Hello ,

I am doing my Engineering Thesis with the use of Sinumerik 808D ADVANCED. For that my thesis supervisor bought a chinese lathe, Sinumerik 808D ADVANCED, 2x Simotics S-1FL6 (PMSM motors, one with a brake and one without a brake), 2x Sinamics V70 with filters. The motor with a brake works as my axis X and the one without a brake works as my Z axis (I am adding the list of components).

It has been a while since I started struggling with some problems:

1) When it comes to connecting axes and making them work in jog mode I had no problem. Then problem occured when I wanted to make an automatic tuning of axes during commissioning. To do that I need my axes to be referenced. I tried to do the referencing but I am able to reference only one of the axes - Z. Referencing cams work fine as I checked their status on Sinumerik. Z axis references itself without any problems but when I want to reference X axis there is a problem. I press the key to reference the axis, the referencing cams works and the motor stops and starts turning the other direction but after 2 full rotations (20mm) it stops and there is an alert: "Axis MX1 zero mark not found". I have been trying to find a solution for that but the only thing I found was "increase the machine data 34060 REFP_MAX_MARKER_DIST, but do not select a value greater than the distance between the 2 zero markers" (http://www.helmancnc.com/sinumerik-alarm-20002-channel-1-axis-2-zero-mark-found/).
As far as I am concerned 20mm is already the maximus value according to that and even if I make it greater it doesn't work. I do not really know what may cause this problem. The encoder reads the position of the axis but it can not find its zero mark.

2) There is a specific output in Sinumerik for spindle - X54 (I personally use the unipolar1 connection. I do not use an encoder for the spindle). There are 3 cables for spindle - AO, AGND and shielding. In Sinumerik I already chose that I am using "unipolar 1" and there is written that AO gives 10V analog voltage and AGND gives 0V signal. I measured that after switching on the spindle and it shows 0V so it seems like the spindle output does not work (?). What type of 0V signal that may be? What may be the problem here?

3) The chinese lathe had a potentiometer to adjust spindle rotation speed. The lathe has 3 pins for that - P1, P2 and P3. I wanted to connect it somehow to the spindle output which I mentioned earlier (X54). I found an electrical diagram of lathe's module which is responsible for spindle. I measured voltage between all pairs of pins and came to the conlcusion that P2 should be connected to AGND and P1 should be connected to AO. Maybe I did not do it correctly. The spindle turns itself when I unplug those lathe's pins from Sinumerik. When I connect those pins to Sinumerik it becomes impossible to turn the whole machine on as there are some problems with electrical safety. Maybe there is some kind of short cut causing the problem (?). Maybe I did not connect it properly. I am adding a piece of that diagram below. Also the lathe had a switch to choose the turning direction of spindle so the potentiometer was only used to increase and decrease speed.

I would be really thankful for solving at least one of those problems. I am slowly approaching my deadline and it means a lot to me . Thank you so much in advance even for reading that.

Hello.

So to be able to help you correctly and save time on analyze.

Could you please share the PLC program and if you have an electrical diagram of the actual wiring it would help me as well.

Riddersholm

Hello.

So to be able to help you correctly and save time on analyze.

Could you please share the PLC program and if you have an electrical diagram of the actual wiring it would help me as well.

 Hello.

Thank you very much for your interest.

I have a default turning PLC program from Sinumerik but I cannot add the attachment here because of the wrong extension of the file. Can I send it to you in other way?

I have the electrical diagram but it is not complete and it is in pieces. I have parts of diagram with connection of:
- digital inputs on Sinumerik (X100 and X101),
- motor module from spindle (added earlier),
- fast input/output (X21 - spindle control),
I know that motor cables should be connected properly to the drives, drives are connected with each other with Drive BUS and they are connected to Sinumerik (I am adding attachment - screens from instruction (it is not the same drive but I was not able to find a better one)).
Connection of setpoint cable of spindle (X54) I metioned and added earlier.

Do you want me to finish the whole diagram, join together and share it?

Hello Jake.

OK - So you used the default turning PLC program.

How is the configuration parameters set for the PLC?

I am thinking about MD14510 and MD14512 parameters.

Also a simple IO list will help me alot, since I can then compare it.

You can Zip the PLC program and maybe a .arc backup of the controller, then you should be able to upload it

Riddersholm

Hello Jake.

OK - So you used the default turning PLC program.

How is the configuration parameters set for the PLC?

I am thinking about MD14510 and MD14512 parameters.

Also a simple IO list will help me alot, since I can then compare it.

You can Zip the PLC program and maybe a .arc backup of the controller, then you should be able to upload it

During the commissioning I can set PLC parameters:
- 14510[0] - 14510[31] and I have them all set for 0 (USER_DATA_INT),
- 14512[0] - 14512[31] and I have them all set for 0H (USER_DATA_HEX),
- 14514[0] - 14514[7] and I have them all set for 0 (USER_DATA FLOAT).
Should I change them somehow?

I will add a screenshot of I/O connected to Sinumerik and the PLC program. Please let me know if that is enough and thank you for your interest.

Hello.

According to you drawing all your feedback for reference and limit switches are NO?

Is this correct?

I do not know if you have the manuals.

But here you can download the following.

SINUMERIK 808D ADVANCED Commissioning Manual

In the Function manual I would like to pay your attenction to 17 - Reference point approach (R1)

SINUMERIK 808D ADVANCED Function Manual

Regarding the motor controller.

It will be an issue that the motor controller expects 102-108V for the speed control.

You might have to do that differently 

Riddersholm

Hello.

According to you drawing all your feedback for reference and limit switches are NO?

Is this correct?

I do not know if you have the manuals.

But here you can download the following.

SINUMERIK 808D ADVANCED Commissioning Manual

In the Function manual I would like to pay your attenction to 17 - Reference point approach (R1)

SINUMERIK 808D ADVANCED Function Manual

 Hello.

I am very sorry. I drew limit switches as NO but in fact they are NC and I have them like that. Reference switches are NO.

Thank you for the second manual. I did not have that one. I will read it and hopefuly on Friday I will be able figure something out. Have a great day !

Riddersholm

Hello.

According to you drawing all your feedback for reference and limit switches are NO?

Is this correct?

I do not know if you have the manuals.

But here you can download the following.

SINUMERIK 808D ADVANCED Commissioning Manual

In the Function manual I would like to pay your attenction to 17 - Reference point approach (R1)

SINUMERIK 808D ADVANCED Function Manual

What bothers me the most is the fact that I was able to reference the Z-axis but I am not able to reference the X-axis. I checked if all parameters of axes are the same and they are actually.