Training manual

Sinumerik 808D Commissioning Guide

Version 05.12
 Workflows

Commissioning
of Prototype
For go to page 5
Machine using
Sample PLC

Series
For Machine go to page 30
Production

PLC program
For design and go to page 35
adjustment

End

808D Turning and Milling Commissioning Guide

Notes

Commissioning Guide 808D Turning and Milling

 Commissioning
of Prototype

Basic Commissioning procedure for prototype machines using the

standard PLC

Delivery
Step 1 Go to page 6
Check

Mounting
Step 2 Go to page 6
Dimensions

Step 3 Wiring Go to page 8

Switch on
Step 4 and Go to page 17
Prepare

Step 5 Commissioning Go to page 19

Diagram

Step 6 Commissioning Go to page 19

the Prototype

End

808D Turning and Milling Page 5 Commissioning Guide

 Commissioning
of Prototype
Machine using
Sample PLC

Delivery Check Step 1 Mounting dimensions Step 2

In the following diagram the most common Siemens components are In the following technical drawing the mounting dimensions for the PPU
shown. For detailed information refer to :- and the MCP are shown.
Commissioning manual: chapter 1 pages 7 to 11 You must provide sufficient space (recommended distance: 80 mm) between
Inverter or servo spindle drive
the maintenance door and the cabinet wall for replacing the battery
PC/PG or CF card:
For further components refer to :-Commissioning manual chapter 2
Spindle encoder
page 13 - 19

Spindle motor
Cut-out dimensions Cabinet panel
USB 80 mm
SINUMERIK
Thickness
808D PPU 2 to 5mm

Handwheels
SINAMICS V60 SINAMICS V60
SINAMICS V60
+24V DC power supply

MCP
Motor Motor Motor

PPU = Panel Processing Unit

MCP = Machine Control Panel

Commissioning Guide Page 6 808D Turning and Milling










Commissioning

of Prototype


Machine using
PPUMCP
Sample PLC

PPU


Mounting dimensions Step 2

In
Inorder
order to
to mount
mountthe
thePPU and MCP
PPU and MCPuse
usethe
theclamps
clamps provided
provided asas shown
shown PPU
below
below
:-

PPU8
MCP6 The clamps are located at the positions indicated with the black triangles.
The
Theblack triangles
clamps can beatseen
are located the in the following
positions picture
indicated withwith red circles.
the black triangles.
8 clamps for mounting PPU. The black triangles can be seen MCP in the following picture with red circles.
8 clamps for mounting PPU. MCP
6 clamps for mounting MCP.
6 clamps for mounting MCP.
BB AA

MCP

X10
BBNC AA

X10
NC




808D Turning and Milling Page 7 Commissioning Guide

 Commissioning

of
Prototype
Machine

Sample


using


PLC






Wiring
Step 3



WhenWhen
connecting the components
connecting the components in the electrical
in the cabinet,
electrical thethe
cabinet, wiring
wiring
should
should comply
comply with with the relevant
the relevant safety
safety standards.
standards.
14

For further
For further information
information referrefer
to :-to :


Commissioning manual 2012-03 PPU front
PPU front


14
V60 manual 2012-03 PPU



In order to connect cables and wires, the location of all connectors and
terminal
In order blockscables
to connect need to be wires,
and known.the location of all connectors and

terminal blocks need to be known.
Connector overview of the PPU is shown:
PPU
Legend
Interface

Comment

Connector overview of the PPU is shown: PPU Back



PPU back 1 X100, X101, X102 Digital inputs
PPU 1 1 X100, X101,
X100,X102
X101,
X102 Digital inputs
PPU back 2 X200, X201 Digital outputs
2 1 5 6 7 8 9 10 12 2 2 X200, X201X200, X201 Digital outputs
2 1 5 6 7 8 9 10 12 3 X21 FAST I/O
3 4 3 X21 X21
X301, X302
FAST I/O
Distributed I/O
I/O
4 X301, X302 Distributed I/O
4 5 X301,
X10X302 Hand-wheel inputs
I/O
5 X10 andwheel inputs
5 6 X60 Spindle encoder interface
6 X10 X60 Spindle encoder interface
6 7 7 X60X54
X54
Analog

spindle interface
Analog spindle interface
7
8 8 X54 X2 X2 RS232 interface
RS232 interface

9 9 X51,X51,
X52,X52,
X53 X53 PulsePulse
drivedrive
interfaces
interfaces
8 X2 RS232
10 10 X30 X30 USB interface,
USB for connection
interface, withwith
for connection the the
MCP
9 X51, X52, X53
11 X1 Power MCP
supply interface, +24V DC power
10 X30 USB,
supply MCP
11 X1 Power supply interface, +24V DC power
11 12 X1- Battery
, interface
supply
+24V DC
12 13 12 - Slot for
the System
Battery Compact Flash Card(CF card)
interface
13 PPU13Front

CF
Slot for the System Compact Flash Card
14 - (CF card)
USB interface



3 4 11 13
3 4 11 13
14 14 USB USB interface
Commissioning


Guide



Page

8
808D Turning and Milling












Commissioning

of Prototype
Machine using


Sample PLC



Wiring
Step3

MCP
MCP back Battery
connection :
BB AA
MCP

BB AA
A battery is placed in the battery compartment, this battery has to be

connected prior to switching on of the control.
X10
NC
X10
NC

1
1

Legend


Interface
Comment



MCP Back
1 1

X10 X10 USBPPU
USB interface, for connection
1 X10 USBPPU
with the PPUU

maintenance door (as P8) battery

(
Battery interface
12 )
battery connector
( 12 )

Note

Battery: Lithium 3V DC

time: 3 years DC
Life:3V
:3V DC
3 (2100)
Note Order number: 6FC5548-0BC00-0AA0.
Connect 3 (2100)
C0BC000AA0
USB cable between X30 on PPU and X10 on MCP.
C0BC000AA0

PPUX30MCPX10USB
808D Turning and Milling
PPUX30MCPX10USB Page 9 Commissioning Guide
















Commissioning



of Prototype


Machine
Selection
using
of 24V DC supply
Sample PLC


The connections for the SINAMICS V60 drives to the PPU are shown.
(X51: axis X for an example).
Wiring Step 3
Selection of 24V DC supply
Those 4 aspects should be considered during selection of 24V DC supply
The connections for the SINAMICS V60 drives to the PPU areIsolation
shown.
Selection of 24V DC supply The connections
(X51: for example).
axis X for an the SINAMICS V60 drives to the PPU are Transformer
shown.
1. 24V DC consumed on 808D : (X51: axis X for an example). Contact
Starting current:5 A (momentary) Breaker 3 phase AC
Isolation
Those4 aspects should be considered
Basic consumption :1.5A during selection of 24V DC supply 380V
Transformer
1. 24V DC consumed on 808D : Contact
2. 24V DC consumed on Sinamics V60 drive:
Starting current:5 A (momentary)
Those 4 aspects should be considered during selection of 24V DC supply Breaker Powersupply 3 phase AC

1. 24V DC consumedV60+1FL5 (w/o: break):0.8A/axes
Basic consumption
on 808D :1.5A Filter option (EMC) 380V

Starting
2. V60+1FL5(w.
current:5
24V DC onbreak):1.2A/axes
A (momentary)
consumed Sinamics V60 drive: Powersupply

Basic
3. consumption
Max. current:1.5A
of(w/o
digital output: 0.25A/Digital output
V60+1FL5 break):0.8A/axes Filter option (EMC)
2. 24V DC consumed on Sinamics V60 drive:
4.

V60+1FL5 Other devices(e.g.:fan, hydraulic/pneumatic valve ):calculation base on name shield
V60+1FL5(w. break):1.2A/axes
(w/o break):0.8A/axes
Consideration
3.

V60+1FL5(w.Max. of redundancy coefficient base on regulation of OEM
current of digital
break):1.2A/axes output: 0.25A/Digital output
3. Max.4.current
Otherofdevices(e.g.:fan,
digital output:hydraulic/pneumatic valve ):calculation base on name shield
0.25A/Digital output
Consideration of redundancy
4. Other devices(e.g.:fan, coefficient base on
hydraulic/pneumatic regulation
valve of OEM base on name shield
):calculation
The connections
Consideration of redundancy forcoefficient
the handbase wheel are shown.
on regulation of OEM +PULS/1(green)
-PULS/2
PULS/2(yellow)
The connections for the hand wheel are shown. +PULS/1(green) +DIR/3 (gray
gray)
(gray)
The connectionsfor the hand wheel are shown. -PULS/2
PULS/2(yellow) -DIR/4
DIR/4 (pink
pink)
(pink)
3 phase AC 220V
+DIR/3 (gray
gray)
(gray) +ENA/5
ENA/5 (brown
brown)
(brown)
3 phase AC 220V
1 -DIR/4
DIR/4 (pink
+ENA/5
pink)
(pink)
ENA/5 (brown
brown)
(brown)
-ENA/6
ENA/6 (white
white)
(white) Encoder cable
1A -ENA/6
ENA/6 (white
white)
(white) Encoder cable
21 1A white
Break cable
2 1A RST/8(white/green) white
3 1A Break cable
3 1B RST/8(white/green)
Set point M24/
M24/9 (red) black
4 1B Set point M24/
M24/9 (red) ALM1/ 10((red/blue)
ALM1/10
10 black
ALM1/cable
4 1B ALM1/10
10(
Power cable
10(red/blue) ALM1/11
ALM1/11(blue)
11(blue)
5 1B cable ALM1/11
Power cable
ALM1/11(blue)
11(blue)
5 +5V RDY1/
RDY1/12(black)
12(black)
X10
X10 66 +5V
RDY1/
RDY1/12(black)
12(black)
RDY2/
RDY2/13(purple)
13(purple)
M
M
RDY2/
RDY2/13(purple)
13(purple)
+24V/14((yellow/white)
+24V/14
77 +24V/14((yellow/white)
+24V/14
M/15((gray/pink)
Z- M/15
M/15((gray/pink)
Z- M/15
88 M24/16(
M24/16(brown/green) M24/16(
M24/16(brown/green)

99
10
10

Commissioning Guide Page 10 808D Turning and Milling




Commissioning


of

Prototype
Machine


using





Sample PLC

Wiring Step 3
The connections of the distributed I/O are shown for the Sample PLC.
Digital Inputs
The connections
The connections of the
of the
distributed
distributed I/O I/O
areare shown
shown forfor
thethe Sample
Sample PLC.
PLC.
Milling
Digital
Digital Inputs
1 Inputs

Milling 1
2
Estop
1 3
Limit
2 4
X+
Estop
Limit X
5 3 Limit X+
Limit
4 Y+

X301 Distributed I/O 1 X100 6 LimitLimit
Y X
7 5 Limit Y+
Limit
6 Z+
X1008 Limit
Limit Z Y
9 7 Limit Z+
+ 24V DC Ref X
10 8 Limit Z
M9
M + 24V DC Ref X +
10
M 24V
M +
24V
11 andheld unit axis X selected 1
12 andheld unit axis Y selected 2
13 11 andheld
andheld unitunit
axisaxis X selected
Z selected Ref
1 Y 3
14 12 andheld
andheld unitunit
4thaxis
axisYselected
selected Ref
2 Z 4
15 13 andheld
andheld unitunit
ICaxisX1 Z selected 3 Ref Y count
Magazine
16 14 andheld
andheld unitunit
IC4th axis selected
X10 X101 5 Magazine
Ref Z at spindle position
6 4
17 15 andheld
andheld unitunit
ICIC X1
X100 Magazine
Magazine
5
count position
at original
X1017
18 16 andheld
andheld unitunit IC X10
enabled Magazine
Magazine
6 at at spindle
release position
position
17 andheld unit IC X100 8
Magazine
Magazine at at original
clamp position
position
External power 7
18 andheld unit enabled Supply + 24V DC
9
Magazine at release position
10 8
External power M9 Magazine at clamp position
Supply + 24V DC +
10
M 24V
+
24V

808D Turning and Milling Page 11 Commissioning Guide


Commissioning




of Prototype



Machine
using
Sample PLC







Wiring Step 3

Milling

Milling
Digital
Digital Inputs
Inputs Digital
Digital outputs
outputs
Digital Inputs Digital outputs

1 1 1 1
+24V +24V
2 2 2 2
3 3 3 3 Working
Working lamplamp
4 4 4 4
Clamp
Clamp
5
remover
remover advancing
advancing
5 5 X2005 Clamp
X200 Clamp remover
remover retracting
retracting
6 6 6 6
X102
X102 Coolant
Coolant level
level lowlow Cooling
Cooling pump pump
7 7 7 7
Cooling
Cooling motor
motor overload
overload 8 8
Lubrication
Lubrication pumppump
8 8
Lubrication
Lubrication level
level lowlow 9 9
9 9
Lubrication
Lubrication motor
motor overload
overload 10 10
10 10
MM M M
+ + + +
24V24V 24V 24V

1 1 1 1
2 2 +24V +24V
2 2
3 Disk magazine:
Disk magazine
magazine: rotating
magazine CW CW
rotating
3 3
3
4 4
4
DiskDisk
magazine: magazine
magazine: rotating
magazine CCWCCW
rotating
4
5 5 5
DiskDisk
magazine: magazine
magazine: in spindle
magazine position
in spindle position

X201 5
X2016 DiskDisk
magazine: magazine in original position
X200
6 6
magazine: magazine in original position
X200 7 6
DiskDisk
magazine: spindle tool release
7 7 7
magazine: spindle tool release
8 8
8 8
9 9 9 9
Handheld unit active
10 10 Handheld unit active
10 10
Connect 24V24V
Connect DC DC
to pin
to pin M M
1 and 10 of +
1 and 10X200:
of X200: +
Otherwise the V60 drive 24V 24V
Otherwise the V60 drive
cannot be enabled.
cannot be enabled.

Commissioning Guide

Page 12

808D Turning and Milling








Commissioning



of Prototype


Machine
using

Sample PLC

The connections of the distributed I/O are shown for the Sample PLC.
Wiring Step 3
Digital Inputs

The connections of the distributed I/O are shown for the Sample PLC. Turning
The connections of the distributed I/O are shown for the Sample PLC.
1
Digital Outputs
Digital2Inputs
Turning 1

3
Estop
4 1
Limit X+
5 2
Limit X
3
Estop

X301 Distributed I/O 1 X100 6 4 Limit X+
7
Limit
Limit Z+X
8 5
6Limit Z
+ 24V DC X100 9 Ref X
107
Limit Z+
M 8M +
Limit Z
+ 24V DC 9
Ref X 24V
10
M
M andheld unit axis X selected
11 +
13 andheld unit axis Z selected
1 24V
2
14 andheld unit 4th axis selected
3
11andheld
15 andheldunit
unitIC
axisX1
X selected Ref Z
4 1
13andheld
16 andheldunit
unitIC
axisX10
Z selected T1
5 2
14andheld
17 andheldunit
unitIC
4th X100
axis selected X101 T2
6 3
15andheld
18 andheldunit
unitenabled
IC X1 T3Ref Z
7 4
16 andheld unit IC X10 T4T1
8 5
17 andheld unit IC X100 External power X101 T5T2
9 6
18 andheld unit enabled Supply + 24V DC T6T3
107
MT4
8 +
External power T5
9 24V
Supply + 24V DC T6
10
M
+
24V

808D Turning and Milling Page 13 Commissioning Guide




Commissioning



of
Prototype


Machine using




Sample PLC

Wiring Step 3


Digital Outputs
Digital
Turning Inputs Turning
Digital Outputs
Digital
Digital Inputs
Inputs Digital Outputs
1 1
+24V
2 1 2 1 +24V
Turret motor overload Work lamp
3 2
3 2 Work lamp
Turret motor
Reserved overload
for other turret 4 3
4 3 Reserved for other turret
5 4 5 4 Tail advancing
X200 Tail advancing
Chuck
5 X200 6 5Tail retracting
X102 6 Coolant
Chucklevel low
7 6 Tail retracting
Cooling pump
X102 6 Coolant level low
7
Cooling pump
Cooling
7 motor overload 8
7
Lubrication pump
8 Cooling motor
Lubrication overload
level low Lubrication
8Chuck pump
8 9
9 Lubrication
Lubricating leveloverload
motor low 9 Chuck
9 10
10
M Lubricating motor overload 10
10
+ M +
M M
24V + 24V +
24V 24V

1 1
1 1+24V
2 2 +24V
2 2Turret motor CW
3 3 Turret motor CW
3 3Turret motor CCW
4 4 Turret motor CCW
4 4Reserved for other turret
5 5
5 X201 Reserved
5Reserved forfor other
other turret
turret
6 X201 6 Reserved forhigh
other turret
X200 6 6Gear change:
X200 7 7 Gear change: high
7 7Gear change: low
8 8
8 8 Gear change: low
9 9
9 9Handheld unit active
10 10 Handheld unit active
10 Connect 24V DC to pin M
10
Connect +
1 and 10 of 24V DC to pin
X200: M
1 and 10 of X200: 24V +
Otherwise the V60 drive 24V
Otherwise the V60 drive
cannot be enabled.
cannot be enabled.

Commissioning Guide

Page 14

808D Turning and Milling









Commissioning


of Prototype





Machine using



Sample PLC
Wiring
The connections for for
thethe
inverter or the spindle drive to the PPU areareStep 3
The connections inverter or the spindle drive to the PPU
shown.
shown.
The
connections for the inverter or the spindle drive to the PPU are shown.
Unipolar connection
Unipolar connection Bipolar connection
Bipolar connection 3AC
3AC380V
380V
3AC 380V
3AC 380V

(black)(black) black
black

black
black
black
black

Spindle/
Spindle/ Spindle/
inverter motor Spindle/
inverter motor inverter
inverter motor
motor

808D Turning and Milling Page 15 Commissioning Guide

 Commissioning



of
Prototype



Machine

using


Sample PLC

Wiring Step 3

The connection overview for Milling is shown. The connection overview for Turning is shown.
The connection
connection
overview
overviewforfor
Milling is shown.
Milling is shown. The connection
The connection overviewoverview forisTurning
for Turning shown. is shown.

Commissioning Guide Page 16 808D Turning and Milling
 Commissioning
of Prototype
Machine using
Sample PLC
Switching on and Prepare for Commissioning Step 4

Before powering on the controller, you should familiarise yourself with the Before the control can be commissioned , loading of standard NC data
operation of the PPU and MCP For detailed information refer to :- have to be carried out,, the password has to be set to manufacturer, the
Commissioning manual chapter 4 page 31 to 33 time and the date have to be set,.
Setting of the password :-
1. Apply 24V DC to the PPU (X1). For detailed information refer to :-
2. Apply 3P 220VAC to V60 drives (L1 L2 L3). Commissioning manual
chapter 4 page 36
2. Check that the status LEDs on the front face of the
PPU are in the ready state. To set the password :-
For detailed information refer to :-Commissioning
manual Chapter 4 page 33 Press button

3. Check that the status LEDs on the front face of the V60 drives are in a Press SK
ready state.
Type inSUNRISE
For detailed information refer to :-
Commissioning manual chapter 4 page 34 Press SK
Status description on SINAMICS V60 Setting of the time and date :-
Item Description For detailed information refer to :-
8.8.8.8.8.8 Initializing the drive, will stay 1 sec Commissioning manual
during the process chapter 4 page 38
S-2 Waiting for 220V power supply To set the time and date :-
S-3 Wait for drive enable from
Terminal 65 at X6 Press SK
S-4 Wait for pulse enable from Type in time and date using the
terminal ENA+ and ENA at X5 keyboard and the and
S-RUN Drive is running properly button
S-A01...S-A45 Alarm codes in the drive system Press SK

808D Turning and Milling Page 17 Commissioning Guide



Commissioning



of Prototype
Machine using


Sample PLC

Switching on and prepare for Commissioning Step 4

Load standard data :-

To set the language:-
PPUThe

control must be powered on.

Press button
PPU Press
SK
When the PPU shows the following
screen:- Select the language with

Press
Press SK

In the following screen select

startup with default data using
button

Press The machine will be commissioned

To accept
the selection.
using the Startup guide.

To set the password as the Sample PLC

will set to NO PASSWORD Where to find the Startup GUIDE :-

For detailed information refer to :-
Press button
The PPU shows this screen.
PPU
Press SK
Type in SUNRISE Press

Press SK
The PPU shows this screen.
PPU

SUNRISE
Commissioning Guide Page 18 808D Turning and Milling

 Commissioning
of Prototype
Machine using
Sample PLC
Commissioning diagram Step 5 Commissioning the prototype Step 6

Commissioning diagram Commissioning the prototype.

Commissioning manual chapter 5 page 41 For further information please go to:
1 Commissioning the prototype. -Commissioning manual chapter 6 page 43
2 Series production
START To start the guide

Press
Commissioning the PLC with the default PLC application
The PPU shows the following screen.
1
Commissioning the NC

Data backup
production archive
Startup archive for the prototype
Press
Series commissioning The PPU shows the following screen.
In the box shown you can enter the
NC data compensation PLC MD values.
2

Data backup
Startup archive
Original status archive for delivery

END

808D Turning and Milling Page 19 Commissioning Guide



Commissioning


of Prototype
Machine using
Sample PLC

Commissioning the prototype

Step 6

MILLING MILLING continued (all default values are set to 0 )

MILLING Set PLC related parameters. MILLING continued (all default values are set to 0 )
MD14512 Function
Set PLC related parameters.
For further information please Bit 7 Bit 6 Bit 5 Bit4 Bit3 Bit2 Bit1 Bit0
For further information please go to : MD14512 Function
go to :- 14512[16] Selction of Z axis: Y axis: X axis: Safty door Safety Chip

Commissioning manual DB4500. axis to be rotary rotary rotary open door remover

chapter 7 page 66 DBB101

6
controlled monitoring
by hand
monitoring monitoring when M1/
M2
activate activate

wheel via programe

MCP Bit 7 Bit 6 Bit 5 Bit d4 Bit 3 Bit 2 Bit 1 Bit 0
14512[17] Selction Tool
DB4500. of magazine
14512[16] Selction of Z axis: Y axis: X axis: Safty door Safety Chip
DBB101 axis to be rotary rotary handwheel open
rotary door activate
remover
7DB4500. controlled monitoring monitor monitoring
controlled when M1/ acti activate
MD14510 PLC interface Unit Range Fuction DBB101 by hand ing axis via M2 vate

MD14510 PLC interface Unit Range Fuction 6 wheel via HHU programe
MCP d
14510[12] DB4500.DBW24 * - =0,vertical =1horizontal 14512[18] One Hardware Fixed External
14510[12] DB4500.DBW24 * - =0,vertical =1horizontal
MD14510[13] DB4500.DBW26 0.1sec 5~200 Spindle breaking time 14512[17]hardware
DB4500. limit is direction stop signal Selction Tool
MD14510[13] DB4500.DBW26 0.1sec 5~200 Spindle breaking time DBB101 limit independent of of the of magazine
MD14510[20] DB4500.DBW40 Max.64 Max Tool number in magazine hand activate
8
DB4500.triggered of the spindle spindle
wheel
per axis PLC
MD14510[20] MD14514
DB4500.DBW40
PLC interface Max.64 Function
Max Tool number in magazine DBB101 application
controlled
axis via
14514[0] DB4500.DBD2000 Tool magazinespindle poisoning angle 7
14512[19] HHU
Delete Spindle
MD14514[1] DB4500.DBD2004 Tool magazine: Preparation position of Z axes DB4500. system break
MD14514 PLC interface Function DBB101
for tool change password activate
9 14512[18] One Hardware Fixed External
MD14514[2] DB4500.DBD2008 Tool magazine: Tool changing posion of Z axes hardware limit is direc stop signal when
14514[0] DB4500.DBD2000
MD14514[3] DB4500.DBD2012Tool magazinespindle poisoning
Tool magazine: velocity angleGo to tool
of Z axis, limit independ tion of of the power
DB4500. triggered ent of the spindle spindle on
change preparation position
DBB101 per axis PLC
MD14514[1] MD14514[4]
DB4500.DBD2004
DB4500.DBD2016Tool magazine: Preparation position
Tool magazinevelocity ofback
of Z axis, Z axes for
to tool application
change preparation position 8
tool change

MD14514[2] DB4500.DBD2008 Tool magazine: Tool changing posion of Z axes 14512[19] Delete Spindle
system break
Commissioning Guide Page 20 808D Turning pass
and Milling
activate
DB4500. word
MD14514[3] DB4500.DBD2012 Tool magazine: velocity of Z axis, Go to tool DBB101 when
power
 Commissioning



of Prototype

Machine using

Standard PLC


Commissioning the prototype
Step 6

TURNING MD14512
TURNING (all
Set PLC default
related values are
parameters. Machine
TURNING (all default values are setFunction
0)
set toFor
be further
zero) information data -
Integer
please go to :- MD14512 Functionality
Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0
Set PLC related parameters.
Commissioning manual 14512[17] Tail- Chuc Disk-
For further information please go Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
stock k style tool
to : func- func- maga-
14512[16] Selction of Z axis: X axis: tion tion zine
DB4500. axis to be
controlled
rotary
monitoring
rotary
monitor
DBB101 One
14512[18] by hand Hardware Fixing Stop
ing Control One
6 wheel via
hardware limit is the signal of drive time
MCP
limit independ- direction for an enable auto-
14512[17] triggered ent of the external Selction matic Tail Chuck HED
of stock function turret
per axis of the spindle spindle hand
lubri-
MD14510
MD14510 PLC Unit
interface
Range unitFunction
Rang Functionality
Subroutine DB4500. (enabled PLC wheel
func
cation activate activate
e DBB101 when bit applica- tion
controlledafter
Machine data - axis via acti
Integer 7 6=0) tion HHU thevate
14510[12] DB4500.DBW24 power-
14510[12] * - JOG key layout=0flat bed;=1, inclined bed
on
14510[20] - 2 to 64 The maximum number 47 - TURRET2_BINT 14512[18] One Hardware Fixed External
40hardware
- 40limit
- is direc 33 -
stop 37-
MD14510 DB4500.DBW26 0.1se of tool5~20 Spindle breaking time
positions limit independ tion of signal of MCP_
DB4500. AXES_C AXES_C EMG_S
[13]14510[21] 0.1s 5 to 30 c Time for 0 locking a 47 - TURRET2_BINT triggered ent of the spindle the
DBB101 TLper axis TL PLC TOP
spindle NCK
turret 8 application
MD14510 DB4500.DBW40 4, 6 Max Tool number in turret.
[20]14510[22] 0.1s 30 to 300 The monitoring time for 47 - TURRET2_BINT
searching a tool(for tool amount >6, PLC to be
48 - TURRET3_CODE_T
programmed 14512[19] MM+ Delete Spindle
14510[24] 1min 5 to 300 Lubrication interval 45 -by customer them
LUBRICATE (option) sys break
14510[25] selves) 45 - LUBRICATE
0.01s 100 to 2000 Lubrication duration DB4500. activate
tem activate
pass
DBB101 word
MD14510 DB4500.DBW42 0.1se 5~30 HED turret: Tool clamping time when
9
[21] c for power
on

MD14510 DB4500.DBW44 0.1se 30~2 HED turret: Time monitoring for

808D Turning and Milling c
[22] 00 tool change Page 21 Commissioning Guide

Commissioning



of Prototype


Machine


using
Sample PLC

Commissioning the prototype

Step 6

Set PLC related Commissioning PLC

Set PLC
Set PLC related
related
parameters Commissioning
Commissioning PLCPLC
parameters
parameters

PLC MD is to be adapted to suit the OEM machine It may be that the machine tool builder requires further PLC functionality,
if this is required the PLC has to be modified.
PLCPLC MD
MD is to is
betoadapted
be adapted to the
to suit suitOEM
the OEM machine
machine It may
ToIt install
may be
be that that
the
PLC the machine
machine
programmingtool tool
builder
tool, builder
follow therequires
requires further
further
information in :- PLC
PLC functionality,
functionality,
if thisif is
this is required
required the the PLC
PLC has has
to be tomodified.
be modified.
PLC Subroutines manual
To install
To install PLCPLC programming
programming tool, tool,
followfollow the information
the information in in
Chapter 2 page 15 to 19 (install PLC programming tool)


Changes will be activated

To make a connection to the PPU, press SK
MD set to default value Then
follow the information in:-
To Subroutines
PLC
To make make a connection
a connection manual toPPU,
to the the PPU, press
press SK SK
MD set to previous value ThenThen
Chapter
followfollow
2the the25information
page to 28 in in
information
Changes
Changes willactivated
will be be activated

To continue press the SK
To continue press the SK
MDto
MD set set to default
default valuevalue
Commissioning Guide Page 22 808D Turning and Milling
MDto
MD set set to previous
previous valuevalue


Commissioning



of
Prototype


Machine using


Sample PLC






Commissioning the prototype
Step 6

Theconnect
The connect status status Basic
Basic digital
digital I/Ocheck
I/O check
Theshould
connect status Basic digital I/O check
should now be now be green.
green.
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
First the Sample PLC blocks should be uploaded to the PC, then the Allfollowing
I/O statusSKs.
mustThe
be checked with the
Firstmodifications
the Samplecan PLC
beblocks
made toshould
achievebe uploaded
the required to the PC, then
functionality. the
Once All I/O status must status is shown
be checked on electrical
with the
the right
drawing
hand
electrical side using the
as shown
drawing usingabove.
the
modifications can be made to achieve the required functionality. Once following SKs. The status is shown ondigital
the right hand side as shown
modifications cancompleted,
be made the
to achieve thebe
required functionality. Once Below are SKs that allow you to select inputs or outputs and
following SKs. The status is shown on the right hand side as shown selection
this has this
beenhas been
completed, PLC should
the PLC should be put put into
into stopstop
andandthethe modified
modi above.
this hasshould
been completed, the into
PLCtheshould be put into stop and the modi ofabove.
the byte required.
fied PLCPLCshould bebe downloaded
downloaded into the PPU. The
PPU. ThePLCPLCmust then
must be be
then Below are SKs that allow you to select digital inputs or outputs and se
fiedrestarted.
PLC should be downloaded into the PPU. The PLC must then be Below are SKs that allow
digitalyou to select digital inputs or outputs and se
restarted. Choose
lection of the byte required. input
restarted. lection of the byte required.

PLC Subroutines manual Choose digital output


Chapter 2 page 31 Choose digital input
Choose digital input
Choose the digital O/I addresses of Pre Byte
Choose digital output
Choose digital output
Choose the digital O/I addresses of Next Byte
Choose the digital O/I addresses of Pre Byte
To continue press the SK Choose the digital
To continue pressO/I
theaddresses
SK of Pre Byte
Choose the digital O/I addresses of Next Byte
808D Turning and Milling Page 23 Choose the digital O/I addresses of Next Byte Guide
Commissioning
 Commissioning


of Prototype


Machine



using


Sample PLC





Commissioning the prototype

Step 6

Edit PLC alarm text Set feed axis parameters.

EditPLC
PLCalarm
alarmtext
text Setfeed
feed axisparame
parame
ForEdit
further information Set
For furtheraxis
information
Forfurther
For furtherinformation
information ters.
ters.
please
pleasego
pleasego to:-
goto:
to: please go
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to:-
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information
Commissioning manual

Commissioning
pleasego
please to: manual
goto:


chapter 7 page 71

The data below must be
set
Theasdata
The default
data below
below values:
mustbe
must beset
set
asdefault
as defaultvalues:
values:
Machine data Setting


30130
2
30130
30130
30240 3 22
34200 2
30240
30240 33
34200
34200 22

You can edit the PLC user alarm text either directly on the HMI, or off line You can edit the axis machine data for the required axis.
You
You
and canedit
can editthe
transferring the PLC
thePLC useralarm
user
file using alarm text
a USBtext eitherdirectly
either
stick. directlyon
onthe
theHMI,
HMI,or oroff
offline
line Youcan
You
Below canSKs
are editthe
edit the axis
axis
that machine
machine
allow data
data
you to for
for
edit, therequired
the required
activate axis.
or setaxis.
as default value.
andare
and
Below transferring
transferring
SKs that the
the fileusing
file
allow using aaUSB
you to USBstick.
import stick.
and export the text file from the Beloware
Below areSKs
SKsthat
thatallow
allowyou
youto
toedit,
edit,activate
activateor
orset
setas
asdefault
defaultvalue.
value.
Beloware
Below areSKs
SKsthat
thatallow
allowyou
youto
toimport
importand andexport
exportthe
thetext
textfile
filefrom
fromthe
the
HMI, and SK that that allows the text file to be directly edited on the HMI. Used to select the axis (X or Z turning or X, Y, or Z milling)
HMI,and
HMI, andSKSKthat
thatthat
thatallows
allowsthe
thetext
textfile
fileto
tobe
bedirectly
directlyedited
editedon onthe
theHMI.
HMI.
Import the backup alarm text into the PPU Usedto
Used toselect
selectthe
theaxis
axis(X
(Xor
orZZturning
turning or
orX,
X,Y,
Y,or
orZZ
milling)
milling)
Importthe
Import thebackup
backupalarm
alarmtext
textinto
intothe
thePPU
PPU
Export the finished alarm text from the PPU Changes will be activated
Exportthe
Export thefinished
finishedalarm
alarmtext
textfrom
fromthe
thePPU
PPU Changes willvalue
beactivated
activated
Edit the alarm text Changes
MD set will
to default be
Editthe
Edit thealarm
alarmtext
text MDset
MD setto
todefault
defaultvalue
value
MD set to previous value
MDset
MD setto
toprevious
previousvalue
value
To continue press the SK To continue press the SK

Commissioning Guide Tocontinue

To continuepress
pressthe
theSK
SK Page 24 Tocontinue
To continuepress808D
press Turning and Milling
theSK
the SK



Commissioning

of Prototype




Machine
using


Sample
PLC

Commissioning the prototype

Step 6

ReferenceReference
axis. axis.
Set
Set spindle
spindleSet parameters.
parameters.
Reference axis. spindle parameters.
For furtherFor
information
furtherFor
information For further
For further information
information
For further information
further information
please go to:-
please go to:
please go please
to:- go to:
please go to: please go to:


Commissioning
manual

Commissioning manual chapter 6 page 44



chapter 6 page 48 The data below must bebe set as
The data below must
The bebelow
data set asmust
set asvalues:
default default
defaultvalues:
values:
Machine
Machine datadata Setting
Setting
Machine data Setting

30130
30130 2
30130 2 2
30240 3
30240 30240 3
30134 0output value is 3Bipolar
0output value is Bipolar value is Bipolar
0output
30134
1output
1output value is
value is Unipolar
Unipolar
30134 1output value is Unipolar
2output
2output value is value is Unipolar
Unipolar
2output value is Unipolar
30200 0: without spindle endcoder
30200 0: without
30200spindle0:endcoder
without spindle endcoder
You can edit the axis machine
the axisdata and the forand
the the
required
for theaxis.
You can edit
Below axisYou
theare can
machine
SKs that
edit
data andmachine
the for data
the required axis. required axis. You can edit the spindle machine data required.
Below areallow
SKs you
that to edit,
allow activate
you or activate
to edit, set as default
or set as default You can
Below are SKs that allow you to edit, activate or set as default Below areedit
You
SKsthe spindle
canthat machine
editallow
the you data
spindle required.
machine
to edit, data required.
activate or set as default
Below are Below
SKs that
areallow
SKs you
that to edit,you
allow activate or activate
to edit, set as default
or set as default

Used
Used to select thetoaxis
select
(X the
Used ortoZaxis (Xthe
select
turn or X,
or Zaxis
turn ororor
Y, (X ZX,mill)
ZY, or or
turn Z mill)
X, Y, or Z mill) Used to select the axis (X or Z turn or X, Y, or Z mill)
Used to select
Usedthe
to axis (Xthe
select or Zaxis
turn(XororX,ZY, or or
turn Z mill)
X, Y, or Z mill)

Changes will be activated Changes will be activated

Changes will be activated
Changes will be activated
Changes will be activated
Changes will be activated
MD set to default
MD setvalue
to default
MD setvalue
to default value MD set to default value
MD set to default
MD setvalue
to default value
MD set to
MD set to previous previous
MD set tovalue
value previous value MD set to previous value
MD set to previous
MD set tovalue
previous value
An axis referenced
An axis referenced Anbe
will axis will be performed
referenced
performed will be performed AxisAxis
willwill
bebereferenced
referenced
Axis will be referenced
To continue
Topress the SK To continue
Topress
To continue press the SK continue press the SK To continue thethe
SKSK
continue
press press the SK






808D Turning and Milling Page 25 Commissioning Guide









Commissioning




of Prototype



Machine using


Generate
Sample
archive.
production
PLC


Set SW limit.
For further information

Commissioning the prototype
For further information Step 6 please go to:
please go to:

Generate
Generate production
production
Set
Set SW limit.
SW limit.
Generate production Set SW limit.

archive. For
archive.
archive. Forfurther
For further
further information
information
information
ForFor
further
For information
further
further information
information please
please
please go
gogoto:
to:-
to:
please gogo
please
please to:
goto:-
to:

Commissioning manual


Commissioning manual

chapter 6 page 49


chapter 6 page 55

To create the production archive press SK Pack. You can edit the axis machine data for the required axis.
Below are SKs that allow you to edit, activate or set as default

To create the production archivearchive

Create production press SK Pack. You can edit the axis machine data for the required axis.
To create
To create thethe production
production archive
archive press
press SKSK Pack.
Pack. You
You
Below can
canare edit
edit the
the
SKs axis
axis
Used
that machine
machine
to
allow data
youdata
select the
to forforactivate
axis
edit, thetheor
(X required
required
Z or
turn axis.
axis.
setor X,default
as Y, or Z mill)
Create production archive Below
Below areare SKs
SKs that
that allow
allow youtotoedit,
you edit,activate
activateororset
setasasdefault
default
Note:
When creating the production Used to select
Changes willthe
beaxis (X or Z turn or X, Y, or Z mill)
activated
Note: Create
backup, storeCreate toproduction
production
archive archive
USB archive
When creating
memory stick.the production Used
Used toto selectthe
select theaxis
axis(X(XororZZturn
turnororX,X,Y,Y,ororZZmill)
mill)
MD set to default value
backup, store archive to USB
Note: stick.
memory
Note: Changes
MD setwill be activated
to previous value
When
When creating
creating thethe production
production Changeswill
Changes willbebeactivated
activated
backup,
backup, storestore archive
archive to USB
to USB MD set to default value
memory
memory stick.
stick. MD
MD set
set totodefault
defaultvaluevalue
MD set to previous value
To continue press the SK To continue press the SK
MD
MD set
set totoprevious
previousvalue value
To continue press the SK
To continue press the SK

Commissioning Guide Page 26 808D Turning and Milling

To To continue
continue press
press thethe
SKSK ToTocontinue
continuepress
pressthe
theSK
SK









Commissioning




of Prototype







Machine using


Sample PLC


Backlash compensation.
Commissioning the prototype

Step 6 Lead screw pitch error
For further information compensation.
Backlash
please compensation.
gocompensation.
to Lead
For screw information
further pitch error
Backlash
Backlash compensation. Lead
Lead screwpitch
screw pitcherror
error
For further information compensation.
please go to

For
For further
further information
information compensation.
compensation.
please
please go
goto:-
to For further
Forfurther
For information
furtherinformation
information
please go to


Commissioning manual
pleasego
please
please gogoto:-
to
to





chapter 6 page 50 Commissioning manual


chapter 6 page 50

You can edit the axis machine data for the required axis. You can edit the axis machine data for the required axis.
You
Below
You can
canare edit
edit thethe
SKs axis
that
axis machine
allow
machineyoudata
todata
forforthe
edit, therequired
required
activate or set axis.
as default
axis. Youcan
Below
You can editthe
areedit
SKs the axis
that
axis machine
allow you to
machine data for
edit,
data for therequired
required
activate
the axis.
or set axis.
as default
You can
Below
Below edit
areare thethat
SKs
SKs axis
thatmachine
allow
allow you
you data
to to foractivate
edit,
edit, the required
activateororsetaxis.
setasasdefault
default You
Belowcan
Below edit
are
are thethat
SKs
SKs axisallow
that machine
allowyou data
youto foractivate
toedit,
edit, the required
activate setaxis.
or set
or as default
as default
Below are SKs that allow you to edit, activate or set as default Below are SKs that allow you to edit, activate or set as default
Used to select the axis (X or Z turn or X, Y, or Z mill) Used to select the axis (X or Z turn or X, Y, or Z mill)

Used
Used toto select
select the
the axis(X(XororZ Zturn
axis turnororX,X,Y,Y,ororZZmill)
mill) Usedtotoselect
Used selectthe
theaxis
axis(X
(Xor
orZZ turn
turn or
or X,
X, Y,
Y, or
or ZZ mill)
mill)

Changes
Used towill be activated
select the axis (X or Z turn or X, Y, or Z mill) Used to enter
Used compensation
to select the axis (Xdata
or Zvia theorHMI
turn X, Y, or Z mill)
Changes
Changes will
will be activated
bevalue
activated Usedtotoenter
Used entercompensation
compensationdata
data via
via the
the HMI
HMI
MD set to default

MD
MD MD toset
set
set toto default
default
previous value
value
value Changes will be activated
Changes will be activated Used to enter compensation data via the HMI
MD Changeswill
willbe
beactivated
activated
MD setset
toto previous
previous value
value Changes
To continue press the SK To continue press the SK
MD set to default value
808D Turning and Milling Page 27 Commissioning Guide
MD set to previous value press the SK
To continue Changes will To
be continue
activatedpress the SK
To continue press the SK To continue press the SK









Commissioning

of
Generate

Prototype


startup
using

nce the Guide is com





Machine
archive.
pleted.
Sample PLC
For further information




please o to:


Commissioning the prototype

Step 6



Generate start-up
Once thetheGuide isis com
GenerateGenerate
startupstartup ncence Guide
the Guide is com
archive.
archive.archive. completed.
pleted.
pleted.
For For For
further
further further information
information
information Generate startup nce the Guide is com
please please
o to: o to:archive. pleted.
please go to:- For further information


Commissioning manual please o to:


chapter 6 page 56

To continue press the SK

To create the Startup archive press SK ack.
To exit the GUIDE press the SK

reate Startup archive To continue

To continue press
press the SK
the SK
To continue
To continue presspress the SK
the SK
ToStart-up
To create the create theToStartup
create thearchive
archive press SK
Startuppress SKpress
Pack.
archive ack.
SK ack.
To create the Startup archive press SK ack. To exit
Tothe
exitGUIDE
thethe
To exit
presspress
GUIDE
GUIDE
the SKtheSK
pressthe SK
To exit the GUIDE press the SK
Note: Create Start-up archive
hen creatin the Startupreate Startup reatearchive
Startup archive
archive,
Note: store archive reate
to USB Startup archive
memory stick
When creatingNote:the Start-up
Note:
archive, store
Note: hen archive tohen
creatin USB creatin the Startup
the Startup
archive, store archive to USB
memory archive,
stick store
hen creatin the Startuparchive
memory stickto USB
memory stick
archive, store archive to USB
memory stick

To continue press the SK

To continue press
the SK
To continue press the SK
To continue
press the SK

Commissioning Guide
To continue
press
the SK Page 28
808D Turning and Milling

 Commissioning
of Prototype
Machine using
Sample PLC
Commissioning the prototype 6

Now that the commissioning

is completed a
SAVE DATA is performed.

To continue press the SK

To continue press the SK

808D Turning and Milling Page 29 Commissioning Guide

 Series
Machine
Production

Basic Commissioning procedure for series machines

Commissioning
To perform the Go To page 29
series

End

Commissioning Guide Page 30 808D Turning and Milling














Series
Machine
Production

For



For further information please go to:
further information please go to:

Load archive file.

For
Loadfurther information
archive file.


Commissioning
the series machine Step 1
please go to:information
For further

please go to:
For further information please
For further go to:-please go to:
information
Load archive
Load file.

archive file.
Commissioning
manual For Forinformation
further further information

chapter 8 page
75 please go please
to:- go to:

Commissioning manual

chapter 8 page 75
Press Followed by
To start the guide

Press
Press Followed
Followed byby
The PPU shows this screen.
Press Followed by
The PPU shows this screen.
The PPU shows this screen.
The PPU shows this screen. To load the production archive press SK Load Archive.

ToTo
load thethe
load production
production archive
archivepress
pressSKSK Load Archive.
To load the production archive press SK Load Archive.
Load Archive.
Press Loads production archive
Loads production archive
Press
Press Press Loads production
Loads productionarchive
archive
Note:
Note:
When loading the production
When loading the production
archive,Note:
use archive on USB
Note: use archive
archive,
memoryWhenstick.loadingon USB
the production
When loading
memoryarchive, thearchive
stick. use production
on USB
archive, use archive
memory stick. on USB
memory stick.

To continue press the SK

To continue press the SKpress the SK
To continue


808D Turning and Milling Page 31 To
continue pressCommissioning

the SK Guide

 Series
Machine
Production

Commissioning the series machine Step 1

Set SW limit. Backlash compensation.

For further information For further information
please go to:- please go to:-
Commissioning manual Commissioning manual
chapter 6 page 50 chapter 6 page 50

You can edit the axis machine data for the required axis. You can edit the axis machine data for the required axis.
Below are SKs that allow you to edit, activate or set as default Below are SKs that allow you to edit, activate or set as default

Used to select the axis (X or Z turn or X, Y, or Z mill) Used to select the axis (X or Z turn or X, Y, or Z mill)

Changes will be activated Changes will be activated

MD set to default value MD set to default value

MD set to previous value MD set to previous value

To continue press the SK To continue press the SK

Commissioning Guide Page 32 808D Turning and Milling

 Series
Machine
Production

Commissioning the series machine Step 1

Lead screw pitch error Generate backup

comp. settings.
For further information For further information
please go to:- please go to:-
Commissioning manual Commissioning manual
chapter 6 page 50 chapter 8 page 77

You can edit the axis machine data for the required axis. To create the start-up archive press SK Pack.
Below are SKs that allow you to edit, activate or set as default

Used to select the axis (X or Z turn or X, Y, or Z mill) Create start-up archive

Note:
When creating the start-up
Changes will be activated
archive, store archive into OEM
directory and on a USB
memory stick
Control will activate MD

To continue press the SK To continue press the SK

808D Turning and Milling Page 33 Commissioning Guide

 PLC program
design and
adjustment

Basic PLC design and adjustment.

Programming
To Do tool Go to page 35
PLC

Signals of
To Do the PLC Go to page 41
interface

To Do Operation Go to page 43
symbols

PLC
To Do Subroutine Go to page 47
library

PLC
To Do Go to page 49
alarm

PLC
To Do Online Go to page 53
diagnosis

End

Commissioning Guide Page 34 808D Turning and Milling

 PLC program
design and
adjustment

Programming tool PLC

In order to connect 808D numerical control system and the machine we Open up the default PLC program and save this file to a new name so
must use Programming Tool PLC V3.2 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
Compiling of the PLC program
Download the PLC program
Upload the PLC program
Monitoring of the PLC conditions

The software is started by double clicking the icon on your desktop.

808D Turning and Milling Page 35 Commissioning Guide

 PLC program
design and
adjustment

Programming tool PLC

The PLC programming tool has included 5 languages that can be selected Overview of PLC programming tool.
when installing the software, you can then choose the display
languages by using the following sequence.

The programming tool will prompt you that the software will close
automatically and you will have to start the programming tool again.

Commissioning Guide Page 36 808D Turning and Milling

 PLC program
design and
adjustment

Programming tool PLC

The address of each instruction can be edited at any time by highlighting Double click this icon.
the instruction.

A connection must be made so that the

PLC programming tool can
communicate with PPU.

Press the Communications

Icon.

808D Turning and Milling Page 37 Commissioning Guide

 PLC program
design and
adjustment

Programming tool PLC

808D can only use Confirm the baud rate setting in 808D
RS232 to is same as the setting in PC
Communicate. (38400 for example)

Same baud rate setting in

Press SK

Illustration

Connection established
Activate the PLC connection setting in 808D (under password sunrise)
Connection activate

Operating processes

3.Refresh
Press key: Follow the steps 1-3 on you PC

Press soft key

1.PPU interface: 2

2.confirm baud rate

setting is same as
the setting on PPU

Commissioning Guide Page 38 808D Turning and Milling

 PLC program
design and
adjustment

Programming tool PLC

The connection is now established. To check syntax errors use compiling after editing and modification of
the PLC program.

The correct system must

Be chosen.

808D Turning and Milling Page 39 Commissioning Guide

 PLC program
design and
adjustment

Programming tool PLC

To compile the To download the

PLC modified PLC program
program press the press icon.
compile icon

Place the PLC into STOP.

The location of the syntax error

can be located easily, using
the bottom window.

Commissioning Guide Page 40 808D Turning and Milling

 PLC program
design and
adjustment

Programming tool PLC

Once the PLC is successfully To place the modified PLC

downloaded, it must be placed program in RUN mode, press icon.
in RUN mode.

808D Turning and Milling Page 41 Commissioning Guide





PLC program


design and
adjustment

Programming tool PLC

To
To displa
To displa display the online
the
the online onlineconditions
con con The
Theblue
The blue blue represents
represents
represents an
anonline an connection
online online connection
ditions ditions
ofofthe of the
thePLC,
PLC, PLC, press
press
press showingshowing the status.
the showing
connection status. the status.

Status : 0:Status
LOW,: 1:
0: HIGH
LOW, 1: HIGH

Commissioning Guide Page 42 808D Turning and Milling



Please

confirm





theprogram
PLC Step 7 connection should be deactivated after the




The signals of the PLC interface and the signals of the input and output.
PLC design
commissioning and
finished

adjustment 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.
Programming tool PLC Signals of the PLC interface
Please confirm the Step 7 connection should be deactivated after the The signals of the PLC interface and the signals of the input and output.
Please confirm the Stepfinished
PLC commissioning 7 connection should be deactivated after the The signals of the PLC interface and the signals of the input and output.
Please confirm the Step 7 connection should be deactivated after the
PLC commissioning finishedPress the soft key TheThe
signals
The
PLC ofPLC
the PLC
program interface
program
exchanges and theinformation
exchanges
information signals
between ofNCK,
the input
between and and
NCK,
HMI,MCP output.
HMI,MCP
I/ and I/
PLC commissioning finished O through the signals of the interface and the signals of the input and
O through the signals of the interface and the signals of the input and
The PLC output.
program exchanges information between NCK, HMI,MCP and I/
output.
O through the signals of the interface and the signals of the input and
output.
Press the soft key The signal of PLC
interface
Press thePress
soft the
keysoft key NCK

The signal of PLC

Component
Of the M/C
Electrical
Disappear ,connection closed PLC interface

MCP
Application NCK The signal of PLC

I/O
Program interface
NCK

Component
Component
M/C
the M/C
Electrical
Electrical
Disappear ,connection closed PLC
Disappear closed

MCP
,connection

MCP
I/O
Disappear ,connection closed HMI Application

I/O
Component
Of the M/C

Of the
The signal of

Electrical
Disappear ,connection closed PLC Program

MCP
input and output

Of
I/O
Application
Program

HMI
The signal of
input and output HMI
The signal of
input
and output

808D Turning and Milling Page 43 Commissioning Guide

 PLC program
design and
adjustment

Signals of the PLC interface

The signals of the interface The signals of the interface

V11000000.1
NCK channel VB16001000
The system provides adequate and clearly
defined signals of the interface

DB1600.DBB2 DB4500.DBB2
DB4500.DBB1 DB2700 .DBB0 DB3100.DBB1 DB3300.DBB1
DB1400.DBB0 DB1600.DBB1 DB2500.DBB1
DB4500.DBB0 DB2500.DBB0 DB2600.DBB0 DB3000.DBB0 DB3200.DBB0
Can keep the DB1600.DBB0 NCK Way selection Channel control
PLC Auxiliary
data area Alarm activation parameter function Signal of control signal signal
Alarm variables

PLC application

DB1100.DBB0 DB1700 DBB0 DB1800.DBB0 DB1900.DBB0

DB3801.DBB x 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

HMI NCK axis

Commissioning Guide Page 44 808D Turning and Milling

 PLC program
design and
adjustment

Operation symbols of PLC programming language

Special mask registers

PLC scan period

always 1 state

SM0.0
PLC scan at Special flag register can simplify the design 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 second

808D Turning and Milling Page 45 Commissioning Guide

 PLC program
design and
adjustment

Operation symbols of PLC programming language

The signal of input and output. Address
Input;
Accumulator carriage and storage
Accumulator carriage: AC (four at most)
Form; Arithmetic accumulators AC0 AC1, logical
I output; Q
accumulator 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
(address mantissa can be divided with noremainder by 2) (address mantissa can be divided with noremainder by 2)
double word ID2, IW8; QD0, QD4 double word MD4, MD28
(address mantissa can be divided with noremainder by 4) (address mantissa can be divided with noremainder by 4)

Commissioning Guide Page 46 808D Turning and Milling

 PLC program
design and
adjustment

Operation symbols of PLC programming language

counter
Plus Minus Plus and
counter minus
Counter: C counter
CD: is
Form; minus
CU: is
condition of counter bit C3, C25; - represents the count
comparison result of the counter and present value.
PV: is LD: is R:
Loading Is resetting
preset
preset
value
value

Style:
plus counter CTU count: counter value+1
R=1 counter resets; counter value>preset value \
Cn=1

minus counter CTD count: counter value -1

LD counter value = preset; value = counter
value=0Cn=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

808D Turning and Milling Page 47 Commissioning Guide

 PLC program

and

design

adjustment

Operation symbols of PLC programming language

Timers
Timers Keep the sequence

Timer:
Timer: TT
Timer enable
Form;
Form; preset value
condition
conditionof
oftimer bit
timer bit T3, T25; represent the
timer value
comparison

result of timer value and preset value
Timer bit T
timer T3,
timer value value
T25; represent timer value

Style;
Style;
open delay
open delaytimer
timer TON IN=1 begin timing IN=0
count
timer valuepreset value
resetting count value>preset
value Tnn=1

close
closedelay
delaytimer
timerTOF IN=1 timer resetting IN=0

begin timing;
begin timing; count
count valuepreset
value>preset value
value T n=0
n
keep delay timer begin timing;
timer
keep delay stops; count IN=1begin
timer CTUD valuepreset value n
timing;

IN=0 timer
Assign stops;
word count value>preset
constant value
to to make counter Tn1
composite

Assign word constant0to T to make counter

composite

Commissioning Guide Page 48 808D Turning and Milling

 PLC program
design and
adjustment

PLC subroutine library

The purpose of the PLC subroutine Library. System resource

In order to simplify design of producer PLC, refined PLC functions resource

which have generality, such as initialization, machine panel signal Input I0.0 to I2.7 (24 inputs of CNC) I3.0 to
processing, abrupt stop processing, shaft enable control, hard limit, I8.7 (48 allocated input)
reference point etc. Producers only need to add the needed subroutines Output Q0.0 to Q1.7 (24 outputs of CNC)
module to main procedure, plus other under action procedures, Q2.0 to Q5.7 (48 allocated output)
then you can complete PLC procedure design very quickly. RAM M0.0 to M255.7 (256 bytes)
PLC system No volatile memory DB1400.DBX0.0 to
Composition of PLC subroutine library. resource DB14000.DBX127.7 (128 bytes)
PLC user alarm DB1600.DBX0.0 to DB16000.DBX15.7
PLC project fileSAMPLE_TURN.PTPapplication program (128 user alarms)
as examples for turning machine Timer T0 to T15 (100ms timer) T16 to T32
(10ms timer)
PLC project fileSAMPLE_MILL.PTP application program counter C0 to C63 (64 counters)
as 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)
Through these application programs as examples, you can
Parameter Statistic REAL: DB4500.DBD2000 to
clearly realize how to create or invoke PLC subroutines.
MD14514(8) DB4500.DBD2028 (8 double)
You can reorganize PLC subroutines or modify some
Programming Subroutine (64) SBR0 to SBR63 (64 subroutines)
internets to realize most machine functions. Test and debug
subroutines of the subroutine library on machines tool resource Symbol table (32) SYM1 to SYM32 (32 symbol tables)
overall according to practical situation to assure the
correctness of subroutine librarys functions.

808D Turning and Milling Page 49 Commissioning Guide

 PLC program
design and
adjustment

PLC subroutine library

A constant definition
All the addresses in PLC subroutine library are programmed by symbols.
Constant input symbol location
All the signals of interfaces are named by symbols and arranged
Constant1 ONE SM0.0
in different symbol table.
Constant2 ZERO M251.0
The name of symbols follows some conventions.
Please refer to the PLC subroutine library instructions.
Invalid output definition
Statistic type symbol address symbol List name Symbol list details
bit NULL_b M255.7 PP module 1 I/O defined by
1 PP_1
byte NULL_B M255 manufacturer
word NULL_W MW254
Long word NULL_DW MD252 4~15 Preset for manufacturer
Send to or from machine
16 IS_MCP
control panel MCP

Commissioning Guide Page 50 808D Turning and Milling

 PLC program
design and
adjustment

PLC subroutine library PLC alarm

A constant definition SBR 39 HANDWHL Hand wheel selection in HMI

The realization of PLC basic functions is the basic condition to SBR 40 AXES_CTL Axis control (feed axis and spindle)
debug driver and 808D system parameter SBR 41 MINI_HHU HHU (hand held unit ) control
SBR 42 SPINDLE Spindle control
Realize through invoking PLC standard subroutine or manual writing
SBR 43 MEAS_JOG Measure in JOG
PLC program : All the reference functions related to safety such as
Emergency stop and limit SBR 44 COOLING Coolant control
Operation function worksmode select, manual control, rate set. SBR 45 LUBRICATE Lubrication control
SBR 46 PI_SERVICE ASUP control
PLC standard subroutine offers adequate NC program selection via
PLC_Select_PP
PLC functions for machine tool SBR 47
PLC PLC
0 to 19 Saved for producers
SBR 48 ServPlan Service planner
SBR 20 AUX_MCP MT auxiliary function
SBR 49 GearChg1_Auto Automatic gear change
SBR 21 AUX_LAMP Working lamp
SBR 50 GearChg2_Virtual Gear change (virtual)
SBR 22 AUX_SAFE_DOOR Safety door
SBR 54 TOOL_DIR Tool change direction control
SBR 23 AUX_CHIP Chip remover SBR 58 Manual machine related
MM_MAIN
PLC_ini_USER_ini Initialize for PLC user data SBR 59 Manual machine related
SBR 31 MM_MCP_808D
(called in SBR 32)
SBR 63 TOGGLE Toggle switch control
SBR 32 PLC_INI PLC initialize
34-36/57/61/62 Reserve for OEM
SBR 33 EMG_STOP Emergency stop
Signal transfer from MCP &
SBR 37 MCP_NCK
HMI to the NCK interface
SBR 38 MCP_Tool_Nr Tool number display on MCP

808D Turning and Milling Page 51 Commissioning Guide

 PLC program
design and
adjustment

PLC subroutine library PLC alarm

PLC standard subroutine PLC alarm is the most effective method provided for users.
can realize adequate
lathe functions Diagnosing of the machine is important.
Complete designed diagnosis scheme 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
Turret2_BIN_T Bi-direction changeable turret 24 VDC
SBR 52
(binary coded)

Digital output
SBR 53 Turret3_CODE_T Bi-direction changeable turret
(coded by turret supplier)
KA1 KM1
SBR 55 Tail_stock_T Tailstock control
SBR 56 Lock_unlock_T Chuck control

PLC standard subroutine N

can realize adequate M

Digital input
milling functions
For milling only
Disk_MGZ_M Disk magazine control (w/o
SBR 60
automatic tool changer)
Normal condition
I/O interface has no output
signal, check hardware
connection
Relay KA1 Works unusually,
check component: hardware
Cooling
pump motor
Protective door lock
Cooling motor thermal protection
Cooling liquid level detection
Cooling pipe pressure test
Contactor KM1 works
unusually, check components
hardware connection and
power supply

Commissioning Guide Page 52 808D Turning and Milling

 PLC program
design and
adjustment

PLC alarm

Alarm PLC signal PLC alarm variable

Alarm attribute Alarm
Conditions of elimination
number setup text
700000 DB1600.DBX0.0 DB16000.DBD1000 MD14516[0] power-on clear after the cancel of alarmyou need to re-power it
on cancel key or after the cancel of alarm you need to use the
700016 DB1600.DBX2.0 DB16000.DBD1064 MD14516[16]
Driver is cancel key or reset key ,then the alarm will be cancelled
not ready
self-cleanafter the cancel of alarmthe alarm will be cancelled by itself
700018 DB1600.DBX2.2 DB16000.DBD1072 MD14516[17] Coolant
motor alarm reaction
overload React by two ways after alarm
PLC reactionthe PLC program written realizes reaction through
corresponding PLC interface, such as cancel the shaft-enable when giving
700127 DB1600.DBX15. DB16000.DBD1508 MD14516 User an alarm.
7 [127] alarm NC reactionevery alarm has a 8 configuration MD14516[0]~ [127].you
127 can set a cancelation condition and alarm reaction of every alarm
according to current condition. The system makes corresponding reaction
System provides users with 128PLC user alarmsEvery user alarm when alarm begins.
has a corresponding NCK address bit:V16000000.0~V160000015.7
The address bit1 can activate the corresponding alarm, reset 0 MD14516[n]
alarm Reset / cancel condition
can cancel the alarm.

In PLC cross referenceyou can find the reason for the PLC alarm bit 7 6 5 4 3 2 1 0 NC start
through looking up reference addresses to make corresponding Read-in fobid
modification.
Power-on All shaft hold
Reset or cancel Emergency stop
key PLC stopping

808D Turning and Milling Page 53 Commissioning Guide

 PLC program
design and
adjustment

PLC alarm

Alarm text. Edit PLC user alarm by USB.

Press button
Create, edit alarm text correctly and reasonably can make users clearly
realize the reason of PLC alarm and locate ,and rule resolve a breakdown. Press SK

Curser over HMI

Press SK

1.choose text PLC alarm textalcu.txt

2.then press vertical soft keycopy
3.press level soft keyUSB and press vertical soft
keypaste

edit PLC user alarm by USB

edit PLC user alarm by HMI

Commissioning Guide Page 54 808D Turning and Milling

 PLC program
design and
adjustment

PLC alarm

Edit PLC user alarm by USB. Find alarm number which needs to be edited and input your own text.

Connect USB storage medium with PC USB, find PLC alarm text which is Save and close file after editing alarm text.
downloaded. And open it by WordPad.
Disconnect USB storage from PC and connect it with USB interface on
the front panel of PPU again

Copy PLC alarm textalcu.txtwhich is edited back in to HMI

statistic.

In <system>operation areapress soft key PLC > edit PLC alarm

text. You can check the result of edit.

808D Turning and Milling Page 55 Commissioning Guide

 PLC program
design and
adjustment

PLC alarm PLC online diagnosis

Edit PLC user alarm by HMI. Check the condition of PLC and judge logical error or external electrical
Create PLC alarm text directly in 808D system. error through displaying PLC program online.

Press button Press button

Press SK Press SK

Press SK Press SK

Symbol display/ D i s p l ay t h e Alter the program

condition of displayed in the
Move the cursor to choose the alarm number address displaying
can close window
which needs to be edited and go into the
condition of alarm text edit.
Find appointed
Press SK target in the display
program
Input alarm text combination key
ALT+S, change in both English and
Chinese input method. On state

ClickOK
after finishing
edit.

Display producer
command online which Display another program in
Press SK PLC needs to open window 2

Commissioning Guide Page 56 808D Turning and Milling

 PLC program
design and
adjustment

PLC online diagnosis

Check the PLC operating status and data. Check the condition of PLC and judge logical error or external electrical
error through displaying PLC program online.
Press button Press button
Press SK
Press SK
Press SK
Press SK
Press SK
Press SK

Running state Operand address condition

PLC program
information

PLC style and

versions

PLC scan period

Display current condition of interface

PLC running time signal or bit, byte, word of I/O

808D Turning and Milling Page 57 Commissioning Guide

 PLC program
design and
adjustment

PLC online diagnosis

Check the correctness of hardware connection through examining the state Check the condition of hardware connection through examining the status
of input point. of input point.
Press button

Press SK

Press SK

Press SK
Move the cursor to the Set the condition of output
operand which needs pointconfirm by
modification

Check if there is any error of

the connection in the input
point according to the value If the compulsive output point,
of the input point. the signal of interface is used in
PLC program, its state will be
Check electrical level of the refreshed by the program.
output point (whether the relay
is in absorption), check if there
is any error in the connection of
the output point.

Commissioning Guide Page 58 808D Turning and Milling

 PLC program
design and
adjustment

PLC online diagnosis

Observe the condition of PLC , judge logical error quickly or external Observe the condition of PLC , judge logical error quickly or external
electrical error through displaying PLC program online. electrical error through displaying PLC program online.

Press button
Press button
Press SK
Press SK

Press SK Press SK

Press SK Press SK

Amend operand address Display whether signals

accurately and confirm of I/O and interfaces are
by soft key. used or not and which
subroutine and network
they are used by.
Display conditions of
input point ,output point,
auxiliary relay and the
signal of interface by
Look up appointed target
listing.
in cross-reference table

808D Turning and Milling Page 59 Commissioning Guide

Notes

Commissioning guide Page 60 808D Turning

Everything ever wanted to know about SINUMERIK 808D:
www.siemens.com.cn/808D

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www.siemens.com/cnc4you

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www.siemens.com/sinumerik/manufacturing-excellence

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Siemens AG Subject to change without prior notice The information provided in this brochure contains merely general
Industry Sector Order No.: descriptions or characteristics of performance which in actual case of
use do not always apply as described or which may change as a result
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91050 ERLANGEN Printed in Germany terms of contract.
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