Hello, I'm having some issues getting an EMCO 320 with a Sinumerik 810T control up and running.  This machine at some point lost it's parameters due to a dead battery, but I've mostly been able to re-comission it using files made from the original paper tapes.  But I'm still having some issues.  I'm getting alarms on the tool turret, but I think they're related to the comissioning data in the files.  I'm also unable to get the spindle to turn, but it might be because of the turret error.  

Is there anywhere that I can get a description of what the different memory locations in %TEA1, %TEA2 and %PCP mean?  I think my problem is that my %PCP file is not loading everything in it becuase there's a m02 stop part of the way through the file and the second part is not going into the control.  how do I get around this?  I'm using PCIN from a windows 2000 machine, and it's definitely transferring data, I just don't know how to check if it's all actually getting in.

#1-- make back up of you %PCP FILE.

then open and edit it using a editor( PCIN has edit or you can use "word pad' as well).

you can delete M02 in the 1st part. and try. be careful don't change any other contents even space.

#2--another safety way is to set your m/c "SETTING DATA" #5016=00101000, I only remember the digit

and I have no Siemens manual on hand, in "5016" there is one bit can help you transfer NC program continuously--that mean transfer will not stop by M02 or M30, as when back up %MPF, NORMALLY IT WILL SAVE all NC programmes--such as

%MPF1

N5 G01 X.01

...

M02

%MPF 2

N5 G00 X-10

M02

================

Maybe this function will help you to transfer PCP file as well. 

you are lucky can get "PCIN" sw, and running , I THINK you use Baud rate 1200 or lower.

try to do as I suggest , and post result , I may help you more.

PS: I have here 2 customers using similar m/c with 810T GA1 , they all lost parameters

PS: %PCP--is PLC program in ASCII CODE. and you can try to find from PC side --PCIN window data transfer --page by page. and also from 810T screen you will see %PCP showing up and keep there until all data finish and delay for couple of second then disappear. 

wompser

Hello, I'm having some issues getting an EMCO 320 with a SINUMERIK 810T control up and running.  This machine at some point lost it's parameters due to a dead battery, but I've mostly been able to re-comission it using files made from the original paper tapes.  But I'm still having some issues.  I'm getting alarms on the tool turret, but I think they're related to the comissioning data in the files.  I'm also unable to get the spindle to turn, but it might be because of the turret error.  

Is there anywhere that I can get a description of what the different memory locations in %TEA1, %TEA2 and %PCP mean?  I think my problem is that my %PCP file is not loading everything in it becuase there's a m02 stop part of the way through the file and the second part is not going into the control.  how do I get around this?  I'm using PCIN from a windows 2000 machine, and it's definitely transferring data, I just don't know how to check if it's all actually getting in.

First of all, thank you very much for your reply nulizhang.  I have just tried what you suggested, but I'm still a little stuck.  I have attached my PCP file as a reference.

I am pretty sure I have all the memory registers correct.
5010=00000000
5011=11000100 <1200 baud, which is the only speed that works for me>
5016=00101000

However, I've tried with the PCP file several times, and the ONLY way it reads to the end is if I delete the M02 and the second % P C P .  If the second "% P C P " is in there, the control obviously stops recieving data as soon as it hits the second "%" sign.  If I entirely delete the second "% P C P" it appears that the data all loads into the machine, but I am not certain it really is... I notice no difference in the controls after I restart the machine, the tool turret error is still there, and I can't operate the spindle.  

So, I guess my question is:  What's really in that second section of the PCP file anyway?  is it critical data for the machine?  Is it perhaps parameters for the toolpost or spindle?  As you can see in my file the PCP data is encoded somehow, and I can't really tell what any of it means.  the TEA1 and TEA2 files are somewhat more readable, someone has put some notes in my paper copies of TEA1 and TEA2 about what some of the values represent.  

Again, thank you for your reply.  I'm stuck and it's easy to get frustrated with this process!

 Hi, I am not sure , you may already try as you said  "and the ONLY way it reads to the end is if I delete the M02 and the second % P C P " . so make sure try this delete M02 and 2nd %PCP. then transfer %PCP file again to see if you wear lucky. PCP is PLC program stored in code format. as I remember in 810T GA1,

Siemens had 2 versions--#1--using PB1 and PB2, #2--using FB1 and FB2, ( not like later version GA2 and GA3, there are OB1, OB2 and more PBxx, and FBxx). here PB1 or FB1 is like later OB1--cycle program.

and PB2 or FB2 is like OB2--they are interrupted program. they all important for control system if m/c build designed  using them.

OK up to now, I may remind you another thing --that is sequence. You may already did like this.

you must transfer %TEA1, THEN %TEA2--THEN POWER UP RESET one time, then going to set up mode again to transfer %PCP. as %PCP need %tea2 parameters to active--PLC MD. if trying correct sequence ,

still not working . My suggestion is, try to conduct m/c builder EMCO . or you can search by Google or direct going to "CNC Zone.com" register and ask help there,

I said I have 2 customers have had same issue as you have. they all got help from CNC zone  

one of them getting good back up data (tea1,tea2,pcp...) from member there for free. as I can only help them to transfer DATA, I have no idea  which data is good or bad.

another thing I want remind you--tool turret error may caused by sensor defective and spindle not running may caused by front door limit switch issue(some time there is alarm 700xxx). spindle drive issue.

I think you know how to try spindle--manually running or in MDI--S100 M03. and do you mean your X and Z moving OK and REF OK?

PS: check you m/c configuration, X/Z/SP drive and motor type, tool  turret  type.

and I will looking for in my Laptop, to see if there still data from one customer, and may send to you .

Again, thank you for your reply.

I did load the programs in the correct order and cycle power between TEA1, TEA2 and the PCP, but I might try that again, just to make sure.  I am working on troubleshooting the turret error on a different thread on practical machinist and CNC-zone.  my leading theory at this point is not that the sensor is bad, but that it is out of sync in the control with the physical encoder.  Working on how to troubleshoot this one, it appears that you watch the diagnostic bit on the control while rotating the encoder by hand... except that I'm not sure how to locate the diagnostic bit on the Sinumerik. 

I will try running the spindle in MDI as you suggest... but think the tool turret error may be what's preventing any spindle movement.   (I don't have a 700XXX alarm, just a 6024 and low pressure central lubrication)  I can jog the axis to reference by holding down AUX ON and the direction at the same time. 

What do you mean by checking my m/c configuration, X/Z/SP drive and motor type, tool  turret  type?  what would I check it against?   I'm not in front of the machine, but they are Baumuller brand I believe, and Sauter brand turret. 

Thank you for you helpful direction, I'll try a few different things based on your suggestions. 

Success!  

So… I think I have solved this problem.  But first of all, let me say I couldn’t have done it with out the input from people on this board, and other sources.  For the benefit of anyone else who comes across this thread or problem in the future, I'll outline the solution. 

The part that through me astray is that there is an error in the "810 / 820 Service Course How to reload your NC?" document that is put out by Siemens!  If you follow the steps exactly, it has you clear your NC and PLC, load %TEA1 and %TEA2 and then restart.  But the next step is where it throws you off:  after rebooting the manual has you RE-CLEAR you PLC and NC and then load the %PCP file… but if you do this it does not work… at least on my machine.

The proper procedure on my machine is to start up into INITIAL CLEAR mode and first clear everything out (PLC initial, NC data, etc.) but don't load default values.  After this, you need to restart the control.  Once restarted you need to get back into INITIAL CLEAR MODE and load %TEA1 and %TEA2.  Once those are reloaded, you need to again restart into INITIAL CLEAR mode, and only then can you load the %PCP file completely.  The machine must have TEA1 and TEA2 in order to fully load the %PCP file.  My control was not fully loading the second section of the PCP file, and apparently this is where all the data for the tool turret indexing resides!  After loading the PCP file, you can format the alarm memory and load the PCA file (alarm file) and any other files you have. 

Phew!!!  Once I finally figured that out, my tool turret indexes no problem, and I'm able to jog the axis without holding down the AUX ON button.  Even better, I went into the overstore section and manually put in some spindle values (S) and spindle rotation direction (M 03) and the spindle is now working!!!  Additionally, I'm not getting the low pressure central lubrication error with the pressure switch bypassed, I need to hook it back up, but perhaps I've solved that error too. 

So I still don’t have everything figured out yet because I can't get the collet closer to manually open or close, and the parts drawer doesn’t operate from the button either, but dang I am getting closer and closer to cutting parts. 

Again, thank to everyone who has been helping me through this, especially "nulizhang" who helped me put 2 and 2 together mentally!

very happy to know you made it.one of my customer has same tool system as yours.

--Sauter brand turret.  and also they need "holding AUX power on to run X, and Z before I correct loaded PCP for them.

however I see you quit familiar with 810T, most "teams words"  exactly like in Siemens books. You know I am former Siemens employee, working with SINUMERIK for > 20 years, I deal with 810T/M from 1989.and 820M/T, 850, 880, and now 840D,840C.and so on.

finally you found issue is loading sequence and operating steps. I hope this "Lesson" will also help other people who using SINUMERIK 810T/M, ALL SINUMERIK 800 system have a important MODE--INI.CLEAR 

WE NEED TO KNOW what we can do, and what should be done in this mode.

take care

PS: my mistake 700XXX alarm should be in 840D , you have 6024, my customer had 70xx and 60xx.but no text, like you said need loading PCA after format AL TX memory. 

PS: again--I just guess why the 2nd part of PCP cannot transfer in. when you clear  PLC and loading default PLC MD , it is not setting for , I mentioned PB2 or FB2, only for PB1 or FB1, but after you transfer back up PLC MD (TEA2) there are setting for PB2(FB2) , so you can transfer them in! just thinking a little deeper-:)

nulizhang

very happy to know you made it.one of my customer has same tool system as yours.

--Sauter brand turret.  and also they need "holding AUX power on to run X, and Z before I correct loaded PCP for them.

however I see you quit familiar with 810T, most "teams words"  exactly like in Siemens books. You know I am former Siemens employee, working with SINUMERIK for > 20 years, I deal with 810T/M from 1989.and 820M/T, 850, 880, and now 840D,840C.and so on.

finally you found issue is loading sequence and operating steps. I hope this "Lesson" will also help other people who using SINUMERIK 810T/M, ALL SINUMERIK 800 system have a important MODE--INI.CLEAR 

WE NEED TO KNOW what we can do, and what should be done in this mode.

take care

PS: my mistake 700XXX alarm should be in 840D , you have 6024, my customer had 70xx and 60xx.but no text, like you said need loading PCA after format AL TX memory. 

PS: again--I just guess why the 2nd part of PCP cannot transfer in. when you clear  PLC and loading default PLC MD , it is not setting for , I mentioned PB2 or FB2, only for PB1 or FB1, but after you transfer back up PLC MD (TEA2) there are setting for PB2(FB2) , so you can transfer them in! just thinking a little deeper-:)

     

Looks like this old thread is still active.  

it's actually good timing for me:  My machine was off for about 6 months as I was moving from one shop to the next... and wouldn't you know it:  my backup battery died!  So I need to reload all of my PLC data again.  Luckily, I learned so much from this thread the FIRST time I did the re-commissioning, hopefully the second time should go much faster.  

I see you uploaded %TEA1 %PCP and %TEA2 to this thread.  Are they machine-specific, or generic enough that anyone with a emco 320 can use these files?  I assumed that the parameters were specific to the machine they were installed on, but perhaps they are more universal?  

--wompser