Siemens SINUMERIK 808D User manual

 
PLC Subroutines Manual
_
_________________
_
_
_________________
_
_
________________
_
_
_
_________________
_
_
_________________
_
_
_________________
_
SINUMERIK
SINUMERIK 808D
PLC Subroutines Manual
Operating Instructions
Valid for:
SINUMERIK 808D Turning (software version: V4.4.2)
SINUMERIK 808D Milling (software version: V4.4.2)
Target group:
OEM engineers
12/2012
6FC5397-2EP10-0BA0
Preface
Overview
1
PLC Programming Tool
2
Descriptions of the PLC
subroutines
3
Use of user alarms in the
PLC subroutines
4
PLC sample applications
5

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 6FC5397-2EP10-0BA0
Ⓟ 12/2012 Technical data 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.

PLC Subroutines Manual
Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0 3
Preface
SINUMERIK 808D documentation
The SINUMERIK 808D documentation consists of the following components:
● Operating Instructions
– Mechanical Installation Manual
– Electrical Installation Manual
– PLC Subroutines Manual
– Function Manual
– Parameter Manual
● Diagnostics Manual
● Commissioning Manual
● Programming and Operating Manual (Turning)
● Programming and Operating Manual (Milling)
● Manual Machine Plus (Turning)
● Online Help for Programming and Operating (Turning)
● Online Help for Programming and Operating (Milling)
● Online Help for Manual Machine Plus (Turning)
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
Target group
This manual is intended for use by the OEM engineers who have basic CNC and PLC
knowledge.
Benefits
This manual enables the intended target group to get detailed information about the PLC
subroutines and how to use them.

Preface
PLC Subroutines Manual
4 Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0
Technical support
Hotline: [phone]
Service and Support China:
www.siemens.com.cn/808D
Worldwide:
http://support.automation.siemens.com
EC Declaration of Conformity
The EC Declaration of Conformity for the EMC Directive can be found on the Internet at
http://support.automation.siemens.com
Here, enter the number 15257461 as the search term or contact your local Siemens office.
Licensing provisions
The SINUMERIK 808D software is protected by national and international copyright laws and
agreements. Unauthorized reproduction and distribution of this software or parts thereof is
liable to prosecution. It will be prosecuted both according to criminal and civil law and may
result in severe penalties or claims for compensation.
In the SINUMERIK 808D, open source software is used. The licensing provisions for this
software are included on the Toolbox DVD and are to be observed accordingly.

PLC Subroutines Manual
Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0 5
Table of contents
Preface ...................................................................................................................................................... 3
1 Overview.................................................................................................................................................... 7
2 PLC Programming Tool ........................................................................................................................... 11
2.1 Installing the 808D Toolbox .........................................................................................................11
2.2 PLC instructions...........................................................................................................................12
2.3 Data management .......................................................................................................................13
2.4 Program organization...................................................................................................................13
2.5 Testing and monitoring your program..........................................................................................14
2.6 Establishing a connection with the RS232 interface....................................................................17
2.7 PLC application Download/Upload/Copy/Compare.....................................................................22
3 Descriptions of the PLC subroutines........................................................................................................ 31
3.1 PLC machine data .......................................................................................................................31
3.2 Conventions for the symbols used in the subroutines .................................................................32
3.3 Subroutine 20 - AUX_MCP (machine auxiliary functions) ...........................................................34
3.4 Subroutine 21 - AUX_LAMP (working lamp)................................................................................35
3.5 Subroutine 22 - AUX_SAFE_DOOR (safe door)..........................................................................35
3.6 Subroutine 23 - AUX_CHIP (chip remover) .................................................................................36
3.7 Subroutine 31 - PLC_ini_USR_ini (user initialization)..................................................................37
3.8 Subroutine 32 - PLC_INI (PLC initialization)................................................................................37
3.9 Subroutine 33 - EMG_STOP........................................................................................................38
3.10 Subroutine 37 - MCP_NCK (MCP and HMI signal processing)...................................................39
3.11 Subroutine 38 - MCP_Tool_Nr (display tool number on the MCP)..............................................40
3.12 Subroutine 39 - HANDWHL (selecting a handwheel according to HMI interface signals) ..........41
3.13 Subroutine 40 - AXIS_CTL (controlling the spindle and axes) ....................................................42
3.14 Subroutine 41 - MINI_HHU (handwheel hand-held unit) .............................................................45
3.15 Subroutine 42 - SPINDLE (spindle control) .................................................................................47
3.16 Subroutine 43 - MEAS_JOG (measurement in the JOG mode) ..................................................48
3.17 Subroutine 44 - COOLING (cooling control)................................................................................49
3.18 Subroutine 45 - LUBRICAT (control of lubricate).........................................................................51
3.19 Subroutine 46 - PI_SERVICE (Asynchronous Subroutine Program)...........................................52
3.20 Subroutine 47 - PLC_Select_PP (PLC selects a subroutine) ......................................................54

Table of contents
PLC Subroutines Manual
6 Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0
3.21 Subroutine 48 - ServPlan (service plan) ..................................................................................... 55
3.22 Subroutine 49 - GearChg1_Auto (automatic spindle gear change)............................................ 56
3.23 Subroutine 50 - GearChg2_Virtual (virtual spindle gear change) ............................................... 57
3.24 Subroutine 51 - Turret1_HED_T (turret with Hall effect device position sensor) ........................ 58
3.25 Subroutine 52 - TURRET2_BIN_T (turret with binary coding function) ...................................... 61
3.26 Subroutine 53 - Turret3_CODE_T (tool change control for turret with coding function) ............. 63
3.27 Subroutine 54 - Turret2_3_ToolDir (tool change direction)......................................................... 65
3.28 Subroutine 55 - Tail_stock_T (Tailstcok control program for turning machines)......................... 67
3.29 Subroutine 56 - Lock_unlock_T (clamping control for turning machines)................................... 68
3.30 Subroutine 58 (MM_MAIN).......................................................................................................... 69
3.31 Subroutine 59 (MM_MCP_808D) ................................................................................................ 72
3.32 Subroutine 60 - Disk_MGZ_M (disk-style tool magazine for milling) .......................................... 73
3.33 Subroutines 34 to 36, 57, 61 and 62........................................................................................... 75
3.34 Subroutine 63 - TOGGLES ......................................................................................................... 75
4 Use of user alarms in the PLC subroutines.............................................................................................. 77
5 PLC sample applications ......................................................................................................................... 79
5.1 PLC sample application (turning)................................................................................................ 79
5.2 PLC sample application (milling)................................................................................................. 82
Index........................................................................................................................................................ 85

PLC Subroutines Manual
Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0 7
Overview 1
The PLC subroutines consist of three project files:
● default_turning.ptp (sample application for turning machines)
● default_milling.ptp (sample application for milling machines)
● default_ManMachPlus_T.ptp (sample application for Manual Machine Plus)
With the sample applications, you can get a good understanding about how to create or call
a PLC subroutine. You can realize most machine functions by re-organizing the PLC
subroutines or modifying some must networks.
WARNING
Make sure that you perform a complete machine test to all subroutines used in your main
program, in order to verify that all the subroutines called by the main program function as
you desire. Failure to observe may cause personal injury or property damage.
System resource distribution
The system resources can be distributed into three parts:
● PLC system
– Inputs
I0.0 to I2.7 (24 inputs of the SINUMERIK 808D)
I3.0 to I8.7 (distributed 48 inputs)
– Outputs
Q0.0 to Q1.7 (16 inputs of the SINUMERIK 808D)
Q2.0 to Q5.7 (distributed 32 outputs)
– Memory
M0.0 to M255.7 (256 bytes)
– Non-volatile memory
DB1400.DBX0.0 to DB1400.DBX127.7 (128 bytes)
– PLC user alarms:
DB1600.DBX0.0 to DB1600.DBX15.7 (128 user alarms)
– Timer
T0 to T15 (100ms timer)
T16 to T63 (10ms timer)
– Counter
C0 to C63 (64 counters)
● NCK
– PLC machine data: MD14510, MD14512, MD 14514
– MD14510 machine data INT: DB4500.DBW0 to DB4500.DBW62 (32 words)
– MD14512 machine data hex: DB4500.DBB1000 to EDB4500.DBB1031 (32 bytes)
– MD14514 machine data real: DB4500.DBD2000 to DB4500.DBD2028 (8 Dword)

Overview
PLC Subroutines Manual
8 Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0
● PLC Programming Tool
– Symbol table: SYM1 to SYM32 (32 symbol tables)
– Subroutine: SBR0 to SBR63 (64 subroutines)
Structure of the symbol tables
The PLC subroutine library has been designed with symbol addressing method, which helps
you easily understand the PLC programs. All the addresses in the subroutine library use
symbols for programming. All the interface signals are named with symbols and assigned to
different symbol tables.
Symbol table Table name Descriptions
1 IO_1 Module I/O are defined by the manufacturer
2 IO_2 Distributed I/O are defined by the manufacturer
3, 5, 7, 13 Reserved for the manufacturer
6 MANMACH JOG function
14 ASUP ASUP function
15 PLC_sel_PP PLC selects part programs
16 IS_MCP Signals from/to the MCP
17 IS_HMI Signals from/to the HMI
18 IS_AUX Auxiliary functions from the NCK
19 IS_NCK Signals from/to the NCK
20 IS_CHA Signals from/to the channel
21 IS_AX1 Signals to/from axis 1
22 IS_AX2 Signals to/from axis 2
23 IS_AX3 Signals to/from axis 3
24 IS_AX4 Signals to/from axis 4
27 MD_PLC PLC machine data
28 ALARM User alarms
29 NV_MEM Non-volatile memory
30 SPC_MEM Special memory bit
31 SBR_MEM Global memory used in the sample applications and subroutines
32 RESVD1 Reserved for the sample applications and subroutines
Structure of the subroutines
Subroutine No. Name Description
0 to 19 - Reserved for the manufacturer
20 AUX_MCP Auxiliary function
21 AUX_LAMP Lamp control, called in the subroutine "AUX_MCP".
22 AUX_SAFE_DOOR Safe door control, called in the subroutine "AUX_MCP" of
a milling application.
23 AUX_CHIP Chip remover control, called in the subroutine
"AUX_MCP" of a milling application.

Overview
PLC Subroutines Manual
Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0 9
Subroutine No. Name Description
31 PLC_ini_USR_INI Reserved for the initialization by the manufacturer (this
subroutine is automatically called by subroutine 32)
32 PLC_INI PLC initialization
33 EMG_STOP Emergency Stop
37 MCP_NCK Signals from the MCP and the HMI are sent to NCK
interfaces
38 MCP_Tool_Nr Display tool numbers via the LED of the MCP
39 HANDWHL Handwheel selection via HMI
40 AXIS_CTL Control of feed axis enable and spindle enable
41 MINI_HHU Handwheel hand held unit
42 SPINDLE Spindle function
43 MEAS_JOG Tool measurement in the JOG mode
44 COOLING Coolant control (Manual Machine key and M code: M07,
M08, M09)
45 LUBRICATE Lubrication control (interval and time)
46 PI_SERVICE ASUP (Asynchronous Subroutine Program)
47 PLC_Select_PP PLC selects a subroutine.
48 ServPlan Service plan
49 Gear_Chg1_Auto Automatic gear change of the spindle
50 Gear_Chg2_Virtual Dummy gear change of the spindle
51 Turret1_HED_T Turret control of the turning machine (turret type: Hall
element transistor, 4/6 position)
52 Turret2_BIN_T Turret control of the turning machine (turret type: position
detection with encodings)
53 Turret3_CODE_T Hydraulic turret control of the turning machine (turret
type: position detection with encodings)
54 Turret2_3_ToolDir Evaluate tool direction and calculate tool position (called
by Turret2_BIN_T, Turret3_CODE_T)
55 Tail_stock_T Tail stock control for the turning machine
56 Lock_unlock_T Clamp or release control for the turning machine
58 MM_MAIN Manual machine
59 MM_MCP_808D Spindle signal processing for the manual machine
60 Disk_MGZ_M Disk tool magazine for a milling machine
61, 62 Reserved for the subroutine
63 TOGGLE Six key-operated switches: K1 to K6
Two delay switches: K7, K8
MCP interface description
Input/output DB number Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0
DB1000.DBB0 M01 Program
test
MDA Single
block
AUTO REF.
POINT
JOG Hand-
wheel
Input (MCP ->
PPU),
DB1000 DB1000.DBB1 Key 16 Key 15 Key 14 Key 13 Key 12 Key 11 Key 10 ROV

Overview
PLC Subroutines Manual
10 Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0
Input/output DB number Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0
DB1000.DBB2 100
(INC)
10 (INC) 1 (INC) Key 21 Key 20 Key 19 Key 18 Key 17
DB1000.DBB3 Key 32 Key 31 Cycle
start
Cycle
Stop
RESET Spindle
right
Spindle
Stop
Spindle
left
DB1000.DBB4 Key 39 Key 38 Key 37 Key 36 RAPID Key 34 Key 33
DB1000.DBB5
DB1000.DBB6
DB1000.DBB7
DB1000.DBB8 Feed override value (in Gray code)
DB1000.DBB9 Spindle override value (in Gray code)
DB1000.DBB10
DB1100.DBB0 LED 8 LED 7 LED 6 LED 5 LED 4 LED 3 LED 2 LED 1
DB1100.DBB1 LED
16
LED 15 LED 14 LED 13 LED 12 LED 11 LED 10 LED 9
DB1100.DBB2 LED
24
LED 23 LED 22 LED 21 LED 20 LED 19 LED 18 LED 17
DB1100.DBB3 LED 30 LED 29 LED 28 LED 27 LED 26 LED 25
DB1100.DBB4
DB1100.DBB5
DB1100.DBB6
DB1100.DBB7
DB1100.DBB8 7 SEG LED 1
DB1100.DBB9 7SEG LED 2
DB1100.DBB10
DB1100.DBB11
Output (PPU -
> MCP),
DB1100
DB1100.DBB12 DP 2 2) DP 1
1)
1) The decimal point of the 7 SEG LED 1.
2) The decimal point of the 7 SEG LED 2.
Note
Interfaces where nothing has been entered are reserved for the next version.
You can understand the relationship between the PLC interface addresses and the
SINUMERIK 808D MCP from the illustration below:

PLC Subroutines Manual
Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0 11
PLC Programming Tool 2
2.1 Installing the 808D Toolbox
You must install the 808D Toolbox on your PC/PG. The 808D Toolbox contains the following
software tools or information:
● Config Data 808D
– System software update
– Examples (EasyXLanguage, symbols for MCP customized keys, template for MCP
strips, PLC subroutine library)
● PLC Programming Tool
The tool for creating PLC user programs
● Windows setup software for toolbox
● User documentation
● License information and conditions about Open Source Software (Readme_OSS)
● SinuComPCIN
Installing the 808D toolbox
The toolbox installation folder is shown below:
To start the installation, double-click the Setup.exe file. In the setup dialog, select one or
multiple options that you desire to install.

PLC Programming Tool
2.2 PLC instructions
PLC Subroutines Manual
12 Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0
2.2 PLC instructions
Various instructions are available in the PLC Programming Tool. You can view them in the
instruction branch on the instruction tree:
You can right-click over an instruction or directly press the F1 key to view its help
information. For example:

PLC Programming Tool
2.3 Data management
PLC Subroutines Manual
Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0 13
2.3 Data management
The data can be broken down into three areas:
● non-retentive data
● retentive data
● machine data for the PLC (this machine data is all active at POWER ON)
Most data, such as the process image, timers, and counters are non-retentive and are
cleared each time the control system is restarted.
For the retentive data, there is a data range of 1400 0000 -1400 0127. This location can be
used to save all the data which is to remain valid after POWER OFF/ON.
With the aid of the PLC-MD (see user interface), you can pre-assign your program with data
or parameterize various parts of the program.
2.4 Program organization
When programming the PLC, you must structure your program into finished program parts
(subroutines). The programming language for S7-200 offers you the capability to set up your
user program in a structured manner.
There are two types of programs:
● The main program
● The subroutine.
Eight levels of programming are possible.

PLC Programming Tool
2.5 Testing and monitoring your program
PLC Subroutines Manual
14 Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0
2.5 Testing and monitoring your program
You can check or perform an error analysis of the user program in two methods:
● The HMI of the SINUMERIK 808D
● The PLC Programming Tool
Testing and monitoring a PLC program with the HMI
There are three ways for program testing and monitoring in the "SYSTEM" operating area:
● "PLC" > "PLC status"
You can input an operand to view its status.
Use the softkey "Operand +" or "Operand -" to increase/decrease the bit of the operand. Use
the "Change" softkey to change the value of the operand and the "Delete all" softkey to
delete all the input operands.
● "PLC" > "Status list"
You can view the status of a PLC signal.

PLC Programming Tool
2.5 Testing and monitoring your program
PLC Subroutines Manual
Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0 15
By default, three signal status lists (inputs, flags and outputs) are displayed in three columns.
You can change column sequence or assign a new signal status list (variables) with the "Edit
pad" softkey:
You can also change the status of a PLC signal with the "Change" softkey.
● "PLC" > "PLC program"

PLC Programming Tool
2.5 Testing and monitoring your program
PLC Subroutines Manual
16 Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0
You can view the status of the main program or use the "Program block" softkey to view the
status of a subroutine:
Two windows are available for you to view the program.
Testing and monitoring a PLC program with the PLC Programming Tool
You can also view the status of your PLC program with the PLC Programming Tool:
1. Establish the communication between the SINUMERIK 808D and the PLC Programming
Tool.
For detailed information about the establishment of the communication between the
SINUMERIK 808D and the PLC Programming Tool, refer to section "Establishing a
connection with the RS232 interface (Page 17)"
2. Use the menu command "Debug > Chart status" to view the status of a PLC signal. You
can also first click the status chart symbol and then click the symbol to view the
status.

PLC Programming Tool
2.6 Establishing a connection with the RS232 interface
PLC Subroutines Manual
Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0 17
2.6 Establishing a connection with the RS232 interface
You can establish a communication between the control system and the PC/PG (PLC
Programming Tool) via the RS232 port.
Activating the connection to the control system
You can activate the connection with the HMI: "SYSTEM" operating area > "PLC" > "STEP 7
connect" > "Connect. ON":
Use the <SELECT> key to select a communication baud rate. The SINUMERIK 808D
supports the following baud rates:
● 9.6 kbps
● 19.2 kbps
● 38.4 kbps
● 57.6 kbps

PLC Programming Tool
2.6 Establishing a connection with the RS232 interface
PLC Subroutines Manual
18 Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0
● 115.2 kbps.
The active or inactive state is retained even after a power-on (except when starting with the
default data). An active connection is displayed by a symbol in the status bar:
Communication settings in the PLC Programming Tool
To setup the PPI parameters in the PLC Programming Tool, proceed as follows:
1. Display the "Communication Links" dialog with menu command "View >
Communications", or click communication button in the View column, or click the
communication symbol in the operations tree:

PLC Programming Tool
2.6 Establishing a connection with the RS232 interface
PLC Subroutines Manual
Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0 19
2. Double click on the "Access point" symbol in the "Communication" window on the right
side:
The "Set PG/PC Interface" dialog is displayed as follows:
3. Check the PG/PC interface being used. For RS232 communication, you must assign the
interface "PLC802(PPI)" to the PLC programming tool.

PLC Programming Tool
2.6 Establishing a connection with the RS232 interface
PLC Subroutines Manual
20 Operating Instructions, 12/2012, 6FC5397-2EP10-0BA0
4. Double click the interface "PLC802(PPI)" or right-click the "Properties" button, and the
property dialog is displayed. Set the baud rate for the transmission rate, which the PLC
Programming Tool will use to communicate:
NOTE: The baud rate you select must be in accordance with what you have set on the
controller side.
5. Open the "Local connection" tab to specify the COM port to which the RS232 (V24) cable
is connected:
6. Click "OK" twice to exit the "Set PG/PC Interface" dialog box.