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Training manual
Commissioning
For of Prototype
go to page 5
Machine using
Sample PLC
Series
For Machine go to page 33
Production
PLC program
For design and go to page 39
adjustment
End
Delivery Go to page 6
Step 1
Check
Mounting
Step 2 Dimen- Go to page 6
sions
Switch on
Step 4 and Go to page 17
Prepare
Commis-
Step 5 sioning Go to page 20
Diagram
Commis-
sioning Go to page 20
Step 6
the
Prototype
End
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of Prototype
Machine using
Sample PLC
In the following diagram the most common Siemens components are In the following technical drawing the mounting dimensions for the PPU and
shown. For detailed information refer to :- the MCP are shown.
Commissioning manual: page 7 to 10 You must provide sufficient space (recommended distance: 80 mm)
Inverter or servo spindle drive
between the maintenance door and the cabinet wall for replacing the
PC/PG battery or CF card:
For further components refer to :-
Commissioning manual page 11 - 16
Spindle encoder
Spindle motor
Cut-out dimensions
USB
Cabinet panel
80 mm
SINUMERIK
808D PPU Thickness
2 to 5mm
Handwheels
Notes
1. PC/PG is not included in Siemens supply range
PPU = Panel Processing Unit
2. "USB", "Handwheel","24V DC power supply", "Emergency stop button", "Inverter or servo spindle drive", "Spindle MCP = Machine Control Panel
encoder" are options.
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Machine using
Sample PLC
In order to mount the PPU and MCP use the clamps provided as shown PPU
below :-
In total 14 clamps are provided together with the delivery of PPU : The clamps are located at the positions indicated with the black triangles.
1. 8 clamps for mounting PPU. The black triangles can be seen in the following picture with red circles.
2. 6 clamps for mounting MCP.
MCP
BB AA
X10
NC
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Machine using
Sample PLC
Wiring Step 3
In order to connect cables and wires, the location of all connectors and
terminal blocks need to be known.
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Machine using
Sample PLC
Wiring Step 3
X10
NC
Note
Battery: Lithium 3V DC 950mAH
Life time: 3 years
Order number: 6FC5247-0AA18-0AA0.
Note Note:
Connect USB cable between X30 on PPU and X10 on MCP. When you have Alarm 2100 the battery must be changed.
808D Turning and Milling Page 9 Commissioning Guide
Commissioning
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Machine using
Sample PLC
Wiring Step 3
Selection of 24V DC supply The connections for the SINAMICS V60 drives to the PPU are shown.
(X51: axis X for an example).
Isolation
These 4 aspects should be considered during selection of 24V DC supply
Transformer
1. 24V DC consumed on 808D : Contact
Starting current:5 A (momentary) Breaker 3 phase AC
Basic consumption :1.5A 380V
2. 24V DC consumed on Sinamics V60 drive: Power-supply
V60+1FL5 (w/o brake):0.8A/axes Filter option (EMC)
V60+1FL5(w. brake):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
1 1A
white
Brake cable
2 -1A RST/8(white/green)
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Machine using
Sample PLC
Wiring Step 3
The connections of the distributed I/O are shown for the default PLC. Pin assignment of X301,X302
Milling Illustration shows the connection
diagram of PPU X301
X301 Distributed I/O
+ 24V DC
M
Milling
Digital Inputs
11 - Handheld unit: axis X selected
12 - Handheld unit: axis Y selected X100
13 - Handheld unit: axis Z selected
1
14 - Handheld unit: 4th axis selected E-stop
2
15 - Handheld unit: INC X1 Limit X+
3
16 - Handheld unit: INC X10 Limit X -
4
17 - Handheld unit: INC X100 Limit Y+
+ 5
18 - Handheld unit: enabled Limit Y-
6
External power 7 Limit Z+
Supply + 24V DC 8 Limit Z-
Distribution I/O board 9 Ref X
For the connection of distribution I/O on X301,X302 distribution I/O board must be 10 M +
configured. MLFB for distribution I/O: 6EP5 406-5AA00 24V
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Machine using
Sample PLC
Wiring Step 3
Milling Milling
Digital Inputs Digital outputs
X101 X200
1 1 +24V
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Machine using
Sample PLC
Wiring Step 3
+ 24V DC
M
Turning
Digital Inputs
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Machine using
Sample PLC
Wiring Step 3
Turning Turning
Digital Inputs Digital Outputs
X101 X200
1 +24V
1
2 2 Work lamp
3 Ref. Z 3
4 T1 4 Tailstock advancing
5 T2 5 Tailstock retracting
6 T3 6 Coolant pump
7 T4 7 Lubrication pump
8 T5 8 Chuck output 1
9 T6 9 Chuck output 2
10 M 10 M
+ +
24V 24V
Attention: It is 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.
X102 X201
+24V
1 1
2 Turret motor overload 2 Turret motor CW
3 Reserved for other turret 3 Turret motor CCW
4 4 Reserved for other turret
5 Chuck open 5 Reserved for other turret
6 Coolant level low 6 Gear change: low
7 Cooling motor overload 7 Gear change: high
8 Lubrication level low 8
9 Lubricating motor overload 9 Handheld unit active
10 M 10 M
+ +
24V 24V
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Machine using
Sample PLC
Wiring Step 3
The connections for the inverter or the spindle drive to the PPU are
shown.
B-N B-N
B B
A-N A-N
A A
(black) black
black
black
Spindle/ Spindle/
inverter motor inverter motor
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Machine using
Sample PLC
Wiring Step 3
The connection overview for Milling is shown. The connection overview for Turning is shown.
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Machine using
Sample PLC
Before powering on the controller, you should familiarise yourself with the Before the control can be commissioned, loading of standard NC data
operation of the PPU and MCP. has to be carried out, the password has to be set to manufacturer, the
For detailed information refer to :- time and the date have to be set.
Commissioning manual page 27 to 29
1. Apply 24V DC to the PPU (X1). Setting of the password.
2. Apply 3P 220VAC to V60 drives (L1 L2 L3). For detailed information refer to :-
Commissioning manual page 31
2. Check that the status LEDs on the front face of the
PPU are in the ready state.
For detailed information refer to :- To set the password :-
Commissioning manual page 30
Press button +
3. Check that the status LEDs on the front face of the V60 drives are in a Press SK
ready state.
V60 digital drive display at this stage, the status should be S- 4. Type in SUNRISE
For detailed information refer to :-
Commissioning manual page 30 Press SK
Status description on SINAMICS V60
Item Description
Setting of the time and date.
For detailed information refer to :-
8.8.8.8.8.8 Initializing the drive, will stay 1 sec Commissioning manual page 34
during the process
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Machine using
Sample PLC
Load standard data :- Reset the password as the Default PLC will set to NO PASSWORD
The control must be powered off on.
Press button +
When the PPU shows the following Press SK
screen:-
Type in SUNRISE
Press
Press SK
Press SK
Press
Select the language with
To accept the selection. Press SK
On power up of the control the current alarms 4060 and 400006 can be
acknowledged with the Reset and Alarm cancel buttons
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Machine using
Sample PLC
There are 4 parameters that have to be set depending on which axis Press (until P01 is displayed)
motor has been used in the construction of the machine. Press Enter
Press (until 0 is displayed)
4Nm 6Nm 7.7Nm 10 Nm Press Enter
Parameter Data Data Data Data Press M repeatedly (until FUnC is displayed)
Press Enter
P20 Kp 0.81 1.2 1.5 2.1 Press (until StorE is displayed)
Press Enter
Drive P21 Tn 17.7 17.7 17.7 18 Press (until YES is displayed)
SINAMICS Press Enter
V60 P30 KV 3 3 3 3
FInISH is displayed
P31 FFW 85 85 85 85 Press M (3 times)
S- 3 is displayed
The four parameters being p20, p21, p30, and p31. Apply 24v dc to terminal 65
S- 4 is displayed
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Machine using
Sample PLC
Commissioning diagram
Commissioning manual page 37 Commissioning the prototype.
For detailed information refer to :-
Commissioning manual page 35
1 Commissioning the prototype.
2 Series production
START
Commissioning the machine with the default PLC application To start the assistant
1 Press
Commissioning the NC
NC data compensation
2 The PPU shows the following
screen.
Data backup In the box shown you can enter the
PLC MD values.
Startup archive (back up to USB)
Original status archive for delivery
END
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Machine using
Sample PLC
SBR 42
MD14514[4] DB4500.DBD2016 Tool magazinevelocity of Z axis, back to tool chan-
ge preparation position
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Machine using
Sample PLC
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Machine using
Sample PLC
PLC MD is to be adapted to suit the 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)
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of Prototype
Machine using
Sample PLC
Commissioning Check
PLC I/Os
The connect status
should now be green.
First the Sample PLC blocks should be uploaded to the PC, then the All I/O status must be checked with the electrical drawing using the
modifications can be made to achieve the required functionality. Once following SKs. The status is shown on the right hand side as shown
this has been completed, the PLC should be put into stop and the mod- above.
ified PLC should be downloaded into the PPU. The PLC must then be Vertical SKs allow you to select digital inputs or outputs and selection of
restarted. the byte required.
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Machine using
Sample PLC
Export the finished alarm text from the PPU Changes will be activated
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Sample PLC
30130 1
30240 2
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Machine using
Sample PLC
Create ser.
Set SW limit.
Start-up archive
For detailed information For detailed information
refer to :- refer to :-
Commissioning manual Commissioning manual
page 66 page 61
Vertical SK allows you to, create the series start-up archive press SK You can edit the axis machine data for the required axis.
Create archive. Vertical SKs allow you to edit, activate or set as default
Note:
When creating the production Changes will be activated
backup, store archive to USB
memory stick. MD set to default value
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Machine using
Sample PLC
Leadscrew
Bcklsh comp.
err. comp.
You can edit the axis machine data for the required axis. You can edit the axis machine data for the required axis.
Vertical SKs allow you to edit, activate or set as default Vertical SKs 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 Used to enter compensation data via the HMI
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Machine using
Sample PLC
Create Create
Start-up archive Start-up archive
For detailed information Once the assistant is
refer to :- completed.
Commissioning manual
page 67
Note:
When creating the Start-up
archive, store archive to USB
memory stick
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of Prototype
Machine using
Sample PLC
Commis-
sioning
To perform
the Go to page 34
series
End
Press Followed by
Note:
When loading the production
archive, use archive on USB
memory stick.
You can edit the axis machine data for the required axis. You can edit the axis machine data for the required axis.
Vertical SKs allow you to edit, activate or set as default Vertical SKs 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)
Leadscrew Data
err. Comp. backup
For detailed information For detailed information
refer to :- refer to :-
Commissioning manual Commissioning manual
page 62 page 67
You can edit the axis machine data for the required axis. Vertical SK allows you to, create the production archive press SK
Vertical SKs allow you to edit, activate or set as default Create archive.
Note:
Changes will be activated When creating the start-up
archive, store archive into OEM
directory and on a USB
memory stick
Control will activate MD
Program-
To Do ming tool Go to page 40
PLC
Signals of
To Do the PLC Go to page 48
interface
Operation Go to page 50
To Do
symbols
PLC
To Do Subroutine Go to page 54
library
PLC Go to page 57
To Do
alarm
PLC
To Do Online Go to page 61
diagnosis
End
In order to edit the PLC program we must use Programming Tool PLC Open the default PLC program and save this file under a new name so
V3.2 or higher . that the default program is not over written.
The PLC programming tool has 5 languages that can be selected when Overview of PLC programming tool.
installing the software, you 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.
The address of each instruction can be edited at any time by highlighting Double click this icon.
the instruction.
Illustration
Connection established
Connection activate
Activate the PLC connection setting in 808D (password set to sunrise)
Press key: +
The connection is now established. To check for syntax errors use compile after editing and modification of
the PLC program.
Online monitoring can be To display the online The blue represents an online connection
used when the PLC pro- conditions of the PLC, showing the status.
gram is in the run mode. press
Please confirm the Step 7 connection should be deactivated after the The signals of the PLC interface and the signals of the input and output.
PLC commissioning has finished
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 cards.
Component
Of the M/C
Electrical
Not present,connection PLC
MCP
I/O
Application
closed
Program
HMI
The signal of
input and output
NCK channel
R R R R R R R
W W W W W W W
W W W W W W
R R R R R
R
PLC application
R R R R
W R R
W W W W W
Special markers
always 1 state
SM0.0
PLC scan at Special marker register can simplify the de-
sign of PLC application program
SM0.1
Buffer data loss
SM0.2
System restarts
SM0.3
SM0.6
1 second pulse
SM0.5
0.5 second 0.5 second
1 minute pulse
SM0.4
30 seconds 30 seconds
double word ID2, ID8; QD0, QD4 double word MD4, MD28
Counter
Plus and
Plus coun- Minus minus
Counter: C
ter counter counter
Form;
condition of counter bit C3, C25; - represents the
comparison result of the counter and present value. CTU CTD CTUD
CU CD CU
CD
R LD R
PV PV PV
Style:
plus counter CTU count: counter value+1
R=1 counter resets; counter value>preset value
Cn=1
PV: is preset CD: is minus CU: is plus count
value count pulse pulse
minus counter CTD count: counter value -1
LD: is Loading R:
LD counter value = preset; value = counter value=0
preset value Is resetting
Cn=1
Timer: T
Timer enable
Form; preset value PV
condition of timer bit T3, T25; represent the
comparison result of timer value and preset value timer value
Timer bit T
timer value T3, T25; represent timer value
Style;
open delay timer TON IN=1 begin timing IN=0
timer resetting count value>preset value Tn=1
!
clearly realize how to create or invoke PLC subroutines.
You can reorganize PLC subroutines or modify some Programming Subroutine (64) SBR0 to SBR63 (64 subroutines)
networks to realize most machine functions. Test and tool resource Symbol table (32) SYM1 to SYM32 (32 symbol tables)
debug subroutines of the subroutine library on machines
overall according to practical situation to assure the
correctness of subroutine librarys functions.
A constant definition All the addresses in PLC subroutine library are programmed by
symbols. All the signals of interfaces are named by symbols and ar-
Constant input symbol address ranged in different symbol table.
The name of symbols follows some conventions.
Constant 1 ONE SM0.0 Please refer to the PLC subroutine library instructions.
Constant 2 ZERO M251.0
Statistic type symbol address symbol List name Symbol list details
bit NULL_b M255.7 1 PP_1 PP module 1 I/O defined by
manufacturer
byte NULL_B MB255
... ... ...
word NULL_W MW254
4~15 Preset for manufacturer
Long word NULL_DW MD252
16 IS_MCP Send to or from machine
control panel MCP
... ... ...
0 to 19 ... Saved for producers SBR 47 PLC_Select_PP PLC NC program selection via
SBR 20 AUX_MCP MT auxiliary function PLC
Digital output
turret (coded by turret suppli-
er)
SBR 55 Tail_stock_T Tailstock control KA1 KM1
SBR 56 Lock_unlock_T Chuck control
Digital input
SBR 60 Disk_MGZ_M Disk magazine control (w/o
automatic tool changer)
Conditions of elimination
Alarm Alarm attrib- Alarm power-on clear after the cancel of alarmyou need to re-power it
PLC signal PLC alarm variable
number ute setup text on
700000 DB1600.DBX0.0 DB16000.DBD1000 MD14516[0] 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
Driver is itself
700016 DB1600.DBX2.0 DB16000.DBD1064 MD14516[16]
not ready
Coolant alarm reaction
700018 DB1600.DBX2.2 DB16000.DBD1072 MD14516[17] motor React by two ways after alarm
overload PLC reactionthe PLC program written realizes reaction through
... ... ... ... corresponding PLC interface, such as cancel the shaft-enable when
giving an alarm.
User
DB1600.DBX15. MD14516 NC reactionevery alarm has a 8 configuration MD14516[0]~ [127].you
700127 DB16000.DBD1508 alarm
7 [127] can set a cancelation condition and alarm reaction of every alarm
127
according to current condition. The system makes corresponding reaction
when alarm begins.
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 MD14516[n] alarm
alarm, reset 0 can cancel the alarm.
NC start inhibit
In PLC cross referenceyou can find the reason for the PLC alarm bit 7 6 5 4 3 2 1 0
through looking up reference addresses to make corresponding mod- Read-in disable
ification. Power off/on
Feed disable
Reset or cancel key
Emergency
PLC stop
Alarm reset /cancel condition
Press button +
Create, edit alarm text correctly and reasonably can make users clearly
realize the reason of PLC alarm and locate ,and rule resolve a Press SK
breakdown.
Curser over HMI
Press SK
Edit PLC user alarm by USB. Find alarm number which needs to be edited and input your own text.
Edit PLC user alarm by HMI. Check the condition of PLC and judge logical error or external electrical
error through displaying PLC program online.
Create PLC alarm text directly in 808D system. Press button +
Press SK Press SK
Click OK after
finishing edit.
Check the PLC operating status and data. Check the condition of PLC and judge logical error or external electrical
error through displaying PLC program online.
Press SK Press SK
Press SK Press SK
PLC program
information
Check the correctness of hardware connection through examining the state Check the condition of hardware connection through examining the status
of input point. of input point.
Press button +
Press SK
Press SK
Press SK
Observe the condition of PLC , judge logical error quickly or external Observe the condition of PLC , judge logical error quickly or external
electrical error through displaying PLC program online. electrical error through displaying PLC program online.
Press button + Press button +
Press SK Press SK
Press SK Press SK
Press SK Press SK
Display conditions of
input point ,output point,
auxiliary relay and the
signal of interface by
listing. Look up appointed target
in cross-reference table
Siemens AG Subject to change without prior The information provided in this brochure contains merely general
Industry Sector notice descriptions or characteristics of performance which in actual case of
Motion Control Systems Order No.: use do not always apply as described or which may change as a result
P.O.Box 3180 Dispostelle 06311 of further development of the products. An obligation to provide the
91050 ERLANGEN W/35557 WERK.52.2.01 WS respective characteristics shall only exist if expressly agreed in the
GERMANY 11113.0 terms of contract.
Printed in Germany All product designations may be trademarks or product names of
Siemens AG 2012 Siemens AG or supplier companies whose use by third parties for
their own purposes could violate the rights of the owners.