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SINUMERIK 840D sl Sinumerik 840D sl Commissioning Documentation Edition 2014.04 Training Manual This document was produced for training purposes Siemens assumes no responsibility for its contents SINUMERIK 840D sl Commissioning Manual for Turning and Milling machines Valid for: Sinumerik 840D sl Software 4.5 Start Contents Machine Test Protocol A002 Service and Commissioning Tools A060 System Overview A061 Menu Structure A021 Access Levels/ Time and Date Settings A041 Machine and Setting Data A003 Battery and Fan Exchange A007 Electronic Logbook A044 Licensing of Options A035 Program Handling A036 NCU Connections and Diagnostics A030 Digital Inputs & Outputs A051 Line and Motor Modules A017 Data Management A010 PCU and TCU Connections and Diagnostics A053 Axis and Drive Diagnostics A008 MCP&PP72/48 Connections and Diagnostic A058 PLC Onboard Diagnostics A031 PLC Alarms and Messages A037 Alarm Structure A033 PLC Functions A026 Creating a PLC Program A101 Servo Optimisation A016 Additional Axis Installation A102 Tool Management A110 Technology Setup Milling A068 Commissioning Sequence A084 Encoder Adjustments A111 Technology Setup Swivel A006 Electrical Cabinet Design A122 Technology Setup Subspindle and Tailstock A011 Run MyScreens Appendix A Hardware Differences Appendix B Technology Settings Appendix C PLC Interface End A121 Technology Setup Y Axis A120 Technology Setup Turning SIEMENS TEST PROTOCOL Machine Test Protocol Sinumerik 840D sl Product / Version Company: Address: Sinumerik 840D sl SW4.5 Machine Range Machine Type - Features Electrical Cabinet Protocol attached Spindle Config MLFB KW Axis Conf MLFB N/M Safety Integrated Protocol Attached Distribution list Name Company / Department e-mail Name Company / Department Title Machine Test Protocol Sinumerik 840D sl Document no File name: Copyright Siemens AG 2013 All Rights Reserved Date Protocol version 1.2 e-mail Machine Test Protocol Sinumerik 840D sl Contents RESPONSIBLE PERSONS: 1.1 Schedule 1.2 Participants carrying-out the test 2.1 SUMMARY AND RESULT Summary 2.2 Result 2.2.1 Exception List 2.3 Release Siemens 2.4 Release from Machine Tool Builder BACK UP 3.1 Modified data 3.2 Data Backup 4.1 CHANGE LOG Changes to the machine SYSTEM DESCRIPTION 5.1 Machine 5.2 Control Page 2/42 Copyright Siemens AG 2012 All Rights Reserved Date: 24.03.2014 Protocol version 1.2 Machine Test Protocol Sinumerik 840D sl 6.1 TEST OBJECTIVE 10 Note 10 FUNCTIONS TESTED 11 DETAILED TEST 13 8.1 Machine area 13 8.1.1 Jog Ref 13 8.1.2 Jog MCP 15 8.1.3 Jog HMI Softkeys 18 8.1.4 MDA Teachin 20 8.1.5 MDA HMI Softkeys 21 8.1.6 MDA MDA Teachin 23 8.1.7 AUTO 24 8.2 Technology 26 8.2.1 Milling General 26 8.2.2 Milling 3+2 27 8.2.3 Milling Axis 28 8.2.4 Turning Basic 29 8.2.5 Turning Advanced 30 8.3 Parameter 32 8.3.1 Machine Builder Options 32 8.3.2 Measure tool 32 8.3.3 Setting data 32 8.3.4 Magazine 33 8.3.5 Tool List 34 8.4 Geometry 35 8.4.1 Circularity test HMI 35 8.4.2 Renishaw circularity test 35 8.5 Safety Integrated 35 8.5.1 Safety related test 35 Page 3/42 Copyright Siemens AG 2012 All Rights Reserved Date: 24.03.2014 Protocol version 1.2 Machine Test Protocol Sinumerik 840D sl 8.6 Password protection 36 8.6.1 Securing data areas 36 8.7 Various 37 Page 4/42 Copyright Siemens AG 2012 All Rights Reserved Date: 24.03.2014 Protocol version 1.2 Appendix C PLC Interface Structure DB31 – DB61 Signals to axis/spindle (PLC NCK) Byte Bit Bit Bit Bit DBB31 Technology Clear synchro-nism Clear synchro-nism Disable synchroni-zation Resynchronize Deselect external stop E Deselect external stop D DBB32 Safety Integr DBB33 Safety Integr Bit Bit Deselect external stop C Deselect external stop A Bit Bit Spindle speed display Seperate feed drive as C axis engaged Select override Bit value Bit value Bit value Bit value DBB34DBB55 Spindle inside clamping DBB56 PLC HMI DBB57 Reserved DBB58 DBB59 Notes Appendix C Page 86 840D sl SINUMERIK Operate Appendix C PLC Interface Structure DB31 – DB61 Byte DBB60 Axis and Spindle DBB61 Axis and Spindle DBB62 Signals from axis/spindle (NCK PLC) Bit Bit Bit Bit DBB64 Axis and Spindle Bit Bit NCU_Link Axis active /Z2-B3/ Spindle /no axis /Z1-S1/ Axial alarm Travel request /Z1-F1/ References synchronizes /Z1 -R1/ 1 Current controller active /Z1-A2/ Speed controller active /Z1-A2/ Position controller active /Z1-A2/ Axis/spindle stationary (n < nmin) /Z1-A2/ Follow-up mode active /Z1-A2/ Axis ready Axis container rotation active /Z2-B3/ Force fixed stop limited / Z1-F1/ Fixed stop reached /Z1-F1/ Activate travel to fixed stop /Z1-F1/ Measurement active Revolutio-nal feedrate active /Z1-V1/ Handwheel overlay active /Z2-H1/ Software cams active / Z1-N3/ Axis stop active /Z2-P2/ PLCcontrolled axis /Z2-P2/ AXRESET DONE /Z2-P2/ HIAxMove active Corr active minus /Z2-B3/ /Z2-M5/ Axis/ spindle disable active DEPBCS active DEPMCS active Travel request Traverse command /Z2-H1/ plus Encoder limit frequency exceeded /Z1-A3/ Bit Position reached with exact stop /Z1-B1/ fine coarse Stop DBB63 Bit plus Handwheel active /Z2-H1/ minus 100 INC 10 INC INC Active machine function /Z2-H1/ DBB65 Axis and Spindle Var INC 10000 INC 1000 INC OEM axis signals (Reserved) DBB66 Axis and Spindle Activate monitoring / Z3-TE6/ DBB67 DBB68 DBB69 PLC axis/ spindle /Z2-K5/ E Neutral axis/ spindle /Z2-K5/ Axis replacement possible /Z2-K5/ New type requested by PLC /Z2-K5/ NCU number in NCU link network D C B D C B A A C Control parameter block B A Repos delay quit DBB70 DBB71 NC axis/spindle in channel /Z2-K5/ PLC axis permanently assigned POS_RESTORED Repos shift valid Repos shift Brake test active REPOS DELAY DBB72 HMI PLC DBB73 HMI PLC Notes 840D sl SINUMERIK Operate Page 87 Appendix C Appendix C PLC Interface Structure DB31 – DB61 Byte Signals from axis/spindle (NCK PLC) Bit Bit Bit Bit Bit Bit Bit Modulo limit enabled active DBB74 Axis DBB75 Axis JOGposition reached Position JOG active DBB76 Axis Rounding axis in position Indexing axis in position JOG fixed-point approach reached Positioning axis /Z2-P2/ JOG fixed-point approach active Path axis Reducedspeed coliF function (REAL format) for positioning axis /Z1-V1/ DBD78 Axis Gear changeover /Z1-S1/ DBB82 Spindle Actual rotat direction CW /Z1-S1/ Speed monitoring /Z1-V1/ Spindle in setpoint range /Z1-S1/ Support area limits violated Active spindle operating mode /Z1-S1/ DBB84 Spindle Control mode Oscillation mode Position-ing mode Synchronous mode Setpoint gear stage /Z1-S1/ C Geometry monitoring /Z1-V1/ Tapping without compensating chuck / Z1-S1/ B Set speed /Z1-S1/ A Speed limit exceeded / Z1-S1/ increased limited CLGON active /Z1-S8/ SUG active (grinding wheel surface speed) Spindle in DBB85 Spindle Const cutting speed active Tool with dynamic limitation position M function (binary) for spindle (M3, M4, M5, M19, M70 and/or via MD specified) /Z1-S1/ DBW86 Spindle S function (floating-point) for spindle /Z1-S1/ DBD88 Spindle Motor brake released DBB92 Drive DBB93 Drive Scratch pulse /Z1-A2/ DBB77 Axis DBB83 Spindle Bit Enable pulses /Z1-A2/ DBB94 Drive n controller integrator disabled /Z1A2/ Drive ready /Z1-A2/ nist nsoll /Z1-A2/ RIL 3) Rampfunction generator Block activ Active motor /Z1-A2/ Active drive parameter set … B A C nist nx nist nmin Md Mdx /Z1-A2/ /Z1-A2/ /Z1-A2/ Ramp-up complete /Z1-A2/ B A Temperature prewarning /Z1 Heat sink Motor Axis control active /Z3-TE6/ Error rotation monitoring DBB95 Drive DBB96 Master/ slave active /Z3-TE3/ Bitwert für CTRLOUT_changed: Change setpoint output as- Master/ Slave Compensation controller activ coarse fine Notes Appendix C Page 88 840D sl SINUMERIK Operate Appendix C PLC Interface Structure DB31 – DB61 Byte Signals from axis/spindle (NCK PLC) Bit Bit Bit Bit Bit Offset after turn-on point / Z3-TE6/ DBB97 Bit OEM-Anwendung Activate mirCoupling active roring /Z3-TE6/ /Z3-TE6/ DBB98 Synchronous spindle Emergency retraction active Accel warning threshold reached Speed warning threshold reached Overlaid motion /Z2-S3/ DBB99 Synchronous spindle Emergency retraction enabled Max acceleration reached Max speed reached Synchronization running Axis accelerating Synchronismoverride back out Oscillation active /Z2-P5/ Oscillation motion active /Z2-P5/ Spark-out active /Z2-P5/ Error in oscillation /Z2-P5/ Oscillation cannot start / Z2-P5/ OscillAxExtReversal active Gantry axis / Z2-G1/ Gantry leading axis /Z2-G1/ Gantry grouping is synchronous /Z2-G1/ Gantry synchroni-zation run ready to start Gantry warning limit exceeded /Z2G1/ Gantry cut-off limit exceeded /Z2-G1/ DBB100 Oscillation DBB101 Gantry Bit Actual value coupling /Z2-S3/ Bit Axis is slave axis /Z3-TE6/ Synchronism /Z2-S3/ coarse fine Slave spindle active /Z2-S3/ Master spindle active /Z2-S3/ DBB102 Gantry Synchronism being considered DBB103 DBB104 Grinding DBB105 Grinding DBB106 Grinding Axis Axis 16 Axis 24 DBB107 Grinding DBB108 Safety Integr DBB109 Safety Integr Axis Axis 15 Axis 23 Axis 31 Axis Axis Axis Axis 14 Active infeed axis /Z2-P5/ Axis 13 Axis 12 Axis 11 Axis 10 Axis Axis 22 Active infeed axis /Z2-P5/ Axis 21 Axis 20 Axis 19 Axis 18 Axis 17 Axis 30 Active infeed axis /Z2-P5/ Axis 29 Axis 28 Communication failure not acknowledged Axis safely referenced CRCerror Axis 27 Status pulses deleted Axis 26 CRC or sign of life error Axis 25 Safe operational stop / safe speed active Actual position > cam position SN 4- SN 4+ DBB110 Safety Integr DBB111 Safety Integr Axis Active infeed axis /Z2-P5/ Axis Axis SN 3- SN 3+ n < nx Safe velocity active SG B Stop E active DBB112 Safety Integr Stop D active Stop C active SN 2A SN 2+ SN 1- SN 1+ Safe zero speed active Stop A/B active Cam range bit for cam track Notes 840D sl SINUMERIK Operate Page 89 Appendix C Appendix C PLC Interface Structure DB31 – DB61 Byte Signals from axis/spindle (NCK PLC) Bit Bit Bit Bit Bit DBB113 Safety Integr Cam range bit for cam track DBB114 Safety Integr Cam range bit for cam track DBB115 Safety Integr Cam range bit for cam track DBB116 Safety Integr Reserved DBB117 Bit DBB119 Safety Integr DBB120 Safety Integr Bit DBB121 Safety Integr DBB122 Safety Integr Bit DBB125 Safety Integr Bit Cam track Bit Bit Cam range bit for cam track Bit Bit Bit Bit Bit Bit 14 Bit 13 Cam range bit for cam track Bit 12 Bit 11 Bit 10 Bit Bit Bit Bit Cam range bit for cam track Bit Bit Bit Bit Bit Bit 14 Bit 13 Cam range bit for cam track Bit 12 Bit 11 Bit 10 Bit Bit Bit Bit Nockenbereichsbit für Nockenspur Bit Bit Bit Bit Bit Bit 14 Bit 13 Bit 10 Bit Bit Bit Bit Bit Bit Bit Bit 10 Bit Bit Nockenbereichsbit für Nockenspur DBB123 Safety Integr DBB124 Safety Integr Bit Reserved DBB118 Safety Integr Bit Bit 12 Bit 11 Cam range bit for cam track Bit Bit Bit Cam range bit for cam track Bit 14 Bit 13 Bit 12 Bit 11 DBB126 Safety Integr DBB127 Safety Integr Program test DBB128 Safety Integr Activate Suppress DBB129 Safety Integr DBB130 Safety Integr DBB131 Safety Integr Notes Appendix C Page 90 840D sl SINUMERIK Operate Appendix C PLC Interface Structure Tool management interface Interface for loading/unloading magazine (DB71) DB71 Byte Interface for loading/unloading magazine (NCK PLC) Bit Bit Bit Bit Bit Bit Bit Bit I2 I1 Interface (I) active DBB0 I8 I7 I6 I5 I4 I3 I16 I15 I14 I13 I12 I11 DBB1 DBB2 I10 I9 Standard end-of-acknowledgement I8 I7 I6 I5 I4 I3 I2 I1 DBB3 I 16 I 15 I 14 I 13 I 12 I 11 I 10 I9 DBB n + Reserved Reserved Positioning Multitool Order from NCProgram Positioning Magazine Relocate Unload Load DBB n + File in extended area (DB1071) Reserved Reserved Reserved Reserved Reserved Reserved Acknowledgemen t Status = DBB n + Assigned channel (8 bit INT) DBB n + Tool management no (8 bit INT) DBD n + Unassigned parameter (Dword) DBD n + Unassigned parameter (Dword) DBD n + 12 Unassigned parameter (Dword) DBW n + 16 Identification for loading/unloading station (Int), (fixed value 9999) DBW n + 18 No of loading station (INT) DBW n + 20 Magazine no (source) for unloading/reloading/positioning (INT) DBW n + 22 Location no (source) for unloading/reloading/positioning (INT) Notes 840D sl SINUMERIK Operate Page 91 Appendix C Appendix C PLC Interface Structure DB71 Byte Interface for loading/unloading magazine (NCK PLC) Bit Bit Bit Bit Bit Bit Bit Bit DBW n + 24 Magazine no (target) for loading/reloading/positioning (INT) DBW n + 26 Location no (target) for loading/reloading/positioning (INT) DBB n + 28 Reserved Loading/ unloading without magazine movement DBB n + 29 Reserved Initial addresses of the loading/unloading stations: Loading/unloading station 1: n= Loading/unloading station 3: Loading/unloading station 2: n= 34 Loading/unloading station 4: n= 64 n= 94 Load interface is responsible for spindle loading and reloading of tools, for relocating tools and for positioning at any location (e.g buffer) Notes Appendix C Page 92 840D sl SINUMERIK Operate Appendix C PLC Interface Structure Interface for spindle as change position (DB72) Signals from spindle (NCK PLC) DB72 Byte Bit Bit Bit Bit Bit Bit Bit Bit Interface (I) active DBB0 I8 I7 I6 I16 I15 I14 I5 I4 I3 I2 I1 I13 I12 I11 I10 I9 DBB1 DBB2 Standard end-of-acknowledgement I8 I7 I6 I5 I4 I3 I2 I1 I 16 I 15 I 14 I 13 I 12 I 11 I 10 I9 OldT in buffer no (n-42) T0 Prepare change Perform change (initiate: M06) Compulsory change DBB3 DBB n Spindle Tool remains in spindle DBB n + File in extended area (DB1072 Replace manual tool Replace manual tool Reserved Acknowledgemen t Status = DBB n + Assigned channel (8 bit INT) DBB n + Tool management no (8 bit INT) DBD n + Unassigned parameter (D word) DBD n + Unassigned parameter (D word) DBD n + 12 Unassigned parameter (D word) DBW n + 18 Buffer identification (Int), (fixed value 9998) (corresponds to ”Target position for new tool”) Relative location (target) in the buffer (INT) DBW n + 20 Magazine no (source) for new tool (INT) DBW n + 22 Location no (source) for new tool (INT) DBW n + 24 Magazine no (target) for old tool (INT) DBW n + 16 Notes 840D sl SINUMERIK Operate Page 93 Appendix C Appendix C PLC Interface Structure Signals from spindle (NCK PLC) DB72 Byte Bit Bit Bit Bit Bit Bit DBW n + 26 Location no (target) for old tool (INT) DBW n + 28 Tool new: location type (INT) DBW n + 30 Tool new: size left (INT) DBW n + 32 Tool new: size right (INT) DBW n + 34 Tool new: size top (INT) DBW n + 36 Tool new: size bottom (INT) DBB n + 38 Tool status for tool new Manual tool DBB n + 39 1:1 Change Master tool to be loaded Bit Bit to be unloaded ignore disabled ID for tools in buffer Tool disabled Tool enabled Active tool Tool status for tool new Tool was in use Tool fixed location coded Tool being changed Prewarning limit reached Tool measured DBW n + 40 Tool new: T no (INT) DBW n + 42 If DBX (n+0.4) = 1, then buffer location of old tool is entered here DBW n + 44 Original magazine of new tool DBW n + 46 Original location of new tool Initial addresses of the buffers: Spindle 1: n= Spindle 2: n = 52 Notes Appendix C Page 94 840D sl SINUMERIK Operate Appendix C PLC Interface Structure Interface for circular magazine (DB73) Signals from circular magazine (NCK PLC) DB73 Byte Bit Bit Bit Bit Bit Bit Bit Bit Interface (I) active DBB0 I8 I7 I6 I5 I4 I3 I2 I1 I16 I15 I14 I13 I12 I11 I10 I9 DBB1 DBB2 DBB3 Standard end-of-acknowledgement I8 I7 I6 I5 I4 I3 I2 I1 I 16 I 15 I 14 I 13 I 12 I 11 I 10 I9 Reserved Replace manual tool Reserved Reserved T0 Reserved Perform change (initiation: T no.) Obligatory change File in extended area (DB1073) Reserved Reserved Reserved Reserved Reserved Reserved Acknowledgement Status = DBB n DBB n + DBB n + Assigned channel (8 bit INT) DBB n + Tool management no (8 bit INT) DBD n + Unassigned parameter (D word) DBD n + Unassigned parameter (D word) DBD n + 12 Unassigned parameter (D word) DBW n + 16 Reserved DBW n + 18 Reserved DBW n + 20 Circular magazine no (INT) DBW n + 22 Location no for new tool (INT) DBW n + 24 Magazine no of the old tool DBW n + 26 Location no for old tool (INT) DBW n + 28 Tool new: location type (INT) DBW n + 30 Tool new: size left (INT) DBW n + 32 Tool new: size right (INT) DBW n + 34 Tool new: size top (INT) DBW n + 36 Tool new: size bottom (INT) Notes 840D sl SINUMERIK Operate Page 95 Appendix C Appendix C PLC Interface Structure Signals from circular magazine (NCK PLC) DB73 Byte Bit Bit Bit Bit Bit Bit Bit to be unloaded ignore disabled Bit Tool status for tool new DBB n + 38 Manual tool 1:1 Change Master tool to be loaded ID for tools in buffer Tool status for tool new DBW n + 39 Tool was in use Tool fixed location coded Tool being changed Prewarning limit reached Prewarning limit reached Tool measured DBW n + 40 Tool new: T no (INT) DBW n + 42 Original location of new tool in this circular magazine Tool disabled Tool enabled Bit Bit Initial addresses of the circular magazines: circular magazine 1: n = 2: n = 48 Interface for loading / unloading (Multitool) (DB1071) DB1071 Byte Loading / unloading points (NCK PLC) Bit Bit Bit Bit Bit Bit Distance code DBW n+0 Number of Multitool locations DBW n+2 Multitool distance DBW n+4 Multitool number DBW n+8 DBW n+10 Multitool location number Toolholder DBW n+12 Reserved DBW n+14 Reserved DBW n+16 Reserved DBW n+18 Notes Appendix C Page 96 840D sl SINUMERIK Operate Appendix C PLC Interface Structure Interface for spindle (Multitool) (DB1072) Spindle (NCK PLC) DB1072 Byte Bit Bit Bit Bit Bit Bit Bit Bit Distance code DBW n+0 Number of Multitool locations DBW n+2 Multitool distance DBW n+4 Multitool number (tool new) DBW n+8 DBW n+10 Multitool location number (tool new) Multitool number (tool old) DBW n+12 Multitool location number (tool old) DBW n+14 Location type DBW n+16 Tool size left DBW n+18 Tool size right DBW n+20 Tool size above DBW n+22 Tool size below DBW n+24 Tool status DBW n+26 T number of the tool DBW n+28 Tool holder DBW n+30 Original magazine of the new tool DBW n+32 Original location of new tool DBW n+34 Reserved DBW n+36 Notes 840D sl SINUMERIK Operate Page 97 Appendix C Appendix C PLC Interface Structure Interface for Revolver (Multitool) (DB 1073) Revolver (NCK PLC) DB1073 Byte Bit Bit Bit Bit Bit Bit Bit Bit Distance code DBW n+0 Number of Multitool locations DBW n+2 Multitool distance DBW n+4 Multitool number (tool new) DBW n+8 DBW n+10 Multitool location numberr (tool new) Multitool number (tool old) DBW n+12 Multitool location numberr (tool old) DBW n+14 Location type DBW n+16 Tool size left DBW n+18 Tool size right DBW n+20 Tool size above DBW n+22 Tool size below DBW n+24 Tool status DBW n+26 T number of the tool DBW n+28 Tool holder DBW n+30 Original magazine of the new tool DBW n+32 Original location of new tool DBW n+34 Reserved DBW n+36 Notes Appendix C Page 98 840D sl SINUMERIK Operate Appendix C PLC Interface Structure Signals to/from the machine control panel and HHU (GD communication) DB77 Byte Signals to and from the machine control panel and HHU Bit Bit Bit Bit Bit Bit DBB0DBB7 Input signals from MCP1 to PLC, MPI Bus (GD communication) DBB8 DBB15 Output signals from MCP1 to PLC, MPI Bus (GD communication) DBD16 Status send MCP1, MPI bus (GD communication) DBD20 Status receive MCP1, MPI bus (GD communication) DBB24 DBB31 Input signals from MCP2 to PLC, MPI bus (GD communication) DBB32 DBB39 Output signals from MCP2 to PLC, MPI bus (GD communication) DBD40 Status send MCP2, MPI bus (GD communication) DBD44 Status receive MCP2, MPI bus (GD communication) DBB48 DBB53 Input signals from HHU to PLC, MPI bus (GD communication) DBB60 DBB79 Output signals from PLC to HHU, MPI bus (GD communication) DBD80 Status Send HHU, MPI bus (GD communication) DBD84 Status Receive HHU, MPI bus (GD communication) Bit Bit Appendix C: END Notes 840D sl SINUMERIK Operate Page 99 Appendix C Appendix C Appendix C PLC Interface Structure Page 100 840D sl SINUMERIK Operate