Siemens SINUMERIK 802S User manual

Start-Up 08/2003 Edition
sinumerik
SINUMERIK 802S base line

SINUMERIK 802S base line
Start-Up
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Technical Manual
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Valid as from
Control system Software version
SINUMERIK 802S base line 4
2003.08 Edition
SINUMERIK 802S base line
Control System
Installing the control system 2
Installing the STEPDRIVE 3
Start-Up 4
Software Update
Technical Appendix 6
5
1

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
1999.02 6FC5597-2AA00-0BP1 A
2002.01 6FC5597-2AA00-0BP2 C
2003.08 6FC5597-4AA01-0BP0 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 his own purposes may violate
the registered holder.
Copyright Siemens AG 2003. All right reserved
The reproduction, transmission or use of this document or its con-
tents is not permitted without express written authority. Offenders will
be liable for damages. All rights, including rights created by patent
grant or registration of a utility model, are reserved.
Exclusion of liability
We have checked that the contents of this document correspond to
the hardware and software described. Nonetheless, differences
might exist and we cannot therefore guarantee that they are com-
pletely identical. The information contained in this document is re-
viewed 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
®

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 in 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.
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Contents
SINUMERIK 802S base line
I
Start-Up
Contents
1. SINUMERIK 802S base line Control System 1-1
1.1 Components of the SINUMERIK 802S base line 1-1
1.2 Technical data 1-3
2. Installing the Control System 2-1
2.1 Installing and Dismantling the SINUMERIK 802S base line 2-1
2.2 Interfaces and cables 2-4
2.3 Connecting the individual components 2-7
2.3.1 Connecting the feed drives and the spindle (X7) 2-7
2.3.2 Connecting the measuring systems (X6) 2-10
2.3.3 Configuration of the RS232 interface connection (X2) 2-11
2.3.4 Connecting handwheels (X10) 2-13
2.3.5 Connecting BERO and NC-READY (X20) 2-14
2.3.6 Connecting the digital inputs (X100 ... X105) 2-16
2.3.7 Connecting the digital outputs (X200 ,X201) 2-18
2.4 Power Supply for CNC (X1) 2-20
2.5 LEDs and Other Elements on CNC 2-21
3. Installing the STEPDRIVE 3-1
3.1 Installing and dismantling the STEPDRIVE C/C+ drive modules 3-1
3.2 Cabling 3-3
3.3 Starting up the drive modules 3-5
4. Start-Up 4-1
!4.1 General 4-1
4.1.1 Access levels 4-2
4.1.2 Structure of machine data (MD) and setting data (SD) 4-3
4.1.3 Handling of machine data 4-4
4.1.4 Data saving 4-4
4.2 Turning on and booting the control system 4-6
4.2.1 Boot messages 4-8
4.3 Starting up the PLC 4-9
4.3.1 Commissioning of the PLC 4-9
4.3.2 Start-up modes of the PLC 4-11
4.3.3 PLC alarms 4-12
4.3.4 Machine control panel area layout 4-17
4.3.5 PLC programming 4-18
4.3.6 Instruction set 4-21
4.3.7 Program organization 4-27
4.3.8 Data organization 4-28
4.3.9 Interface to the control system 4-28
4.3.10 Testing and monitoring the user program 4-28
4.4 PLC applications “Download/Upload/Copy/Compare 4-29
4.5 User Interface 4-31
4.6 Technology Setting 4-31
4.7 Commissioning 4-32
4.7.1 Entering the general machine data 4-32
4.7.2 Starting up the axes 4-34
4.7.3 Starting up the spindle 4-44
4.7.4 Completing the Start-Up 4-49
4.7.5 Cycle start-up 4-50
4.8 Series machine start-Up 4-51

Contents
II SINUMERIK 802S base line
Start-Up
5. Software Update 5-1
5.1 Updating the system software using a PC/PG 5-1
5.2 Update errors 5-2
6. Technical Appendix 6-1
6.1 List of machine and setting data 6-1
6.1.1 Display machine data 6-2
6.1.2 General machine data 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 6-16
6.2 PLC user interface signals 6-17
6.2.1 Address ranges 6-17
6.2.2 Retentive data area 6-18
6.2.3 CNC signals 6-19
6.2.4 Channel signals 6-21
6.2.5 Axis/spindle signals 6-28
6.2.6 Signals from/to MMC 6-33
6.2.7 Machine control panel signals (MCP signals) 6-35
6.2.8 PLC machine data 6-36
6.2.9 User alarm 6-38
6.3 PLC user program for turning (SAMPLE) 6-40
6.3.1 Function 6-40
6.3.2 Input/output configuration 6-43
6.3.3 Definition of user keys 6-44
6.3.4 PLC machine data 6-46
6.3.5 SAMPLE program structure 6-50
6.3.6 User alarm 6-52
6.3.7 Start-Up of SAMPLE program 6-53
6.4 Unipolar spindle 6-55

SINUMERIK 802S base line 1-1
Start-Up
SINUMERIK 802S base line 1
Control System
1.1 Components of the SINUMERIK 802S base line
What is SINUMERIK 802S base line?
The SINUMERIK 802S base line is a microprocessor-controlled numerical
control system for economic machine tools with stepper motor drives.
Hardware components
The SINUMERIK 802S base line is a compact CNC unit. It consists of the
following areas (see figure 1-1):
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OD!Lfzt
MDE
Fyufsobm!tqjoemf!esjwf
Tufq!Esjwft
Tufq!n pupst
Fig. 1-1 Components of SINUMERIK 802S base line (turning variant)
LCD
NC Keys
MCP Area
External spindle drive
Step motors
Step Drives

SINUMERIK 802S base line Control System
1-2 SINUMERIK 802S base line
Start-Up
Software components
The SINUMERIK 802S base line comprises the following software components,
which can be ordered:
zSystem 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 802S base line to the machine
functions (see also Description of Functions “Integrated User
Program for SINUMERIK 802S base line”).
zToolbox
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 tool
zUpdate diskettes
Update program with operator prompting system
802S base line system software, packed, for loading and programming
the SINUMERIK 802S base line via an update program.
User data User data are:
zMachine data
zSetting data
zTool data
zR parameters
zZero offsets
zCompensation data
zPart programs
zStandard 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).
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