808 1-Sinumerik

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Training manual
Sinumerik 808D Commissioning Guide

Version 07.12
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Notes
Commissioning guide
Page 2
808D Turning and Milling
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Notes
808D turning and milling
Page 3
Commissioning guide
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Notes
Commissioning Guide
Page 4
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Workflows
For
Commissioning of Prototype Machine using Sample PLC
go to page 7
For
Series Machine Production
go to page 33
For
PLC program design and adjustment
go to page 39
End
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Commissioning Guide
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Notes
Commissioning Guide
Page 6
Commissioning of Prototype
Basic Commissioning procedure for prototype machines using the Sample PLC
Delivery Check Go to page 8
Step 1
Step 2
Mounting Dimensions
Go to page 8
Step 3
Wiring
Go to page 10
Step 4
Switch on and Prepare Commissioning Diagram Commissioning the Prototype
Go to page 19
Step 5
Go to page 21
Step 6
Go to page 21
End
808D Turning and Milling Page 7 Commissioning Guide
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Step 1 Mounting dimensions Step 2 In the following technical drawing the mounting dimensions for the PPU and the MCP are shown. You must provide sufficient space (recommended distance: 80 mm) between the maintenance door and the cabinet wall for replacing the battery or CF card: For further components refer to :-Commissioning manual page 11 - 16
Delivery Check
In the following diagram the most common Siemens components are shown. For detailed information refer to :Commissioning manual: page 7 to 10
Inverter or servo spindle drive PC/PG
Spindle encoder
Spindle motor USB
Cut-out dimensions Cabinet panel

80 mm
SINUMERIK 808D PPU
Thickness 2 to 5mm
Handwheels SINAMICS V60 +24V DC power supply SINAMICS V60 SINAMICS V60
Emergency stop button
808D MCP
Motor
Motor
Motor
Notes 1. PC/PG is not included in Siemens supply range 2. "USB", "Handwheel","24V DC power supply", "Emergency stop button", "Inverter or servo spindle drive", "Spindle encoder" are options.
PPU = Panel Processing Unit MCP = Machine Control Panel

Page 8 808D Turning and Milling
Commissioning Guide
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Step 2 PPU
Mounting dimensions
In order to mount the PPU and MCP use the clamps provided as shown below :-
In total of 14 clamps are provided together with the delivery of PPU : 1. 8 clamps for mounting PPU. 2. 6 clamps for mounting MCP.
The clamps are located at the positions indicated with the black triangles. The black triangles can be seen in the following picture with red circles.
MCP
BB AA
X10 NC
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Commissioning Guide
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Step 3
14
Wiring
When connecting the components in the electrical cabinet, the wiring should comply with the relevant safety standards. For further information refer to :Commissioning manual 2012-05 V60 manual 2012-05 In order to connect cables and wires, the location of all connectors and terminal blocks need to be known. Connector overview of the PPU is shown: PPU back
2 1 5 6 7 8 9 10 12
PPU front
Legend PPU Back 1 2 3 4 5 6 7 8 9 10 11 12 13
Interface X100, X101, X102 X200, X201 X21 X301, X302 X10 X60 X54 X2 X51, X52, X53 X30 X1 -
Comment Digital inputs Digital outputs FAST I/O Distributed I/O Hand-wheel inputs Spindle encoder interface Analog spindle interface RS232 interface Pulse drive interfaces USB interface, for connection with the MCP Power supply interface, +24V DC power supply Battery interface Slot for the System Compact Flash Card (CF card) USB interface
11
13
PPU Front 14 Page 10
Commissioning Guide
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Step 3 MCP back Battery connection : A battery is placed in the battery compartment, this battery has to be connected prior to switching on of the control.
Wiring
BB
AA
X10 NC
Legend Interface MCP Back 1 X10
Comment USB interface, for connection with the PPU maintenance door (as P8) battery Battery interface battery connector
Note Connect USB cable between X30 on PPU and X10 on MCP.
Note Battery: Lithium 3V DC Life time: 3 years Order number: 6FC5548-0BC00-0AA0.

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Step 3 The connections for the SINAMICS V60 drives to the PPU are shown. (X51: axis X for an example). Isolation Transformer
3 phase AC 380V
Wiring Selection of 24V DC supply
Those 4 aspects should be considered during selection of 24V DC supply 1. 24V DC consumed on 808D : Starting current:5 A (momentary) Basic consumption :1.5A 2. 24V DC consumed on Sinamics V60 drive: V60+1FL5 (w/o break):0.8A/axes V60+1FL5(w. break):1.2A/axes 3. Max. current of digital output: 0.25A/Digital output 4. Other devices(e.g.:fan, hydraulic/pneumatic valve ):calculation base on name shield Consideration of redundancy coefficient base on regulation of OEM
Contact Breaker Power-supply Filter option (EMC)
The connections for the hand wheel are shown.
+PULS/1(green) -PULS/2(yellow) +DIR/3 (gray) -DIR/4 (pink) +ENA/5 (brown) -ENA/6 (white)
3 phase AC 220V
Encoder cable white Break cable
1 2 3 4 5
1A -1A 1B -1B +5V M Set point cable

RST/8(white/green) M24/9 (red) ALM1/10(red/blue) ALM1/11(blue) RDY1/12(black) RDY2/13(purple) +24V/14(yellow/white) Z-M/15(gray/pink) M24/16(brown/green)
black Power cable
X10
6 7 8 9 10
Warning: connection error between X5 and X6 may cause damage on the drive.
Commissioning Guide Page 12 808D Turning and Milling
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Step 3
Pin assignment of X301,X302
Wiring
The connections of the distributed I/O are shown for the Sample PLC. Milling Illustration shows the connection diagram of PPU X301 (same as X302)
X301 Distributed I/O
+ 24V DC M Milling Digital Inputs

1 2 3 4
11 - Handheld unit: axis X selected 12 - Handheld unit: axis Y selected 13 - Handheld unit: axis Z selected 14 - Handheld unit: 4th axis selected 15 - Handheld unit: INC X1 16 - Handheld unit: INC X10 17 - Handheld unit: INC X100 18 - Handheld unit: enabled
+ External power Supply + 24V DC
X100
Distribution I/O board For the connection of distribution I/O on X301,X302 distribution I/O board must be configured. MLFB for distribution I/O: 6EP5 406-5AA00
E-stop Limit X+ Limit X 5 Limit Y+ 6 Limit Y7 Limit Z+ 8 Limit Z9 Ref X 10 M
+ 24V
Commissioning Guide
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Step 3 Milling Digital outputs
1 2 3 4
+24V
Wiring Milling Digital Inputs

1 2 3 4
X101
5 6 7 8 9 10
Ref Y Ref Z Magazine count Magazine at spindle position Magazine at original position Magazine at release position Magazine at clamp position M + 24V
Working lamp Clamp remover advancing Clamp remover retracting Cooling pump Lubrication pump M
X200
5 6 7 8 9 10
+ 24V
Attention: It is still necessary to connect 24V DC to pin 1 and 0V DC to pin 10 of X200 provided that X200 was not connected with any digital outputs, Otherwise the V60 drive will not be enabled.
1 2 3 4 5 1 2 3 4
+24V
X102
X201
5 6 7 8 9 10
Coolant level low 7 Cooling motor overload 8 Lubrication level low 9 Lubrication motor overload 10 M
Disk magazine: magazine rotating CW Disk magazine: magazine rotating CCW Disk magazine: magazine in spindle position Disk magazine: magazine in original position Disk magazine: spindle tool release Handheld unit active M
+ 24V
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+ 24V
Commissioning Guide
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Step 3
Pin assignment of X301,X302
Wiring
The connections of the distributed I/O are shown for the Sample PLC. Turning Illustration shows the connection diagram of PPU X301 (same as X302)
X301 Distributed I/O
+ 24V DC M Turning Digital Inputs 11 - Handheld unit: axis X selected 13 - Handheld unit: axis Z selected 14 - Handheld unit: axis 4th selected 15 - Handheld unit: INC X1 16 - Handheld unit: INC X10 17 - Handheld unit: INC X100 18 - Handheld unit: enabled External power Supply + 24V DC
For the connection of distribution I/O on X301,X302 distribution I/O board must be configured. MLFB for distribution I/O: 6EP5 406-5AA00 808D Turning and Milling Page 15
1 2 3 4 5
E-stop Limit X+ Limit X -
X100
6 7 8
Limit Z+ Limit Z9 Ref X 10 M
+ 24V
Commissioning Guide
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Step 3 Turning Digital Outputs
1 2 3 4
+24V
Wiring Turning Digital Inputs

1 2 3 4
X101
Ref. X 5 T1 T2 6 T3 7 T4 8 T5 9 T6 10 M
Work lamp Tail advancing Tail retracting Cooling pump Lubrication pump Chuck M + 24V
X200
5 6 7 8 9 10
+ 24V
Attention: It is still necessary to connect 24V DC to pin 1 and 0V DC to pin 10 of X200 provided that X200 was not connected with any digital outputs, Otherwise the V60 drive will not be enabled.
1 2 3 4 5 1
+24V
Turret motor overload Reserved for other turret X201
2 3 4 5 6 7 8 9 10
X102
Chuck 6 Coolant level low 7 Cooling motor overload 8 Lubrication level low 9 Lubricating motor overload 10 M
Turret motor CW Turret motor CCW Reserved for other turret Reserved for other turret Gear change: high Gear change: low Handheld unit active M
+ 24V
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+ 24V
Commissioning Guide
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Step 3
Wiring
The connections for the inverter or the spindle drive to the PPU are shown.
Unipolar connection
3AC 380V
Bipolar connection
3AC 380V
B-N
B
B-N
B
A-N A
A-N A
(black)
black
black black
Spindle/ inverter motor
Spindle/ inverter motor
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Commissioning Guide
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Step 3 The connection overview for Turning is shown.
Wiring The connection overview for Milling is shown.
Commissioning Guide
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Step 4 Before the control can be commissioned , loading of standard NC data have to be carried out,, the password has to be set to manufacturer, the time and the date have to be set,. Setting of the password :For detailed information refer to :Commissioning manual page 31 To set the password :Press button Press SK Type in SUNRISE Press SK +
Switching on and Prepare for Commissioning
Before powering on the controller, you should familiarise yourself with the operation of the PPU and MCP For detailed information refer to :Commissioning manual : page 27 to 29 1. Apply 24V DC to the PPU (X1). 2. Apply 3P 220VAC to V60 drives (L1 L2 L3). 2. Check that the status LEDs on the front face of the PPU are in the ready state. For detailed information refer to :-Commissioning manual page 30 3. Check that the status LEDs on the front face of the V60 drives are in a ready state. For detailed information refer to :Commissioning manual page 30
Status description on SINAMICS V60 Item 8.8.8.8.8.8 S-2 S-3 S-4 S-RUN S-A01...S-A45 Description Initializing the drive, will stay 1 sec during the process Waiting for 220V power supply Wait for drive enable from Terminal 65 at X6 Wait for pulse enable from terminal ENA+ and ENA at X5 Drive is running properly Alarm codes in the drive system
Setting of the time and date :For detailed information refer to :Commissioning manual page 34 To set the time and date :Press SK Type in time and date using the keyboard and the and button Press SK
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Step 4 To set the language:Press button Press SK Select the language with Press SK +
Switching on and prepare for Commissioning Load standard data :The control must be powered on. When the PPU shows the following screen:Press
In the following screen select startup with default data using button Press To accept the selection. To set the password as the Sample PLC will set to NO PASSWORD Press button Press SK Type in SUNRISE Press SK
Commissioning Guide
The machine will be commissioned using the Startup assistant. Where to find the Startup assistant :For detailed information refer to :Commissioning manual page 35 The PPU shows this screen.
+ Press The PPU shows this screen.
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Step 5 Commissioning the prototype Commissioning the prototype. For further information please go to: Commissioning manual page 35 Step 6
Commissioning diagram Commissioning diagram Commissioning manual page 37 1 Commissioning the prototype. 2 Series production START Commissioning the PLC with the default PLC application 1 Commissioning the NC Data backup production archive Startup archive for the prototype
To start the assistant Press The PPU shows the following screen.
Series commissioning NC data compensation Data backup Startup archive (back up to USB) Original status archive for delivery
Press The PPU shows the following screen. In the box shown you can enter the PLC MD values.
END
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Commissioning Guide
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Step 6 MILLING continued (all default values are set to be zero)
MD14512 Function
Commissioning the prototype MILLING Set PLC related parameters. For further information please go to :Commissioning manual page 42
Bit 7 14512[16] MD14510 14510[12] MD14510[13] MD14510[20] PLC interface DB4500.DBW24 DB4500.DBW26 DB4500.DBW40 Unit * 0.1sec Range 5~200 Max.64 Fuction =0,vertical =1horizontal 14512[17] Spindle breaking time Max Tool number in magazine
Selction of axis to be controlled by hand wheel via MCP
Bit 6
Z axis: rotary monitoring
Bit 5
Y axis: rotary monitoring
Bit 4
X axis: rotary monitoring
Bit 3
Safty door open when M1/ M2 programe d Selction of handwheel controlled axis via HHU
Bit 2
Safety door activate
Bit 1
Chip remover activate
Bit 0
DB4500.D BB1016
DB4500.D BB1017
Tool magazine activate
MD14514 14514[0] MD14514[1]
PLC interface DB4500.DBD2000 DB4500.DBD2004
Function Tool magazinespindle poisoning angle Tool magazine: Preparation position of Z axes for tool change Tool magazine: Tool changing posion of Z axes Tool magazine: velocity of Z axis, Go to tool change preparation position Tool magazinevelocity of Z axis, back to tool change preparation position
14512[18]
DB4500.D BB1018
One hardware limit triggered per axis
Hardware limit is independent of the PLC application
Fixed direction of spindle
External stop signal of the spindle
MD14514[2] MD14514[3]
DB4500.DBD2008 DB4500.DBD2012
14512[19]
DB4500.D BB1019
Delete system password when power on
Spindle break activate
MD14514[4]
DB4500.DBD2016
Commissioning Guide
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Step 6 TURNING (all default values are set to be zero)
MD14512 Bit 7 14512[16]
Selction of axis to be controlled by hand wheel via MCP
Commissioning the prototype TURNING (all default values are set to be zero) Set PLC related parameters. For further information please go to :Commissioning manual page 39
Functionality
Bit 6
Z axis: rotary monitoring
Bit 5
Bit 4
X axis: rotary monitoring
Bit 3
Bit 2
Bit 1
Bit 0
DB4500.D BB1016
14512[17]
MD14510 14510[12] MD14510 [13] MD14510 [20]
PLC interface DB4500.DBW24 DB4500.DBW26 DB4500.DBW40
unit * 0.1se c
Rang e 5~20 0 4, 6
Functionality
DB4500.D BB1017
=0flat bed;=1, inclined bed

14512[18] Spindle breaking time
One hardware limit triggered per axis Hardware limit is independent of the PLC application Fixed direction of spindle External stop signal of the spindle
Selction of handwheel controlled axis via HHU
Tailstock function activate
Chuck function activate
HED turret activate
DB4500.D BB1018
Max Tool number in turret.
(for tool amount >6, PLC to be programmed by customer themselves) DB4500.DBW42 DB4500.DBW44 0.1se c 0.1se c 5~30 30~2 00 HED turret: Tool clamping time for HED turret: Time monitoring for tool change
14512[19]
MD14510 [21] MD14510 [22]
DB4500.D BB1019
MM+ (option) activate
Delete system password when power on
Spindle break activate
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Commissioning Guide
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Step 6 Commissioning PLC
Commissioning the prototype Set PLC related parameters
PLC MD is to be adapted to suit the OEM machine
It may be that the machine tool builder requires further PLC functionality, if this is required the PLC has to be modified. To install PLC programming tool, follow the information in :PLC Subroutines manual page 11 to 12 (install PLC programming tool) To make a connection to the PPU, press SK Then follow the information in:PLC Subroutines manual page 19 to 22
Changes will be activated MD set to default value MD set to previous value To continue press the SK
Commissioning Guide
To continue press the SK

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Step 6 Basic digital I/O check
Commissioning the prototype The connect status should now be green.
First the Sample PLC blocks should be uploaded to the PC, then the modifications can be made to achieve the required functionality. Once this has been completed, the PLC should be put into stop and the modified PLC should be downloaded into the PPU. The PLC must then be restarted. PLC Subroutines manual page 23-30
All I/O status must be checked with the electrical drawing using the following SKs. The status is shown on the right hand side as shown above. Below are SKs that allow you to select digital inputs or outputs and selection of the byte required. Choose digital input Choose digital output Choose the digital O/I addresses of Pre Byte Choose the digital O/I addresses of Next Byte

808D Turning and Milling Page 25

Commissioning Guide
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Step 6 Set feed axis parameters. For further information please go to:Commissioning manual page 56
The data below must be set as default values:
Machine data Setting
Commissioning the prototype Edit PLC alarm text For further information please go to:Commissioning manual page 48
30130 30240 34200 You can edit the PLC user alarm text either directly on the HMI, or off line and transferring the file using a USB stick. Below are SKs that allow you to import and export the text file from the HMI, and SK that that allows the text file to be directly edited on the HMI. Import the backup alarm text into the PPU Export the finished alarm text from the PPU Edit the alarm text
2 3 2
You can edit the axis machine data for the required axis. Below are SKs that allow you to edit, activate or set as default value.
Used to select the axis (X or Z turning or X, Y, or Z milling) Changes will be activated MD set to default value MD set to previous value

Commissioning Guide Page 26

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Step 6 Set spindle parameters. For further information please go to:Commissioning manual page 57
The data below must be set as default values:
Machine data 30130 30240 30134 Setting 1 2 0output value is Bipolar 1output value is Unipolar 2output value is Unipolar 0: without spindle endcoder
Commissioning the prototype Reference axis. For further information please go to:Commissioning manual page 59
30200
You can edit the axis machine data and the for the required axis. Below are SKs that allow you to edit, activate or set as default
You can edit the spindle machine data required. Below are SKs that allow you to edit, activate or set as default Used to select the axis (X or Z turn or X, Y, or Z mill)
Used to select the axis (X or Z turn or X, Y, or Z mill)
Changes will be activated MD set to default value MD set to previous value An axis referenced will be performed To continue press the SK
Changes will be activated MD set to default value MD set to previous value Axis will be referenced To continue press the SK
Commissioning Guide
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Step 6 Set SW limit. For further information please go to:Commissioning manual page 61
Commissioning the prototype Generate production archive. For further information please go to:Commissioning manual page 66
To create the production archive press SK Pack.
You can edit the axis machine data for the required axis. Below are SKs that allow you to edit, activate or set as default
Create production archive Used to select the axis (X or Z turn or X, Y, or Z mill) Note: When creating the production backup, store archive to USB memory stick.
Changes will be activated MD set to default value MD set to previous value


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Step 6 Lead screw pitch error compensation. For further information please go to:Commissioning manual page 62
Commissioning the prototype Backlash compensation. For further information please go to:Commissioning manual page 62
Used to enter compensation data via the HMI
Changes will be activated


Commissioning Guide
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Step 6 Once the assiatant is completed.
Commissioning the prototype Generate start-up archive. For further information please go to:Commissioning manual page 67
To create the Start-up archive press SK Pack.
To continue press the SK To exit the assistant press the SK
Create Start-up archive
Note: When creating the Start-up archive, store archive to USB memory stick

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Step 6
Commissioning the prototype Now that the commissioning is completed a SAVE DATA is performed.
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Commissioning Guide
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Notes
Commissioning guide
Page 32
Basic Commissioning procedure for series machines
To perform
Commissioning the series
Go to page 34
End
Page 33
Commissioning Guide
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Step 1 Load archive file. For further information please go to:Commissioning manual page 71
Commissioning the series machine For further information please go to:Commissioning manual page 35
To start the assistant Press Followed by
The PPU shows this screen. To load the production archive press SK Load Archive.
Press
Loads production archive
Note: When loading the production archive, use archive on USB memory stick.

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Step 1 Backlash compensation. For further information please go to:Commissioning manual page 62
Commissioning the series machine Set SW limit. For further information please go to:Commissioning manual page 61


Commissioning Guide
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Step 1 Generate backup settings. For further information please go to:Commissioning manual page 67
Commissioning the series machine Lead screw pitch error comp. For further information please go to:Commissioning manual page 62
To create the start-up archive press SK Pack.
Create start-up archive
Changes will be activated
Note: When creating the start-up archive, store archive into OEM directory and on a USB memory stick
Control will activate MD


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Step 1 Now that the commissioning is completed a SAVE DATA is performed.
Commissioning the series machine To continue press the SK To exit the assistant press the SK

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Notes
Commissioning Guide
Page 38
Basic PLC design and adjustment.
To Do
Programming tool PLC Signals of the PLC interface
Go to page 40
To Do
Go to page 48
To Do
Operation symbols
Go to page 50
To Do
PLC Subroutine library
Go to page 54
To Do
PLC alarm
Go to page 57
To Do
PLC Online diagnosis
Go to page 61
End
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Open up the default PLC program and save this file to a new name so that the default program is not over written.
Programming tool PLC In order to connect 808D numerical control system and the machine we must use Programming Tool PLC V3.2 or higher . Using the PLC programming tool you can:Create the PLC program Edit the PLC program Make a connection between the programming tool and the system Compiling of the PLC program Download the PLC program Upload the PLC program Monitoring of the PLC conditions The software is started by double clicking the icon on your desktop.
Commissioning Guide
Page 40
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Overview of PLC programming tool.
Programming tool PLC The PLC programming tool has included 5 languages that can be selected when installing the software, you can then choose the display languages by using the following sequence.
The programming tool will prompt you that the software will close automatically and you will have to start the programming tool again.
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Double click this icon.
Programming tool PLC The address of each instruction can be edited at any time by highlighting the instruction.
A connection must be made so that the PLC programming tool can communicate with PPU. Press the Communications Icon.
Commissioning Guide
Page 42
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Confirm the baud rate setting in 808D is same as the setting in PC (38400 for example)
Programming tool PLC 808D can only use RS232 to Communicate.
Same baud rate setting on PC
Press SK
Illustration Connection established
Activate the PLC connection setting in 808D (under password sunrise)
Connection activate
Follow the steps 1-3 on you PC Operating processes Press key: Press soft key +
1.PPU interface: 2
3.Refresh
2.confirm baud rate setting is same as the setting on PPU
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Commissioning Guide
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To check syntax errors use compiling after editing and modification of the PLC program.
Programming tool PLC The connection is now established.
The correct system must Be chosen.
Commissioning Guide
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To download the modified PLC program press icon.
Programming tool PLC To compile the PLC program press the compile icon
Place the PLC into STOP.
The location of the syntax error can be located easily, using the bottom window.
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Commissioning Guide
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To place the modified PLC program in RUN mode, press icon.
Programming tool PLC Once the PLC is successfully downloaded, it must be placed in RUN mode.
Commissioning Guide
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To display the online conditions of the PLC, press The blue represents an online connection showing the status.
Programming tool PLC Online monitoring can be used when PLC program is in running mode.
Status : 0: LOW, 1: HIGH
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Commissioning Guide
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Signals of the PLC interface The signals of the PLC interface and the signals of the input and output. The PLC program exchanges information between NCK, HMI,MCP and I/O through the signals of the interface and the signals of the input and output. Press the soft key
Programming tool PLC Please confirm the Step 7 connection should be deactivated after the PLC commissioning finished
NCK
The signal of PLC interface
Electrical Component Of the M/C
The signal of input and output
HMI
Commissioning Guide
Page 48
MCP
I/O
Disappear ,connection closed
PLC Application Program
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The signals of the interface DB1100.DBX0.1 DB1600.DBB1000 R W
DB2700.DBB0 DB2600.DBB0
Signals of the PLC interface The signals of the interface NCK channel R W R W
DB1600.DBB2 DB1600.DBB1 DB1600.DBB0
R W
DB4500.DBB2 DB4500.DBB1 DB4500.DBB0
R W
R W
R W
DB1400.DBB0
Can keep the data area
V2500 33 V2500 33 V2500 V2500 2 DB2500.DBB1 V2500 xxxDB2500.DBB0 xxx

Auxiliary function
Alarm activation Alarm variables W R
PLC parameter
NCK Signal of control W R
Way selection signal W R
Channel control signal W R
W R
W R PLC application
R W
R W
DB1700 DBB0
R W
DB1800.DBB0
R W
DB1900.DBB0
R W
R W
MCP signal W R
Program control signal W R HMI
HMI Selection signal W R
Hand-wheel selection signal W R
V3804 xx x V3803 x DB3801.DBB V3802

Axis control signal W R
DB3800.DBB x
V3904 DBBx V3903 xx DB3901. V3902 x

Shaft state signals W R
DB3900.DBBx
NCK axis
Operation symbols of PLC programming language Special mask registers PLC scan period always 1 state
SM0.0
PLC scan at
SM0.1
Buffer data loss
Special flag register can simplify the design of PLC application program
SM0.2
System restarts SM0.3 2 x PLC scan period
SM0.6
1 second pulse
SM0.5
0.5 second 1 minute pulse 0.5 second
SM0.4
30 seconds
30 seconds
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Accumulator carriage and storage Accumulator carriage: AC (four at most) Input; I output; Q Form; Arithmetic accumulators AC0 AC1, logical accumulator AC2, AC3. Flag register: M
Operation symbols of PLC programming language The signal of input and output. Address
form bit byte word I0.0, I4.6; IB4, IB12; QB3, QB7 Q2.1, Q1.7
bit byte word
M0.1, MB21,
M124.5 MB12
IW2, IW4; QW0, QW6 (address mantissa can be divided with no remainder by 2) double word ID2, IW8; QD0, QD4 (address mantissa can be divided with no remainder by 4)
MW22, MW106 (address mantissa can be divided with no remainder by 2) double word MD4, MD28 (address mantissa can be divided with no remainder by 4)
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Commissioning Guide
Operation symbols of PLC programming language counter Counter: C Form; condition of counter bit C3, C25; - represents the comparison result of the counter and present value. CU PV: is R preset value PV Plus Minus counter CD: is CTD minus CD count LD LD: is PV Loading preset value Plus and minus counter CTUD CU: is CU CD R: R Is resetting PV
CTU
Style: plus counter CTU count: counter value+1 R=1 counter resets; counter value>preset value Cn=1 minus counter CTD count: counter value -1 LD counter value = preset; value = counter value=0 Cn=1 plus and minus counter CTUD plus counter: counter value+1 minus counter: counter value R=1 counter resets: counter value>preset value C=1
Commissioning Guide
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Keep the sequence Timer enable
Operation symbols of PLC programming language Timers Timer: T Form; condition of timer bit T3, T25; represent the comparison result of timer value and preset value timer value T3, T25; represent timer value
preset value PV timer value Timer bit T
Style; open delay timer TON IN=1 begin timing IN=0 timer resetting count value>preset value Tn=1 close delay timer TOF IN=1 timer resetting IN=0 begin timing; count value>preset value Tn=0 keep delay timer CTUD IN=1begin timing; IN=0timer stops; count value>preset value Tn1 Assign word constant0 to T to make counter composite
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System resource resource Input
PLC subroutine library The purpose of the PLC subroutine Library. In order to simplify design of producer PLC, refined PLC functions which have generality, such as initialization, machine panel signal processing, abrupt stop processing, shaft enable control, hard limit, reference point etc. Producers only need to add the needed subroutines module to main procedure, plus other under action procedures ,then you can complete PLC procedure design very quickly. Composition of PLC subroutine library. PLC project fileSAMPLE_TURN.PTPapplication program as examples for turning machine PLC project fileSAMPLE_MILL.PTP application program as examples for milling machine
Through these application programs as examples, you can clearly realize how to create or invoke PLC subroutines. You can reorganize PLC subroutines or modify some internets to realize most machine functions. Test and debug subroutines of the subroutine library on machines overall according to practical situation to assure the correctness of subroutine librarys functions.
I0.0 to I2.7 (24 inputs of CNC) I3.0 to I8.7 (48 allocated input) Output Q0.0 to Q1.7 (24 outputs of CNC) Q2.0 to Q5.7 (48 allocated output) RAM M0.0 to M255.7 (256 bytes) PLC system No volatile memory DB1400.DBX0.0 to resource DB14000.DBX127.7 (128 bytes) PLC user alarm DB1600.DBX0.0 to DB16000.DBX15.7 (128 user alarms) Timer T0 to T15 (100ms timer) T16 to T32 (10ms timer) counter C0 to C63 (64 counters) Parameter Statistic INT: DB4500.DBW0 to MD14510(32) DB4500.DBW62 (32 double word) Parameter Statistic HEX: DB4500.DBB1000 to NC resource MD14514(32) DB4500.DBB1031 (32 bytes) Parameter Statistic REAL: DB4500.DBD2000 to MD14514(8) DB4500.DBD2028 (8 double) SBR0 to SBR63 (64 subroutines) Programming Subroutine (64) tool resource Symbol table (32) SYM1 to SYM32 (32 symbol tables)
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All the addresses in PLC subroutine library are programmed by symbols. All the signals of interfaces are named by symbols and arranged in different symbol table. The name of symbols follows some conventions. Please refer to the PLC subroutine library instructions.
PLC subroutine library
A constant definition Constant input Constant 1 Constant 2 symbol ONE ZERO location SM0.0 M251.0
Invalid output definition Statistic type bit byte word Long word symbol NULL_b NULL_B NULL_W NULL_DW address M255.7 M255 MW254 MD252 symbol 1 ... 4~15 16 ... IS_MCP ... List name PP_1 ... Symbol list details PP module 1 I/O defined by manufacturer ... Preset for manufacturer Send to or from machine control panel MCP ...
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SBR 39 SBR 40 SBR 41 SBR 42 SBR 43 SBR 44 SBR 45 SBR 46 SBR 47 SBR 48 SBR 49 SBR 50 SBR 54 SBR 58 SBR 59 SBR 63 34-36/57/61/62 HANDWHL AXES_CTL MINI_HHU SPINDLE MEAS_JOG COOLING LUBRICATE PI_SERVICE PLC_Select_PP PLC ServPlan GearChg1_Auto GearChg2_Virtual TOOL_DIR MM_MAIN MM_MCP_808D TOGGLE Hand wheel selection in HMI Axis control (feed axis and spindle) HHU (hand held unit ) control Spindle control Measure in JOG Coolant control Lubrication control ASUP control NC program selection via PLC Service planner Automatic gear change Gear change (virtual) Tool change direction control Manual machine related Manual machine related Toggle switch control Reserve for OEM
PLC subroutine library A constant definition The realization of PLC basic functions is the basic condition to debug driver and 808D system parameter
Realize through invoking PLC sample subroutine or manual writing PLC program : All the reference functions related to safety such as Emergency stop and limit Operation function worksmode select, manual control, rate set.
PLC sample subroutine offers adequate PLC functions for machine tool 0 to 19 SBR 20 SBR 21 SBR 22 SBR 23 SBR 31 SBR 32 SBR 33 SBR 37 SBR 38 ... AUX_MCP AUX_LAMP AUX_SAFE_DOOR AUX_CHIP PLC_ini_USER_ini PLC_INI EMG_STOP MCP_NCK MCP_Tool_Nr Saved for producers MT auxiliary function Working lamp Safety door Chip remover Initialize for PLC user data (called in SBR 32) PLC initialize Emergency stop Signal transfer from MCP & HMI to the NCK interface Tool number display on MCP
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PLC alarm PLC sample subroutine can realize adequate lathe functions Turret1_HED_T Turret2_BIN_T Turret3_CODE_T HED turret control Bi-direction changeable turret (binary coded) Bi-direction changeable turret (coded by turret supplier) Tailstock control Chuck control PLC sample subroutine can realize adequate milling functions Disk_MGZ_M Disk magazine control (w/o automatic tool changer) PLC alarm is the most effective method provided for users. Diagnosing of the machine is important. Complete designed diagnosis scheme can help users understand the cause and the location of breakdown immediately. 24 VDC Digital output L 380 VAC
PLC subroutine library
For turning only SBR 51 SBR 52 SBR 53
SBR 55 SBR 56
Tail_stock_T Lock_unlock_T
KA1
KM1
For milling only SBR 60
N M Digital input Cooling pump motor
For detail information please refer to PLC Subroutines manual Page 35 - 76
Normal condition I/O interface has no output signal, check hardware connection Relay KA1 Works unusually, check component: hardware
Protective door lock Cooling motor thermal protection Cooling liquid level detection Cooling pipe pressure test Contactor KM1 works unusually, check components hardware connection and power supply
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Alarm attribute setup Alarm text Conditions of elimination power-on clear after the cancel of alarmyou need to re-power it on cancel key or after the cancel of alarm you need to use the cancel key or reset key ,then the alarm will be cancelled self-clean after the cancel of alarm the alarm will be cancelled by itself alarm reaction React by two ways after alarm PLC reactionthe PLC program written realizes reaction through corresponding PLC interface, such as cancel the shaft-enable when giving an alarm. NC reactionevery alarm has a 8 configuration MD14516[0]~ [127].you can set a cancelation condition and alarm reaction of every alarm according to current condition. The system makes corresponding reaction when alarm begins. MD14516[n] bit
Power off/on Reset or cancel key
PLC alarm
Alarm PLC signal number
PLC alarm variable
700000 DB1600.DBX0.0 DB16000.DBD1000 MD14516[0] ... ... ... ...
Driver is not ready Coolant 700018 DB1600.DBX2.2 DB16000.DBD1072 MD14516[17] motor overload 700016 DB1600.DBX2.0 DB16000.DBD1064 MD14516[16] 700127 ... ... ... ... User alarm 127
DB1600.DBX15. MD14516 DB16000.DBD1508 7 [127]
System provides users with 128 PLC user alarmsEvery user alarm has a corresponding NCK address bit:DB1600.DBX0.0 ~ DB1600.DBX15.7 The address bit1 can activate the corresponding alarm, reset 0 can cancel the alarm. In PLC cross referenceyou can find the reason for the PLC alarm through looking up reference addresses to make corresponding modification.
alarm 6 5 4 3 2 1 0
NC start inhibit Read-in disable Feed disable Emergency PLC stop
Alarm reset /cancel condition Commissioning Guide Page 58 808D Turning and Milling
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Edit PLC user alarm by USB. Press button Press SK Curser over HMI Press SK +
PLC alarm Alarm text. Create, edit alarm text correctly and reasonably can make users clearly realize the reason of PLC alarm and locate ,and rule resolve a breakdown.
1.choose text PLC alarm textalcu.txt 2.then press vertical soft key copy 3.press level soft keyUSB and press vertical soft keypaste
edit PLC user alarm by USB edit PLC user alarm by HMI
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Find alarm number which needs to be edited and input your own text. Save and close file after editing alarm text. Disconnect USB storage from PC and connect it with USB interface on the front panel of PPU again Copy PLC alarm textalcu.txtwhich is edited back in to HMI statistic. In <system>operation areapress soft key PLC > edit PLC alarm text. You can check the result of edit.
PLC alarm Edit PLC user alarm by USB. Connect USB storage medium with PC USB, find PLC alarm text which is downloaded. And open it by WordPad.
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PLC online diagnosis Check the condition of PLC and judge logical error or external electrical error through displaying PLC program online. Press button Press SK Press SK Symbol display/ address displaying Find appointed target in the display program Display the condition of can close Alter the program displayed in the window +
PLC alarm Edit PLC user alarm by HMI. Create PLC alarm text directly in 808D system. Press button Press SK Press SK Move the cursor to choose the alarm number which needs to be edited and go into the condition of alarm text edit. Press SK +
Input alarm text combination key ALT+S, change in both English and Chinese input method.
On state
Click OK after finishing edit. Display producer command online which PLC needs to open
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Press SK
Display another program in window 2

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Check the condition of PLC and judge logical error or external electrical error through displaying PLC program online. Press button Press SK Press SK Press SK Operand address condition +
PLC online diagnosis Check the PLC operating status and data. Press button Press SK Press SK Press SK Running state +
PLC program information
PLC style and versions
PLC scan period
PLC running time
Display current condition of interface signal or bit, byte, word of I/O
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Check the condition of hardware connection through examining the status of input point.
PLC online diagnosis Check the correctness of hardware connection through examining the state of input point. Press button Press SK Press SK Press SK Move the cursor to the operand which needs modification Set the condition of output pointconfirm by +
Check if there is any error of the connection in the input point according to the value of the input point.
Check electrical level of the output point (whether the relay is in absorption), check if there is any error in the connection of the output point.
If the compulsive output point, the signal of interface is used in PLC program, its state will be refreshed by the program.
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Observe the condition of PLC , judge logical error quickly or external electrical error through displaying PLC program online. Press button Press SK Press SK Press SK +
PLC online diagnosis Observe the condition of PLC , judge logical error quickly or external electrical error through displaying PLC program online. Press button Press SK Press SK Press SK +
Amend operand address accurately and confirm by soft key.
Display whether signals of I/O and interfaces are used or not and which subroutine and network they are used by.
Display conditions of input point ,output point, auxiliary relay and the signal of interface by listing.
Look up appointed target in cross-reference table
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Notes
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Notes
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Notes
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Commissioning guide
Everything ever wanted to know about SINUMERIK 808D: www.siemens.com.cn/808D Everything about shopfloor manufacturing: www.siemens.com/cnc4you Everything about the SINUMERIK Manufacturing Excellence portfolio of services: www.siemens.com/sinumerik/manufacturing-excellence Information about CNC training: www.siemens.com/sinumerik/training
Siemens AG Industry Sector Motion Control Systems P.O.Box 3180 91050 ERLANGEN GERMANY
Subject to change without prior notice Order No.: Dispostelle 06311 W/35557 WERK.52.2.01 WS 11113.0 Printed in Germany Siemens AG 2012
The information provided in this brochure contains merely general descriptions or characteristics of performance which in actual case of use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.

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Sinumerik 808D Commissioning Guide

808D Turning and Milling

808D turning and milling

808D Turning and Milling

Commissioning of Prototype Machine using Sample PLC

Series Machine Production

PLC program design and adjustment

808D Turning and Milling

808D Turning and Milling

Switch on and Prepare Commissioning Diagram Commissioning the Prototype

Commissioning of Prototype Machine using Sample PLC

Spindle motor USB

Cut-out dimensions Cabinet panel

SINUMERIK 808D PPU

Emergency stop button

PPU = Panel Processing Unit MCP = Machine Control Panel

Commissioning of Prototype Machine using Sample PLC

808D Turning and Milling

Commissioning of Prototype Machine using Sample PLC

Legend PPU Back 1 2 3 4 5 6 7 8 9 10 11 12 13

PPU Front 14 Page 10

Commissioning of Prototype Machine using Sample PLC

Legend Interface MCP Back 1 X10

Note Battery: Lithium 3V DC Life time: 3 years Order number: 6FC5548-0BC00-0AA0.

Commissioning of Prototype Machine using Sample PLC

Wiring Selection of 24V DC supply

Contact Breaker Power-supply Filter option (EMC)

The connections for the hand wheel are shown.

1A -1A 1B -1B +5V M Set point cable

black Power cable

Commissioning of Prototype Machine using Sample PLC

+ 24V DC M Milling Digital Inputs

+ External power Supply + 24V DC

E-stop Limit X+ Limit X 5 Limit Y+ 6 Limit Y7 Limit Z+ 8 Limit Z9 Ref X 10 M

808D Turning and Milling

Commissioning of Prototype Machine using Sample PLC

Wiring Milling Digital Inputs

Commissioning of Prototype Machine using Sample PLC

X301 Distributed I/O

E-stop Limit X+ Limit X -

Limit Z+ Limit Z9 Ref X 10 M

Commissioning of Prototype Machine using Sample PLC

Wiring Turning Digital Inputs

Turret motor overload Reserved for other turret X201

Commissioning of Prototype Machine using Sample PLC

Spindle/ inverter motor

Spindle/ inverter motor

808D Turning and Milling

Commissioning of Prototype Machine using Sample PLC

Wiring The connection overview for Milling is shown.

808D Turning and Milling

Commissioning of Prototype Machine using Sample PLC

Switching on and Prepare for Commissioning

808D Turning and Milling

Commissioning of Prototype Machine using Sample PLC

+ Press The PPU shows this screen.

808D Turning and Milling

Commissioning of Prototype Machine using Sample PLC

808D Turning and Milling

Commissioning of Prototype Machine using Sample PLC

Tool magazine activate