En 808D Commissioning Guide 2013-09

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Training manual
Sinumerik 808D ADVANCED Commissioning Guide

Version 2013-09
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Notes
Commissioning Guide Page 2 808D ADVANCED Turning and Milling

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Product identification / SINUMERIK 808D ADVANCED
The warranty is connected to the product serial number of the Press softkey to enter the screen of service axes ( see picture 2).
808D ADVANCED.
You can find the product serial number: Press softkey to enter the screen of version data ( see picture 3).
On the back of PPU system hardware.
product serial
number
Picture 2
Or on the display.
After switch-on, press the “Shift” and “Alarm” keys together.
Then press the “Extension” button
This will enter into the system area.（see picture 1） Picture 3
Picture 1 You can find the serial number information which needs to be registered
starting with the letters “SZV”.
For any question about ”SZV” serial number and the steps to register ,
Please contact the Siemens Technical Support & Service Hotline:
+86 4008104288
808D ADVANCED Turning and Milling Page 3 Commissioning Guide

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Notes

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Workflows
Commissioning
For of Prototype
go to page 7
Machine using
Sample PLC
Series
For Machine go to page 53
Production
PLC program
For design and go to page 73
adjustment
End

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Notes

Commissioning
of Prototype s
Basic Commissioning procedure for prototype machines using the

Sample PLC
Delivery Go to page 8 Go to page 32

Step 1 Step 7 Options
Check
Mounting Commis-
Step 2 Dimen- Go to page 8 Step 8 sioning Go to page 33
sions Diagram
Commis-
sioning Go to page 33
Step 3 Wiring Go to page 11 Step 9
the
Prototype
ToolBox Cabinet Go to page 50

Step 4 Go to page 22 Step 10
Software Design
Switch on
Step 5 and Go to page 26 End
Prepare
Step 6 Licences Go to page 31

Commissioning
of Prototype
Machine using s
Sample PLC
Delivery check Step 1 Mounting dimensions Step 2
In the following diagram the most common Siemens components are In order to mount the PPU and MCP use the clamps provided as shown
shown. For detailed information refer to :- below :-
Commissioning manual page 13
Inverter or servo spindle drive
PC/PG
Spindle encoder
Spindle motor
USB stick
SINUMERIK
808D ADVANCED PPU
In total 14 clamps are provided together with the delivery of PPU :
1. 8 clamps for mounting PPU.
Handwheels SINAMICS V70 SINAMICS V70 SINAMICS V70 2. 6 clamps for mounting MCP.
Factory Network
Terminator
In the following technical drawing the mounting dimensions for the PPU
and the MCP are shown.
+24V DC power supply
You must provide sufficient space (recommended distance: 80 mm)
between the maintenance door and the cabinet wall for replacing the
CF card:
For further components refer to :-
Emergency stop button 808D MCP Commissioning manual page 21
Motor Motor Motor
Notes：
1. PC and memory stick is not included in scope of delivery.
2. "USB", "Handwheel","24V DC power supply", "Emergency stop button", "Inverter or servo spindle drive", "Spindle
encoder" are also not included in scope of delivery.

Commissioning
of Prototype
Machine using s
Sample PLC
Mounting dimensions Step 2
The cut-out dimensions for the 808D ADVANCED horizontal PPU and PPU
MCP.
Cut-out dimensions
808D PPU
MCP
808D MCP
BB AA
X10
NC
PPU = Panel Processing Unit The clamps are located at the positions indicated with the black triangles.
MCP = Machine Control Panel The black triangles can be seen in the above picture highlighted with red
circles.

Commissioning
of Prototype
Machine using s
Sample PLC
Mounting dimensions Step 2
The cut-out dimensions for the 808D ADVANCED vertical PPU and
MCP.
Cut-out dimensions
PPU
808D PPU
808D MCP
MCP
The clamps are located at the positions indicated with the black triangles. MCP
The black triangles can be seen in the following picture with red circles. Vertical MCP without handwheel Vertical MCP with ingrate handwheel

Commissioning
of Prototype
Machine using
Sample PLC
s
Mounting dimensions Step 2 Wiring Step 3
In the following diagram, the mounting dimensions for the V70 drives are The connections for the SINAMICS V70 drives to the PPU are shown.
shown.
You must provide sufficient space (recommended distances are shown) 3 phase 380V AC line
around the cabinet wall for air circulation: supply Drive bus terminator
For further components refer to :- L1 l2 l3
Commissioning manual page 25 Circuit breaker (optional)
Switches off the power
supply to protect the
network when overcurrent
SINUMERIK 808D ADVANCED
occurs
Line filter (optional)

> 100 mm
Protects the network from

harmonic load and/or
interference voltages.
Emergency stop button

(optional)
Stops a motor in emergency
cases.
SINAMICS V70 SINAMICS V70 SINAMICS V70

Servo drive Servo drive Servo drive
Braking resistor (optional)
Power cable
Absorb excess regenerative
> 20 mm > 20 mm energy in the DC link when
24 V DC power supply
the capacity of the internal
SINIMICS V70 servo
> 20 mm > 20 mm braking resistor is insufficient
drive
Brake cable
> 100 mm
Encoder cable
Accessories not included in the
scope of delivery
Connections not necessarily

required
SIMOTICS S-1FL6 servo
Shielding layer
Electrical cabinet motor
For further information refer to :-

Commissioning
of Prototype
Machine using s
Sample PLC
Wiring Step 3
When connecting the components in the electrical cabinet, the wiring Legend Interface Comment
should comply with the relevant safety standards. PPU Back
For further information refer to :- 1 X100, X101, X102 Digital inputs
Commissioning manual page 35 2 X200, X201 Digital outputs
3 X21 FAST I/O
V70 Operating Instructions manual 4 X301, X302 Distributed I/O
5 X10 Hand-wheel inputs
In order to connect cables and wires, the location of all connectors and 6 X60 Spindle encoder interface
terminal blocks need to be known. 7 X54 Analog spindle interface
8 X2 RS232 interface
Connector overview of the horizontal and vertical PPU is shown: 9 X126 M3 Drive Bus
10 X30 USB interface, for connection with the
PPU back MCP
2 1 5 6 7 8 12 9 10 11 X1 Power supply interface, +24V DC power
supply
12 X130 Ethernet
13 - Slot for the System Compact Flash Card
(CF card)
PPU Front
14 - USB interface
14
PPU front
3 4 11 13

Commissioning
of Prototype
Machine using s
Sample PLC
Wiring Step 3
PPU back Legend Interface Comment

PPU Back
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
13 8 X2 RS232 interface
9 X126 M3 Drive Bus
11 10 X30 USB interface, for connection with the
MCP
12 11 X1 Power supply interface, +24V DC power
10 supply
8
12 X130 Ethernet
13 - Slot for the System Compact Flash Card
(CF card)
3 PPU Front
14 - USB interface
5 14
PPU front
1 2 6 7 4

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Commissioning
of Prototype
Machine using
Sample PLC
Wiring Step 3
MCP back Selection of 24V DC supply
BB AA
These 4 aspects should be considered during selection of 24V DC supply

X10 1. 24V DC consumed on 808D :
NC
 Starting current:5 A (momentary)
 Basic consumption :1.5A
2. 24V DC consumed on Sinamics V70 drive:
1  V70+1FL6 (w/o brake):0.8A/axes
 V70+1FL6 (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 plate.
Consideration of redundancy coefficient base on regulation of OEM
X10
NC
MCP back The connections on PPU for the handwheel are shown.
X10
1 1A
2 -1A
3 1B
4 -1B
5 +5V
Legend Interface Comment
6 M
MCP Back
7
1 X10 USB interface, for connection with the
8
PPU
9
Note 10
Connect USB cable between X30 on PPU and X10 on MCP.

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Commissioning
of Prototype
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
10 M +
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 24V

Commissioning
of Prototype
Machine using s
Sample PLC
Wiring Step 3
Milling Milling
Digital inputs Digital outputs
X101 X200
1 1 +24V
2 Ref Y 2 Working lamp

3 Ref Z 3
4 Magazine count 4 Chip remover forward
5 Magazine at spindle position 5 Chip remover reverse
6 Magazine at original position 6 Cooling pump
7 Magazine at release position 7 Lubrication pump
8 Magazine at clamp position 8 Safety door open
9 9
10 M 10 M
+ +
24V 24V
X102 X201
1 +24V
1
2 2 Disk magazine: magazine rotating CW
3 3 Disk magazine: magazine rotating CCW
4 4 Disk magazine: magazine in spindle position
5 5 Disk magazine: magazine in original position
6 Coolant level low 6 Disk magazine: spindle tool release
7 Cooling motor overload 7
8 Lubrication level low 8
9 Lubrication motor overload 9 Handheld unit active
10 M M +
+ 10
24V 24V

Commissioning
of Prototype
Machine using s
Sample PLC
Wiring Step 3
Pin assignment of X301,X302

The connections of the distributed I/O are shown for the default PLC.
Turning Illustration shows the connection

diagram of PPU X301
X301 Distributed I/O
+ 24V DC
M Turning
Digital inputs
11 - Handheld unit: axis X selected X100

13 - Handheld unit: axis Z selected 1
14 - Handheld unit: axis 4th selected 2 E-stop
15 - Handheld unit: INC X1 3 Limit X+
16 - Handheld unit: INC X10 4 Limit X -
17 - Handheld unit: INC X100 5
18 - Handheld unit: enabled 6
+
7 Limit Z+
External power 8 Limit Z-
Supply + 24V DC 9 Ref X
10 M
+
For the connection of distribution I/O on X301,X302 distribution I/O board 24V
must be configured. MLFB for distribution I/O: 6EP5 406-5AA00
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Commissioning
of Prototype
Machine using
Sample PLC
Wiring Step 3
Turning Turning
Digital inputs Digital Outputs
X101 X200
1 1 +24V
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
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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Commissioning
of Prototype
Machine using
Sample PLC
Wiring Step 3
The connections for the inverter or the spindle drive to the PPU are shown.
Unipolar connection Bipolar connection 3AC 380V

3AC 380V
SINUMERIK 808D SINUMERIK 808D

ADVANCED PPU ADVANCED PPU
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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Commissioning
of Prototype
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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Commissioning
of Prototype
Machine using
Sample PLC
Wiring Step 3
Recommended safety wiring of emergency stop with OFF3 and delayed Recommended safety wiring of emergency stop (simple)
STO (OFF2)
808D ADVANCED 808D ADVANCED
Emergency button
NCK PLC 65
NCK PLC
663
Stop button (non safe)

+24v +24v +24v +24v
Contact with
Ø Ø Drive Bus Ø Ø Drive Bus Delayed safety Ø Ø Drive Bus Ø Ø Drive Bus
contact
STO STO STO STO
V70 V70 V70 V70

STO1
STO2
STO1
STO2
STO1
STO2
STO1
STO2
Commissioning
of Prototype
Machine using
Sample PLC
s
Toolbox software Step 4
The 808D ADVANCED toolbox The software licence agreement has to be “accepted” and continued with
In order to integrate the 808D ADVANCED to a machine tool, software tools “Next”.
are required. The tools enable the machine tool builder to create the PLC
program for the machine.
These tools, including service tools are supplied on a CD, the CD is called
the Toolbox CD and is included in the scope of delivery.
Software included in the toolbox:
 AMM (Data transfer, commissioning tool)

 Programming tool PLC (Creating & loading PLC projects)
 PLC Library (PLC example files)
 SinucomPCIN (Data transfer)
Use the “setup.exe” In some cases, an extra language has to be selected.

file to install software
on to PC/PG.
For further
information refer to :-
Commissioning
manual page 20
Double-click the “Setup.exe”

Commissioning
of Prototype
Machine using
Sample PLC
s
In some cases, an earlier version of a program may already be installed, in Basic Information
this case the software must be un-installed first, then start the installation
again and select the required software from the list. The AMM software program is a multifunctional tool which is used for data
transfer, service, and commissioning tasks.
The program is part of the toolbox supplied with each controller and is
installed as per instructed previous. Data resident on the controller can be
saved to an external computer for backup purposes. This data can be
transferred back to the controller as and when required.
Alternatively, data created off-line, such as NC part programs can be
transferred to the controller in the same way.
The software includes a feature called “Remote control”, this allows the
screen of the controller to be remotely viewed and changed, it is also
possible to make changes to data using this feature.

During the installation various dialogue boxes will appear. The dialogue
boxes should be acknowledged and where necessary installation data
should be entered and confirmed.
Installing all the software packages will take approximately 30 minutes.
When the installation has finished icons will be placed on the desk top.

Commissioning
of Prototype
Machine using
Sample PLC
s
Testing the connection to PLC Programming Tool. Select the active ethernet adaptor.
A connection must be made so that the PLC programming tool can

communicate with PPU, first startup the PLC programming tool software.

Commissioning manual
page 210
Click the Communications

Icon.
Activate the PLC connection setting in 808D (password set to “sunrise”)
Press key: +
Press key:
Double click highlighted area.
Press “Serv. Displ.” SK

Commissioning
of Prototype
Machine using
Sample PLC
s
Press “Service control” SK Enter the “direct connect” IP address

in the remote address field of the
programming tool.
Double click the “Double click to
refresh” field to activate the
connection.
The connection is now established, this is shown by a green box.
Press “Direct connect.” SK

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Commissioning
of Prototype
Machine using
Sample PLC
Switching on and prepare for commissioning Step 5
Before powering on the controller, you should familiarise yourself with the Every time a new connection is established between the NC and the drive,
operation of the PPU and MCP. the NC automatically compares the drive data with the data backup on the
NC.
For detailed information refer to :- If no data backup files can be found, the NC creates a new backup file
Commissioning manual page 77 automatically with the following dialog displaying on the screen:
1. Apply 24V DC to the PPU (X1). For detailed information refer to :-

2. Apply 3P 220VAC to V70 drives (L1 L2 L3). Commissioning manual page 89
3. Check that the status LED’s on the front face of the PPU are in
the ready state.
For detailed information refer to :-

Status description on front LED’s of PPU
LED Colour Description
POK Green The power supply for the CNC is switched on.
Green The CNC is ready and the PLC is run mode.
RDY Yellow The PLC is in stop mode.

If the drive data is different from the 808D backup data, a data synchroni-
Red The CNC is in stop mode. zation is required for synchronizing the drive data files between the NC
and the drives.
Green The CNC temperature is out of range
TEMP
Unlit The CNC temperature is within the specified range.

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Commissioning
of Prototype
Machine using
Sample PLC
4. Check that the status LED’s on the front face of the V70 drives are in a LED status indicators
ready state. Two LED status indicators (RDY and COM) are available to indicate drive
V70 digital drive display at this stage, the status should be S - off. readiness status and communication status respectively.
Status on power up with Status on power up with

absolute encoder incremental encoder Status LED’s indicator colour Status description
24v control board
- Off power supply is miss-
ing
Status description on SINAMICS V70 Green Continuously lit Drive is ready
RDY Enable signal is

Item Description Continuously lit missing or drive is in
Red start-up states
8.8.8.8.8.8 Initializing the drive, will take 20 –30 sec
during the process Flash at 1Hz Alarms or faults occur
------- Drive is busy Orange Flash at 2Hz Servo drive is located

Communication with
S - Off Operating display: servo off - Off
CNC is not active
Communication with
r -0 Drive is running properly Flash at 0.5Hz
CNC is active
COM Green
SD card operating
A 01...A 45 Alarm code Flash at 2Hz
(read or write)
Communication with
F 01...F 45 Fault code Red Continuously lit
CNC is in error

Commissioning
of Prototype
Machine using s
Sample PLC
V70 Drive: Before the control can be commissioned, loading of standard NC data
has to be carried out, the password has to be set to manufacturer, and
Loading of “Default data” the time and the date have to be set.
Setting of the password.
Remove drive bus cable from terminal X10 For detailed information refer to :-
Press M repeatedly (until “FUnC” is displayed) Commissioning manual page 92
Press OK
Press ▼(until “dEFAUL” is displayed)
Press OK for more than 2 sec To set the password :-
Screen will go blank (wait about 20sec)
(Screen will display “S OFF” or a fault code) Press button +
Press SK
Saving data.
Type in “SUNRISE”
Press M repeatedly (until “FUnC” is displayed)
Press OK Press SK
Press ▼(until “SAvE” is displayed)
Press OK for more than 2 sec
Screen will go blank (wait about 20sec) Setting of the time and date.
(Screen will display “S OFF” or a fault code) For detailed information refer to :-
Replace drive bus cable to terminal X10 Commissioning manual page 93
To set the time and date :-
Press SK
Press SK
Type in time and date using the key-

board and the and
button

s
Commissioning
of Prototype
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
To set the language:-
Press button +
In the following screen select
“start-up with default data” using Press SK
button
Select the language with
Press Press SK
To accept the selection.

Loading system languages:-
You can load a new system language or update an existing language on
On power up of the control the current alarms 4060 and 400006 can be the controller.
acknowledged with the “Reset” and “Alarm cancel” buttons Siemens will provide each language in the form of an archive file.


s
Commissioning
of Prototype
Machine using
Sample PLC
licences Step 6
In order to active an
“Option”, a new licence key
must be obtained and
entered as a numerical
key.
For further information
refer to :-
page 94
Press button +
Press button
Press the SK Press the SK
Enter the numerical key

obtained from Siemens
into the boxes.
Press the SK To activate press the SK

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Commissioning
of Prototype
Machine using
Sample PLC
Options Step 7
To active an “Option”, enter

the screen and select the
required “Options”.
For further components

refer to :-
page 95
Press button +
Press button
Press the SK Press the SK
Enter the number of

additional axis or “select”
the required option using
the button.
Press the SK To activate press the SK

s
Commissioning
of Prototype
Machine using
Sample PLC
Commissioning diagram Step 8 Commissioning the prototype Step 9
Commissioning diagram
Commissioning the prototype.
1 Commissioning the prototype. For detailed information refer to :-
2 Series production Commissioning manual page 99
The startup assistant is used to commissioning the prototype

START
Commissioning the machine with the default PLC application To start the assistant
1 Press
Commissioning the NC
The PPU shows the following

Data backup
screen.
 production archive
 Start-up archive for the prototype
Series commissioning Press
NC data compensation
2 The PPU shows the following
screen.
Data backup In the box shown you can enter the
PLC MD values, required for the
 Start-up archive (back up to USB)
standard PLC program.
 Original status archive for delivery
END

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Commissioning
of Prototype
Machine using
Sample PLC
Commissioning the prototype Step 9
Set PLC MILLING continued

parameters
MD14512 Functionality
For detailed information refer to :- Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
14512[16] Selection Z axis: Y axis: X axis: Safety Safety Chip
DB4500.D of axis to rotary rotary rotary door open door remover
be monitoring monitoring monitoring when M1/ activate activate
BB1016 controlled M2
by hand programe
wheel via d
MD14510 PLC interface Unit Range Function MCP
14510[12] DB4500.DBW24 * 0 or 1 vertical =0 - horizontal=1 SBR 39 SBR 22 SBR 22 SBR 23
MD14510[13] DB4500.DBW26 0.1sec 5~200 Spindle braking time 14512[17] Selection Tool
of maga-
SBR 42 hand- zine
DB4500.D wheel activate
MD14510[20] DB4500.DBW40 2~64 Max Tool number in magazine BB1017 controlled
SBR 51 - 52 axis via SBR 52
HHU - 53
MD14510[24] DB4500.DBW48 1min 5~300 Lubrication interval
SBR 45 14512[18] One Hardware Fixed External Auto-
hardware limit is direction stop signal matic
limit independ- of spindle of the lubrica-
MD14510[25] DB4500.DBW50 0.01s 100~2000 Lubrication duration DB4500.D triggered ent of the spindle tion
SBR 45 BB1018 per axis PLC after first
application power-
on
MD14514 PLC interface Function SBR 40 SBR 40 SBR 33
MD14514[0 DB4500.DBD2000 Tool magazine：spindle poisoning angle 14512[19] Delete Spindle

system brake
pass- activate
MD14514[1] DB4500.DBD2004 Tool magazine: Preparation position of Z axes for DB4500.D word
tool change BB1019 when
power
on SBR 42
MD14514[2] DB4500.DBD2008 Tool magazine: Tool changing posion of Z axes
14512[20] Spindle
MD14514[3] DB4500.DBD2012 Tool magazine: velocity of Z axis, Go to tool change enable
preparation position cancel
DB4500.D
MD14514[4] DB4500.DBD2016 Tool magazinevelocity of Z axis, back to tool change BB1020 SBR 40
preparation position

s
Commissioning
of Prototype
Machine using
Sample PLC
Set PLC TURNING continued

parameters
MD14512 Functionality
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Commissioning manual page 100 14512[16] Selection Z axis: X axis: Safety Safety
of axis to rotary rotary door open door
be monitoring monitoring when M1/ activate
DB4500.DB controlled M2
B1016 by hand programe
wheel via d
MCP
SBR 39 SBR 22 SBR 22
14512[17] Selection Tail- Chuck HED

of stock func- turret
MD14510 PLC interface unit Range Functionality hand-
DB4500.DB wheel
function tion activate
B1017 controlled activate activate
14510[12] DB4500.DBW24 * - flat bed=0 - inclined bed = 1 axis via
HHU SBR 51 -
52
MD14510[13] DB4500.DBW26 0.1sec 5~200 Spindle braking time
SBR 42 14512[18] One Hardware Fixed External Automatic
hardware limit is direc- stop lubrica-
MD14510[20] DB4500.DBW40 4, 6 limit independ- tion of signal of tion
Max Tool number in turret. DB4500.DB triggered ent of the spindle the after first
SBR 51 - 52 B1018 per axis PLC spindle power-on
(for tool amount >6, PLC to be
applica-
programmed by customer them- tion
selves)
SBR 40 SBR 40 SBR 33
MD14510[21] DB4500.DBW42 0.1sec 5~30 HED turret: Tool clamping time for
SBR 51 - 52 14512[19] MM+ Delete Spindle
(option) system brake
password activate
MD14510[22] DB4500.DBW44 0.1sec 30~200 HED turret: Time monitoring for DB4500.DB activate when
SBR 51 - 52 tool change B1019 power on
SBR 53
SBR 58 -
59 SBR 42
MD14510[24] DB4500.DBW48 1min 5~300 Lubrication interval
SBR 45
14512[20] Spindle
enable
MD14510[25] DB4500.DBW50 0.01s 12~2000 Lubrication duration cancel
DB4500.DB
SBR 45
B1020 SBR 40

s
Commissioning
of Prototype
Machine using
Sample PLC
Set PLC Commissioning

parameters 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 8
(install PLC programming tool)
To make a connection to the PPU, press SK

Then follow the information in:-
Changes will be activated PLC Subroutines manual page 18
MD set to default value
MD set to previous value
To continue press the SK To continue press the SK

s
Commissioning
of Prototype
Machine using
Sample PLC
Commissioning Check
PLC I/O’s
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 this following SK’s. The status is shown on the right hand side as shown
has been completed, the PLC should be put into stop and the modified above.
PLC should be downloaded into the PPU. The PLC must then be Vertical SK’s allow you to select digital inputs or outputs and selection of
“restarted”. the byte required.
PLC Subroutines manual page 25

Choose digital input
Choose digital output
Choose the digital O/I addresses of Byte -
Choose the digital O/I addresses of Byte +

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Commissioning
of Prototype
Machine using
Sample PLC
Create PLC Drive

alarm texts configuration
For detailed information For detailed information
refer to :- refer to :-
Commissioning manual Commissioning manual
page 103 page 104
V70 Drive:
You can edit the PLC user alarm text either directly on the HMI, or off line
by transferring the file using a USB stick. Set “address data” for each axis:
Vertical SK’s 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. Remove drive bus cable from terminal X10
Press OK
Import the backup alarm text into the PPU Press ▼(until “Addr” is displayed)
Press OK
Export the finished alarm text from the PPU Press ▼(until desired address is displayed)
Press M
Edit the alarm text Press ▼(until “SAvE” is displayed)
Press OK
If “SAvE” is displayed
Press M (2 times)
(Screen will display “S OFF” or a fault code)
To continue press the SK Replace drive bus cable to terminal X10
Drives must now be powered off/on
s
Commissioning
of Prototype
Machine using
Sample PLC
Drive Drive
configuration configuration
For detailed information
refer to :-
page 105
Starts the configuring of the V70 drive. Starts the configuration of spindle motor
The control will identify all

motors on the M3 Drive Bus

s
Commissioning
of Prototype
Machine using
Sample PLC
Drive Drive
Spindle on analog
Select the motor from the table that matches the motor name plate. All axis motors are indentified
Starts the configuring of the motor data to the drive Starts the configuration of each unidentified spindle
motor
The control will write motor

information

s
Commissioning
of Prototype
Machine using
Sample PLC
Drive Drive
You can edit the spindle machine data for the required axis. All axis and spindle motors are indentified.
Vertical SK’s allow you to edit, activate or set as default value.

s
Commissioning
of Prototype
Machine using
Sample PLC
Drive Set axis

configuration parameters
First drive data for each For detailed information
axis will be save to the refer to :-
drive. Commissioning manual
page 106
The data below must be
Setting Setting
Machine Data data： data：
ABS INC
encoder encoder
30130 1 1
30240 4 1
34200 0 1
34210 1 0
You can edit the axis machine data for the required axis.
Vertical SK’s allow you to edit, activate or set as default value.
Followed by creating the drive data Used to select the axis (X or Z turning or X, Y, or Z
backup files for each axis. milling)
Changes will be activated
To continue press the SK

s
Commissioning
of Prototype
Machine using
Sample PLC
Referencing Set spindle

debugging parameters

page 108 page 110
The data below must be set as
default values:
Machine data Setting
30130 1
30240 2
0：output value is Bipolar

30134 1or2：output value is
Unipolar
You can edit the axis machine data and the for the required axis. 30200
0: without spindle encoder
1: with spindle encoder
Vertical SK’s allow you to edit, activate or set as default
You can edit the spindle machine data required.
Vertical SK’s allow you to edit, activate or set as default
Used to select the axis (X or Z turn or X, Y, or Z mill)


An axis can be referenced
Test spindle in MDA mode
s
Commissioning
of Prototype
Machine using
Sample PLC
Create ser.
Set SW limit
Start-up archive
page 113 page 114
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 SK’s allow you to edit, activate or set as default
Create production archive

Note:
When creating the production Changes will be activated
backup, store archive to USB
memory stick. MD set to default value

s
Commissioning
of Prototype
Machine using
Sample PLC
Leadscrew
Bcklsh comp.
err. comp.
page 115 page 115
You can edit the axis machine data for the required axis. You can edit the axis machine data for the required axis.
Vertical SK’s allow you to edit, activate or set as default Vertical SK’s 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
MD set to previous value Changes will be activated

s
Commissioning
of Prototype
Machine using
Sample PLC
Drive optimization Drive optimization
For detailed information Move axis into a safe

refer to :- position to avoid collisions
Commissioning manual when the axis moves.
page 117
Press the "options" and

choose the optimization
strategy as needed
There are three “Optimization

strategy”:-
1 Moderate measurement
2 Aggressive measurement
3 Conservative measurement
Press “Start Optim.” SK
to start optimization of all
axis, Using the selected
strategy.
Select the required strategy.
The following window will be shown.

s
Commissioning
of Prototype
Machine using
Sample PLC
Preliminary high Preliminary low

frequency speed frequency speed
measurement takes place measurement takes place
with the first of two with the first of two
passes. passes.
To continue press the BUTTON To continue press the BUTTON
High frequency speed Low frequency speed

passes. passes.

s
Commissioning
of Prototype
Machine using
Sample PLC
Drive optimization
The system will After the full optimization

automatically tune, using testing is completed, the
the results of MX1 axis system will automatically
high and low frequency give a list of parameters
measurement as shown. before and after optimiza-
tion of each axis data.
Press “activate”
SK makes the
data active.
The axis optimization operation process will now optimise MZ1 axis of high
and low frequency measurement process. (a repeat of the 8 passes as Press “Next” SK to continue
shown on previous page)
The system will The system will

automatically tune, using automatically be
the results of MZ1 axis optimized after the
high and low frequency machine data is written to
measurement as shown. the NC and drives.
Once successfully saved
the system will
automatically jump to the
next step "to establish the
machine debug file"

s
Commissioning
of Prototype
Machine using
Sample PLC
Create Create
Start-up archive Start-up archive
For detailed information Once the assistant is
refer to :- completed.
page 119

Vertical SK allows you to, create the “production archive” press SK “Create
archive”.
Create Start-up archive
Note:
When creating the Start-up
archive, store archive to USB
memory stick and Archive
folder.
To continue press button +

s
Commissioning
of Prototype
Machine using
Sample PLC
Commissioning the prototype Step 9 Electrical cabinet design Step 10
Now that the It may be preferable to always use cooler units as this allows the cabinet
commissioning is to be sealed which is the best option for stopping the entry of
completed a “SAVE contaminants. Within the cabinets it may also be necessary to install fans
DATA” should be to ensure the air is circulated and prevent “Hot spots” from forming.
performed.
The technical specifications of the individual hardware component will
provide details of the power loss measured in Watts.
Calculations are made to see if the cabinet can dissipate the heat
naturally.
The cabinet manufacturer can supply details of the heat-loss of the
cabinet.
Natural heat dissipation occurs through the cabinet walls providing the wall
is in free air and not against a wall for example.
A general rule is that the energy dissipated is approximately 50Watts/m²of
To continue press the SK free cabinet wall assuming a 10°temperature difference between the
cabinet and the outside air.

s
Commissioning
of Prototype
Machine using
Sample PLC
Electrical cabinet design Step 10
Correct installation of fans Correct installation of cooling units
For cabinets it is possible that the cooling can be achieved with fans The cool air should be directed to the bottom of the drive. The natural
drawing air from the outside via a filter. Natural convection causes the convection will draw the air through the drives.
warm air to exit via a filter. The cool air from the cooling unit should not be directed straight onto/into
The fact that air is being drawn directly from the outside means that this the drives, it should be allowed to mix with the warmer air already in the
system can never be airtight. Having a fan for the inlet side only ensures cabinet, this will minimise the risk of condensation forming.
that the cabinet is positively Cabinet top mounted
pressurised which helps keep Outlet cooling units require
contaminants from entering. via filter a method of directing
It is extremely important that the cool air from the Outlet
the filters are service regularly cooling unit to the
to avoid ingress of bottom of the drives.
contaminants and to maintain In the case of a door
the efficiency of the cooling mounted unit it may
process. be necessary to
direct the cool air ≥ 200mm Cooling
with the use of a unit
Drive
baffle. Drive
equipment
equipment
Baffle
Temp.
Meas.
Fan & filter type cooling Temperature point
Cabinet door Inlet
system Measuring points mounted cooling unit.
Inlet via
Fan &
filter unit

s
Notes

s
Notes

Series
Machine
Production
s
Basic Commissioning procedure for series machines
Commis-
sioning Go to page 54
Step 1
the
series
Add Go to page 61
Step 2
4th Axis
End

Series
Machine
Production
s
Commissioning the series machine Step 1
To start the assistant Load

archive file
Press button +
For detailed information
refer to :-
First set the Pass word.
Followed by page 123
Press
The PPU shows this screen.
Press
Vertical SK allows you to load the “production archive” press SK “Load

Archive”.
Loads production archive
Note:
When loading the production
archive, use archive on USB
memory stick.

Series
Machine
Production
s
Set SW limit Bcklsh comp.

page 114 page 115
You can edit the axis machine data for the required axis. You can edit the axis machine data for the required axis.
Vertical SK’s allow you to edit, activate or set as default Vertical SK’s 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 Changes will be activated
MD set to default value MD set to default value
MD set to previous value MD set to previous value

Series
Machine
Production
s
Leadscrew Drive optimization

Drive optimization
err. Comp.
page 115 page 117
Press the "options".

strategy as required.
There are three

You can edit the axis machine data for the required axis. “Optimization strategy”:-
Vertical SK’s allow you to edit, activate or set as default 1 Moderate measurement
2 Aggressive measure-
ment
3 Conservative measure-
Used to select the axis (X or Z turn or X, Y, or Z mill) ment
Select the
Changes will be activated required strategy.
To continue press
“OK” SK
Control will activate MD

Series
Machine
Production
s
Move axis into a safe Preliminary high

position to avoid collisions frequency speed
when the axis moves. measurement takes place
with the first of two
passes.
To continue press the BUTTON
High frequency speed

measurement takes place
with the first of two
Press “Start Optim.” SK passes.
to start optimization of
selected axis, Using the
selected strategy.
To continue press the SK To continue press the BUTTON

Series
Machine
Production
s
Preliminary low The system will

frequency speed automatically tune, using
measurement takes place the results of MX1 axis
with the first of two high and low frequency
passes. measurement as shown.
The axis optimization operation process will now optimise MZ1 axis of high
To continue press the BUTTON and low frequency measurement process. (a repeat of the 8 passes as
shown on previous page)
Low frequency speed
measurement takes place
with the second of two
passes. The system will
automatically tune, using
the results of MX1 axis
high and low frequency
measurement as shown.
To continue press the BUTTON

Series
Machine
Production
s
Drive optimization Data

Drive optimization backup
After the full optimization For detailed information

testing is completed, the refer to :-
system will automatically Commissioning manual
give a list of parameters page 68
before and after optimiza-
SK makes the
data active.
Press “Next” SK to continue Vertical SK allows you to, create the “production archive” press SK
“Create archive”.
Create start-up archive

The system will
automatically be
optimized after the Note:
machine data is written to When creating the start-up
the NC and drives. archive, store archive into OEM
Once successfully saved directory and on a USB
the system will memory stick
machine debug file"

Series
Machine
Production
s
“Series Assistant” has Now that the

now finished, with green commissioning is
“ticks” in the status completed a “SAVE
column. DATA” should be
performed.
To Continue press button + To continue press the SK

Series
Machine
Production
s
Add 4th axis Step 2
A common requirement is for a standard machine to be fitted with an

additional axis. This requirement usually arises after the machine has left
the factory. Reconfiguring the drives will result in any user settings of the
existing drives being overwritten by default data.
Step 1 Set options for adding 4th axis
When a license key is

entered, the
corresponding option is
used to activate the
function.
For more information see: Press “Options” SK
Commissioning Manual
page 94
Press button +
First set the password.
Press button
Press “Serv. Displ.” SK
Press “Version” SK
Enter the number of added value needs to be activated, press "NCK Re-
set" SK

Series
Machine
Production
s
Add 4th axis Step 2
Step 2 The additional axes Machine Data settings Modify MD19100

Press the following buttons
Modify MD20070 and MD20080
Press the following buttons + → → →
+ → → → Turning
If you only need to add an
Turning additional axis, modify 19100 = 4
To add an additional axis, modify
20070 [3] = 2 If you need to add two additional
20080 [3] = axis name to be axis, modify 19100 = 5
displayed
To add two additional axes, modify
20070 [3] = 2, 20070 [4] = 5
20080 [3] = first axis letter to be
displayed
20080 [4] = second axis letter to be
displayed
Milling
Milling You need to add an additional
You need to add an additional axis, axis, modify
modify 19100 = 5
20070 [4] = 5
20080 [4] = axis letter to be
displayed

Series
Machine
Production
s
Add 4th axis Step 2
Set PLC MD 14215[20] set bit 1&2 Drive configuration
V70 Drive:
Set “address data” for

each axis:
Press “Activate” SK
With these Machine Data modification, the additional axes will be

displayed within the system.
Step 3 Drive configuration

Remove drive bus cable from terminal X10
Press OK
To configure the 4th axis Press ▼(until “Addr” is displayed)
drive Press OK
Press ▼(until desired address is displayed)
First set the password. Press M
Press ▼(until “SAvE” is displayed)
Press button + Press OK
If “SAvE” is displayed
Press M (2 times) Type of machine Turning Milling
(Screen will display “S OFF” or The number of
a fault code) 1 2 1
additional axes
Replace drive bus cable to
terminal X10 Drive address
Drives must now be powered 12 12 / 15 15
data（ P 0918 ）
off/on

Series
Machine
Production
s
Add 4th axis Step 2
Drive configuration Drive configuration
You can start the drive axis configuration by using the vertical SK. All BISS motors will automatically identified.
All TTL motors will have to be configured individually.
Starts the configuring of the V70 drive. Starts the configuration of each unidentified motor.
The control will identify all

motors on the M3 Drive Bus

Series
Machine
Production
s
Add 4th axis Step 2
Drive configuration Drive configuration
Select the motor from the table that matches the motor name plate. All axis motors are indentified.
Starts the configuring of the motor data to the drive. Starts the configuration of each unidentified spindle motor.
The control will write motor

information

Series
Machine
Production
s
Add 4th axis Step 2
Drive configuration Step 4 Setting MD for additional axis
Each drive will have a MD to consider and set before the “Optimization of the drives.
backup file created that Referencing MD
will contain each drive SW limits MD
data. Backlash MD
Leadscrew error comp. MD
Step 5 Drive Optimization
To optimize the 4th axis

drive
First set the password.
Press button +

Series
Machine
Production
s
Add 4th axis Step 2
Press the "options" SK. Move axis into a safe

position to avoid collisions
when the axis moves.

strategy as needed
There are three “Optimization

strategy”:-
1 Moderate measurement
2 Aggressive measurement
3 Conservative measurement
Press “Start Optim.” SK
to start optimization of
the selected axis, Using
Select the required strategy. the selected strategy.

Series
Machine
Production
s
Add 4th axis Step 2
Preliminary high Preliminary low

frequency speed frequency speed
passes. passes.
High frequency speed Low frequency speed

passes. passes.

Series
Machine
Production
s
Add 4th axis Step 2
The system will After the full optimization

automatically tune, using testing is completed, the
the results of MA1 axis system will automatically
high and low frequency give a list of parameters
measurement as shown. before and after optimiza-
SK makes the
data active.
Press “Next” SK to continue
The system will

automatically be
optimized after the
machine data is written to
the NC and drives.
Once successfully saved
the system will
machine debug file"

Series
Machine
Production
s
Add 4th axis Step 2
Step 6 Backing up Using the cursor “up and

down” buttons to select
Now that the 4th axis is location for “archive file”
completed a new
“Archive” should be
Created. To continue press the button
To Continue press button
Curser down to highlight

“Create start-up archive”

Series
Machine
Production
s
Add 4th axis Step 2
When the “Start-up Now that the 4th axis is

archive” is completed the completed a “SAVE
window will Disappear. DATA” should be
performed.

s
Notes

s
PLC program
design and
adjustment
Basic PLC design and adjustment.
Program-
To Do ming tool Go to page 74
PLC
Signals of
To Do the PLC Go to page 80
interface
Operation Go to page 82
To Do
symbols
PLC
To Do Subroutine Go to page 86
library
PLC Go to page 89
To Do
alarm
PLC
To Do Online Go to page 93
diagnosis
End

PLC program
design and
adjustment
s
Programming tool PLC
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
V3.2.4 or higher . that the default program is not over written.
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
Compile the PLC program
Download the PLC program
Upload the PLC program
Monitor the PLC
The software is started by double clicking the icon on your desktop.

PLC program
design and
adjustment
s
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.

PLC program
design and
adjustment
s
The address of each instruction can be edited at any time by highlighting The correct PLC type must be chosen.
the instruction.

PLC program
design and
adjustment
s
To compile the PLC program. To download the modified PLC program.

Press the “compile” icon
Press icon.
The location of the syntax error can be located easily, using the
information contained in the status window.
Place the PLC into STOP.

PLC program
design and
adjustment
s
To place the modified PLC program in RUN mode.
Press icon.
Once the PLC is successfully downloaded, it must be placed in RUN

mode.

PLC program
design and
adjustment
s
Online monitoring can be used when the PLC program is in the run mode. Please confirm the Step 7 connection should has been deactivated
To display the online conditions of the PLC. after the PLC commissioning has finished.
Press SK
Press button +
Press button
The blue represents an online connection showing the status.
Status : 0: LOW, 1: HIGH

PLC program
design and
adjustment
s
Programming tool PLC Signals of the PLC interface
Press SK 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 cards.
The signal of PLC

interface
NCK
Press SK
Component
Of the M/C
Electrical
PLC
MCP
I/O
Application
Program
HMI
The signal of
input and output
The IP ADDRESS window will

disappear, and the “Direct connect.” SK will change to gray in colour.

PLC program
design and
adjustment
s
Signals of the PLC interface
The signals of the interface
NCK channel
R R R R R R R
W W W W W W W
DB1600.DBB2 DB4500.DBB2 V2500

V2500
V2500 333
DB1600.DBB1 DB4500.DBB1 V2500
V2500 32
DB2500.DBB1
DB2700.DBB0 DB3100.DBB1 DB3300.DBB1
DB1400.DBB0
DB1600.DBB0 DB4500.DBB0 xxx
xxxDB2500.DBB0 DB2600.DBB0 DB3000.DBB0 DB3200.DBB0
Can keep the NCK Way selection
Alarm activation PLC Channel control
data area Auxiliary function Signal of
Alarm variables parameter signal signal
control
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
DB1100.DBB0 DB1700 DBB0 DB1800.DBB0 DB1900.DBB0 V3804

V3803
V3802 xxx x
DB3801.DBB
V3904
V3903
V3902 xxx
DB3901. DBBx
DB1000.DBB0 Program control HMI Hand-wheel DB3800.DBB x DB3900.DBBx
MCP signal signal Selection signal selection signal
Axis control Shaft state
signal signals
W W W W W W
R R R R R R
HMI NCK axis

PLC program
design and
adjustment
s
Operation symbols of PLC programming language
Special markers
PLC scan period
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
2 x PLC scan period
SM0.6
1 second pulse
SM0.5
0.5 second 0.5 second
1 minute pulse
SM0.4
30 seconds 30 seconds

PLC program
design and
adjustment
s
The signal of input and output. Accumulator transport and storage
Address Accumulator transport: AC (max 4 Accumulators)
Input; I output; Q Form; Arithmetic accumulators AC0 AC1, logical accu-

mulator AC2, AC3.
form Flag register: M
bit I0.0, I4.6; Q2.1, Q1.7 bit M0.1, M124.5
byte IB4, IB12; QB3, QB7 byte MB21, MB12
word IW2, IW4; QW0, QW6 word MW22, MW106
double word ID2, ID8; QD0, QD4 double word MD4, MD28

PLC program
design and
adjustment
s
Counter
Plus and
Plus Minus minus
Counter: C
counter 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
plus and minus counter CTUD plus counter:

counter value+1；
minus counter: counter value R=1 counter

resets: counter value>preset value C=1

PLC program
design and
adjustment
s
Timers Keep the sequence
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
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

PLC program
design and
adjustment
s
PLC subroutine library
The purpose of the PLC subroutine library. System resource
In order to simplify PLC design, refined PLC functions which have

generality, such as initialization, machine panel signal processing, abrupt resource
stop processing, shaft enable control, hard limit, reference point etc. Input I0.0 to I2.7 (24 inputs of CNC) I3.0 to
Producers only need to add the needed subroutines module to main I8.7 (48 allocated input)
procedure, plus other under action procedures, then you can complete Output Q0.0 to Q1.7 (24 outputs of CNC)
PLC procedure design very quickly. Q2.0 to Q5.7 (48 allocated output)
RAM M0.0 to M255.7 (256 bytes)
Composition of PLC subroutine library. 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
PLC project file：SAMPLE_TURN.PTP（application program as
(128 user alarms)
examples for turning machine） Timer T0 to T15 (100ms timer) T16 to T32
(10ms timer)
PLC project file：SAMPLE_MILL.PTP （ application program as counter C0 to C63 (64 counters)
examples for milling machine） 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
Through these application programs as examples, you can MD14514(8) DB4500.DBD2028 (8 double)
!
clearly realize how to create or invoke PLC subroutines. You Programming Subroutine (64) SBR0 to SBR63 (64 subroutines)
can reorganize PLC subroutines or modify some networks to tool resource Symbol table (32) SYM1 to SYM32 (32 symbol tables)
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
library’s functions.

PLC program
design and
adjustment
s
A constant definition All the addresses in PLC subroutine library are programmed by symbols.
All the signals of interfaces are named by symbols and arranged in
Constant input symbol address 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
Zero output definition
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
…... …... …...

PLC program
design and
adjustment
s
A constant definition. SBR 39 HANDWHL Hand wheel selection in HMI

SBR 40 AXES_CTL Axis control (feed axis and
When using the PLC sample subroutine or manual writing PLC program : spindle)
All the reference functions related to safety such as Emergency stop, and limit
switches. SBR 41 MINI_HHU HHU (hand held unit ) control
The operation function works：mode select, manual control, rate set.
SBR 42 SPINDLE Spindle control
SBR 43 MEAS_JOG Measure in JOG
PLC sample subroutine offers adequate PLC functions for machine
tool. SBR 44 COOLING Coolant control
SBR 45 LUBRICATE Lubrication control
SBR 46 PI_SERVICE ASUP control
0 to 19 ... Saved for producers SBR 47 PLC_Select_PP PLC NC program selection via
SBR 20 AUX_MCP MT auxiliary function PLC
SBR 21 AUX_LAMP Working lamp SBR 48 ServPlan Service planner
SBR 22 AUX_SAFE_DOOR Safety door SBR 49 GearChg1_Auto Automatic gear change
SBR 23 AUX_CHIP Chip remover
SBR 50 GearChg2_Virtual Gear change (virtual)
SBR 31 PLC_ini_USER_ini Initialize for PLC user data
(called in SBR 32) SBR 54 TOOL_DIR Tool change direction control
SBR 32 PLC_INI PLC initialize SBR 58 MM_MAIN Manual machine related
SBR 33 EMG_STOP Emergency stop SBR 59 MM_MCP_808D Manual machine related
SBR 37 MCP_NCK Signal transfer from MCP &
SBR 63 TOGGLE Toggle switch control
HMI to the NCK interface
SBR 38 MCP_Tool_Nr Tool number display on MCP 34-36/57/61/62 … Reserve for OEM

PLC program
design and
adjustment
s
PLC subroutine library PLC alarm
PLC sample subroutine also offers adequate lathe functions. Diagnosing of the machine is important.
Complete diagnosis of the external electrics can help users understand the
For turning only cause and the location of breakdown immediately.
SBR 51 Turret1_HED_T HED turret control
L 380 VAC
SBR 52 Turret2_BIN_T Bi-direction changeable 24 VDC
turret (binary coded)
SBR 53 Turret3_CODE_T Bi-direction changeable
Digital output
turret (coded by turret sup-
plier)
SBR 55 Tail_stock_T Tailstock control KA1 KM1
SBR 56 Lock_unlock_T Chuck control
PLC sample subroutine can realize adequate milling functions. N

M
Cooling
For milling only pump motor
Digital input
SBR 60 Disk_MGZ_M Disk magazine control (w/o
automatic tool changer)
Protective door lock
For detail information please refer to:- Cooling motor thermal protection
PLC Subroutines manual Page 35 Cooling liquid level detection
Normal condition Cooling pipe pressure test
I/O interface has no output

signal, check hardware
connection Contactor KM1 works
unusually, check components
Relay KA1 Works unusually, hardware connection and
check component: hardware power supply

PLC program
design and
adjustment
s
PLC alarm
System provides users with 128 PLC user alarms. Every user alarm has Conditions of alarm cancel/reset.
a corresponding NCK address bit:DB1600.DBX0.0 ~ DB1600.DBX15.7 power-on clear ： after the cancel of alarm, you need to re-power it on
The address bit ”1” can activate the corresponding alarm, reset “0” can cancel key or ： after the cancel of alarm, you need to use the
cancel the alarm. cancel key or reset key, then the alarm will be cancelled .
After the cancel of alarm, the alarm displayed will disappear by itself.
In PLC cross reference，you can find the reason for the PLC alarm
through looking up reference addresses to make corresponding
Alarm reaction.
modification.
React by two ways after alarm
PLC reaction：the PLC program detects the reaction through the
corresponding PLC interface, such as cancel the axis-enable when giving
Alarm Alarm attrib- Alarm an alarm.
PLC signal PLC alarm variable
number ute setup text NC reaction：every alarm has a 8 configuration MD14516[0]~ [127].you
700000 DB1600.DBX0.0 DB16000.DBD1000 MD14516[0] can set a cancelation condition and alarm reaction of every alarm
according to current condition. The system makes corresponding reaction
…… …... …... …... …... when the alarm begins.
Driver is
700016 DB1600.DBX2.0 DB16000.DBD1064 MD14516[16]
not ready
Coolant
700018 DB1600.DBX2.2 DB16000.DBD1072 MD14516[17] motor MD14516[n]
overload alarm
…… …... …... …... …... NC start inhibit

bit 7 6 5 4 3 2 1 0
User
DB1600.DBX15. MD14516 Read-in disable
700127 DB16000.DBD1508 alarm
7 [127]
127 Power off/on
Feed disable
Reset or cancel key
Emergency
PLC stop
Alarm reset /cancel condition

PLC program
design and
adjustment
s
PLC alarm
Alarm text. Edit PLC user alarm by USB.
Create or edit alarm text correctly and reasonably can make users clearly Press button +
realize and understand the reason of PLC alarm then locate and resolve a
breakdown. Press SK
Curser over HMI
Press SK
1. Choose text “PLC alarm text（alcu.txt）

2. Then press vertical soft key “copy”,
3. Press horizontal soft key“USB” and press vertical soft key “paste”.
1. edit PLC user alarm using USB
2. edit PLC user alarm using HMI

PLC program
design and
adjustment
s
PLC alarm
Edit PLC user alarm by USB. Find alarm number which needs to be edited and input your own text.
Save and close file after editing alarm text.

Connect USB storage medium with PC USB, find PLC alarm text which is
downloaded. And open it by WordPad. Remove USB storage from PC and connect it with USB interface on the
front panel of PPU again.
Copy “PLC alarm text（alcu.txt)” which is copied back in to “HMI statis-

tic”.
In <system>operation area，press soft key “PLC” > “edit PLC alarm

text”. You can check the result of edit.

PLC program
design and
adjustment
s
PLC alarm PLC online diagnosis
Edit PLC user alarm by HMI. Check the condition of PLC using “PLC program” and decide logical error
or external electrical error online.
Create PLC alarm text directly in 808D Advanced system. Press button +
Press button + Press SK
Press SK Press SK
Press SK Symbol display/ Display the Alter the program

address condition of “can displayed in the
Move the cursor to choose the alarm number which needs to be edited displaying close” window
and go into the condition of alarm text edit.
Press SK
Find appointed
target in the
Change alarm text.
display program
Input alarm text in Chinese, combination key ALT+S, will give you Chinese
input characters.
On state
Display another
program in
Press SK window 2
PLC program
design and
adjustment
s
PLC online diagnosis
Check the PLC operating status and data. Check the condition of PLC using “PLC status display” and decide logical
error or external electrical error online.
Press button + Press button +

Press SK Press SK
Press SK Press SK
Press SK Press SK
Running state Operand address Value
PLC program
information
PLC style and

versions
PLC scan period
PLC running time

PLC program
design and
adjustment
s
Check the status of hardware connection through examining the state of Check the condition of hardware connection through examining the status
input value. of input point.
Press button +
Press SK
Press SK
Press SK
Check if there is any errors of the connection in the input value according
to the PLC status display screen.
Move the cursor to the operand Set the condition of output point,
which needs modification and press confirm by pressing
“Change”
Check electrical level of the output point If the output is forced, and the signal of
(whether the relay is in absorption), interface is used in PLC program, its
check if there is any error in the connec- state will be refreshed by the PLC
tion of the output point. program.

PLC program
design and
adjustment
s
Observe the condition of PLC , judge logical error quickly or external Check the condition of PLC , judge logical error quickly or external elec-
electrical error through displaying PLC program online. trical error through displaying PLC program online.
Press button + Press button +
Press SK Press SK
Press SK Press SK
Press SK Press SK
Amend operand address

accurately and confirm by soft Look for the target address in cross-reference table
key.
Display conditions of inputs,

outputs, auxiliary relay, and the
signal of interface by listing.
The target address can be displayed and show whether signals of I/O or
interfaces are used or not and which subroutine and network they are
used in.

s
Notes

Everything ever wanted to know about SINUMERIK 808D:
www.automation.siemens.com/mcms/m2/en/automation-systems/cnc-sinumerik/sinumerik-controls/sinumerik-
808/Pages/sinumerik-808.aspx
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 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 WÜ/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.

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Sinumerik 808D ADVANCED Commissioning Guide

Commissioning Guide Page 2 808D ADVANCED Turning and Milling

Then press the “Extension” button

This will enter into the system area.（see picture 1） Picture 3

808D ADVANCED Turning and Milling Page 3 Commissioning Guide

Commissioning Guide Page 4 808D ADVANCED Turning and Milling

808D ADVANCED Turning and Milling Page 5 Commissioning Guide

Commissioning Guide Page 6 808D ADVANCED Turning and Milling

Basic Commissioning procedure for prototype machines using the

Delivery Go to page 8 Go to page 32

ToolBox Cabinet Go to page 50

Step 6 Licences Go to page 31

808D ADVANCED Turning and Milling Page 7 Commissioning Guide

Delivery check Step 1 Mounting dimensions Step 2

Motor Motor Motor

Commissioning Guide Page 8 808D ADVANCED Turning and Milling

Mounting dimensions Step 2

808D ADVANCED Turning and Milling Page 9 Commissioning Guide

Mounting dimensions Step 2

Commissioning Guide Page 10 808D ADVANCED Turning and Milling

Line filter (optional)

Protects the network from

Emergency stop button

SINAMICS V70 SINAMICS V70 SINAMICS V70

Connections not necessarily

For further information refer to :-

Commissioning Guide Page 12 808D ADVANCED Turning and Milling

PPU back Legend Interface Comment

808D ADVANCED Turning and Milling Page 13 Commissioning Guide

MCP back Selection of 24V DC supply

These 4 aspects should be considered during selection of 24V DC supply

Commissioning Guide Page 14 808D ADVANCED Turning and Milling

808D ADVANCED Turning and Milling Page 15 Commissioning Guide

2 Ref Y 2 Working lamp

Commissioning Guide Page 16 808D ADVANCED Turning and Milling

Pin assignment of X301,X302

Turning Illustration shows the connection

X301 Distributed I/O

11 - Handheld unit: axis X selected X100

Commissioning Guide Page 18 808D ADVANCED Turning and Milling

Unipolar connection Bipolar connection 3AC 380V

SINUMERIK 808D SINUMERIK 808D

808D ADVANCED Turning and Milling Page 19 Commissioning Guide

Commissioning Guide Page 20 808D ADVANCED Turning and Milling

808D ADVANCED 808D ADVANCED

Stop button (non safe)

V70 V70 V70 V70

Software included in the toolbox:

 AMM (Data transfer, commissioning tool)

Use the “setup.exe” In some cases, an extra language has to be selected.

Double-click the “Setup.exe”

Commissioning Guide Page 22 808D ADVANCED Turning and Milling

For further information refer to :-

808D ADVANCED Turning and Milling Page 23 Commissioning Guide

A connection must be made so that the PLC programming tool can

For further information refer to :-

Click the Communications

Activate the PLC connection setting in 808D (password set to “sunrise”)

Press “Serv. Displ.” SK

Commissioning Guide Page 24 808D ADVANCED Turning and Milling

Press “Service control” SK Enter the “direct connect” IP address

The connection is now established, this is shown by a green box.

Press “Direct connect.” SK