Siemens SINUMERIK 808D Installation guide

Sinumerik 808D ADVANCED Commissioning Guide
Version 2013-09
s
Training manual

Commissioning Guide Page 2 808D ADVANCED Turning and Milling
Notes
s

808D ADVANCED Turning and Milling Page 3 Commissioning Guide
s
The warranty is connected to the product serial number of the
808D ADVANCED.
You can find the product serial number:
On the back of PPU system hardware.
Picture 1
product serial
number
Or on the display.
After switch-on, press the “Shift” and “Alarm” keys together.
Then press the “Extension” button
This will enter into the system area.（see picture 1）
Press softkey to enter the screen of service axes ( see picture 2).
Press softkey to enter the screen of version data ( see picture 3).
You can find the serial number information which needs to be registered
starting with the letters “SZV”.
For any question about ”SZV” serial number and the steps to register ,
Please contact the Siemens Technical Support & Service Hotline:
[phone]
Picture 2
Picture 3
Product identification / SINUMERIK 808D ADVANCED

Commissioning Guide Page 4 808D ADVANCED Turning and Milling
Notes
s

808D ADVANCED Turning and Milling Page 5 Commissioning Guide
s
Workflows
End
Commissioning
of Prototype
Machine using
Sample PLC
Series
Machine
Production
PLC program
design and
adjustment
go to page 7
go to page 53
go to page 73
For
For
For

Commissioning Guide Page 6 808D ADVANCED Turning and Milling
Notes
s

808D ADVANCED Turning and Milling Page 7 Commissioning Guide
s
Basic Commissioning procedure for prototype machines using the
Sample PLC
Commissioning
of Prototype
Delivery
Check
Mounting
Dimen-
sions
Wiring
ToolBox
Software
Switch on
and
Prepare
Licences
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6
Go to page 8
Go to page 8
Go to page 11
Go to page 22
Go to page 26
Go to page 31
End
Options
Step 7 Go to page 32
Commis-
sioning
Diagram
Step 8 Go to page 33
Commis-
sioning
the
Prototype
Step 9 Go to page 33
Cabinet
Design
Step 10 Go to page 50

Commissioning Guide Page 8 808D ADVANCED Turning and Milling
s
Commissioning
of Prototype
Machine using
Sample PLC
In the following diagram the most common Siemens components are
shown. For detailed information refer to :-
Commissioning manual page 13
In the following technical drawing the mounting dimensions for the PPU
and the MCP are shown.
You must provide sufficient space (recommended distance: 80 mm)
between the maintenance door and the cabinet wall for replacing the
CF card:
For further components refer to :-
Commissioning manual page 21
Delivery check Mounting dimensionsStep 1 Step 2
Spindle encoder
USB stick
Handwheels
+24V DC power supply
808D MCP
Motor Motor Motor
SINUMERIK
808D ADVANCED PPU
PC/PG
Spindle motor
Inverter or servo spindle drive
Notes：
1. PC and memory stick is not included in scope of delivery.
2. "USB", "Handwheel","24V DC power supply", "Emergency stop button", "Inverter or servo spindle drive", "Spindle
encoder" are also not included in scope of delivery.
Emergency stop button
Factory Network
SINAMICS V70 SINAMICS V70 SINAMICS V70
In order to mount the PPU and MCP use the clamps provided as shown
below :-
In total 14 clamps are provided together with the delivery of PPU :
1. 8 clamps for mounting PPU.
2. 6 clamps for mounting MCP.
Terminator

808D ADVANCED Turning and Milling Page 9 Commissioning Guide
s
BB AA
X10
NC
Commissioning
of Prototype
Machine using
Sample PLC
Mounting dimensions Step 2
MCP
The clamps are located at the positions indicated with the black triangles.
The black triangles can be seen in the above picture highlighted with red
circles.
PPU = Panel Processing Unit
MCP = Machine Control Panel
The cut-out dimensions for the 808D ADVANCED horizontal PPU and
MCP.
Cut-out dimensions
PPU
808D PPU
808D MCP

Commissioning Guide Page 10 808D ADVANCED Turning and Milling
s
Commissioning
of Prototype
Machine using
Sample PLC
Mounting dimensions Step 2
The clamps are located at the positions indicated with the black triangles.
The black triangles can be seen in the following picture with red circles.
MCP
PPU
MCP
Vertical MCP without handwheel Vertical MCP with ingrate handwheel
808D PPU
808D MCP
The cut-out dimensions for the 808D ADVANCED vertical PPU and
MCP.
Cut-out dimensions

808D ADVANCED Turning and Milling Page 11 Commissioning Guide
s
Commissioning
of Prototype
Machine using
Sample PLC
Mounting dimensions Step 2
The connections for the SINAMICS V70 drives to the PPU are shown.
Wiring Step 3
In the following diagram, the mounting dimensions for the V70 drives are
shown.
You must provide sufficient space (recommended distances are shown)
around the cabinet wall for air circulation:
For further components refer to :-
Commissioning manual page 25
Electrical cabinet
> 20 mm
> 20 mm
> 20 mm > 20 mm
> 100 mm
> 100 mm
SINAMICS V70
Servo drive
SINAMICS V70
Servo drive
SINAMICS V70
Servo drive
For further information refer to :-
Circuit breaker (optional)
Switches off the power
supply to protect the
network when overcurrent
occurs
Line filter (optional)
Protects the network from
harmonic load and/or
interference voltages.
Braking resistor (optional)
Absorb excess regenerative
energy in the DC link when
the capacity of the internal
braking resistor is insufficient
SINUMERIK 808D ADVANCED
Emergency stop button
(optional)
Stops a motor in emergency
cases.
24 V DC power supply
Brake cable
Encoder cable
Power cable
3 phase 380V AC line
supply
L1 l2 l3
SIMOTICS S-1FL6 servo
motor
SINIMICS V70 servo
drive
Accessories not included in the
scope of delivery
Connections not necessarily
required
Shielding layer
Drive bus terminator

Commissioning Guide Page 12 808D ADVANCED Turning and Milling
s
Commissioning
of Prototype
Machine using
Sample PLC
Wiring Step 3
PPU front
14
In order to connect cables and wires, the location of all connectors and
terminal blocks need to be known.
Connector overview of the horizontal and vertical PPU is shown:
PPU back
When connecting the components in the electrical cabinet, the wiring
should comply with the relevant safety standards.
For further information refer to :-
Commissioning manual page 35
V70 Operating Instructions manual
Legend Interface Comment
PPU Back
1 X100, X101, X102 Digital inputs
2 X200, X201 Digital outputs
3 X21 FAST I/O
4 X301, X302 Distributed I/O
5 X10 Hand-wheel inputs
6 X60 Spindle encoder interface
7 X54 Analog spindle interface
8 X2 RS232 interface
9 X126 M3 Drive Bus
10 X30 USB interface, for connection with the
MCP
11 X1 Power supply interface, +24V DC power
supply
12 X130 Ethernet
13 - Slot for the System Compact Flash Card
(CF card)
PPU Front
14 - USB interface
8 9 10
11 13
765
43
2 1 12

808D ADVANCED Turning and Milling Page 13 Commissioning Guide
s
Commissioning
of Prototype
Machine using
Sample PLC
Wiring Step 3
PPU back Legend Interface Comment
PPU Back
1 X100, X101, X102 Digital inputs
2 X200, X201 Digital outputs
3 X21 FAST I/O
4 X301, X302 Distributed I/O
5 X10 Hand-wheel inputs
6 X60 Spindle encoder interface
7 X54 Analog spindle interface
8 X2 RS232 interface
9 X126 M3 Drive Bus
10 X30 USB interface, for connection with the
MCP
11 X1 Power supply interface, +24V DC power
supply
12 X130 Ethernet
13 - Slot for the System Compact Flash Card
(CF card)
PPU Front
14 - USB interface
PPU front
14
8
9
10
11
13
76
5
4
3
21
12

Commissioning Guide Page 14 808D ADVANCED Turning and Milling
s
Commissioning
of Prototype
Machine using
Sample PLC
Wiring Step 3
The connections on PPU for the handwheel are shown.
1A
-1A
1B
-1B
+5V
M
1
2
3
4
5
6
7
8
9
10
X10
Legend Interface Comment
MCP Back
1 X10 USB interface, for connection with the
PPU
BB AA
X10
NC
MCP back
1
Note
Connect USB cable between X30 on PPU and X10 on MCP.
Selection of 24V DC supply
These 4 aspects should be considered during selection of 24V DC supply
1. 24V DC consumed on 808D :
 Starting current:5 A (momentary)
 Basic consumption :1.5A
2. 24V DC consumed on Sinamics V70 drive:
 V70+1FL6 (w/o brake):0.8A/axes
 V70+1FL6 (w. brake): 1.2A/axes
3. Max. current of digital output: 0.25A/Digital output
4. Other devices (e.g. fan, hydraulic/pneumatic valve ):calculation base on name plate.
Consideration of redundancy coefficient base on regulation of OEM
MCP back
X10
NC

808D ADVANCED Turning and Milling Page 15 Commissioning Guide
s
E-stop
Limit X+
Limit X -
Limit Y+
Limit Y-
Limit Z+
Limit Z-
Ref X
M
1
2
3
4
5
6
7
8
9
10
X100
+
24V
Milling
Digital inputs
X301 Distributed I/O
Milling
Commissioning
of Prototype
Machine using
Sample PLC
Wiring Step 3
11 - Handheld unit: axis X selected
12 - Handheld unit: axis Y selected
13 - Handheld unit: axis Z selected
14 - Handheld unit: 4th axis selected
15 - Handheld unit: INC X1
16 - Handheld unit: INC X10
17 - Handheld unit: INC X100
18 - Handheld unit: enabled
+ 24V DC
External power
Supply + 24V DC
+
M
Distribution I/O board
For the connection of distribution I/O on X301,X302 distribution I/O board
must be configured. MLFB for distribution I/O: 6EP5 406-5AA00
Pin assignment of X301,X302
Illustration shows the connection
diagram of PPU X301
The connections of the distributed I/O are shown for the default PLC.

Commissioning Guide Page 16 808D ADVANCED Turning and Milling
s
Commissioning
of Prototype
Machine using
Sample PLC
Wiring Step 3
Ref Y
Ref Z
Magazine count
Magazine at spindle position
Magazine at original position
Magazine at release position
Magazine at clamp position
M
1
2
3
4
5
6
7
8
9
10 +
24V
X101
+24V
Disk magazine: magazine rotating CW
Disk magazine: magazine rotating CCW
Disk magazine: magazine in spindle position
Disk magazine: magazine in original position
Disk magazine: spindle tool release
Handheld unit active
M
1
2
3
4
5
6
7
8
9
10 +
24V
X201
Coolant level low
Cooling motor overload
Lubrication level low
Lubrication motor overload
M
1
2
3
4
5
6
7
8
9
10
X102
+
24V
Milling
Digital inputs
+24V
Working lamp
Chip remover forward
Chip remover reverse
Cooling pump
Lubrication pump
Safety door open
M
1
2
3
4
5
6
7
8
9
10 +
24V
X200
Milling
Digital outputs

808D ADVANCED Turning and Milling Page 17 Commissioning Guide
s
Commissioning
of Prototype
Machine using
Sample PLC
Wiring Step 3
Turning
Digital inputs
The connections of the distributed I/O are shown for the default PLC.
Turning
+ 24V DC
11 - Handheld unit: axis X selected
13 - Handheld unit: axis Z selected
14 - Handheld unit: axis 4th selected
15 - Handheld unit: INC X1
16 - Handheld unit: INC X10
17 - Handheld unit: INC X100
18 - Handheld unit: enabled
External power
Supply + 24V DC
+
M
Illustration shows the connection
diagram of PPU X301
For the connection of distribution I/O on X301,X302 distribution I/O board
must be configured. MLFB for distribution I/O: 6EP5 406-5AA00
Pin assignment of X301,X302
X301 Distributed I/O
E-stop
Limit X+
Limit X -
Limit Z+
Limit Z-
Ref X
M
1
2
3
4
5
6
7
8
9
10
X100
+
24V

Commissioning Guide Page 18 808D ADVANCED Turning and Milling
s
Turret motor overload
Reserved for other turret
Chuck open
Coolant level low
Cooling motor overload
Lubrication level low
Lubricating motor overload
M
1
2
3
4
5
6
7
8
9
10
X102
+
24V
+24V
Work lamp
Tailstock advancing
Tailstock retracting
Coolant pump
Lubrication pump
Chuck output 1
Chuck output 2
M
1
2
3
4
5
6
7
8
9
10 +
24V
X200
+24V
Turret motor CW
Turret motor CCW
Reserved for other turret
Reserved for other turret
Gear change: low
Gear change: high
Handheld unit active
M
1
2
3
4
5
6
7
8
9
10 +
24V
X201
Turning
Digital Outputs
Commissioning
of Prototype
Machine using
Sample PLC
Wiring Step 3
Ref. Z
T1
T2
T3
T4
T5
T6
M
1
2
3
4
5
6
7
8
9
10 +
24V
X101
Turning
Digital inputs

808D ADVANCED Turning and Milling Page 19 Commissioning Guide
s
Commissioning
of Prototype
Machine using
Sample PLC
Wiring Step 3
The connections for the inverter or the spindle drive to the PPU are shown.
Unipolar connection 3AC 380V
Spindle/
inverter motor
(black)
Bipolar connection 3AC 380V
black
black
black
Spindle/
inverter motor
B-N
A
A-N
B
B-N
A
A-N
B
SINUMERIK 808D
ADVANCED PPU
SINUMERIK 808D
ADVANCED PPU

Commissioning Guide Page 20 808D ADVANCED Turning and Milling
s
Commissioning
of Prototype
Machine using
Sample PLC
Wiring
The connection overview for milling is shown.
Step 3
The connection overview for turning is shown.