DANGER indicates that death or severe personal injury will result if proper precautions are not taken.

Transcription

1 Delivery check 1 Mounting 2 SINUMERIK SINUMERIK 808D Connecting 3 Switching on and preparing for commissioning 4 Commissioning diagram 5 Default PLC applications 6 Commissioning the prototype 7 Series production 8 Other frequently used functions 9 A 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

2 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: Trademarks 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. All names identified by are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner. Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions. Siemens AG Industry Sector Postfach NÜRNBERG GERMANY Order number: 6FC5397-4EP10-0BA0 P 02/2015 Subject to change Copyright Siemens AG All rights reserved

3 Table of contents 1 Delivery check Mounting Mounting the controller Mounting the drive Mounting the motor Connecting Interface overview Connecting the battery Connecting according to the default PLC program Connection Overview Switching on and preparing for commissioning Switching on controller PPU keyboard function MCP mode changeover Status LEDs Password Access levels Setting a password Setting the date and time Introduction to the onboard assistants Commissioning diagram Default PLC applications Turning Milling PLC user alarms General information Alarm properties Activating the PLC user alarms Editing a PLC user alarm text Commissioning the prototype Commissioning the controller Entering machine data Setting the axis-relevant parameters Enabling the position control... 58, 01/2015, 6FC5397-4EP10-0BA0 3

4 Table of contents Setting the leadscrew pitch, deceleration ratio, and motor rotation direction Setting the axis speed and acceleration Setting the position-loop gain Setting the spindle-relevant parameters Approaching the reference point Compensation parameter settings Setting the software limit switches Setting backlash compensation Making leadscrew error compensation Setting protection levels Data backup Creating a series archive Creating a start-up archive for the prototype Restoring the control system with the start-up archive file Series production Uploading the series archive for series commissioning Data settings for individual machine Setting the software limit switches Setting the backlash Making leadscrew error compensation Data backup Overview Creating an original status archive Creating the start-up archive Restoring the control system Other frequently used functions Playing a slide show Defining the service planner Using the OEM startup screen and the OEM machine logo A Appendix A.1 Cutting reserved holes A.2 Inserting, printing or cutting the MCP strips A.3 Basic knowledge about NC programming A.4 Selection of the transformers A.5 Parameter list A.5.1 Basic machine data A.5.2 SINAMICS V60 parameters A.6 Diagnostics A.6.1 SINUMERIK 808D alarms A.6.2 SINAMICS alarms A Overview of alarms A Alarm list A Errors during drive self-test A Other faults , 01/2015, 6FC5397-4EP10-0BA0

5 Table of contents A Display data list A.7 PLC user interfaces A.7.1 Addressing ranges A.7.2 MCP A Signals from MCP A Signals to MCP A Reading/writing NC data: Job A Reading/writing NC data: Result A PI service: Job A PI service: Result A.7.3 Retentative data area A.7.4 User Alarms A User alarms: Activating A Variables for user alarms A Active alarm response A Acknowledgement of alarms A.7.5 Axis/spindle signals A Transferred M and S functions, axis specific A Signals to axis/spindle A Signals from axis/spindle A.7.6 PLC machine data A INT values (MD USER_DATA_INT) A HEX values (MD USER_DATA_HEX) A FLOAT values (MD USER_DATA_FLOAT) A User alarm: Configuring (MD USER_DATA_PLC_ALARM) A.7.7 Signals from/to HMI A Program control signals from the HMI (retentive area) (also refer to signals at channel DB3200) A Program selection from PLC (retentive area) A Checkback signal: Program selection from HMI (retentive area) A Signals from HMI A Signals from PLC A Signals to maintenance planners A Signals from maintenance planners A Signals from operator panel (retentive area) A General selection/status signals from HMI (retentive area) A General selection/status signals to HMI (retentive area) A.7.8 Auxiliary functions transfer from NC channel A Overview A Decoded M signals (M0 to M99) A Transferred T functions A Transferred M functions A Transferred S functions A Transferred D functions A Transferred H functions A.7.9 NCK signals A General signals to NCK A General signals from NCK A Signals at fast inputs and outputs A Signals from fast inputs and outputs A.7.10 Channel signals A Signals to NC channel , 01/2015, 6FC5397-4EP10-0BA0 5

6 Table of contents A Signals from NC channel A.7.11 Signals, synchronized actions A Signals, synchronized actions to channel A Signals, synchronized actions from channel A Reading and writing PLC variables A.7.12 Axis actual values and distance-to-go A.7.13 Maintenance scheduler: User interface A Initial (start) data A Actual data A.7.14 User interface for Ctrl-Energy Index , 01/2015, 6FC5397-4EP10-0BA0

7 Delivery check 1 System overview The SINUMERIK 808D is an economic CNC solution for milling and turning machines in the global market. For the turning variant, it is designed to control three axes, including two feed axes via two pulse drive interfaces (with SINAMICS V60) and one spindle via one analog spindle interface. For the milling variant, it is designed to control four axes, including three feed axes via three pulse drive interfaces (with SINAMICS V60) and one spindle via one analog spindle interface., 01/2015, 6FC5397-4EP10-0BA0 7

8 Delivery check The following diagram shows a system configuration example for the SINUMERIK 808D control system: 10) Note: The following devices in this diagram are not standard system components: - PC - USB - Handwheel - +24VDC power supply - Inverter or servo spindle drive - Spindle motor - Spindle encoder 11) 12) 6) 1) 13) 3) 2) 4) 9) 7) 8) 5) Figure 1-1 SINUMERIK 808D control system overview (taking a milling machine for an example) 11), 12), 13): For detailed information on cable shield connection, refer to Section "Connecting according to the default PLC program (Page 22)". 8, 01/2015, 6FC5397-4EP10-0BA0

9 Delivery check NOTICE Using a copper protective earth conductor with a cross section of 10 mm 2 to connect the PE terminal of V60 to the protective earth. For the NC and 24 VDC power supply, there are no special requirements of the cross section of the copper protective earth conductor. For the inverter or servo spindle drive, it is recommended to refer to the relevant specifications to confirm the cross section of the copper protective earth conductor. Note For a turning machine, you need two sets of setpoint cable + SINAMICS V60 drive + power cable + brake cable (if necessary) + encoder cable + 1FL5 servomotor. Legend Name Order number 1) PPU141.1, turning 6FC5370-1AT00-0AA0 (English) 6FC5370-1AT00-0CA0 (Chinese) PPU141.1, milling 6FC5370-1AM00-0AA0 (English) 6FC5370-1AM00-0CA0 (Chinese) 2) MCP 6FC5303-0AF35-0AA0 (English) 6FC5303-0AF35-0CA0 (Chinese) 3) Setpoint cable (PPU141.1 to CPM60.1) 6FC5548-0BA00-1AF0 (5 m) 6FC5548-0BA00-1AH0 (7 m) 6FC5548-0BA00-1BA0 (10 m) 4) SINAMICS V60 Controlled Power Module (CPM60.1) 6SL3210-5CC14-0UA0 (4 A) 6SL3210-5CC16-0UA0 (6 A) 6SL3210-5CC17-0UA0 (7 A) 6SL3210-5CC21-0UA0 (10 A) 5) 1FL5 Motor 1FL5060-0AC21-0AA0 (4 Nm, with key, without brake) 1FL5060-0AC21-0AG0 (4 Nm, without key, without brake) 1FL5062-0AC21-0AA0 (6 Nm, with key, without brake) 1FL5062-0AC21-0AG0 (6 Nm, without key, without brake) 1FL5064-0AC21-0AA0 (7.7 Nm, with key, without brake) 1FL5064-0AC21-0AG0 (7.7 Nm, without key, without brake) 1FL5066-0AC21-0AA0 (10 Nm, with key, without brake) 1FL5066-0AC21-0AG0 (10 Nm, without key, without brake) 1FL5060-0AC21-0AB0 (4 Nm, with key, with brake) 1FL5060-0AC21-0AH0 (4 Nm, without key, with brake) 1FL5062-0AC21-0AB0 (6 Nm, with key, with brake) 1FL5062-0AC21-0AH0 (6 Nm, without key, with brake) 1FL5064-0AC21-0AB0 (7.7 Nm, with key, with brake) 1FL5064-0AC21-0AH0 (7.7 Nm, without key, with brake) 1FL5066-0AC21-0AB0 (10 Nm, with key, with brake) 1FL5066-0AC21-0AH0 (10 Nm, without key, with brake) 6) Setpoint cable (PPU141.1 to inverter or servo spindle drive) 6FC5548-0BA05-1AD0 (3 m) 6FC5548-0BA05-1AF0 (5 m) 6FC5548-0BA05-1AH0 (7 m) 6FC5548-0BA05-1BA0 (10 m) 6FC5548-0BA05-1CA0 (20 m), 01/2015, 6FC5397-4EP10-0BA0 9

10 Delivery check Legend Name Order number 7) Power cable (unshielded) 6FX6002-5LE00-1AD0 (3 m) 6FX6002-5LE00-1AF0 (5 m) 6FX6002-5LE00-1AH0 (7 m) 6FX6002-5LE00-1BA0 (10 m) 8) Brake cable (unshielded) 6FX6002-2BR00-1AD0 (3 m) 6FX6002-2BR00-1AF0 (5 m) 6FX6002-2BR00-1AH0 (7 m) 6FX6002-2BR00-1BA0 (10 m) 9) Encoder cable (shielded) 6FX6002-2LE00-1AD0 (3 m) 6FX6002-2LE00-1AF0 (5 m) 6FX6002-2LE00-1AH0 (7 m) 6FX6002-2LE00-1BA0 (10 m) 10) Inverter or servo spindle drive From Siemens or a third-party manufacturer Check list Table 1-1 Component PPU package Quantity (pieces) Panel Processing Unit (PPU) 1 Mounting clamps with screws 8 Connectors I/O connectors: 7 24 V power input connector: 1 Table 1-2 MCP package Component Quantity (pieces) Machine Control Panel (MCP) 1 MCP connection cable (for connecting the MCP to the PPU, max. 50 cm) 1 Mounting clamps with screws 6 Pre-printed MCP strip, Milling 1 set of 6 pieces Blank strip paper, A4 size 1 Product Information for MCP 1 Table 1-3 CNC accessories Component Quantity (pieces) Setpoint cable to SINAMICS V60 (for feed axis) 2 (turning) or 3 (milling) Setpoint cable to Siemens inverter or third-party drive (for spindle) 1 Note Emergency stop button is not included in our scope of delivery. You can, if necessary, contact your local Siemens salesperson for it. Table 1-4 SINAMICS V60 package Component Quantity (pieces) SINAMICS V60 1 Getting Started 1 Cable clamps 2 Table 1-5 1FL5 motor package Component Quantity (pieces) 1FL5 motor 1 Data sheet for 1FL5 motor 1 10, 01/2015, 6FC5397-4EP10-0BA0

11 Delivery check Table 1-6 Cables individually packaged Component Quantity (pieces) Power cable (unshielded) 1 Brake cable (unshielded) 1 Encoder cable (shielded) 1 Cabinet grounding guide Figure 1-2 Cabinet grounding, 01/2015, 6FC5397-4EP10-0BA0 11

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 2 as illustrated below. Figure 1-3 Busbar grounding 12, 01/2015, 6FC5397-4EP10-0BA0

13 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., 01/2015, 6FC5397-4EP10-0BA0 13

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) 14, 01/2015, 6FC5397-4EP10-0BA0

15 Mounting 2.2 Mounting the drive Mounting clearance (in mm) To ensure easy maintenance purpose, you must provide sufficient clearance (recommended distance: 80 mm) between the maintenance door and the cabinet wall for replacing the battery and CF card: 1 Cabinet panel 2 Maintenance door 2.2 Mounting the drive Cut-outs and mounting dimensions Figure 2-4 4/6/7 A version (in mm), 01/2015, 6FC5397-4EP10-0BA0 15

16 Mounting 2.2 Mounting the drive Figure A version (in mm) Mounting method Minimum mounting clearance 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. To ensure adequate cooling, as a minimum, maintain the specified clearance between drives, one drive and another device/inner panel of the cabinet. Figure 2-6 Drive mounting clearance (in mm) Using the cable clamps supplied If the CE marking requirements for cables are mandatory, the line supply cable and the power cable used must all be shielded cables. In this case, you can use the cable clamps as a ground connection between the cable shield and a common ground point. Clamps can also be helpful in better fixing cables (the unshielded power cable and the line supply cable) in place. 16, 01/2015, 6FC5397-4EP10-0BA0

17 Mounting 2.2 Mounting the drive The illustration below shows you how to use the clamps to fix both cables and to make a shield connection with the cable. Power cable (shielded) Figure 2-7 Cable fixing with two cable clamps CAUTION Make sure that the clamp for fixing the shielded power cable has a good contact with the cable shield. Note Siemens does not provide the shielded power cable. Please prepare the shielded power cable by yourselves for CE certification. After the installation, it is recommended that the terminal screws should be checked to ensure that they are tight. Reference For further information about the drive mounting, refer to SINAMICS V60 Getting Started., 01/2015, 6FC5397-4EP10-0BA0 17

18 Mounting 2.3 Mounting the motor 2.3 Mounting the motor Mounting dimensions (mm) Motor type A (in mm) B (in mm) 4 Nm 163 (205) 80 6 Nm 181 (223) Nm 195 (237) Nm 219 (261) 136 Note Value in brackets is the length of a motor with a built-in brake unit. Motors with plain shaft have the same dimensions. Reference For further information about the motor, refer to 1FL5 Motor Technical Data. 18, 01/2015, 6FC5397-4EP10-0BA0

19 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, 01/2015, 6FC5397-4EP10-0BA0 19

20 Connecting 3.2 Connecting the battery Legend Interface Comment Rear 1 X100, X101, X102 Digital inputs 2 X200, X201 Digital outputs 3 X21 FAST I/O 4 X301, X302 Distributed I/O 5 X10 Hand-wheel inputs 6 X60 Spindle encoder interface 7 X54 Analog spindle interface 8 X2 RS232 interface 9 X51, X52, X53 Pulse drive interfaces 10 X30 USB interface, for connection with the MCP 11 X1 Power supply interface, +24V DC power supply 12 - Battery interface 13 - Slot for the System CompactFlash Card (CF card) Front 14 - USB interface Interface overview on the Machine Control Panel (MCP) Figure 3-2 Interface layout Legend Interface Comment Rear 1 X10 USB interface, for connection with the PPU 20, 01/2015, 6FC5397-4EP10-0BA0

21 Connecting 3.2 Connecting the battery 3.2 Connecting the battery A battery has been pre-assembled on the back cover of the PPU. The battery is not connected when delivered. You must plug the battery connector into the battery interface by yourself before switching the controller on. You can access it after removing the maintenance door: 1 Maintenance door 3 Battery interface 2 Battery 4 Battery connector Note When connecting the battery, ensure that the groove is at the upper side; otherwise, the alarm "NCK battery alarm" will be output after you switch on the controller, and you could lose your data after an unexpected power failure if you do not insert the battery connector correctly. Note Battery Life time: 3 years Replacement: do not replace the battery when the controller is switched off; otherwise, your data can be lost. Order number: 6FC5247-0AA18-0AA0., 01/2015, 6FC5397-4EP10-0BA0 21

22 Connecting 3.3 Connecting according to the default PLC program 3.3 Connecting according to the default PLC program The SINUMERIK 808D has integrated with a default PLC application. If you perform the commissioning work with the default PLC application, perform wiring as follows. Connecting the digital inputs and outputs Figure 3-3 Connecting the digital inputs and outputs (Milling) 22, 01/2015, 6FC5397-4EP10-0BA0

23 Connecting 3.3 Connecting according to the default PLC program Figure 3-4 Connecting the digital inputs and outputs (Turning), 01/2015, 6FC5397-4EP10-0BA0 23

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) 1) Figure 3-6 Connecting the SINAMICS V60 (X51: axis X) 1) If necessary, you can also serially connect an emergency stop switch between the 65 enable signal and the 24V signal. 24, 01/2015, 6FC5397-4EP10-0BA0

25 Connecting 3.3 Connecting according to the default PLC program Note Filter A line filter (rated current: 16 A, protection level: IP20) is required so that the system can pass the CE certification (radiated emission test or conducted emission test). The order number of Siemens recommended filter is 6SN1111-0AA01-1BA1. Note Circuit breaker You can install a mains linear breaker (rated current: 15 A for 7 A or 10 A version of the drive and 10 A for 4 A or 6 A version of the drive; rated voltage: 250 VAC) to protect the system. Connecting the inverter or the servo spindle drive PPU Figure 3-7 Connecting the inverter or the servo spindle drive (unipolar) 1) 10 V analog voltage 2) 0 V signal 3) Use twisted pair cables for signals A/A_N, B/B_N, Z/Z_N, and +5 V/M., 01/2015, 6FC5397-4EP10-0BA0 25

26 Connecting 3.3 Connecting according to the default PLC program PPU Figure 3-8 Connecting the inverter or the servo spindle drive (bipolar) 1) +/- 10 V analog voltage 2) 0 V signal 3) Use twisted pair cables for signals A/A_N, B/B_N, Z/Z_N, and +5 V/M. Note Cables for connecting X21 must be shielded ones. Connecting the handwheel Figure 3-9 Connecting the handwheel 26, 01/2015, 6FC5397-4EP10-0BA0

27 Connecting 3.4 Connection Overview 3.4 Connection Overview, 01/2015, 6FC5397-4EP10-0BA0 27

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. 28, 01/2015, 6FC5397-4EP10-0BA0

29 Switching on and preparing for commissioning 4 DANGER Carrying out of repairs Anywhere in the automation equipment where faults might cause physical injury or major material damage, in other words, where faults could be dangerous, additional external precautions must be taken, or facilities must be provided, that guarantee or enforce a safe operational state, even when there is a fault (e.g. using an independent limit value switch, mechanical locking mechanisms, EMERGENCY STOP/EMERGENCY OFF devices). 4.1 Switching on controller Before switching on Make sure that: You have finished the mechanical installation of the whole system based on the information included in the chapter "Mounting (Page 13)" or the Mechanical Installation Manual. You have completed the wirings of the whole system according to the information included in the chapter "Connecting (Page 19)" (if you use the default PLC program) or the Electrical Installation Manual. Switching on Do as follows: 1. Power on the mains supply. 2. When the NC enters the main screen, check the NC normal status according to the status LEDs on the PPU. POK: green RDY: green TEMP: unlit For detailed information about the status LEDs, refer to the section "Status LEDs (Page 32)". 3. Check the drive normal status: "S-run" is displayed. LED "RDY/JOG": green LED "ERR": dark For detailed information about the SINAMICS V60 drives, refer to the SINAMICS V60 Getting Started., 01/2015, 6FC5397-4EP10-0BA0 29

30 Switching on and preparing for commissioning 4.2 PPU keyboard function 4.2 PPU keyboard function Legend Name Description 1 Return key Returns to higher level menu 2 Horizontal softkeys Call corresponding menu functions 3 Extension key Reserved. No function 4 Vertical softkeys Call corresponding menu functions 5 Operating area keys Opens the "MACHINE" operating area Opens the "PROGRAM" operating area Opens the "OFFSET" operating area Opens the "PROGRAM MANAGER" operating area Opens the "ALARM" operating area Combines with the <SHIFT> key to open the "SYSTEM" area Opens the "CUSTOM" operating area 30, 01/2015, 6FC5397-4EP10-0BA0

31 Switching on and preparing for commissioning 4.3 MCP mode changeover 4.3 MCP mode changeover Use the machine control panel (MCP) to make changeover between the JOG mode, the Ref Point mode, the AUTO mode and the MDA mode. The MCP key layout is shown below: Legend Name Description 1 Mode navigation Enters the Ref. Point mode for reference point approach keys Enters the JOG mode (manual operation) Enters the AUTO mode (automatic operation) Enters the MDA mode (manual program input and automatic execution) 2 Incremental feed keys Axis traverses at the increment of 1 Axis traverses at the increment of 10 Axis traverses at the increment of Axis traversing keys Move an axis (X, Y, Z) 4 RESET key Resets NC programs Cancels alarms, 01/2015, 6FC5397-4EP10-0BA0 31

32 Switching on and preparing for commissioning 4.4 Status LEDs 4.4 Status LEDs LEDs on the PPU The following LEDs are installed on the SINUMERIK 808D PPU. The individual LEDs and their functions are described in the table below. Table 4-1 Status and error displays LED Color Significance POK Green Power supply is OK. RDY Green Ready for operation TEMP Yellow Temperature exceeds the limit For more information, refer to error description in the SINUMERIK 808D Diagnostics Manual. LEDs on the SINAMICS V60 drives Figure 4-1 SINAMICS V60 status LEDs 32, 01/2015, 6FC5397-4EP10-0BA0

33 Switching on and preparing for commissioning 4.5 Password Table 4-2 Description of the LED status Status LED 1 Status LED 2 Description 7-segment LED display description RDY/JOG Green LED ERR Red LED Dark Dark No 24 V DC Input/Drive Defect Dark Dark Flashing at 1 Hz Drive not ready Current status Green Dark Drive ready Depends on the current menu operation Dark Red Drvie error Alarm code Green Red Initialization Display " " Flashing at 1 Hz Dark JOG mode Display "J-run" 4.5 Password Access levels Purpose Access levels/passwords are necessary to prevent system data damages caused by unexpected mistake operations. Cases You must set a password for an access level under following cases: Data restoring Software update Password has been deleted A higher or lower access level is required Access levels The SINUMERIK 808D provides a concept of access levels for enabling data areas. You can view such information from the table below: Table 4-3 Access level Access level Default password Target group Manufacturer SUNRISE OEMs Customer CUSTOMER End users No password - -, 01/2015, 6FC5397-4EP10-0BA0 33

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: Inputting or modifying part of the machine data Programming Setting offsets Measuring tools For the function areas listed below, the input and modification of data depends on the protection level you have set: Tool offsets Work offsets Setting data RS232 settings Program creation / program correction You can set the protection levels for these function areas via the display machine data (USER_CLASS...): "SYSTEM" operating area > "Mach. data" > "Expert list" > "Display MD". Note For detailed information about the display machine data, refer to the Parameter Manual. Note For detailed information about how to set the access levels, refer to Programming and Operating Manual. Access levels: Manufacturer, Customer Both access levels require a password. You can change the password only after being activated with the access level "Manufacturer". If you forget your password, you can carry out an NC start-up: "SYSTEM" operating area > "Start-up" > "NC" > "Power-up with default data". This will reset all passwords to their defaults according to the software release you have acquired. Note Before performing a start-up with default data, you must backup your data; otherwise, you will lose your data. For detailed information about how to do data backup, refer to section "Data backup (Page 77)". 34, 01/2015, 6FC5397-4EP10-0BA0

35 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 Setting a password The control system is delivered without a password. You must input the password of "SUNRISE" to perform the commissioning work. Perform the following steps to input the password: 1. In the "SYSTEM" operating area (key combination: + ), press the vertical softkey "Set password". The message text at the bottom of the screen shows "No password set": 2. Enter "SUNRISE" and press the "Accept" softkey. 3. The message text now shows "Access level: Manufacturer", which indicates that you have successfully set the password. Note You can change the default password to you by using the "Change password" softkey. You can also delete the current password to protect your settings by pressing the "Delete password" softkey. After the series production, you must press the "Delete password" softkey to exit the "Manufacturer" access level., 01/2015, 6FC5397-4EP10-0BA0 35

36 Switching on and preparing for commissioning 4.6 Setting the date and time 4.6 Setting the date and time At delivery, the system date and time remain at the factory settings, and thus you must manually modify the date and time. Proceed as follows to set the date and time: 1. Press + to enter the "SYSTEM" operating area, then press the softkey "Date time". 2. Input your date and time. 3. Press the "OK" softkey to confirm your settings. 36, 01/2015, 6FC5397-4EP10-0BA0

37 Switching on and preparing for commissioning 4.7 Introduction to the onboard assistants 4.7 Introduction to the onboard assistants The SINUMERIK 808D system software has three onboard assistants: Startup assistant (requires "Manufacturer" access level) This on-board assistant is designed to help you commission the prototype. With this assistant, you can complete basic machine tool functions. Series assistant (requires "Manufacturer" access level) This on-board assistant is designed to help you correctly finish the series machine commissioning. Operation assistant (requires "Customer" access level) This onboard assistant is designed to help you learn about the basic operations of the machining process. Where can I find the assistants? Press the <MENU FUNCTION> key on the PPU to call the assistants:, 01/2015, 6FC5397-4EP10-0BA0 37

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 corresponding assistant Press to start the assistant Press to return to the main screen of the onboard assistants Press any operating area key (CUSTOM excluded) to exit the main screen of the onboard assistants and enter the corresponding operating area Press to enter the current task or a task that is prior to the current task Note: This softkey becomes active when you move the cursor key to a valid task. 38, 01/2015, 6FC5397-4EP10-0BA0

39 Commissioning diagram 5 You can commission the SINUMERIK 808D in two ways: Alternative 1: with the onboard assistants Alternative 2: without the onboard assistants When commissioning with the onboard assistants, just follow the assistants step by step. In this manual, only the second way is described. To do the commissioning work without the onboard assistants, proceed as follows:, 01/2015, 6FC5397-4EP10-0BA0 39

40 Commissioning diagram 40, 01/2015, 6FC5397-4EP10-0BA0

41 Default PLC applications Turning Overview of the PLC subroutines Subroutine No. Name Description 0 to 19 - Reserved for the manufacturer 20 AUX_MCP Auxiliary function 21 AUX_LAMP Lamp control, called in the subroutine "AUX_MCP". 31 PLC_ini_USR_INI Reserved for the initialization by the manufacturer (this subroutine is automatically called by subroutine 32) 32 PLC_INI PLC initialization 33 EMG_STOP Emergency Stop 37 MCP_NCK Signals from the MCP and the HMI are sent to NCK interfaces 38 MCP_Tool_Nr Display tool numbers via the LED of the MCP 39 HANDWHL Handwheel selection via HMI 40 AXIS_CTL Control of feed axis enable and spindle enable 41 MINI_HHU Handwheel hand held unit 42 SPINDLE Spindle function 43 MEAS_JOG Tool measurement in the JOG mode 44 COOLING Coolant control (Manual Machine key and M code: M07, M08, M09) 45 LUBRICATE Lubrication control (interval and time) 46 PI_SERVICE ASUP (Asynchronous Subroutine Program) 47 PLC_Select_PP PLC selects a subroutine. 48 ServPlan Service plan 49 Gear_Chg1_Auto Automatic gear change of the spindle 50 Gear_Chg2_Virtual Dummy gear change of the spindle 51 Turret1_HED_T Turret control of the turning machine (turret type: Hall element transistor, 4/6 position) 52 Turret2_BIN_T Turret control of the turning machine (turret type: position detection with codings) 53 Turret3_CODE_T Hydraulic turret control of the turning machine (turret type: position detection with codings) 54 Turret2_3_ToolDir Evaluate tool direction and calculate tool position (called by Turret2_BIN_T, Turret3_CODE_T) 55 Tail_stock_T Tail stock control 56 Lock_unlock_T Clamp or release control 58 MM_MAIN Manual machine 59 MM_MCP_808D Spindle signal processing for the manual machine 61, 62 Reserved for the subroutine 63 TOGGLE Six key-operated switches: K1 to K6 Two delay switches: k7, K8, 01/2015, 6FC5397-4EP10-0BA0 41

42 Default PLC applications 6.1 Turning Definition of user-defined keys on the MCP User-defined key 1 User-defined key 2 User-defined key 3 User-defined key 4 User-defined key 5 User-defined key 6 Working lamp Manual cooling Manual tool change Manual chuck clamping and unclamping Chuck clamping internally/externally Tailstock Structure of the sample application (OB1) Call Conditions Subroutine Name Description First scan (SM0.1) PLC_INI (SBR32) PLC initialization Each scan (SM0.0) EMG_STOP (SBR33) Emergency Stop control Each scan (SM0.0) MCP_NCK (SBR37) Transferring MCP and HMI signals to the NCK interface Each scan (SM0.0) HANDWHL (SBR39) Selecting a hand wheel through the interface signal DB1900.DBB1xxx Each scan (SM0.0) AXIS_CTL (SBR40) Coordinate enabling control, hardware limit, etc. Each scan (SM0.0) COOLING (SBR44) Cooling control Each scan (SM0.0) TURRET1 (SBR46) HALL effect device turret control Each scan (SM0.0) ServPlan (SBR48) Maintenance plan example: first task PLC user alarms Alarm No. Interface Address Alarm Description From SBR DB1600.DBX1.2 HHU is active SBR41: MINI_HHU DB1600.DBX1.3 Not able to lock tool in expected time DB1600.DBX1.4 Spindle in braking progress SBR42: SPINDLE DB1600.DBX1.5 Operation while chuck is not locked SBR56: Lock_unlock_T DB1600.DBX1.6 Gear-change time out SBR49: GearChg1_Auto DB1600.DBX1.7 Gear level position error DB1600.DBX2.0 Drives not ready SBR33: EMG_STOP DB1600.DBX2.1 Operate chuck when spindle or part program is running SBR56: Lock_unlock_T DB1600.DBX2.2 Cooling motor overload SBR44: COOLING DB1600.DBX2.3 Coolant liquid position in low level DB1600.DBX2.4 Lubrication motor overload SBR45: LUBRICAT DB1600.DBX2.5 Lubricant liquid position in low level DB1600.DBX2.6 Turret motor overload SBR51: Turret1_HED_T DB1600.DBX2.7 Programmed tool number > max. turret on turret number SBR52: Turret2_BIN_T SBR53: Turret3_CODE_T DB1600.DBX3.0 Max. tool number setting error DB1600.DBX3.1 No position signals from turret DB1600.DBX3.2 Not able to find expected tool in monitor time 42, 01/2015, 6FC5397-4EP10-0BA0

43 Default PLC applications 6.1 Turning Alarm No. Interface Address Alarm Description From SBR DB1600.DBX3.3 Approach reference point again after rotation monitoring SBR40: AXIS_CTL DB1600.DBX3.4 Tool is not locked SBR53: Turret3_CODE_T DB1600.DBX6.1 Reference point X-axis not reached SBR58: MM_MAIN DB1600.DBX6.2 Reference point Z-axis not reached SBR58: MM_MAIN DB1600.DBX6.3 Wrong spindle direction started SBR58: MM_MAIN DB1600.DBX6.4 Watchdog timer JOG-program SBR58: MM_MAIN DB1600.DBX6.5 Spindle override not 100% SBR58: MM_MAIN DB1600.DBX6.6 Spindle is not started SBR58: MM_MAIN DB1600.DBX6.7 Feed override = 0% SBR58: MM_MAIN DB1600.DBX7.0 Change of spindle direction not possible in thread SBR58: MM_MAIN DB1600.DBX7.3 Safe door not closed, NC start not possible SBR22: AUX_SAFE_DOOR DB1600.DBX7.4 Channel not in reset, change PRT not possible SBR37: MCP_NCK 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[21] 0.1s 5 to 30 Time for locking a turret 14510[22] 0.1s 30 to 300 The monitoring time for searching a tool 14510[24] 1 min 5 to 300 Lubrication interval 14510[25] 0.01s 100 to 2,000 Lubrication duration, 01/2015, 6FC5397-4EP10-0BA0 43

44 Default PLC applications 6.1 Turning MD14512 Machine data - Hex Function Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit [16] Handwheel assignment with the MCP Control of Z axis rotation monitoring Control of X axis rotation monitoring 14512[17] Selection between handwheel and hand-held unit (0: handwheel; 1: hand-held unit) 14512[18] Each feed axis has a hardware limit switch (activated when Bit 6 = 0) 14512[19] Manual machine function (this function becomes active if you install licensed turning machine system and call it with a PLC subroutine) The hardware limit is independent of a PLC program Spindle positioning direction Signal that external spindle stops Tail stock function Clamping function Automatic lubrication after the first poweron (factory setting) Password clearing by power-on (0: delete the password; 1: do not delete the password) Function of spindle braking 44, 01/2015, 6FC5397-4EP10-0BA0

45 Default PLC applications 6.2 Milling 6.2 Milling Overview of the PLC subroutines Subroutine No. Name Description 0 to 19 - Reserved for the manufacturer 20 AUX_MCP Auxiliary function 21 AUX_LAMP Lamp control, called in the subroutine "AUX_MCP". 22 AUX_SAFE_DOOR Safe door control, called in the subroutine "AUX_MCP" of a milling application. 23 AUX_CHIP Chip remover control, called in the subroutine "AUX_MCP" of a milling application. 31 PLC_ini_USR_INI Reserved for the initialization by the manufacturer (this subroutine is automatically called by subroutine 32) 32 PLC_INI PLC initialization 33 EMG_STOP Emergency Stop 37 MCP_NCK Signals from the MCP and the HMI are sent to NCK interfaces 38 MCP_Tool_Nr Display tool numbers via the LED of the MCP 39 HANDWHL Handwheel selection via HMI 40 AXIS_CTL Control of feed axis enable and spindle enable 41 MINI_HHU Handwheel hand held unit 42 SPINDLE Spindle function 43 MEAS_JOG Tool measurement in the JOG mode 44 COOLING Coolant control (Manual Machine key and M code: M07, M08, M09) 45 LUBRICATE Lubrication control (interval and time) 46 PI_SERVICE ASUP (Asynchronous Subroutine Program) 47 PLC_Select_PP PLC selects a subroutine. 48 ServPlan Service plan 49 Gear_Chg1_Auto Automatic gear change of the spindle 50 Gear_Chg2_Virtual Dummy gear change of the spindle 58 MM_MAIN Manual machine 59 MM_MCP_808D Spindle signal processing for the manual machine 61, 62 Reserved for the subroutine 63 TOGGLE Six key-operated switches: K1 to K6 Two delay switches: K7, K8 Definition of user-defined keys on the MCP User-defined key 1 User-defined key 2 User-defined key 3 User-defined key 4 User-defined key 5 User-defined key 6 User-defined key 7 User-defined key 8 Working lamp Manual cooling Safe door Manual clockwise rotation of the tool magazine Manual reset of the tool magazine Manual counter-clockwise rotation of the tool magazine Removing chip forward Removing chip backward, 01/2015, 6FC5397-4EP10-0BA0 45

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 Each scan (SM0.0) AXIS_CTL (SBR40) Coordinate enabling control, hardware limit, etc. Each scan (SM0.0) COOLING (SBR44) Cooling control Each scan (SM0.0) LUBRICATE (SBR45) Lubrication control PLC user alarms Alarm No. Interface Address Alarm Description From SBR DB1600.DBX1.2 HHU is active SBR41: MINI_HHU DB1600.DBX1.3 Not able to lock tool in expected time DB1600.DBX1.4 Spindle in braking progress SBR42: SPINDLE DB1600.DBX1.6 Gear-change time out SBR49: GearChg1_Auto DB1600.DBX1.7 Gear level position error DB1600.DBX2.0 Drives not ready SBR33: EMG_STOP DB1600.DBX2.1 Operate chuck when spindle or part program is running SBR56: Lock_unlock_T DB1600.DBX2.2 Cooling motor overload SBR44: COOLING DB1600.DBX2.3 Coolant liquid position in low level DB1600.DBX3.3 Approach reference point again after rotation monitoring SBR40: AXIS_CTL DB1600.DBX3.5 Reminding information for 1st service plan SBR48:ServPlan DB1600.DBX3.6 Alarm for 1st service plan DB1600.DBX3.7 Magazine not in spindle position or original position DB1600.DBX4.0 Magazine in spindle position and original position DB1600.DBX4.1 Magazine turn key when magazine or spindle not ready DB1600.DBX4.2 Block search, tool in spindle <> programmed tool SBR60: Disk_MGZ_M SBR60: Disk_MGZ_M SBR60: Disk_MGZ_M SBR60: Disk_MGZ_M DB1600.DBX4.3 Spindle not reach tool-release pos. in time SBR60: Disk_MGZ_M DB1600.DBX4.4 Spindle not reach tool-lock pos. in time SBR60: Disk_MGZ_M DB1600.DBX7.3 Safe door not closed, NC start not possible SBR22: AUX_SAFE_DOOR DB1600.DBX7.4 Channel not in reset, change PRT not possible SBR37: MCP_NCK 46, 01/2015, 6FC5397-4EP10-0BA0

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 Lubrication duration MD14512 Machine data - Hex Function Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit [16] Handwheel assignment with the MCP Control of Z axis rotation monitoring Control of Y axis rotation monitoring Control of X axis rotation monitoring When the function of safe door is active, it can be triggered by M01/M [17] Selection between handwheel and handheld unit (0: handwheel; 1: hand-held unit) 14512[18] Each feed axis has a hardware limit switch (activated when Bit 6 = 0) 14512[19] Manual machine function (this function becomes active if you install licensed turning machine system and call it with a PLC subroutine) The hardware limit is independent from a PLC program Spindle positioning direction Signal that external spindle stops Function of safe door Automatic lubrication after the first power-on (factory setting) Password clearing by power-on (0: delete the password; 1: do not delete the password) Function of chip remover Function of spindle braking Tool magazine, 01/2015, 6FC5397-4EP10-0BA0 47

48 Default PLC applications 6.3 PLC user alarms 6.3 PLC user alarms General information PLC user alarms can be used as one of the most effective diagnosis methods. The SINUMERIK 808D control system provides 128 PLC user alarms (700xxx). Each alarm corresponds with an alarm variable that is relevant to an alarm text, and each alarm corresponds with a machine data MD14516 used to configure alarm properties Alarm properties Alarm responses You can configure the response of the control system after a user alarm is output: PLC STOP: When the user alarm is output, PLC detection stops, interface signal "NC RDY" is disabled and all outputs are disabled. EMERGENCY STOP: The user alarm automatically activates interface signal "EMER STOP". Feed disabled for all axes: The user alarm automatically activates interface signal "Feed disable". Read-in disabled: The user alarm automatically activates interface signal "Read-in disable". NC Start disabled: The user alarm automatically activates interface signal "NC Start disable". Only display: No response occurs when the user alarm is output. Only alarm number and alarm text are displayed. Cancelling methods You can configure a cancelling method for a PLC user alarm. There are totally three cancelling methods available: POWER ON: cancel the user alarm by re-powering on the control system after clearing the conditions for the alarm. <ALARM CANCEL> key on the PPU or <RESET> key on the MCP: cancel the user alarm by pressing the <ALARM CANCEL> key or the <RESET> key after clearing the conditions for the alarm. Auto-cancelling: the user alarm disappears automatically after clearing the conditions for the alarm. 48, 01/2015, 6FC5397-4EP10-0BA0

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 If both bit 7 and bit 6 are "0", the user alarm is an "auto-cancelling" alarm. If bits 5 to 0 are all "0", the user alarm is a "display-only" alarm. You can directly use the alarm response in a PLC application. PLC user alarms list with corresponding interface addresses and MD14516 No. Alarm description Interface address MD DB1600.DBX0.0 MD14516[0] HHU is active DB1600.DBX1.2 MD14516[10] Not able to lock tool in expected time DB1600.DBX1.3 MD14516[11] Spindle in braking progress DB1600.DBX1.4 MD14516[12] Operation while chuck is not locked DB1600.DBX1.5 MD14516[13] Gear-change time out DB1600.DBX1.6 MD14516[14] Gear level position error DB1600.DBX1.7 MD14516[15] Drives not ready DB1600.DBX2.0 MD14516[16] Operate chuck when spindle or part program is running DB1600.DBX2.1 MD14516[17] Cooling motor overload DB1600.DBX2.2 MD14516[18] Coolant liquid position in low level DB1600.DBX2.3 MD14516[19] Lubrication motor overload DB1600.DBX2.4 MD14516[20] Lubricant liquid position in low level DB1600.DBX2.5 MD14516[21] Turret motor overload DB1600.DBX2.6 MD14516[22] Programmed tool number > max. turret on turret number DB1600.DBX2.7 MD14516[23] Max. tool number setting error DB1600.DBX3.0 MD14516[24] No position signals from turret DB1600.DBX3.1 MD14516[25] Not able to find expected tool in monitor time DB1600.DBX3.2 MD14516[26] Approach reference point again after rotation monitoring DB1600.DBX3.3 MD14516[27], 01/2015, 6FC5397-4EP10-0BA0 49

50 Default PLC applications 6.3 PLC user alarms No. Alarm description Interface address MD Tool is not locked DB1600.DBX3.4 MD14516[28] Reminding information for 1st service plan DB1600.DBX3.5 MD14516[29] Alarm for 1st service plan DB1600.DBX3.6 MD14516[30] Magazine not in spindle position or original position DB1600.DBX3.7 MD14516[31] Magazine in spindle position and original position DB1600.DBX4.0 MD14516[32] Magazine turn key when magazine or spindle not ready DB1600.DBX4.1 MD14516[33] Block search, tool in spindle <> programmed tool DB1600.DBX4.2 MD14516[34] Spindle not reach tool-release position in time DB1600.DBX4.3 MD14516[35] Spindle not reach tool-lock position in time DB1600.DBX4.4 MD14516[36] DB1600.DBX4.5 MD14516[37] DB1600.DBX6.0 MD14516[48] Reference point X-axis not reached DB1600.DBX6.1 MD14516[49] Reference point Z-axis not reached DB1600.DBX6.2 MD14516[50] Wrong spindle direction started DB1600.DBX6.3 MD14516[51] Watchdog timer JOG-program DB1600.DBX6.4 MD14516[52] Spindle override not 100% DB1600.DBX6.5 MD14516[53] Spindle is not started DB1600.DBX6.6 MD14516[54] Feed override = 0% DB1600.DBX6.7 MD14516[55] Change of spindle direction not possible in thread DB1600.DBX7.0 MD14516[56] DB1600.DBX7.1 MD14516[57] Safe door not closed, NC start not possible DB1600.DBX7.3 MD14516[59] Channel not in reset, change PRT not possible DB1600.DBX7.4 MD14516[60] DB1600.DBX15.7 MD14516[127] Activating the PLC user alarms The control system provides totally 128 PLC user alarms. Each user alarm has a corresponding NCK address. Setting "1" for an address activates its corresponding alarm, while resetting "0" for this address clears the alarm. Each user alarm also corresponds to a 64-bit alarm variable DB1600.DBD1000 to DB1600.DBD1508. Value of a variable can be inserted into the displayed alarm text according to the data type defined by the alarm text. Available data types for the alarm variables are shown as follows: %d: decimal %x: hex %b: binary %o: octal %u: unassigned integral %f: floating You can insert a variable into your alarm text to display variable information. For example, "Signal of cooling start is active but the contactor KM %d does not absorb." 50, 01/2015, 6FC5397-4EP10-0BA0

51 Default PLC applications 6.3 PLC user alarms PLC user alarms list with corresponding interface addresses and variables No. Alarm description Interface address Variable DB1600.DBX0.0 DB1600.DBD DB1600.DBX1.1 DB1600.DBD HHU is active DB1600.DBX1.2 DB1600.DBD Not able to lock tool in expected time DB1600.DBX1.3 DB1600.DBD Spindle in braking progress DB1600.DBX1.4 DB1600.DBD Operation while chuck is not locked DB1600.DBX1.5 DB1600.DBD Gear-change time out DB1600.DBX1.6 DB1600.DBD Gear level position error DB1600.DBX1.7 DB1600.DBD Drives not ready DB1600.DBX2.0 DB1600.DBD Operate chuck when spindle or part program is running DB1600.DBX2.1 DB1600.DBD Cooling motor overload DB1600.DBX2.2 DB1600.DBD Coolant liquid position in low level DB1600.DBX2.3 DB1600.DBD Lubrication motor overload DB1600.DBX2.4 DB1600.DBD Lubricant liquid position in low level DB1600.DBX2.5 DB1600.DBD Turret motor overload DB1600.DBX2.6 DB1600.DBD Programmed tool number > max. turret on turret number DB1600.DBX2.7 DB1600.DBD Max. tool number setting error DB1600.DBX3.0 DB1600.DBD No position signals from turret DB1600.DBX3.1 DB1600.DBD Not able to find expected tool in monitor time DB1600.DBX3.2 DB1600.DBD Approach reference point again after rotation monitoring DB1600.DBX3.3 DB1600.DBD Tool is not locked DB1600.DBX3.4 DB1600.DBD Reminding information for 1st service plan DB1600.DBX3.5 DB1600.DBD Alarm for 1st service plan DB1600.DBX3.6 DB1600.DBD Magazine not in spindle position or original position DB1600.DBX3.7 DB1600.DBD Magazine in spindle position and original position DB1600.DBX4.0 DB1600.DBD Magazine turn key when magazine or spindle not ready DB1600.DBX4.1 DB1600.DBD Block search, tool in spindle <> programmed tool DB1600.DBX4.2 DB1600.DBD Spindle not reach tool-release position in time DB1600.DBX4.3 DB1600.DBD Spindle not reach tool-lock position in time DB1600.DBX4.4 DB1600.DBD DB1600.DBX4.5 DB1600.DBD DB1600.DBX6.0 DB1600.DBD Reference point X-axis not reached DB1600.DBX6.1 DB1600.DBD Reference point Z-axis not reached DB1600.DBX6.2 DB1600.DBD Wrong spindle direction started DB1600.DBX6.3 DB1600.DBD Watchdog timer JOG-program DB1600.DBX6.4 DB1600.DBD Spindle override not 100% DB1600.DBX6.5 DB1600.DBD Spindle is not started DB1600.DBX6.6 DB1600.DBD Feed override = 0% DB1600.DBX6.7 DB1600.DBD1220, 01/2015, 6FC5397-4EP10-0BA0 51

52 Default PLC applications 6.3 PLC user alarms No. Alarm description Interface address Variable Change of spindle direction not possible in thread DB1600.DBX7.0 DB1600.DBD DB1600.DBX7.1 DB1600.DBD Safe door not closed, NC start not possible DB1600.DBX7.3 DB1600.DBD Channel not in reset, change PRT not possible DB1600.DBX7.4 DB1600.DBD DB1600.DBX15.7 DB1600.DBD1508 Note For more information about NC-PLC interfaces, refer to the SINUMERIK 808D Parameter Manual Editing a PLC user alarm text For the SINUMERIK 808D control system, you have two methods to edit a PLC user alarm text: the HMI a USB stick Editing a PLC user alarm with the HMI To edit a PLC user alarm text with the HMI, proceed as follows: 1. In the "SYSTEM" operating area (press key combination: + ), press the "PLC" softkey. 2. Press the "Edit PLC alarm text" softkey. 3. Use the up/down arrow key to locate your target alarm text: 52, 01/2015, 6FC5397-4EP10-0BA0

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" operating area > "Change language"), and then call the simplified Chinese with the key combination ALT + S when typing in your text. Editing a PLC user alarm with a USB stick To edit a PLC user alarm text with a USB stick, proceed as follows: 1. Insert the USB stick into the USB interface at the front of the PPU. 2. In the "SYSTEM" operating area (press key combination: : + ), press softkeys "Sys. data" > "808D data", and enter the folder "HMI data" using the <INPUT> key., 01/2015, 6FC5397-4EP10-0BA0 53

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. Remove the USB stick and insert it into the PC USB interface. 6. Find the downloaded PLC alarm text file. By default, the alrm text file in English is named "alcu_eng": 7. Open the alarm text file with Wordpad, and you can view the PLC alarm text list. 8. Find the alarm text you want to edit and type in your own text. In this example, text for PLC alarm is changed to "For test": 9. After editing the necessary alarm text, close it by saving. 10. Remove the USB stick from your PC and insert it into the USB interface at the front of the PPU again. 54, 01/2015, 6FC5397-4EP10-0BA0

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)" by pressing the <INPUT> key twice. 13. Press the "Paste" vertical softkey to replace existing PLC alarm text file. The HMI will restart to apply the change to the PLC alarm text file (alcu...txt). 14. After the HMI restart, return to the "SYSTEM" operating area, and press softkeys "PLC" > "Edit PLC alarm text". Now you can view the results of what you have edited:, 01/2015, 6FC5397-4EP10-0BA0 55

56 Default PLC applications 6.3 PLC user alarms 56, 01/2015, 6FC5397-4EP10-0BA0

57 Commissioning the prototype Commissioning the controller Entering machine data Note Entering the machine data (MD) Make sure that the current access level is "Manufacturer". The most important machine data of the individual subareas are listed here to assist you. You can find a detailed description of the machine data and interface signals in the Parameter Manual with cross-references to the section on function description. Use the relevant softkeys to select the following machine data areas and to change the machine data if necessary: Basic list ("SYSTEM" operating areas -> "Mach. data" -> "Basic list") Basic machine data Expert list ("SYSTEM" operating areas -> "Mach. data" -> "Expert list") General machine data Axis machine data Channel machine data Display machine data Activating conditions The control system has defined four activating conditions. Each machine has a corresponding activating condition: PO: Power On (activate by powering on) RE: Reset (activate by pressing the "RESET" key) CF: Config (activate by pressing the "Activate" vertical softkey) IM: Immediate (activated immediately after your change) Note The activating condition for a machine data is shown at the end of the data line in the parameter lists. For information about basic machine data, refer to the section "Basic machine data (Page 93)"; for information about all the machine data, refer to the SINUMERIK 808D Parameter Manual., 01/2015, 6FC5397-4EP10-0BA0 57

58 Commissioning the prototype 7.1 Commissioning the controller Setting the axis-relevant parameters Enabling the position control By default, each axis is a simulation axis. This means that the control system neither produces an instruction that is output to the drive, nor reads position signals from the motor. You can enable the position control of this axis by setting the machine data shown in the table below so that the axis goes into the operating state: No. Name Unit Set Value Description CTRLOUT_TYPE - 2 Control setpoint output type ENC_TYPE - 3 Encoder feedback type Setting the leadscrew pitch, deceleration ratio, and motor rotation direction The actual moving distance depends on the parameter settings of the drive system. The parameters are shown in the table below: No. Name Unit Default Value Description LEADSCREW_PITCH mm 10 Leadingscrew pitch DRIVE_AX_RATIO_DEN UM [0 to 5] DRIVE_AX_RATIO_NOM ERA [0 to 5] - 1 Number of gearbox teeth at the drive end (denominator of the deceleration ratio) - 1 Number of gearbox teeth at the leading screw end (numerator of the deceleration ratio) Note For the spindle, index [0] means that both the denominator and the numerator are inactive, index [1] means the deceleration ratio of the first gearbox, index [2] that of the second gearbox, and the rest may be deducted in the same way. For the feed axes, you must set the deceleration ratio at index [0]. For the deceleration ratio of a turning machine, you must enter a same value from the index [0] to [5] both for the denominator and the numerator; otherwise, the alarm will occur during the machining of screw threads. If the motion direction of this axis does not correspond with the motion direction defined by the machine, you can modify it by setting the machine data shown in the table below: No. Name Unit Set Value Description AX_MOTION_DIR - 1 Motor runs clockwise (factory setting) -1 Motor runs counter-clockwise 58, 01/2015, 6FC5397-4EP10-0BA0

59 Commissioning the prototype 7.1 Commissioning the controller Setting the axis speed and acceleration You can configure the axis velocity and the acceleration by setting parameters shown in the table below: No. Name Unit Value Description MAX_AX_VELO mm/min * Maximum axis velocity JOG_VELO_RAPID mm/min * JOG rapid velocity JOG_VELO mm/min * JOG velocity AX_VELO_LIMIT mm/min * Axis velocity limit Note The value of MD36200 should be 10% higher than that of MD 32000; otherwise, alarm occurs. No. Name Unit Value Description MAX_AX_ACCEL m/s 2 * Maximum acceleration (standard value: 1 m/s 2 ) Setting the position-loop gain You can configure the position loop gain by setting the parameters shown in the following table: No. Name Unit Value Description POSCTRL_GAIN - * Position controller gain or servo gain factor (standard value: 1) Note The position-loop gain influences the position following error, so when setting this parameter, you must make adjustments with reference to the actual position precision of the axes., 01/2015, 6FC5397-4EP10-0BA0 59

60 Commissioning the prototype 7.1 Commissioning the controller Setting the spindle-relevant parameters The SINUMERIK 808D control system controls one analog spindle, and you can commission the spindle by setting the parameters listed below: Table 7-1 Enabling the position control No. Name Unit Value Description CTRLOUT_TYPE - 1 Control setpoint output type ENC_TYPE - 2 Encoder feedback type Setting the machine spindle outputs as unipolar/bipolar setpoint output Table 7-2 Setting the machine spindle outputs as unipolar/bipolar setpoint output No. Name Unit Value Description IS_UNIPOLAR_OUTPUT[0] - 0 Setpoint output is bipolar. - 1 Setpoint output is unipolar. 2 Setpoint output is unipolar; signals from pin 8 and pin 9 of the X21 (FAST I/O) are used. Note When MD30134 = 1: X21-8 = Servo enable; X21-9 = Spindle CCW. When MD30134 = 2: X21-8 = Servo enable, spindle CW; X21-9 = Servo enable, spindle CCW. For details, refer to information about connecting the inverter or servo spindle drive in the section "Connecting according to the default PLC program (Page 22)". If the spindle has no encoder feedback: No. Name Unit Value Description NUM_ENCS - 0 Spindle without encoder SIMU_AX_VDI_OUTPUT - 1 Axis signals output for simulation axes ENC_IS_DIRECT - 0 Direct measuring system (no compilation to load position) Table 7-3 Spindle machine data No. Name Unit Value Description ENC_RESOL IPR 2048 Encoder pulses/steps per revolution (encoder No.) MAX_AX_VELO mm/min * Maximum axis velocity RATED_VELO RPM 1900 Rated motor speed AX_VELO_LIMIT[0] to [5] RPM 575 Threshold value for velocity monitoring 60, 01/2015, 6FC5397-4EP10-0BA0

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 occurs. Fill in weighted machine data No. Name Unit Value Description ENC_FREQ_LIMIT Hz 300,000 Encoder limit frequency = Motor rated velocity/60 x Encoder resolution Table 7-4 For spindle with selective gearbox No. Name Unit Value Description GEAR_STEP_CHANGE_ENA BLE GEAR_STEP_MAX_VELO[0] to [5] GEAR_STEP_MAX_VELO_LI MIT[0] to [5] - 0 Gear change active. Spindle has several steps - * Maximum speed for gear stage change (gear stage number): 0 to 5 - * Maximum speed of gear stage (gear stage number): 0 to AX_VELO_LIMIT[0] to [5] - * Threshold value for velocity monitoring (control parameter set number): 0 to DRIVE_AX_RATIO_DENUM[0] to [5] DRIVE_AX_RATIO_NUMERA[ 0] to [5] - * Denominator load gearbox (control parameter number): 0 to 5 - * Numerator load gearbox (control parameter set): 0 to 5 Note A maximum of 5 spindle gear stages can be available. Assigning the same parameters to the index [0] and [1] can activate gear changes (1 to 5) just by setting the corresponding interface signals via the PLC application., 01/2015, 6FC5397-4EP10-0BA0 61

62 Commissioning the prototype 7.1 Commissioning the controller Approaching the reference point Principles for approaching the reference point Zero mark is away from the reference cam (MD: REFP_SEARCH_MARKER_REVERS = 0) Vc VM Vp 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) Rv Shift of the reference point (MD34080: REFP_MOVE_DIST + MD34090: REFP_MOVE_DIST_CORR) Rk Set position of the reference point (MD34100: REFP_SET_POS [0]) Zero mark is above the reference point Vc Velocity for searching for the reference cam (MD34020: REFP_VELO_SEARCH_CAM) VM Velocity for searching for the zero mark (MD34040: REFP_VELO_SEARCH_MARKER) Vp Position velocity (MD34070: REFP_VELO_POS) Rv Shift of the reference point (MD34080: REFP_MOVE_DIST + MD34090: REFP_MOVE_DIST_CORR) Rk Set position of the reference point (MD34100: REFP_SET_POS [0]) 62, 01/2015, 6FC5397-4EP10-0BA0

63 Commissioning the prototype 7.1 Commissioning the controller Relevant parameters No. Name Unit Value Description REFP_CAM_DIR_IS_MINUS - 0, 1 Direction for approaching the reference point: 0: + 1: REFP_VELO_SEARCH_CAM mm/min * Velocity for searching for the reference cam REFP_VELO_SEARCH_MARKER mm/min * Velocity for searching for the zero mark REFP_SEARCH_MARKER_REVERSE - 0, 1 Direction for searching for the zero mark: 0: + 1: REFP_MAX_MARKER_DIST mm * Checking the maximum distance from the reference cam REFP_VELO_POS mm/min * Positioning velocity for approaching the reference point REFP_MOVE_DIST mm * Reference point distance (with marker) REFP_MOVE_DIST_CORR mm * Correction of reference point distance REFP_CAM_SHIFT mm * Shift of the reference cam REFP_CAM_MARKER_DIST mm * Distance between the reference cam and the first zero mark REFP_SET_POS mm * Reference point position for incremental system ENC_REFP_MODE - 2 Referencing mode Note You must set the length of the reference cam based on the velocity set by MD An axis can stop above the cam after it approaches the cam at the velocity set by MD34020 and then decelerates to "0". Approaching the reference point To approach the reference point, you can proceed as follows: 1. Press the REF. POINT key on the MCP to enter the "Reference point" mode; 2. Keep the direction key pressed for the axis approaching the reference point until the symbol is displayed on the screen. Figure 7-1 Example (turning), 01/2015, 6FC5397-4EP10-0BA0 63

64 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. If you have defined positions of the reference cam and the hardware limit switch as shown in the above figure, you can approach the reference point in the trigger mode by setting MD11300: No. Name Unit Value Description JOG_INC_MODE_LEVELTRIGGRD - 0 The trigger mode for returning to the reference point. Note To modify this parameter, the access level "Manufacturer" is required Compensation parameter settings Setting the software limit switches You can set the software limit switches by configuring the parameters described in the following table: No. Name Unit Value Description POS_LIMIT_MINUS mm * - software limit switch POS_LIMIT_PLUS mm * + software limit switch Setting backlash compensation You can set the backlash compensation by configuring the parameter shown in the table below: No. Name Unit Value Description Backlash mm * Backlash compensation is active after reference point approach. 64, 01/2015, 6FC5397-4EP10-0BA0

65 Commissioning the prototype 7.1 Commissioning the controller Making leadscrew error compensation No. Name Unit Fixed value Description MM_ENC_COMP_MAX_POINTS The max. number of intermediate points for interpolation compensation Compensation theory Structure of the compensation arrays $AA_ENC_COMP [0, 0, AX3] = 0.0 Error value at the lowest point $AA_ENC_COMP [0, 1, AX3] = 0.0 Error value at the position of the lowest point + 1 $AA_ENC_COMP [0, 2, AX3] = 0.0 Error value at the position of the lowest point + 2 $AA_ENC_COMP [0, 3, AX3] = 0.0 Error value at the position of the lowest point $AA_ENC_COMP [0, 123, AX3] = 0.0 Error value at the position of the lowest point $AA_ENC_COMP [0, 124, AX3] = 0.0 Error value at the position of the lowest point $AA_ENC_COMP_STEP [0, AX3] = 0.0 Measurement distance (in mm) $AA_ENC_COMP_MIN [0, AX3] = 0.0 The lowest point (absolute) $AA_ENC_COMP_MAX [0, AX3] = 0.0 The highest point (absolute) $AA_ENC_COMP_IS_MODULO [0, AX3] = 0.0 (for the turning axis), 01/2015, 6FC5397-4EP10-0BA0 65

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" >: Leadscrew error compensation). 3. Copy it with the "Copy" softkey. 4. Press the "USB" softkey and paste the compensation file into the USB stick by pressing the "Paste" softkey. 5. Unplug the USB stick from the PPU, and insert it into a USB port of your PC. 6. Open the compensation file with the WordPad in the USB stick (default name: complete.eec). 7. Move the axis to be compensated based on the pre-set minimum position, maximum position and measurement distance. 8. Measure each error with a laser interferometer. 9. Record the error values into the compensation file, and delete the check code (for the compensation point). For example: 10. Re-insert the USB stick into the USB interface at the front PPU. Copy the modified compensation file from the USB stick and paste it under the original directory ("SYSTEM" operating area > "Sys data" > "808D data" > "NCK/PLC data": Leadscrew error compensation) to replace the old compensation file. 11. Wait for a few seconds: replacing the old compensation file can cause a PLC restart. 12. Set MD32700 = 1 ("SYSTEM" operating area > "Mach. data"> "Basic list"). 13. The compensation values are effective after returning to the reference point. 14. Move the axes in JOG mode, and you can view the actual compensation value under "SYSTEM" operating area > "Serv. displ."> "Service axes": Abs. compens. value meas. system 1. 66, 01/2015, 6FC5397-4EP10-0BA0

67 Commissioning the prototype 7.1 Commissioning the controller Method 2: 1. Follow steps 1 to 4 in method Press the <PROGRAM MANAGER> key. 3. Copy the compensation file from the USB to NC 4. Press the extension softkey ">>" and change the compensation file to a program file with the "Rename" softkey. For example, press the "Rename" softkey >change "COMPLETE.EEC" to "COMPLETE.MPF": 5. Press the <INPUT> key to open the program file: 6. Measure each error with a laser interferometer., 01/2015, 6FC5397-4EP10-0BA0 67

68 Commissioning the prototype 7.1 Commissioning the controller 7. Record the measurement values in the COMPLETE.MPF for the corresponding axis, and delete the check code (for the compensation point). For example: 8. Press the "Execute" softkey. The SINUMERIK 808D enters the AUTO mode. 9. Press the <CYCLE START> key to execute COMPLETE.MPF. And the recorded compensation values will be saved into the SINUMERIK 808D. 10. Set MD32700 = 1 ("SYSTEM" operating area > "Mach. data" > "Basic list"). 11. Restart the NC ("SYSTEM" operating area > "Start-up" > NC: Standard power-up). 12. The compensation values are effective after returning to the reference point. 13. Move the axes in JOG mode, and then you can view the actual compensation value under "SYSTEM" operating area > " Serv. displ." > "Service axes": Abs. compens. value meas. system Setting protection levels The SINUMERIK 808D control system has defined protection levels for user data. You can set protection levels for the following user data: Tool offsets Zero offsets Setting data R parameters Part programs RS232 settings PLC projects Protected work areas 68, 01/2015, 6FC5397-4EP10-0BA0

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"): No. Name Value Description 207 USER_CLASS_READ_TOA 3 to 7 Protection level: read, for tool offsets 208 USER_CLASS_WRITE_TOA_GEO 3 to 7 Protection level: write, for tool geometry 209 USER_CLASS_WRITE_TOA_WEAR 3 to 7 Protection level: write, for tool wear data 210 USER_CLASS_WRITE_ZOA 3 to 7 Protection level: write, for zero offsets 212 USER_CLASS_WRITE_SEA 3 to 7 Protection level: write, for setting data 213 USER_CLASS_READ_PROGRAM 3 to 7 Protection level: read, for part programs 214 USER_CLASS_WRITE_PROGRAM 3 to 7 Protection level: write, for part programs 215 USER_CLASS_SELECT_PROGRAM 3 to 7 Protection level: select, for part programs 218 USER_CLASS_WRITE_PRA 3 to 7 Protection level: write, for R parameters 219 USER_CLASS_SET_V24 3 to 7 Protection level: set, for RS232 settings 221 USER_CLASS_DIR_ACCESS 3 to 7 Protection level: directory access 222 USER_CLASS_PLC_ACCESS 3 to 7 Protection level: PLC project access 223 USER_CLASS_WRITE_PWA 3 to 7 Protection level: protected work area access User data with protection level 3 can be read or written with access level "Customer" or higher. User data with protection level 4 can be read or written only when the PLC address DB2600.DBX0.7 is set to "1". User data with protection level 5 can be read or written only when the PLC address DB2600.DBX0.6 is set to "1". User data with protection level 6 can be read or written only when the PLC address DB2600.DBX0.5 is set to "1". User data with protection level 7 can be read or written without any password or PLC interface signal. For detailed information about the PLC user interface, refer to the section "PLC user interfaces (Page 106)"., 01/2015, 6FC5397-4EP10-0BA0 69

70 Commissioning the prototype 7.2 Data backup 7.2 Data backup Creating a series archive After commissioning the prototype, you must create a series archive for series production. The series archive file includes the following data: Machine and setting data PLC data (for example, PLC program and PLC alarm texts) User cycles and part programs Tool and work offset data R variables HMI data (for example, OEM Online Help and OEM Manual) You can back up the production archive in two ways: Internal: on the CNC controller External: on a USB stick To create a series archive, proceed as follows: 1. In the "SYSTEM" operating area (key combination: + ), press the "Archv." softkey. 2. Select the option of "Create series start-up archive" and press the "OK" softkey: You must select a back-up path from the list to store the production archive file: OEM files: folder on the CNC controller for storing OEM files User files: folder on the CNC controller for storing end-user files USB: USB stick The default name of the data archive is "arc_product.arc". You can use your favourite name for it. 70, 01/2015, 6FC5397-4EP10-0BA0

71 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 Comment 4. Press the "OK" softkey to create the data archive. Note Do not remove the USB stick during the data back-up Creating a start-up archive for the prototype After commissioning the prototype, you must also create a start-up archive for the data backup of the prototype itself. The start-up archive file includes the following data: Machine and setting data Compensation data PLC data (for example, PLC program and PLC alarm texts) User cycles and part programs Tool and work offset data R variables HMI data (for example, OEM Online Help and OEM Manual) You can also back up the start-up archive in two ways: Internal: on the CNC controller External: on an USB stick, 01/2015, 6FC5397-4EP10-0BA0 71

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". You can use your own name for it. 3. Select the target directory and press the <INPUT> key to enter the directory and press the "OK" softkey to proceed: In the "Archive information" box that follows, you can enter the information below: Archive creator Archive version Comment 4. Press the "OK" softkey to create the data archive. Note Do not remove the USB stick during the data back-up. 72, 01/2015, 6FC5397-4EP10-0BA0

73 Commissioning the prototype 7.2 Data backup Restoring the control system with the start-up archive file You can, if necessary, restore the system of the prototype machine by uploading the start-up archive file. To upload the start-up archive, perform the following operations: 1. In the "SYSTEM" operating area, press the "Archv." softkey. 2. Select the option "Restore start-up archive": Press the "OK" softkey: 3. Find the backed-up path and press the <INPUT> key to enter the directory. Select the backed-up data archive and press the "OK" softkey: 4. Check the archive information and press the "OK" softkey to proceed if the selected data archive is correct:, 01/2015, 6FC5397-4EP10-0BA0 73

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. 74, 01/2015, 6FC5397-4EP10-0BA0

75 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. To upload the production archive, proceed as follows: 1. In the "SYSTEM" operating area, press the "Archv." softkey. 2. Select the option "Restore start-up archive": Press the "OK" softkey: 3. Find the back-up path and press the <INPUT> key to enter the directory. Select the backed-up data archive and press the "OK" softkey:, 01/2015, 6FC5397-4EP10-0BA0 75

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. 7. The CNC controller restarts after successfully uploading the production archive. Note Successfully uploading the data archive can delete the password. You must set the password again in the "SYSTEM" operating area. 76, 01/2015, 6FC5397-4EP10-0BA0

77 Series production 8.2 Data settings for individual machine 8.2 Data settings for individual machine Setting the software limit switches Refer to the section "Setting the software limit switches (Page 64)" Setting the backlash Refer to the section "Setting backlash compensation (Page 64)" Making leadscrew error compensation Refer to the section "Making leadscrew error compensation (Page 65)". 8.3 Data backup Overview After the series production, you can do the data backup of individual machine for delivery in two ways: Creating an original status archive: data backup only on the CNC controller Creating a start-up archive: data backup either on the CNC controller or on an external USB stick The original status archive and the start-up archive contain exactly the same data: Machine and setting data Compensation data PLC data (for example, PLC program and PLC alarm texts) User cycles and part programs Tool and work offset data R-parameter HMI data (for example, OEM Online Help and OEM Manual), 01/2015, 6FC5397-4EP10-0BA0 77

78 Series production 8.3 Data backup 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. In the "Archive information" box that follows, you can enter the information below: Archive creator Archive version Comment 2. Press the "OK" softkey to create the data archive Creating the start-up archive When creating the start-up archive for the series production, follow exactly the same procedures used to create the start-up archive for the prototype. Refer to the section "Creating a start-up archive for the prototype (Page 71)" for details. 78, 01/2015, 6FC5397-4EP10-0BA0

79 Series production 8.3 Data backup 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. In the "SYSTEM" operating area (key combination: + ), press the "Archv." softkey. 2. Select the option "Restore start-up archive from the default directory", and press the "OK" softkey: Note: The option "Restore start-up archive from the default directory" is displayed only when you have created the original status archive. 3. Check the archive information and press the "OK" softkey to proceed; otherwise, press the "Cancel" softkey to cancel the restore operation., 01/2015, 6FC5397-4EP10-0BA0 79

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. Restore the control system with the start-up archive When restoring the control system with a start-up archive, you can follow exactly the same procedures used to restore the prototype machine. For details, refer to the section "Restoring the control system with the start-up archive file (Page 73)". 80, 01/2015, 6FC5397-4EP10-0BA0

81 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. Creating a slide show By default, the slide show of Siemens product information is provided. You can create the desired slide show as follows: 1. Prepare your own slides and save them in the respective language folders on a USB stick. Name each folder according to the following convention. Chinese: folder name = "chs"; English: folder name = "eng"; Portuguese: folder name = "ptb"; Russian: folder name = "rus". The SINUMERIK 808D supports two kinds of image formats: *.png *.bmp Image size is recommended to be 640*480 pixels for the best display effect. Name each slide according to the following syntax: slide%u.png or slide%u.bmp Here "%u" is the number sequence starting with "1". For example, slide1.png, slide2.png, slide3.png... If your slides include both PNG-format images and BMP-format images, then number them separately. During the slide show, the PNG-format images will have a higher priority over the BMP-format images. 2. Insert the USB stick into the USB interface at the front of the PPU., 01/2015, 6FC5397-4EP10-0BA0 81

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" softkey: 4. Press the "808D data" softkey. Enter directory "HMI data" > "OEM slideshow (*.bmp; *.png)" by pressing the <INPUT> key twice.press the "Paste" softkey: 5. Press the key combination <CTRL> + <D>, and now you can view the slideshow you have created. Note Using MD9001 TIME_BTWEEN_SLIDES ("SYSTEM" operating area >"Mach. Data" > "Expert list" > "Display MD") you can set the time between slides. Press the key combination <CTRL> + <D> again to exit the slide show. 82, 01/2015, 6FC5397-4EP10-0BA0

83 Other frequently used functions 9.2 Defining the service planner 9.2 Defining the service planner The SINUMERIK 808D has the service planning function. With this function, you can specify the service timer and define your own service information. This section shows you how to define the OEM service planner. Creating a new service task To create a new service task, perform the following steps: + 1. Enter the desired operating area. 2. Enter the main screen of service planning. 3. Create a new task. Enter values in the respective fields. 4. Confirm the above input to complete creating the new task., 01/2015, 6FC5397-4EP10-0BA0 83

84 Other frequently used functions 9.2 Defining the service planner Viewing the service task To edit the created service task, proceed as follows: + 1. Enter the desired operating area. 2. Enter the main screen of HMI data. 3. Enter the folder related to HMI data. 4. Navigate to the last folder. 5. Press this key to open the folder. 6. Copy the desired service planner text. 7. Press this softkey to enter the screen form of user cycle. 84, 01/2015, 6FC5397-4EP10-0BA0

85 Other frequently used functions 9.2 Defining the service planner 8. Press this softkey to paste the copied text into the screen form of user cycle. 9. Press this softkey to view the service task. Editing the service task + 1. Enter the desired operating area. 2. Enter the main screen of service planning. 3. Press this softkey to enter the screen form of task change. 4. Change the task description in the following box as desired. 4. Confirm the above input to complete changing the task., 01/2015, 6FC5397-4EP10-0BA0 85

86 Other frequently used functions 9.3 Using the OEM startup screen and the OEM machine logo 9.3 Using the OEM startup screen and the OEM machine logo The SINUMERIK 808D uses the SIEMENS start-up screen and machine logo by default. If necessary, you can use you own start-up screen and machine logo. Using the OEM startup screen The default start-up screen is shown below: To change it to your own start-up screen, proceed as follows: 1. Prepare the image of the start-up screen and save it on a USB stick. The SINUMERIK 808D supports a start-up screen in the BMP format and with a maximum size of 640*480 pixels (W*H). Name the image as "startup.bmp". 2. Insert the USB stick into the USB interface at the front of the PPU. 3. Press softkeys "Sys. data" > "USB" in the "SYSTEM" operating area. Find the start-up screen file and copy it with the "Copy" softkey. 4. Press the "808D data" softkey. Press the <INPUT> key to enter "HMI data" > "Customized bitmaps". The default start-up screen and machine logo are placed under the "Customized bitmaps" folder: OEM machine logo (mtbico.bmp) OEM start-up splash screen (startup.bmp) Press the "Paste" softkey to replace the default startup screen with your own start-up screen. 86, 01/2015, 6FC5397-4EP10-0BA0

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. Using the OEM machine logo Machine logo can be displayed in the "Machine" operating area. The default machine logo is displayed as follows:, 01/2015, 6FC5397-4EP10-0BA0 87

88 Other frequently used functions 9.3 Using the OEM startup screen and the OEM machine logo To use your own machine logo, proceed as follows: 1. Prepare your own machine logo and save it on a USB stick. The SINUMERIK 808D supports the OEM machine logo in the BMP format with a maximum size of 124*19 pixels (W*H). Name the image as "mtbico.bmp". Note that a machine logo with the size of 124*19 pixels can make the best effect. 2. Insert the USB stick into the USB interface at the front of the PPU. 3. Press softkeys "Sys. data" > "USB" in the "SYSTEM" operating area. Find the machine logo and copy it with the "Copy" softkey: 4. Press the "808D data" softkey. Press the <INPUT> key to enter "HMI data" > "Customized bitmaps". The default startup screen and machine logo are placed under the "Customized bitmaps" folder: OEM machine logo (mtbico.bmp) OEM start-up splash screen (startup.bmp) Press the "Paste" softkey to replace the default machine with your own machine logo. 5. Press Ctrl + R to restart the HMI. You can view your own machine logo in the "Machine" operating area. Note To restore the default "SIEMENS" logo display, delete the customized bitmap file (mtbico.bmp) from the control system. 88, 01/2015, 6FC5397-4EP10-0BA0

89 Appendix A A.1 Cutting reserved holes On the MCP, three reserved holes with a standard diameter of 16 mm are available for you to install necessary devices according to your own needs: Figure A-1 Reserved holes To cut a reserved hole, proceed as follows: Figure A-2 Cutting reserved holes, 01/2015, 6FC5397-4EP10-0BA0 89

90 Appendix A.2 Inserting, printing or cutting the MCP strips A.2 Inserting, printing or cutting the MCP strips Inserting the MCP strips The MCP strips for the SINUMERIK 808D (Turning) are already pre-assembled into the MCP. If you are using the control system of Milling version, you need to take these preassembled strips out firstly, and then insert the MCP strips for the Milling version into the MCP by yourself. To insert the MCP strips, follow the order shown as follows with reference to the marks (M1 to M6, T1 to T6) on the strips: Printing customized MCP strips Siemens provides you a symbol library for customized MCP keys. You can print customized strips with the A4-size blank paper included in the delivered MCP package. You can find the symbol library in the Toolbox (...\ \examples\MCP). Siemens also provides you with a template file for printing customized strips. Key positions in the template accord with real key layout on the MCP. You can copy symbols from the symbol library and paste them to the key positions that you want to use customized symbols. You can find the template file in the Toolbox (...\ \examples\MCP). Cutting customized MCP strips The delivered A4-size paper has been pre-cut with boundaries. You just need to tear them off after printing customized symbols. 90, 01/2015, 6FC5397-4EP10-0BA0

91 Appendix A.3 Basic knowledge about NC programming A.3 Basic knowledge about NC programming Theory Table A- 1 Commands M3 M4 Tn G00 G01 G02 G03 Nn Basic NC 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. When G01 is active in the program, the axis traverses at the programmed feedrate in a straight line, according to the feedrate type defined by G94 (F as the feedrate in mm/min) / G95 (F as the feedrate in rev/min of the spindle). CW circular interpolation CCW circular interpolation Block number - subblock n = an integer at the range of 0 to 99,999,999 Programming under the MDA mode (example) PPU: + MCP: Figure A-3 NC programming (example), 01/2015, 6FC5397-4EP10-0BA0 91

92 Appendix A.4 Selection of the transformers References Programming and Operating Manual (Turning) Programming and Operating Manual (Milling) A.4 Selection of the transformers You can select the appropriate transformers according to the desired motor combinations. Recommended transformer type Supply voltage Connection group Impedance voltage (Uk%) V/220 V SG series 3AC isolating servo transformer 3 AC 380 / 220 V 50/60 Hz Y/Y-12 No-load current (%) For a transformer =< 1.0 kva, the no-load current < 18%; Power selection according to possible motor combinations For a transformer > 1.0 kva, the no-load current < 14%. 4 Nm 1.0 kva 4 Nm + 4 Nm + 10 Nm 2.0 kva 6 Nm 1.5 kva 4 Nm + 6 Nm + 6 Nm 2.0 kva 7.7 Nm 2.0 kva 4 Nm + 6 Nm Nm 2.0 kva 10 Nm 2.0 kva 4 Nm + 6 Nm + 10 Nm 2.0 kva 4 Nm + 4 Nm 1.5 kva 4 Nm Nm Nm 2.0 kva 4 Nm + 6 Nm 1.5 kva 4 Nm Nm + 10 Nm 2.5 kva 4 Nm Nm 1.5 kva 4 Nm + 10 Nm + 10 Nm 2.5 kva 4 Nm + 10 Nm 2.0 kva 6 Nm + 6 Nm + 6 Nm 2.0 kva 6 Nm + 6 Nm 1.5 kva 6 Nm + 6 Nm Nm 2.0 kva 6 Nm Nm 2.0 kva 6 Nm + 6 Nm + 10 Nm 2.5 kva 6 Nm + 10 Nm 2.0 kva 6 Nm Nm Nm 2.5 kva 7.7 Nm Nm 2.0 kva 6 Nm Nm + 10 Nm 2.5 kva 7.7 Nm + 10 Nm 2.5 kva 6 Nm + 10 Nm + 10 Nm 3.0 kva 10 Nm + 10 Nm 3.0 kva 7.7 Nm Nm Nm 2.5 kva 4 Nm + 4 Nm + 4 Nm 1.5 kva 7.7 Nm Nm + 10 Nm 3.0 kva 4 Nm + 4 Nm + 6 Nm 1.5 kva 7.7 Nm + 10 Nm + 10 Nm 3.0 kva 4 Nm + 4 Nm Nm 2.0 kva 10 Nm + 10 Nm + 10 Nm 3.5 kva CAUTION To reduce the risk of electric shock, interference from power supply and electromagnetic field, an isolating transformer is necessary for the 3AC 380V mains system. 92, 01/2015, 6FC5397-4EP10-0BA0

93 Appendix A.5 Parameter list A.5 Parameter list A.5.1 Basic machine data No. Name Default Range Type Unit Activating JOG_INC_MODE_LEVELTRIGGRD 1 - BOOL - PO INC and REF in JOG mode * USER_DATA_INT[0]... [31] 0-62,768 to 32,767 DWORD - PO User data (INT) * USER_DATA_HEX[0]... [31] 0H 0 to 0x0FF BYTE - PO User data (HEX) * USER_DATA_FLOAT[0]... [7] e+038 to 3.4e+038 DOUBLE - PO User data (float) REFP_NC_START_LOCK 1 - BOOL - RE NC start disable without reference point SIMU_AX_VDI_OUTPUT FALSE - BOOL - PO Axis signals output for simulation axes FIX_POINT_POS[0]... [3] DOUBLE mm, degrees PO Fixed-value positions of axis with G CTRLOUT_TYPE 0 0 to 3 BYTE - PO Output type of setpoint IS_UNIPOLAR_OUTPUT[0] 0 0 to PO Setpoint output is unipolar NUM_ENCS 1 0 to 1 BYTE - PO Number of encoders ENC_TYPE 0 0 to 5 BYTE - PO Encoder type of actual value sensing (actual position value) ENC_RESOL[0] 10,000 DWORD - PO Encoder lines per revolution LEADSCREW_PITCH DOUBLE mm PO Pitch of leadscrew ENC_IS_DIRECT FALSE, FALSE - BYTE - PO Direct measuring system (no compilation to load position) DRIVE_AX_RATIO_DENOM[0]... [5] 1 1 to 2,147,000,000 DWORD - PO Denominator load gearbox, 01/2015, 6FC5397-4EP10-0BA0 93

94 Appendix A.5 Parameter list No. Name Default Range Type Unit Activating DRIVE_AX_RATIO_NUMERA[0] to DWORD - PO [5] 2,147,000,000 Numerator load gearbox STEP_RESOL[0] 10, to 100,000 DWORD - PO Steps per stepper motor revolution MAX_AX_VELO 10,000 (mm/min) (rpm) Maximum axis velocity JOG_VELO_RAPID 10,000 (mm/min) (rpm) Rapid traverse in JOG mode JOG_VELO 20,000 (mm/min) 5.55 (rpm) Jog axis velocity POS_AX_VELO 10,000 (mm/min) (rpm) Initial setting for positioning axis velocity - DOUB LE mm/min, rpm - DOUBLE mm/min, rpm - DOUBLE mm/min, rpm - DOUBLE mm/min, rpm AX_MOTION_DIR 1-1 to 1 DWORD - PO Traversing direction (not control direction) ENC_FEEDBACK_POL[0] 1-1 to 1 DWORD - PO Sign actual value (control direction) POSCTRL_GAIN[0]... [5] to DOUBLE User defined CF Servo gain factor RATED_VELO[0] 1, DOUBLE rpm CF Rated motor speed MAX_AX_ACCEL[0]... [4] [0]...[2]: DOUBLE mm/s 2, CF [3]...[4]: 1.0 rev/s 2 Maximum axis acceleration Backlash[0] DOUBLE mm CF Backlash ENC_COMP_ENABLE[0] 0 - BOOL - CF Encoder/spindle error compensation REFP_CAM_IS_ACTIVE 1 - BOOL - RE Axis with reference point cam REFP_CAM_DIR_IS_MINUS 0 - BOOL - RE Approach reference point in minus direction CF RE RE RE 94, 01/2015, 6FC5397-4EP10-0BA0

95 Appendix A.5 Parameter list No. Name Default Range Type Unit Activating REFP_VELO_SEARCH_CAM 5, DOUBLE mm/min, RE (mm/min) (rpm) rpm Reference point approach velocity REFP_VELO_SEARCH_MARKER[0] (mm/min) (rpm) Creep velocity REFP_SEARCH_MARKER_REVER SE[0] Direction reversal to reference cam - DOUBLE mm/min, rpm 0 - BOOL - RE REFP_MAX_MARKER_DIST[]0[ DOUBLE mm, degrees Maximum distance to reference mark REFP_VELO_POS 10, (mm/min) (rpm) Reference point positioning velocity - DOUBLE mm/min, rpm REFP_MOVE_DIST[0] DOUBLE mm, degrees RE Reference point distance REFP_MOVE_DIST_CORR[0] DOUBLE mm, degrees RE Reference point offset/absolute offset REFP_CAM_SHIFT DOUBLE mm RE Electronic cam offset for incremental measuring system REFP_CAM_MARKER_DIST DOUBLE mm PO Reference cam/reference mark distance REFP_SET_POS[0]... [3] DOUBLE mm, degrees RE Reference point for incremental system ENC_REFP_MODE 1 0 to 8 BYTE - PO Referencing mode GEAR_STEP_CHANGE_ENABLE 0 - BOOL - RE Parameterize gear stage change * SPIND_VELO_LIMIT 10, DOUBLE rpm PO Maximum spindle speed GEAR_STEP_MAX_VELO[0]... [5] [0]...[1]: 500 [2]: 1,000 [3]: 2,000 [4]: 4,000 [5]: 8,000 - DOUBLE rpm CF Maximum speed for gear stage change RE RE RE, 01/2015, 6FC5397-4EP10-0BA0 95

96 Appendix A.5 Parameter list No. Name Default Range Type Unit Activating GEAR_STEP_MIN_VELO[0]... [5] [0]...[1]: 50 - DOUBLE rpm CF [2]: 400 [3]: 800 [4]: 1,500 [5]: 3,000 Minimum speed for gear stage change GEAR_STEP_MAX_VELO_LIMIT[0] [0]...[1]: DOUBLE rpm CF... [5] [2]: 1,000 [3]: 2,000 [4]: 4,000 [5]: 8,000 Maximum speed for gear stage GEAR_STEP_MIN_VELO_LIMIT[0]... [0]...[1]: 5 - DOUBLE rpm CF [5] [2]: 10 [3]: 20 [4]: 40 [5]: 80 Minimum speed for gear stage POS_LIMIT_MINUS -100,000,000 - DOUBLE mm, degrees RE 1st software limit switch minus Access level: Manufacturer POS_LIMIT_PLUS 100,000,000 - DOUBLE mm, degrees RE 1st software limit switch plus POS_LIMIT_MINUS2-100,000,000 - DOUBLE mm, degrees RE 2nd software limit switch minus POS_LIMIT_PLUS2 100,000,000 - DOUBLE mm, degrees RE 2nd software limit switch plus AX_VELO_LIMIT[0]... [5] 11,500 (mm/min) 31,944 (rpm) - DOUBLE mm/min, rpm CF Threshold value for velocity monitoring MM_ENC_COMP_MAX_POINTS DWORD - PO Number of intermediate for interpolar compensation (SRAM) The machine data followed by an asterisk (*) have the access level of "Customer", while those without an asterisk have the access level of "Manufacturer". 96, 01/2015, 6FC5397-4EP10-0BA0

97 Appendix A.5 Parameter list A.5.2 SINAMICS V60 parameters Par. No. Name Range Default Increment Unit Effective P01 Parameter write protection Immediately 0: Sets all parameters other than P01 as read-only parameters. 1: Sets all parameters to be both readable and writable. P01 automatically resets to 0 after power-on! P05 Internal enable Immediately 0: JOG mode can be enabled externally. 1: JOG mode can be enabled internally. P05 automatically resets to 0 after power-on! P16 Maximum motor current % Power On Specifies the maximum motor current (2 x rated motor current) of your choice. P20 Speed loop proportional gain Depends on drive 0.01 Nm*s/rad Immediately version Factory defaults: 4 Nm: 0.81; 6 Nm: 1.19; 7.7 Nm: 1.50; 10 Nm: 2.10 Note: Default value varies with software version. This parameter specifies the proportional gain (Kp, proportional component) of speed control loop. The bigger the value, the higher the gain and rigidity. The setting depends on specific drive and load. Generally, the bigger the load inertia, the bigger the value is to set. However, if there is no oscillation occurring in the system, you can set the value as big as possible. P21 Speed loop integral time Depends on drive 0.1 ms Immediately constant version Factory defaults: 4 Nm: 17.7; 6 Nm: 17.7; 7.7 Nm: 17.7; 10 Nm: 18.0 Note: Default value varies with software version. This parameter specifies the integral action time (Tn, integral component) of speed control loop. The smaller the value, the higher the gain and rigidity. The setting depends on specific drive and load. P26 Maximum motor speed 0-2,200 2, rpm Power On Sets the maximum possible motor speed. P30 Position loop proportional gain ,000/min Immediately 1. This parameter specifies the proportional gain of position loop. 2. The bigger the value, the higher both the gain and rigidity, and at the same pulse command frequency the smaller the position hysteresis. However, excessively high value setting may cause system oscillation or overshooting. 3. The setting depends on specific drive and load. P31 Position loop feedforward gain % Immediately, 01/2015, 6FC5397-4EP10-0BA0 97

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. Increasing the feedforward gain of position loop improves the high-speed response characteristics of the control system, but meanwhile causes the system's position loop unstable and liable to oscillation. 4. Unless very high response characteristics are necessary, set the feedforward gain of position loop to 0. P34 Maximum following error pulses Immediately This parameter specifies the maximum possible following error. When the actual following error is larger than the setpoint, the drive sends an over-position alarm (A43) P36 Input pulse multiplier 1, 2, 4, 5, 8, 10, 16, 20, 100, 1, Power On This parameter specifies the input pulse multiplier. For example, when P36 = 100, input frequency = 1 khz, output frequency = 1 khz x 100 = 100 khz. Note: Pulse frequency setpoint = Actual pulse frequency x input pulse multiplier; This parameter is applicable only when the software version is V01.06 or later; When P36 = 100 or 1,000, speed stability will decrease with higher multiplication factor. P41 Brake open delay 20-2, ms Power On The setpoint transfer after drive enable is delayed by this time. Drive can be enabled under the following conditions: A: When the following three conditions are all met: 1. Terminal 65 (external enable) has been enabled; 2. The drive has received an enable signal from NC; 3. No alarm is detected by the drive. B: When the following two conditions are both met: 1. Terminal 65 (control enable) has been activated; 2. Motor operates in "JOG-RUN" mode (enabled from function menu ) C: When the following two conditions are both met: 1. P05 = 1 (The JOG mode can be enabled internally); 2. Motor operates in "JOG-RUN" mode (enabled from function menu ) P42 Brake close time while motor 20-2, ms Power On operation When motor speed exceeds 30 rpm, the drive generates an alarm. If, within the specified brake close time (P42), the actual motor speed remains bigger than brake close speed setpoint (P43), brake is closed after the specified brake close time (P42) expires. P43 Brake close speed while 0-2, r/min Power on motor operation When motor speed exceeds 30 rpm, the drive generates an alarm. If, within the specified brake close time (P42), the actual motor speed becomes smaller than the P43 setpoint, brake is closed when the actual speed reaches the speed setpoint. P44 Drive enable time after the 20-2, ms Power on brake close When motor speed is lower than 30 rpm, the drive remains enabled within the time period set by P44 after brake close. 98, 01/2015, 6FC5397-4EP10-0BA0

99 Appendix A.6 Diagnostics Par. No. Name Range Default Increment Unit Effective P46 JOG speed 0-2, rpm Immediately This parameter specifies the motor speed in JOG mode. P47 P99 Ramp-up/-down time constant s Power on This parameter defines the time period when the motor ramps up from 0 rpm to 2,000 rpm or ramps down from 2, 000 rpm to 0 rpm. Reserved for Siemens internal use only A.6 Diagnostics A.6.1 SINUMERIK 808D alarms Some alarms may occur during the commissioning work. In the "ALARM" operating area, you can press the <HELP> key to call the help information for an alarm. For details about it, refer to the Diagnostics Manual. A.6.2 A Table A- 2 SINAMICS alarms Overview of alarms Overview of alarms Alarm code Alarm name Description A01 Power board ID number Unable to identify the power board error A02 Parameter error Parameter validation error (CRC error, encoder type or parameter header invalid) A03 Memory-write failure Unable to write data to memory A04 Control voltage error Control voltage is lower than 3.5 V. A05 IGBT overcurrent IGBT is detected overcurrent. A06 lnternal chip overcurrent Internal chip is detected overcurrent. A07 Grounding short circuit Grouding short circuit occurs during drive initialization A08 Endoder UVW sginals error Signals from encoder phases U, V, W are detected all the same (all high or all low) A09 Encoder TTL signals error TTL pulse error A14 Internal error Software failure A21 DC link overvoltage DC link voltage is higher than 405 V A22 IT protection IGBT current exceeds the upper limit for 300 ms A23 DC link undervoltage DC link voltage is lower than 200 V A41 Overspeed Actual motor speed is higher than 2200 rpm A42 IGBT overtemperature IGBT becomes overheating A43 Over-position Position offset is out of limit A44 I 2 T protection Motor load exceeds nominal motor torque A45 Emergency stop Enable signal from Terminal 65 is lost during normal drive operation, 01/2015, 6FC5397-4EP10-0BA0 99

100 Appendix A.6 Diagnostics A Alarm list Alarm code Background Possible Cause Remedy Result Acknowledgement A01 Power board is broken Replace the drive with a new one A02 The memory is damaged due to unexpected poweroff during data saving Restore default parameters A03 Memory is damaged Replace the drive with a new one A04 A05 This alarm may occur when the DC link is connected This alarm may occur when the motor is running The 24 V DC supply is abnormal The drive is defective 1. There is a short-circuit between terminals U, V, W and PE on the drive 2. bad grounding 3. motor insulation is broken 4. the drive is broken Check the 24 V DC supply Replace the drive with a new one 1. check the wiring 2. make a correct grounding 3. replace the motor with a new one 4. replace the drive with a new one Free stop Free stop Free stop Free stop Free stop Power on Power on Power on Power on Power on A06 This alarm may occur when the DC link is connected This alarm may occur when the motor is running 1. There is a short-circuit between terminals U, V, W and PE on the drive 2. bad grounding 3. motor insulation is broken the drive is broken 1. check the wiring or whether the connection to U, V or W is broken 2. make a correct grounding 3. replace the motor with a new one Free stop Power on 4. replace the drive with a new one A07 This alarm may occur when the DC link is connected This alarm may occur when the motor is running 1. IGBT module is broken 2. There is a short-circuit between U, V or W and PE 1. replace the drive with a new one 2. Check the wiring Free stop Power on A08 1. UVW signals of the encoder are bad 1. replace the encoder with a new one Free stop Power on 2. bad cable 3. bad cable shielding 2. check the interface circuit of the encoder 4. bad wiring of the shielded ground cable 5. there is a failure in the interface circuit of the encoder 100, 01/2015, 6FC5397-4EP10-0BA0

101 Appendix A.6 Diagnostics Alarm code Background Possible Cause Remedy Result Acknowledgement A09 1. connection failure of encoder ABZ 1. check the wiring of encoder cable Free stop Power on 2. bad cable 3. bad cable shielding 2. check the interface circuit of the encoder 4. bad wiring of the shielded grounded cable 5. there is a failure in the interface circuit of the encoder A14 There is failure at the internal software Reset by power-on Free stop Power on A short-circuit occurs to the encoder Check the wiring of encoder A21 This alarm may occur when the 24 V DC supply is connected There is a failure at the circuit board Replace the drive with a new one Free stop Press Enter key on the operator panel or terminal RST of X6 interface This alarm may occur when the DC link is connected 1. the mains supply voltage is too high 2. the waveform of mains supply voltage is abnormal Check the power supply This alarm may occur when the motor is running 1. disconnection of the internal brake resistor 2. the internal brake resistor is broken Replace the drive with a new one Brake loop has no enough space 1. lower the start-stop frequency 2. reduce the limit value of current 3. reduce load inertia 4. use another drive and motor with higher frequencies A22 The motor is mechanically blocked Overload Check the mechanical load 1. lighten the load 2. use another drive and motor with higher frequencies Free stop Press Enter key on the operator panel or terminal RST of X6 interface A23 1. circuit board fails 2. fuse of the power is burnt out 3. rectifier is broken Replace the drive with a new one Free stop Press Enter key on the operator panel or terminal RST of X6 interface, 01/2015, 6FC5397-4EP10-0BA0 101

102 Appendix A.6 Diagnostics Alarm code Background Possible Cause Remedy Result Acknowledgement 1. low supply voltage Check the power supply 2. insufficient supply power capacity 3. transient power failure A41 This alarm may occur when the 24 V DC supply is connected This alarm may occur when the motor is running Circuit board fails The encoder fails The encoder fails The encoder cable is badly connected Replace the drive with a new one Replace the motor with a new one Replace the drive with a new one Replace the motor with a new one Emergency stop (the motor will stop with the maximum energy or torque) Press Enter key on the operator panel or terminal RST of X6 interface This alarm may occur when the motor starts running 1. terminals U, V and W on the motor are wrongly connected 2. the encoder is wrongly wired Check the wiring A42 Ambient temperature is too high The drive is overloaded Circuit board fails Check the ambient temperature Check the drive load Replace the drive with a new one Emergency stop (the motor will stop with the maximum energy or torque) Press Enter key on the operator panel or terminal RST of X6 interface A43 This alarm may occur when the 24 V DC supply is connected The motor does not rotate or reversely rotate if the command pulse is input after DC-link and mains line are connected Circuit board fails 1. terminals U, V and W on the motor is wrongly connected 2. encoder cable is wrongly connected Encoder fails Replace the drive with a new one Check the wiring Replace the motor with a new one Emergency stop (the motor will stop with the maximum energy or torque) Press Enter key on the operator panel or terminal RST of X6 interface This alarm may occur when the motor is running The permitted maximum position difference is too small Set a wider value range for the detection of position over-tolerance (P34) The position loop gain is too small Give more gains No enough torque Check the limit value of current Reduce the load Use a drive and motor with higher frequencies Low speed Check the maximum speed limitation (refer to parameter P26) 102, 01/2015, 6FC5397-4EP10-0BA0

103 Appendix A.6 Diagnostics Alarm code Background Possible Cause Remedy Result Acknowledgement Command pulse frequency is too high 1. Lower the frequency 2. Check whether P36 has the right value A44 This alarm may occur when the 24 V DC supply is connected This alarm may occur when the DC link is connected The circuit board fails The rated torque is exceeded Replace the drive with a new one 1. check the load 2. lower the start/stop frequency 3. use drive and motor with more power Emergency stop (the motor will stop with the maximum energy or torque) Press Enter key on the operator panel or terminal RST of X6 interface The brake is not open Check whether the brake is open or not The motor is not stable 1. modify the gain value 2. lessen load inertia The encoder is wrongly wired Check the wiring A45 The 65 enable signal is lost when the motor is running Check the 65 enable terminal Emergency stop (the motor will stop with the maximum energy or torque) Press Enter key on the operator panel or terminal RST of X6 interface Note Alarms with alarm code < A21 can be cancelled by power-on, while alarms with alarm code A21 can be cancelled by RST terminal. A Errors during drive self-test The drive module always conducts a self-test at every power-on. If any error occurs during this period, the drive screen form will show one of the following error codes: Drive display Description Cause Remedy Error 1 RAM damaged Replace the drive Error 2 Flash damaged Replace the drive Error 3 Program copy error Replace the drive, 01/2015, 6FC5397-4EP10-0BA0 103