Contents

Page

1 Preconditions and Visual Inspection ................................................... 1-1

1.1 Preconditions ......................................................................................... 1-1
1.2 Visual inspection .................................................................................... 1-1
1.2.1 Notes and handling modules ................................................................... 1-1
1.2.2 Earthing ................................................................................................. 1-3
1.2.3 Position encoders ................................................................................... 1-4
1.2.4 Cable laying ........................................................................................... 1-4
1.2.5 Cables ................................................................................................... 1-4
1.2.6 Shielding ................................................................................................ 1-4
1.2.7 Interference suppression ............................................................. 1-4
1.2.8 Operator panel ....................................................................................... 1-5
1.2.9 Overall condition .................................................................................... 1-5
1.2.10 Batteries ................................................................................................. 1-5
1.3 Export version ........................................................................................ 1-6
1.4 China export version (Software Version 3 onwards) ............................ 1-6

2 Installation Checklist ........................................................................... 2-1

3 Drive Optimization ............................................................................... 3-1

3.1 Control direction of feed axes .checking and adjustment ......................... 3-1

a 3.2
3.3
3.4
Definition of maximum setpoint and tacho-generator compensation ..........
Multgain NC MD 260*.............................................................................
Servo gain factor (Kv factor) ........................................................
3-3
3-4
3-5
3.5 Acceleration NC MD 276’ ....................................................................... 3-7
3.6 Position monitoring ................................................................................. 3-9
3.6.1 Exact stop limit coarse and fine (NC MD 204* and 208”) .......................... 3-9
3.6.2 Clamping tolerance (NC MD 2127 ................................................. 3-9
3.6.3 Zero-speed monitoring ............................................................... 3-9
3.7 Contour monitoring ................................................................................. 3-10

0 4 Overview of Modules and Standard Jumperings ................................ 4-1

4.1 Overview of modules .............................................................................. 4-1
4.2 Operator panel module locations ............................................................. 4-2
4.3 NC bus structure .................................................................................... 4-3
4.4 PLC connection options .......................................................................... 4-5
4.4.1 PLC 1 module locations (central controller) ............................................. 4-5
4.4.2 PLC 2 module locations (external) ........................................................... 4-8
4.4.3 PLC 1: 130 WB ...................................................................................... 4-10
4.4.4 PLC 1: 130 WB, PLC 2: 130 WB with SlNUMERlK expansion unit ........... 4-11
4.4.5 PLC1 150S/U ........................................................................................ 4-12
4.4.6 PLCl 150S/U, PLC 150SiU ................................................................... 4-13
4.4.7 PLCl 130WB, PLC2 150S/U ................................................................. 4-14
4.5 Power supply units ................................................................................. 4-15
6EW1861-1A. and -2A. power supply unit (power supply unit in
central controller) ................................................................................... 4-15
6EW18.61-3M power supply unit (power unit in operator panel) ............... 4-18
 .
4.5.3 6ES5955-3LC13 and 6ES5955-3NC12 power supply units
(EU power supply units) ......................................................................... 4-20
4.6 6FX1120-4BA communication CPU (COM CPU) and operator panel CPU
(BT CPU) ............................................................................................. 4-21
4.7 6FX1120-5 NC CPU .............................................................................. 4-23
4.8 Memory modules ................................................................................... 4-24
4.8.1 6FX1120-7BA memory module ............................................................... 4-24
4.8.2 6FX1128-1BA memory module ............................................................... 4-25
4.8.3 6FX1126-7BA memory module ............................................................... 4-26
4.8.4 .
6FX1126-OB EPROM RAM submodule ....;............................................. 4-28
4.8.5 .
6FX1128.48 EPROM submodule ........................................................... 4-29
4.8.6 6FX1126-6BA RAM submodule (SMD) .................................................... 4-29
4.8.7 6FX1126-2BA RAM submodule ............................................................... 4-30
4.9 6FX1126-88 measuring-circuit module .................................................... .4.32
4.10 .
6FX1121-48 measuring-circuit module ................................................... 4-34
4.1 1 6FX1121-8BB (-8BA) multiport ............................................................... 4-38
4.12 6FX1120-3 link module ........................................................................... 4-40
4.13 .. ..
6ES5 304-3UA and 6ES5 314-3UA link modules ................................. 4-43
4.14 6ES5300-3, 301-3, 310.3, 312-3 link modules ......................................... 4-45
4.15 6FX1121-2BA00 interface module ........................................................... 4-45
4.16 6FX1126-1AA video module ................................................................... 4-46
4.17 6FX1126-4AA colour display memory module .......................................... 4-49
4.18 Colour monitor ....................................................................................... 4-49
4.1 9 6FX1124-6AA inputloutput submodule(l/O submodule) ............................ 4-50
4.20 ..
6FX1126.5AA HANDWHEEL MODULE (MPG) ..................................... 4-53
4.21 Machine control panel ............................................................................ 4-53
4.22 Adressing of 110 modules ....................................................................... 4-54

5 Voltage and Functional Tests ............................................................. 5-1

5.1 Voltage test ........................................................................................... 5-1
5.1.1 Voltage supply ....................................................................................... 5-1
5.1.2 Limit temperature ................................................................................... 5-2
5.1.3 Fan monitoring ....................................................................................... 5-2
5.1.4 Direct voltage + 5V ................................................................................ 5-3
5.1.5 Direct voltage + 5V external ................................................................... 5-3
5.2 Functional test ....................................................................................... 5-5
5.2.1 CPU monitoring ..................................................................................... 5-5
5.2.2 EPROM check ....................................................................................... 5-5
5.2.3 Brightness adjustment ............................................................................ 5-7
5.3 Drift compensation (from Software Version 03) ....................................... 5-8

6 Standard Installation Sequence .......................................................... 6-1

6.1 Standard installation shown as a flowchart .............................................. 6-2
6.1.1 NC ON (overall reset chart and setting standard NC MD) ........................ 6-3
6.1.2 NC machine data ................................................................................... 6-4
6.1.3 PLC machine data ................................................................................. 6-5
6.1.4 Alarm processing ................................................................................... 6-6
6.13 Axis installation (simplified flowchart) ...................................................... 6-7
6.1.6 Spindle installation ................................................................................. 6-8

7 PLC Description (130 WB) ................................................................... 74

7.1 General ................................................................................................. 7-1 .

7.1.1 Installation of 130 WB PLC with SINUMERIK 850 .................................... 7-i

. 7.1.2 Installation of 150S/U PLC with SINUMERIK 850 ..................................... 7-1
7.2 PLC DIAGNOSIS .................................................................................... 7-2
7.3 PLC STATUS ......................................................................................... 7-3
7.3.1 Operation of the PLC STATUS ............................................................... 7-3
7.3.2 PLC STATUS selection .......................................................................... 7-4
7.3.3 PLC block overview ................................................................................ 7-5

8 Machine Interface ................................................................................ 8-1

8.1 ..
Actual-value input measuring circuit (6FX1 121.4B module) ................... 8-1
8.1.1 Connector pin assignments ..................................................................... 8-1
8.1.2 Differential input ..................................................................................... 8-2
8.1.3 Equivalent circuit diagram with differential input ....................................... 8-3
8.1.4 Equivalent circuit diagram for actual-value input with integrated EXE ........ 8-4
8.1.5 Complement with integrated EXE ............................................................ 8-5
8.1.6 Input signals with integrated EXE ............................................................ 8-6
8.2 Setpoint output measuring circuit (6FX1 121-48 and
6FX1 126.88 . module) ............................................................................ 8-7
8.2.1 Connector pin assignment ...................................................................... 8-7
8.2.2 Equivalent circuit diagram of the set speed output (for one axis) .............. 8-8
8.3 Serial interface (V.24 (RS 232C)+20 mA) ............................................... 8-8
8.4 ..
Handwheel interface module (6FX1 126-5AA ) ........................................ 8-10
8.4.1 Connector pin assignments ..................................................................... 8-10
8.4.2 Equivalent circuit diagram ....................................................................... 8-10
8.5 Short-circuiting connector for actual-value input ....................................... 8-11
8.6 Measuring pulse inputs (sensors) ............................................................ 8-12

9 NC Machine Data/PLC Machine Data/NC Setting Data ....................... 9-1

9.1 General .................................................................................................. 9-1
9.1.1 Control configuration .............................................................................. 9-1
9.1.2 Notes on configuration ............................................................................ 9-2
9.2 Mode selection ....................................................................................... 9-5
9.2.1 Installation mode “INITIAL CLEAR” ......................................................... 9-6
9.2.2 Normal mode (with MD modification) ....................................................... 9-8
9.2.3 Installation mode .................................................................................... 9-9
9.3 NC machine data ................................................................................... 9-9
9.3.1 General .................................................................................................. 9-9
9.3.2 Position control, input and measuring system resolution ........................... 9-10
9.3.3 Input units .............................................................................................. 9-11
9.3.4 Other machine data ................................................................................ 9-11
9.3.5 NC MD description ................................................................................. 9-11
9.3.5.1 General values ....................................................................................... 9-12
9.3.5.2 Channel-specific values .......................................................................... 9-59
9.3.5.3 Axis-specific values/spindle-specific values .............................................. 9-64
9.3.5.4 Machine data bits ................................................................................... 9-110
9.4 PLC machine data .................................................................................. 9-177
9.4.1 General .................................................................................................. 9-177
9.4.2 PLC machine data bits for basic program ................................................ 9-178
9.4.3 PLC machine data words for user program .............................................. 9-194
9.4.4 PLC machine data bits for user program ................................................. 9-194
9.5 Cycle machine data (Cycle MD) .............................................................. 9-195
9.6 NC setting data (SD) .............................................................................. 9-197
9.6.1 General .................................................................................................. 9-197
9.6.2 Zero offsets (ZO) ................................................................................... 9-198
9.6.3 R parameters ......................................................................................... 9-199
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9.6.4 Spindle setting data ............................................................................... 9-200
9.6.5 General NC setting data ......................................................................... 9-201
9.6.6 Channel-specific NC setting data ............................................................ 9-201
9.6.7 Axial NC setting data .............................................................................. 9-201
9.6.8 General NC setting data bits ................................................................... 9-202
9.6.9 NC setting data bits for serial interfaces .................................................. 9-203
9.6.10 Axial NC setting data bits ....................................................................... 9-206
9.7 Cycle setting data (Cycle SD) ................................................................. 9-207

10 Machine Operation/Service Data ......................................................... 10-1

10.1 Jog mode .............................................................................................. 10-1
10.2 Programmed operation ........................................................................... 10-2
10.3 Functional test with NC test tape ............................................................ 10-2
10.4 Axis and spindle service data ................................................................. 10-3
10.4.1 Axis service data .................................................................................... 10-3
10.4.2 Spindle service data ............................................................................... 10-4

11 Description of Operation ..................................................................... 11-1

11.1 Axis movements (available soon) ............................................................ 11-1
11.2 Spindle control ....................................................................................... 11-1
11.2.1 Corresponding data ................................................................................ 11-1
11.2.2 S analog (M3. M4. M5) .......................................................................... 11-1
11.2.3 M19 (oriented spindle stop) .................................................................... 11-2
11.2.4 Spindle influencing by PLC ..................................................................... 11-10
11.3 Approach to reference point ................................................................... 11-12
11.3.1 Corresponding MD ................................................................................. 11-12
11.3.2 Automatic identification of direction with approach to
reference point ...................................................................................... 11-12
11.3.3 Approach to reference point without automatic identification
of direction ............................................................................................ 11-12
11.3.3.1 Approach to reference point with automatic identification
of direction ............................................................................................ 11-15
11.4 Leadscrew error compensation (SSFK) ................................................... 11-16
11.4.1 Corresponding data ................................................................................ 11-16
11.4.2 Functional description ............................................................................ 11-17
11.5 Rotary axis functions .............................................................................. 11-25
11.5.1 Corresponding data ................................................................................ 11-25
11.5.2 Functional description ............................................................................ 11-25
11.6 Warm restart .......................................................................................... 11-27
1.6.1 Corresponding data ................................................................................ 11-27
1.6.2 Functional description ............................................................................ 11-27
1.7 Axis-specific resolutions (from Software Version 03) ................................ 11-31
1.7.1 Corresponding data ................................................................................ 11-31
1.7.2 General remarks on the axis-specific resolutions ..................................... 11-31
1.7.3 Input, display and position control resolution ........................................... 11-32
1.7.4 Block diagram of the resolutions ............................................................. 11-33
1.7.5 Resolution codes ................................................................................... 11-34
1.7.6 Permissable combinations ...................................................................... 11-35
1.7.7 The influence of resolution on speed ...................................................... 11-37
11.7.8 Maximum speed for thread cutting .......................................................... 11-39
11.7.9 Maximum traverse range ........................................................................ 11-40
11.7.10 Influence on the display .......................................................................... 11-43 .
11.7.11 Influence on the modesifunction ............................................................. 11-43
0 11.8 Coordinate transformation .......................................................................
Corresponding data ................................................................................
11-45
11-45
11.8.1
0 11.8.2
11.8.3
Function description of coordinate transformation ....................................
The trarisformation data set ....................................................................
11-45
11-47
11.8.4 Transformation parameters ..................................................................... 11-49
11.8.5 Machine data for fictitious axes ............................................................... 11-51
11.8.6 NC PLC interface signals ........................................................................ 11-52
.
i1 8.7 Explanation of the programming and operation of
coordinate transformation ....................................................................... 11-53
11.8.8 Examples of coordinate transformation .................................................... 11-55
11.8.8.1 Example of the coordinate transformation TRANSMIT .............................. 11-55
11A8.2 Example of 2D coordinate transformation ................................................ 11-56
11.8.8.3 Example of 3D coordinate transformation ................................................ 11-57

12 Alarms .................................................................................................. 12-1

12.1 List of alarms ......................................................................................... 12-1
12.2 Alarm numbers and groups/clearing of alarms ......................................... 12-1
12.3 Priority of the alarms .............................................................................. 12-3
12.4 Alarm display ......................................................................................... 12-3
12.5 Alarm description ................................................................................... 12-6
12.5.1 -
Alarm list POWER ON (1 15) ................................................................ 12-6
12.5.2 Alarm list V.24 (RS 232 C) ..................................................................... 12-9
12.5.3 Alarm list POWER ON (40 .81) .............................................................. 12-13
12.5.4 Alarm list RESET ................................................................................... 12-18
12.5.5 Alarm list RESET/general ........................................................................ 12-25
12.5.6 Alarm list RESETlspindle-specific............................................................ 12-36
12.5.7 Alarm list ERASE ................................................................................... 12-37
12.5.8 Alarm list RESET/axis-specific ................................................................ 12-51

13 Notes of Fault Procedure ..................................................................... 13-1

13.1 General .................................................................................................. 13-1
13.2 Faults in operator panel area ................................................................... 13-2
13.3 Table of faults ........................................................................................ 13-3
13.4 Module exchange ................................................................................... 13-5

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