Siemens SINUMERIK 808D Quick start guide

Commissioning Manual
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SINUMERIK
SINUMERIK 808D
Commissioning Manual
Commissioning Manual
Valid for the following control systems:
SINUMERIK 808D Turning (software version: V4.4.2)
SINUMERIK 808D Milling (software version: V4.4.2)
Target group:
Electrical engineers, calibration engineers and testing
01/2015
6FC5397-4EP10-0BA0
Delivery check
1
Mounting
2
Connecting
3
Switching on and preparing
for commissioning
4
Commissioning diagram
5
Default PLC applications
6
Commissioning the prototype
7
Series production
8
Other frequently used
functions
9
Appendix
A

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 6FC5397-4EP10-0BA0
Ⓟ02/2015 Subject to change
Copyright © Siemens AG 2012.
All rights reserved
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.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

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Table of contents
1 Delivery check ........................................................................................................................................... 7
2 Mounting.................................................................................................................................................. 13
2.1 Mounting the controller ...........................................................................................................13
2.2 Mounting the drive ..................................................................................................................15
2.3 Mounting the motor.................................................................................................................18
3 Connecting .............................................................................................................................................. 19
3.1 Interface overview...................................................................................................................19
3.2 Connecting the battery............................................................................................................21
3.3 Connecting according to the default PLC program.................................................................22
3.4 Connection Overview..............................................................................................................27
4 Switching on and preparing for commissioning........................................................................................ 29
4.1 Switching on controller............................................................................................................29
4.2 PPU keyboard function ...........................................................................................................30
4.3 MCP mode changeover ..........................................................................................................31
4.4 Status LEDs ............................................................................................................................32
4.5 Password ................................................................................................................................33
4.5.1 Access levels ..........................................................................................................................33
4.5.2 Setting a password .................................................................................................................35
4.6 Setting the date and time........................................................................................................36
4.7 Introduction to the onboard assistants....................................................................................37
5 Commissioning diagram .......................................................................................................................... 39
6 Default PLC applications ......................................................................................................................... 41
6.1 Turning....................................................................................................................................41
6.2 Milling......................................................................................................................................45
6.3 PLC user alarms .....................................................................................................................48
6.3.1 General information ................................................................................................................48
6.3.2 Alarm properties......................................................................................................................48
6.3.3 Activating the PLC user alarms ..............................................................................................50
6.3.4 Editing a PLC user alarm text.................................................................................................52
7 Commissioning the prototype .................................................................................................................. 57
7.1 Commissioning the controller .................................................................................................57
7.1.1 Entering machine data............................................................................................................57
7.1.2 Setting the axis-relevant parameters......................................................................................58
7.1.2.1 Enabling the position control...................................................................................................58

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7.1.2.2 Setting the leadscrew pitch, deceleration ratio, and motor rotation direction........................ 58
7.1.2.3 Setting the axis speed and acceleration................................................................................ 59
7.1.2.4 Setting the position-loop gain................................................................................................. 59
7.1.3 Setting the spindle-relevant parameters ................................................................................ 60
7.1.4 Approaching the reference point............................................................................................ 62
7.1.5 Compensation parameter settings......................................................................................... 64
7.1.5.1 Setting the software limit switches......................................................................................... 64
7.1.5.2 Setting backlash compensation ............................................................................................. 64
7.1.5.3 Making leadscrew error compensation.................................................................................. 65
7.1.5.4 Setting protection levels......................................................................................................... 68
7.2 Data backup........................................................................................................................... 70
7.2.1 Creating a series archive ....................................................................................................... 70
7.2.2 Creating a start-up archive for the prototype ......................................................................... 71
7.2.3 Restoring the control system with the start-up archive file .................................................... 73
8 Series production..................................................................................................................................... 75
8.1 Uploading the series archive for series commissioning......................................................... 75
8.2 Data settings for individual machine ...................................................................................... 77
8.2.1 Setting the software limit switches......................................................................................... 77
8.2.2 Setting the backlash............................................................................................................... 77
8.2.3 Making leadscrew error compensation .................................................................................. 77
8.3 Data backup........................................................................................................................... 77
8.3.1 Overview ................................................................................................................................ 77
8.3.2 Creating an original status archive......................................................................................... 78
8.3.3 Creating the start-up archive.................................................................................................. 78
8.3.4 Restoring the control system ................................................................................................. 79
9 Other frequently used functions ............................................................................................................... 81
9.1 Playing a slide show .............................................................................................................. 81
9.2 Defining the service planner .................................................................................................. 83
9.3 Using the OEM startup screen and the OEM machine logo.................................................. 86
A Appendix.................................................................................................................................................. 89
A.1 Cutting reserved holes ........................................................................................................... 89
A.2 Inserting, printing or cutting the MCP strips........................................................................... 90
A.3 Basic knowledge about NC programming ............................................................................. 91
A.4 Selection of the transformers................................................................................................. 92
A.5 Parameter list......................................................................................................................... 93
A.5.1 Basic machine data................................................................................................................ 93
A.5.2 SINAMICS V60 parameters ................................................................................................... 97
A.6 Diagnostics............................................................................................................................. 99
A.6.1 SINUMERIK 808D alarms...................................................................................................... 99
A.6.2 SINAMICS alarms.................................................................................................................. 99
A.6.2.1 Overview of alarms ................................................................................................................ 99
A.6.2.2 Alarm list .............................................................................................................................. 100
A.6.2.3 Errors during drive self-test.................................................................................................. 103
A.6.2.4 Other faults........................................................................................................................... 104

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A.6.2.5 Display data list.....................................................................................................................104
A.7 PLC user interfaces ..............................................................................................................106
A.7.1 Addressing ranges................................................................................................................106
A.7.2 MCP ......................................................................................................................................108
A.7.2.1 Signals from MCP.................................................................................................................108
A.7.2.2 Signals to MCP .....................................................................................................................108
A.7.2.3 Reading/writing NC data: Job ...............................................................................................109
A.7.2.4 Reading/writing NC data: Result...........................................................................................109
A.7.2.5 PI service: Job ......................................................................................................................109
A.7.2.6 PI service: Result..................................................................................................................110
A.7.3 Retentative data area ...........................................................................................................110
A.7.4 User Alarms ..........................................................................................................................110
A.7.4.1 User alarms: Activating.........................................................................................................110
A.7.4.2 Variables for user alarms......................................................................................................110
A.7.4.3 Active alarm response ..........................................................................................................111
A.7.4.4 Acknowledgement of alarms.................................................................................................111
A.7.5 Axis/spindle signals...............................................................................................................111
A.7.5.1 Transferred M and S functions, axis specific........................................................................111
A.7.5.2 Signals to axis/spindle ..........................................................................................................111
A.7.5.3 Signals from axis/spindle ......................................................................................................113
A.7.6 PLC machine data ................................................................................................................116
A.7.6.1 INT values (MD 14510 USER_DATA_INT) ..........................................................................116
A.7.6.2 HEX values (MD 14512 USER_DATA_HEX) .......................................................................116
A.7.6.3 FLOAT values (MD 14514 USER_DATA_FLOAT)...............................................................116
A.7.6.4 User alarm: Configuring (MD 14516 USER_DATA_PLC_ALARM) ......................................116
A.7.7 Signals from/to HMI ..............................................................................................................117
A.7.7.1 Program control signals from the HMI (retentive area) (also refer to signals at channel
DB3200)................................................................................................................................117
A.7.7.2 Program selection from PLC (retentive area) .......................................................................117
A.7.7.3 Checkback signal: Program selection from HMI (retentive area) .........................................117
A.7.7.4 Signals from HMI ..................................................................................................................118
A.7.7.5 Signals from PLC..................................................................................................................118
A.7.7.6 Signals to maintenance planners..........................................................................................118
A.7.7.7 Signals from maintenance planners .....................................................................................119
A.7.7.8 Signals from operator panel (retentive area) ........................................................................119
A.7.7.9 General selection/status signals from HMI (retentive area)..................................................119
A.7.7.10 General selection/status signals to HMI (retentive area)......................................................120
A.7.8 Auxiliary functions transfer from NC channel .......................................................................120
A.7.8.1 Overview ...............................................................................................................................120
A.7.8.2 Decoded M signals (M0 to M99)...........................................................................................121
A.7.8.3 Transferred T functions.........................................................................................................121
A.7.8.4 Transferred M functions........................................................................................................121
A.7.8.5 Transferred S functions ........................................................................................................122
A.7.8.6 Transferred D functions ........................................................................................................122
A.7.8.7 Transferred H functions ........................................................................................................122
A.7.9 NCK signals ..........................................................................................................................122
A.7.9.1 General signals to NCK ........................................................................................................122
A.7.9.2 General signals from NCK ....................................................................................................123
A.7.9.3 Signals at fast inputs and outputs.........................................................................................123
A.7.9.4 Signals from fast inputs and outputs.....................................................................................124
A.7.10 Channel signals ....................................................................................................................125
A.7.10.1 Signals to NC channel ..........................................................................................................125

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A.7.10.2 Signals from NC channel ..................................................................................................... 127
A.7.11 Signals, synchronized actions.............................................................................................. 130
A.7.11.1 Signals, synchronized actions to channel............................................................................ 130
A.7.11.2 Signals, synchronized actions from channel........................................................................ 130
A.7.11.3 Reading and writing PLC variables...................................................................................... 131
A.7.12 Axis actual values and distance-to-go ................................................................................. 131
A.7.13 Maintenance scheduler: User interface ............................................................................... 132
A.7.13.1 Initial (start) data .................................................................................................................. 132
A.7.13.2 Actual data ........................................................................................................................... 132
A.7.14 User interface for Ctrl-Energy .............................................................................................. 133
Index...................................................................................................................................................... 135

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Delivery check
1
System overview
The
SINUMERIK 808D
is an economic CNC solution for milling and turning machines in the
global market. For the turning variant, it is designed to control three axes, including two feed
axes via two pulse drive interfaces (with SINAMICS V60) and one spindle via one analog
spindle interface. For the milling variant, it is designed to control four axes, including three
feed axes via three pulse drive interfaces (with SINAMICS V60) and one spindle via one
analog spindle interface.

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The following diagram shows a system configuration example for the SINUMERIK 808D
control system:
11) 12)
5)
2)
6)
3)
4)
7)
8)
9)
10)
13)
1)
Note:
The following devices in this diagram
are not standard system components:
- PC
- USB
- Handwheel
- +24VDC power supply
- Inverter or servo spindle drive
- Spindle motor
- Spindle encoder
Figure 1-1 SINUMERIK 808D control system overview (taking a milling machine for an example)
11), 12), 13): For detailed information on cable shield connection, refer to Section "Connecting according to the default PLC
program (Page 22)".

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NOTICE
Using a copper protective earth conductor with a cross section of 10 mm2to connect the
PE terminal of V60 to the protective earth. For the NC and 24 VDC power supply, there are
no special requirements of the cross section of the copper protective earth conductor. For
the inverter or servo spindle drive, it is recommended to refer to the relevant specifications
to confirm the cross section of the copper protective earth conductor.
Note
For a turning machine, you need two sets of setpoint cable + SINAMICS V60 drive + power
cable + brake cable (if necessary) + encoder cable + 1FL5 servomotor.
Legend
Name
Order number
1) PPU141.1, turning 6FC5370-1AT00-0AA0 (English)
6FC5370-1AT00-0CA0 (Chinese)
PPU141.1, milling 6FC5370-1AM00-0AA0 (English)
6FC5370-1AM00-0CA0 (Chinese)
2) MCP 6FC5303-0AF35-0AA0 (English)
6FC5303-0AF35-0CA0 (Chinese)
3) Setpoint cable (PPU141.1 to CPM60.1)
6FC5548-0BA00-1AF0 (5 m)
6FC5548-0BA00-1AH0 (7 m)
6FC5548-0BA00-1BA0 (10 m)
4) SINAMICS V60 Controlled Power Module
(CPM60.1)
6SL3210-5CC14-0UA0 (4 A)
6SL3210-5CC16-0UA0 (6 A)
6SL3210-5CC17-0UA0 (7 A)
6SL3210-5CC21-0UA0 (10 A)
5) 1FL5 Motor
1FL5060-0AC21-0AA0 (4 Nm, with key, without brake)
1FL5060-0AC21-0AG0 (4 Nm, without key, without brake)
1FL5062-0AC21-0AA0 (6 Nm, with key, without brake)
1FL5062-0AC21-0AG0 (6 Nm, without key, without brake)
1FL5064-0AC21-0AA0 (7.7 Nm, with key, without brake)
1FL5064-0AC21-0AG0 (7.7 Nm, without key, without brake)
1FL5066-0AC21-0AA0 (10 Nm, with key, without brake)
1FL5066-0AC21-0AG0 (10 Nm, without key, without brake)
1FL5060-0AC21-0AB0 (4 Nm, with key, with brake)
1FL5060-0AC21-0AH0 (4 Nm, without key, with brake)
1FL5062-0AC21-0AB0 (6 Nm, with key, with brake)
1FL5062-0AC21-0AH0 (6 Nm, without key, with brake)
1FL5064-0AC21-0AB0 (7.7 Nm, with key, with brake)
1FL5064-0AC21-0AH0 (7.7 Nm, without key, with brake)
1FL5066-0AC21-0AB0 (10 Nm, with key, with brake)
1FL5066-0AC21-0AH0 (10 Nm, without key, with brake)
6) Setpoint cable (PPU141.1 to inverter or servo
spindle drive)
6FC5548-0BA05-1AD0 (3 m)
6FC5548-0BA05-1AF0 (5 m)
6FC5548-0BA05-1AH0 (7 m)
6FC5548-0BA05-1BA0 (10 m)
6FC5548-0BA05-1CA0 (20 m)

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Legend
Name
Order number
7) Power cable (unshielded)
6FX6002-5LE00-1AD0 (3 m)
6FX6002-5LE00-1AF0 (5 m)
6FX6002-5LE00-1AH0 (7 m)
6FX6002-5LE00-1BA0 (10 m)
8) Brake cable (unshielded)
6FX6002-2BR00-1AD0 (3 m)
6FX6002-2BR00-1AF0 (5 m)
6FX6002-2BR00-1AH0 (7 m)
6FX6002-2BR00-1BA0 (10 m)
9) Encoder cable (shielded)
6FX6002-2LE00-1AD0 (3 m)
6FX6002-2LE00-1AF0 (5 m)
6FX6002-2LE00-1AH0 (7 m)
6FX6002-2LE00-1BA0 (10 m)
10) Inverter or servo spindle drive From Siemens or a third-party manufacturer
Check list
Table 1- 1 PPU package
Component
Quantity (pieces)
Panel Processing Unit (PPU)
1
Mounting clamps with screws
8
Connectors •I/O connectors: 7
•24 V power input connector: 1
Table 1- 2 MCP package
Component
Quantity (pieces)
Machine Control Panel (MCP)
1
MCP connection cable (for connecting the MCP to the PPU, max. 50 cm)
1
Mounting clamps with screws
6
Pre-printed MCP strip, Milling
1 set of 6 pieces
Blank strip paper, A4 size
1
Product Information for MCP
1
Table 1- 3 CNC accessories
Component
Quantity (pieces)
Setpoint cable to SINAMICS V60 (for feed axis)
2 (turning) or 3 (milling)
Setpoint cable to Siemens inverter or third-party drive (for spindle)
1
Note
Emergency stop button is not included in our scope of delivery. You can, if necessary, con-
tact your local Siemens salesperson for it.
Table 1- 4 SINAMICS V60 package
Component
Quantity (pieces)
SINAMICS V60
1
Getting Started
1
Cable clamps
2
Table 1- 5 1FL5 motor package
Component
Quantity (pieces)
1FL5 motor
1
Data sheet for 1FL5 motor
1

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Table 1- 6 Cables individually packaged
Component
Quantity (pieces)
Power cable (unshielded)
1
Brake cable (unshielded)
1
Encoder cable (shielded)
1
Cabinet grounding guide
Figure 1-2 Cabinet grounding

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Note that the PE/PEN busbar in the cabinet must connect to the ground through a grounding cable with a cross section ≥
10 mm2as illustrated below.
Figure 1-3 Busbar grounding

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Mounting
2
2.1
Mounting the controller
Cut-out dimensions
Figure 2-1 Cut-out dimensions (in mm)
Note
Make sure there is enough space around the PPU and the MCP for tightening the screws in
the control cabinet.

Mounting
2.1 Mounting the controller
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Mounting dimensions
Figure 2-2 Mounting dimensions for PPU (in mm)
Figure 2-3 Mounting dimensions for MCP (in mm)

Mounting
2.2 Mounting the drive
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Mounting clearance (in mm)
To ensure easy maintenance purpose, you must provide sufficient clearance (recommended
distance: 80 mm) between the maintenance door and the cabinet wall for replacing the
battery and CF card:
①Cabinet panel ②Maintenance door
2.2
Mounting the drive
Cut-outs and mounting dimensions
Figure 2-4 4/6/7 A version (in mm)

Mounting
2.2 Mounting the drive
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Figure 2-5 10 A version (in mm)
Mounting method
With 4xM5 preassembled screws, the drive can be mounted
vertically
onto the inner panel of
the cabinet. The maximum screw torque must be 2.0 Nm.
Minimum mounting clearance
To ensure adequate cooling, as a minimum, maintain the specified clearance between
drives, one drive and another device/inner panel of the cabinet.
Figure 2-6 Drive mounting clearance (in mm)
Using the cable clamps supplied
If the CE marking requirements for cables are mandatory, the line supply cable and the
power cable used must all be shielded cables. In this case, you can use the cable clamps as
a ground connection between the cable shield and a common ground point.
Clamps can also be helpful in better fixing cables (the unshielded power cable and the line
supply cable) in place.

Mounting
2.2 Mounting the drive
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The illustration below shows you how to use the clamps to fix both cables and to make a
shield connection with the cable.
Power cable (shielded)
Figure 2-7 Cable fixing with two cable clamps
CAUTION
Make sure that the clamp for fixing the shielded power cable has a good contact with the
cable shield.
Note
Siemens does not provide the shielded power cable. Please prepare the shielded power
cable by yourselves for CE certification.
After the installation, it is recommended that the terminal screws should be checked to
ensure that they are tight.
Reference
For further information about the drive mounting, refer to SINAMICS V60 Getting Started .

Mounting
2.3 Mounting the motor
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2.3
Mounting the motor
Mounting dimensions (mm)
Motor type
A (in mm)
B (in mm)
4 Nm 163 (205) 80
6 Nm 181 (223) 90
7.7 Nm 195 (237) 112
10 Nm 219 (261) 136
Note
Value in brackets is the length of a motor with a built-in brake unit.
Motors with plain shaft have the same dimensions.
Reference
For further information about the motor, refer to 1FL5 Motor Technical Data .

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Connecting
3
3.1
Interface overview
Interface overview on the Panel Processing Unit (PPU)
NOTICE
The + 24 V and M signals of X200 must be connected; otherwise, the communication
between the PPU and the drives does not function as it should.
Figure 3-1 Interface layout

Connecting
3.2 Connecting the battery
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Legend
Interface
Comment
Rear
①X100, X101, X102 Digital inputs
②X200, X201 Digital outputs
③X21 FAST I/O
④X301, X302 Distributed I/O
⑤X10 Hand-wheel inputs
⑥X60 Spindle encoder interface
⑦X54 Analog spindle interface
⑧X2 RS232 interface
⑨X51, X52, X53 Pulse drive interfaces
⑩X30 USB interface, for connection with the MCP
⑪X1 Power supply interface, +24V DC power supply
⑫- Battery interface
⑬- Slot for the System CompactFlash Card (CF card)
Front
⑭- USB interface
Interface overview on the Machine Control Panel (MCP)
Figure 3-2 Interface layout
Legend
Interface
Comment
Rear
①X10 USB interface, for connection with the PPU