Machine Translated by Google

Start-Up 08/2003 Edition

sinumerik
SINUMERIK 802C base line
Machine Translated by Google
Machine Translated by Google

SINUMERIK 802C base line

SINUMERIK 802C base line

Start-Up
Control System 1

Installing the control system 2

Installing the Drives 3

Technical Manual

Start-Up 4

Software Update 5

Technical Appendix 6

Valid as from

Control system Software version

SINUMERIK 802C base line 4

2003.08 Edition
Machine Translated by Google

®
SINUMERIK Documentation

Key to editions

The editions listed below have been published prior to the current edition.

The column headed “Note” lists the amended sections, with reference to the previous edition.

Marking of edition in the “Note” column:

A ... ...New documentation.

B ... ...Unchanged reprint with new order number.
C ... ... Revised edition of new issue.

Edition Order No. note

2000.04 6FC5597-3AA20-0BP1 TO

2002.01 6FC5597-3AA20-0BP2 c
2003.08 6FC5597-4AA21-0BP0 c

Trademarks

SIMATIC®, SIMATIC HMI®, SIMATIC NET®, SIMODRIVE®, SINUMERIK®, and SIMOTION® are registered
trademarks of SIEMENS AG.

Other names in this publication might be trademarks whose use by a third party for their own purposes may violate
the registered holder.

Copyright Siemens AG 2003. All rights reserved Exclusion of liability

The reproduction, transmission or use of this document or its contents We have checked that the contents of this document correspond to
is not permitted without express written authority. Offenders will the hardware and software described. nevertheless, differences
be liable for damages. All rights, including rights created by patent might exist and we cannot therefore guarantee that they are
grant or registration of a utility model, are reserved. completely identical. The information contained in this document is
re-reviewed regularly and any necessary changes will be included in the
next edition. We welcome suggestions for improvement.

© Siemens AG, 2003

Subject to technical changes without notice.

Siemens-Aktiengesellschaft. SINUMERIK 802S/802C base line

Machine Translated by Google

safety notices This Manual contains notices intended to ensure your personal safety, as well as to protect products
and connected equipment against damage. Safety notices are highlighted by a warning triangle and
presented in the following categories depending on the degree of risk involved:

Danger
! Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury or in substantial property damage.

Warning
! Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury or in substantial property damage.

Caution
! Used with safety alert symbol indicates a potentially hazardous situation which, if
not avoided, may result in minor or moderate injury or property damage.

Caution
Used without safety alert symbol indicates a potentially hazardous situation
which, if not avoided, may result in property damage.

Notice
Indicates important information relating to the product or highlights part of the
documentation for special attention.

Qualified person The unit may only be started up and operated by qualified person or persons.
Qualified personnel as referred to in the safety notices provided in this document
are those who are authorized to start up, earth and label units, systems and
circuits in accordance with relevant safety standards.

Proper use Please observe the following:

Warning
The unit may be used only for the applications described in the catalog or the
! technical description, and only in combination with the equipment, components
and devices of other manufacturers as far as this is recommended or permitted
by Siemens.
This product must be transported, stored and installed as intended, and
maintained and operated with care to ensure that it functions correctly and safely.
Machine Translated by Google
Machine Translated by Google

Contents

Contents

1. SINUMERIK 802C base line Control System Components of the 1-1

1.1 SINUMERIK 802C base line Technical data 1-1
1.2 1-3

2. Installing the Control System Installing and 2-1

2.1 Dismantling the SINUMERIK 802C base line Interfaces and cables 2-1
2.2 Connecting the individual 2-4
23 components Connecting the feed drives and the 2-8
2.3.1 spindle (X7) 2-8
2.3.2 Connecting the measuring systems (X3 ... X6) 2-11
2.3.3 Configuration of the RS232 interface connection (X2) 2-12
2.3.4 Connecting handwheels (X10) 2-14
2.3.5 Connecting NCREADY (X20) 2-15
2.3.6 Connecting the digital inputs (X100 ... X105) 2-17
2.3.7 Connecting the digital outputs (X200,X201) 2-19
2.4 Power Supply for CNC (X1) 2-21
2.5 LEDs and Other Elements on CNC 2-22

3. Installing the Drives 3-1

4. Start-Up 4.1 4-1

General 4.1.1 Access 4-1
levels Structure of machine 4-2
4.1.2 data (MD) and setting data (SD) 4-3
4.1.3 Handling of machine data 4.1.4 4-4
Data saving 4.2 4-4
Turning on and booting the control system Boot 4-6
4.2.1 messages Starting 4-8
4.3 up the PLC Commissioning 4-9
4.3.1 of the PLC Start-up modes of the 4-10
4.3.2 PLC 4.3.3 PLC alarms 4.3.4 4-11
Machine control panel area 4-12
layout 4.3.5 PLC programming 4.3.6 Instruction set 4.3.7 4-16
Program organization 4.3.8 Data 4-18
organization 4.3.9 Interface to 4-21
the control system 4.3.10 Testing and 4-28
monitoring the user program 4.4 4-29
4-29
4-29
PLC applications “Download/Upload/Copy/Compare 4-30
4.5 User Interface 4-32
4.6 Technology Setting 4-32
4.7 Commissioning 4-33
4.7.1 Entering the general machine data 4-33
4.7.2 Starting up the axes 4-35
4.7.3 Starting up the spindle 4-44
4.7.4 Completing the Start-Up 4-46
4.7.5 Cycle start-up 4-46
4.8 Series machine start 4-47

5. Software Update Updating 5-1

5.1 the system software using a PC/PG Update errors 5-1
5.2 5-2

SINUMERIK 802C base line Yo

Start-Up
Machine Translated by Google

Contents

6. Technical Appendix 6.1 List of 6-1

machine and setting data 6.1.1 Display machine data 6-1
General machine data 6-2
6.1.2 6-4
6.1.3 Channel–specific machine data 6-5
6.1.4 Axis–specific machine data 6-6
6.1.5 Setting data 6-15
6.2 PLC user interface signals 6-16
6.2.1 Address ranges 6.2.2 6-16
Retentive data area 6-17
6.2.3 CNC signals 6.2.4 6-18
Channel signals 6.2.5 Axis/ 6-20
spindle signals Signals from/to MMC 6-27
6.2.6 6-30
6.2.7 Machine control panel signals (MCP signals) 6-32
6.2.8 PLC machine data 6-33
6.2.9 User alarm 6-35
6.3 Unipolar spindle 6-37

II SINUMERIK 802C base line

Start-Up
Machine Translated by Google

SINUMERIK 802C base line 1

Control System

1.1 Components of the SINUMERIK 802C base line

What is SINUMERIK 802C base line?

The SINUMERIK 802C base line is a microprocessor-controlled numerical
control system for economical machine tools with analog drives.

Hardware components
The SINUMERIK 802C base line is a compact CNC unit. It consists of the following
areas (see figure 1-1):

LCD
MCP Area

NC Keys
SIMODRIVE
SIMODRIVE
611U/
base
line

Fig. 1-1 Components of SINUMERIK 802C base line (turning variant)

SINUMERIK 802C base line 1-1
Start-Up
Machine Translated by Google

SINUMERIK 802C base line Control System

software components
The SINUMERIK 802C base line comprises the following software components, which can be ordered:

System software on the permanent flash memory of the CNC

Boot software
loads the remaining system software from the permanent memory into the user memory
(DRAM) and starts the system.

MMC software (Man Machine Communication),

implements all operating functions
NCK software (NC Kernel)
implements all NC functions. This software controls an NC channel with
a maximum of 3 movement axes and a spindle.
PLC software (Programmable Logic Control)
executes the integrated PLC user program cyclically.
Integrated PLC user program
intended to adjust the SINUMERIK 802C base line to the machine
functions (see also Description of Functions “Integrated User Program
for SINUMERIK 802C base line”).
Toolbox
WinPCIN transfer program for a PC/PG (programming device) to transfer
user data and programs
text manager
Cycle kit for loading into the control system using WinPCIN
User program library
Technological machine data files
Programming tools
Update diskettes
Update program with operator prompting system
802C base line system software, packed, for loading and programming
the SINUMERIK 802C base line via an update program.

User data User data are:

Machine data
Setting data
Tool data
R parameters
Zero offsets
Compensation data
Part programs
Standard cycles

Data saving Modified user data are saved for at least 50 h after power off or power failure.
After then, they might get lost.

Warning
!
To avoid data loss, the operator must carry out data saving (see Section 4.1.4).

1-2 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

SINUMERIK 802C base line Control System

1.2 Technical data

Connected load Table 1–1 Connected load

parameters Min. Typ. Max. unit
Supply voltage 20.4 24 28.8V
Ripple 3.6 Vss
Current consumption from 24V 1.5 TO

Power dissipation of CNC 35 W

Start-up current 4 TO

Weight Table 1–2 Weight

components Weight [g]
CNC 4500

Dimensions Table 1–3 Component dimensions

components Dimensions LxWxD [mm]
CNC 420x300x83

Environmental operating conditions

Table 1–4 Environmental operating conditions
parameters
Temperature range 0...55 °C
Permissible relative humidity 5...95 % without condensation
air pressure 700...1,060 hPa

The operating conditions comply with IEC 1131–2.

Installation in a housing absolutely (eg cubicle) is necessary for operation.

Transport and storage conditions

Table 1–5 Transport and storage conditions
parameters
Temperature range Transport: –40...70 °C
Storage: -20 ... 55 °C
Permissible relative air humidity 5...95 % without condensation
air pressure 700...1,060 hPa
Transport height –1,000...3,000 m
Free fall in transport package ÿ1,200mm

Protective quality and degree of protection

Class of protection I to IEC 536.
No PE terminal required.
Foreign matter and water protection to IEC 529.
For CNC:IP 54 front IP 00 rear

SINUMERIK 802C base line 1-3

Start-Up
Machine Translated by Google

SINUMERIK 802C base line Control System

1-4 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Installing the Control System 2

2.1 Installing and Dismantling the SINUMERIK 802C base line

Warning
Do not install when the equipment is under power!
!
The modules contain electrostatically sensitive devices.
It must be ensured that persons without ESD protection never touch printed circuit
boards or components when handling operator and machine control panels.

approach Due to the compactness, it is very convenient to install and dismantle the control
system.
1. Fix the system in the machine control station.
2. Screw the system in place with 8 M4 x 16 assembled screws. The maximum
allowed torque for the screws is 1.5 Nm.

Notice
Prior to installation, the machine control panel can be provided with an emergency
stop button. If it is not required, the opening must be covered with the supplied
self-adhesive cover.

Dismantling the control system

The control system is dismantled as described above in the reverse order.

Warning
Do not dismantle when the equipment is under power!

SINUMERIK 802C base line 2-1

Start-Up
Machine Translated by Google

Installing the Control System

Mounting dimensions
The dimensions shown below are important for installing the control system:

802C base line

Fig. 2-1 Mounting dimensions for 802C base line

2-2 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Installing the Control System

1) Thread plugging M4 ÿ 5 hole (8x)

Fig. 2-2 Mounting dimensions for 802C base line

SINUMERIK 802C base line 23

Start-Up
Machine Translated by Google

Installing the Control System

2.2 Interfaces and cables

Position of the interfaces and elements

Fig. 2-3 Rear of CNC system

Interfaces CNC
X1 power supply terminals (DC24V)
3-pin screw-type terminal block for connecting the 24 V load power
supply
X2 RS232 interface (V24)
9-pin sub-D plug connector
X3 to X5 measuring system interfaces (ENCODER)
three 15-pin sub-D plug connectors for connecting incremental position
encoders (RS422)
X6 spindle interface (ENCODER)
15-pin sub-D socket for connecting a spindle incremental position
encoder(RS422)
X7 drive interface (AXIS)
50-pin sub-D socket connector for connecting the power sections for a
maximum of four analog drives including spindle
X10 handwheel interface (MPG)
10-pin front connector for connecting the handwheels

2-4 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Installing the Control System

X20 digital inputs (DI)

10-pin front connector for connecting the NC READY relay

GAVE

X100 to X105
10-pin front connector for connecting digital inputs
X200 and X201
10-pin front connector for connecting digital outputs

Operating elements Start-up switch S3

Fuse Fuse F1, externally designed to allow users for convenient replacement.

S2 and D15 These elements are provided only for debugging internally.

SINUMERIK 802C base line 2-5

Start-Up
Machine Translated by Google

Installing the Control System

Connecting cables The components are wired up as shown in the Connection Diagram 2–4 and
2-5. For the cables required, please refer to the diagram below.

P24
DC24V M Wire(1.0...2.0 mm2 )

option
6FX2003-0DS00
6FX8002-1AA01-1..0
x2

RS232 RS232 Communication

Isolator
with Computer

CNC
1FK7 Servo Motor

power
Module
6SN1146-...
AXIS/ 611U
X7

6FX2002-3AD01-1..0
6SN1118-0NK
SPINDLE
611U Power Cable
6SN1118-0NK 6FX5002-5.A.1-1..0
Signal Cable
6FX8002-2CJ10-1..0 6FX5002-2CF02-1.. 0
ENCODER 1
X3

ENCODER 2
x4

ENCODER 3
X5
X6

SPINDLE 1PH Spindle

ENCODER Spindle 6FX5002-2CD01-1BB0 Engine

MPG 6FX8002-2BB01-1..0
Encoder
x10

Hand Wheels 1...2

External
Spindle
X20

GAVE NC READY

IN
0.0...0.7
IN
X105
X104
X103

1.0...1.7 signal
X102
X101
X100

2.0...2.7 1...48
3.0...3.7 Wire(0.14...1.5 mm2 )
4.0...4.7
M
5.0...5.7
P24
OUT OUT
X201

0.0...0.7 load
X200

1.0...1.7 M Wire(0.14...1.5 mm2 ) 1...16

M P24 M P24
24VDC 24VDC

Fig. 2-4 Connection Diagram for SINUMERIK 802C base line with SIMODRIVE 611U

2-6 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Installing the Control System

P24
DC24V

x1
M Wire(1.0...2.0 mm2 )

option
6FX2003-0DS00
6FX8002-1AA01-1..0 RS232 Communication
x2

RS232
Isolator with Computer

CNC
1FK7 Servo Motor

SIMODRIVE
base line
AXIS/ 6FX2002-3AD01-1..0
X7

6FC5548-0AC..-0AA0
SPINDLE
Power Cable
6FX5002-5DA01-1..0
Position Feeback
ENCODER 1 6FX5002-2CJ00-1..0 Spindle Controller Cable
ENCODER 2 6FX5002-2CF02-1..0
X3

ENCODER 3
x4
X5

SPINDLE
X6

1PH Spindle
ENCODER Engine

Encodre
Spindle
external
MPG 6FX8002-2BB01-1..0
Hand Wheels 1…2
x10
X20

GAVE

NC READY

IN
0.0...0.7
IN
X105

1.0...1.7
X104

Signal
X103
X102

2.0...2.7
X101

1...48
X100

3.0...3.7 Wire(0.14...1.5 mm2 )

4.0...4.7
M
5.0...5.7
P24
OUT OUT
Load
X201

0.0...0.7
1...16
X200

1.0...1.7 M Wire(0.14...1.5 mm2 )

M P24 M P24
24VDC 24VDC

Fig. 2-5 Connection Diagram for SINUMERIK 802C base line with SIMODRIVE base line

SINUMERIK 802C base line 2-7

Start-Up
Machine Translated by Google

Installing the Control System

2.3 Connecting the individual components

Connecting the components

Please note the following:

Notice
Use only shielded cable and make sure that the shield is connected to the
metal or metal plated connector casing on the control side. For the purpose of
isolating the analog setpoint signal from low-frequency interference, we
recommend not to ground the shield on the drive side.
The preassembled cable offered as accessories provides optimum protection
against interference.

General procedure:
Proceed as follows to connect the individual components:
1. Connect the cables to the components as shown in Fig. 2–4 or Fig. 2-5.
2. Fix the sub-D connector in place using the knurled screws.

2.3.1 Connecting the feed drives and the spindle (X7)

Pin assignments For connector on the CNC side

Feed drive interface
Connector designation: X7
AXIS 1–4
Connector type: 50-pin sub-D plug connector
Table 2-1 Pin assignments of connector X7
X7
Pin Signal Type Pin 1 AO1 AO 18 2 Signal Type Pin Signal Type
AGND2 AO 19 3 AO3 AO 20 4 nc 34 AGND1 AO
AGND4 AO 21 5 22 6 23 7 24 8 25 9 nc 35 AO2 AO
26 10 27 11 28 12 29 13 30 14 SE1.1 nc 36 AGND3 AO
31 15 SE2.1 32 16 SE3 .1 33 17 nc 37 AO4 AO
SE4.1 nc M VO 38 nc
nc M VO 39 nc
nc M VO 40 nc
nc M VO 41 42 nc
nc nc 43 nc
nc nc 44 nc
nc nc 45 nc
nc nc 46 nc
nc nc 47 nc
K nc 48 SE1.2 K
K nc 49 SE2.2 K
K nc 50 SE3.2 K
K SE4.2 K

2-8 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Installing the Control System

Signal names Description

AOn Analog Command Value
AGNDn Analog Ground
SEn.1; SEn.2 Servo Enable Relay
M Ground (not to be connected)
n = 1...4 Number of Axis

Signal Specification: +/-10V for Analog Outputs

Signal level RS422

Signal type
VO Signal output
K Switching contact

Axis assignment
X axis
1 and axis
2 Z axis
34 Spindle
Table 2–2 Cable assignment (for type 6FX2 002-3AD01)
CNC Side Wire Drive Side
PIN Core Color Signal Name black brown PIN
14 red 1st axis 1.9
47 1.65
34 1.14
3. 4 1 orange 1.56
18
1 yellow 2nd axis 2.9
15 green 2.65
blue 2.14
48 purple 2.56
2 gray 3rd axis 3.9
35 pink 3.65
16 white/black 3.14
white/brown 3.56
50 33
49 17
white/red Spindle 4.9
36 white/orange 4.65
3 white/yellow 4.14
17 50 4 37 white/green 4.56

SINUMERIK 802C base line 2-9

Start-Up
Machine Translated by Google

Installing the Control System

Drives with analog interface

Signals:
A voltage and an enable signal are output.
AOn (SETPOINT)
Analog voltage signal in the range ± 10 V to output a speed setpoint
AGNDn (REFERENCE SIGNAL)
Reference potential (analog ground) for the setpoint signal, internally
connected to logic ground.
SEn (SERVO ENABLE)
Relay contact pair controlling the enable of the power section, eg of a
SIMODRIVE drive unit controlled via a PLC program.
Signal parameters
The setpoint is output as an analog differential signal.
Table 2–3 Electrical parameters of the signal outputs for step-switching drives
parameters min Max unit
Voltage range –10.5 10.5 V
Output current –3 3 mA

Relay contact
Table 2–4 Electrical parameters of the relay contacts
parameters Max. unit
switching voltage 50 V
switching current TO

switching power 1 30 GOES

Cable length: max. 35m

2-10 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Installing the Control System

2.3.2 Connecting the measuring systems (X3...X6)

Pin assignment of the connector on the CNC side

Measuring system interface (incremental encoder)
Connector designation: X3...X6
ENCODER

Connector type: 15-pin sub-D plug connector

Table 2–5 Pin assignment of the female connector X3 ... X6

Pin signal Type Pin signal Type

nc 9M VO
1 nc 10Z Yo 8
fifteen
23 nc 11 Z_N Yo

4 P5_MS 5 VO 12 B_N Yo

nc 13B Yo
9 1

6 P5_MS VO 14 A_N Yo

7M8 VO 15 A Yo

nc

Signal names Description

TO; A_N Track A

B; B_N Track B

Z; Z_N Zero Reference Mark

P5_MS +5.2V Supply Voltage

M ground

Signal Specification: RS422

Signal type
VO Voltage output (supply)
Yo

5V input (5V signal)

Connectable encoder types

Incremental 5 V encoders can be connected directly.

Characteristics The encoders must meet the following requirements:

Transmission method: Differential transmission with 5 V square-wave signals

Output signals: Track A as true and denied signal (Ua1, Ua1 )

Track B as true and denied signal (Ua2, Ua2 )

Zero signal N as true and denied signal (Ua0, Ua 0 )

Max. output frequency: 1.5 MHz

Phase offset between
tracks A and B: 90º ± 30º

Current onsumption: max. 300mA

SINUMERIK 802C base line 2-11

Start-Up
Machine Translated by Google

Installing the Control System

Cable lengths The maximum cable length depends on the specifications of the encoder
power supply and on the transmission frequency.
To provide fault-free operation, make sure that the following values are not
exceeded when using preassembled interconnecting cables from SIEMENS:
Table 2–6 Maximum cable lengths depending on the encoder power supply
Max. Wire
Supply Voltage Tolerance Current Consumption
Length
5V DC 4.75V...5.25V < 300 mA < 25m
5V DC 4.75V...5.25V 220 mA 35m

Table 2–7 Maximum cable lengths depending on the transmission frequency

Incremental Frequency Max. Cable Length

Encoder Type 1MHz 10m
500kHz 35m

2.3.3 Configuration of the RS232 interface connection (X2)

Pin of assignment connector on the CNC side

RS232 interface

Connector designation: X2
RS232

Connector type: 9-pin sub-D plug connector

Table 2–8 Pin assignment of connector

Pin Name Type Pin Name Type

1 6 DSR Yo

2 RxD Yo 7 RTS O 6 1

3 TxD EITHER 8 CTS Yo

9 5
4 DTR EITHER 9
5M VO

Signal description:
RxD Receive Data
TxD Transmit Data
RTS Request to send
CTS Clear to send
DTR Data Terminal Ready
DSR Data Set Ready
M ground

Signal level
RS232

2-12 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Installing the Control System

Signal type
Yo

Input
EITHER
Output
VO Voltage output

Cable for WinPCIN Table 2–9 Cable for WinPCIN: Pin assignment of the Sub-D connector
9-Pin Yam 25-Pin
1 Shield 1
2 RxD 2
3 TxD 3
4 DTR 6
5M 6 7
DSR twenty

7 RTS 5
8 CTS 4
9

Or
9-Pin Yam 9-Pin
1 Shield 1
2 RxD 3
3 TxD 2
4 DTR 6
5M 6 5
DSR 4
7 RTS 8
8 CTS 7
9

2 2
0.1mm 0.1mm
RxD 2 3 TxD RxD 2 2 RxD
TxD 3 2 RxD TxD 3 3 TxD
DTR 4 6 DSR DTR 4 6 DSR
0V 5 5 0V 0V 5 7 0V
DSR 6 4 DTR DSR 6 2 0 DTR
RTS 7 CTS 8 RTS 7 CTS 5
CTS 8 RTS 7 CTS 8 RTS 4

Fig. 2-5 Communication connector RS232(X2)

SINUMERIK 802C base line 2-13

Start-Up
Machine Translated by Google

Installing the Control System

2.3.4 Connecting handwheels (X10)

Pin of assignment connector on the CNC side

Handwheel interface
Connector designation: X10
MPG
Connector type: 10-pin mini–Combicon plug connector
Table 2–10 Pin assignment of connector X10
x10
Pin Yam Type
A1 Yo

1
1 A1_N Yo

2 B1 Yo

3 B1_N Yo

4 P5_MS VO
5 M5_MS VO
6 A2 Yo

7 A2_N Yo

8 B2 Yo
10
9 10 B2_N Yo

Signal names
A1, A1_N Track A, true and negated (handwheel 1)
B1, B1_N Track B, true and negated (handwheel 1)
A2, A2_N Track A, true and negated (handwheel 2)
B2, B2_N Track B, true and negated (handwheel 2)
P5_MS 5.2 V supply voltage for handwheels
M Supply ground

Signal level
RS422

Signal type
VO Voltage output
Yo

Input (5V signal)

Handwheels Two electronic handwheels can be connected which must meet the following
requirements:
Transmission method: 5 V square-wave (TTL level or RS422)

Signals: Track A as true and denied signal (Ua1, Ua1 )

Track B as true and denied signal (Ua2, Ua2 )

Max. output frequency: 500kHz
Phase offset between
tracks A and B: 90º ± 30º
Supply: 5V, max. 250 Ma

2-14 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Installing the Control System

2.3.5 Connecting NCREADY (X20)

Pin of assignment connector on the CNC side

NCREADY interface

Connector designation: X20

GAVE

Connector type: 10-pin plug connector

Table 2–11 Pin assignment of connector X20
X20
Pin signal Type
1 NCRDY_1 K eleven

2 NCRDY_2 K
3 I0 / BERO1 Not defined
4 I1/BERO2 Not defined
5 I2/BERO3 Not defined
6 I3/BERO4 Not defined
7 I4/MEPU1 Not defined
8 I5/MEPU2 Not defined
9 L- SAW twenty

10 L- SAW

Signal description:
NCRDY_1…2 NC-READY-Contact, max. current is 2A at 150VDC or
125VAC)
I0...I6 L- Fast digital input 0 … 6
Reference potential for digital input

Signal type
K Switching contact

NC–READY output Readiness in the form of a relay contact (NO); can be integrated into the
EMERGENCY STOP circuit.

Table 2–12 Electrical parameters of the NCREADYrelay contact

parameters Max. unit
DC switching voltage 50 V
switching current TO

switching power 1 30 GOES

SINUMERIK 802C base line 2-15

Start-Up
Machine Translated by Google

Installing the Control System

Pin number of
X20
relay
1
NC_RDY

2
1P5

Fig. 2-5
The NCREADY is an internal relay of NC. 1 and 2 are the two contacts of this
relay. It will open when NC is not ready, and close after NC is ready for
operation.

2-16 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Installing the Control System

2.3.6 Connecting the digital inputs (X100 ... X105)

Pin assignment for connector

Interface for the digital inputs
Connector designation: X100, X101, X102, X103, X104, X105
IN

Connector type: 10-pin plug connector

Table 2–13 Connector pin assignment
X100
Pin Yam Type
nc
X100
1 DI0 GAVE

2 DI1 GAVE 0
1
3 DI2 GAVE
2
4 DI3 GAVE 3
4
5 DI4 GAVE
5
6 DI5 GAVE 6
7 DI6 GAVE
7
M
8 DI7 GAVE

9 10 M SAW

X101
Pin Yam Type
nc
X101
1 DI8 GAVE

2 DI9 GAVE 8
9
3 DI10 GAVE
10
4 DI11 GAVE eleven

12
5 DI12 GAVE
13
6 SAY 13 GAVE 14
7 DI14 GAVE fifteen

M
8 DI15 GAVE

9 10 M SAW

X102
Pin Yam Type
nc
X102
1 DI16 GAVE

2 DI17 GAVE
16
17
3 DI18 GAVE
18
4 DI19 GAVE 19

5 DI20 GAVE
twenty

twenty-one

6 DI21 GAVE
22
7 DI22 GAVE 23
M
8 DI23 GAVE

9 10 M SAW

SINUMERIK 802C base line 2-17

Start-Up
Machine Translated by Google

Installing the Control System

X103
Pin Yam Type
nc X103

1 DI24 GAVE
24
2 DI25 GAVE 25
3 DI26 GAVE
26
27
4 DI27 GAVE
28
5 DI28 GAVE 29
30
6 DI29 GAVE
31
7 DI30 GAVE
M
8 DI31 GAVE

9 10 M SAW

X104
Pin Yam Type
nc X104
1 DI32 GAVE

2 DI33 GAVE
32
33
3 DI34 GAVE
3. 4

4 DI35 GAVE 35
36
5 DI36 GAVE
37
6 DI37 GAVE 38
7 DI38 GAVE 39
M
8 DI39 GAVE

9 10 M SAW

X105
Pin Yam Type
nc X105
1 DI40 GAVE

2 DI41 GAVE
40
41
3 DI42 GAVE
42
4 DI43 GAVE 43
44
5 DI44 GAVE
Four. Five

6 DI45 GAVE 46
7 DI46 GAVE 47
M
8 DI47 GAVE

9 10 M SAW

Signal names
DI0...47 24V digital inputs

Signal type
SAW
Voltage input
GAVE
Input (24V signal)
Table 2–14 Electrical parameters of the digital inputs
Parameter Value unit note
“1” signal, voltage range “1” 15...30 V
signal, current consumption “0” signal, 2...15 mA
voltage range –3...5 V or input open
Signal delay 0 1 0.5...3 ms
Signal delay 1 0 0.5...3 ms

2-18 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Installing the Control System

2.3.7 Connecting the digital outputs (X200, X201)

Connector pin assignment

Interface for digital outputs

Connector designation: X200, X201

OUT

Connector type: 10-pin plug connector

Table 2–15 Connector pin assignment

X200

Pin Yam Type

1P24 SAW X200
1P24
1 DO0/CW EITHER

0/CW
2 DO1/CCW EITHER
1/CCW
3 DO2 EITHER
2
3
4 DO3 EITHER
4
5 DO4 EITHER 5
6
6 DO5 EITHER

7
7 DO6 EITHER M
8 DO7 EITHER

9 10 M SAW

X201

Pin Yam Type

2P24 SAW X201
2P24
1 DO8 EITHER

8
2 DO9 EITHER
9
3 DO10 EITHER
10
eleven

4 DO11 EITHER
12
5 DO12 EITHER 13
14
6 DO13 EITHER

fifteen

7 DO14 EITHER
M
8 DO15 EITHER

9 10 M SAW

Signal Description:

DO0 ... DO13 Digital output 0...13, Max. current 500mA.

DO0/ CW Digital output 0 / Unipolar Spindle CW Direction, Max. current

500mA.

DO1/ CCW Digital output 1 / Unipolar Spindle CCW Direction, Max. current
500mA.

1P24, M Power supply for the digital outputs 0...7

2P24, M Power supply for the digital outputs 8...15

Signal type

SAW
Voltage input
EITHER
Output (24V signal)

SINUMERIK 802C base line 2-19

Start-Up
Machine Translated by Google

Installing the Control System

Table 2–16 Electrical parameters of the digital outputs

parameters value unit note
“1” signal, nominal voltage 24 V
Voltage drop max. 3 V
“1” signal, output current 0.5 TO Simultaneity factor
0.5 per 16 outputs
“0” signal, leakage current max. 2 mA

2-20 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Installing the Control System

2.4 Power Supply for CNC (X1)

Screw terminal block

The 24 V DC load power supply unit required for supplying CNC is connected
to screw-type terminal block X1.

Characteristics of the load power supply

The 24 V DC voltage must be generated as a functional extra-low voltage with
safe electrical Isolation (to IEC 204–1, Section 6.4, PELV).
Table 2–17 Electrical parameters of the load power supply
parameters Min. Max. Unit Conditions
Voltage range mean value 20.4 28.8V
Ripple 3.6 Vss
Non-periodic overvoltage 35V 500 ms cont.
50s recovery
Rated current consumption 1.5A
Starting current 4A

Pin assignment on the CNC side

Table 2–18 Pin assignment of screw terminal block X1
Terminal
PE PE
1 M ground
23 P24 DC 24V

SINUMERIK 802C base line 2-21

Start-Up
Machine Translated by Google

Installing the Control System

2.5 LEDs and Other Elements on CNC

Error and status LEDs

There are three LEDs on the front panel of the CNC.

Fig. 2-6 Operator panel and user interfaces

ERR (network) group error

This LED indicates an error condition of the CNC.

POK (green) Power OK

The power supply is ready.

DAY (yellow) Diagnostics

This LED indicates various diagnostic states. Under normal operating conditions,
this LED flashes 1:1.

2-22 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Installing the Control System

Start-up switch (S3) This rotary switch is intended to assist start-up.

Position 0: Normal operation
Positions 1–4: Start-up
cf. also Section 4.2, Table 4–2

Fuse (F1) This design allows users to replace the fuse very conveniently when the fuse is
broken.

S2 and D15 They are provided only for debugging internally.

Grounding Screw In order to ensure the system functions correctly and safely, the CNC must be
grounded through the grounding screw on the rear side of CNC.

SINUMERIK 802C base line 2-23

Start-Up
Machine Translated by Google

Installing the Control System

2-24 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Installing the Drives 3

References
Manufacturer documentation of the drives

SINUMERIK 802C base line 3-1

Start-Up
Machine Translated by Google

Installing the Drives

3-2 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up 4
4.1 General
Start-up requirements
The following is required:
User Manual: Operation and Programming, SINUMERIK 802C base line

PC/PG (programming device) only for data saving and series start–up Toolbox on CD.

The CD is either supplied with the control system or can be ordered separately.

Contents
WINPCIN for data transfer via the V24 interface from/to external
PC/PG
Cycle pack Turning and Milling
The mechanical and electrical installation of the equipment must be completed.

Notice
For installation refer to the installation notes provided in section 2.

The control system with its components has been powered up without errors.

Start–up sequence The SINUMERIK 802C base line can be stratified up as follows:
1. Check whether the ENC has powered up.
2. PLC start-up 3.
Technology setting 4. Set
general machine data.
5. Set axis/machine–specific machine data.
Match encoder with spindle
Match setpoint with spindle
6. Dry run for axes and spindle(s)
7. Drive optimization
8. Complete start-up, data saving

SINUMERIK 802C base line 4-1

Start-Up
Machine Translated by Google

Start-Up

4.1.1 Access levels

Protection levels The SINUMERIK 802C base line provides a protection level concept for
enabling data areas. The protection levels range from 0 to 7 where by 0 is the
highest and 7 the lowest level.
The control system comes with default passwords for protection levels 2 and 3.
If necessary these passwords can be changed by the appropriate authorized
person
Table 4–1 Protection level concept
Protection
Disabled via Data Area
level
0 Siemens, reserved
Siemens, reserved
1 Password: EVENING (default) Machine manufacturer
2 Password: CUSTOMER (default) Authorized operator, setter
34 No password or Authorized operator, setter
user IS from PLC ÿ NCK
5 User IS from PLC ÿ NCK
6 User IS from PLC ÿ NCK
7 User IS from PLC ÿ NCK

Protection levels 2 ... 3

The protection levels 2 and 3 require a password. The passwords can be
changed after activation. For example, if the passwords are no longer known,
the control system must be reinitialized (booting in Start–Up Switch position
1). This will reset all passwords to the default settings for this software version.
If the password is deleted, protection level 4 is applicable.
The password remains set until it is reset using the Delete password softkey;
POWER ON will not reset the password.

Protection levels 4 ... 7

Protection level 4 is automatically set when no password is entered. If required,
the protection levels 4 ... 7 can be set from the user program via the user
interface.

See Section 6.1.1 “Display Machine Data”.

How to set the access levels is described in the User's Guide “Operation and
Programming”.

4-2 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

4.1.2 Structure of machine data (MD) and setting data (SD)

Number and name Machine data (MD) and setting data (SD) are differed either by numbers or
names. Both the number and the name are displayed on the screen.
Parameters:
Activation
Protection level
unit
Standard value

Range of values

Activation The activation levels are listed according to their priority. Any data changes
come into effect after:

POWER ON (po) switching on/off the SINUMERIK 802C base line

NEW_CONF (cf)
Activate MD softkey on the operator panel
RESET key on the operator panel
Modifications at the block limits are possible while the program is
running.
RESET (re) RESET key on the operator panel or M2/M30 at the end of
the program
IMMEDIATELY (im) after entering a value

Protection level To display machine data, protection level 4 (or higher) must be activated.
Start–up or machine data input generally requires protection level 2 or higher
(password “EVENING”).

unit Depending on the MD SCALING_SYSTEM_IS_METRIC, the physical units of

the MD are set as follows:
MD10240 = 1 MD10240 = 0
Mm in
mm/min in/min
m/ in/s2
s2 in/s3
m/s3 mm/rev in/rev

If no physical units are applicable to the MD, the field contains a “–”.

Notice

The default setting of the machine data is

MD10240 SCALING_SYSTEM_IS_METRIC = 1 (metric).

Default data This is the default value for the machine or setting data.

SINUMERIK 802C base line 4-3

Start-Up
Machine Translated by Google

Start-Up

Range of values (minimum and maximum values)

...specifies the input limits. If no range of values is specified, then the input limits
are defined by the data type, and the field is marked with “***“.

4.1.3 Handling of machine data

Handling methods
Display
Input via keys and V24 interface
Making backup copies and reading in/reading out data via the V24 interface

These back-up copies contain

machine data
line check sums and
machine data numbers.

Aborting when loading MD

If incorrect machine data files are read into the control system, an alarm is output.

At the end of reading, an alarm with the number of errors is displayed.

4.1.4 Data saving

Internal data saving The data in the memory backed up for a limited period can be saved internally in the

permanent memory of the control system.

An internal data backup should be carried out if the control system has been
switched off for more than 50 hours (at least 10 min/day with controller ON).
It is recommended to carry out internal data saving whenever important data
changes have been made.

Notice
During the internal data backup, a memory copy of the memory backed up for a
limited time is made and stored in the permanent memory. Selective data backup
(eg only the machine data and not the part programs) is not possible.

Saving data internally:

Use the ETC key to extend the menu in the Diagnosis/Start–up menu and press
the Save data softkey.
Loading data from an internal data backup:
Boot the control system using the start–up switch, position 3

4-4 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

If the data in the backed–up memory area is lost, on POWER ON the data saved in the permanent
memory area are automatically reloaded into the memory.

Notice

The note “4062 Data backup copy has been loaded” appears.

External data saving In addition to the internal data backup, the user data of the control system can and must also be saved
externally.
External data saving requires a PC/PG (programming device) with V24 interface and the WinPCIN
tool (included in the tool box).
External data saving should be performed whenever substantial changes in the data have been
made, as well as always at the end of start–up.
External data backup variants: Saving

data externally: 1. The data

record is read out completely, creating the series start-up file.
This is intended for series start-up or to restore the control system status after replacing
hardware components or after data loss.
2. Files are read in or read out by areas. The following user data can be selected as individual
files:
Data

Machine data

Setting data
Tool data

R parameters
Zero offset

Compensation data (LEC)

Part programs
Standard cycles

Saving data externally: Use

the Services/Data outp. menu to transfer the following user data as individual files to an external PC
via the V24 interface.

Loading data from an external data backup into the control system: Press the Start data
inp. softkey in the Services menu.

SINUMERIK 802C base line 4-5

Start-Up
Machine Translated by Google

Start-Up

4.2 Turning on and booting the control system

Procedure
Inspect the system visually for:
proper mechanical installation with tight electrical connections
supply voltages
connections for shielding and grounding.
Turn on the control system.

Notice
Providing memory and start–up switch S3 are set correctly (see Fig.2–6), the
control system boots.

Start–up switch S3 (hardware)

The CNC is provided with a start–up switch to assist start–up of the control
system.
This switch can be actuated using a screw driver.
Table 4–2 Start–up switch settings
Position Meaning
Normal power-up
01 Power-up with default machine data (user data determined by the
software version)
2 System software update
3 Power-up with saved data
4 PLC stop
5 Reserve
6 Assigned
7 Assigned
The switch position comes into effect with next power-up and is displayed on
the screen when the control system powers up.

Start–up switch (software)

In addition to the hardware start–up switch, the following functions can also be
carried out in the Diagnosis/Start–up/Start–up switch menu:
normal boot (Start-up switch position 0)
Boot with default machine data (Start–up switch position 1)
Boot with saved data (Start-up switch position 3)
These power-up functions have a higher priority than the hardware start-up
switch.

Booting the control system

When the control system is turned on for the first time, an initial state of the
control system is established automatically. All memory areas are initialized
and are loaded with previously stored default data.
The PLC area of retentive bit memories is explicitly erased.

4-6 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

The control system changes to the JOG/Ref.point approach mode and the yellow DIAG LED
flashes (see Fig. 2–6).
This initial state is the precondition for error–free start–up of the control system.

When the control system is already turned on, start–up is also possible in the Diagnosis menu (see
User Manual).

Normal booting (Start-up switch position 0)

Result
User data exists, no boot Control system changes to JOG/
mistake Ref.point approach mode, yellow LED
DIAG (see Fig. 4–1) flashes.
Data in user memory faulty Backed–up user data are loaded from the permanent
memory into the user memory (as in start–up switch position
3). If no valid user data are in the permanent memory, the
default data is loaded (as in start–up switch position 1).

Any deviations from normal booting are displayed on the

screen.

Booting with default machine data (Start–up switch position 1)

Result
The user memory area not loaded with default data is erased, and the default
machine data is loaded from the permanent memory into the user memory.

Booting with saved data (Start–up switch position 3)

Result
The user data backed up on the permanent memory are loaded into the user memory.

Contrast control See User's Guide “Operation and Programming”

SINUMERIK 802C base line 4-7

Start-Up
Machine Translated by Google

Start-Up

4.2.1 Boot messages

Displays on the screen

When the control system is booting, test patterns or boot information are displayed on the
screen as progress displays.
After the control system has booted without errors, it changes to the JOG/Ref.point approach mode,
and the yellow DIAG LED (see Fig. 4–1) flashes.

Boot errors Boot errors are displayed either on the screen or via the LED (see Fig. 4–1 in the following).

The ERR flashes, and the DIAG LED does not flash.

Fig. 4-1 LED

Table 4–3 Boot errors

Error Message Remedial Action

MISTAKE 1. Switch off the control system and back on again (POWER
EXCEPTION ON).
MISTAKE 2. Inform the hotline if necessary.
DRAM 3. Carry out a software update.
MISTAKE 4. Replace the hardware components.
BOOT
MISTAKE
NO BOOT2
MISTAKE
NO SYSTEM
MISTAKE
LOAD NC
NO SYSTEM–LOADER
MISTAKE
LOAD NC
CHECKSUM–ERROR
MISTAKE
LOAD NC
DECOMPRESS–
MISTAKE
MISTAKE
LOAD NC
INTERNAL–ERROR 1

4-8 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

4.3 Starting up the PLC

General The PLC is a store-programmable logic controller for simple machines. It has no hardware of its own
and is used as a PLC software in the SINUMERIK 802C base line control system.

The task of the PLC is to control machine-related functional sequences.

The PLC executes the user program cyclically. A PLC cycle is always executed in the same sequence
of order.

Update process image (inputs, outputs, user interface, timers)

Process communication requests (Operator Panel, PLC 802 Programming
Tools)
Execute user program
Evaluate alarms

Output process image (outputs, user interface)

The PLC executes the user program cyclically, starting from the first up to the final operation. Access
from user program is only carried out via the process image and not directly to the hardware inputs or
outputs. The hardware inputs and outputs are updated by the PLC at the beginning and at the end of
program execution. The signals are thus stable over a PLC cycle.

The user program can be created by means of the PLC 802 Programming Tool using the S7-200
programming language in conjunction with ladder diagrams (LAD). A ladder diagram is a graphical
programming language to represent electrical circuit diagrams.

This Documentation describes the program structure and the instruction set of the PLC in detail.

SINUMERIK 802C base line 4-9

Start-Up
Machine Translated by Google

Start-Up

4.3.1 Commissioning of the PLC

The SINUMERIK 802C base line comes to the user with a simulation program included.

The SAMPLE user program is stored in the permanent memory. This sample program and the
documentation are included in the SINUMERIK 802SC base line Toolbox component “PLC802SC
base line Library”.
The simulation program is intended for the first function test of the control system after assembling
the control.

Internal simulation program The

simulation program is an integral part of the 802C base line system software. It allows operation of
the control system even without connection to input and output terminals. The user program processes
all firmly defined keys and the default setting of the axis keyboard (default).

Axes and spindle are switched to simulation mode. No real axis movement is carried out. The Axis/
Spindle Disable user signal is set for each axis. For this reason, the movements of both axes and
spindle are simulated virtually. The user can use this program to test the interrelation of the
components integrated in CNC.

approach
Set MD20700 to zero.

Use the Diagnosis/StartUp switch/PLC softkey to select Simulation.

You can check the current setting via Diagnosis/Service display/Version /PLC application.

Select the desired key and check your setting by pressing the key.

Supported keys
Mode selection

Axis keys

NC keys

Notice

The Increment key is only active in the JOG mode. The toggle function can be used to set increments
in the range between 1,10,100, or 1000. Check the response by pressing the axis direction keys.

Reference Point is not supported.

4-10 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

Standard user program

The control system comes with a universal program, the customer can
choose the technology mode (Turning or Milling) with PLC user machine data.

4.3.2 Start-up modes of the PLC

The PLC can activate its start-up modes from two places.

Table 4–4 Start-up modes

Start-Up Switch Operator Panel PLC Program program Retention Data MD for the PLC
Start Up Menu Selection Status (Backed-Up) in the User
Interface
*
CNC start-up
Normal power-up Normal power-up User program Run Unchanged Accept active
Position 0 MD PLC
Power-up with Power-up with default User program Run Deleted Standard PLC MD
default values values
Position 1
Power-up with Power-up with saved User program Run saved data saved
saved data data MD PLC
Position 3
PLC Stop Unchanged Stop Unchanged Accept active
after POWER ON MD PLC
Position 4
**
PLC start up
Restart User program Run Unchanged Accept active
MD PLC
Restart User program Stop Unchanged Accept active
and debug mode MD PLC
Restart with simulation Simulation run Unchanged Accept active
program MD PLC

overall reset User program Run Deleted Accept active

MD PLC
Overall reset and User program Stop Deleted Accept active
debug mode MD PLC

* Diagnosis/Start up / Start up switch / CNC softkey

** Diagnosis/Start up / Start up switch / PLC softkey
The start-up switch PLC Stop can be activated either during operation or
power-up.
The debug mode (see “Operation and Programming”, Chapter 7) causes the
PLC to remain in PLC Stop after the control system has powered up. All
power-up modes that have been set either via softkeys or via hardware start-up
switches will only come into effect after the next power-up of the control
system. The hardware start-up switch “PLC STOP” (position 4) is active
immediately. The priority of the power-up modes activated via the softkeys on
the operator panel is higher than that of the hardware start-up switches.
Example:
Hardware start-up switch position 3
Restart from operator panel
Restart is active from next power-up of the control system

SINUMERIK 802C base line 4-11

Start-Up
Machine Translated by Google

Start-Up

The Run mode activates the cyclic mode.

In the Stop mode, the following actions are initiated: All hardware

outputs are disabled.

The NC Ready relay is inactive.

No cyclic operation (active user program is not executed)

Process image is no longer updated (“frozen”)

Emergency Stop active

The user can also use the PLC 802 Programming Tool to start the Stop or Run modes.

A corrected or new project can only be loaded into the control system in the Stop mode. The user
program comes only into effect with next power-up or when the Run mode is active.

4.3.3 PLC alarms

The control system displays a maximum of 8 PLC alarms (system alarms or user alarms).

The PLC manages the alarm information per PLC cycle. It stores or deletes the alarms in the alarm list
according to their occurrence. The first alarm in the list is generally the last alarm occurred.

If more than 8 alarms occur, the first seven alarms occurred are displayed, and the last one with the
highest cancel priority is displayed.

Alarm response and cancel criterion

Furthermore, the PLC manages the alarm responses. The alarm responses are always active,
regardless of the number of active alarms. Depending on the type of the alarm response, the PLC
triggers an appropriate response.

Each alarm requires a cancel criterion to be defined. The PLC uses the SELF-CLEARING criterion as
default criterion.

Cancel criteria are:

POWERONCLEAR: The alarm is canceled by switching off/switching on the control system.

CANCEL CLEAR: The alarm is canceled by pressing the Cancel key or the Reset key
(analogously to CNC alarms).

SELF-CLEARING: The alarm is cleared because the cause resulting in the alarm has been
eliminated or does not exist any longer.

Desired alarm responses are defined for each alarm in the PLC. By default, the PLC uses the
SHOWALARM response (bit0 - bit5 = 0).

Possible alarm responses are:

PLC Stop: The user program is no longer executed, the NC Ready relay drops out, and the
hardware outputs are disabled (OUTDS).

EMERGENCY STOP: The PLC provides the EMERGENCY STOP signal to the CNC in the
user interface after the user program has been executed.

4-12 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

Feed disable: The PLC provides the Feed Disable signal to the CNC in
the user interface after the user program has been executed.
Read-in disable: The CNC provides the Read-in Disable signal to the
CNC in the user interface after the user program has been executed.
NC Start inhibited: The PLC provides the NC Start Inhibited signal to the
CNC after the user program has been executed.
SHOWALARM: This alarm has no alarm response (bit0 - bit5 =0).

Priority of cancel conditions

The cancel conditions have the following priority:
POWER ON CLEAR - system alarms (highest priority)
CANCEL CLEAR - system alarms
SELF-CLEARING - system alarms
POWER-ON CLEAR - user alarms
CANCEL CLEAR - user alarms

SELF-CLEARING - user alarm (lowest priority)

System alarms see Diagnostics Guide

User alarms The user interface “1600xxxx” provides the user with two sub-ranges for setting
to user alarm.

Sub-range 0: 4 x 8 bits to set user alarms (0 -> 1 edge)

'' ''
Byte 0 : Bit0 => 1st user alarm 700000
'' ''
Byte 3 : Bit7 => 32nd user alarm 700031
Sub-range 1: User alarm variables
The respective bit (sub-range 0) with a 0/1 edge change will activate a new
user alarm.
Sub-range 1 is intended for additional user information.
Sub-range 2 can be used to analyze the active alarm responses.
Sub-range 1 can only be read or written as a double word. Sub-range 2 channel
only be read.
You can delete self-clearing alarms by resetting the respective bit in the
variable range ''1600xxxx'' in sub-range 0 (1 -> 0 edge).
The remaining user alarms are cleared by the PLC after detecting the
respective cancel condition. If the alarm is still present, the alarm occurs again.

SINUMERIK 802C base line 4-13

Start-Up
Machine Translated by Google

Start-Up

User alarm activation

Inter-
User
final in-
interface
terface

alarm handler Feed disable in the CNC is

Feed disable active
activate for all axes as long as the
PLC user alarm is active.

User program

Example:
Feed disable=0
User alarm with feed
disable

alarm handler
Module:
Analyze user alarm

PLC cycle

Fig. 4-2 User alarm with Feed Disable alarm response

Configuring user alarms

Each alarm is assigned a configuration byte. The user alarms can be configured
by the user in machine data 14516_MN_USER_DATA_PLC_ALARM.
Default setting MD 14516: 0 => SHOW ALARM/SELF-CLEARING user alarm
Configuration byte structure:
Bit0 - bit5: Alarm responses
Bit6 - bit7 : Cancel criterion
Alarm responses: Bit0 - bit 5 = 0: Showalarm (default)
Bit0 = 1: NC Start inhibited
Bit1 = 1: Read-in disable
Bit2 = 1: Feed disable for all axes
Bit3 = 1: EMERGENCY STOP
Bit4 = 1: PLC Stop
Bit5 = Reserved
Cancel criteria: Bit6 + bit7 = 0: SELF-CLEARING alarm (default)
Bit6 = 1: CANCEL CLEAR alarm
Bit7 = 1: POWERONCLEAR alarm

Alarm texts The user has two possibilities to define his own alarms.
using the “Edit PLC txt” softkey (See “Operation and Programming”,
Chapter 7)

4-14 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

using the “Text Manager” in Toolbox CD

The procedure is described in the Toolbox readme file.
Alarm texts are structured as follows:
Alarm number Flag 1 Flag2 text

Notice
The text must be put in inverted commas ('' '')!
Adhere to the given text structure.

Table 4–5 Example

Alarm Number Flag 1 Flag 2 text
700000 0 0 “User alarm 1”

700000 0 0 “ '' // 1st user alarm, text is assigned by the user

700001 0 0 “ '' // 2nd user alarm, text is assigned by the user

700002 0 0 “ '' // 3rd user alarm, text is assigned by the user

700003 0 0 “ '' // 4th user alarm, text is assigned by the user

700004 0 0 “ '' // 5th user alarm, text is assigned by the user

700005 0 0 “ '' // 6th user alarm, text is assigned by the user

...
700031 0 0 “ '' // 32nd user alarm, the text is assigned by the user

number
The alarm text must be here
Comment line (does not appear in the
dialog window of the Operator Panel)
If no user alarm text is assigned by the user, the operator panel will display only
the alarm number.
The % character in the alarm text is the code for the additional variable. The
variable type is the representation type of the variable.
The following variable types are possible:
%D ... Integer decimal number
% I ... Integer decimal number
%U ... Unsigned decimal number
%O ... Integer octal number
%X ... Integer hexadecimal number
%B ... Binary representation of 32-bit value
% F... 4 byte floating point number

SINUMERIK 802C base line 4-15

Start-Up
Machine Translated by Google

Start-Up

User alarm text examples

700000 “ '' // Only user alarm number
“
700001 Hardware limit switch X + axis
700002 “ %D '' // Only variable as an integer decimal number
“
700003 Alarm number with fixed alarm text and variable %X ''
''
700004 “ %U Alarm number with variable and fixed alarm text
“
700005 Rotation monitoring of axis active : %U ''
Operator panel display: 700005 Rotation monitoring of axis active : 1
or 700005 Rotation monitoring of axis active : 3

4.3.4 Machine control panel area layout

The machine control panel area in the standard version has been configured
for economical turning machines (2 axes and one spindle).
The user can use the keys K1 – K12 and the associated LEDs (the same
applies to keys K1 ... K12) for its own purposes.
The keys K22-K30 should be used as axis keys (see sample program
SAMPLE). The programmer can assign the axis keys depending on his
particular machine type.
The keys K31-K36 are used as axis override and spindle override buttons.

Notice
When delivery, the SINUMERIK 802SC base line is provided with inserted
stripes (10 provided, 3 of them are inserted as standard for turning technology),
which consists of all the combinations for both turning and milling technologies.
It is also possible for the user to customize keys K1…K12. The method in
details is explained in Toolbox.

4-16 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

Layout when delivered Key assignment

Available as accessory: Emergency K1…K39 keys 1…39

Stop Switch (see user interface)

Fig. 4-3 Layout of machine control panel area

+Y

-AND

horizontal turning machine vertical milling machine

Fig. 4-4 Examples for the assignment of the axis keyboard

SINUMERIK 802C base line 4-17

Start-Up
Machine Translated by Google

Start-Up

4.3.5 PLC programming

The PLC user program is created using the PLC 802 Programming Tool.
The Documentation “S7-200 Automation System, System Manual'' describes
how this tool is operated for S7-200. The PLC 802 Programming Tool is to be
understood as a subset of this Documentation.

Compared with the S7-200 MicroWin basic system, please note the following:
The PLC 802 Programming Tool is delivered in the English language
version.

The user program can only be programmed using ladder diagram.

Only a subset of the S7-200 programming language is supported.
The compilation of the user program is carried out either offline on a
programming device (PG)PC or semi-automatically when downloading
into the control system.
The project can be loaded into the control system (download).
It is also possible to load the project from the control system (upload).
Direct data addressing is not possible; therefore, no programming errors
will result during the operation.
The data/process information must be managed by the user in
according to the particular type.
Example:
Information 1 T value DWord memory size (32-bit)
Information 2 Override Byte memory size (8-bit)
User data
Byte 0 DWord (Information 1)
Byte 4 Byte (Information 2)
The user is not allowed to access both of these data at the same time;
Otherwise, the relevant data access rules must be observed.
Furthermore, the data direction in the memory model (alignment) and the data
type must be observed for all data.
Example:
Flag bit MB0.1,MB3.5
Flag byte MB0,MB1,MB2
Flag word MW0,MW2,MW4
MW3, MW5...are not permissible
Flag double-word MD0,MD4,MD8
MD1,MD2,MD3, MD5 ... are not permissible
Table 4–6 PLC data types permitted in the control system

Address Range for

Size Range for Arithmetical
Data Type
Alignment Logic Operations
operations
BOOL 1 bit 1 1 byte 0, 1 -
BYTE 1 2 bytes 2 00...FF 0...+255
WORD 0000...FFFF -32 768...767 + 32

DWORD 4 bytes 4 0000 0000... -2 147 483

(Double Word) FFFF FFFF 648...
+2 147 483 647
REAL - +/-10-37... +/-1038
4 bytes 4

4-18 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

PLC projects In any case, the PLC 802 Programming tool manages one project (logic
operations, symbols and comments). The download function is intended to
store all important information of a project in a control system.
The control system is able to store max. 4,000 instructions and 1,000 symbols.
The required PLC memory is influenced by the following components:
Number of instructions
Number and length of the symbol names
Number and length of the comments

S7-200 A ladder diagram is a graphical programming language similar to electric circuit

diagrams.

ladder diagram When creating a program using the ladder diagram form, then you will work
with graphical components to create the networks of your logics. To create your
program, you can use the following elements:
Contacts constitute a switch through which the current can flow. Current,
however, it will only flow through a normally open contact if the contact is
closed (logical value 1). Current will flow through a normally closed
contact or a denied contact (NOT) if the contact is open (logical value
0).
Coils constitute a relay or an output which is updated by the signal flow.
Boxes constitute a function (eg a timer, counter or arithmetic operation)
which is carried out at the moment when the signal flow reaches the box.
A network consists of the elements mentioned above, forming a closed circuit.
The current flows from the left conductor bar (in the ladder diagram symbolized
by a vertical line at the left window) through the closed contacts, enabling coils
or boxes.

Overview of commands
Table 4–7 Operand identifiers
Operand ID Description Range
V Data V0.0 to V79999999.7 (see Table 4-8)
T Timers T0 to T15
c Counters C0 to C31
Yo

Map of digital inputs Map I0.0 to I7.7

Q of digital outputs Q0.0 to Q7.7
M Flags M0.0 to M127.7
YE Special flags SM0.0 to SM 0.6 (see Table 4-10)
A.C. ACCU AC0...AC3

Table 4–8 Generating the addresses for the V range (see user interface)
Type Code Range No.
Subrange Offset Addressing
(DB No.) (Channel/ Axis No.) 00
00 0 000 symbolic
(00-79) (00-99) (0-9) (000-999) (8-digit)

SINUMERIK 802C base line 4-19

Start-Up
Machine Translated by Google

Start-Up

Table 4–9 802C base line ranges of operands

Accessed by: Memory Type Bit (Byte.bit) SINUMERIK 802C base line
14000000.0-79999999.7
0.0 - 7.7
0.0 - 7.7
0.0 - 127.7
0.0 – 0.6
0 – 15
0 - 31
0.0 - 59.7
Byte 14000000-79999999
0-7
0-7
0 - 127
VIQM 0
SM 0 - 59
0-3
words TCL 14000000-79999998
VB 0–6
IB 0–6
QB 0 - 126
0 - 15
0 – 31
MB 0 - 58
0-3
SMB LB AC VW IW QW MW TC LW AC Double Word
14000000-79999994
VD
ID 0–4
Q.D. 0–4
M.D. 0 – 124
L.D. 0 - 56
A.C. 0–3

Table 4–10 Special Flag SM Bit Definition

SM Bits Description
SM 0.0 Flags with defined ONE signal
SM 0.1 Initial position: first PLC cycle '1', following cycles '0'
SM 0.2 Buffered data lost - applicable only to the first PLC cycle ('0'
data ok, '1' - data lost)
SM 0.3 POWER ON: first PLC cycle '1', following cycles '0'
SM 0.4 60 s cycle (alternating '0' for 30 s, then '1' for 30 s)
SM 0.5 1 s cycle (alternating '0' for 0.5 s, then '1' for 0.5 s)
SM 0.6 PLC cycle (alternating, one “0” cycle, then one “1” cycle)

4-20 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

4.3.6 Instruction set

A detailed description of the instructions is to be found in the help system of the

PLC 802 Programming Tool (Help > Contents and Index, “SIMATIC LAD
Instructions”) and in the Documentation “S7-200 Automation System, CPU22x
System Manual.
Table 4–11 Instruction set
BASIC BOOLEAN INSTRUCTIONS
instruction Ladder Symbol Valid Operands
Load normal open Bit V, I, Q, M, SM, T, C, L
And n=1 close
Or n=0 open
Load Not normal close Bit V, I, Q, M, SM, T, C, L
And Not n=0 close
Or Not n=1 open
Output prior 0, n=0 Bit V, I, Q, M, T, C, L
prior 1, n=1
Set prior 0, not set Bit V, I, Q, M, T, C, L
(1 Bit) prior 1 or ÿ Yes

Reset prior 0, no reset V, I, Q, M, T, C, L

Bit
(1 Bit) prior 1 or ÿ
R

OTHER BOOLEAN INSTRUCTIONS

instruction Ladder Symbol Valid Operands
Edge Up prior ÿ close
Q
(1 PLC cycle)
Edge Down prior ÿ close
N
(1 PLC cycle)
Logical Not prior 0, later 1
prior 1, later 0
No operation n n = 0...255
NOPE

BYTE COMPARES (Unsigned)

instruction Ladder Symbol Valid Operands
Load Byte = a = b close to a: VB, IB, QB, MB,
And Byte = a ÿ b open ==B SMB, AC,
Or Byte = b Constant, L.B.
LoadByte to to b: VB, IB, QB, MB,
And Byte a < b open > =B SMB, AC,
Or Byte b Constant, L.B.

LoadByte to to

And Byte a > b open < =B

Or Byte b

SINUMERIK 802C base line 4-21

Start-Up
Machine Translated by Google

Start-Up

WORD COMPARES (Signed)

Instruction Ladder Symbol Valid Operands
Load Word = a = b close to a: VW, T, C, IW, QW,
And Word = a ÿ b open ==I MW, AC, Constant,
Or Word = b
L.W.

Load Word to to
b: VW, T, C, IW, QW,
And Word MW, AC, Constant,
a < b open > =I
Or Word L.W.
b
Load Word to to

And Word a > b open < =I

Or Word b

DOUBLE WORD COMPARES (Signed)

instruction Ladder Symbol Valid Operands
Load DWord = a = b close to to: VD, ID, QD, MD, AC,
And DWord = a ÿ b open ==D Constant, L.D.
Or DWord = b b: VD, ID, QD, MD, AC,
Load DWord to to
Constant, L.D.
And DWord a < b open > =D
Or DWord b
Load DWord to to

And DWord a > b open < =D

Or DWord b

REAL WORD COMPARES (Signed)

instruction Ladder Symbol Valid Operands
Load RWord = a = b close to to: VD, ID, QD, MD, AC,
And RWord = a ÿ b open = =R Constant, L.D.
Or RWord = b b: VD, ID, QD, MD, AC,
Load RWord to to Constant, L.D.
And RWord a < b open > =R
Or RWord b
Load RWord to to

And RWord a > b open < =R

Or RWord b

4-22 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

TIMER
instruction Ladder Symbol Valid Operands
TimervRetentiv EN=1, Start Enable: (IN)
Txxx
and On Delay EN=0, Stop S0
TONR
If TValue Txxx: T0 - T15
IN
Tbit=1 Preset: (PT)
VW, T, C, IW, QW,
M.W., A.C.,
P.T. Constant
100 ms T0 - T15
Timer On Delay EN=1, Start Txxx Enable: (IN)
EN=0, Stop S0
TON
If TValue Txxx: T0 - T15
IN
Tbit=1 Preset: (PT)
VW, T, C, IW, QW,
M.W., A.C.,
P.T. Constant
100 ms T0 - T15
Timer Of Delay If TValue < PT, Txxx Enable: (IN)
Tbit=1 S0
TOF
Txxx: T0 - T15
IN
Preset: (PT)
VW, T, C, IW, QW,
M.W., A.C.,
P.T. Constant
100 ms T0 - T15

COUNTER
instruction Ladder Symbol Valid Operands
Cxxx
Count Up CU ½, Value+1 Cnt Up: (CU)
R=1, Reset S1
If CValue C.U. CTU Reset: (R)
Cbit=1 S0
R Cxxx: C0 - 31
PV
Preset: (PV)
VW, T, C, IW, QW,
M.W., A.C.,
Constant, L.W.
Count CU ½, Value+1 Cxxx
Cnt Up: (CU)
Up/Down CD ½, Value-1 S2
R=1, Reset C.U. CTUD Cnt Dn: (CD)
If CValue CD S1
Cbit=1 R
Reset: (R)
PV
S0
Cxxx: C0 - 31
Preset: (PV)
VW, T, C, IW, QW,
M.W., A.C.,
Constant, L.W.
Cxxx
Count Down If CValue = 0, Cnt Down: (CD)
Cbit=1 S2
CD CTD Reset: (R)
L.D.
S0
PV Cxxx: C0 - 31
Preset: (PV)
VW, T, C, IW, QW,
M.W., A.C.,
Constant, L.W.

SINUMERIK 802C base line 4-23

Start-Up
Machine Translated by Google

Start-Up

MATH OPERATIONS
instruction Ladder Symbol Valid Operands
Word Add If EN = 1, b Enable: EN
ADD_I
Word Subtract = a + bb = In: VW, T, C, IW, QW,
b-a IN ENO
M.W., A.C., Constant, L.W.
IN 1
Out: VW, T, C, IW, QW, MW,
IN2 OUT
A.C., L.W.

DWord Add If EN = 1, b Enable: EN

SUB_DI
DWord Subtract = a + bb = In: VD, ID, QD, MD, AC,
IN ENO
b-a Constant, L.D.
IN 1
Out: VD, ID, QD, MD, AC,
IN2 OUT L.D.

Multiply If EN = 1, b Enable: EN
MUL
= axb In: VW, T, C, IW, QW, MW,
IN ENO
A.C., Constant, L.W.
IN 1
Out: VD, ID, QD, MD, AC,
IN2 OUT L.D.

Divide If EN = 1, b Enable: EN
DIV
=b In: VW, T, C, IW, QW, MW,
Out: IN ENO
A.C., Constant, L.W.
IN 1
16 bit Out: VD, ID, QD, MD, LD
remainder IN2 OUT
Out+2:
16 bit
quotient
Add If EN = 1, b Enable: EN
ADD_R
Subtract = a + bb = In: VD, ID, QD, MD, AC,
IN ENO
Real Numbers b-a Constant, L.D.
IN 1
Out: VD, ID, QD, MD, AC,
IN2 OUT L.D.

Multiply If EN = 1, b Enable: EN
MUL_R
Divide = axbb = b In: VD, ID, QD, MD, AC,
IN ENO
Real Numbers Constant, L.D.
IN 1
Out: VD, ID, QD, MD, AC,
IN2 OUT L.D.

4-24 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

INCREMENT, DECREMENT
instruction Ladder Symbol Valid Operands
Increase If EN = 1, Enable: EN
Decrement a=a+1 INC_B
In: VB, IB, QB, MB, AC,
a=a-1 IN ENO Constant LB
Byte
Out: VB, IB, QB, MB, AC,
IN OUT L.B.

Increase If EN = 1, Enable: EN
Decrement a=a+1 INC_W
In: VW, T, C, IW, QW, MW,
words a=a-1 IN ENO
A.C., Constant, L.W.
a = /a Out: VW, T, C, IW, QW, MW,
IN OUT A.C., L.W.

Increase If EN = 1, Enable: EN
Decrement. a=a+1 INC_DW
In: VD, ID, QD, MD, AC,
a=a-1 IN ENO
Constant, L.D.
Out: VD, ID, QD, MD, AC,
IN OUT L.D.

SINUMERIK 802C base line 4-25

Start-Up
Machine Translated by Google

Start-Up

LOGIC OPERATIONS
instruction Ladder Symbol Valid Operands
Byte AND If EN = 1, Enable: EN
WAND_B
Byte OR b = a AND bb In: VB, IB, QB, MB, AC,
IN ENO
Byte XOR = a OR bb = Constant, L.B.
IN 1
a XOR b Out: VB, IB, QB, MB, AC, LB
IN 2 OUT

Word AND If EN = 1, Enable: EN

WAND_W
Word OR b = a AND bb In: VW, T, C, IW, QW, MW,
IN ENO
Word XOR = a OR bb = A.C., Constant, L.W.
IN 1
a XOR b Out: VW, T, C, IW, QW, MW,
IN 2 OUT
A.C., L.W.

DWord AND If EN = 1, Enable: EN

WXOR_DW
DWord OR b = a AND bb In: VD, ID, QD, MD, AC,
IN ENO
DWord XOR = a OR bb = Constant, L.D.
IN 1
a XOR b Out: VD, ID, QD, MD, AC, LD
IN 2 OUT

Invert Byte If EN = 1, Enable: EN

INV_B
a = /a In: VB, IB, QB, MB, AC,
IN ENO
Constant, L.B.
Out: VB, IB, QB, MB, AC, LB
IN OUT

Reverse Word If EN = 1, Enable: EN

INV_W
a = /a In: VW, T, C, IW, QW, MW,
IN ENO
A.C., Constant, L.W.
Out: VW, T, C, IW, QW, MW,
IN OUT
A.C., L.W.

Invert DWord If EN = 1, Enable: EN

INV_DW
a = /a In: VD, ID, QD, MD, AC,
IN ENO
Constant, L.D.
Out: VD, ID, QD, MD, AC, LD
IN OUT

4-26 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

SHIFT AND ROTATE OPERATIONS

instruction Ladder Symbol Valid Operands
Shift Right If EN = 1, a Enable: EN
Shift Left = a SR c bits a = a SHL_B
In: VB, IB, QB, MB, AC,
SL c bits IN ENO Constant, L.B.
IN Out: VB, IB, QB, MB, AC
N OUT Count: VB, IB, QB, MB,
A.C., Constant, L.B.
Shift Right If EN = 1, a Enable: EN
Shift Left = a SR c bits a = a SHL_W In: VW, T, C, IW, QW, MW,
SL c bits A.C., Constant, L.W.
IN ENO
IN Out: VW, T, C, IW, QW, MW,
A.C., L.W.
N OUT
Count: VB, IB, QB, MB,
A.C., Constant, L.B.
DWord Shift R If EN = 1, a Enable: EN
DWord Shift L = a SR c bits a = a SHL_DW In: VD, ID, QD, MD, AC,
SL c bits Constant, L.D.
IN ENO
IN Out: VD, ID, QD, MD, AC,
OUT L.D.
N
Count: VB, IB, QB, MB,
A.C., Constant, L.B.

CONVERSION OPERATIONS
instruction Ladder Symbol Valid Operands
Convert Double If EN = 1, Enable: EN
DI_REAL
Word Integer to a Real convert the IN ENO In: VD, ID, QD, MD, AC,
double word Constant, L.D.
integer i to a IN OUT Out: VD, ID, QD, MD, AC,
real number o. L.D.

Convert a Real to a If EN = 1, Enable: EN

TRUNC
Double convert the real In: VD, ID, QD, MD, AC,
IN ENO
Word Integer number i to a Constant, L.D.
double word IN OUT Out: VD, ID, QD, MD, AC,
integer o. L.D.

Instruction Ladder Symbol Valid Operands

n Enable: EN Label:
Jump to Label If EN = 1, go to label n.
WORD: 0-127
JMP

Label Label marker for n Label: WORD: 0-127

LBL
the jump.

Conditional If EN = 1, exit the Enable: EN

Return desde subroutine. RET
Subroutine
Conditional End If EN = 1, END terminates Enable: EN
the main scan. END

Subroutine If EN ÿ, go to Label: Constant: 0-63

n
subroutine n.
SBR
IN

x1 x2 x3

(x... optional parameters)

SINUMERIK 802C base line 4-27

Start-Up
Machine Translated by Google

Start-Up

MOVE, FILL AND FIND OPERATIONS Instruction

Ladder Symbol Valid Operands If EN = 1, Enable: EN copy i to o.
Move Byte
MOV_B
In: VB, IB, QB, MB, AC, Constant,
IN ENO
LB Out: VB, IB,
QB, MB, AC, LB
IN OUT

Move Word If EN = 1, Enable: EN

MOV_W
copy i to o. In: VW, T, C, IW, QW, MW,
IN ENO
A.C., Constant, L.W.
Out: VW, T, C, IW, QW, MW,
IN OUT
A.C., L.W.

Move DWord If EN = 1, copy i to Enable: EN

MOV_DW
o. In: VD, ID, QD, MD, AC,
IN ENO
Constant, L.D.
Out: VD, ID, QD, MD, AC, LD
IN OUT

Move Real If EN = 1, Enable: EN

MOV_R
copy i to o. In: VD, ID, QD, MD, AC,
IN ENO
Constant, L.D.
Out: VD, ID, QD, MD, AC, LD
IN OUT

Swap Bytes If EN = 1, Enable: EN

SWAP
exchange MSB and In: VW, IW, QW, MW, T, C,
IN ENO
LSB of w. A.C., L.W.

IN

4.3.7 Program organization

Each programmer should divide the user program into several closed program
sections (subroutines). The S7-200 programming language allows the user to
create structured user programs. There are two program types - main programs
and subroutines. Eight program levels are possible.
A PLC cycle can be a multiple of the control-internal interpolation cycle (IPO
cycle). The manufacturing machine must set the PLC cycle according to its/her
own requirements (see machine data “PLC_IPO_TIME_RATIO”). The IPO/PLC
ratio of 1:1 is the fastest possible cyclic processing.
Example: The programmer programs a sequence control in the main program
using his own defined cycle counter. The sequence control defines all cyclic
signals in the subroutine (UP0); UP1/UP2 is called every two cycles, and UP 3
controls all signals in steps of three cycles.

4-28 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

4.3.8 Data organization

The data can be divided into three areas:

non-retentive data
retain data

machine data for the PLC (All these machine data are active after POWER ON.)

Most data, such as process map, timers and counters, are non-retentive data and deleted with each
power-up.

The user has a certain area available for the retentive data (data range 14000000 -140000xx ). All
data that are desired to remain their validity even after POWER ON can be stored in this area.

The user can use the PLC MD (see user interface) to load his program with default data or to
parameterize various program sections.

4.3.9 Interface to the control system

This interface can be selected on the operator panel using the soft keys Diagnosis \ Start-up \ STEP7
connect.
The V24 interface remains active even after restart or normal power-up. The connection (STEP7
connect active) to the control system can be checked in the PLC 802 Programming Tool menu “PLC/
Information”. If the interface is active, eg the active PLC mode (Run/Stop) is displayed in this window.

4.3.10 Testing and monitoring the user program

The user program can be analyzed or checked for errors using the following methods:

PLC Status menu (OP)

Status list menu (OP)
PLC 802 Programming Tool (see Help menu > Contents and Index,
“Debugging” or documentation “S7-200 Automation System”, Section
“Testing and Monitoring Your Program”)

SINUMERIK 802C base line 4-29

Start-Up
Machine Translated by Google

Start-Up

4.4 PLC applications “Download/Upload/Copy/Compare”

The user can save or copy PLC applications in the control system or overwrite
them by another PLC project.
This is possible using the
Programming Tool 802
WinPCIN (binary file)

PT PLC 802

Download/ 1
Upload/
Compare

CNC permanent
1
memory
PLC
projects
2 3
PLC user PLC machine
texts data

2
Toolbox 1 2
PLC
applications

123
WINPCIN
Start-up series

Fig. 4–5 PLC applications in the control system

Download This function is used to write the transferred data to the permanent memory (load
memory) of the control system.
Download the PLC project using the PLC 802 Programming Tool (Step 7
connect on)
Series start-up using the WinPCIN tool (PLC MD, PLC project and user
alarm texts) Data In

4-30 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

The loaded PLC user program is transferred from the permanent memory to the user memory when the
control is booted next time; it will be active from this moment.

Upload The PLC applications can be saved using the PLC 802 Programming Tool or the WINPCIN tool.

Upload PLC project using the PLC 802 Programming Tool (Step 7 connect on)

Read out the project from the control system to reconstruct the current project in the PLC 802
Programming Tool.
Series start-up “Start-up Data” using the tool WINPCIN (PLC MD, PLC Project and user alarm
texts) Data Out Read out PLC applications using
the Tool WINPCIN (PLC Project information and user alarm texts) Data Out

Compare The project in the PLC 802 Programming Tool is compared with the project contained in the permanent
memory (load memory) of the CNC.

Versions display Calling via the softkey Diagnosis / Service Display / Version(PROJECT)

The transmitted project including user program, which is active in the PLC after the control system
has powered up.
The programmer can use the first comment line in the program title of the PLC 802 Programming
Tool for his own additional information in the version display (see “View Properties”).

SINUMERIK 802C base line 4-31

Start-Up
Machine Translated by Google

Start-Up

4.5 User Interface

This interface includes all signals between CNC/PLC and HMI/PLC. In addition,
the PLC decodes the auxiliary function commands for simple further processing
in the user program.

4.6 Technology Setting

Overview The SINUMERIK 802C base line is supplied with the default machine data as a
control system for turning machines (2 axes, 1 spindle). If you wish to set another
technology (eg milling), the relevant machine data file must be loaded from the
tool box into the control system.
The file with the technology machine data must be loaded after the control system
has booted successfully, but prior to commissioning.

Sequence of operations
To change the technology setting, proceed as follows:
Make a V24 link between PG/PC and the control system.
Turn on the control system and wait until it has booted without errors.
Press the Start data inp. softkey in the Services menu (use the V24 default
interface settings).
Select the technology machine data file techmill.ini (included in the toolbox)
required for milling and transfer it to the PG/PC using WinPCIN.
After the file has been transferred correctly, carry out POWER ON.
The SINUMERIK 802C base line is now preset to the desired technology.
Example: techmill. ini
Default: 3 axes (X, Y and Z), 1 spindle, no transversal axis, G17 etc.
If you wish to reconfigure a SINUMERIK 802C base line control system to turning,
carry out POWER ON with the default machine data (start-up switch position 1).

Notice
All memory areas are initialized or loaded with stored default values (machine
data).

The basic configuration of the SINUMERIK 802C must be carried out during the
commissioning prior to the general configuration (MD input).
This need not to be done when series start-up is carried out. The configured
machine data are contained in the series start-up file.

4-32 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

4.7 Commissioning

Initializing the control system

Turn on the control system.
The SINUMERIK 802C base line will load the standard machine data automatically.

4.7.1 Entering the general machine data

Overview To make your work easier, the most important machine data of the individual subranges are listed. If
more detailed information is required, the user is referred to the relevant chapters/sections of this
manual. The machine data and interface signals are described in detail in the descriptions of functions
to which reference is made in the relevant lists.

Notice

The general machine data are selected such (default values) that only a few machine data parameters
have to be modified.

Entering the machine data (MD)

Before the machine data can be entered, the password for protection level 2 or 3 must be entered.

The following machine data ranges must be selected and modified (if necessary) using the appropriate
softkeys:
General machine data

Axis machine data

Other machine data

Display machine data

Once entered, these data are immediately written to the data memory.
The machine data are activated depending on the Activation setting of the appropriate machine data,
Section 4.1.2.

Notice

Since these data are only stored in the memory backed up for a limited period of time, a data backup
is necessary (see Section 4.1.4).

Machine data The following machine data list contains all general and other machine data and setting data, which
can be changed if necessary.

SINUMERIK 802C base line 4-33

Start-Up
Machine Translated by Google

Start-Up

number Description Default Value

10074 Division ratio of the PLC task factor for main run 2
11100 Number of auxiliary function groups 1
11200 Standard machine data loaded on next Power On OH
11210 MD backup of changed MD only 0FH
11310 Threshold for direction change of handwheel 2
11320 Handwheel pulses per detent position (handwheel 1
number): 0...1
20210 Maximum angle for compensation blocks with TRC 100
20700 NC–Start disable without reference point 21000 Circle 1
end point monitoring constant 22000 Auxiliary function 0.01
group (aux. fct. no. in channel): 1
0...49
“”
22010 Auxiliary function type (aux. fct. no. in channel):
0...49
22030 Auxiliary function value (aux. fct. no. in channel): 0
0...49
22550 New tool compensation for M function 0

Setting data
number Explanation DefaultValue
41110 Jog feed rate 0
41200 Spindle speed 0
42000 Start angle 0
42100 Dry run feedrate 5000

4-34 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

4.7.2 Starting up the axes

Overview The SINUMERIK 802C base line has up to three servo motor feedrate axes (X,
Y and Z). The servo motor drive signals are output at connector X7 for the:
X axis (SW1, BS1, RF1.1, RF1.2)
Y axis (SW2, BS2, RF2.2, RF2.2)
Z axis (SW3, BS3, RF3.1, RF3.2)
Spindle (SW4, RF4.1, RF4.2)

Simulation/servo motor drive

Setpoint output and pulse feedback can be switched between simulation and drive
operation using the axis MD 30130_CRTLOUT_TYPE and 30240_ENC_TYPE.
Table 4–12
MD Simulation Normal Operation
30130 Value = 0 Value = 1
To test the axis, the current The setpoint signals for stepper
value is fed back internally as motor operation are output at
an actual value. No setpoint connector X7. Real axis traversal is
output at connector X7. possible using a servo motor.
30240 Value = 0 Value = 2
Internal pulse feedback from
setpoint output to current value input
“ON”

Machine data for axes and spindle

number Explanation Default Value
30130 Output type of setpoint (setpoint branch): 30200 Number 0
of encoders 30240 Type of actual 1
value acquisition (actual position 0
value) (encoder no.)
0: Simulation
2: Square–wave generator, standard encoder
(press multiplication)
30350 Output of axis signals with simulation axes 31020 0
Encoder markings per revolution (encoder no.) 2048
31030 Pitch of leadscrew 31040 10
Encoder mounted directly to the machine 0
(encoder no:)
31050 Denominator load gearbox (control parameter 1
no.): 0...5
31060 Numerator load gearbox (control parameter set 1
no.): 0...5
31070 Denominator resolving gearbox (encoder no.) 1
31080 Numerator resolver gearbox (encoder no.) 1
32100 Traversing direction (not control direction) 1
32110 Sign current value (control direction) (encoder 1
No.)
32200 Servo gain factor (control parameter set no.): 1
0...5
32250 Rated output voltage 80
32260 Rated motor speed (setpoint branch): 0 3000

SINUMERIK 802C base line 4-35

Start-Up
Machine Translated by Google

Start-Up

number Explanation Default Value

32700 Interpolatory compensation (encoder no.): 0.1 33050 0
Traversing distance for lubrication from PLC 35010 Gear change 100,000,000
possible. Spindle has several gears 0
steps
35040 Own spindle reset 0
35100 Maximum spindle speed 10000
35110 Maximum speed for gear change (gear stage 500,...
no.): 0..5
35120 Minimum speed for gear change (gear stage fifty,...
no.): 0..5
35130 Maximum speed of gear stage (gear stage no.): 500,...
0...5
35140 Minimum speed of gearstage (gear stage no.): 5,...
0...5
35150 Spindle speed tolerance 35160 0.1
Spindle speed limitation from PLC 35220 Speed for 1000
reduced acceleration 35230 Reduced acceleration 1.0
35300 Position control switch–on speed 0.0
35350 Direction of rotation when positioning 35400 500
Reciprocation speed 35410 Acceleration during reciprocating 3
35430 Starting direction during 500
reciprocation 35440 Reciprocation time for M3 direction 16
354 50 Reciprocation time for M4 direction 35510 Feedrate 0
enable for spindle stopped 36000 1
0.5
0
Exact positioning coarse (only 0.04

SPOS)
36010 Exact positioning fine 0.01
(only
SPOS)
36020 Delay exact positioning fine 1
(only
SPOS)
36030 Zero-speed tolerance 0.2
(only
SPOS)
36040 Delay zero–speed monitoring 0.4
(only
SPOS)
36050 Clamping tolerance 0.5
(only
SPOS)
36060 Maximum velocity/speed ”axis/spindle stopped” 5 (axis);
(only 0.0138
SPOS) (spindle)
36200 Threshold value for velocity monitoring (control 11500 (axis);
parameter set no.): 0...5 31.94 (spindle)
36300 Encoder limit frequency 36302 300000
Encoder limit frequency at which encoder is 99.9
switched on again. (Hysteresis)

4-36 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

number Explanation Default Value

36310 Zero mark monitoring (encoder no.): 0
0.1 0: Zero mark monitoring off, HW encoder
monitoring on
1–99, >100: Number of recognized zero mark
errors during monitoring
100: Zero mark monitoring off, HW encoder
monitoring off
36400 Contour Tol 36610 1
Duration of the deceleration ramp for error states 0.05
36620 Cutout delay servo enable 0.1
36700 Automatic drift compensation 0
36710 Drift limit value for automatic drift compensation 1
36720 Drift basic value 0

Matching encoder to axis/spindle

Machine data for encoder adjustment

number Description Spindle
31040 Encoder mounted directly to the machine 0 1
(encoder no.)
31020 Encoder markings per revolution Incr. /rev. Incr. /rev.
(encoder no.)
31080 Numerator resolver gearbox (encoder Engine revs Load rev.
No.)
31070 Denominator resolver gearbox (encoder Enc. reverse Enc. revs
No.)
31060 Numerator load gearbox (control parameter Engine revs Engine
set no.): 0...5 revs
31050 Denominator load gearbox (control Load revs Load revs
parameter no.): 0...5

Example 1 for encoder matching:

Spindle with rotary encoder (500 pulses) mounted directly on the motor. The
internal multiplication factor is 4. The internal computational resolution
amounts to 1,000 increments per degree.

360 degrees MD 31080

Internal resolution = ------------------------- x --------------------- -- x 1000
MD 31020 x 4 MD 31070

360 x 1 x 1000
Internal resolution = ---------------------------- = 180
500 x 4 x 1

One encoder increment corresponds to 180 internal increments. One encoder

increment corresponds to 0.18 degrees (minimum positioning step).
Example 2 for encoder matching:
Spindle with rotary encoder on motor (2,048 pulses), internal multiplication = 4,
2 speed stages exist:

SINUMERIK 802C base line 4-37

Start-Up
Machine Translated by Google

Start-Up

Gear stage 1: Motor/spindle = 2.5/1

Gear stage 2: Motor/spindle = 1/1
Gear stage 1
360 degrees MD 31080 MD 31050
Internal resolution = ------------------------- x --------------------- ----- x ------------------- x 1000incr/deg
MD 31020 x 4 MD 31070 MD 31060

360 1 1
Internal resolution = ----------------- x ------------- x ------------ x 1000pulses/ deg = 17.5781
4 x 2048 1 2.5

One encoder increment corresponds to 17.5781 internal increments. One

encoder increment corresponds to 0.0175781 degrees (minimum positioning
step).
gear stage 2
360 degrees MD 31080 MD 31050
Internal resolution = ------------------------- x --------------------- ----- x ------------------- x 1000incr/deg
MD 31020 x 4 MD 31070 MD 31060

360 1 1
Internal resolution = ----------------- x ------------- x ------------ x 1000pulses/ deg = 43.945
4 x 2048 1 1

One encoder increment corresponds to 43,945 internal increments. One

encoder increment corresponds to 0.043945 degrees (minimum positioning
step).

Machine data default settings for analog motor axes

The machine data list below contains the default machine data with their
recommended settings with the analog motor axes connected.
After they have been set, the axis are ready to be traversed, as far as the
machine data are concerned, and only fine settings have to be done.
Default Setting or
number Description value remark
30130 Output type of setpoint 0 1
(setpoint branch): 0
30240 Type of current value acquisition (current 0 2
position value) (encoder no.)
0: Simulation
2: External encoder
31020 Encoder markings per revolution 2048 Steps encoder per
(encoder no.)
revolution
31030 Pitch of leadscrew 10 Leadscrew
pitch
31050 Denominator load gearbox 1 Load gear
(control parameter no.): 0...5 transmission
ratios
31060 Nominator load gearbox 1 Load gear
(control parameter no.) 0...5 transmission
ratios
(MD31080:MD
31050)
31070 Denominator resolve gearbox 1 Load gear
(control parameter no.): 0...5 transmission
ratios

4-38 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

Default Setting or
number Description value remark
31080 Nominator resolve gearbox 1 Load gear
(control parameter no.): 0...5 transmission
ratios
(MD31080:MD
31050)
32000 Maximum axis velocity 10000 30,000 (max.
axis velocity)
32100 Traversing direction (not control direction) 0 Reversal of
direction of
movement
32110 Sign current value (control direction) 0 Measuring
(encoder no.) system
reversal
32200 Servo gain factor 1.0 1.0 (position
(control parameter set no.): 0...5 controller gain)
32250 Rated output voltage 80% The speed
defined in
MD32260 is
reached at the
setpoint of 8 V
32260 Rated motor speed (setpoint branch): 0 3000 Motor speed
34070 Reference point positioning velocity 300 Positioning
velocity when
referencing
34200 Type of position measuring system 1 Zero pulse
1: Zero pulse (on encoder track)
36200 Threshold value for velocity monitoring 11500 Threshold
(control parameter set no.): 0...5 monitoring for
velocity
monitoring in
the axis
31.94 Threshold
value for
speed
monitoring in
the spindle

To solve monitoring problems, the following machine data must be set.

number Description Default Value Setting or Remark

36000 Exact positioning coarse 0.04 36010 Exact Exact stop coarse
positioning fine 0.01 36020 Delay exact positioning fine Exact stop fine
1.0 Positioning deal
time
36060 Maximum velocity/speed 5.0 Threshold velocity
“axis/spindle stopped” for “Axis at
“standstill”
0.013889 Threshold velocity
for “Spindle at
“standstill”

SINUMERIK 802C base line 4-39

Start-Up
Machine Translated by Google

Start-Up

Parameterization example
Encoder: 2500 [10,000 pulses per motor revolution]
Load gear: 1:1
Leadscrew pitch: 10mm
Motor speed: 1,200 rpm
MD 30130 =1
MD 30240 =2
MD 31020 =2500
MD 32250 =80%
MD 32260 =1,200 rpm MD 32000
=12,000 mm/min The hardware of the

drive must be set such that it will reach exactly 1,200 rpm at 8 V.

servo gain The servo gain default setting is Kv=1 (corresponds to 1mm following error at a
velocity of 1m/min).
The servo gain can or has to be adapted according to the particular mechanical
conditions. Too high gain will result in vibrations, too low gain in a too high
following error. It is imperative that the drive observes the set speed characteristic
(MD32250, MD32260). In addition, the continuous characteristic of the speed
when passing zero is also imperative.

Service display of the axis behavior

Servo Trace To provide axis service, the Servo Trace function is integrated in the Diagnosis
menu, which can be used for graphical representation of the axis setpoint speed.

The Trace function is selected in the Diagnosis/Service display/Servo Trace

operating area (cf. User Manual “Operation..”).

Dynamic adaptation for thread G331/G332

function The dynamic response of spindle and involved axis for the function G331/G332-
thread interpolation - can be adapted to the “slower” control loop.
Usually, this concerns the Z axis, which is adapted to the more inert response of
the spindle.
If an exact adjustment is carried out, it is possible to sacrifice of a compensating
chuck for tapping. At least, higher spindle speeds/smaller compensation paths
can be achieved.

Activation The values for the adaptation are entered in MD 32910 DYN_MATCH_TIME [n],
usually for the axis. The adaptation is only possible if MD 32900
DYN_MATCH_ENABLE =1 has been set for the axis/spindle.

4-40 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

With active function G331/G332, parameter block n (0...5) of the axis of MD

32910 becomes automatically active, which acts corresponding to the gear
stage for the spindle. The gear stage is dependent on the spindle speed with
M40 or is directly set by M41...M45 (see also Section 4.5.3 Start-up of the
spindle).
number Explanation Default Value
32900 Dynamic response adaptation 0
32910 Time constant of dynamic adaptation (control 0.0
parameter set no): 0...5

Determination of value
The dynamic value of the spindle is stored for each individual stage in MD
32200 POSCTRL_GAIN[n] as closed-loop gain. An adaptation of the axis to
these values must be made in MD 32910 DYN_MATCH_TIME [n] in
according to the following instructions:
1 1
MD 32910 DYN_MATCH_TIME[n] =
Kv[n] Spindle Kv[n] axis
The entry to be made in MD 32910 requires the time unit s. The values of MD
32200 POSCTRL_GAIN[n] for spindle and axis must be converted accordingly:
1000
-----------
Kv[n] spindle = POSCTRL_GAIN[n] spindle
60
1000
Kv[n] axis = POSCTRL_GAIN[n] axis
-----------------
60

When using further gear stages with G331/G332, the adaptation must also be
carried out in these parameter blocks.
Example for adaptation of the dynamic response of the Z axis/spindle:
1st gear stage -> parameter block[1],
for spindle-Kv, MD 32200 POSCTRL_GAIN[1] = 0.5 is entered,
for axis Z-Kv, MD 32200 POSCTRL_GAIN[1] = 2.5 is entered.,
The searched entry for the Z axis in

1 1
MD 32910 DYN_MATCH_TIME[1] =
Kv[1]Spindle Kv[1] z

1 1 60
MD 32910 DYN_MATCH_TIME[1] = ( = 0.0960s
)x
0.5 2.5 1000

If necessary, for fine adaptation, in practice a more exact value must be

determined.
When traversing axis (eg Z axis) and spindle, the exact value for POSCTRL_
GAIN is displayed on the service display.
MD 32900 DYN_MATCH_ENABLE must be set to = 1.
Example: service display for Z axis with POSCTRL_GAIN : 62 in 1,000/min
Exact calculation:
1 1 60
MD 32910 DYN_MATCH_TIME[1] = ( ) x0.0954s
0.5 2,437 1000

SINUMERIK 802C base line 4-41

Start-Up
Machine Translated by Google

Start-Up

In practice, this value can be optimized. To this aim, the thread is first tested with
compensating chuck and the calculated values. Then the values should be
modified sensitively such that the difference path in the compensating chuck
approximates to zero.
Now, the POSCTRL_GAIN values displayed on the service display for axis and
spindle should be identical.

Notice
If MD 32900 DYN_MATCH_ENABLE has been set to “1” for the drilling axis, it
should also be set to “1” for all interpolating axes. This increases the traversing
accuracy along the contour. However, the entries for these axes in MD 32910
DYN_MATCH_TIME [n] must be left at the value “0”.

Backlash compensation

Overview The falsification of axis travel due to mechanical backlash can be compensated
(cf. Technical Manual “Description of Functions”).

function The axis-specific current value is corrected by the backlash compensation value
(MD32450 BACKLASH) with each change of the traversing direction.

Activation The backlash compensation is active in all operating modes only after referencing.

Leadscrew error compensation (LEC)

Overview The compensation values are determined by means of the measured error curve
and entered in the control system using special system variables during start–up.
The compensation tables (cf. Technical Manual “Description of Functions”) must
be created in the form of NC programs.

function The leadscrew error compensation (LEC) changes the axis–specific current
position by the associated compensation value.
If the compensation values are too high, an alarm message can be output (eg
contour monitoring, speed setpoint limitation).

Activation The LEC is only activated in all operating modes if the following requirements are met:

The number of compensation intermediate points must be defined. They are only
active after Power ON (MD: MM_ENC_MAX_POINTS).

Caution
Changing the MD: MM_CEC_MAX_POINTS[t] or MM_ENC_COMP_MAX
!
_POINTS automatically reorganizes the NC user memory when the control
system is booting. All user data stored in the user memory (eg drive and MMC
machine data, tool offsets, part programs, compensation tables etc.) are deleted.

4-42 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

Enter the compensation value for the intermediate point N in the compensation value table
(ENC_COMP_[0,N,Axi]).
Select the distance between the individual intermediate points (ENC_COMP_STEP [0,Axi]).

Select the start position (ENC_COMP_MIN [0,Axi]).

Defines the end position (ENC_COMP_MAX [0,Axi]).
In the NC, set MD: ENC_COMP_ENABLE(0)=0. This is the only way to load the compensation
table.
The compensation values for the machine axes are entered into the NC memory by means of a part
program (see also example in the Manual “Description of Functions”)

Approach the reference points in the axes. Then start the NC program with the leadscrew error
compensation table. The reference points must then be approached once more to set the LEC active.
The LEC function is activated by setting the MD: ENC_COMP_ENABLE(0)=1 for each machine axis.

Another possibility to create the LEC compensation table is by reading out the LEC file from the NC
via the V24 interface.

MD: MM_ENC_MAX_POINTS must be set depending on the number of axes to be compensated.

Select Service using the softkey, put the cursor to Data, and press the Show softkey. Then select
“Leadscrew Error” using the cursor and press the Data Out softkey.

Enter compensation values, intermediate point distance, start and end position in the received file
_N_COMPLETE_EEC by means of the editor (eg in the WINPCIN/OUT program). Then re-read the
edited file into the control system.
Approach the reference point in the axes and set MD: ENC_COMP_ ENABLE (0)=1. The LEC is thus
activated.

SINUMERIK 802C base line 4-43

Start-Up
Machine Translated by Google

Start-Up

4.7.3 Starting up the spindle

Overview With the SINUMERIK 802C base line, the spindle is a subfunction of the entire
axis functionality. The machine data of the spindle are therefore to be found
under the axis machine data (from MD35000). For this reason, data have to be
entered for the spindle, too; these data are described for axis start–up.

Notice
With SINUMERIK 802C base line, the 4th machine axis (SP) is fixed for the
spindle.

The spindle settings for the 4th machine axis are contained in the default
machine data.
The spindle setpoint (+10 V analog voltage signal) is output to X7. The
spindle measuring system must be connected to X6.

Spindle modes The following modes are possible for the spindle:
Control mode (M3, M4, M5)
Oscillating mode (to assist gearbox change)
Positioning mode (SPOS)

MD for spindle see MD for axis and spindle

SD for spindle
number Description Default Value
43210 Program spindle speed limitation G25 0
43220 Progr. spindle speed limitation G26 1000
43230 Spindle speed limitation with G96 100

Spindle MD parameterization
Spindle machine data are entered depending on the gear stages. each gear
stage is assigned a parameter record.
The set of parameters corresponding to the current gear stage is selected.
Example: 1st gear stage set of parameters [1]

Notice
The field containing the parameter “0” is not used for the spindle machine data.

Machine data for setpoint and actual values

Setpoints:
MD 30130 CTRLOUT_TYPE [AX4] = 1
Current values:
MD 30200 NUM_ENCS[AX4] = 0 ; Spindle without encoder
MD 30200 NUM_ENCS[AX4] = 1 ; Spindle with encoder
MD 30240 ENC_TYPE[AX4] = 2 ; Type of encoder

4-44 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

Interface signals of the spindle

Interface signals
“Speed change” 39032000 Bit 3
“Current gear stage” 38032000 bits 0 to 2
“No speed monitoring on gear change”
38032000 bit 6
“Speed is changed” 38032000 Bit 3
“Set gear stage” 39032000 bits 0 to 2
“Positioning mode” 39032002 bit 5
“Oscillating through PLC”38032002 bit 4
“Oscillating mode” 39032002 bit 6
“Control mode” 39032002 bit 7
“Traversing minus” 39030004 bit 6
“Traversing plus” 39030004 bit 7

Reciprocation mode for gear change

The reciprocation mode of the spindle is intended to facilitate the gear change.
For reciprocation mode, the following axis MD and interface signals are
relevant:
MD Description
35400 Reciprocation speed
35410 Acceleration when reciprocating
35430 Start direction in reciprocation
35440 Reciprocation time for M3 direction
35450 Reciprocation time for M4 direction

Interface signals “Change gear” 39032000 bit 3

“Reciprocation speed” 38032002 bit 5
“Reciprocating by PLC” 38032002 bit 4
“Set direction of rotation CCW” 38032002 bit 7

SINUMERIK 802C base line 4-45

Start-Up
Machine Translated by Google

Start-Up

4.7.4 Completing the Start-Up

After start-up of the control system by the machine manufacturer, the following should
be observed prior to delivery to the final customer: 1. Change
the default password for access level 2 from ”EVENING” to your own password.

If the machine manufacturer uses the password “EVENING” for access level 2
during the start-up work, the password must be changed.
Press the Change passw softkey.
Enter the new password and press OK to confirm.
Note the password in the Manufacturer Documentation.
2. Reset the access level.
To save the data which has been set during the start-up, an internal data saving
is required. To this aim, set access level 7 (final customer); Otherwise, access
level 2 will also be saved.
Press the Delete passw softkey.
The access level will be reset.
3. Carry out internal data saving.
Press the Save data softkey.

4.7.5 Cycle start-up

Sequence of operations
When loading cycles into the control system, adhere to the following sequence of
operations:
1. Save tool offset data and zero offsets either on the FLASH or on the PG
(programming device).
These data can be selected in the Services menu by pressing the Data outp./
data...soft key.
2. Load all files of the selected technology path from the toolbox diskette into the control
system via the V24 interface.
3. Carry out POWER ON.
4. Reload the recovered data.

4-46 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Start-Up

4.8 Series machine start–up

Functionality The objective of series machine start–up is:

after commissioning, in order to bring another control system connected to
the same machine type with minimum effort to the condition as after
commissioning;
or
under service conditions (after replacing hardware components), to bring a
new control system to the initial state with minimum effort.

Precondition To carry out commissioning, a PC/PG provided with a V24 interface for data transfer
from/to the control system is necessary.
In the PC/PG, the WINPCIN tool must be used.

Sequence of operations
1. Create the series machine start–up file (transfer from the control system to the
PC/PG).: Make
a V24 cable connection between the PC/PG (COM port) and the SINUMERIK
802C base line (X2).
Select Binary format and the same baud rate both in the WinPCIN tool and
SINUMERIK 802C base line communication setting menu Make
the following settings in WINPCIN tool:
Receive data
Select the path where you want to save your data
Save
The PC/PG will set itself to “Receive” and will wait for data from the control system.

Enter the password for protection level 2 in the control system.

Call the Services/RS232 setting menu.
Select the Start–up data line from the Services menu and press Start data
output. to output the series machine start–up file.
2. Reading in the series machine start–up file into the SINUMERIK 802C
base line:
Enter the V24 interface settings as described under 1).
Press the Data In Start button in the Service menu. The control system is
thus ready to receive data.
Use the WINPCIN tool in the PC/PG to select the series start–up file from the
DATA_OUT menu and start data transfer.
The control system is brought to “RESET with rebooting” three times during
and at the end of data transfer. On completion of error–free data transfer, the
control system is completely configured and ready to operate.

SINUMERIK 802C base line 4-47

Start-Up
Machine Translated by Google

Start-Up

Series machine start–up file

The series machine start–up file contains:
machine data
R parameters
display and alarm text files
display machine data
PLC user program main

programs subroutines

cycles
Leadscrew error compensation data

4-48 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Software Update 5

5.1 Updating the system software using a PC/PG

General The following reasons may require a system software update:

You wish to install new system software (new software version).
After hardware replacement, if software versions other than the supplied
are to be loaded.

Preconditions To change the system software of the SINUMERIK 802C base line, you will
need the following:
Update software (Toolbox)
A PG/PC with V24 interface (COM1 or COM2) and an appropriate cable.

Update procedure As far as not yet done, carry out external data saving before you update your
updating system software (see Section 4.1.4 “Data Saving”).
1. Turn the start-up switch S3 to position “2” (software update on permanent
memory).
2. Run Winpcin, make selection of binary format, 115200 of baud rate, then
choose file named ENC0.abb under the path \system in toolbox CD.
“
3. Power on message WAIT FOR SYSTEM – SW ” appeared on the
screen.

4. Winpcin starts to transfer ENC0.abb.

5. Switch off system until “UPDATE OK” appeared on the screen.
6. Turn the start-up switch S3 to position “1” (start-up with standard data)
switch on the control system again.
7. Prior to the next POWER ON start-up switch to “0“ position.

Notice

Reload the externally saved user standard data via V24.

SINUMERIK 802C base line 5-1

Start-Up
Machine Translated by Google

Software Update

5.2 Update errors

Table 5–1 Update errors

Error Text Explanation Remedial Action
MISTAKE Error when updating the system software via V24 Repeat
UPDATE update
Data already in receive buffer (send from PC Check link
side started too early) between
Error when erasing the FLASH memory control
system and
Error when writing to the FLASH memory PC/PG
check
Inconsistent data (incomplete or faulty) Toolbox

SINUMERIK Update without programming the code

802C base FLASH completed (no data received, transfer
line not started)
UPDATE NO
DATA

5-2 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Technical Appendix 6

6.1 List of machines and setting data

data type BOOLEAN Machine data bit (1 or 0)

BYTE Integer values (from –128 to 127)
DOUBLE Real and integer values
(from ±4.19 x 10–307 to ±1.67 x 10308)
DWORD Integer values (from –2.147 x 109 to 2.147 x 109 )
STRING Character string (max. 16 characters) consisting of
upper–case letters with digits and underscore
UNSIGNED WORD Integer values (from 0 to 65536)
SIGNED WORD Integer values (from –32768 to 32767)
UNSIGNED DWORD Integer values (from 0 to 4294967300)
SIGNED DWORD Integer values (from –2147483650 to 2147483649)
WORD Hex values (from 0000 to FFFF)
DWORD Hex values (from 00000000 to FFFFFFFF)
FLOAT DWORD Real values (from ±8.43 x 10–37 to ±3.37 x 1038)

SINUMERIK 802C base line 6-1

Start-Up
Machine Translated by Google

Technical Appendix

6.1.1 Display machine data

number MD Name
Representation Name, Miscellaneous activated User Class w/r
unit Standard value Minimum value Maximum value Data type

202 $MM_FIRST_LANGUAGE
Decimal Foreground language 1 Power On 23
0 1 2 Byte

203 $MM_DISPLAY_RESOLUTION
Decimal Display resolution 3 0 Power On 23
0 5 Byte

206 $MM_USER_CLASS_WRITE_TOA_GEO
Decimal User class Write tool geometry 3 Immediately 2/3
0 0 7 Byte

207 $MM_USER_CLASS_WRITE_TOA_WEAR
Decimal User class Write tool wear data 3 Immediately 2/3
0 0 7 Byte

208 $MM_USER_CLASS_WRITE_ZOA
Decimal User class Write settable zero offset 3 Immediately 2/3
0 07 Byte

210 $MM_USER_CLASS_WRITE_SEA
Decimal User class Write setting data 3 Immediately 2/3
0 0 7 Byte

216 $MM_USER_CLASS_WRITE_RPA
Decimal User class Write R parameters 3 Immediately 2/3
0 0 7 Byte

217 $MM_USER_CLASS_SET_V24
Decimal User class Set V24 3 Immediately 2/3
0 0 7 Byte

219 $MM_USER_CLASS_DIR_ACCESS
Decimal User class access directory 3 Immediately 2/3
0 0 7 Byte

243 V24_PG_PC_BAUD
Bit PG: Baud rate (300, 600, 1200, 2400, 4800, 9600, Immediately 3/3
19200, 38400)
7 0 7 Byte

277 $MM_USER_CLASS_PLC_ACCESS
Decimal User class access PLC project 3 Immediately 2/3
0 0 7 Byte

6-2 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Technical Appendix

278 $MM_NCK_SYSTEM_FUNC_MASK
Decimal Option data to enable system-specific functions POWER ON 2/2
0 0 0 fifteen
Byte

280 $MM_V24_PPI_ADDR_PLC
Decimal PPI address of the PLC 2 POWER ON 3/3
0 0 126 BYTE

281 $MM_V24_PPI_ADDR_NCK
Decimal PPI address of the NCK 3 POWER ON 3/3
0 0 126 BYTE

282 $MM_V24_PPI_ADDR_MMC
Decimal PPI address of the HMI 4 POWER ON 3/3
0 0 126 BYTE

283 $MM_V24_PPI_MODEM_ACTIVE
Decimal Modem active Immediately 3/3
0 0 0 1 BYTE

284 $MM_V24_PPI_MODEM_BAUD
Decimal Modem baud rate Immediately 3/3
0 7 5 9 BYTE

285 $MM_V24_PPI_MODEM_PARITY
Decimal Modem parity 0 Immediately 3/3
0 0 2 BYTE

288 $MM_STARTUP_PICTURE_TIME
Decimal Average time of start up picture visibility in POWER ON 2/2
second
0 5 0 10 BYTE

SINUMERIK 802C base line 6-3

Start-Up
Machine Translated by Google

Technical Appendix

6.1.2 General machine data

Number MD Name
unit Name, Miscellaneous activated
HW/function Standard value Minimum value Maximum value D type User
class

10074 PLC_IPO_TIME_RATIO
– PLC task factor for main run POWER ON
2 1 fifty DWORD 2/7

10240 SCALING_SYSTEM_IS_METRIC
– Basic system metric POWER ON
1 *** *** BOOLEAN 2/7
_always

11100 AUXFU_MAXNUM_GROUP_ASSIGN
– Number of auxiliary functions distr. amongst aux. fct. POWER ON
groups
_always 1 1 fifty BYTE 2/7

11200 INIT_MD
HEX Standard machine data loaded on next Power On _always 0x0F POWER ON
– – BYTE 2/7

11210 UPLOAD_MD_CHANGE_ONLY
HEX Saving only of modified MD (value=0: complete= no RESTART
difference)
- 0x0F - - BYTE 2/7

11310 HANDWH_REVERSE
– Threshold for direction change handwheel 0.0 POWER ON
_always 2 plus BYTE 2/7

11320 HANDWH_IMP_PER_LATCH
– Handwheel pulses per detent position (handwheel POWER ON
number): 0...1
_always eleven.
– – DOUBLE 2/7

11346 HANDWH_TRUE_DISTANCE
– Handwheel POWER ON
_always 0 0 3 BYTE 2/2

14510 USER_DATA_INT [n]

kB User data (INT) 0 ... 31 _always POWER ON
– 0 – DWORD 2/7

14512 USER_DATA_HEX [n]

kB User data (Hex) 0 ... 31 POWER ON
– 0 0 0xFF BYTE 2/7

6-4 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Technical Appendix

14514 USER_DATA_FLOAT [n]

– User data (Float) 0...7 POWER ON
– 0.0 ... ... DOUBLE 2/7

14516 USER_DATA_PLC_ALARM [n]

– User data (Hex) Alarm bit 0 ... 31 0 0 POWER ON
– 0xFF BYTE 2/7

6.1.3 Channel–specific machine data

Number MD Name
unit Name, Miscellaneous activated
HW/function Standard value Minimum value Maximum value D type User
class

20210 CUTCOM_CORNER_LIMIT
Degrees Maximum angle for compensation blocks with TRC POWER ON
_always 100 0.0 150. DOUBLE 2/7

20700 REFP_NC_START_LOCK
– NC–Start disable without reference point 0 RESET
_always 1 1 BOOLEAN 2/7

21000 CIRCLE_ERROR_CONST
mm Circle end point monitoring constant _always POWER ON
0.01 0.0 plus DOUBLE 2/7

22000 AUXFU_ASSIGN_GROUP
– Auxiliary function group (aux. fct. no. in channel): 0...49 POWER ON
_always 1 1 fifteen BYTE 2/7

22010 AUXFU_ASSIGN_TYPE
– Auxiliary function type (aux. fct. no. in channel): 0...49 POWER ON
_always ,, – – STRING 2/7

22030 AUXFU_ASSIGN_VALUE
– Auxiliary function value (aux. fct. no. in channel): 0...49 POWER ON
_always 0 – – DWORD 2/7

22550 TOOL_CHANGE_MODE
– New tool compensation for M function 0 POWER ON
_always 0 1 BYTE 2/7

27800 TECHNOLOGY_MODE
– Technology in the channel (value=0: milling, value=1: NEW CONF
turning)
1 0 1 BYTE 2/7

SINUMERIK 802C base line 6-5

Start-Up
Machine Translated by Google

Technical Appendix

6.1.4 Axis–specific machine data

Number MD Name
unit Name, Miscellaneous activated
HW/function Standard value Minimum value Maximum value D type User
class

30130 CTRLOUT_TYPE
– Output type of setpoint (setpoint branch): 0 0 POWER ON
_always 0 2 BYTE 2/7

30134 IS_UNIPOLAR_OUTPUT[0]
– Setpoint output is unipolar : 0 0 POWER ON
_always 0 2 BYTE 2/2

30200 ENCS_NUM
– Anzahl der Geber (1 oder kein Geber für die Spindel) RESTART
1 0 1 BYTE 2/7

30240 ENC_TYPE
– Type of actual value acquisition (actual position value) POWER ON
(encoder no.)
0: Simulation
2: Square–wave generator, standard encoder (press
multiplication)
3: Encoder for stepper motor
_always 0, 0 0 4 BYTE 2/7

30350 SIMU_AX_VDI_OUTPUT
– Output of axis signals with simulation axes POWER ON
0 *** *** BOOLEAN 2/7
_always

30600 FIX_POINT_POS
mm, Fixed–value positions of axis with G75 (position no.) POWER ON
degrees
_always 0.0 – – DOUBLE 2/7

31000 ENC_IS_LINEAR
– Direct measuring system (linear scale) (encoder no.) POWER ON
0 *** *** BOOLEAN 2/7
_always

31010 ENC_GRID_POINT_DIST
mm Division period for linear scales (encoder no.) _always 0.0 POWER ON
0.01 plus DOUBLE 2/7

31020 ENC_RESOL
– Encoder markings per revolution (encoder no.) 2048 POWER ON
_always 0.0 plus DWORD 2/7

6-6 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Technical Appendix

31030 LEADSCREW_PITCH
mm Pitch of leadscrew _always 10.0 POWER ON
0.0 plus DOUBLE 2/7

31040 ENC_IS_DIRECT
–
Encoder mounted directly to the machine (encoder no:) POWER ON
*** ***
_always 0 BOOLEAN 2/7

31050 DRIVE_AX_RATIO_DENOM
–
Denominator load gearbox (control parameter no.): 0...5 POWER ON
_always 1, 1, 1, 1, 1, 1 2147000000 1 DWORD 2/7

31060 DRIVE_AX_RATIO_NUMERA
–
Numerator load gearbox (control parameter set no.): 0...5 POWER ON
_always 1, 1, 1, 1, 1, 1 2147000000 1 DWORD 2/7

31070 DRIVE_ENC_RATIO_DENOM
– POWER ON
Denominator resolve gearbox (encoder no.)
_always 1 1 2147000000 DWORD 2/7

31080 DRIVE_ENC_RATIO_NUMERA
– POWER ON
Numerator resolve gearbox (encoder no.) 1
_always 1 2147000000 DWORD 2/7

31090 JOG_INCR_WEIGHT
mm, Evaluation of an increment with INC/handwheel RESET
degrees

32000 MAX_AX_VELO
mm/min, Maximum axis velocity rev/ NEW CONF
min
_always 10000. 0.0 plus DOUBLE 2/7

32010 JOG_VELO_RAPID
mm/min, Rapid treverse in jog mode rev/min RESET

_always 10000. 0.0 plus DOUBLE 2/7

32020 JOG_VELO
mm/min, Jog axis velocity rev/ RESET
min
_always 2000. 0.0 plus DOUBLE 2/7

32070 CORR_VELO
% Axis velocity for handwheel override, ext. ZO, cont. RESET
dressing, distance control
_always fifty 0.0 plus DWORD 2/7

SINUMERIK 802C base line 6-7

Start-Up
Machine Translated by Google

Technical Appendix

32100 AX_MOTION_DIR
– Traversing direction (not control direction) –1 POWER ON
_always 1 1 DWORD 2/7

32110 ENC_FEEDBACK_POL
– Sign current value (control direction) (encoder no.) POWER ON
_always 1 -1 1 DWORD 2/7

32200 POSCTRL_GAIN
1000/min Servo gain factor (control parameter set no.): 0...5 NEW CONF
_always (2.5; 2.5; 2.5; 1), ... 0.0 plus DOUBLE 2/7

32250 RATED_OUTVAL
% Rated output voltage (brauch setprint):0 _always NEW CONF
80 0.0 10 DOUBLE 2/7

32260 RATED_VELO
rev/min Rated motor speed (setpoint branch): 0 NEW CONF
_always 3000 0.0 plus DOUBLE 2/7

32300 MAX_AX_ACCEL
mm/s^2, Axis acceleration NEW CONF
rev/s^2
1 0 *** DOUBLE 2/7
_always

32420 JOG_AND_POS_JERK_ENABLE
- Enable axial jerk limitation 0 NEW CONF
*** *** BOOLEAN 2/2
_always

32430 JOG_AND_POS_,AX_JERK
- Axial jerk NEW CONF
10 -9 *** DOUBLE 2/2
_always 1000 (mm/s^3)
2777.77
(degrees/s^3)

32450 BACKLASH
mm Backlash _always NEW CONF
* * DOUBLE 2/7
0.000

32700 ENC_COMP_ENABLE
– Interpolatory compensation (encoder no.): 0.1 POWER ON
0 *** *** BOOLEAN 2/7
_always

32900 DYN_MATCH_ENABLE
– Dynamic response adaptation 0 0 NEW_CONF
1 BYTE 2/7

6-8 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Technical Appendix

32910 DYN_MATCH_TIME
–
Time constant of dynamic adaptation (control parameter set NEW_CONF
no): 0...5
0 0.0 plus DOUBLE 2/7

32920 AC_FILTER_TIME
yes
Smoothing factor time constant for adaptive control POWER ON
_always 0.0 0.0 plus DOUBLE 2/7

33050 LUBRICATION_DIST
Traversing distance for lubrication from PLC mm, NEW CONF
SDR.
_always 100000000 0.0 plus DOUBLE 2/7

34000 REFP_CAM_IS_ACTIVE
– RESET
Axis with reference point cam 1
*** ***
_always BOOLEAN 2/7

34010 REFP_CAM_DIR_IS_MINUS
– RESET
Approach reference point in minus direction
*** ***
_always 0 BOOLEAN 2/7

34020 REFP_VELO_SEARCH_CAM
mm/min, Reference point approach velocity rev/min RESET

_always 5000.0 0.0 plus DOUBLE 2/7

34030 REFP_MAX_CAM_DIST
mm, Maximum distance to reference cam RESET
SDR.
_always 10000.0 0.0 plus DOUBLE 2/7

34040 REFP_VELO_SEARCH_MARKER
mm/min, Creep speed (encoder no.) rev/min RESET

_always 300.0 0.0 plus DOUBLE 2/7

34050 REFP_SEARCH_MARKER_REVERSE
– RESET
Direction reversal to reference cams (encoder no.)
*** ***
_always 0 BOOLEA 2/7

34060 REFP_MAX_MARKER_DIST
mm, Maximum distance to reference mark. Max. distance to 2 RESET
SDR. reference marks
for distance–coded measuring systems.
_always 20.0 0.0 plus DOUBLE 2/7

SINUMERIK 802C base line 6-9

Start-Up
Machine Translated by Google

Technical Appendix

34070 REFP_VELO_POS
mm/min, Reference point positioning velocity rev/min RESET

_always 1000.0 0.0 plus DOUBLE 2/7

34080 REFP_MOVE_DIST
mm, Reference point distance/target point for distance–coded RESET
SDR. system
_always –2.0 – – DOUBLE 2/7

34090 REFP_MOVE_DIST_CORR
mm, Reference point offset/absolute offset distance–coded POWER ON
SDR.
_always 0.0 – – DOUBLE 2/7

34092 REFP_CAM_SHIFT
mm, Electr. cam offset of incremental measuring systems with RESET
SDR. equidistant zero marks
_always 0.0 0.0 plus DOUBLE 2/7

34100 REFP_SET_POS
mm, Reference point value/irrelevant for distance–coded RESET
SDR. system: 0...3
_always 0., 0., 0., 0. – – DOUBLE 2/7

34110 REFP_CYCLE_NR
– Sequence of axes in channel–specific referencing RESET
-1: No mandatory reference point for NC Start
0: No channel–specific reference–point approach
1–15: Sequence in channel–specific reference point
approaches
_always 1 -1 31 DWORD 2/7

34200 ENC_REFP_MODE
– Type of position measuring system POWER ON
0: No ref. point appr.; if an absolute encoder exists:
REFP_SET_POS accepted
1: Zero pulse (on encoder track)
_always 1 0 6 BYTE 2/7

35010 GEAR_STEP_CHANGE_ENABLE
– Gear change possible. Spindle has several gear steps POWER ON
0 *** *** BOOLEAN 2/7
_always

35040 SPIND_ACTIVE_AFTER_RESET
– Own spindle reset 0 POWER ON
*** *** BOOLEAN 2/7
_always

35100 SPIND_VELO_LIMIT
rev/min Maximum spindle speed _always POWER ON
10000 0.0 plus DOUBLE 2/7

6-10 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Technical Appendix

35110 GEAR_STEP_MAX_VELO
rev/min Maximum speed for gear change (gear stage no.): 0..5 NEW CONF
_always 0.0 500, 500, 1000, plus DOUBLE 2/7
2000, 4000, 8000

35120 GEAR_STEP_MIN_VELO
rev/min Minimum speed for gear change (gear stage no.): 0..5 NEW CONF
_always 50, 50, 400, 800, 0.0 plus DOUBLE 2/7
1500, 3000

35130 GEAR_STEP_MAX_VELO_LIMIT
rev/min Maximum speed of gear stage (gear stage no.): 0...5 NEW CONF
_always 0.0 500, 500, 1000, 2000, plus DOUBLE 2/7
4000, 8000

35140 GEAR_STEP_MIN_VELO_LIMIT
rev/min Minimum speed of gearsetp (gear stage no.): 0...5 _always 5, NEW CONF
5,10, 20, 40, 80 0.0 plus DOUBLE 2/7

35150 SPIND_DES_VELO_TOL
Factor Spindle speed tolerance RESET
_always 0.1 0.0 1.0 DOUBLE 2/7

35160 SPIND_EXTERN_VELO_LIMIT
rev/min Spindle speed limitation from PLC _always 1000 NEW CONF
0.0 plus DOUBLE 2/7

35200 GEAR_STEP_SPEEDCTRL_ACCEL
rev/s^2 Acceleration in speed control mode [gear stage no.]: 0...5 NEW CONF
***
_always 30, 30, 25, 20, 15, 10 2 DOUBLE 2/7

35210 GEAR_STEP_POSCTRL_ACCEL
rev/s^2 Acceleration in position control mode (gear stage no.): NEW CONF
1...5
***
_always 30, 30, 25, 20, 15, 10 2 DOUBLE 2/7

35220 ACCEL_REDUCTION_SPEED_POINT
Factor Speed for reduced acceleration _always 1.0 0.0 RESET
1.0 DOUBLE 2/7

35230 ACCEL_REDUCTION_FACTOR
Factor Reduced acceleration _always RESET
0.0 0.0 0.95 DOUBLE 2/7

35240 ACCEL_TYPE_DRIVE
– RESET
Type of acceleration 00 1
BOOLEAN 2/7

SINUMERIK 802C base line 6-11

Start-Up
Machine Translated by Google

Technical Appendix

35300 SPIND_POSCTRL_VELO
rev/min Position control switch–on speed _always 500 NEW CONF
0.0 plus DOUBLE 2/7

35350 SPIND_POSITIONING_DIR
– Direction of rotation when positioning 3 RESET
_always 3 4 BYTE 2/7

35400 SPIND_OSCILL_DES_VELO
rev/min Reciprocation speed NEW CONF
_always 500 0.0 plus DOUBLE 2/7

35410 SPIND_OSCILL_ACCEL
rev/s^2 Acceleration during reciprocating NEW CONF
16 2 *** DOUBLE 2/7
_always

35430 SPIND_OSCILL_START_DIR
- Starting direction during reciprocation RESET
0-2: As last direction of rotation (zero-speed M3)
3: M3 direction
4: M4 direction
_always 0 0 4 BYTE 2/7

35440 SPIND_OSCILL_TIME_CW
yes
Reciprocation time for M3 direction 1.0 NEW CONF
_always 0.0 plus DOUBLE 2/7

35450 SPIND_OSCILL_TIME_CCW
yes
Reciprocation time for M4 direction 0.5 NEW CONF
_always 0.0 plus DOUBLE 2/7

35500 SPIND_ON_SPEED_AT_IPO_START
- Feed enable for spindle in setp. Range RESET
_always 1 0 2 BYTE 2/2

35510 SPIND_STOPPED_AT_IPO_START
– Feedrate enable for spindle stopped 0 RESET
*** *** BOOLEAN 2/7
_always

36000 STOP_LIMIT_COARSE
Exact positioning coarse mm, NEW CONF
SDR.
_always 0.04 0.0 plus DOUBLE 2/7

36010 STOP_LIMIT_FINE
mm, Exact positioning fine NEW CONF
SDR.
_always 0.01 0.0 plus DOUBLE 2/7

6-12 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Technical Appendix

36020 POSITIONING_TIME
yes
Delay exact positioning fine 1.0 NEW CONF
_always 0.0 plus DOUBLE 2/7

36030 STANDSTILL_POS_TOL
mm, Zero-speed tolerance NEW CONF
SDR.
_always 0.2 0.0 plus DOUBLE 2/7

36040 STANDSTILL_DELAY_TIME
yes
Delay zero–speed monitoring 0.4 0.0 NEW CONF
_always plus DOUBLE 2/7

36050 CLAMP_POS_TOL
Clamping tolerance mm, NEW CONF
SDR.
_always 0.5 0.0 plus DOUBLE 2/7

36060 STANDSTILL_VELO_TOL
mm/min, Maximum velocity/speed ”axis/spindle stopped” rev/min NEW CONF

_always 5 (0.014) 0.0 plus DOUBLE 2/7

36100 POS_LIMIT_MINUS
mm, 1st software limit switch minus RESET
SDR.
–100000000 – – DOUBLE 2/7
_always

36110 POS_LIMIT_PLUS
mm, 1st software limit switch plus RESET
SDR.
100000000 – – DOUBLE 2/7
_always

36120 POS_LIMIT_MINUS2
mm, 2nd software limit switch minus RESET
SDR.
–100000000 – – DOUBLE 2/7
_always

36130 POS_LIMIT_PLUS2
mm, 2nd software limit switch plus RESET
SDR.
100000000 – – DOUBLE 2/7
_always

36200 AX_VELO_LIMIT
mm/min, Threshold value for velocity monitoring NEW CONF
rev/min (control parameter set no.): 0...5
_always 11500., 11500., 0.0 plus DOUBLE 2/7
11500., 11500., ...

SINUMERIK 802C base line 6-13

Start-Up
Machine Translated by Google

Technical Appendix

36300 ENC_FREQ_LIMIT
Hz Encoder limit frequency POWER ON
_always 300000 0 plus DOUBLE 2/7

36302 ENC_FREQ_LIMIT_LOW
% Encoder limit frequency at which encoder is switched on NEW CONF
again. (Hysteresis)
_always 99.9 0 100 DOUBLE 2/7

36310 ENC_ZERO_MONITORING
– NEW CONF
Zero mark monitoring (encoder no.): 0.1
0: Zero mark monitoring off, encoder HW monitoring on
1–99, >100: Number of recognized zero mark errors
during monitoring
100: Zero mark monitoring off, encoder HW monitoring off
_always 0, 0 0.0 plus DWORD 2/7

36400 CONTOUR_TOL
Contour monitoring tolerance band mm, NEW CONF
SDR.
*** ***
_always 1.0 DOUBLE 2/2

36500 ENC_CHANGE_TOL
mm, deg Portion of distance for backlash working _always NEW CONF
0.1 0.0 plus DOUBLE 2/7

36610 AX_EMERGENCY_STOP_TIME
yes
Duration of the deceleration ramp for error states 0.05 NEW CONF
_always 0.0 plus DOUBLE 2/7

36620 SERVO_DISABLE_DELAY_TIME
yes
Cutout delay servo enable 0.1 NEW CONF
_always 0.0 plus DOUBLE 2/7

36700 DRIFT_ENABLE
– NEW CONF
Automatic drift compensation 0
*** ***
_always BOOLEAN 2/7

36710 DRIFT_LIMIT
% Drift limit value for automatic drift compensation _always 1.000 NEW CONF
0.0 plus DOUBLE 2/7

36720 DRIFT_VALUE
% Drift basic value _always 0.0 NEW CONF
DOUBLE 2/7

38000 MM_ENC_COMP_MAX_POINTS
– POWER ON
Number of intermediate points for interpolatory
compensation (SRAM)
_always 0, 0 0 5000 DWORD 2/7

6-14 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Technical Appendix

6.1.5 Setting data

Number MD Name
unit Name, Miscellaneous activated
HW/function Standard value Minimum value Maximum value D type User
class

41110 JOG_SET_VELO
mm/min Axis speed for JOG Immediately
_always 0.0 0.0 plus DOUBLE 4/4

41200 JOG_SPIND_SET_VELO
rev/min Speed for spindle JOG mode _always 0.0 Immediately
0.0 plus DOUBLE 4/4

43210 SPIND_MIN_VELO_G25
rev/min Progr. spindle speed limitation G25 Immediately
_always 0.0 0.0 plus DOUBLE 4/4

43220 SPIND_MAX_VELO_G26
rev/min Progr. spindle speed limitation G26 _always 1000 Immediately
0.0 plus DOUBLE 4/4

43230 SPIND_MAX_VELO_LIMS
rev/min Spindle speed limitation with G96 _always 100 Immediately
0.0 plus DOUBLE 4/4

52011 STOP_CUTCOM_STORE
Alarm response for TRC and feedforward stop –1 0 Immediately
1 BOOLEAN 4/4

SINUMERIK 802C base line 6-15

Start-Up
Machine Translated by Google

Technical Appendix

6.2 PLC user interface signals

The following tables of the user interface signals between PLC and CNC (and
vice versa) are handled by the integrated fixed user program.
These signals can be displayed using PLC Status in the Diagnosis/Start-Up/PLC Status
menu.

6.2.1 Address ranges

Operand Identifier Description Range

V Data V0.0 to V79999999.7 (see
below)
T Timers T0 to T15
c Counters C0 to C31
Yo

Image of digital inputs I0.0 to I7.7

Q Image of digital outputs Q0.0 to Q7.7
M Flags M0.0 to M127.7
YE Special flags SM0.0 to SM 0.6 (see below)
A.C. ACCU AC0...AC3

Generating the V address range

Type Range No.
Identifier (Channel / Subrange Offset Addressing
(DB No.) Axis No.)
10 00 0 000 symbolic
(10–79) (00–99) (0–9) (000–999) (8-digit)

Definition of special flag bits (SM) (read-only)

SM Bits Description
SM 0.0 Flags with a defined ONE signal
SM 0.1 Initial position: first PLC cycle '1', following cycles '0'
SM 0.2 Buffered data lost – only valid in the first PLC cycle ('0' – data
ok, '1' – data lost)
SM 0.3 Power On: first PLC cycle '1', following cycles '0'
SM 0.4 60 s clock (alternating '0' for 30 s, then '1' for 30 s)
SM 0.5 1 s clock (alternating '0' for 0.5 s, then '1' for 0.5 s)
SM 0.6 PLC cycle clock (alternating one cycle '0', then one cycle '1')

Notice

All empty user interface fields in the following tables are Reserved for
SIEMENS and may neither be written, nor evaluated by the user!
All fields with a “0” contain the value “logic =”.

Variable access rights

is used to mark a read-only range
[r] [r/w] is used to mark a read/write range

6-16 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Technical Appendix

6.2.2 Retentive data area

1400 Retentive Data [r/w]

data block CNC interface -----> PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
User Data
14000000

User Data
14000001

User Data
14000002

...

...

...

User Data
14000062

User Data
14000063

SINUMERIK 802C base line 6-17

Start-Up
Machine Translated by Google

Technical Appendix

6.2.3 CNC signals

2600 General signals to CNC [r/w]

data block PLC Interface -----> CNC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Protection level
26000000 Acknowl. EMER-
45 6 7 EMER- GENCY
GENCY STOP
STOP
Request Request
26000001 distances current
to go by distances
the axes to go by
the axes

26000002

26000003

2700 General signals from CNC [r]

data block CNC interface -----> PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
EMER-
27000000 GENCY
STOP
active

27000001

27000002 Drive
ready
Ambient CNC
27000003 Tempera- alarm
ture present
alarm

6-18 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Technical Appendix

3000 Mode signals to CNC [r/w]

data block PLC Interface -----> CNC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
mode mode
30000000 Reset change
lock JOG AUTO MDA
Machine function
30000001
REF TEACH
IN

30000002

30000003

3100 Mode signals from CNC [r]

data block CNC interface -----> PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
active mode
31000000
READY JOG AUTO MDA
Activate machine function
31000001
REF TEACH

SINUMERIK 802C base line 6-19

Start-Up
Machine Translated by Google

Technical Appendix

6.2.4 Channel signals

Control signals to CNC channel

3200 Signals to CNC channel [r/w]
data block PLC Interface -----> CNC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Activate Activate Activate
32000000 dry run M01 Single
feed Block4)
Activate Activate
32000001 Program Referenc-
Test ing
Activate
32000002 skip
block

32000003

Feed override 2)
32000004
H.G.F. AND d c b TO

Rapid traverse override 3)

32000005
H.G.F. AND d c b TO

Feed 1) Rapid program Delete Read-in Feed

32000006 override traverse level distance disabled lock
enabled override abortion to go
enabled
CNC stop CNC stop CNC start
32000007 axes plus CNC stop to block CNC start
inhibited
spindle limit

Notes: 1)+ Feed override enabled Even if the feed verrideisnot enabled (=100%), the
0% position is active.
2)+ Feed override 31 positions (Gray code) with 31 MD for % weighting
3)+ Rapid traverse override 31 positions (Gray code) with 31 MD for %
weighting
4)+ Single Block Use the softkey to select Single Block Type Preselection
(SBL1/SBL2) see “User Manual”

6-20 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Technical Appendix

Control signals to axes in the WCS

3200 Signals to CNC Channel [r/w]
data block PLC Interface -----> CNC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Axis 1 in WCS
32001000 Traversing keys Rapid Travers- Activate handwheel
traverse Feeding key
+ - override lock stop 2 1
Axis 1 in WCS
32001001 Machine function
Continue 1000 INC 100 INC 10 INC 1 INC
ous

32001002

32001003

Axis 2 in WCS
32001004 Traversing keys Rapid Travers- Activate handwheel
traverse Feeding key
override lock
+ - 2 1
Stop
Axis 2 in WCS
32001005 Machine function
Continue 1000 INC 100 INC 10 INC 1 INC
ous

32001006

32001007

Axis 3 in WCS
32001008 Traversing keys Rapid Traversi- feed Activate handwheel
traverse ng key
+ - override lock stop 2 1
Axis 3 in WCS
32001009 Machine function
Continue 1000 INC 100 INC 10 INC 1 INC
ous

32001010

32001011

SINUMERIK 802C base line 6-21

Start-Up
Machine Translated by Google

Technical Appendix

Status signals from CNC channel

3300 Signals from CNC channel [r]
data block CNC interface -----> PLC
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

33000000 M0/M1
active
program block
33000001 test M2/M30 search Revolutionary Referenc-
feed ing
active active active active active

33000002

Channel state program status

33000003 Interrupted Interrupted

Reset active aborted stopped waiting running

CNC CNC
33000004 alarm alarm All axes All axes
with channel- stopped Referen-ced
stop of specific
machining present

present

33000005

33000006

33000007

6-22 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Technical Appendix

Status signals: Axes in WCS

3300 Signals from CNC channel [r]
data block CNC interface -----> PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Axis 1 in WCS
33001000 Traversing Handwheel active
command
plus minus 2 1
Axis 1 in WCS
33001001 Machine function
Continue 1000 INC 100 INC 10 INC 1 INC
ous

33001002

33001003

Axis 2 in WCS
33001004 Traversing Handwheel active
command
plus minus 2 1
Axis 2 in WCS
33001005 Activate machine function
Continue 1000 INC 100 INC 10 INC 1 INC
ous

33001006

33001007

Axis 3 in WCS
33001008 Traversing Handwheel active
command
plus minus 2 1
Axis 3 in WCS
33001009 Activate machine function
Continue 1000 INC 100 INC 10 INC 1 INC
ous

33001010

33001011

SINUMERIK 802C base line 6-23

Start-Up
Machine Translated by Google

Technical Appendix

Transfer of auxiliary functions from the CNC channel

2500 Auxiliary functions from CNC channel [r]
data block PLC Interface
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Modify
25000000 decoded
M
functions
0-99

25000001 Modify
T funct. 1

25000002

25000003

6-24 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Technical Appendix

Decoded M signals (M0 - M99)

2500 M functions from CNC channel [r]
data block CNC Interface
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Dynamic M functions
25001000
M7 M6 M5 M4 M3 M2 M1 M0
Dynamic M functions
25001001
M15 M14 M13 M12 M11 M10 M9 M8
Dynamic M functions
25001002
M23 M22 M21 M20 M19 M18 M17 M16
...

...

...

Dynamic M functions
25001012
M99 M98 M97 M96

25001013

25001014

25001015

Notes: + Static M functions must be generated by the PLC user from the dynamic M
functions.
+ Dynamic M functions are decoded by the basic program (M00 to M99).

SINUMERIK 802C base line 6-25

Start-Up
Machine Translated by Google

Technical Appendix

Transferred T functions
2500 T functions from CNC channel [r]
data block PLC Interface
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

25002000 T function 1 (DINT)

25002004

25002008

25002012

6-26 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Technical Appendix

6.2.5 Axis/spindle signals

Signals to axis/spindle
Common signals to axis/spindle
3800...3803 Signals to axis/spindle [r/w]
Data block PLC Interface -----> CNC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Feed override
380x0000
HGFEDCBA
Axes/
380x0001 Override Position Follow-up spindle
enabled encoder 1 mode lock
Clamping Delete
380x0002 process distance Servo
running to go/ enable
spindle
reset
Speed/
380x0003 spindle
speed
limitation
Traversing keys Rapid Travers- Feed Activate handwheel
380x0004 traverse ing stop
plus minus override key Spindle 2 1
lock stop
Machine function
380x0005 Continue 1000 100 10 1
ous INC INC INC INC

380x0006

380x0007

Signals to axis
3800...3802 Signals to axis [r/w]
data block PLC Interface -----> CNC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Delay 2nd software limit Hardware limit switch
Ref.-point switch
380x1000 approaches
(axis) plus minus plus minus

380x1001
(axis)

380x1002
(axis)

380x1003
(axis)

SINUMERIK 802C base line 6-27

Start-Up
Machine Translated by Google

Technical Appendix

Signals to spindle
3803 Signals to spindle [r/w]
data block PLC Interface -----> CNC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Gear is Current gear stage
38032000 changed
(spindle) c b TO

Spindle
feed
38032001 Invest override
(spindle) M3/M4 valid
Set direction of Recipro- Recipro-
rotation catting catting
38032002 speed by PLC
(spindle) CCW CW
Spindle override
38032003
(spindle) h g F AND d c b TO

General signals from axis/spindle

3900...3903 Signals from axis/spindle [r]
data block CNC interface -----> PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Position reached Reference- Encoder Spindle/
390x0000 with exact with exact ced/ limit no axis
pos. pos., frequency
fine coarse Synchronized 1 exceeded
1
speed Axis/spin Follow-up
dle active
390x0001 Current Controller Position stopped
controller controller
active active active (n < nmin)

390x0002

390x0003

Motion command Handwheel active

390x0004
plus minus 2 1
Activate machine function
390x0005 Continue 1000 100 10 1
ous INC INC INC INC

390x0006

390x0007

6-28 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Technical Appendix

Signals from axis

3900...3903 Signals from axis [r]
data block CNC interface -----> PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
390x1000
(axis)

390x1001
(axis)

390x1002 Lubrica-
(axis) tion press
390x1003
(axis)

Signals from spindle

3903 Signals from spindle [r]
data block CNC interface -----> PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Gear stage set
39032000 change
gear
(spindle) c b TO

Current Spindle Set Set speed

direction
39032001 of within set speed speed limit
rotation
(spindle) CW range increased limited exceeded
Activate spindle mode Tapping
39032002 Reciprocal Control Position- without
cating ing compen-
sating
(spindle) mode mode mode Chuck

39032003
(spindle)

SINUMERIK 802C base line 6-29

Start-Up
Machine Translated by Google

Technical Appendix

6.2.6 Signals from/to MMC

Program control signals from MMC (retentive area) (see also signals to channel V32000000)
1700 MMC signals [r]
data block MMC Interface -----> PLC
DBB Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
dry run
17000000 feed M01
(MMC ---> selected selected
PLC)
program Feed
17000001 test override
(MMC --> selected for fast
PLC) traverse
selected
Select
17000002 skip
(MMC --> block
PLC)

17000003
(MMC --->
PLC)

Dynamic mode signals from MMC

1800 Signals from MMC [r]
data block MMC Interface -----> PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

18000000

Machine function
18000001
TEACH
IN

18000002

18000003

6-30 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Technical Appendix

General selection/status signals from MMC (retentive area)

1900 MMC Signals [r]
data block MMC Interface -----> PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
19001000
(MMC --->
PLC)
19001001
(MMC --->
PLC)
19001002
(MMC --->
PLC)
19001003 Axis number for handwheel 1
(MMC ---> machine b TO

PLC) axis
19001004 Axis number for handwheel 2
(MMC ---> machine b TO

PLC) axis
19001005
(MMC --->
PLC)
19001006
(MMC --->
PLC)

Control signals to operator panel (retentive range)

1900 Signals to operator panel [r/w]
data block PLC Interface -----> MMC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
OP
19005000
key lock
19005001

19005002

19005003

SINUMERIK 802C base line 6-31

Start-Up
Machine Translated by Google

Technical Appendix

6.2.7 Machine control panel signals (MCP signals)

Status signals from MCP

1000 Signals from MCP [r]

MCP Interface ----->PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
K14 K13 K6 K5 K4 K3 K2 K1
User- User- User- User- User- User-
10000000 JOG INC
defined defined defined defined defined defined

K22 K21 K20 K19 K18 K17 K16 K15

10000001 Axis key Spindle Spindle Spindle MDA SBL AUTO REF
start - stop start +
K30 K29 K28 K27 K26 K25 K24 K23
10000002 Axis key Axis key Axis key Axis key Axis key Axis key Axis key Axis key

K10 K9 K8 K7 K39 K38 K37

User- User- User- User-
10000003 NC NC STOP NC
defined defined defined defined
START RESET

Feed override
10000004 K12 K11 K35 K33 K31
Feed
User- User- Feed Feed
override
defined defined override - override +
100%
Spindle override
10000005 K36 K34 K32
Spindle
Spindle override Spindle
override - override +
100%

Control signals to MCP

1100 Signals to MCP [r/w]

PLC Interface -----> MCP
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
LED8 LED7 LED6 LED5 LED4 LED3 LED2 LED1
11000000 User- User- User- User- User- User- User- User-
defined defined defined defined defined defined defined defined
LED16 LED15 LED14 LED13 LED12 LED11 LED10 LED9
11000001 Spindle Feed Spindle Feed User- User- User- User-
override override override override defined defined defined defined

6-32 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Technical Appendix

6.2.8 PLC machine data

INT values (MD 14510 USER_DATA_INT)

4500 Signals from CNC [r]
data block CNC interface -----> PLC
Byte

45000000 Int value (WORD/ 2 bytes)

45000002 Int value (WORD/ 2 bytes)

45000004 Int value (WORD/ 2 bytes)

45000006 Int value (WORD/ 2 bytes)

45000060 Int value (WORD/ 2 bytes)

45000062 Int value (WORD/ 2 bytes)

HEX values (MD 14512 USER_DATA_HEX)

4500 Signals from CNC [r]
data block CNC interface -----> PLC
Byte

45001000 Hex value (BYTE)

45001001 Hex value (BYTE)

45001002 Hex value (BYTE)

45001003 Hex value (BYTE)

45001030 Hex value (BYTE)

45001031 Hex value (BYTE)

SINUMERIK 802C base line 6-33

Start-Up
Machine Translated by Google

Technical Appendix

FLOAT values (MD 14514 USER_DATA_FLOAT)

4500 Signals from NCK [r]
data block CNC interface -----> PLC
Byte

45002000 Float value (REAL/ 4 bytes)

45002004 Float value (REAL/ 4 bytes)

45002008 Float value (REAL/ 4 bytes)

45002012 Float value (REAL/ 4 bytes)

45002016 Float value (REAL/ 4 bytes)

45002020 Float value (REAL/ 4 bytes)

45002024 Float value (REAL/ 4 bytes)

45002028 Float value (REAL/ 4 bytes)

HEX-BYTE values (MD 14516 USER_DATA__PLC_ALARM)

4500 Signals from NCK [r]
data block NCK Interface -----> PLC
Byte

45003000 Alarm reaction / clear criterion of alarm 700000

45003001 Alarm reaction / clear criterion of alarm 700001

45003002 Alarm reaction / clear criterion of alarm 700002

45003031 Alarm reaction / clear criterion of alarm 700031

6-34 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Technical Appendix

6.2.9 User alarm

Alarm activation
1600 Alarm activation [r/w]
data block PLC Interface -----> MMC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Activation of Bit 1 Bit 0
alarm no.
16000000
700007 700006 700005 700004 700003 700002 700001 700000
Activation of alarm no.
16000001
700015 700014 700013 700012 700011 700010 700009 700008
Activation of alarm no.
16000002
700023 700022 700021 700020 700019 700018 700017 700016
Activation of alarm no.
16000003
700031 700030 700029 700028 700027 700026 700025 700024

Variable for alarm

1600 Variable for alarm [r/w]
data block PLC Interface -----> MMC
Byte

16001000 Variable for alarm 700000

16001004 Variable for alarm 700001

16001008 Variable for alarm 700002

...

16001116 Variable for alarm 700029

16001120 Variable for alarm 700030

16001124 Variable for alarm 700031

SINUMERIK 802C base line 6-35

Start-Up
Machine Translated by Google

Technical Appendix

Activate alarm response

1600 Activate alarm response [r]
data block PLC Interface -----> MMC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Feed Read-in NC start
lock disable inhibited
PLC- NOT- of all
16002000
STOP AUS axes

16002001

16002002

16002003

Current axis value and distances to go

5700...5704 Signals from axis/spindle [r]
data block PLC Interface -----> MMC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

570x0000 Axis current value (REAL)

570x0004 Axis distance to go (REAL)

6-36 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Technical Appendix

6.3 Unipolar spindle

A spindle that requires not a positive voltage of +/-10 volts, but a positive voltage
and separate binary sign signals for controlling is called unipolar spindle. The
voltage is output via the analog spindle setpoint output, and the sign signals via
binary outputs.
The 802SC base line is able to run a unipolar spindle.

Configuring The “Unipolar spindle” mode is set via the axis machine data
MD 30134 IS_UNIPOLAR_OUTPUT of the spindle. There are 2 different modes
for controlling the unipolar spindle.
MD input value “0”:
Bipolar setpoint output with positive/negative voltage
The PLC output bits O0 and O1 may be used by the PLC.
MD input value “1”:
Unipolar setpoint output with positive voltage
The PLC output bits O0 and O1 must not be used by the PLC.
PLC output bit O0 = servo enable
PLC output bit O1 = negative direction of travel
MD input value “2”:
Unipolar setpoint output with positive voltage
The PLC output bits O0 and O1 must not be used by the PLC.
PLC output bit O0 = servo enable positive direction of travel
PLC output bit O1 = servo enable negative direction of travel

Special features
1. The spindle must be the 4th axis.
2. The binary outputs used for the unipolar spindle must not be used by the PLC.
This must be guaranteed by the user, as they are not any monitoring
functions in the control system. Not observing this fact will result in undesired
reactions of the control system.

SINUMERIK 802C base line 6-37

Start-Up
Machine Translated by Google

Technical Appendix

6-38 SINUMERIK 802C base line

Start-Up
Machine Translated by Google

Suggestions
SIEMENS AG
Corrections
A&D MC BMS for Publication/Manual:
Postfach 3180
SINUMERIK 802C base line
D–91050 Erlangen
(Tel. +49 180 / 5050 – 222 [Hotline]
Fax +49 9131 / 98 – 2176 [Documentation]
Mailto: [email protected]) Manufacturer Documentation

Start-Up
desde
Order No.: 6FC5597–4AA21–0BP0
Yam Edition: 08.03

Company/dept.
Should you come across any main errors
street when reading this publication, please notify
us on this sheet.
Zip code: City:
Telephone: / Suggestions for improvement are also
welcome.
Facsimile: /

Suggestions and/or corrections

Machine Translated by Google
Machine Translated by Google
Machine Translated by Google

Siemens AG
Automatisierungs- und Antriebstechnik
Motion Control Systems
Postfach 3180, D – 91050 Erlangen © Siemens AG 2003
Subject to change without prior notice
Germany Order No.: 6F5597-4AA21-0BP0

www.ad.siemens.de Printed in the Federal Republic of Germany