Siemens SINUMERIK 808D Quick start guide

© Siemens AG 2017. All rights reserved
01/2017 1
SINUMERIK
SINUMERIK 808D, SINUMERIK 808D ADVANCED
Commissioning Manual
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The
notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage
have no safety alert symbol. These notices shown below are graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of
injury to persons with a safety alert symbol may also include a warning relating to property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by
personnel qualified
for the specific task in accordance with
the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their
training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products
and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage,
installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any
problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed.

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Preface
Applicable products
This manual is valid for the following control systems:
Control system
Software version
SINUMERIK 808D ADVANCED T (Turning)
SINUMERIK 808D ADVANCED M (Milling)
V4.7.4: PPU161.3/PPU160.2 with spindle/feed servo system
SINUMERIK 808D (Turning)
SINUMERIK 808D (Milling)
V4.7.4: PPU141.2 with feed servo system
Documentation components and target audience
End-user documentation
Target audience
Programming and Operating Manual (Turning)
Programmers and operators of turning machines
Programming and Operating Manual (Milling)
Programmers and operators of milling machines
Programming and Operating Manual (ISO Turning/Milling) Programmers and operators of turning/milling machines
Programming and Operating Manual (Manual Machine Plus
(MM+), Turning)
Programmers and operators of turning machines
Diagnostics Manual Mechanical and electrical designers, commissioning engi-
neers, machine operators, and service and maintenance
personnel
Manufacturer/service documentation
Target audience
Commissioning Manual Installation personnel, commissioning engineers, and ser-
vice and maintenance personnel
Function Manual
Mechanical and electrical designers, technical professionals
Parameter Manual
Mechanical and electrical designers, technical professionals
Service Manual Mechanical and electrical designers, technical profession-
als, commissioning engineers, and service and maintenance
personnel
Readme file
Third-party software - Licensing terms and copyright information
My Documentation Manager (MDM)
Under the following link you will find information to individually compile your documentation based on the Siemens content:
www.siemens.com/mdm
Standard scope
This manual only describes the functionality of the standard version. Extensions or changes made by the machine tool
manufacturer are documented by the machine tool manufacturer.
Technical support
Country
Hotline
1)
Further service contact information:
•Worldwide Web site:
https://support.industry.siemens.com/cs/ww/en/
•Chinese Web site:
http://www.siemens.com.cn/808D
Germany
[phone]
China [phone]
1) You can find more hotline information at the worldwide Web site given above.

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EC Declaration of Conformity
The EC Declaration of Conformity for the EMC Directive can be found on the Internet at
http://www.siemens.com/automation/service&support.
Here, enter the number "
67385845
" as the search term or contact your local Siemens office.
Product maintenance
The components are subject to continuous further development within the scope of product maintenance (improvements to
robustness, discontinuations of components, etc).
These further developments are "spare parts-compatible" and do not change the article number.
In the scope of such spare parts-compatible further developments, connector positions are sometimes changed slightly. This
does not cause any problems with proper use of the components. Please take this fact into consideration in special
installation situations (e.g. allow sufficient clearance for the cable length).
Use of third-party products
This document contains recommendations relating to third-party products. Siemens accepts the fundamental suitability of
these third-party products.
You can use equivalent products from other manufacturers.
Siemens does not accept any warranty for the properties of third-party products.

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Table of contents
Preface.................................................................................................................................................................. 2
1 Safety instructions.................................................................................................................................................11
1.1 Fundamental safety instructions ........................................................................................................... 11
1.1.1 General safety instructions.................................................................................................................... 11
1.1.2 Handling electrostatic sensitive devices (ESD)..................................................................................... 15
1.1.3 Industrial security .................................................................................................................................. 15
1.1.4 Residual risks of power drive systems .................................................................................................. 16
1.2 Carrying out of repairs........................................................................................................................... 16
2 Preparation before commissioning.........................................................................................................................17
2.1 Scope of delivery................................................................................................................................... 17
2.1.1 SINUMERIK 808D ADVANCED control system.................................................................................... 17
2.1.1.1 System overview................................................................................................................................... 17
2.1.1.2 PPU and MCP....................................................................................................................................... 18
2.1.1.3 Drives and motors................................................................................................................................. 20
2.1.1.4 Cables and connectors ......................................................................................................................... 27
2.1.1.5 Options.................................................................................................................................................. 29
2.1.1.6 Spare parts ........................................................................................................................................... 34
2.1.2 SINUMERIK 808D control system......................................................................................................... 35
2.1.2.1 System overview................................................................................................................................... 35
2.1.2.2 PPU and MCP....................................................................................................................................... 36
2.1.2.3 Drives and motors................................................................................................................................. 36
2.1.2.4 Cables................................................................................................................................................... 39
2.1.2.5 Options.................................................................................................................................................. 40
2.2 Commissioning software tools .............................................................................................................. 41
2.2.1 Installing the software tools................................................................................................................... 41
2.2.2 Establishing a connection with the software tools ................................................................................. 43
2.2.2.1 Configuring the firewall.......................................................................................................................... 43
2.2.2.2 Connecting with PLC Programming Tool .............................................................................................. 44
2.2.2.3 Connecting with AMM ........................................................................................................................... 51
2.3 Personal computer................................................................................................................................ 54
3 Mounting...............................................................................................................................................................55
3.1 Mounting the PPU and MCP................................................................................................................. 55
3.1.1 Outline dimensions (unit: mm) .............................................................................................................. 55
3.1.2 Cut-out dimensions and mounting clearance........................................................................................ 58
3.1.3 Mounting the PPU and MCP with the companion clamps..................................................................... 59
3.2 Mounting the drive................................................................................................................................. 61
3.2.1 Mounting the SINAMICS V70 drive....................................................................................................... 61
3.2.1.1 Mounting orientation and clearance...................................................................................................... 61
3.2.1.2 Drill patterns and outline dimensions .................................................................................................... 62
3.2.1.3 Mounting the drive................................................................................................................................. 64
3.2.2 Mounting the SINAMICS V60 drive....................................................................................................... 65
3.2.2.1 Mounting orientation and clearance...................................................................................................... 65
3.2.2.2 Drill patterns and outline dimensions .................................................................................................... 65
3.2.2.3 Mounting the drive................................................................................................................................. 66
3.3 Mounting the motor ............................................................................................................................... 67
3.3.1 Mounting the SIMOTICS S-1FL6 motor ................................................................................................ 67
3.3.1.1 Mounting orientation and outline dimensions........................................................................................ 67
3.3.1.2 Mounting the motor ............................................................................................................................... 71
3.3.2 Mounting the SIMOTICS S-1FL5 motor ................................................................................................ 72
3.3.2.1 Mounting orientation and outline dimensions........................................................................................ 72
3.3.2.2 Mounting the motor ............................................................................................................................... 72
3.3.3 Mounting the SIMOTICS M-1PH1 main motor...................................................................................... 73
3.3.3.1 Mounting orientation and outline dimensions........................................................................................ 73
3.3.3.2 Mounting the motor ............................................................................................................................... 76

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3.4 Electrical cabinet design........................................................................................................................78
3.4.1 Correct installation of fans.....................................................................................................................78
3.4.2 Correct installation of cooling units........................................................................................................79
3.5 Notes on the laying of cables in drag chains .........................................................................................79
4 System connection................................................................................................................................................ 80
4.1 System connection overview.................................................................................................................81
4.2 Interfaces on the PPU ...........................................................................................................................84
4.2.1 Control elements on the PPU................................................................................................................84
4.2.2 Status LEDs on the PPU .......................................................................................................................85
4.2.3 PPU interface overview .........................................................................................................................86
4.2.4 Connecting the PPU..............................................................................................................................87
4.2.5 Digital input interfaces - X100, X101, X102...........................................................................................88
4.2.6 Digital output interfaces - X200, X201 ...................................................................................................89
4.2.7 Fast input/output - X21 ..........................................................................................................................90
4.2.8 Distributed I/O - X301, X302..................................................................................................................91
4.2.9 Handwheel inputs - X10 ........................................................................................................................95
4.2.10 Drive Bus interface - X126 (PPU161.3 and PPU160.2 only) .................................................................96
4.2.11 Pulse drive interfaces - X51, X52, X53 (PPU141.2 only).......................................................................97
4.2.12 Analog spindle interface - X54, spindle encoder interface - X60 ...........................................................99
4.2.13 Ethernet interface - X130.....................................................................................................................101
4.2.14 Power supply interface - X1.................................................................................................................102
4.2.15 RS232 interface - X2 (PPU160.2 only)................................................................................................102
4.2.16 USB interface - X30.............................................................................................................................103
4.2.17 USB interface on the front cover of the PPU .......................................................................................104
4.2.18 Maintenance door/slot for the system CF card....................................................................................104
4.3 Interfaces on the MCP.........................................................................................................................105
4.3.1 Control elements on the MCP .............................................................................................................105
4.3.2 MCP interface overview.......................................................................................................................106
4.4 Interfaces on the SINAMICS V70 servo system..................................................................................107
4.4.1 Status LEDs on the SINAMICS V70 drive ...........................................................................................107
4.4.2 Interface overview ...............................................................................................................................108
4.4.2.1 SINAMICS V70 feed servo system......................................................................................................108
4.4.2.2 SINAMICS V70 spindle servo system .................................................................................................110
4.4.3 Main circuit interfaces..........................................................................................................................112
4.4.4 Connecting the 24 V power supply/STO - X6......................................................................................114
4.4.5 Connecting the holding brake - X7 (feed drive only)............................................................................117
4.4.6 Connecting the encoder - X9...............................................................................................................118
4.4.7 Connecting an external braking resistor ..............................................................................................121
4.5 Interfaces on the SINAMICS V60 servo system..................................................................................121
4.5.1 Status LEDs on the SINAMICS V60 drive...........................................................................................121
4.5.2 Main circuit interfaces..........................................................................................................................122
4.5.3 Connecting the holding brake - X3 ......................................................................................................122
4.5.4 Connecting the 24 V power supply - X4 ..............................................................................................122
4.5.5 Setpoint interface - X5.........................................................................................................................123
4.5.6 Digital I/O interface - X6 ......................................................................................................................123
4.5.7 Connecting the encoder - X7...............................................................................................................124
4.5.8 Signal sequence example ...................................................................................................................125
4.6 Connecting the SINAMICS V70 servo system.....................................................................................126
4.6.1 Connecting the drive to motor .............................................................................................................126
4.6.2 Connecting the terminal boxes of the 1PH1 motor..............................................................................130
4.7 Connecting the SINAMICS V60 servo system.....................................................................................132
4.7.1 Connecting the drive with the SINUMERIK 808D control system........................................................132
4.7.2 Connecting the drive with the SIMATIC PLC.......................................................................................134
4.8 Switching on the drive .........................................................................................................................135
4.8.1 Switching on the SINAMICS V70 drive................................................................................................136
4.8.1.1 Jog test................................................................................................................................................136
4.8.1.2 Configuring Drive Bus addresses ........................................................................................................138
4.8.2 Switching on the SINAMICS V60 drive................................................................................................139
4.9 Switching on the control system ..........................................................................................................141
5 Initial system setup ............................................................................................................................................. 142

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5.1 System startup menu .......................................................................................................................... 142
5.2 Synchronizing drive data files between NC and drive (PPU161.3 and PPU160.2 only)...................... 143
5.3 Setting the password........................................................................................................................... 144
5.4 Setting the date and time .................................................................................................................... 146
5.5 Setting the user interface language .................................................................................................... 146
5.5.1 Changing the system language........................................................................................................... 146
5.5.2 Loading system languages ................................................................................................................. 147
5.6 Activating the optional functions.......................................................................................................... 148
6 Commissioning the PLC......................................................................................................................................150
6.1 PLC programming conventions........................................................................................................... 150
6.2 Signal overview of PLC interface ........................................................................................................ 150
6.3 Operation symbols of PLC programming languages........................................................................... 151
6.4 PLC sample applications..................................................................................................................... 156
6.4.1 PLC sample application (turning) ........................................................................................................ 156
6.4.2 PLC sample application (milling)......................................................................................................... 158
6.5 PLC machine data............................................................................................................................... 160
6.6 PLC subroutine library......................................................................................................................... 162
6.6.1 Overview............................................................................................................................................. 162
6.6.2 Conventions for the symbols used in the subroutines......................................................................... 165
6.6.3 Subroutine 20 - AUX_MCP (machine auxiliary functions) ................................................................... 166
6.6.4 Subroutine 21 - AUX_LAMP (working lamp) ....................................................................................... 166
6.6.5 Subroutine 22 - AUX_SAFE_DOOR (safety door) .............................................................................. 167
6.6.6 Subroutine 23 - AUX_CHIP (chip conveyor) ....................................................................................... 168
6.6.7 Subroutine 24 - AUX_3Color_LAMP ................................................................................................... 169
6.6.8 Subroutine 31 - PLC_ini_USR_ini (user initialization).......................................................................... 169
6.6.9 Subroutine 32 - PLC_INI (PLC initialization) ....................................................................................... 170
6.6.10 Subroutine 33 - EMG_STOP............................................................................................................... 170
6.6.11 Subroutine 37 - MCP_NCK (MCP and HMI signal processing)........................................................... 171
6.6.12 Subroutine 38 - MCP_Tool_Nr (display tool number on the MCP) ...................................................... 173
6.6.13 Subroutine 39 - HANDWHL (selecting a handwheel according to HMI interface signals)................... 173
6.6.14 Subroutine 40 - AXIS_CTL (controlling the spindle and axes) ............................................................ 174
6.6.15 Subroutine 41 - MINI_HHU (handwheel on hand-held unit) ................................................................ 176
6.6.16 Subroutine 42 - SPINDLE (spindle control)......................................................................................... 177
6.6.17 Subroutine 43 - MEAS_JOG (measurement in JOG mode)................................................................ 178
6.6.18 Subroutine 44 - COOLING (cooling control)........................................................................................ 179
6.6.19 Subroutine 45 - LUBRICAT (control of lubricate) ................................................................................ 180
6.6.20 Subroutine 46 - PI_SERVICE.............................................................................................................. 181
6.6.21 Subroutine 47 - PLC_Select_PP (PLC selects a subroutine) .............................................................. 183
6.6.22 Subroutine 48 - ServPlan (service planner) ........................................................................................ 183
6.6.23 Subroutine 49 - GearChg1_Auto (automatic spindle gear change)..................................................... 184
6.6.24 Subroutine 50 - GearChg2_Virtual (virtual spindle gear change)........................................................ 185
6.6.25 Subroutine 51 - Turret1_HED_T (turret with Hall effect device position sensor) ................................. 186
6.6.26 Subroutine 52 - Turret2_BIN_T (turret with binary coding function) .................................................... 188
6.6.27 Subroutine 53 - Turret3_CODE_T (tool change control for turret with coding function) ...................... 190
6.6.28 Subroutine 54 - Turret2_3_ToolDir (tool change direction).................................................................. 192
6.6.29 Subroutine 55 - Tail_stock_T (Tailstock control program for turning machines).................................. 193
6.6.30 Subroutine 56 - Lock_unlock_T (clamping control for turning machine).............................................. 194
6.6.31 Subroutine 58 (MM_MAIN).................................................................................................................. 195
6.6.32 Subroutine 59 (MM_MCP_808D) ........................................................................................................ 197
6.6.33 Subroutine 60 - Disk_MGZ_M (disk-style tool magazine used for milling)........................................... 198
6.6.34 Subroutine 62 - Trg_key_OR............................................................................................................... 200
6.6.35 Subroutine 63 - TOGGLES ................................................................................................................. 204
6.6.36 Subroutines 0 to 19, 34 to 36, 57, and 61 ........................................................................................... 204
6.7 PLC Programming Tool....................................................................................................................... 205
6.7.1 Overview of PLC Programming Tool................................................................................................... 205
6.7.2 Renaming the default program............................................................................................................ 206
6.7.3 Changing the display language........................................................................................................... 207
6.7.4 Selecting a target system.................................................................................................................... 208
6.7.5 Downloading/uploading/comparing PLC applications ......................................................................... 209

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6.7.6 Compiling and monitoring programs....................................................................................................217
6.8 PLC alarms..........................................................................................................................................218
6.8.1 Alarm cancel/reset and reaction ..........................................................................................................220
6.8.2 Editing PLC alarm texts.......................................................................................................................220
6.9 PLC diagnostics ..................................................................................................................................223
6.10 Handwheel assignment .......................................................................................................................226
7 Commissioning the prototype machine ................................................................................................................ 227
7.1 Overview on commissioning and operation wizards............................................................................227
7.2 Commissioning the PLC......................................................................................................................229
7.2.1 Setting PLC related parameters ..........................................................................................................229
7.2.2 Downloading and commissioning PLC programs................................................................................230
7.2.3 Checking I/O address assignment.......................................................................................................231
7.2.4 Editing PLC alarm texts.......................................................................................................................231
7.3 Configuring the drives (PPU161.3 and PPU160.2 only)......................................................................232
7.4 Setting basic parameters.....................................................................................................................235
7.4.1 Setting feed axis parameters...............................................................................................................235
7.4.2 Commissioning the referencing function..............................................................................................236
7.4.3 Setting spindle parameters..................................................................................................................238
7.5 Creating series archives......................................................................................................................239
7.6 Setting compensation data..................................................................................................................240
7.6.1 Setting software limit switch data ........................................................................................................240
7.6.2 Setting backlash compensation data...................................................................................................241
7.6.3 Setting leadscrew error compensation data ........................................................................................242
7.7 Tuning drive performance (PPU161.3 and PPU160.2 only)................................................................243
7.8 Creating prototype machine commissioning archives..........................................................................246
8 Commissioning the turret/magazine..................................................................................................................... 248
8.1 PLC subroutines for tool change .........................................................................................................248
8.2 Calling cycles for tool change..............................................................................................................248
9 Series machine commissioning ........................................................................................................................... 249
9.1 Loading series commissioning archives ..............................................................................................249
9.2 Setting software limit switch data ........................................................................................................250
9.3 Setting backlash compensation data...................................................................................................250
9.4 Setting leadscrew error compensation data ........................................................................................250
9.5 Tuning drive performance (PPU161.3 and PPU160.2 only)................................................................250
9.6 Creating startup archives.....................................................................................................................250
10 Network functions ............................................................................................................................................... 251
10.1 Network configuration..........................................................................................................................251
10.2 Configuring the network drive..............................................................................................................252
10.3 Configuring the firewall........................................................................................................................254
11 Measurement functions....................................................................................................................................... 255
11.1 Fast inputs and outputs .......................................................................................................................255
11.2 Probe commissioning ..........................................................................................................................256
12 Extended drive commissioning ............................................................................................................................ 257
12.1 Configuring the additional axis ............................................................................................................257
12.1.1 Configuring the additional axis for SINUMERIK 808D ADVANCED control system............................257
12.1.1.1 Configuring an additional feed axis......................................................................................................257
12.1.1.2 Configuring an additional spindle ........................................................................................................260
12.1.2 Configuring the additional axis for SINUMERIK 808D control system.................................................264
12.2 Configuring the Y axis on a turning machine.......................................................................................265

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12.2.1 Setting parameters for the Y axis........................................................................................................ 265
12.2.2 Measuring the tool manually (with the Y axis)..................................................................................... 266
13 Other frequently used functions ...........................................................................................................................270
13.1 Playing a slide show............................................................................................................................ 270
13.2 Defining the service planner................................................................................................................ 272
13.3 Using the machine manufacturer's startup screen and machine logo................................................. 273
13.4 Creating user cycles............................................................................................................................ 277
13.4.1 Creating the user cycle file.................................................................................................................. 277
13.4.2 Creating the user cycle alarm file........................................................................................................ 279
13.4.3 Creating the user cycle bitmap file...................................................................................................... 279
13.4.4 Creating the extended user text file..................................................................................................... 279
13.4.5 Creating the user cycle softkey index file............................................................................................ 280
13.4.6 Creating the user cycle parameter file................................................................................................. 280
13.4.7 Transferring the desired files to the control system............................................................................. 281
13.4.8 Calling the created user cycle............................................................................................................. 284
13.5 Using the machine manufacturer's machine data descriptions ........................................................... 286
13.6 Using the machine manufacturer's R variable names......................................................................... 287
13.7 PI service functions............................................................................................................................. 288
13.8 CNC lock function ............................................................................................................................... 289
13.8.1 Function overview ............................................................................................................................... 289
13.8.2 Creating the activation file................................................................................................................... 291
13.8.3 Importing the activation file ................................................................................................................. 292
13.8.4 Extending the CNC lock function......................................................................................................... 293
13.8.5 Deactivating the CNC lock function..................................................................................................... 294
13.8.6 OEM PIN forgotten.............................................................................................................................. 296
13.8.7 Other information ................................................................................................................................ 296
14 Customizing HMI display with EasyXLanguage scripts .........................................................................................298
14.1 Scope of functions............................................................................................................................... 298
14.2 Fundamentals of configuration............................................................................................................ 299
14.3 Configuration files (EasyXLanguage scripts) ...................................................................................... 300
14.4 Structure of configuration file .............................................................................................................. 301
14.5 Language dependency........................................................................................................................ 302
14.6 Creating language-dependent texts .................................................................................................... 302
14.7 XML identifier...................................................................................................................................... 302
14.7.1 General structure ................................................................................................................................ 302
14.7.2 Instruction/identifier description........................................................................................................... 303
14.7.3 System variables................................................................................................................................. 323
14.7.4 Color coding........................................................................................................................................ 323
14.7.5 Special XML syntax............................................................................................................................. 323
14.7.6 Operators ............................................................................................................................................ 324
14.7.7 Generating softkey menus and dialog forms....................................................................................... 324
14.8 Generating user menus....................................................................................................................... 349
14.8.1 Creating processing cycle forms ......................................................................................................... 349
14.8.2 Substitution characters........................................................................................................................ 352
14.9 Addressing components...................................................................................................................... 352
14.9.1 PLC addressing .................................................................................................................................. 352
14.9.2 Addressing NC variables..................................................................................................................... 353
14.9.3 Generating NC/PLC addresses during the runtime............................................................................. 353
14.9.4 Addressing drive components............................................................................................................. 353
14.9.5 Addressing machine and setting data ................................................................................................. 354
14.9.6 Addressing the user data .................................................................................................................... 355
14.10 Predefined functions ........................................................................................................................... 355
15 Technical data.....................................................................................................................................................383

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15.1 SINUMERIK 808D/SINUMERIK 808D ADVANCED............................................................................383
15.2 Servo drives ........................................................................................................................................384
15.2.1 SINAMICS V70 feed drives .................................................................................................................384
15.2.2 SINAMICS V70 spindle drives.............................................................................................................386
15.2.3 SINAMICS V60 servo drives ...............................................................................................................388
15.3 Servo motors.......................................................................................................................................390
15.3.1 SIMOTICS S-1FL6 feed motors ..........................................................................................................390
15.3.2 SIMOTICS S-1FL5 servo motors.........................................................................................................394
15.3.3 SIMOTICS M-1PH1 main motors ........................................................................................................396
15.4 Cables .................................................................................................................................................408
15.4.1 Drive Bus cable for the SINUMERIK 808D ADVANCED.....................................................................408
15.4.2 Cables for the SINAMICS V70 servo system ......................................................................................408
15.4.3 Cables for the SINAMICS V60 servo system ......................................................................................409
15.5 Transformers for the SINAMICS V60 servo system ............................................................................410
15.6 Address of CE-authorized manufacturer .............................................................................................411
16 Parameter list ..................................................................................................................................................... 411
16.1 Basic machine data .............................................................................................................................411
16.2 SINAMICS V70 parameters.................................................................................................................416
16.2.1 V70 parameters on BOP .....................................................................................................................418
16.2.2 Drive basic list on HMI.........................................................................................................................425
16.3 SINAMICS V60 parameters.................................................................................................................427
17 PLC user interface .............................................................................................................................................. 431
17.1 Signals from/to the MCP......................................................................................................................431
17.2 Reading/Writing NC data.....................................................................................................................433
17.2.1 Reading/writing NC data: Job..............................................................................................................433
17.2.2 Reading/writing NC data: Result .........................................................................................................433
17.3 PI Service............................................................................................................................................434
17.3.1 PI service: Job.....................................................................................................................................434
17.3.2 PI service: Result ................................................................................................................................434
17.4 Retentive data area .............................................................................................................................434
17.5 User Alarms.........................................................................................................................................435
17.5.1 User alarms: Activating........................................................................................................................435
17.5.2 Variables for user alarms.....................................................................................................................435
17.5.3 Active alarm response.........................................................................................................................436
17.5.4 Alarm acknowledgement .....................................................................................................................436
17.6 Signals from/to HMI.............................................................................................................................436
17.6.1 Program control signals from the HMI (retentive area)........................................................................436
17.6.2 Program selection from PLC (retentive area) ......................................................................................437
17.6.3 Checkback signal: Program selection from HMI (retentive area).........................................................437
17.6.4 Signals from HMI.................................................................................................................................437
17.6.5 Signals from PLC ................................................................................................................................437
17.6.6 Signals to maintenance planners ........................................................................................................438
17.6.7 Signals from maintenance planners ....................................................................................................438
17.6.8 Signals from operator panel (retentive area) .......................................................................................439
17.6.9 General selection/status signals from HMI (retentive area).................................................................439
17.6.10 General selection/status signals to HMI (retentive area) .....................................................................439
17.7 Auxiliary functions transfer from NC channel.......................................................................................440
17.7.1 Overview .............................................................................................................................................440
17.7.2 Decoded M signals (M0 to M99)..........................................................................................................441
17.7.3 Transferred T functions .......................................................................................................................441
17.7.4 Transferred M functions.......................................................................................................................441
17.7.5 Transferred S functions .......................................................................................................................442
17.7.6 Transferred D functions.......................................................................................................................442
17.7.7 Transferred H functions.......................................................................................................................442
17.8 NCK signals.........................................................................................................................................442
17.8.1 General signals to NCK.......................................................................................................................442

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17.8.2 General signals from NCK .................................................................................................................. 443
17.8.3 Signals at fast inputs and outputs ....................................................................................................... 443
17.8.4 Signals from fast inputs and outputs ................................................................................................... 444
17.9 Channel signals .................................................................................................................................. 445
17.9.1 Signals to NC channel......................................................................................................................... 445
17.9.2 Signals from NC channel .................................................................................................................... 447
17.10 Axis/spindle signals............................................................................................................................. 450
17.10.1 Transferred M and S functions, axis specific....................................................................................... 450
17.10.2 Signals to axis/spindle......................................................................................................................... 450
17.10.3 Signals from axis/spindle .................................................................................................................... 453
17.11 PLC machine data............................................................................................................................... 455
17.11.1 INT values (MD 14510 USER_DATA_INT) ......................................................................................... 455
17.11.2 HEX values (MD 14512 USER_DATA_HEX)...................................................................................... 455
17.11.3 FLOAT values (MD 14514 USER_DATA_FLOAT).............................................................................. 455
17.11.4 User alarm: Configuring (MD 14516 USER_DATA_PLC_ALARM) ..................................................... 456
17.12 Signals, synchronized actions............................................................................................................. 456
17.12.1 Signals, synchronized actions to channel ........................................................................................... 456
17.12.2 Signals, synchronized actions from channel ....................................................................................... 456
17.12.3 Reading and writing PLC variables..................................................................................................... 456
17.13 Axis actual values and distance-to-go................................................................................................. 457
17.14 Maintenance scheduler: User interface............................................................................................... 457
17.14.1 Initial (start) data ................................................................................................................................. 457
17.14.2 Actual data.......................................................................................................................................... 457
17.15 User interface for ctrl energy............................................................................................................... 458
A Appendix ............................................................................................................................................................459
A.1 Operation and display......................................................................................................................... 459
A.1.1 Operating the SINAMICS V70 Basic Operator Panel (BOP)............................................................... 459
A.1.1.1 BOP overview ..................................................................................................................................... 459
A.1.1.2 Parameter structure ............................................................................................................................ 463
A.1.1.3 Actual status display ........................................................................................................................... 464
A.1.1.4 Basic operations ................................................................................................................................. 464
A.1.1.5 Auxiliary functions ............................................................................................................................... 466
A.1.2 Operating the SINAMICS V60 Basic Operator Panel (BOP)............................................................... 471
A.1.2.1 BOP overview ..................................................................................................................................... 471
A.1.2.2 Main menu .......................................................................................................................................... 471
A.1.2.3 Function menu .................................................................................................................................... 473
A.1.2.4 Parameter setting menu...................................................................................................................... 475
A.1.2.5 Data display menu .............................................................................................................................. 476
A.1.2.6 Setpoints from the PPU....................................................................................................................... 476
A.2 Replacing the fan for the V70 drive..................................................................................................... 477
A.3 Replacing the fan for the 1PH1 motor................................................................................................. 480
A.4 Assembling the power cable for the 1PH1 motor................................................................................ 480
A.5 Assembling the line supply terminal for the drive ................................................................................ 483
A.6 Cutting reserved holes in the MCP ..................................................................................................... 483
A.7 Customizing pre-defined labeling strips for keys of the MCP.............................................................. 484
A.8 Diagnostics ......................................................................................................................................... 485
A.8.1 SINUMERIK 808D/SINUMERIK 808D ADVANCED alarms................................................................ 485
A.8.2 SINAMICS V70 faults and alarms ....................................................................................................... 486
A.8.2.1 General information about faults and alarms ...................................................................................... 486
A.8.2.2 List of faults and alarms ...................................................................................................................... 487
A.8.3 SINAMICS V60 faults and alarms ....................................................................................................... 499
A.8.3.1 Overview............................................................................................................................................. 499
A.8.3.2 Common faults and alarms ................................................................................................................. 499
A.8.3.3 Errors during drive self-test ................................................................................................................. 502
A.8.3.4 Other faults ......................................................................................................................................... 502
A.9 AMM communication tool.................................................................................................................... 503
A.9.1 File management and transfer ............................................................................................................ 503
A.9.2 Remote control.................................................................................................................................... 505
A.9.2.1 Configuring the remote control............................................................................................................ 505

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A.9.2.2 Operating the HMI via remote control..................................................................................................507
A.9.2.3 Saving the remote control screen as a picture ....................................................................................508
1
Safety instructions
1.1
Fundamental safety instructions
1.1.1
General safety instructions
DANGER
Danger to life due to live parts and other energy sources
Death or serious injury can result when live parts are touched.
•Only work on electrical devices when you are qualified for this job.
•Always observe the country-specific safety rules.
Generally, six steps apply when establishing safety:
1. Prepare for shutdown and notify all those who will be affected by the procedure.
2. Disconnect the machine from the supply.
–Switch off the machine.
–Wait until the discharge time specified on the warning labels has elapsed.
–Check that it really is in a no-voltage condition, from phase conductor to phase conductor and phase
conductor to protective conductor.
–Check whether the existing auxiliary supply circuits are de-energized.
–Ensure that the motors cannot move.
3. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or water.
4. Isolate or neutralize all hazardous energy sources by closing switches, grounding or short-circuiting or
closing valves, for example.
5. Secure the energy sources against switching on again.
6. Ensure that the correct machine is completely interlocked.
After you have completed the work, restore the operational readiness in the inverse sequence.
WARNING
Danger to life through a hazardous voltage when connecting an unsuitable power supply
Touching live components can result in death or severe injury.
•Only use power supplies that provide SELV (Safety Extra Low Voltage) or PELV- (Protective Extra Low
Voltage) output voltages for all connections and terminals of the electronics modules.
WARNING
Danger to life when live parts are touched on damaged motors/devices
Improper handling of motors/devices can damage them.
For damaged motors/devices, hazardous voltages can be present at the enclosure or at exposed components.
•Ensure compliance with the limit values specified in the technical data during transport, storage and
operation.
•
Do not use any damaged motors/devices.
WARNING
Danger to life through electric shock due to unconnected cable shields
Hazardous touch voltages can occur through capacitive cross-coupling due to unconnected cable shields.
•As a minimum, connect cable shields and the cores of cables that are not used at one end at the grounded
housing potential.

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WARNING
Danger to life due to electric shock when not grounded
For missing or incorrectly implemented protective conductor connection for devices with protection class I, high
voltages can be present at open, exposed parts, which when touched, can result in death or severe injury.
•
Ground the device in compliance with the applicable regulations.
WARNING
Danger to life due to electric shock when opening plug connections in operation
When opening plug connections in operation, arcs can result in severe injury or death.
•Only open plug connections when the equipment is in a no-voltage state, unless it has been explicit
ly stated
that they can be opened in operation.
WARNING
Danger to life through electric shock due to the residual charge of the power component capacitors
Because of the capacitors, a hazardous voltage is present for up to 5 minutes after the power supply has been
switched off. Contact with live parts can result in death or serious injury.
•
Wait for 5 minutes before you check that the unit really is in a no-voltage condition and start work.
NOTICE
Material damage due to loose power connections
Insufficient tightening torques or vibrations can result in loose electrical connections. This can result in damage due to fire,
device defects or malfunctions.
•Tighten all power connections with the specified tightening torques, e.g. line supply connection, motor connection, DC
link connections.
•
Check all power connections at regular intervals. This applies in particular after transport.
WARNING
Danger to life due to fire spreading if housing is inadequate
Fire and smoke development can cause severe personal injury or material damage.
•Install devices without a protective housing in a metal control cabinet (or protect the device by another equivalent
measure) in such a way that contact with fire is prevented.
•
Ensure that smoke can only escape via controlled and monitored paths.
WARNING
Danger to life from electromagnetic fields
Electromagnetic fields (EMF) are generated by the operation of electrical power equipment, such as transformers,
converters, or motors.
People with pacemakers or implants are at particular risk in the immediate vicinity of this equipment.
•
If you have a heart pacemaker or implant, maintain a minimum distance of 2 m from electrical power equipment.
WARNING
Danger to life from permanent-magnet fields
Even when switched off, electric motors with permanent magnets represent a potential risk for persons with heart
pacemakers or implants if they are close to converters/motors.
•If you have a heart pacemaker or implant, maintain a minimum distance of 2 m.
•When transporting or storing permanent-magnet motors always use the original packing materials with the warning
labels attached.
•Clearly mark the storage locations with the appropriate warning labels.
•
IATA regulations must be observed when transported by air.

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WARNING
Danger to life through unexpected movement of machines when using mobile wireless devices or mobile phones
Using mobile wireless devices or mobile phones with a transmit power > 1 W closer than approx. 2 m to the components
may cause the devices to malfunction, influence the functional safety of machines therefore putting people at risk or
causing material damage.
•
Switch the wireless devices or mobile phones off in the immediate vicinity of the components.
WARNING
Danger to life due to the motor catching fire in the event of insulation overload
There is higher stress on the motor insulation through a ground fault in an IT system. If the insulation fails, it is possible that
death or severe injury can occur as a result of smoke and fire.
•Use a monitoring device that signals an insulation fault.
•
Correct the fault as quickly as possible so the motor insulation is not overloaded.
WARNING
Danger to life due to fire if overheating occurs because of insufficient ventilation clearances
Inadequate ventilation clearances can cause overheating of components with subsequent fire and smoke. This can cause
severe injury or even death. This can also result in increased downtime and reduced service lives for devices/systems.
•
Ensure compliance with the specified minimum clearance as ventilation clearance for the respective component.
WARNING
Danger of an accident occurring due to missing or illegible warning labels
Missing or illegible warning labels can result in accidents involving death or serious injury.
•Check that the warning labels are complete based on the documentation.
•Attach any missing warning labels to the components, in the national language if necessary.
•
Replace illegible warning labels.
NOTICE
Device damage caused by incorrect voltage/insulation tests
Incorrect voltage/insulation tests can damage the device.
•Before carrying out a voltage/insulation check of the system/machine, disconnect the devices as all converters and
motors have been subject to a high voltage test by the manufacturer, and therefore it is not necessary to perform an
additional test within the system/machine.
WARNING
Danger to life when safety functions are inactive
Safety functions that are inactive or that have not been adjusted accordingly can cause operational faults on machines that
could lead to serious injury or death.
•Observe the information in the appropriate product documentation before commissioning.
•Carry out a safety inspection for functions relevant to safety on the entire system, including all safety-related
components.
•Ensure that the safety functions used in your drives and automation tasks are adjusted and activated through
appropriate parameterizing.
•Perform a function test.
•Only put your plant into live operation once you have guaranteed that the functions relevant to safety are running
correctly.
Note
Important safety notices for Safety Integrated functions
If you want to use Safety Integrated functions, you must observe the safety notices in the Safety Integrated manuals.

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WARNING
Danger to life or malfunctions of the machine as a result of incorrect or changed parameterization
As a result of incorrect or changed parameterization, machines can malfunction, which in turn can lead to injuries or death.
•Protect the parameterization (parameter assignments) against unauthorized access.
•
Respond to possible malfunctions by applying suitable measures (e.g. EMERGENCY STOP or EMERGENCY OFF).
WARNING
Risk of injury caused by moving parts or parts that are flung out
Touching moving motor parts or drive output elements and loose motor parts that are flung out (e.g. feather keys) in
operation can result in severe injury or death.
•Remove any loose parts or secure them so that they cannot be flung out.
•Do not touch any moving parts.
•Safeguard all moving parts using the appropriate safety guards.
WARNING
Danger to life due to fire if overheating occurs because of insufficient cooling
Inadequate cooling can cause overheating resulting in death or severe injury as a result of smoke and fire. This can also
result in increased failures and reduced service lives of motors.
•
Comply with the specified coolant requirements for the motor.
WARNING
Danger to life due to fire as a result of overheating caused by incorrect operation
When incorrectly operated and in the case of a fault, the motor can overheat resulting in fire and smoke. This can result in
severe injury or death. Further, excessively high temperatures destroy motor components and result in increased failures
as well as shorter service lives of motors.
•Operate the motor according to the relevant specifications.
•Only operate the motors in conjunction with effective temperature monitoring.
•
Immediately switch off the motor if excessively high temperatures occur.
CAUTION
Risk of injury due to touching hot surfaces
In operation, the motor can reach high temperatures, which can cause burns if touched.
•Mount the motor so that it is not accessible in operation.
Measures when maintenance is required:
•Allow the motor to cool down before starting any work.
•
Use the appropriate personnel protection equipment, e.g. gloves.

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1.1.2
Handling electrostatic sensitive devices (ESD)
Electrostatic sensitive devices (ESD) are individual components, integrated circuits, modules or devices that may be
damaged by either electric fields or electrostatic discharge.
NOTICE
Damage through electric fields or electrostatic discharge
Electric fields or electrostatic discharge can cause malfunctions through damaged individual components,
integrated circuits, modules or devices.
•Only pack, store, transport and send electronic components, modules or devices in their original packaging
or in other suitable materials, e.g conductive foam rubber of aluminum foil.
•Only touch components, modules and devices when you are grounded by one of the following methods:
–Wearing an ESD wrist strap
–Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring
•Only place electronic components, modules or devices on conductive surfaces (table with ESD surface,
conductive ESD foam, ESD packaging, ESD transport container).
1.1.3
Industrial security
Note
Industrial security
Siemens provides products and solutions with industrial security functions that support the secure operation of plants,
systems, machines and networks.
In order to protect plants, system
s, machines and networks against cyber threats, it is necessary to implement – and
continuously maintain
– a holistic, state-of-the-
art industrial security concept. Siemens products and solutions only represent
one component of such a concept.
The customer
is responsible for preventing unauthorized access to its plants, systems, machines and networks. Systems,
machines and components should only be connected to the enterprise network or the internet if and to the extent necessary
and with appropriate securi
ty measures (e.g. use of firewalls and network segmentation) in place.
Additionally, Siemens’ guidance on appropriate security measures should be taken into account. For more information about
industrial security, please visit:
Industrial security (
http://www.siemens.com/industrialsecurity).
Siemens’ products and solutions undergo continuous development to make them more secure. Siemens strongly
recommends to apply product updates as soon as availa
ble and to always use the latest product versions. Use of product
versions that are no longer supported, and failure to apply latest updates may increase customer’s exposure to cyber
threats.
To stay informed about product updates, subscribe to the Siemen
s Industrial Security RSS Feed at:
Industrial security (
http://www.siemens.com/industrialsecurity).
WARNING
Danger to life as a result of unsafe operating states resulting from software manipulation
Software manipulations (e.g. viruses, trojans, malware or worms) can cause unsafe operating states in your system that
may lead to death, serious injury, and property damage.
•Keep the software up to date.
•Incorporate the automation and drive components into a holistic, state-of-the-art industrial security concept for the
installation or machine.
•Make sure that you include all installed products into the holistic industrial security concept.
•Protect files stored on exchangeable storage media from malicious software by with suitable protection measures, e.g.
virus scanners.

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1.1.4
Residual risks of power drive systems
When assessing the machine- or system-related risk in accordance with the respective local regulations (e.g., EC Machinery
Directive), the machine manufacturer or system installer must take into account the following residual risks emanating from
the control and drive components of a drive system:
1. Unintentional movements of driven machine or system components during commissioning, operation, maintenance, and
repairs caused by, for example,
–Hardware and/or software errors in the sensors, control system, actuators, and cables and connections
–Response times of the control system and of the drive
–Operation and/or environmental conditions outside the specification
–Condensation/conductive contamination
–Parameterization, programming, cabling, and installation errors
–Use of wireless devices/mobile phones in the immediate vicinity of electronic components
–External influences/damage
–X-ray, ionizing radiation and cosmic radiation
2. Unusually high temperatures, including open flames, as well as emissions of light, noise, particles, gases, etc., can occur
inside and outside the components under fault conditions caused by, for example:
–Component failure
–Software errors
–Operation and/or environmental conditions outside the specification
–External influences/damage
3. Hazardous shock voltages caused by, for example:
–Component failure
–Influence during electrostatic charging
–Induction of voltages in moving motors
–Operation and/or environmental conditions outside the specification
–Condensation/conductive contamination
–External influences/damage
4. Electrical, magnetic and electromagnetic fields generated in operation that can pose a risk to people with a pacemaker,
implants or metal replacement joints, etc., if they are too close
5. Release of environmental pollutants or emissions as a result of improper operation of the system and/or failure to
dispose of components safely and correctly
6. Influence of network-connected communication systems, e.g. ripple-control transmitters or data communication via the
network
For more information about the residual risks of the drive system components, see the relevant sections in the technical user
documentation.
1.2
Carrying out of repairs
DANGER
Carrying out of repairs
Anywhere in the automation equipment where faults might cause physical injury or major material damage, in other words,
where faults could be dangerous, additional external precautions must be taken, or facilities must be provided, that
guarantee or enforce a safe operational state, even when there is a fault (e.g. using an independent limit value switch,
mechanical locking mechanisms, EMERGENCY STOP/EMERGENCY OFF devices).

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2
Preparation before commissioning
2.1
Scope of delivery
2.1.1
SINUMERIK 808D ADVANCED control system
2.1.1.1
System overview
The SINUMERIK 808D ADVANCED control system is an economic numerical control system for milling or turning machines.
The SINUMERIK 808D ADVANCED controller, coupled with the high performance SINAMICS V70 feed/spindle drive,
SIMOTICS S-1FL6 feed motor, and SIMOTICS M-1PH1 main motor, is able to control up to five axes including analog/digital
spindles.
Control system versions
Control system
SINUMERIK 808D ADVANCED T
SINUMERIK 808D ADVANCED M
Applicable machine tools
Turning machines
Milling machines
PPU
PPU variants
PPU161.3
PPU160.2
PPU161.3
PPU160.2
Applicable software ver-
sion
V4.7.4 V4.7.4 V4.7.4 V4.7.4
Panel layout
Horizontal
Vertical
Horizontal
Vertical
Operator panel with Eng-
lish keys
√√√√
Operator panel with Chi-
nese keys
√√√√
MCP Configurable MCPs are available in the following versions:
•Horizontal MCP, with English keys and override switches
•Horizontal MCP, with Chinese keys and override switches
•Horizontal MCP, with Chinese keys and a reserved slot for the handwheel (applicable to turning ma-
chines only)
•Vertical MCP, with English keys and a reserved slot for the handwheel
•Vertical MCP, with Chinese keys and a reserved slot for the handwheel
•Vertical MCP, with English keys and an override switch for the spindle
•
Vertical MCP, with Chinese keys and an override switch for the spindle
Number of
configurable
axes
Total
Up to 5
Up to 5
Standard axes
3
3
4
4
Additional axes (license
required)
2 2 1 1
Communication with drive
Drive Bus interface
Drive Bus interface
Configurable drives
SINAMICS V70 feed/spindle drive
SINAMICS V70 feed/spindle drive
Configurable motors SIMOTICS S-1FL6/SIMOTICS M-
1PH1
SIMOTICS S-1FL6/SIMOTICS M-
1PH1
√: available

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2.1.1.2
PPU and MCP
Components in the panel processing unit (PPU) package
Component
Quantity (pieces)
Illustration
Article number
PPU 1 Horizontal
version
(PPU161.3)
Turning
6FC5370-2AT03-0AA0 (English)
6FC5370-2AT03-0CA0 (Chinese)
Milling
6FC5370-2AM03-0AA0 (English)
6FC5370-2AM03-0CA0 (Chinese)
Vertical
version
(PPU160.2)
Turning
6FC5370-2BT02-0AA0 (English)
6FC5370-2BT02-0CA0 (Chinese)
Milling
6FC5370-2BM02-0AA0 (English)
6FC5370-2BM02-0CA0 (Chinese)
Drive Bus termi-
nator
1 6FC5548-0BA21-0AA0
Mounting
clamps with
screws
•PPU161.3: 8
•PPU160.2: 10
Connectors
8
Seven I/O connectors and one 24 V power input connector
Readme file
1
Third-party software - Licensing terms and copyright information

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Components in the machine control panel (MCP) package
Component
Quantity (piec-
es)
Illustration
Article number
MCP 1 Horizontal MCP, with
override switches
6FC5303-0AF35-0AA0 (English)
6FC5303-0AF35-0CA0 (Chinese)
Horizontal MCP, with a
reserved slot for the
handwheel
6FC5303-0AF35-1CA0 (Chinese)
Vertical MCP, with an
override switch for the
spindle
6FC5303-0AF35-2AA0 (English)
6FC5303-0AF35-2CA0 (Chinese)
Vertical MCP, with a
reserved slot for the
handwheel
6FC5303-0AF35-3AA0 (English)
6FC5303-0AF35-3CA0 (Chinese)
MCP connecting
cable
1 (for connect-
ing the MCP to
the PPU)
Mounting
clamps with
screws
•Horizontal
MCP: 6
•Vertical
MCP: 8
Pre-defined
labeling strips
for keys of the
MCP, milling *
1
Blank strip pa-
per, A4 size *
1
* Not provided in the package for the horizontal MCP with a reserved slot for the handwheel.

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2.1.1.3
Drives and motors
SINAMICS V70 feed servo system
Components in the SINAMICS V70 feed drive package
Component
Quantity
(pieces)
Illustration
Outline dimension
(Width × Height ×
Depth, mm)
Frame
size 1)
Rated output
current (A)
Article number
SINAMICS
V70 feed
drive
1 80 × 180 × 200 FSA
1.2
6SL3210-5DE12-4UA0
3.0
6SL3210-5DE13-5UA0
100 × 180 × 220 FSB 4.6 6SL3210-5DE16-0UA0
5.3
6SL3210-5DE17-8UA0
7.8 6SL3210-5DE21-0UA0
140 × 260 × 240 FSC
11.0
6SL3210-5DE21-4UA0
13.2 6SL3210-5DE21-8UA0
Shielding
plate
1 (FSA) For all shielded cables of the drive
2
(FSB/FSC)
For all shielded cables of the drive
For the line supply cable of the drive
Connectors 4 (FSA)/2
(FSB/FSC) Line supply connector (FSA only)
Motor power/braking resistor connector (FSA only)
Holding brake connector
STO/24 V power supply connector
User docu-
mentation
1 Safety Instructions
1) For more information about the different frame sizes, see Section "Drill patterns and outline dimensions (Page 62)".