810 installation guide

SINUMERIK 810 GA3 SINUMERIK 820 GA3 Software Version 3 Installation InstructionsInstallation Guide 01.93 Edition

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SINUMERIK 810/820, Basic Version 3 (GA 3) General Documentation

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SINUMERIKFB-PLC, Package 1 Tool Management User Shop Floor Storage Module Installation Guide - Instructions - Lists Measuring Cycles Version 10 Installation Guide Spare Parts List

SINUMERIK 810 GA3 SINUMERIK 820 GA3 Software Version 3 Installation InstructionsService Documentation Installation Guide

Applies to:

ControlSINUMERIK 810M SINUMERIK 810T SINUMERIK 820M SINUMERIK 820T

Software VersionBasic Version 3 Basic Version 3 Basic Version 3 Basic Version 3 3 3 3 3

January 1993 Edition

SINUMERIK documentationPrinting history Brief details of this edition and previous editions are listed below. The status of each edition is shown by the code in the Remarks column.

Status code in Remarks column:A . . . New documentation. B . . . Unrevised reprint with new Order No. C . . . Revised edition with new status. If factual changes have been made on a page since the last edition, this is indicated by a new edition coding in the header on that page.

Edition 11.90 09.91 01.93

Order No. 6ZB5 410-0DL02-0AA0 6ZB5 410-0DL02-0AA1 6ZB5 410-0DL02-0AA2

Remarks A C C

Other functions not described in this documentation might be executable in the control. This does not, however, represent an obligation to supply such functions with a new control or when servicing. This publicaation was produced on the Siemens 5800 Office System. Subject to change without prior notice. The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved.

Siemens AG 1990 All Rights Reserved

Preliminary remarks

Notes for the reader This documentation is intended for specialists involved in the installation and servicing of the SINUMERIK 810, Basic Version 3 (brief designation: GA3) and SINUMERIK 820, Basic Version 3. The Installation Guide for the SINUMERIK 810 GA3/820 GA3 is broken down into two parts: Installation Instructions Installation Lists

Preconditions and Visual Inspection

1

Installation Checklist

2

Overview of Modules and Standard Jumperings

3

Voltage and Functional Tests / Drift

4

Standard Installation

5

PLC Description

6

Machine Interface

7

NC Machine Data

8

Setting Data

9

Description of Operation

10

Alarms

11

Contents

Page 1 1.1 1.2 1.3 1.3.1 1.3.2 1.3.3 1.4 1.5 1.6 1.6.1 1.6.2 1.6.3 Preconditions and Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . Preconditions for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preliminary remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual inspection of system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Position encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable laying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overall condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery adjacent to power supply unit . . . . . . . . . . . . . . . . . . . . . . . . . Battery backup of the RAM memory . . . . . . . . . . . . . . . . . . . . . . . . . . Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 11 11 13 13 13 13 13 13 13 14 14 14

2


...................................

21

3 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.4.1 3.1.4.2 3.1.5 3.1.6 3.1.6.1 3.1.6.2 3.1.7 3.1.8 3.1.9 3.1.10 3.1.10.1 3.1.10.2 3.1.11 3.1.12 3.1.13 3.2 3.2.1 3.2.2 3.2.2.1 3.2.2.2 3.2.2.3 3.3 3.3.1 3.3.2

Overview of Modules and Standard Jumperings .............. Basic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SINUMERIK 810 GA3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SINUMERIK 820 GA3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview of modules 810 GA3/820 GA3 . . . . . . . . . . . . . . . . . . . . . . . Power supply units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power supply unit 24V DC (SINUMERIK 810 GA3) . . . . . . . . . . . . . . . 220 V AC power supply unit (SINUMERIK 820 GA3) . . . . . . . . . . . . . . CPU module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Video interface modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Video interface module, colour and monochrome ................ Video interface module, monochrome . . . . . . . . . . . . . . . . . . . . . . . . . (Vacant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interface module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Memory modules (only needed when UMS used) . . . . . . . . . . . . . . . . Measuring-circuit modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPC measuring circuit modules 6FX1 121-4BA . . (standard measuring circuit module) . . . . . . . . . . . . . . . . . . . . . . . . . . HMS measuring circuit module 6FX1 145-6B 00 ................ Monitor control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I/O submodules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handwheel submodule (MPG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P06 expansion unit (Mini EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview of modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jumperings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interface CU/MPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input module for Mini EU: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output module for Mini EU: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P08 expansion unit (Maxi EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview of modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLC expansion unit (P08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 31 31 32 33 34 34 35 36 37 37 37 37 38 38 311 311 312 316 317 319 320 320 321 321 322 323 324 324 324

3.4 3.5 3.5.1 3.5.2

Interface CU modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master PLC link modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master PLC link module (in the SINUMERIK) . . . . . . . . . . . . . . . . . . . . Master PLC link module (in the SIMATIC) . . . . . . . . . . . . . . . . . . . . . .

325 326 326 327

4 4.1 4.1.1 4.1.2 4.1.3 4.2 4.2.1 4.2.2 4.2.3 4.3

Voltage and Functional Tests/Drift . . . . . . . . . . . . . . . . . . . . . . . . . Voltage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limit temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct voltage+5 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CPU monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EPROM CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brightness adjustment on screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drift compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 41 41 41 41 41 41 42 43 43

5 5.1 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6 5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.4.7 5.4.8 5.4.9 5.4.10 5.4.11 5.5

Standard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard installation sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard insallation shown as a flowchart . . . . . . . . . . . . . . . . . . . . . . NC ON (overall reset chart and setting standard MD) . . . . . . . . . . . . . . NC machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLC machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLC user program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed settings for gear stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Acceleration time constants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing the spindle in MDA mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle installation in sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axis installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feedback polarity of the feed axes - checking and adjustment ....... Position control resolution, input resolution . . . . . . . . . . . . . . . . . . . . . Maximum speed of the axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Definition of the maximum setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable incremental weighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Closing of position control loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Traversing the axes in JOG mode . . . . . . . . . . . . . . . . . . . . . . . . . . . Multgain NC MD 260* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servo gain factor Kv factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axis installation sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reading in machine data from the UMS . . . . . . . . . . . . . . . . . . . . . . .

51 51 54 55 56 57 58 59 510 510 511 511 511 511 512 513 513 514 515 515 515 516 516 517 518 520 522 523

6 6.1 6.2 6.2.1 6.2.2

PLC Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLC MD, PLC MD bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MODE switching (types of operation) . . . . . . . . . . . . . . . . . . . . . . . . .

61 61 61 61 63

6.2.3 6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.4 6.4.1 6.4.2 6.5

MD description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLC installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NC machine data for PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Link PLC PG 750/685/675/670/635/615 ..................... Programmer commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLC operating system (OS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The following functions are available in PLC OS . . . . . . . . . . . . . . . . . Test mode - demo program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLC STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65 621 621 621 622 625 625 625 626 626

7 7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 7.2 7.2.1 7.2.2 7.3 7.4 7.5 7.5.1 7.5.2 7.6

Machine Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Actual-value input measuring circuit . . . . . . . . . . . . . . . . . . . . . . . . . . Connector pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalent circuit diagram with differential input . . . . . . . . . . . . . . . . . . Equivalent circuit diagram for actual-value input with integrated EXE . . . Complement with integrated EXE . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input signals with integrated EXE . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setpoint output measuring circuit (6FX1 121-4B...) . . . . . . . . . . . . . . . X141 connector pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalent circuit diagram (for one axis) . . . . . . . . . . . . . . . . . . . . . . . Sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial interface (RS 232/V.24+20 mA) . . . . . . . . . . . . . . . . . . . . . . . . Handwheel interface module (6FX1 126-5AA.) . . . . . . . . . . . . . . . . . . . Connector pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalent circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Short-circuiting connector for actual-value input . . . . . . . . . . . . . . . . . .

71 71 71 72 73 74 75 76 77 77 78 79 711 712 712 712 713

8 8.1 8.2 8.3

NC Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of the NC MD values . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of the NC MD bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81 81 83 870

9 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11

Setting Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Softkey assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Zero offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programmable ZO +external ZO . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additive ZO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General and axis-specific SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General and RS 232 (V.24) - SD bits . . . . . . . . . . . . . . . . . . . . . . . . . Axis-specific bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle of rotation, for channels 1 and 3 separately . . . . . . . . . . . . . . . . Scale modification, for channels 1 and 3 separately . . . . . . . . . . . . . . .

91 91 91 91 92 93 94 96 97 910 910 911

10 10.1 10.1.1 10.1.2 10.1.3 10.1.4 10.2 10.2.1 10.2.2 10.2.2.1 10.2.2.2 10.3 10.4 10.4.1 10.4.2 10.5 10.5.1 10.5.2 10.5.3 10.1.4 10.5.5 10.5.6 10.5.7 10.6 10.6.1 10.6.2 10.6.3 10.6.4 10.7 10.7.1 10.7.2 10.7.2.1 10.7.2.2 10.7.2.3 10.7.3 10.7.3.1 10.7.3.3 10.8 10.8.1 10.8.2 10.8.3 10.9 10.9.1 10.9.2 10.9.3 10.9.3.1 10.9.3.2 10.9.3.3 10.9.3.4 10.9.3.5 10.9.3.6 10.9.3.7 10.9.4 10.10

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corresponding MD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S analog (Mn=3, Mn=4, Mn=5) ............................ Mn=19 (oriented spindle stop) ............................. Spindle influencing by PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approach to reference point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corresponding MDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification of direction with approach to reference point .......... Approach to reference point without automatic identification of direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approach to reference point with automatic identification of direction . . . Leadscrew error compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotary axis function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Function description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On-the-fly synchronization of rotary axis (option) . . . . . . . . . . . . . . . . . Allocation of rotary axis to spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . Reference points for the spindle and for the associated rotary axis .... Selection and deselection of rotary axis mode . . . . . . . . . . . . . . . . . . . Block search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Behaviour in spindle mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Behaviour in rotary axis mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interpolatory tapping/thread cutting without compensating chuck (G36) . Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostics/start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Different input, position control and display resolutions . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Combinations with linear axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum velocities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coding of the resolutions with linear axes . . . . . . . . . . . . . . . . . . . . . . Combinations of resolutions with linear axes . . . . . . . . . . . . . . . . . . . . Combinations with rotary axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum velocities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Combinations of resolutions with rotary axes . . . . . . . . . . . . . . . . . . . . Tapping with dynamic following error compensation (optional) . . . . . . . . Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of the new machine data . . . . . . . . . . . . . . . . . . . . . . . . . Note the following NC data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Block transfer (options C69) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sources of error for the Block transfer function ................ Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unsecured data transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Secured data transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data transfer procedure 3964R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmitting with procedure 3964R . . . . . . . . . . . . . . . . . . . . . . . . . . Receiving with procedure 3964R . . . . . . . . . . . . . . . . . . . . . . . . . . . . Message frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Message frame interchange between host computer and NC . . . . . . . . Message frame error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Integrated tool management (OPTION N05) . . . . . . . . . . . . . . . . . . . .

101 101 101 101 102 1010 1011 1011 1011 1011 1014 1016 1025 1025 1025 1027 1028 1029 1030 1033 1033 1033 1033 1034 1034 1034 1035 1035 1036 1036 1036 1036 1037 1039 1041 1041 1044 1046 1046 1047 1050 1050 1050 1052 1052 1052 1053 1053 1054 1054 1055 1056 1058 1058

10.10.1 10.10.2 10.11 10.11.1 10.11.2 10.11.3 10.11.4 10.11.5 10.12 10.12.1 10.12.2 10.12.3 10.12.4 10.12.5 10.12.6 10.12.7 10.13 10.13.1 10.13.2 10.13.2.1 10.13.2.2 10.13.2.3 10.13.2.4 10.13.2.5 10.13.3 10.13.4 10.14 10.14.1 10.14.2 10.14.3 10.14.4 10.14.5 10.15 10.16 10.17 10.17.1 10.17.2 10.18 10.19 10.20

Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Host PLC link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jumpering on the link modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Function blocks , error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coordinate transformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Function description of coordinate transformation . . . . . . . . . . . . . . . . Transformation data record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine data for fictitiuous axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . NC PLC interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Explanation of the programming and operation of coordinate transformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Examples of coordinate transformation TRANSMIT . . . . . . . . . . . . . . . Axis duplication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corresponding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLC/NC interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mode functionality when the Axis duplication function is active ..... Automatic and MDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Allowance for compensations when axis duplication is active . . . . . . . . Complete machining (special function) . . . . . . . . . . . . . . . . . . . . . . . . Basic function conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Software cams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Function description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mode of operation in the individual operating modes . . . . . . . . . . . . . . R parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLC interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu insertions by the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indirect addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service data for spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Channel structure of SINUMERIK 810 GA3/820 GA3 . . . . . . . . . . . . . . Hardware and software version display . . . . . . . . . . . . . . . . . . . . . . . . Integrated PLC auxiliary axes (OPTION N06) . . . . . . . . . . . . . . . . . . .

1059 1059 1060 1060 1060 1061 1065 1066 1068 1068 1068 1069 1071 1071 1072 1074 1075 1076 1076 1076 1077 1078 1078 1079 1081 1082 1083 1083 1085 1086 1086 1087 1089 1093 1095 1096 1097 1098 10100 10101

11 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 11.10 11.11

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display of all messages and alarms with DIAGNOSIS softkey . . . . . . . . Alarm numbers and alarm groups / Clearing alarms . . . . . . . . . . . . . . . Alarm display on screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm list POWER ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS232C (V.24) Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axis-specific RESET alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General RESET alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESET alarms spindle-specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm list ACKNOWLEDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

111 111 112 112 114 114 117 1111 1118 1123 1137 11-38

01.93

1 Preconditions and Visual Inspection 1.1 Preconditions for installation

11.1

Preconditions and Visual InspectionPreconditions for installationElectrical and mechanical installation of the machine must have been completed and the axes prepared for operation (to be confirmed by the customer). Customer PLC program operational and pretested. Measuring system installed and wired as far as SINUMERIK (visual check). Applies only with analog link to drive. If the customer has fitted adapter plugs in the measuring-circuit leads: Check for proper connection, strain relief and above all the prescribed shielding.

Cables connected to the machine. Cable shields run to the control neutral point as per Interface Description. Flexible earth wires installed (visual check): Earth bar in SINUMERIK interface unit 10 mm2 Earth bar in machine column interface unit 10 mm2 All earthing points on the equipment are connected

Customer personnel support for work on the interface unit, machine operation and customer-produced PLC program. Recommendation: Limit travel ranges (greater clearance distances) by displacing the end stop (EMERGENCY STOP cam).

The specified machine data must be available. Test tapes must be available for checking machine-specific functions.

1.2

Preliminary remarks

Synthetic or rubber soiling, and in particular synthetic flooring and carpeting, may produce static charging of several kilovolts in human beings. Integrated circuits are sensitive as far as high-voltage discharge of this type is concerned. Consequently, never touch the printed conductors or components without first discharging on an earthed system part. Modules and power supply cables should only be withdrawn or inserted with the control disconnected. Even with the control disconnected, attention should be paid to static charging to prevent short-circuiting across the VCC RAM printed conductors, otherwise data in the buffered CMOS RAM memories may be corrupted or printed conductors may even burn out.

Siemens AG

1990 All Rights Reserved

6ZB5 410-0DL02

11

SINUMERIK 810 GA3/820 GA3 (IA)

1 Preconditions and Visual Inspection 1.2 Preliminary remarks

11.90

MOS

Caution! Observe safety regulations!

MOS

Caution! Observe safety regulations!

MOS is a technology used to produce integrated digital circuits. MOS stands for Metal Oxide Silicon. Its principal advantages are: Simple transistor design High component density Extremely low power consumption

Identification on packaging

MOS

Identification on printed circuit board

M O S

Caution! The printed circuit board is fitted with MOS chips. To prevent these chips from being irreparably damaged, equipotential bonding must be ensured prior to installing the PCB. Remove the PCB together with the conductive foam plastic from the packaging and touch an earthed system part. Do not touch the printed conductors and components! Note in packaging. Additional notes: Do not open the special packaging unnecessarily. Store only in the black (conductive) foam plastic. Do not bring into contact with plastic materials (possibility of static charging). Disconnect power supply prior to installation and removal.

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1 Preconditions and Visual Inspection 1.3 Visual inspection of system

1.3 1.3.1

Visual inspection of system Earthing

Proper earthing to divert external malfunctions is vital for trouble-free operation. It must be ensured that the earth wires are not kinked and have the necessary cross-section (see also Instruction Manual).

1.3.2

Position encoders

Particular attention is to be paid to the prescribed installation of the graduated scales (air gap etc.) and the pulse generators (coupling), see also Heidenhain Installation and Adjustment Instructions. Check for correct wiring and fixed location of the connectors. Other makes of position encoder may result in inaccuracy and surface quality problems.

1.3.3

Cable laying

It should be ensured as far as possible that power cables and control cables are isolated. Do not produce earth loops since such loops or non-regulation earthing may generate a ripple voltage affecting the speed controller setpoint. Smooth running at minimum speeds is then no longer guaranteed. Is there any kinking (fibre-optics cables)? Proper running of cables? Cable dragging?

1.4

Shielding

The overall shields of all cables running to or from the control must be earthed at the control via the connectors (see Interface Description Part 2, Section 4 Voltage and Functional Tests/Drift).

1.5

Operator panel

Check that the pushbuttons, keys, lamps, symbols and screen are in order.

1.6

Overall condition

Check the module mounts and cover plates. Check whether the front panel screws have been tightened (M connection). Accessory pack: Log book and complete parts list available? (The parts list is included with the original delivery note and must be inserted in the log book). When replacing modules or in the event of a fault, check all ICs in sockets for correct location and fit. Check jumper assignment on modules.

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1 Preconditions and Visual Inspection 1.6.1 Battery adjacent to power supply unit

09.91

1.6.1

Battery adjacent to power supply unit

The battery holder is located on the right-hand side of the monitor housing. The battery should only be replaced under power so that the stored data is not lost. The battery voltage is continuously monitored. Alarm 1 is displayed if the voltage drops below 2.7V. Battery type: Backup period: Note: 3 x 1.5 V (mignon cell, LR 6) Approx. 1 year The power supply can be unplugged while the device is not under power without data being lost. Only change the battery while the control is under power.

1.6.2

Battery backup of the RAM memory

While the control is not under power the RAM memory on the CPU must be backed up by a battery. The battery next to the power supply unit backs up the RAM. In this way the following data remain stored: PLC user program User texts (PLC alarm texts and PLC message texts) Machine data Part programs Tool offsets R parameters Zero offsets Setting data Real-time clock

1.6.3

Cables

Check all cables in accordance with the cable and equipment overview (in Interface Description 2). This applies particularly to cables produced by the customer. A random check should be made on at least one connector (particular attention must be paid to conductive elastomer connections!). In the event of failure to comply with our guidelines, the responsible sales point must be advised and any necessary corrective measures instigated. Ensure that any fibre-optics cables are properly installed (bend radius as prescribed in installation specifications).

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2 Installation Checklist

2


810 (GA3) 820 (GA3) Cycles used T M Serial No. Software Version

Installation sequence Section 1 of the Installation Guide must be observed! Copy installation checklist. Mark Yes/No as applicable after each section has been completed. Enter all required values where stated. Complete the NC machine data list. PLC machine data list and setting data list after installation.

First installation Name Date Office

Second installation

Manufacturer:

Customer:

Address

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11.90

Explanations of the following points are to be found in the individual sections of this guide. 1. Are the preconditions for installation fulfilled as described in Section 1? 2. Visual inspection: Supply connection, EMERGENCY STOP, earthing, position encoders, cable laying, shielding, keyboard, overall condition ok? yes no

yes yes yes yes

no no no no

3. Voltage test performed as described in Section 4? 4. Standard installation completed and the customer specific machine data entered? 5. PLC program entered and tested (safety functions)? 6. Position control loops of axes installed and the following checked: Axis speeds / tacho generator compensation / multiplication factors / servo gain (KV factor) / acceleration / exact stop / position control loop monitors / analog spindle speed / traversing ranges? 7. Have all JOG functions been tested? Has the function check with the test program been performed by the customer? 8. Was a data backup made of the following data: NC machine data, PLC machine data PLC message and alarm texts Zero offsets Setting data R parameters Tool offsets

yes yes yes

no no no

yes yes yes yes yes yes yes

no no no no no no no

9. Was this data placed at the machine? 10. Installation checklist filled in completely (NC MD, PLC MD, setting data, options), put with the log book and placed at the control? 11. Were the following functions explained to the customer: drift compensation, reference point setting, backlash compensation? 12. Has the installation protocol been signed by the customer?

yes yes yes

no no no

Signatures

1st installation------------------------------------

2nd installation----------------------------------

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NC machine data list Units: See detailed description of machine data. This list is to be completed following commissioning and attached to the log book with the punched tape. No. 1 3 5 6 7 8 9 10 11 13 14 15 16 17 20 100/ 121 131/ 146 147/ 154 155 156 157200/223

Value

DesignationSpeed behind pre-lim. sw. Corner deceleration rate. No. of MIB parameters Threshold for CRC insertion Circle end pos. monitoring. Max. number of PPs>s Error window repos. Feed after block search ID word Number of TO parameters Cycles MD (from) Cycles MD (to) Cycles SD (from) Cycles SD (to) Large circular buffer Positions of feedrate override switch Positions of spindle override switch Positions of rapid traverse override switch Sampling time position controller Cutout delay servo enable Control type software version display Keypad assignments SIN. 810 Threshold value circle center offset Language selection Selection rotary axis mode Deselection rotary axis mode Reset pos. for G group 0 channel 1 Reset pos. for G group 0 channel 2 Reset pos. for G group 2 channel 1 Reset pos. for G group 2 channel 2 Reset pos. for G group 5 channel 1 Reset pos. for G group 5 channel 2 Reset pos. for G group 7 channel 1 Reset pos. for G group 7 channel 2 Reset pos. for G group 11 channel 1 Reset pos. for G group 11 channel 2 Axis assignment 1st axis Axis assignment 2nd axis Axis assignment 3rd axis Axis assignment 4th axis Axis assignment 5th axis Axis assignment 6th axis Axis assignment 7th axis

No. 2040 2041 2042 2043 2044 2045 2046 2080 2081 2082 2083 2084 2085 2086 2120 2121 2122 2123 2124 2125 2126 2160 2161 2162 2163 2164 2165 2166 2200 2201 2202 2203 2204 2205 2206 2240 2241 2242 2243 2244 2245 2246 2280 2281 2282

Value

DesignationExact stop course 1st axis Exact stop course 2nd axis Exact stop course 3rd axis Exact stop course 4th axis Exact stop course 5th axis Exact stop course 6th axis Exact stop course 7th axis Exact stop fine 1st axis Exact stop fine 2nd axis Exact stop fine 3rd axis Exact stop fine 4th axis Exact stop fine 5th axis Exact stop fine 6th axis Exact stop fine 7th axis Zero speed control Zero speed control Zero speed control Zero speed control Zero speed control Zero speed control Zero speed control No effect No effect No effect No effect No effect No effect No effect Backlash compensation Backlash compensation Backlash compensation Backlash compensation Backlash compensation Backlash compensation Backlash compensation Software limit switch 1 pos Software limit switch 1 pos Software limit switch 1 pos Software limit switch 1 pos Software limit switch 1 pos Software limit switch 1 pos Software limit switch 1 pos Software limit switch 1 neg Software limit switch 1 neg Software limit switch 1 neg

225 250 260 261 1080 1081 1100 1101 1120 1121 1140 1141 1180 1181 2000 2001 2002 2003 2004 2005 2006

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01.93

No. 2283 2284 2285 2286 2320 2321 2322 2323 2324 2325 2326 2360 2361 2362 2363 2364 2365 2366 2400 2401 2402 2403 2404 2405 2406 2440 2441 2442 2443 2444 2445 2446 2480 2481 2482 2483 2484 2485 2486 2520 2521 2522 2523 2524

Value

DesignationSoftware limit switch 1 neg Software limit switch 1 neg Software limit switch 1 neg Software limit switch 1 neg Software limit switch 2 pos Software limit switch 2 pos Software limit switch 2 pos Software limit switch 2 pos Software limit switch 2 pos Software limit switch 2 pos Software limit switch 2 pos Software limit switch 2 neg Software limit switch 2 neg Software limit switch 2 neg Software limit switch 2 neg Software limit switch 2 neg Software limit switch 2 neg Software limit switch 2 neg Reference point value Reference point value Reference point value Reference point value Reference point value Reference point value Reference point value Reference point shift Reference point shift Reference point shift Reference point shift Reference point shift Reference point shift Reference point shift Tool reference value Tool reference value Tool reference value Tool reference value Tool reference value Tool reference value Tool reference value Kv factor Kv factor Kv factor Kv factor Kv factor

No. 2525 2526 2560 2561 2562 2563 2564 2565 2566 2600 2601 2602 2603 2604 2605 2606 2640 2641 2642 2643 2644 2645 2646 2680 2681 2682 2683 2684 2685 2686 2720 2721 2722 2723 2724 2725 2726 2760 2761 2762 2763 2764 2765 2766

ValueKv factor Kv factor

Designation

Difference time constant Difference time constant Difference time constant Difference time constant Difference time constant Difference time constant Difference time constant Multgain Multgain Multgain Multgain Multgain Multgain Multgain Drive error threshold Drive error threshold Drive error threshold Drive error threshold Drive error threshold Drive error threshold Drive error threshold Max. command speed Max. command speed Max. command speed Max. command speed Max. command speed Max. command speed Max. command speed Drift compensation Drift compensation Drift compensation Drift compensation Drift compensation Drift compensation Drift compensation Acceleration Acceleration Acceleration Acceleration Acceleration Acceleration Acceleration

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No. 2800 2801 2802 2803 2804 2805 2806 2840 2841 2842 2843 2844 2845 2846 2880 2881 2882 2883 2884 2885 2886 2920 2921 2922 2923 2924 2925 2926 2960 2961 2962 2963 2964 2965 2966 3000 3001 3002 3003 3004 3005 3006 3040 3041 3042 3043 3044 3045 3046

ValueMax. speed Max. speed Max. speed Max. speed Max. speed Max. speed Max. speed

Designation

No. 3160 3161 3162 3163 3164 3165 3166 3200 3201 3202 3203 3204 3205 3206 3240 3241 3242 3243 3244 3245 3246 3280 3281 3282 3283 3284 3285 3286 3320 3321 3322 3323 3324 3325 3326 3360 3361 3362 3363 3364 3365 3366 3400 3401 3402 3403 3404 3405 3406

Value

DesignationPointer compensation pos. Pointer compensation pos. Pointer compensation pos. Pointer compensation pos. Pointer compensation pos. Pointer compensation pos. Pointer compensation pos. Pointer compensation neg. Pointer compensation neg. Pointer compensation neg. Pointer compensation neg. Pointer compensation neg. Pointer compensation neg. Pointer compensation neg. Distance between 2 values Distance between 2 values Distance between 2 values Distance between 2 values Distance between 2 values Distance between 2 values Distance between 2 values Compensation value Compensation value Compensation value Compensation value Compensation value Compensation value Compensation value Contour monit. tol. band Contour monit. tol. band Contour monit. tol. band Contour monit. tol. band Contour monit. tol. band Contour monit. tol. band Contour monit. tol. band Threshold contour speed Threshold contour speed Threshold contour speed Threshold contour speed Threshold contour speed Threshold contour speed Threshold contour speed Tool change position Tool change position Tool change position Tool change position Tool change position Tool change position Tool change position

Ref. point cutoff speed Ref. point cutoff speed Ref. point cutoff speed Ref. point cutoff speed Ref. point cutoff speed Ref. point cutoff speed Ref. point cutoff speed Jog feedrate Jog feedrate Jog feedrate Jog feedrate Jog feedrate Jog feedrate Jog feedrate Jog rapid traverrse Jog rapid traverrse Jog rapid traverrse Jog rapid traverrse Jog rapid traverrse Jog rapid traverrse Jog rapid traverrse Ref. point approach speed Ref. point approach speed Ref. point approach speed Ref. point approach speed Ref. point approach speed Ref. point approach speed Ref. point approach speed Incremental feedrate Incremental feedrate Incremental feedrate Incremental feedrate Incremental feedrate Incremental feedrate Incremental feedrate Interpolation parameter Interpolation parameter Interpolation parameter Interpolation parameter Interpolation parameter Interpolation parameter Interpolation parameter

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No. 3440 3441 3442 3443 3444 3445 3446 3480 3481 3482 3483 3484 3485 3486 3520 3521 3522 3523 3524 3525 3526 3600 3601 3602 3603 3604 3605 3606 3640 3641 3642 3643 3644 3645 3646 3680 3681 3682 3683 3684 3685 3686 3720 3721 3722 3723 3724 3725 3726 3760 3761 3762

Value

DesignationModulo f. endless rot. axis with LEC* Modulo f. endless rot. axis with LEC* Modulo f. endless rot. axis with LEC* Modulo f. endless rot. axis with LEC* Modulo f. endless rot. axis with LEC* Modulo f. endless rot. axis with LEC* Modulo f. endless rot. axis with LEC* Software Exe Software Exe Software Exe Software Exe Software Exe Software Exe Software Exe 2nd Kv factor 2nd Kv factor 2nd Kv factor 2nd Kv factor 2nd Kv factor 2nd Kv factor 2nd Kv factor Sym. time constant Sym. time constant Sym. time constant Sym. time constant Sym. time constant Sym. time constant Sym. time constant No. pulses var. incr. weighting No. pulses var. incr. weighting No. pulses var. incr. weighting No. pulses var. incr. weighting No. pulses var. incr. weighting No. pulses var. incr. weighting No. pulses var. incr. weighting Travel for var. incr. weighting Travel for var. incr. weighting Travel for var. incr. weighting Travel for var. incr. weighting Travel for var. incr. weighting Travel for var. incr. weighting Travel for var. incr. weighting Delay zero speed control Delay zero speed control Delay zero speed control Delay zero speed control Delay zero speed control Delay zero speed control Delay zero speed control Prelimit switch Prelimit switch Prelimit switch

No. 3763 3764 3765 3766 3800 3801 3802 3803 3804 3805 3806 3840 3841 3842 3843 3844 3845 3846 3880 3881 3882 3883 3884 3885 3886 3920 3921 3922 3923 3924 3925 3926 4000 4001 4010 4011 4020 4021 4030 4031 4040 4041 4050 4051 4060 4061 4070 4071 4080 4081 4090 4091

Value

DesignationPrelimit switch Prelimit switch Prelimit switch Prelimit switch 2nd Kv factor for G36 2nd Kv factor for G36 2nd Kv factor for G36 2nd Kv factor for G36 2nd Kv factor for G36 2nd Kv factor for G36 2nd Kv factor for G36 Grad. period of linear scale Grad. period of linear scale Grad. period of linear scale Grad. period of linear scale Grad. period of linear scale Grad. period of linear scale Grad. period of linear scale Weighting factor Weighting factor Weighting factor Weighting factor Weighting factor Weighting factor Weighting factor Absolute offset Absolute offset Absolute offset Absolute offset Absolute offset Absolute offset Absolute offset Spindle assignment Spindle assignment Drift compensation Drift compensation Zero mark offset Zero mark offset Max. speed gear 1 Max. speed gear 1 Max. speed gear 2 Max. speed gear 2 Max. speed gear 3 Max. speed gear 3 Max. speed gear 4 Max. speed gear 4 Max. speed gear 5 Max. speed gear 5 Max. speed gear 6 Max. speed gear 6 Max. speed gear 7 Max. speed gear 7

* LEC = leadscrew error compensation

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No. 4100 4101 4110 4111 4120 4121 4130 4131 4140 4141 4150 4151 4160 4161 4170 4171 4180 4181 4190 4191 4200 4201 4210 4211 4220 4221 4230 4231 4240 4241 4250 4251 4260 4261 4270 4271 4280 4281 4290 4291 4300 4301 4310 4311 4320 4321 4330 4331

Value

DesignationMax. speed gear 8 Max. speed gear 8 Min. speed gear 1 Min. speed gear 1 Min. speed gear 2 Min. speed gear 2 Min. speed gear 3 Min. speed gear 3 Min. speed gear 4 Min. speed gear 4 Min. speed gear 5 Min. speed gear 5 Min. speed gear 6 Min. speed gear 6 Min. speed gear 7 Min. speed gear 7 Min. speed gear 8 Min. speed gear 8 Accel. time const gear 1 Accel. time const gear 1 Accel. time const gear 2 Accel. time const gear 2 Accel. time const gear 3 Accel. time const gear 3 Accel. time const gear 4 Accel. time const gear 4 Accel. time const gear 5 Accel. time const gear 5 Accel. time const gear 6 Accel. time const gear 6 Accel. time const gear 7 Accel. time const gear 7 Accel. time const gear 8 Accel. time const gear 8 Cutoff speed M19 gear 1 Cutoff speed M19 gear 1 Cutoff speed M19 gear 2 Cutoff speed M19 gear 2 Cutoff speed M19 gear 3 Cutoff speed M19 gear 3 Cutoff speed M19 gear 4 Cutoff speed M19 gear 4 Cutoff speed M19 gear 5 Cutoff speed M19 gear 5 Cutoff speed M19 gear 6 Cutoff speed M19 gear 6 Cutoff speed M19 gear 7 Cutoff speed M19 gear 7

No. 4340 4341 4350 4351 4360 4361 4370 4371 4380 4381 4390 4391 4400 4401 4410 4411 4420 4421 4430 4431 4440 4441 4450 4451 4460 4461 4470 4471 4480 4481 4490 4491 4500 4501 4510 4511 4520 4521 4590 4591 10960 10961 10962 10963 10964 10965 10966

Value

DesignationCutoff speed M19 gear 8 Cutoff speed M19 gear 8 Gain M19 gear 1 Gain M19 gear 1 Gain M19 gear 2 Gain M19 gear 2 Gain M19 gear 3 Gain M19 gear 3 Gain M19 gear 4 Gain M19 gear 4 Gain M19 gear 5 Gain M19 gear 5 Gain M19 gear 6 Gain M19 gear 6 Gain M19 gear 7 Gain M19 gear 7 Gain M19 gear 8 Gain M19 gear 8 Positional tolerance M19 Positional tolerance M19 Spindle speed tolerance Spindle speed tolerance Max. spindle speed tolerance Max. spindle speed tolerance Zero-speed tolerance Zero-speed tolerance Delay servo enable Delay servo enable Minimum motor speed Minimum motor speed Set speed Set speed Reciprocation speed Reciprocation speed Max. spindle speed Max. spindle speed Spindle pos. ext. M19 Spindle pos. ext. M19 No. pulses spindle encoder No. pulses spindle encoder Fictitious 2nd ref. point Fictitious 2nd ref. point Fictitious 2nd ref. point Fictitious 2nd ref. point Fictitious 2nd ref. point Fictitious 2nd ref. point Fictitious 2nd ref. point

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Bits No.

Bits

7

60 0

50 0

40 0

3

2

1

0

No. 5500 5501 5520 5521 5540 5541 5580 5581 5600 5601 5602 5603 5604 5605 5606 5640 5641 5642 5643 5644 5645 5646 5680 5681 5682 5683 5684 5685 5686 5720 5721 5722 5723 5724 5725 5726

7

6

5

4

3

2

1

0

5000 0 5001 0 5002 5003 5004 5005 5006 5007 5008 5009 5010 5011 5012 5013 5014 5015 5016 5018 5040 5041 5042 5061 5062 5063 5064 5065 5066 5200 5201 5210 5211 5400 5401 5460 5461 5480 5481

0

0

0

0

0

0

28

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Bits No. 5760 5761 5762 5763 5764 5765 5766 5800 5801 5802 5803 5804 5805 5806

Bits

7

6

5

4

3

2

1

0

No. 5840 5841 5842 5843 5844 5845 5846

7

6

5

4

3

2

1

0

The compensation flags for leadscrew error compensation (MD 6000 - 6249) must, if necessary, be written on a separate sheet.

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PLC machine data list No. 0 1 2 3 4 5 6 7 8 9 10 1000 1001 1002 1003 1004 1005 1006 10071st PLC user MD 2nd PLC user MD 3rd PLC user MD 4th PLC user MD 5th PLC user MD 6th PLC user MD 7th PLC user MD 8th PLC user MD

Value

DesignationInterrupt input byte no. Max. interpreter runtime 0B1+0B2 PLC call OB1 Max. interpr. 0B2

Units No.%

Bits

7

6

5

4

30

20

10

00

IPO clock s

2000 2001 2002 2003 3000 3001 3002 3003

Scan time monitor No. of last S5 time

ms

No. of interf. for DB37 Selection Kbyte for DB area

Setting data lists Bits No. Bits

7

60 0

50 0

40 0

30 0

20

10

0

No.

7

6

5

4

3

2

1

0

5000 0 5001 0 5010 5011 5012 5013 5014 5015 5016 5017

5018 5019 5020 5021 5022 5023 5024 5025 0 5026 5027 5028 5029 5600 5601 5602 5603 5604

0

0

0

0

0

0

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Options list Yes No Order code A04 A05 A21 A22 A23 B01 B02 B03 B21 B25 B52 B60 B61 B65 B70 B73 B75 B78 C47 C48 C49 C60 C62 Options 4th axis 5th axis 1st auxiliary axis 2nd auxiliary axis 3rd auxiliary axis (M) (M) (T) (T) (T) Remarks 2nd meas. circuit module

Tape reader I. T61 without winder Tape reader I. T40 with winder Tape reader I. T40 with winder Tape reader l. T41 with small front panel Program sequencing with diskette drive Interpol. tapping/threading (G36) Spline interpolation 3D/helical interpolation Transmit Polar coordinates, drilling and milling patterns Cylindrical interpolation Blueprint programming Inprocess (high-speed) measurement Program memory expansion to 64 Kbytes Program memory expansion to 96 Kbytes Program memory expansion to 128 Kbytes PLC controlled, serial interface 2nd V.24 (RS 232) interface

Otherwise as for T40

-

810M GA3

No PLC memory expansion possible

C69 E31 E36

Block transfer Thread cutting and feedrate per revolution Tapping without compensation chuck 810M Precondition 1 meas.circuit and F05

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Yes

No

Order code E42 B86 B88 F05 F06 F72 H56 J16 J23 J24 J25 J53 J54 J55 J26 J27 J28 J29 J31 J35 J36 J39 J03 J81 J82 J82 J85 J96

Options Oriented spindle stop M19 Software cam Axis duplication Analog spindle speed for spindle 1 Analog spindle speed for spindle 2 External data input (from the PLC) Leadscrew error compensation Graphics simulation French/German Italian/German Spanish/German French/English Italian/English Spanish/English Dutch/German Russian/German Swedish/German Finnish/German Polish/German Hungarian/German Czech/German Turkish/German Color monitor Integr. machine control panel (SINUMERIK 810 only) Integr. cust. operator panel (SINUMERIK 820 only) Rapid traverse override switch (SINUMERIK 820 only) Ext. machine control panel for 5 axes External machine control panel (7 axes with rotary switch x, z, c, 4, 5, 6, 7)

Remarks Analog spindle speed F05 and F06

Only for 810M

No J82, J85 or J97 No J81

No J81, J96 No J81, J95

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Yes

No

Order code

Options Measuring-circuit modules EXE cannot be fitted EXE can be fitted with 1 5/10-fold EXE with 2 5/10-fold EXE with 3 5/10-fold EXE HMS module 3 actual values (width 20 mm) HMS module 3 actual values 3 setpoints (width 40 mm) HMS module 3 actual values 6 setpoints (width 40 mm) HMS module 3 actual values 3 setpoints HMS/absolute submodule for 3 axes (width 40 mm) I/O submodule, basic submodule with mounting plate I/O submod., expans. submod. I/O submod., expans. submod. I/O submodule, basic submodule (64 inputs) Handwheel interface submodule Handwheel interface submodule with mounting plate

Remarks

K20 K21 K23 K24 K25 K70

K71

K72

K75

M01 M02 M03 M04 M10 M11 M41 M42 M43 M44 M49

M01 or M04 M01 or M04

M01 or M04

I/O submodule, basic submodule P07 required with mounting plate, w/o cable I/O submodule, expansion submodule (identical with M02) I/O submodule, expansion submodule (identical with M03) M41 or M44 required M41 or M44 required

I/O submodule, basic submodule P07 required (64 inputs) Round cable 1m (for I/O submodules) M01, M04, M11

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Yes

No

Order code M50

Options Round cable 5m (for I/O submodules) Ribbon cable for connecting: 1 submodule 2 submodules 3 submodules 4 submodules 5 submodules (5th submodule handwheel) Ribbon cable for P07+I/O basic submodule Ribbon cable for P07+I/O basic submodule+ 1 I/O expansion module Ribbon cable for P07+I/O basic submodule+ 2 I/O expansion modules Ribbon cable for P07+I/O basic submodule+ 3 I/O expansion modules Integrated auxiliary axis RAM-UMS-SUBMODULE 128 Kbytes RAM-UMS-SUBMODULE 256 Kbytes Configurability+UMS-EPROMsubmodule 128 Kbytes not programmed Configurability+UMS-EPROMsubmodule 256 Kbytes not programmed INPUT/OUTPUT modules for PLC expansion unit 32 inputs type K 32 inputs type U 32 inputs 0.5A type K 32 inputs 0.5A type U 16 outputs 2A type U 16 outputs 1A type K 64 inputs type SINUMERIK 32 outp. 0.5A, type SINUMERIK 32 outp. 2A, type SINUMERIK Link to SIMATIC S5 (master PLC)

Remarks M01, M04, M11 M49 bzw. M50 erforderlich

M51 M52 M53 M54 M55 M62 M63

Precondition N96

M64

M65

N06 N23 N24 N31

Precondition P06 or P08,F72

N32

N60 N61 N65 N66 N68 N70 N71 N72 N73 N75

P06/P08 P06/P08 P06/P08 P06/P08 P06/P08 P06/P08 P06/P08 P06/P08 P06/P08

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Yes

No

Order code N96 P06 P07 P08

Options MPC link module PLC expansion unit with 10 standard slots Distributed link of I/O submodules PLC expansion unit (maxi-EU)

Remarks

Excludes P07 or P08 Excludes P06 or P08 Prerequisite N96

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3 Overview of Modules and Standard Jumperings 3.1 Basic system

3

Overview of Modules and Standard JumperingsBasic system SINUMERIK 810 GA3

3.1. 3.1.1

In order to save space when mounting the control on the machine and to avoid problems when linking various control components, the SINUMERIK 810 GA3 was designed as a compact unit where the numerical control (NC), programmable logic controller (PLC), control keyboard and monitor are integrated into a single housing. Screen with softkeys

SINUMERIK

SIEMENS

Keyboard and display panel

Integrated machine control panel

Video interface

CPU with arithmetic coprocessor Interface

Memory module (only if UMS)

Measuring circuits (option)

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3 Overview of Modules and Standard Jumperings 3.1.2 SINUMERIK 820 GA3

01.93

3.1.2 SINUMERIK 820 GA3Screen with softkeys

SINUMERIK

SIEMENS

Keys and display panel

Assignable keys

Video interface

Colour memory only with colour monitor Memory module (only if UMS) Interface

CPU with arithmetic coprocessor

Measuring-circuit modules (option)

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3 Overview of Modules and Standard Jumperings 3.1.3 Overview of modules SINUMERIK 810 GA3/820 GA3

3.1.3

Overview of modules 810 GA3/820 GA36EV3 055-0BC 6EW1 861-3A.. 6FX1 138-5B... 6FX1 151-1BA.. 6FX1 151-1BB 6FX1 121-2BC.. 6FX1 128-1BA.. - UMS 128 Kbyte - UMS 128 Kbyte (N11) - UMS 256 Kbyte (N12) - UMS 128 Kbyte (N13) - UMS 256 Kbyte (N14) 6FX1 128-4BB00 6FX1 128-4BD00 6FX1 128-4BC00 6FX1 126-6BA00 6FX1 135-3BA00 6FX1 121-4BA02 6FX1 121-4BB02 6FX1 145-6B.. 6FX1 120-0BB 6FX1 124-6AA01 6FX1 124-6AA02 6FX1 126-5AA.. 6FX1 132-1BA.. for Mini EU for Mini EU 6FX1 125-7BA.. 6FX1 122-8B.. 6FX1 132-1BB.. 6EW1 861-3A.. 6FX1 136-2BA.. 6FX1 135-6BA00 6FX1 135-7BB00..

+ 24V DC power supply unit 220V AC power supply unit (for SINUMERIK 820 GA3) CPU with ACOP Video interface module 7220 (monochrome and colour) Video interface module (monochrome screen only) Interface module (orange terminal connector for sensor) Memory module EPROM submodule standard EPROM submodule EPROM submodule RAM submodule RAM submodule

Measuring-circuit module (20mm wide) DAC Measuring-circuit module (40mm wide - for EXE) DAC HMS measuring circuit module Monitor adapter (brightness+contrast) I/O PCBs MPG submodule for 3 handwheels CUMPC interface Input module Output module

CC interface for MPS for Maxi EU Power supply unit for Maxi EU

CU submodule interface (link module) Master PLC link module (in the SINUMERIK) S5 link module (in the SIMATIC)

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3 Overview of Modules and Standard Jumperings 3.1.4 Power supply units

11.90

3.1.4

Power supply units

3.1.4.1 Power supply unit 24V DC (SINUMERIK 810 GA3)6EV3 055-0BC Brief description: X111 +24 V Fan

Key for hardware reset on the front panel +5V adjustment potentiometer on the front panel +5V/0V measuring sockets (power supply unit output voltage) on the front panel Fan connection X111 (terminals on front panel) Fan OK signal (fan control) as floating relay output (100V/ 250mA; insulation voltage against housing 100V) Power supply unit OK signal as a floating relay contact (100V/250mA; insulation voltage against housing 100V) fed to front panel terminals.

+24 V 0V

X121

NC ON

X131 Reset

When the control is delivered the fan control has to act directly on the power supply enable. This is achieved by jumpers of fan control with enable: X141.1 with X 141.3 and X 141.2 with X 141.4 Both jumpers are inserted during manufacturing in the works.

5V Ass. ment 5V0V

Enable Fan Control Power Supply O.K. X141

Fan control can be used As power supply enable Note: in this case the power supply is immediately shut down when the fan control responds.

To trigger externally implemented shutdown logic for delayed shutdown of the power supply.

The power supply unit should be switched off by the fan control one minute at the latest after the monitoring response, otherwise the control may overheat and cause damage.

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3 Overview of Modules and Standard Jumperings 3.1.4 Power supply unit

3.1.4.2 220V AC power supply unit (SINUMERIK 820 GA3)6EW1 861-

Reset key +5V Adjustment

Hardware reset key +5V adjustment Measuring sockets

5V6 5 4 3 2 1

0V

Enable

6 5 4 3 2 1

Terminals must be connected Fan OK signal Power supply OK signal

Fan Control Power Supply OK X111

Mains Connection 220 V, 50/60 Hz5

NC ON4 3 2 1

5 4 3 2 Earth

NC ON 220 V AC/50 Hz

U V/N PE X121

Fan control can be used As power supply enable Note: in this case the power supply is immediately shut down when the fan control responds. To trigger externally implemented shut-down logic for delayed shutdown of the power supply.

The power supply unit should be switched off by the fan control one minute at the latest of the monitoring response, otherwise the control may overheat and cause damage.

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3 Overview of Modules and Standard Jumperings 3.1.5 CPU module

09.91

3.1.5

CPU module

6FX1 138-5BB.. Clock frequency: 16 MHz

CPU fault (red LED) RAMs

MPC interface

X111

MPC 2

Restart EPROMs 1st RS 232C (V.24) 20 mA

X121

CSR

D94 D95 2 stat. RAMs S1ACOP

Type: 27 256 (16k words, 16 bit wide)

80C1862nd RS 232C (V.24)

Bus connector

X131 X431 S2 S31 3 5 7 9 11 13 15 17

2 4 6 8 10 12 14 16 18

Quartz oscillator

Quartz oscillator

Standard jumpering:

S1 open S2 open S3 closed

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3 Overview of Modules and Standard Jumperings 3.1.6 Video interface modules

3.1.6

Video interface modules

3.1.6.1 Video interface module, colour and monochrome6FX1 151-1BA.. Can be used for colour and for monochrome monitor. To monitor adapter

DIP-FIX switches S1, S2:

S31 3 2

Address jumpering2 4 6 8 10 12 14 16

S28 6 4 2 7 5 3 1 2 16

S1 S11 15

1 3 5 7 9 11 13 15

Identification register SINUMERIK 810/820 with monochrome screen2 4 6 8

SINUMERIK 820 with colour screen2 4 6 8

S21 3 5 7

S21 3 5 7

without IBM character set

S2

S2

with IBM character set

3.1.6.2 Video interface module, monochrome6FX1 151-1BB.. This module can only be used with a monochrome monitor.

3.1.7

(Vacant)

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3 Overview of Modules and Standard Jumperings 3.1.8 Interface module

01.93

3.1.8

Interface module

6FX1 121-2BC..

W1

W2

System Software

S1.1 S3.1 S1.2 S3.2

A

B

S2.1

S2.2 I/O submodule interface

123456

Module indentification:

W1 W2

closed closed

Sensor 1:

Soldering pins:

AB open

Sensor 1:

S1.1 S2.1 S3.1 S1.2 S2.2 S3.2

open open open open open open

See Section 7.3 for sensor coding.

3.1.9

Memory modules (only needed when UMS used)

A memory submodule may only be plugged in to slot 3. Module for 3 x 256 Kbyte EPROM:Slot 3 (below) Slot 2 (centre) Slot 1 (above)

6FX1 128-1BA..

Slots 1 and 2 must not be used. UMS submodules W3 W2 W1

W6

A C B

W4 W5

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3 Overview of Modules and Standard Jumperings 3.1.9 Memory module

Jumpers: W1 W2 W3 W4 W5 W6 A-B closed closed closed closed closed closed closed printed conductor module identification printed conductor module identification printed conductor printed conductor

If the UMS is pulled out when the control is switched off, it takes about 10 minutes for the UMS data to be deleted in the RAM. Only then does alarm 11 appear.

UMS modules for slot 3 a) EPROM submodule: 6FX1 128-4BC00 6FX1 128-4BD00 (256 Kbytes) (128 Kbytes)

D4

D3

D2

D1

B3

B2

B4

B1

Jumpers: B1 B2 B3 B4 b) closed open open closed EPROM submodule: (Standard UMS, standard cycles) 6FX1 822-0BX03 6FX1 822-1BX03 (128 Kbytes, for T) (128 Kbytes, for M)

D4free

D3standard cycles

D2free

D1standard cycles

B3

B2

B4

B1

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3 Overview of Modules and Standard Jumperings 3.1.9 Memory module

11.90

Jumpers: B1 B2 B3 B4 c) open open open closed RAM submodule: 6FX1 126-6BA00 (128 Kbytes)

W2

W1

Jumpers: W 1 closed W 2 open Components on front and rear. d) RAM submodule: 6FX1 135-6BA00 (256 Kbytes)

Note: No jumpers to be taken into account!

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3 Overview of Modules and Standard Jumperings 3.1.10 Measuring-circuit modules

3.1.10

Measuring-circuit modules

3.1.10.1 SPC measuring circuit module 6FX1 121-4BA . . (standard measuring circuit module)For analog setpoint output DAC: 6FX1 121-4BA . . 20 mm 6FX1 121-4BB . . 40 mm (EXE) Act. 3X121 2 1 +5V 2

Set 1,2,3X141 2

Act. 1X131 1 +5V

Act. 2X111 1 +5V

S3 DAC DAC PAD DAC

S2

S1

SPC

SPC

SPC

Bus connector

Interface description: 3 actual values 3 analog setpoints (command values) No NC-RDY relays No servo enable input Non-floating servo enable

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3.1.10.2 HMS measuring circuit module=A =B with submodule interface without submodule interface Actual 3 X131 R82 S521

6FX1 145-6B 00

40 mm wide 20 mm wide Actual 2 X121 Actual 1 X111 R136 S721

U12/X12 I/U

R101

S621

U7/X17 I/U

U23/X23 I/U

S11 S12 S13

Bus connector

Encoder power supply: from NC power supply+5 V ext. (option)

S5 (S6, S7) 2 17, +5 V 20 encoder power supply

+5 V

(

R 82 R 101 R 136

)

1 X111 X121 X131

0V

8

(

)

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Jumpers S11, S12 and S13 are open. Each of the two HMS measuring circuit modules contains 3 measuring circuit/actual value inputs for connecting 3 axes with incremental position encoders. On the double-width module, 3 additional submodule slots are provided into each of which 1 analog measuring circuit setpoint submodule (HMS setpoint submodule) or 1 SIPOS absolute encoder submodule+1 measuring circuit setpoint submodule can be plugged. Both modules can be combined such that the double-width HRS measuring circuit module contains the measuring circuit setpoint submodules for all 6 axes/spindles (in this case, however, no SIPOS absolute encoder submodule can be inserted). Note: The SIPOS absolute encoder submodule can be inserted only in the upper 2 submodule slots of the HMS measuring circuit module. An I/U hybrid that can be plugged on the module enables also linear scales with unconditioned current signals to be connected to the HMS module. Each of the 3 measuring system inputs on the HMS module can be provided with an I/U hybrid.

10

1

I/U hybrid

11X111

2X121 X131 front

The I/U hybrid is inserted into the socket with pins 2 and 11 pointing to the front as shown above. The colour dot on the hybrid marks pin 1. I/U hybrid (I/U: current/voltage conversion) The HMS measuring circuit module can be used only for SIPOS encoders with unconditioned voltage signals as standard. Linear scales with unconditioned current signals can also be used as options if a I/U hybrid is inserted into the relevant jumpering socket (U12, U17, U23) in place of the short-circuiting connector. This direct connection is only possible up to a lead length of 18m for reasons of interference immunity. For lead lengths exceeding 18 m a converter box converting the current signals into voltage signals must be provided. The I/U hybrid must be installed as described in the Installation Instructions.

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Order number: I/U hybrid: 6FC3 988-7CN

Amplifier for unconditioned current signals (l>18 m) Order number: Encoder signal routing interface Connector designations U12 (X12), U17 (X17), U23 (X23) 20-pin IC socket (DIL 20) used to connect a current/voltage converter hybrid when employing encoders with unconditioned current signals (option). Order number: 6FC3 988-7CN +5V -15V 0V +15V RN RP BN BP AN AP 11 12 13 14 15 16 17 18 19 20 . . . . . 10 ...... 9 ...... 8 ...... 7 ...... 6 ...... 5 ...... 4 ...... 3 ...... 2 ...... 1 +5V -15V 0V +15V R1N R1P B1N B1P A1N A1P 6FC9 320-4HM12

A1P A1N B1P B1N R1P R1N AP AN BP BN RP RN

Encoder signal Encoder signal Encoder signal Encoder signal Encoder signal Encoder signal Encoder signal Encoder signal Encoder signal Encoder signal Encoder signal Encoder signal

A *A B *B R *R A *A B *B R *R

(Unconditioned voltage or current signal) (Unconditioned voltage or current signal) (Unconditioned voltage or current signal) (Unconditioned voltage or current signal) (Unconditioned voltage or current signal) (Unconditioned voltage or current signal) (Unconditioned voltage signal) (Unconditioned voltage signal) (Unconditioned voltage signal) (Unconditioned voltage signal) (Unconditioned voltage signal) (Unconditioned voltage signal)

When using encoders supplying unconditioned voltage signals (standards) (SIPOS encoders), the interfaces are fitted with short-circuiting encoding connectors (X12, X17, X23) connecting opposite pins (1-20, 2-19, 3-18, ...). The power supply pins are already interconnected on the module.

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HMS setpoint submodule 6FX1 132-5BA00 The submodule is plugged on the relevant interface in the HMS measuring circuit module 6FX1 145-6BA00 (double width with submodule interface). Setpoints of up to 3 axes/spindles can be output via a submodule. Up to 2 HMS setpoint submodules can be plugged in the HMS measuring circuit module. The additional submodule can be used only in conjunction with the HMS measuring circuit module 6FX1 145-6BB00 (single width without submodule interface). For the SINUMERIK 810 this results in the following maximum configuration (with SINUMERIK 820 more space is available in the subrack): 1 1 2 HMS measuring circuit module with submodule interface HMS measuring circuit module without submodule interface HMS setpoint submodule

and the following minimum configuration when using HMS: 1 1 HMS measuring circuit module with submodule interface HMS setpoint submodule

Limitation: If a SIPOS absolute encoder submodule is plugged into the HMS measuring circuit module, only 1 HMS setpoint submodule can be additionally inserted into this module. Output for servo enable

+24 Vext + Output (SCE) max. load 100 mA short-circuit proof

Mext

SIPOS absolute encoder submodule G33961-A3729-L1 1 SIPOS absolute encoder submodule can be inserted into the double-width HMS measuring circuit module using the upper 2 submodule slots. This allows simulation of absolute measuring values for all 3 inputs. In this case, however, only 1 HMS setpoint submodule can be plugged at the same time. A battery submodule can be plugged on the SIPOS absolute encoder submodule to store absolute values in the event of power failure. SIPOS absolute encoder 6FC9 320-3CT Multiturn absolute encoder with 2500 increments. This includes the cable 6FC9 344-4D . The SIPOS encoder system is a multiturn absolute encoder working on an absolute basis at POWER ON and on an incremental basis during operation.

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To reduce the size of the encoder, part of its electronics has been arranged on another submodule, i. e. the absolute submodule. The control requests from the absolute encoder the absolute value of the encoder after every POWER ON and then calculates the absolute machine position.The absolute encoder then acts as a standard incremental encoder with amplified sine/cosine output signals. The absolute information is derived from the encodered dial information as a cyclically absolute value and the reading of the battery-backed revolutions counter. The backup battery covering 3 axes is located on the absolute submodule. Basic encoder data: Max. sampling frequency: Dial increments: Revolutional information: Starting accuracy: Error information: Backup period: 500 kHz 2500 16 bits 1 m, with 10 mm spindle pitch (10 000 increments/rev) 8 bits 5800 hours for 3 encoders, own battery monitor

The condition of the backup battery is checked every 10 minutes also during operation and an error message is displayed in the control in the event of malfunction. An additional backup in the encoder enables the measuring circuit module or the encoder cable to be exchanged without absolute information being lost. This backup can be maintained over a period of 5 hours. SIPOS unconditioned signal encoder 6FC9 320-CS Multiturn incremental encoder with 2500 pulses/rev, limiting frequency 500 kHz. The cable 6FC9 344-4D is included.

3.1.11 Monitor control unitThis module is part of the monitor. The monitor has already been adjusted in the works. If the brightness must be adapted to a special working environment, this can be done with the potentiometer BRIGHTNESS.

V-LIN CONTRAST H-CENTER

V-HOLD FOCUS V-SIZE

Sub-BRIGHTNESS

BRIGHTNESS

To video module

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3 Overview of Modules and Standard Jumperings 3.1.12 I/O submodules

3.1.12 I/O submodulesUp to 4 submodules can be connected to the interface module. Submodule with 2 input connectors: 6FX 1124-6AA01

64 (2 x 32) inputs 24V 32 outputs : 24 outputs each 400 mA, 24V DC, short-circuit-proof (bytes 0 - 2) One of the red LEDs V35, V36 or V37 flashes when short-circuit is indicated. 8 outputs each 100 mA, 24V DC, not short-circuit-proof (byte 3) 32 outputs B1 B2 32 inputs 32 inputs

F1 LED V37 V36 V35

B3

S2

S1

Jumpers:B 1 open B 2 closed B 3 open F1 6.3 A fuse (for 24V)

Submodule with 3 input connectors: 6FX 1124-6AA02 (Retrofit order no.: 6FC3 984-3RB (Basic submodule with mounting plate, Retrofit order no.: 6FC3 984-3RA)

32 inputs 24V 32 inputs 24V (including 10 double-function inputs machine control panel for 2 axis selector switches) 32 outputs: 24 outputs each 400 mA, 24V, short-circuit-proof (bytes 0-2) One of the red LEDs V35, V36 or V37 flashes when short-circuiting is indicated. 8 outputs each 100 mA, 24V, not short-circuit-proof (byte 3) Voltage applied to+24V and M-out.

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32 outputs

32 inputs

10 inputs

32 inputs

F1 LED V37 V36 V35

B2

B1

B3

S2

S1

Jumpers: B1 B2 B3 F1 open closed open 6.3 A fuse for outputs and external measuring systems

Submodule with 3 input connectors: 6FX1 124-6AB02 (Retrofit order no.: 6FC3 984-3RC) (Basic submodule with mounting plate, Retrofit order no.: 6FC3 984-3RD) 32 inputs 24 V 32 inputs 24 V (including 10 double-function inputs machine control panel for 2 axis selector switches ) Voltage applied to+24V and M-out. 10 32 inputs inputs

32 inputs

F1

B2

B1

B3

S1

Jumpers: B1 B2 B3 F1 open closed open 6.3 A fuse for external measuring systems

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Switch position for S1 / S2 on individual submodules SubSubSubSubmodule 1 module 2 module 3 module 4 S1 S2 0 0 1 1 2 2 3 3 4 3 2 1 0 9 5 6 7 8

S1 / S2

S1: Address setting for inputs S2: Address setting for outputs Determination of location of short-circuit Red LED Submodule 1 Submodule 2 Submodule 3 Submodule 4 Max. current V37 QB 0 QB 4 QB 8 QB 12 400 mA V36 QB1 QB 5 QB 5 QB13 400 mA V35 QB 2 QB 6 QB 10 QB 14 400 mA No LED QB 3 QB 7 QB 11 QB 15 100 mA

3.1.13 Handwheel submodule (MPG)6FX1 126-5AA . .

B 1 B 2

(B-C) (A-B)

closed open

MPG 1

MPG 2

MPG 3

4 3 2 1

5 C 0 S1

B1 B

B2 A

S1 always in position 0

Jumper B2 must not be closed, otherwise handwheel operation is not guaranteed.

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3 Overview of Modules and Standard Jumperings 3.2 P06 expansion unit (Mini EU)

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3.2 3.2.1

P06 expansion unit (Mini EU) Overview of modulesOrder No.Order code

Designation

1 2

3 4

5 6 7 8 9 10 11 12

BUS / MINI EU

570348 9001 00

CU/MPC interface with power supply I-interf., 32 inputs 20 mm O-interf., 32 outp. 0.5 A 20 mm O-interf., 16 outp. 40 mm I-interf., 32 inputs 20 mm O-interf., 32 outp. 0.5 A 20 mm O-interf., 16 outp. 40 mm I-interf., 16 inputs 20 mm I-interf., 64 inputs 20 mm O-interf., 32 outp. 0.5 A 20 mm O-interf., 32 outp. 40 mm 2A 2A 2A

6FX 1132-1BA01

N60 N65 N70 N61 N66 N68 N69 N71 N72 N73 Option

6FC9 320-8AA 6ES5 432-3BA11 6FC9 320-8AB 6ES5 445-3AA12 6FC9 320-8AC 6ES5 444-3AA12 6FC3 988-4DB 6ES5 420-4UA11 6FC3 988-4DG 6ES5 441-4UA11 6FC3 988-4DJ 6ES5 454-4UA11 6FC3 988-4DK 6ES5 432-4UA11 6FC3 986-4DM 6FX1 125-7BA00 6FC3 986-4DN 6FX1 122-8BA01/ 8BA01 6FC3 986-4DP 6FX1 122-8BB01/ 8BB01

Basic version

A description of modules N61, N66, N68 and N69 can be found in the corresponding SIMATIC Product Manual.

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3 Overview of Modules and Standard Jumperings 3.2.2 Jumperings

3.2.2

Jumperings

3.2.2.1 Interface CU/MPCInterface module for mini EU : 6FX 1132-1BA . . ( - 1BB . . without power supply for maxi EU) always at slot 1 of mini EU

SIMATIC BUS CONNECTOR

SINUMERIK BUS CONNECTOR

W1 W2 X3

W3

F1

F2

MPCX2

S6 S7

Temperature sensor

S1

7 . . 24V DC in 5V DC out 0 . . 5A DC out

S2

X111

X121

0V

+24V

Output

Input from CPU X111

Test 0-5V

0V +24V power supply connection

EU No. (expansion unit) always set to 0 Reset

Power supply OK (green LED) Out DS (output disable) (red LED)

F1 F2 W1 W2 W3 X3 S1 S2 S6 S7

4.0 A power supply 1.6 A fan fuse closed: (test panel) - internal printed conductor - internal printed conductor closed: OUT-DS from central unit (CPU) active - temperature switch closed: shutdown in the event of over-temperature after 20 sec. closed: (test panel) closed: (test panel)

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3.2.2.2 Input module for Mini EU:6FX1 125-7BA.. 64 inputs

X121

X111

X1

X2

S

R

Busstecker

Jumper:

S-R closed

Address setting on the DIP-FIX socket X1 and X2

L X1 X2 K

N

P

M

U

8 Input byte 0-7 8-15 16-23 24-31 32-39 40-47 48-55 56-63 x: DIP-FIX closed x x x x

16

32

64

128

W1 W2

W3

All DIP-FIX of X2 are always closed Connector X111: e.g. IB0-3 Connector X121: e.g. IB4-7

x x x x x x x x

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3 Overview of Modules and Standard Jumpering 3.2.2.3 Output module for Mini EU

3.2.2.3 Output module for Mini EU:6FX1 122-8B.. 32 outputs 0.5 A/2.0 A

Bus connector X1 P X111 E F G U H X141

R

S

Jumpers: R-S open P-U open E-F open G-H open

1

2

X121 +24V ext. 1 M ext. 1

X131

1

2 +24V ext. 2 M ext. 2

V1 (left LED) for connector X131 (e.g. AB 2-3) V2 (right LED) for connector X121 (e.g. AB 0-1) V1/V2 signal short-circuit or thermal overload

Address setting on the DIP-FIX socket 1

X1

4 Output byte 0 ... 3 4 ... 7 8 ... 11 12 ... 15 16 ... 19 20 ... 23 24 ... 27 28 ... 31 x x x x

8

16

32

64

128

A

C

The outputs are shortcircuit-proof against earth and are switched off separately. x x x x x x x x

x: DIP-FIX closed

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3 Overview of Modules and Standard Jumperings 3.3 P08 expansion unit (Maxi EU)

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3.3 3.3.1

P08 expansion unit (Maxi EU) Overview of modulesOrder No.1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

DesignationSIMATIC bus connectors SINUMERIK bus connectors Power supply unit CC interface MPC

6EW1 861-3A 6FX 1132-1BB01

Digital input module 6FX1 125-7BA00 64 inputs N71 Digital output module 0.5A 6FX1 122-8BC01 32 outputs N72 Digital output module 2A 6FX1 122-8BD01 32 outputs N73 SIMATIC I/O Single width (20mm) N61, N66 SIMATIC I/O Double width (40mm) N68, N70

Basic version

Option

Alternative

A description of the SIMATIC I/O devices can be found in the corresponding SIMATIC Product Manual.

3.3.2

PLC expansion unit (P08)

X111 Connection to 6FX1 138-5BA.., Connector X111

X121

CC interface MPC (N96) 6FX 1132-1B..

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3 Overview of Modules and Standard Jumperings 3.4 Interface CU modules

3.4

Interface CU modules

Distributed connection for I/O submodule 6FX 1136-2BA.. (Handwheel submodule can not be connected)Temperature sensor Test 0-5V (measuring sockets) Power Supply OK (red LED) Out-DS instruction output disable (green LED) Reset for power supply EU No. (expansion unit No.) always 0

Connection for I/O submodules (up to 4)

9

0 1 2 3

H1 H2 X1 S3 F1 S1

8 7 6 5 4

S2

LS3 LS1

MPCF2 LS2 X111 X121 X131 Input from CPU Connector X111 S4

1234

Output +24V ext. M ext.

X121 is available to connect further MPC nodes

F1 F2 S4 LS1 LS2 LS3

fuse 2.0A slow fuse 1.6A fast (power supply ) closed (for test panel) open (closed: connect M ext. to shield) open (closed: input +24V via X111 Pin 1) closed (for test panel)

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3 Overview of Modules and Standard Jumperings 3.5 Master PLC link modules

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3.5 3.5.1

Master PLC link modules Master PLC link module (in the SINUMERIK)

6FX1 135-6BA

Red LED Rotary switch (positions 0 to 9)

8 H1 S6 S1 1

5

4

8

5 S2 S4 S5 S7

3

Master PLC link interface

1

4

12

X111

X11

Bus connector

Standard jumpering: S1 S2 S4 S5 S6 position 1 18 closed 27 closed closed closed 18 open 27 open 36 open 45 open 23 closed 36 open 45 open

S7

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1990 All Righ

810 installation guide

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