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.
!
!
!
!

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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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).
!

SINUMERIK 802S base line Control System
SINUMERIK 802S base line
1-3
Start-Up
1.2 Technical data
Connected load Table 1–1 Connected load
Parameter Min. Typ. Max. Unit
Supply voltage 20.4 24 28.8 V
Ripple 3.6 Vss
Current consumption from 24 V 1.5 A
Power dissipation of CNC 35 W
Start-up current 4 A
Weight Table 1–2 Weight
Component Weight [g]
CNC 4500
Dimensions Table 1–3 Component dimensions
Component Dimensions LxWxD [mm]
CNC 420 x 300 x 83
Environmental operating conditions
Table 1–4 Environmental operating conditions
Parameter
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 (e.g. cubicle) is absolutely necessary for operation.
Transport and storage conditions
Table 1–5 Transport and storage conditions
Parameter
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 ≤1,200 mm
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 802S base line Control System
1-4 SINUMERIK 802S base line
Start-Up

SINUMERIK 802S base line 2-1
Start-Up
Installing the Control System 2
2.1 Installing and Dismantling the SINUMERIK 802S 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!
!
!

Installing the Control System
2-2 SINUMERIK 802S base line
Start-Up
Mounting dimensions
The dimensions shown below are important for installing the control system:
Fig. 2-1 Mounting dimensions for 802S base line

Installing the Control System
SINUMERIK 802S base line
2-3
Start-Up
1) Thread plugging M4 or ø5 hole (8x)
Fig. 2-2 Mounting dimensions for 802S base line

Installing the Control System
2-4 SINUMERIK 802S base line
Start-Up
2.2 Interfaces and cables
Position of the interfaces and elements
Fig. 2-3 Rear of CNC system
Interfaces CNC
zX1 power supply terminals (DC24V)
3-pin screw-type terminal block for connecting the 24 V load power
supply
zX2 RS232 interface (V24)
9-pin sub-D plug connector
zX6 spindle interface (ENCODER)
15-pin sub-D socket for connecting a spindle incremental position
encoder(RS422)
zX7 drive interface (AXIS)
50-pin sub-D socket connector for connecting the power sections for a
maximum of four analog drives including spindle
zX10 handwheel interface (MPG)
10-pin front connector for connecting the handwheels
zX20 digital inputs (DI)
10-pin front connector for connecting BERO proximity switches

Installing the Control System
SINUMERIK 802S base line
2-5
Start-Up
DI/O
zX100 to X105
10-pin front connector for connecting digital inputs
zX200 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.

Installing the Control System
2-6 SINUMERIK 802S base line
Start-Up
Connecting cables The components are wired up as shown in the Connection Diagram 2–4. For
the cables required, please refer to the diagram below.
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Fig. 2-4 Connection Diagram for SINUMERIK 802S base line

Installing the Control System
SINUMERIK 802S base line
2-7
Start-Up
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. 2–3.
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 Signal Type Pin Signal Type
1 n.c. 18 ENABLE1 O 34 n.c. AO
2 n.c. 19 ENABLE1_N O 35 n.c. AO
3 n.c. 20 ENABLE2 O 36 n.c. AO
4 AGND4 AO 21 ENABLE2_N O 37 AO4 AO
5 PULS1 O 22 M VO 38 PULS1_N O
6 DIR1 O 23 M VO 39 DIR1_N O
7 PULS2_N O 24 M VO 40 PULS2 O
8 DIR2_N O 25 M VO 41 DIR2 O
9 PULS3 O 26 ENABLE3 O 42 PULS3_N O
10 DIR3 O 27 ENABLE3_N O 43 DIR3_N O
11 PULS4_N O 28 ENABLE4 O 44 PULS4 O
12 DIR4_N O 29 ENABLE4_N O 45 DIR4 O
13 n.c. 30 n.c. 46 n.c.
14 n.c. 31 n.c. 47 n.c.
15 n.c. 32 n.c. 48 n.c.
16 n.c. 33 n.c. 49 n.c.
17 SE4.1 K 50 SE4.2 K

Installing the Control System
2-8 SINUMERIK 802S base line
Start-Up
Signal Description
Stepper Interface
PULSn; PULSn_N Stepper Clock
DIRn; DIRn_N Stepper Revolution Direction
ENABLEn; ENABLEn_N Stepper Enable
M Ground (not to be connected when using differential
signals)
Analog Spindle Interface
Aon Analog Command Value
AGNDn Analog Ground
SEn.1; SEn.2 Servo Enable Relay
n = 1...4 Number of Axis
Signal Specification: +/-10V for Analog Outputs
RS422 for Stepper Signals
Axis assignment
1Xaxis
2Yaxis
3Zaxis
4 Spindle
Table 2–2 Cable assignment (for type 6FX2 002-3AD02)
CNC Side Cable Drive Side
PIN Core Color Signal Name PIN
5black P1
38 brown P1N
6red D1
39 orange D1N
18 yellow E1
19 green
1st axis
E1N
40 White/grey P2
7 Brown/black P2N
41 Blue D2
8 Violet D2N
20 Grey E2
21 White
2nd axis
E2N
9 white/black P3
42 white/brown P3N
10 brown/red D3
43 brown/orange D3N
26 White/red E3
27 White/orange
3rd axis
E3N
17 White/yellow 9
50 White/green 65
4 White/blue 14
1
17
18
34
33
50
37 White/violet
Spindle
56