Sinumerik 828d ошибка 700018

4.1.6

Alarm description

The motor of the cooling system is overloaded. The coolant function cannot be used normally, and the control system issues

an alarm.

PLC information

PLC address: DB1600.DBX2.2

Subroutine: COOLING (SBR 44)

Remedy

● Check whether the overload protection switch of the cooling motor works.

● Check the interface X102 on the back of the PPU for the following:

–

Whether the connection of pin 7 is loose/broken

–

Whether pin 10 is connected to 0 V properly

4.1.7

Alarm 700021

Alarm description

This alarm appears because the lubricating oil level in the oil box is lower than the minimum set value. It may cause

mechanical damage if no remedies are taken in time.

PLC information

PLC address: DB1600.DBX2.5

Subroutine: LUBRICAT (SBR 45)

Remedy

● Check whether the lubricating oil level is too low and add lubricating oil in time.

● Check the relevant interfaces on the back of the PPU for the following:

–

Whether the input terminals are damaged/loose

–

Whether pin 10 is connected to 0 V properly

4.1.8

Alarm 700029

Alarm description

It is not a fault but a reminder that the first service plan preset on the control system is approaching.

PLC information

PLC address: DB1600.DBX3.5

Subroutine: PI_SERVICE (SBR 46)

34

Service Manual

01/2017

Legal information

Warning notice system

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.

DANGER

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

WARNING

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

CAUTION

indicates that minor personal injury can result if proper precautions are not taken.

NOTICE

indicates that property damage can result if proper precautions are not taken.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

Qualified Personnel

The product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.

Proper use of Siemens products

Note the following:

WARNING

Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks

All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of Liability

We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AG	Order number: 6FC5397-4EP10-0BA0	Copyright © Siemens AG 2012.
Industry Sector	01/2015 Subject to change	All rights reserved
Postfach 48 48
90026 NÜRNBERG
GERMANY

Table of contents

1	Delivery check ………………………………………………………………………………………………………………………….	7
2	Mounting………………………………………………………………………………………………………………………………..		11
	2.1	Mounting the controller ……………………………………………………………………………………………..	11
	2.2	Mounting the drive ……………………………………………………………………………………………………	13
	2.3	Mounting the motor…………………………………………………………………………………………………..	16
3	Connecting …………………………………………………………………………………………………………………………….		17
	3.1	Interface overview…………………………………………………………………………………………………….	17
	3.2	Connecting the battery………………………………………………………………………………………………	19
	3.3	Connecting according to the default PLC program………………………………………………………..	20
	3.4	Connection Overview………………………………………………………………………………………………..	25
4	Switching on and preparing for commissioning…………………………………………………………………………….	27
	4.1	Switching on controller………………………………………………………………………………………………	27
	4.2	PPU keyboard function ……………………………………………………………………………………………..	28
	4.3	MCP mode changeover …………………………………………………………………………………………….	29
	4.4	Status LEDs …………………………………………………………………………………………………………….	30
	4.5	Password ………………………………………………………………………………………………………………..	31
	4.5.1	Access levels …………………………………………………………………………………………………………..	31
	4.5.2	Setting a password …………………………………………………………………………………………………..	33
	4.6	Setting the date and time…………………………………………………………………………………………..	34
	4.7	Introduction to the onboard assistants…………………………………………………………………………	35
5	Commissioning diagram …………………………………………………………………………………………………………..	37
6	Default PLC applications ………………………………………………………………………………………………………….	39
	6.1	Turning……………………………………………………………………………………………………………………	39
	6.2	Milling……………………………………………………………………………………………………………………..	43
	6.3	PLC user alarms ………………………………………………………………………………………………………	46
	6.3.1	General information ………………………………………………………………………………………………….	46
	6.3.2	Alarm properties……………………………………………………………………………………………………….	46
	6.3.3	Activating the PLC user alarms ………………………………………………………………………………….	48
	6.3.4	Editing a PLC user alarm text …………………………………………………………………………………….	50
7	Commissioning the prototype ……………………………………………………………………………………………………	55
	7.1	Commissioning the controller …………………………………………………………………………………….	55
	7.1.1	Entering machine data………………………………………………………………………………………………	55
	7.1.2	Setting the axis-relevant parameters …………………………………………………………………………..	56
	7.1.2.1	Enabling the position control………………………………………………………………………………………	56
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Table of contents

Table of contents

A.6.2.5	Display data list………………………………………………………………………………………………………	102
A.7	PLC user interfaces ………………………………………………………………………………………………..	104
A.7.1	Addressing ranges………………………………………………………………………………………………….	104
A.7.2	MCP ……………………………………………………………………………………………………………………..	106
A.7.2.1	Signals from MCP…………………………………………………………………………………………………..	106
A.7.2.2	Signals to MCP ………………………………………………………………………………………………………	106
A.7.2.3	Reading/writing NC data: Job …………………………………………………………………………………..	107
A.7.2.4	Reading/writing NC data: Result……………………………………………………………………………….	107
A.7.2.5	PI service: Job ……………………………………………………………………………………………………….	107
A.7.2.6	PI service: Result……………………………………………………………………………………………………	108
A.7.3	Retentative data area ……………………………………………………………………………………………..	108
A.7.4	User Alarms …………………………………………………………………………………………………………..	108
A.7.4.1	User alarms: Activating……………………………………………………………………………………………	108
A.7.4.2	Variables for user alarms…………………………………………………………………………………………	108
A.7.4.3	Active alarm response …………………………………………………………………………………………….	109
A.7.4.4	Acknowledgement of alarms…………………………………………………………………………………….	109
A.7.5	Axis/spindle signals…………………………………………………………………………………………………	109
A.7.5.1	Transferred M and S functions, axis specific………………………………………………………………	109
A.7.5.2	Signals to axis/spindle …………………………………………………………………………………………….	109
A.7.5.3	Signals from axis/spindle …………………………………………………………………………………………	111
A.7.6	PLC machine data ………………………………………………………………………………………………….	114
A.7.6.1	INT values (MD 14510 USER_DATA_INT) ………………………………………………………………..	114
A.7.6.2	HEX values (MD 14512 USER_DATA_HEX) ……………………………………………………………..	114
A.7.6.3	FLOAT values (MD 14514 USER_DATA_FLOAT)………………………………………………………	114
A.7.6.4	User alarm: Configuring (MD 14516 USER_DATA_PLC_ALARM) ………………………………..	114
A.7.7	Signals from/to HMI ………………………………………………………………………………………………..	115
A.7.7.1	Program control signals from the HMI (retentive area) (also refer to signals at channel
	DB3200)………………………………………………………………………………………………………………..	115
A.7.7.2	Program selection from PLC (retentive area) ……………………………………………………………..	115
A.7.7.3	Checkback signal: Program selection from HMI (retentive area) …………………………………..	115
A.7.7.4	Signals from HMI ……………………………………………………………………………………………………	116
A.7.7.5	Signals from PLC……………………………………………………………………………………………………	116
A.7.7.6	Signals to maintenance planners………………………………………………………………………………	116
A.7.7.7	Signals from maintenance planners ………………………………………………………………………….	117
A.7.7.8	Signals from operator panel (retentive area) ………………………………………………………………	117
A.7.7.9	General selection/status signals from HMI (retentive area)…………………………………………..	117
A.7.7.10	General selection/status signals to HMI (retentive area)………………………………………………	118
A.7.8	Auxiliary functions transfer from NC channel ……………………………………………………………..	118
A.7.8.1	Overview ……………………………………………………………………………………………………………….	118
A.7.8.2	Decoded M signals (M0 to M99)……………………………………………………………………………….	119
A.7.8.3	Transferred T functions……………………………………………………………………………………………	119
A.7.8.4	Transferred M functions…………………………………………………………………………………………..	119
A.7.8.5	Transferred S functions …………………………………………………………………………………………..	120
A.7.8.6	Transferred D functions …………………………………………………………………………………………..	120
A.7.8.7	Transferred H functions …………………………………………………………………………………………..	120
A.7.9	NCK signals …………………………………………………………………………………………………………..	120
A.7.9.1	General signals to NCK …………………………………………………………………………………………..	120
A.7.9.2	General signals from NCK ……………………………………………………………………………………….	121
A.7.9.3	Signals at fast inputs and outputs……………………………………………………………………………..	121
A.7.9.4	Signals from fast inputs and outputs………………………………………………………………………….	122
A.7.10	Channel signals ……………………………………………………………………………………………………..	123
A.7.10.1	Signals to NC channel …………………………………………………………………………………………….	123
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Table of contents

System overview

The SINUMERIK 808D is an economic CNC solution for milling and turning machines in the global market. For the turning variant, it is designed to control three axes, including two feed axes via two pulse drive interfaces (with SINAMICS V60) and one spindle via one analog spindle interface. For the milling variant, it is designed to control four axes, including three feed axes via three pulse drive interfaces (with SINAMICS V60) and one spindle via one analog spindle interface.

The following diagram shows a system configuration example for the SINUMERIK 808D control system:

Figure 1-1 SINUMERIK 808D control system overview (taking a milling machine for an example)

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Delivery check

Delivery check

Check list

Table 1- 1	PPU package
Component		Quantity (pieces)
Panel Processing Unit (PPU)	1
Mounting clamps with screws	8
Connectors		• I/O connectors: 7
		• 24 V power input connector: 1
Table 1- 2 MCP package
Component				Quantity (pieces)
Machine Control Panel (MCP)			1
MCP connection cable (for connecting the MCP to the PPU, max. 50 cm)	1
Mounting clamps with screws			6
Pre-printed MCP strip, Milling			1 set of 6 pieces
Blank strip paper, A4 size			1
Product Information for MCP			1
Table 1- 3 CNC accessories
Component			Quantity (pieces)
Setpoint cable to SINAMICS V60 (for feed axis)		2 (turning) or 3 (milling)
Setpoint cable to Siemens inverter or third-party drive (for spindle)	1

Note

Emergency stop button is not included in our scope of delivery. You can, if necessary, contact your local Siemens salesperson for it.

	Table 1- 4	SINAMICS V60 package
	Component		Quantity (pieces)
	SINAMICS V60	1
	Getting Started	1
	Cable clamps	2
	Warranty Card	1
	Table 1- 5	1FL5 motor package
	Component		Quantity (pieces)
	1FL5 motor		1
	Data sheet for 1FL5 motor	1
	Table 1- 6 Cables individually packaged
	Component		Quantity (pieces)
	Motor cable (unshielded)	1
	Brake cable (unshielded)	1
	Encoder cable (shielded)	1
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Delivery check

2.1Mounting the controller

Cut-out dimensions

Figure 2-1 Cut-out dimensions (in mm)

Note

Make sure there is enough space around the PPU and the MCP for tightening the screws in the control cabinet.

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Mounting

2.1 Mounting the controller

Mounting dimensions

Figure 2-2 Mounting dimensions for PPU (in mm)

Figure 2-3 Mounting dimensions for MCP (in mm)

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Mounting

2.2 Mounting the drive

Mounting clearance (in mm)

To ensure easy maintenance purpose, you must provide sufficient clearance (recommended distance: 80 mm) between the maintenance door and the cabinet wall for replacing the battery and CF card:

Cabinet panel

Maintenance door

2.2Mounting the drive

Cut-outs and mounting dimensions

Figure 2-4 4/6/7 A version (in mm)

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Mounting

2.2 Mounting the drive

Figure 2-5 10 A version (in mm)

Mounting method

With 4xM5 preassembled screws, the drive can be mounted vertically onto the inner panel of the cabinet. The maximum screw torque must be 2.0 Nm.

Minimum mounting clearance

To ensure adequate cooling, as a minimum, maintain the specified clearance between drives, one drive and another device/inner panel of the cabinet.

Figure 2-6 Drive mounting clearance (in mm)

Using the cable clamps supplied

If the CE marking requirements for cables are mandatory, the line supply cable and the motor cable used must all be shielded cables. In this case, you can use the cable clamps as a ground connection between the cable shield and a common ground point.

Clamps can also be helpful in better fixing cables (the unshielded motor cable and the line supply cable) in place.

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Mounting

2.2 Mounting the drive

The illustration below shows you how to use the clamps to fix both cables and to make a shield connection with the cable.

Figure 2-7 Cable fixing with two cable clamps

CAUTION

Make sure that the clamp for fixing the shielded motor cable has a good contact with the cable shield.

Note

Siemens does not provide the shielded motor cable. Please prepare the shielded motor cable by yourselves for CE certification.

After the installation, it is recommended that the terminal screws should be checked to ensure that they are tight.

Reference

For further information about the drive mounting, refer to SINAMICS V60 Getting Started.

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Mounting

2.3 Mounting the motor

2.3Mounting the motor

Mounting dimensions (mm)

Motor type	A (in mm)	B (in mm)
4 Nm	163 (205)	80
6 Nm	181 (223)	90
7.7 Nm	195 (237)	112
10 Nm	219 (261)	136

Note

Value in brackets is the length of a motor with a built-in brake unit.

Motors with plain shaft have the same dimensions.

Reference

For further information about the motor, refer to 1FL5 Motor Technical Data.

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3.1Interface overview

Interface overview on the Panel Processing Unit (PPU)

NOTICE

The + 24 V and M signals of X200 must be connected; otherwise, the communication between the PPU and the drives does not function as it should.

Figure 3-1 Interface layout

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Connecting

3.2 Connecting the battery

Legend	Interface	Comment
Rear
	X100, X101, X102	Digital inputs
	X200, X201	Digital outputs
	X21	FAST I/O
	X301, X302	Distributed I/O
	X10	Hand-wheel inputs
	X60	Spindle encoder interface
	X54	Analog spindle interface
	X2	RS232 interface
	X51, X52, X53	Pulse drive interfaces
	X30	USB interface, for connection with the MCP
	X1	Power supply interface, +24V DC power supply
	—	Battery interface
	—	Slot for the System CompactFlash Card (CF card)
Front
	—	USB interface

Interface overview on the Machine Control Panel (MCP)

Figure 3-2 Interface layout

Legend	Interface	Comment
Rear
	X10	USB interface, for connection with the PPU

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Connecting

3.2 Connecting the battery

3.2Connecting the battery

A battery has been pre-assembled on the back cover of the PPU.

The battery is not connected when delivered. You must plug the battery connector into the battery interface by yourself before switching the controller on. You can access it after removing the maintenance door:

	Maintenance door		Battery interface
	Battery		Battery connector

Note

When connecting the battery, ensure that the groove is at the upper side; otherwise, the alarm «NCK battery alarm» will be output after you switch on the controller, and you could lose your data after an unexpected power failure if you do not insert the battery connector correctly.

Note

Battery

Life time: 3 years

Replacement: do not replace the battery when the controller is switched off; otherwise, your data can be lost.

Order number: 6FC5247-0AA18-0AA0.

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Connecting

3.3 Connecting according to the default PLC program

3.3Connecting according to the default PLC program

The SINUMERIK 808D has integrated with a default PLC application. If you perform the commissioning work with the default PLC application, perform wiring as follows.

Connecting the digital inputs and outputs

Figure 3-3 Connecting the digital inputs and outputs (Milling)

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Connecting

3.3 Connecting according to the default PLC program

Figure 3-4 Connecting the digital inputs and outputs (Turning)

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Connecting

3.3 Connecting according to the default PLC program

Connecting the distributed I/O

Figure 3-5 Connecting the distributed I/O

Connecting the SINAMICS V60 (take X51: axis X for an example)

Figure 3-6 Connecting the SINAMICS V60 (X51: axis X)

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Connecting

3.3 Connecting according to the default PLC program

Note

Filter

A line filter (rated current: 16 A, protection level: IP20) is required so that the system can pass the CE certification (radiated emission test or conducted emission test). The order number of Siemens recommended filter is 6SN1111-0AA01-1BA1.

Note

Circuit breaker

You can install a mains linear breaker (rated current: 15 A for 7 A or 10 A version of the drive and 10 A for 4 A or 6 A version of the drive; rated voltage: 250 VAC) to protect the system.

Connecting the inverter or the servo spindle drive

Figure 3-7 Connecting the inverter or the servo spindle drive (unipolar)

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Connecting

3.3 Connecting according to the default PLC program

Figure 3-8 Connecting the inverter or the servo spindle drive (bipolar)

Note

Cables for connecting X21 must be shielded ones.

Connecting the handwheel

Figure 3-9 Connecting the handwheel

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Connecting

3.4 Connection Overview

3.4Connection Overview

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Connecting

3.4 Connection Overview

Note

For the turning variant, connection to X52 is optional and depends upon whether you use the software option «additional axis». If you desire to configure the control system to control a rotary axis or an additional linear axis, connect X52 to a SINAMICS V60 which connects to a servo motor.

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Switching on and preparing for commissioning

4

DANGER

Carrying out of repairs

Anywhere in the automation equipment where faults might cause physical injury or major material damage, in other words, where faults could be dangerous, additional external precautions must be taken, or facilities must be provided, that guarantee or enforce a safe operational state, even when there is a fault (e.g. using an independent limit value switch, mechanical locking mechanisms, EMERGENCY STOP/EMERGENCY OFF devices).

4.1Switching on controller

Before switching on

Make sure that:

●You have finished the mechanical installation of the whole system based on the information included in the chapter «Mounting (Page 11)» or the Mechanical Installation Manual.

●You have completed the wirings of the whole system according to the information included in the chapter «Connecting (Page 17)» (if you use the default PLC program) or the Electrical Installation Manual.

Switching on

Do as follows:

1.Power on the mains supply.

2.When the NC enters the main screen, check the NC normal status according to the status LEDs on the PPU.

POK: green RDY: green TEMP: unlit

For detailed information about the status LEDs, refer to the section «Status LEDs (Page 30)».

3.Check the drive normal status:

–«S-run» is displayed.

–LED «RDY/JOG»: green

–LED «ERR»: dark

For detailed information about the SINAMICS V60 drives, refer to the SINAMICS V60 Getting Started.

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Switching on and preparing for commissioning

4.2 PPU keyboard function

4.2PPU keyboard function

Legend	Name	Description
	Return key	Returns to higher level menu
	Horizontal softkeys	Call corresponding menu functions
	Extension key	Reserved. No function
	Vertical softkeys	Call corresponding menu functions
	Operating area keys		Opens the «MACHINE» operating area
			Opens the «PROGRAM» operating area
			Opens the «OFFSET» operating area
			Opens the «PROGRAM MANAGER» operating area
			• Opens the «ALARM» operating area
			• Combines with the <SHIFT> key to open the
			«SYSTEM» area
			Opens the «CUSTOM» operating area

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Switching on and preparing for commissioning

4.3 MCP mode changeover

4.3MCP mode changeover

Use the machine control panel (MCP) to make changeover between the JOG mode, the Ref Point mode, the AUTO mode and the MDA mode.

The MCP key layout is shown below:

Legend	Name	Description
	Mode navigation			Enters the Ref. Point mode for reference point approach
	keys
				Enters the JOG mode (manual operation)
				Enters the AUTO mode (automatic operation)
				Enters the MDA mode (manual program input and auto-
				matic execution)
	Incremental feed			Axis traverses at the increment of 1
	keys
				Axis traverses at the increment of 10
				Axis traverses at the increment of 100
	Axis traversing keys	Move an axis (X, Y, Z)
	RESET key	•	Resets NC programs
		•	Cancels alarms

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Switching on and preparing for commissioning

4.4 Status LEDs

4.4Status LEDs

LEDs on the PPU

The following LEDs are installed on the SINUMERIK 808D PPU.

The individual LEDs and their functions are described in the table below.

Table 4- 1 Status and error displays

LED	Color	Significance
POK	Green	Power supply is OK.
RDY	Green	Ready for operation
TEMP	Yellow	Temperature exceeds the limit

For more information, refer to error description in the SINUMERIK 808D Diagnostics Manual.

LEDs on the SINAMICS V60 drives

Figure 4-1 SINAMICS V60 status LEDs

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Switching on and preparing for commissioning

4.5 Password

Table 4- 2 Description of the LED status

Status LED 1	Status LED 2	Description	7-segment LED display description
RDY/JOG	ERR
Green LED	Red LED
Dark	Dark	No 24 V DC Input/Drive Defect	Dark
Dark	Flashing at 1 Hz	Drive not ready	Current status
Green	Dark	Drive ready	Depends on the current menu opera-
			tion
Dark	Red	Drvie error	Alarm code
Green	Red	Initialization	Display «8.8.8.8.8.8.»
Flashing at 1 Hz	Dark	JOG mode	Display «J-run»

4.5Password

4.5.1Access levels

Purpose

Access levels/passwords are necessary to prevent system data damages caused by unexpected mistake operations.

Cases

You must set a password for an access level under following cases:

●Data restoring

●Software update

●Password has been deleted

●A higher or lower access level is required

Access levels

The SINUMERIK 808D provides a concept of access levels for enabling data areas. You can view such information from the table below:

Table 4- 3 Access level

	Access level	Default password	Target group
	Manufacturer	SUNRISE	OEMs
	Customer	CUSTOMER	End users
	No password	—	—
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Switching on and preparing for commissioning

4.5 Password

With the access level «Manufacturer», you can perform the following operations:

●Inputting or modifying all the machine data

●Commissioning work

With the access level «Customer», you can perform the following operations:

●Inputting or modifying part of the machine data

●Programming

●Setting offsets

●Measuring tools

For the function areas listed below, the input and modification of data depends on the protection level you have set:

●Tool offsets

●Work offsets

●Setting data

●RS232 settings

●Program creation / program correction

You can set the protection levels for these function areas via the display machine data (USER_CLASS…): «SYSTEM» operating area > «Mach. data» > «Expert list» > «Display MD».

Note

For detailed information about the display machine data, refer to the Parameter Manual.

Note

For detailed information about how to set the access levels, refer to Programming and Operating Manual.

Access levels: Manufacturer, Customer

Both access levels require a password.

You can change the password only after being activated with the access level «Manufacturer».

If you forget your password, you can carry out an NC start-up: «SYSTEM» operating area > «Start-up» > «NC» > «Power-up with default data». This will reset all passwords to their defaults according to the software release you have acquired.

Note

Before performing a start-up with default data, you must backup your data; otherwise, you will lose your data. For detailed information about how to do data backup, refer to section «Data backup (Page 75)».

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Switching on and preparing for commissioning

4.5 Password

Access level: No password

If you have deleted your password or do not set a password, you only have the access right of viewing above-mentioned function areas.

Note

The system has no password by default.

4.5.2Setting a password

The control system is delivered without a password. You must input the password of «SUNRISE» to perform the commissioning work.

Perform the following steps to input the password:

1.In the «SYSTEM» operating area (key combination: + ), press the vertical softkey «Set password». The message text at the bottom of the screen shows «No password set»:

2.Enter «SUNRISE» and press the «Accept» softkey.

3.The message text now shows «Access level: Manufacturer», which indicates that you have successfully set the password.

Note

You can change the default password to you by using the «Change password» softkey.

You can also delete the current password to protect your settings by pressing the «Delete password» softkey.

After the series production, you must press the «Delete password» softkey to exit the «Manufacturer» access level.

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Commissioning Manual, 12/2014, 6FC5397-4EP10-0BA0	33

Switching on and preparing for commissioning

4.6 Setting the date and time

4.6Setting the date and time

At delivery, the system date and time remain at the factory settings, and thus you must manually modify the date and time. Proceed as follows to set the date and time:

1.Press + to enter the «SYSTEM» operating area, then press the softkey «Date time».

2. Input your date and time.

3. Press the «OK» softkey to confirm your settings.

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34	Commissioning Manual, 12/2014, 6FC5397-4EP10-0BA0

Switching on and preparing for commissioning

4.7 Introduction to the onboard assistants

4.7Introduction to the onboard assistants

The SINUMERIK 808D system software has three onboard assistants:

●Startup assistant (requires «Manufacturer» access level)

This on-board assistant is designed to help you commission the prototype. With this assistant, you can complete basic machine tool functions.

●Series assistant (requires «Manufacturer» access level)

This on-board assistant is designed to help you correctly finish the series machine commissioning.

●Operation assistant (requires «Customer» access level)

This onboard assistant is designed to help you learn about the basic operations of the machining process.

Where can I find the assistants?

Press the <MENU FUNCTION> key on the PPU to call the assistants:

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Switching on and preparing for commissioning

4.7 Introduction to the onboard assistants

How can I use the assistants?

Status indicators:

Completed task

Current task

Partially completed task group

Uncompleted task

Press one of the three softkeys to access the corresponding assistant

Press to start the assistant

Press to return to the main screen of the onboard assistants

Press any operating area key (CUSTOM excluded) to exit the main screen of the onboard assistants and enter the corresponding operating area

Press to enter the current task or a task that is prior to the current task

Note: This softkey becomes active when you move the cursor key to a valid task.

	Commissioning Manual
36	Commissioning Manual, 12/2014, 6FC5397-4EP10-0BA0

Commissioning diagram

5

You can commission the SINUMERIK 808D in two ways:

●Alternative 1: with the onboard assistants

●Alternative 2: without the onboard assistants

When commissioning with the onboard assistants, just follow the assistants step by step.

In this manual, only the second way is described. To do the commissioning work without the onboard assistants, proceed as follows:

Commissioning Manual
Commissioning Manual, 12/2014, 6FC5397-4EP10-0BA0	37

Commissioning diagram

Default PLC applications

6

6.1Turning

Overview of the PLC subroutines

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

6.1 Turning

Definition of user-defined keys on the MCP

User-defined key 1	Working lamp
User-defined key 2	Manual cooling
User-defined key 3	Manual tool change
User-defined key 4	Manual chuck clamping and unclamping
User-defined key 5	Chuck clamping internally/externally
User-defined key 6	Tailstock

Structure of the sample application (OB1)

Call Conditions		Subroutine Name	Description
First scan (SM0.1)			PLC_INI (SBR32)		PLC initialization
Each scan (SM0.0)		EMG_STOP (SBR33)	Emergency Stop control
Each scan (SM0.0)		MCP_NCK (SBR37)	Transferring MCP and HMI signals to the NCK interface
Each scan (SM0.0)		HANDWHL (SBR39)	Selecting a hand wheel through the interface signal
							DB1900.DBB1xxx
Each scan (SM0.0)		AXIS_CTL (SBR40)	Coordinate enabling control, hardware limit, etc.
Each scan (SM0.0)		COOLING (SBR44)	Cooling control
Each scan (SM0.0)		TURRET1 (SBR46)	HALL effect device turret control
Each scan (SM0.0)		ServPlan (SBR48)		Maintenance plan example: first task
PLC user alarms
Alarm No.			Interface Address			Alarm Description	From SBR
700010		DB1600.DBX1.2		HHU is active	SBR41: MINI_HHU
700011		DB1600.DBX1.3		Not able to lock tool in expected time
700012		DB1600.DBX1.4		Spindle in braking progress	SBR42: SPINDLE
700013		DB1600.DBX1.5		Operation while chuck is not locked	SBR56: Lock_unlock_T
700014		DB1600.DBX1.6		Gear-change time out	SBR49: GearChg1_Auto
700015		DB1600.DBX1.7		Gear level position error
700016		DB1600.DBX2.0		Drives not ready	SBR33: EMG_STOP
700017		DB1600.DBX2.1		Operate chuck when spindle or part program is	SBR56: Lock_unlock_T
						running
700018		DB1600.DBX2.2		Cooling motor overload	SBR44: COOLING
700019		DB1600.DBX2.3		Coolant liquid position in low level
700020		DB1600.DBX2.4		Lubrication motor overload	SBR45: LUBRICAT
700021		DB1600.DBX2.5		Lubricant liquid position in low level
700022		DB1600.DBX2.6		Turret motor overload	SBR51: Turret1_HED_T
700023		DB1600.DBX2.7		Programmed tool number > max. turret on turret	SBR52: Turret2_BIN_T
						number		SBR53: Turret3_CODE_T
700024		DB1600.DBX3.0		Max. tool number setting error
700025		DB1600.DBX3.1		No position signals from turret
700026		DB1600.DBX3.2		Not able to find expected tool in monitor time
								Commissioning Manual
40							Commissioning Manual, 12/2014, 6FC5397-4EP10-0BA0

									Default PLC applications
									6.1 Turning
	Alarm No.	Interface Address			Alarm Description		From SBR
	700027	DB1600.DBX3.3		Approach reference point again after rotation		SBR40: AXIS_CTL
					monitoring
	700028	DB1600.DBX3.4		Tool is not locked		SBR53: Turret3_CODE_T
	700049	DB1600.DBX6.1		Reference point X-axis not reached		SBR58: MM_MAIN
	700050	DB1600.DBX6.2		Reference point Z-axis not reached		SBR58: MM_MAIN
	700051	DB1600.DBX6.3		Wrong spindle direction started		SBR58: MM_MAIN
	700052	DB1600.DBX6.4		Watchdog timer JOG-program		SBR58: MM_MAIN
	700053	DB1600.DBX6.5		Spindle override not 100%		SBR58: MM_MAIN
	700054	DB1600.DBX6.6		Spindle is not started		SBR58: MM_MAIN
	700055	DB1600.DBX6.7		Feed override = 0%		SBR58: MM_MAIN
	700056	DB1600.DBX7.0		Change of spindle direction not possible in		SBR58: MM_MAIN
					thread
	700059	DB1600.DBX7.3		Safe door not closed, NC start not possible		SBR22:
									AUX_SAFE_DOOR
	700060	DB1600.DBX7.4		Channel not in reset, change PRT not possible		SBR37: MCP_NCK
	Relevant machine data
	MD14510		Unit	Range		Function
	Machine data — Integer
	14510[12]		*	0 to 1		JOG key layout
	14510[20]		—	2 to 64		The maximum number of tool positions
	14510[21]		0.1s	5 to 30		Time for locking a turret
	14510[22]		0.1s	30 to 300		The monitoring time for searching a tool
	14510[24]		1 min	5 to 300		Lubrication interval
	14510[25]		0.01s	100 to 2,000	Lubrication duration

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Myp1cBel_ru

%_N_MYPLC_UK_COM

;$PATH=/_N_MB_DIR

700000
0 0 «Приводы станка не
готовы»

700001
0 0 «Выключился защитный
автомат двигателя гидравлики»

700002
0 0 «Выключился некоторый
защитный автомат асинхронных двигателей»

700003
0 0 «Ошибка смазки
направляющей нижнего суппорта
«

700004
0 0 «Ошибка смазки
направляющей задней бабки»

700005
0 0 «Ошибка смазки
направляющей верхнего суппорта»

700006
0 0 «Ошибка смазочной
константы 14510[0] <200-990>»

700007
0 0 «Количество смазочных
впрысков вне диапазона 14510[1]
<1-5>»

700008
0 0 «Ошибка смазки блоков
люнета»

700009
0 0 «Ошибка смазочной
константы 14510[4] <60 — 990>»

700010
0 0 «Перемена зажимного
режима при M3/M4»

700011
0 0 «Старт главного
шпинделя и деталь не зажата»

700013
0 0 «Ошибка положения
зажимного цилиндра патрона при M3/M4»

700014
0 0 «Ошибка давления
зажимного цилиндра патрона при M3/M4»

700020
0 0 «Ошибка положения
пиноли задней бабки при M3/M4»

700021
0 0 «Ошибка давления
пиноли задней бабки при M3/M4»

700022
0 0 «Задняя бабка в левом
лимитном положении»

700023
0 0 «M62/M63/M64 и пиноль
задней бабки не задвинута»

700024
0 0 «Временной контроль
за функцией M62/M63/M64»

700025
0 0 «M66 — а шпиндель
работает»

700027
0 0 «Временной контроль
функции M65 или M66»

700032
0 0 «Сжатая кнопка C-STOP»

700033
0 0 «Станок выключен»

700034
0 0 «Аварийные выключатели
шунтированы»

700035 0 0 «Аварийное положение оси +X»

700036 0 0 «Аварийное положение оси -X»

700037 0 0 «Аварийное положение оси +Z»

700038 0 0 «Аварийное положение оси -Z»

700039 0 0 «Аварийное положение оси +W»

700040 0 0 «Аварийное положение оси -W»

700041
0 0 «Приводы блокированы
открытым кожухом»

700042
0 0 «Низкий уровень
гидравлического масла»

700043
0 0 «Загрязненный фильтр
гидравлического масла»

700044
0 0 «Низкий уровень
смазочного масла»

700045
0 0 «Низкий уровень
смазочного масла блоков люнета»

700046
0 0 «CNC не готова»

700047 0 0 «Корпус люнета не выдвинут
относительно обрабатываемой детали»

700048
0 0 «Сухари люнета
несовершенно разжаты»

700049
0 0 «Низкое зажимное
давление люнета»

700050
0 0 «Зажимной цилиндр
патрона в крайнем положении»

700051
0 0 «Низкое давление в
зажимном цилиндре патрона»

700052
0 0 «Пиноль задней бабки
в левом лимитном положении»

700053
0 0 «Низкое давление
пиноли задней бабки»

700054
0 0 «Корпус задней бабки
в левом крайнем положении»

700055
0 0 «Пиноль не задвинута
— корпус задней бабки нельзя перемещать»

700056
0 0 «Эталонируй оси или
после RESET позволено движение осей»

700059
0 0 «Старт цикла блокирован
положением зам. кнопки кожуха»

700060
0 0 «Инструментальная
головка не вышла в позицию»

700100
0 0 «Ошибка четности
кода позиции инструментальной головки»

700101
0 0 «Заданная позиция
инструментальной головки вне диапазона»

700103
0 0 «Функция люнета
ошибочная в отношении к его состоянию»

700104
0 0 «Ошибка давления
сухарей люнета при M3/M4»

700105
0 0 «Временной контроль
за арретированием инструментальной
головки»

700106
0 0 «Временной контроль
за вращением инструментальной головки»

700108
0 0 «Временной контроль
за функцией люнета «

700109
0 0 «M79, a шпиндель работает»

700110 0 0 «Ошибка управления кожухом»

700111
0 0 «Защитные рейки
кожуха были нажаты»

700112
0 0 «Временной контроль
за функцией M51 или M52»

700115 0 0 «Временной
контроль за функцией SPOS — установка
позиции главного шпинделя
«

700116 0 0 «Функции
М3 / М4 и режим оси С — активный»

700117
0 0 «Временной контроль
за функцией М14 или M15»

700118
0 0 «М14 — а ось С не
находится в эталонном положении»

700119
0 0 «M14 — а шпиндель не
ориентирован «

700120 0 0 «Временной контроль за
переключением — функция M41/M42»

700121
0 0 «M41/M42 — а главный
шпиндель находится в режиме оси C»

700125
0 0 «Временной контроль
за ориентацией инструментального
шпинделя»

700126
0 0 «Перегрузка двигателя
транспортера стружки»

700127
0 0 «Ошибка измерительного
щупа»

700132
0 0 «Слабая батарея щупа»

700134
0 0 «Стоп перемещения
осей переключателем»

700135
0 0 «Стоп перемещения
осей и шпинделя переключателем»

700136
0 0 «Действительная
скорость вращения главного шпинделя
слишком высока»

700138
0 0 «Не достигнуто
заданное число оборотов главного
шпинделя»

700139
0 0 «Действительные
обороты инструментального шпинделя
слишком высоки»

700141
0 0 «Заданная скорость
вращения инструментального шпинделя
не достигнута»

700143
0 0 «Стоп оборотов с
ручного переносного пульта»

700144
0 0 «Стоп подач с ручного
переносного пульта»

700145
0 0 «Двигатель оси С — в
промежуточном положении»

700146
1 0 «Не установлена
ступень переключения для главного
шпинделя»

700149
0 0 «Функция M2=3/M2=4 и
T-функции программированы в одном блоке»

M02

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