  • Page 70: Data Backup

    Commissioning the prototype 7.2 Data backup Data backup 7.2.1 Creating a series archive After commissioning the prototype, you must create a series archive for series production. The series archive file includes the following data: ● Machine and setting data ● PLC data (for example, PLC program and PLC alarm texts) ●...

  • Page 71: Creating A Start-Up Archive For The Prototype

    Commissioning the prototype 7.2 Data backup 3. Press the <INPUT> key to enter selected directory and press the "OK" softkey to proceed: In the "Archive information" box that follows, you can enter the following information: – Archive creator – Archive version –...
  • Page 72 Commissioning the prototype 7.2 Data backup To create a start-up archive, proceed as follows: 1. In the "SYSTEM" operating area (key combination: ), press the "Archv." softkey. 2. Select the option "Create start-up archive": Press the "OK" softkey and the following window opens: The default name of the data archive is "arc_startup.arc".

  • Page 73: Restoring The Control System With The Start-Up Archive File

    Commissioning the prototype 7.2 Data backup 7.2.3 Restoring the control system with the start-up archive file You can, if necessary, restore the system of the prototype machine by uploading the start-up archive file. To upload the start-up archive, perform the following operations: 1.
  • Page 74 Commissioning the prototype 7.2 Data backup 5. Press "OK" to confirm the warning information: 6. Now the upload starts: It will take you several minutes to complete the upload. 7. The CNC controller restarts after successfully uploading the start-up archive. Note Since the system restoring can delete the password, you must input your password again when the CNC controller restarts.

  • Page 75: Series Production

    Series production Uploading the series archive for series commissioning You can use the production archive to do series commissioning for series production. The series archive is created during the commissioning of the prototype. For details about the creating of the production archive, refer to the section "Creating a series archive (Page 70)". You must upload the production archive to the CNC controllers for series commissioning.
  • Page 76 Series production 8.1 Uploading the series archive for series commissioning 4. Check the archive information and press the "OK" softkey to proceed if the selected data archive is correct: 5. Press "OK" to confirm the warning information: 6. Now the upload begins: It will take you several minutes to complete the upload.

  • Page 77: Data Settings For Individual Machine

    Series production 8.2 Data settings for individual machine Data settings for individual machine 8.2.1 Setting the software limit switches Refer to the section "Setting the software limit switches (Page 64)". 8.2.2 Setting the backlash Refer to the section "Setting backlash compensation (Page 64)". 8.2.3 Making leadscrew error compensation Refer to the section "Making leadscrew error compensation (Page 65)".

  • Page 78: Creating An Original Status Archive

    Series production 8.3 Data backup 8.3.2 Creating an original status archive To create an original status archive, proceed as follows: 1. In the "SYSTEM" operating area (key combination: ), press the "Archv." softkey. 2. Select the option of "Create start-up archive in the default directory" and press the "OK" softkey: 1.

  • Page 79: Restoring The Control System

    Series production 8.3 Data backup 8.3.4 Restoring the control system You can, if necessary, restore the control system either with the original status archive or with the start-up archive. Restore the control system with the original status archive Proceed as follows to restore the CNC controller with the original status archive: 1.
  • Page 80 Series production 8.3 Data backup 4. Press the "OK" softkey to confirm the warning information and the system restoring begins: 5. Wait until the CNC controller restarts and the control system has been successfully restored. Note Since the system restoring can delete the password, you must input your password again when the CNC controllers restarts.

  • Page 81: Other Frequently Used Functions

    Other frequently used functions Playing a slide show The SINUMERIK 808D has a function of playing a slide show. You can create a slide show to display your product information. Playing a slide show You can press the key combination <CTRL> + <D> on the PPU to show a slide show and press the key combination again to exit the slide show.
  • Page 82 Other frequently used functions 9.1 Playing a slide show 3. In the "SYSTEM" operating area, press softkey "Sys. data" > "USB". Select all the language folders for slide show by using the <Mark all> softkey or you can select the desired language folder by moving the cursor up and down, and then press the "Copy"...

  • Page 83: Defining The Service Planner

    9.2 Defining the service planner Defining the service planner The SINUMERIK 808D has the service planning function. With this function, you can specify the service timer and define your own service information. This section shows you how to define the OEM service planner.
  • Page 84 Other frequently used functions 9.2 Defining the service planner Viewing the service task To edit the created service task, proceed as follows: Enter the desired operating area. Enter the main screen of HMI data. Enter the folder related to HMI data. Navigate to the last folder.
  • Page 85 Other frequently used functions 9.2 Defining the service planner Press this softkey to paste the copied text into the screen form of user cycle. Press this softkey to view the service task. Editing the service task Enter the desired operating area. Enter the main screen of service planning.

  • Page 86: Using The Oem Startup Screen And The Oem Machine Logo

    9.3 Using the OEM startup screen and the OEM machine logo Using the OEM startup screen and the OEM machine logo The SINUMERIK 808D uses the SIEMENS start-up screen and machine logo by default. If necessary, you can use you own start-up screen and machine logo.
  • Page 87 Other frequently used functions 9.3 Using the OEM startup screen and the OEM machine logo 5. Press Ctrl + R to restart the HMI. You can view your own start-up screen in the process of control system start-up. Note To restore the default start-up screen, delete the customized bitmap file (startup.bmp) from the control system.
  • Page 88 To use your own machine logo, proceed as follows: 1. Prepare your own machine logo and save it on a USB stick. The SINUMERIK 808D supports the OEM machine logo in the BMP format with a maximum size of 124*19 pixels (W*H).

  • Page 89: Appendix

    Appendix Cutting reserved holes On the MCP, three reserved holes with a standard diameter of 16 mm are available for you to install necessary devices according to your own needs: Figure A-1 Reserved holes To cut a reserved hole, proceed as follows: Figure A-2 Cutting reserved holes Commissioning Manual...

  • Page 90: Inserting, Printing Or Cutting The Mcp Strips

    A4-size blank paper included in the delivered MCP package. You can find the symbol library in the Toolbox (...\04040000\examples\MCP). Siemens also provides you with a template file for printing customized strips. Key positions in the template accord with real key layout on the MCP. You can copy symbols from the symbol library and paste them to the key positions that you want to use customized symbols.

  • Page 91: Basic Knowledge About Nc Programming

    Appendix A.3 Basic knowledge about NC programming Basic knowledge about NC programming Theory Table A- 1 Basic NC commands Commands Descriptions Spindle rotates CW Spindle rotates CCW Activate or change to a new tool. n = tool number When G00 is active in the program, the axis traverses at the maximum axis speed in a straight line.

  • Page 92: Selection Of The Transformers

    Appendix A.4 Selection of the transformers References Programming and Operating Manual (Turning) Programming and Operating Manual (Milling) Selection of the transformers You can select the appropriate transformers according to the desired motor combinations. Recommended transformer type 380 V/220 V SG series 3AC isolating servo transformer Supply voltage 3 AC 380 / 220 V 50/60 Hz...

  • Page 93: Parameter List

    Appendix A.5 Parameter list Parameter list A.5.1 Basic machine data Name Default Range Type Unit Activating 11300 JOG_INC_MODE_LEVELTRIGGRD BOOL INC and REF in JOG mode 14510 * USER_DATA_INT[0] ... [31] -62,768 to DWORD 32,767 User data (INT) 14512 * USER_DATA_HEX[0] ... [31] 0 to 0x0FF BYTE User data (HEX)
  • Page 94 Appendix A.5 Parameter list Name Default Range Type Unit Activating 31060 DRIVE_AX_RATIO_NUMERA[0] ... 1 to DWORD 2,147,000,000 Numerator load gearbox 31400 STEP_RESOL[0] 10,000 100 to 100,000 DWORD Steps per stepper motor revolution 32000 MAX_AX_VELO 10,000 DOUB mm/min, rpm (mm/min) 27.77 (rpm) Maximum axis velocity 32010 JOG_VELO_RAPID...
  • Page 95 Appendix A.5 Parameter list Name Default Range Type Unit Activating 34020 REFP_VELO_SEARCH_CAM 5,000.0 DOUBLE mm/min, (mm/min) 13.88 (rpm) Reference point approach velocity 34040 REFP_VELO_SEARCH_MARKER[0] 300.0 DOUBLE mm/min, (mm/min) 0.833 (rpm) Creep velocity 34050 REFP_SEARCH_MARKER_REVER BOOL SE[0] Direction reversal to reference cam 34060 REFP_MAX_MARKER_DIST[]0[ 20.0...
  • Page 96 Appendix A.5 Parameter list Name Default Range Type Unit Activating DOUBLE 35120 GEAR_STEP_MIN_VELO[0] ... [5] [0]...[1]: 50 [2]: 400 [3]: 800 [4]: 1,500 [5]: 3,000 Minimum speed for gear stage change 35130 GEAR_STEP_MAX_VELO_LIMIT[0] [0]...[1]: 500 DOUBLE rpm ... [5] [2]: 1,000 [3]: 2,000 [4]: 4,000 [5]: 8,000...

  • Page 97: Sinamics V60 Parameters

    Appendix A.5 Parameter list A.5.2 SINAMICS V60 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! Internal enable Immediately...
  • Page 98 Appendix A.5 Parameter list Par. No. Name Range Default Increment Unit Effective 1. This parameter specifies the feedforward gain of position loop. 2. Setting the value to 100 % means position hysteresis is always 0 at any pulse command frequency. 3.

  • Page 99: Diagnostics

    10.0 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. Reserved for Siemens internal use only Diagnostics A.6.1 SINUMERIK 808D alarms Some alarms may occur during the commissioning work.

  • Page 100: Alarm List

    Appendix A.6 Diagnostics A.6.2.2 Alarm list Alarm Background Possible Cause Remedy Result Acknowledgement code Power board is broken Replace the drive with a Free stop Power on new one The memory is damaged Restore default parame- Free stop Power on due to unexpected power- ters off during data saving...
  • Page 101 Appendix A.6 Diagnostics Alarm Background Possible Cause Remedy Result Acknowledgement code Free stop Power on 1. connection failure of 1. check the wiring of encoder ABZ encoder cable 2. bad cable 2. check the interface circuit of the encoder 3. bad cable shielding 4.
  • Page 102 Appendix A.6 Diagnostics Alarm Background Possible Cause Remedy Result Acknowledgement code Check the power supply 1. low supply voltage 2. insufficient supply pow- er capacity 3. transient power failure This alarm may Circuit board fails Replace the drive with a Emergency Press Enter key on occur when the...

  • Page 103: Errors During Drive Self-Test

    Appendix A.6 Diagnostics Alarm Background Possible Cause Remedy Result Acknowledgement code Command pulse frequency 1. Lower the frequency is too high 2. Check whether P36 has the right value This alarm may The circuit board fails Replace the drive with a Emergency Press Enter key on occur when the...

  • Page 104: Other Faults

    Appendix A.6 Diagnostics A.6.2.4 Other faults 1. Motor speed incorrect – Description: The actual motor position is always wrong, and the motor speed is not right, either. – Cause: The pulse signal from the NC to drive is incorrect. – Remedy: Check the pulse signal line connection 2.
  • Page 105 Appendix A.6 Diagnostics Figure A-4 Special data displays (D10, D11, D12, D80, D82) Commissioning Manual Commissioning Manual, 01/2015, 6FC5397-4EP10-0BA0...

  • Page 106: Plc User Interfaces

    Appendix A.7 PLC user interfaces PLC user interfaces A.7.1 Addressing ranges Table A- 3 Operand identifier Address identifier Description Range Data DB1000 to DB7999 DB9900 to DB9906 Times 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...
  • Page 107 INT/WORD DINT/DWORD/REAL Note All the empty fields in the user interface are "reserved for Siemens" and may neither be written to nor evaluated. Fields designated with "0" always have the value "logical 0". If there is no data format information, you can read or write to all the specified data formats.

  • Page 108: Mcp

    Appendix A.7 PLC user interfaces A.7.2 A.7.2.1 Signals from MCP DB1000 From the MCP [r] Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 DBB0 PROGRAM SINGLE AUTO REF. Hand-wheel TEST BLOCK POINT DBB1 Key 16...

  • Page 109: Reading/Writing Nc Data: Job

    Appendix A.7 PLC user interfaces A.7.2.3 Reading/writing NC data: Job DB1200 Reading / writing NC data [r/w] PLC -> NCK interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Write varia- Start Number of variables DB1200 ...

  • Page 110: Pi Service: Result

    Appendix A.7 PLC user interfaces A.7.2.6 PI service: Result DB1200 Reading / writing NC data [r] PLC -> NCK interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 5000 Error in job Job com- pleted 5001...

  • Page 111: Active Alarm Response

    Appendix A.7 PLC user interfaces A.7.4.3 Active alarm response DB1600 Active alarm response [r] PLC -> HMI interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 2000 Acknowledge Acknowledge PLC STOP EMERGENCY Feedrate Read-in...
  • Page 112 Appendix A.7 PLC user interfaces Traversing keys Rapid trav- Traverse Feedrate Activate handwheel erse over- key disable stop/spindle Plus Minus ride stop Machine function Continuous Var. INC 1000 INC 1000 INC 100 INC 10 INC 1 INC traversing Contour- handwheel direction of rotation inverted...

  • Page 113: Signals From Axis/Spindle

    Appendix A.7 PLC user interfaces 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 Motor se-...
  • Page 114 Appendix A.7 PLC user interfaces AxStop active Travel command Travel request Handwheel active (bit/binary coded) Plus Minus Plus Minus Active machine function Continuous Var. INC 10000 INC 1000 INC 100 INC 10 INC 1 INC Contour- handwheel direction of rotation inverted Parameter set, servo PLC axis,...
  • Page 115 Appendix A.7 PLC user interfaces Signals from drive 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 4000 Holding RLI active brake opened 4001...

  • Page 116: Plc Machine Data

    Appendix A.7 PLC user interfaces A.7.6 PLC machine data A.7.6.1 INT values (MD 14510 USER_DATA_INT) DB4500 Signals from NCK [r16] NCK -> PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Int value (WORD/2 byte) A.7.6.2 HEX values (MD 14512 USER_DATA_HEX)

  • Page 117: Signals From/To Hmi

    Appendix A.7 PLC user interfaces A.7.7 Signals from/to HMI A.7.7.1 Program control signals from the HMI (retentive area) (also refer to signals at channel DB3200) DB1700 Signals, HMI [r/w] HMI -> PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2...

  • Page 118: Signals From Hmi

    Appendix A.7 PLC user interfaces A.7.7.4 Signals from HMI DB1800 Signals from HMI [r] HMI -> PLC interface (signals are only present for PLC cycle) Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Reset Start...

  • Page 119: Signals From Maintenance Planners

    Appendix A.7 PLC user interfaces 4003 Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- edgement edgement edgement edgement edgement edgement edgement edgement DB1800 Deactivation [r/w] Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 5000 Acknowl-...

  • Page 120: General Selection/Status Signals To Hmi (Retentive Area)

    Appendix A.7 PLC user interfaces A.7.7.10 General selection/status signals to HMI (retentive area) DB1900 Signals to HMI [r/w] PLC -> HMI interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 5000 OP key block 5002...

  • Page 121: Decoded M Signals (M0 To M99)

    Appendix A.7 PLC user interfaces A.7.8.2 Decoded M signals (M0 to M99) Note The signals are output for the duration of a PLC cycle. DB2500 M functions from NCK channel [r] 1) 2) NCK -> PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4...

  • Page 122: Transferred S Functions

    Appendix A.7 PLC user interfaces A.7.8.5 Transferred S functions DB2500 S functions from NCK channel [r] NCK -> PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 4000 S function 1 (REAL) (DINT) 4004 Extended address S function 1 (byte) 4008...

  • Page 123: General Signals From Nck

    Appendix A.7 PLC user interfaces A.7.9.2 General signals from NCK DB2700 General signals from NCK [r/w] NCK -> PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 EMERGEN CY OFF active Inch meas- Probe actuated...

  • Page 124: Signals From Fast Inputs And Outputs

    Appendix A.7 PLC user interfaces 1009 Overwrite mask for external digital NCK outputs 1010 Value from PLC for external digital NCK outputs 1011 Setting mask for external NCK outputs A.7.9.4 Signals from fast inputs and outputs DB2900 Signals from fast inputs and outputs [r] PLC ->...

  • Page 125: Channel Signals

    Appendix A.7 PLC user interfaces To use the machine function signals in DB3000.DBB2, you must set the "INC inputs in the operating-mode signal range active" signal (DB2600.DBX1.0) to "1". DB3100 Mode signals from NCK [r] NCK -> PLC interface Byte Bit 7 Bit 6 Bit 5...
  • Page 126 Appendix A.7 PLC user interfaces Activate machine-related protection zone Area 10 Area 9 Activate channel-specific protection zone Area 5 Area 5 Area 5 Area 5 Area 5 Area 5 Area 5 Area 5 Activate channel-specific protection zone Area 10 Area 9 Do not Deactivate Activate fixed feedrate...

  • Page 127: Commissioning Manual Commissioning Manual, 01/2015, 6Fc5397-4Ep10-0Ba0

    Appendix A.7 PLC user interfaces 1005 Axis 2 in Work Machine function Continuous Var. INC 10000 INC 1000 INC 100 INC 10 INC 1 INC traversing 1007 Invert con- tour hand- wheel direction 1008 Axis 3 in Work Traversing keys Rapid trav- Traversing Feedrate...
  • Page 128 Appendix A.7 PLC user interfaces Contuour handwheel active (bit/binary coded) Invert con- Protection tuour zone not handwheel guranteed direction Machine-related protection zone preactivated Area 8 Area 7 Area 6 Area 5 Area 4 Area 3 Area 2 Area 1 Machine-related protection zone preactivated Area 10 Area 9 Channel-specific protection zone preactivated...
  • Page 129 Appendix A.7 PLC user interfaces 1005 Axis 2 in Work Machine function Continuous Var. INC 10000 INC 1000 INC 100 INC 10 INC 1 INC traversing 1007 Contour handwheel direction of rotation inverted 1008 Axis 3 in Work Traversing command Travel request Handwheel active (bit/binary coded) Plus...

  • Page 130: Signals, Synchronized Actions

    Appendix A.7 PLC user interfaces 4006 Dormant ASUP ac- ASUP tive Active 4008 Active the transformation number 4009 Reserved 4011 G functions from NCK channel DB3500 G functions from NCK channel [r] NCK -> PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3...

  • Page 131: Reading And Writing Plc Variables

    Appendix A.7 PLC user interfaces A.7.11.3 Reading and writing PLC variables DB4900 PLC variables [r/w] PLC interface Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Offset [0] … … 4095 Offset [4095] Note The programming engineer (NCK and PLC) is responsible for organizing (structuring) this memory area.

  • Page 132: Maintenance Scheduler: User Interface

    Appendix A.7 PLC user interfaces A.7.13 Maintenance scheduler: User interface A.7.13.1 Initial (start) data DB9903 Initial data table [r16] Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Interval 1 [h] Time of the first warning 1 [h] Number of warnings to be output 1 Reserved 1 Interval 2 [h]...

  • Page 133: User Interface For Ctrl-Energy

    Appendix A.7 PLC user interfaces A.7.14 User interface for Ctrl-Energy Table A- 7 Energy saving profile DB9906 Ctrl energy Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Control signals Set time to Immeadi- pre-warning ately acti-...
  • Page 134 Appendix A.7 PLC user interfaces 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 Commissioning Manual Commissioning Manual, 01/2015, 6FC5397-4EP10-0BA0...

  • Page 135: Index

    Index General signals from NCK, 123 Access levels, 33 General signals to NCK, 122 Active alarm reponse, 111 Actual data, 132 Alarm acknowledgement, 111 approaching the reference point, 62 Axis actual values and distance-to-go, 131 H functions from NCK channel, 122 axis velocity and the acceleration, 59 HEX values, 116 Initial data, 132...
  • Page 136 Index User interface for ctrl energy, 133 PI service: Job, PI service: Result, position-loop gain, 59 Printing customized MCP strips, 90 Variables for user alarms, 110 Program control from the HMI (retentive area), 117 Program selection via lists, 117 Reading / writing NC data: Job, Reading / writing NC data: Result, Reading and writing PLC variables, 131 Retentative data, 110...

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