Gsk983t-h Version Tv3.0ab-8 PLC User Manual

GSK983T-H Turning CNC System
PLC Manual
Version TV3.0AB-8 (Special for China Jinan 1 machine tool factory)
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TV3.0AB-8 Version PLC User Manual of GSK983T-H Turning CNC System
CONTENTS
1 GSK983T-H MACHINE OPERATION PANEL AND RELEVANT ADDRESSES DIAGNOSIS ................................ 1 2 I/O INTERFACE SETTING OF TV3.0AB-8 VERSION PLC ........................................................................... 3 3 PC PARAMETERS OF TV3.0AB-8 VERSION PLC ...................................................................................... 8 4 M CODES SIGNIFICANCE OF TV3.0AB-8 VERSION PLC ......................................................................... 12 5 TOOLPOST FUNCTION ............................................................................................................................... 13 6 OPERATION PANEL X AXIS DIRECTION KEY ADJUSTMENT (FRONT TOOLPOST AND REAR TOOLPOST).... 14 7 ZERO RETURN OF THE MACHINE FEEDING AXIS ....................................................................................... 15 8 SPINDLE FUNCTION .................................................................................................................................. 15 9 SPINDLE ALARM ........................................................................................................................................ 16 10 EXTERNAL MPG ..................................................................................................................................... 16 11 SPINDLE AUTOMATIC CHUCK FUNCTION ................................................................................................. 17 12 TAILSTOCK FUNCTION............................................................................................................................. 17 13 CENTER FUNCTION ................................................................................................................................. 18 14 CENTER DRILL DEVICE CONTROL FUNCTION ......................................................................................... 19 15 AXES RAPID MOVE ADJUSTMENT (G0 SPEED ADJUSTMENT) ................................................................ 19 16 LUBRICATION FUNCTION ......................................................................................................................... 20 17 COOLING FUNCTION ............................................................................................................................... 20 18 OVERTRAVEL RELEASE .......................................................................................................................... 20 19 CHIP REMOVAL FUNCTION ...................................................................................................................... 20 20 SPINDLE FEED AXIS INTERLOCK SWITCH ON PANEL .............................................................................. 20 21 SAFETY DOOR FUNCTION ....................................................................................................................... 21 22 FEEDER FUNCTION ................................................................................................................................. 21 23 TAILSTOCK RELEASE/CLAMP .................................................................................................................. 21 24 CENTER JIG RELEASE/CLAMP ................................................................................................................ 22 25 PLC VERSION DISPLAY ........................................................................................................................... 22 26 TV3.0AB-8 PLC ALARM LIST OF GSK983T-H CNC SYSTEM ............................................................. 22 PLC VERSION UPGRADE FORM ..................................................................................................................... 25
GSK983T-H machine operation panel and relevant addresses diagnosis
AUTO 36.0 7.0 7.5 7.1 7.2 7.3 7.4 36.5 36.1 36.2 36.3 36.4 ZERO
EDIT MDI
MANUAL MPG
MACHINE
POS RECORD 36.6 7.6
USER 1 36.7 7.7
USER 3
USER 7
CENTER
44.0
50.0
FW/BK
13.0
13.1
50.1
13.2
X 37.1 8.1 8.3 F50 X10 40.3 9.3 F100 X100 41.3 10.3 37.3 8.4 X1 37.4
F0 SINGLE
SKIP 37.5 8.5
DRY 37.6 8.6
USER 2 37.7 8.7
USER 4
USER 8
SAFETY DOOR
44.1
50.5
50.6
12.5
12.1
12.2
Z 40.0 9.0 9.1 9.2 40.1 40.2
RAPID Z
OPTIONAL STOP 40.4 9.4
MACHINE LOCK 40.5 9.4
M.S.T. LOCK 40.6 9.6
PROG RESTART 40.7 9.7
USER 5
USER 9
CHIP
44.2
44.3
REMOVAL
12.5
12.6
44.4
12.7
X 41.1 10.1
CCW 41.4 10.4
STOP 41.5 10.5
CW 41.6 10.6
ORIENTATION 41.7 10.7
USER 6
USER 10
COOLING
45.0
45.1
45.2
11.0
11.1
11.2
OVERTRAVEL
TAILSTOCK
RELEASE/
CHUCK
CLAMP
FW/BK
LIGHT FEED HOLD CYCLE
44.5
12.3
50.7
50.2
11.3 11.5
11.7
45.3
13.3
LUBRICATING
ZERO X
45.4 START
44.6
12.4
51.0
13.4
50.3
11.6
11.4 45.5
CHANGE
ZERO Z
TOOL
Addresses of wave band switch PLC address 52.0 52.1 52.2 52.3 52.4 52.5 52.6 52.7 Signal name OV1 OV2 OV4 OV8 OV16 SPA SPB SPC DP5 wave band switch pin-out number Afeedrate override switch Ffeedrate override switch Bfeedrate override switch Efeedrate override switch Cfeedrate override switch Aspindle override switch Fspindle override switch Bspindle override switch I/0 I I I I I I I I
LED
Lock addresses PLC address 53.6 Signal name FM Signal function Safety door I/O I
Switch addresses PLC address 53.0 53.1 53.4 53.5 Signal name ST1 SP1 SPFL1 SPFL2 Signal function External cycle start External feed hold Spindle feed hold (3-position switch) Spindle feed axis hold (3-position switch)
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13.6
51.1
13.5
50.4
I/O I I I I
External MPG I/O interface PLC address 54.0 54.2 54.5 54.6 54.7 Signal name HX HZ 1 10 100 Signal function (Hand box ) X axis (Hand box ) Z axis Hand box override X 1 Hand box override X 10 Hand box override X 100 I/O I I I I I
I/O interface setting of TV3.0AB-8 version PLC

PLC address X32.0 X32.1 X32.2 X32.3 X32.4 X32.5 X32.6 X32.7 X32.COM X33.0 X33.1 X33.2 X33.3 X33.4 X33.5 X33.6 X33.7 X33.COM X34.0 X34.1 X34.2 X34.3 X34.4 X34.5 X34.6 X34.7 X34.COM X38.0 X38.1 LUB.L UINT.I COM FEED.AL FEND.AL Lubricant level alarm input Program input interruption X34 common terminal Feeder abnormal alarm Feeder no feeding alarm
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Signal name +LX -LX DZ.ST HYP.ALM AIRP.ALM *DECX TL.ST CK.ST COM *+LZ *-LZ FUM GR1.M GR2.M *DECZ SPFAN.A T.OVAL COM
Signal function +X limit (unused, short-circuit to 0V) -X limit (unused, short-circuit to 0V) Center FW/BK switch Hydraulic pressure detect Air pressure detect X zero return deceleration switch Tailstock FW/BK switch (pedal) Chuck release/clamp switch (pedal) X32 common terminal +Z limit (short-circuit to 0V if unused) (fixed) - Z limit ( short-circuit to 0V if unused) (fixed) Shield door detect Spindle gear detect 1 Spindle gear detect 2 Z zero return deceleration switch Spindle fan alarm Toolpost motor overload X33 common terminal (fixed) (fixed)
I /O I I I I I I I I I I I I I I I I
SHIP.ALM HY.OV COOL.OV
Chip conveyor overload input Hydraulic motor overload input Pump motor overload input
I I I I I I I
X38.2 X38.3 X38.4 X38.5 X38.6 X38.7 X38.COM 0V 0V +24V +24V
F.FIN ST2 ESP IT.X TL+ TLCOM 0V 0V +24V +24V
Feeder feeding finish signal External cycle start Emergency stop (fixed) Tailstock release Collector hold out Collector retract X38 common terminal Output 0V terminal Output 0V terminal Output +24V terminal Output +24V terminal
I I I I I I O O O O
PLC address X48.0 X48.1 X48.2 X48.3 X48.4 X48.5 X48.6 X48.7 X48.COM X43.0 X43.1 X43.2 X43.3 X43.4 X43.5 X43.6 X43.7 X43.COM X35.0 X35.1 X35.2 X35.3 X35.4 X35.5 X35.6 X35.7 X35.COM
Signal name T1/SEN.B T2/SEN.C T3/SEN.D T4/SEN. T5/SEN.A T6/SEN.E T7/SEN.F T8 COM TCP
Signal function T1/Toolpost encoder signal T2/Toolpost encoder signal T3/Toolpost encoder signal T4/Toolpost encoder signal (for tool No.10 or 12) T5/Tools parity check T6/Tool disk stop and clamping enable signal T7/Tool disk clamping signal T8 X48 common terminal Toolpost clamping signal
I/O I I I I I I I
COM WZ.F WZ.B CK.UCL CK.CL ZX.F ZX.B
X43 common terminal Tailstock forward in-position Tailstock backward in-position Chuck release in-position Chuck clamp in-position Center drill forward in-position Center drill backward in-position I I I I I I
COM
X35 common terminal

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X40.0 X40.1 X40.2 X40.3 X40.4 X40.5 X40.6 X40.7 X40.COM 0V 0V +24V +24V *SRDY ZSP SAR COM 0V 0V +24V +24V Spindle ready Spindle zero speed detect Spindle speed in-position detect X40 common terminal Output 0V terminal Output 0V terminal Output +24V terminal Output +24V terminal O O O O I I I SOR.I Spindle orientation over I
PLC address Y0.0 Y0.1 Y0.2 Y0.3 Y0.4 Y0.5 Y0.6 Y0.7 Y1.0 Y1.1 Y1.2 Y1.3 Y1.4 Y1.5 Y1.6 Y1.7 Y2.0 Y2.1 Y2.2 Y2.3 0V +24V
Signal name LAMP.O TCW.O TCCW.O M03.O M04.O OR.TL LUB.M CL.M CK+.O CK-.O TL+.O TL-.O M33.O M32.O GR1.O GR2.O GR3.O GR4.O GRE.L YEW.L 0V +24V
Signal function Machine working light Toolpost CW Toolpost CCW Spindle CW Spindle CCW Overtravel release Lubricating pump start Coolant pump start Chuck clamped Chuck release Tailstock forward Tailstock backward Center hole device forward Center hole device retract Spindle gear 1 output Spindle gear 2 output Spindle gear 3 output Spindle gear 4 output Green alarm indicator Yellow alarm indicator Output 0V terminal Output +24V terminal
I/O O O O O O O O O O O O O O O O O O O O O O O
PLC address Y3.0
Signal name T.UNCL
Signal function Tool disk release

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I/O O
Y3.1 Y3.2 Y3.3 Y3.4 Y3.5 Y3.6 Y3.7 Y6.0 Y6.1 Y6.2 Y6.3 Y6.4 Y6.5 Y6.6 Y6.7 Y2.4 Y2.5 Y2.6 Y2.7 0V +24V
T.CL PS.CW PS.CCW DZ+.O DZ-.O WZT.O ZXZ.O CKUCL.O SLSL+
Tool disk clamped Chip conveyor CW Chip conveyor CCW Center forward Center backward Tailstock release Center jig release Feeding change enable signal Collector hold out Collector retract
O O O O O O O O O O
RED.L SPZD.O ERST M19.O 0V +24V
Red alarm indicator Spindle brake External alarm reset Spindle orientation Output 0V terminal Output +24V terminal
O O O O O O
Input signal level description: The input signal level selection of the new I/O unit (X1) matching with GSK983T-H/V model is more flexible than the previous one, it can choose the high level validity according to external signals or the low level input validity according to the external signal requirement on this unit. Method: a new common input terminal COM is added to the start point of each group input signal in this new I/O unit. As the COM terminal is connected with the switch power +24V, the 8 input interfaces are active for 0V; as the COM terminal is connected with the switch power 0V, the 8 input interfaces are active for +24V. When the input is active, the relevant PLC diagnosis address interface is 1.
Wiring for low level input active Machine side

Switch power box
983 system I/O unit (X1) side
Machine detection switches
Machine detection switches
All the output signals in this system are low level(0V), which cant be selected and changed. If the input is active, the relevant PLC output address interface is 1.
PC parameters of TV3.0AB-8 version PLC

3001 7 ABS Factory setting Bit7 0: 1: Bit6 0: 1: Bit5 0: 1: Bit4 0: ABS: 0 6 CKCH.I 0 5 SPS/M 0 4 SP.SH 0 3 CK.SH 1 2 ZSP.C 1 1 SAR.C 1 0 TCSEL 0
MANUAL ABSOLUTE switch shield
MANUAL ABSOLUTE shielded, its menu switch inactive MANUAL ABSOLUTE active and its menu switch active CKCH.I: inactive active SPS/M: S, M function selection for spindle gears: Chuck clamping detect:
M function S function SP.SH: Spindle alarm input signal *SRDY check in CNC running
Check *SRDY signal; the alarm input interface is disconnected to 0V, CNC cant run automatically. Not detect *SRDY signal. CK.SH: Chuck release/clamp detect for spindle
1: Bit3 0: 1: Bit2
Not detect. Detect. ZSP.C: Spindle zero input signal detect as releasing chuck
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0: 1: Bit1 0: 1: Bit0
Not detect. Detect. In Auto mode, only ZSP signal arrives, can the chuck release signal be output. SAR.C: Spindle speed in-position input signal detect by S code.
Not detect. It is over as S code is output. Detect. S code is not over till SAR signal arrives. Electrical and gang toolpost selection
TCSEL: 0: 1:
Electrical toolpost Gang toolpost
3002
7
X.DIRE
6
SP.CH
5 AIR.CH 0
4 STSP.SH 0
3 WK.EN 0
2 ZZAU+ 0
1 XZAU+ 0
0 MPG.EN 0
Factory setting Bit7
X.DIRE: panel X axis direction select (front, rear toolpost select) 0: 1: Not reversing (front toolpost) Reversing (rear toolpost) Polarity select of spindle analog voltage output
Bit6
SP.CH: 0: 1:
M3 and M4 are both positive (0~10V). M3 is positive and M4 is negative (-10~10V). Pneumatic/hydraulic chuck select
Bit5
AIR.CH: 0: 1:
Hydraulic Pneumatic
Bit4 STSP.SH: Extended feed hold and cycle start on operation panel 0: 1: Bit3 Active inactive Chuck internal and external clamping select
WK.EN: 0: 1:
External Internal Automatic zero return direction of Z axis
Bit2
ZZAU+: 0: 1:
Positive Negative Automatic zero return direction of X axis
Bit1
XZAU+: 0: 1:
Positive Negative MPG selection

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Bit0
MPG.EN:
0: 1:
Panel External hand box
3003
7 WZ
6 TENCO.AL 0
5 LUB.ALM 0
4 COOL.ALM 0
3 HY.ALM 0
2 PS.ALM 0
1 AIRP.ALM 0
0 HYP.ALM 0
Factory setting Bit7 0: 1: Bit6 0: 1: Bit5 0: 1: Bit4 0: 1: Bit3 0: 1:
WZ: Tailstock action restriction Active Inactive TENCO.AL: Active Inactive LUB.ALM: Normally-close/ normally-open select of lubricant level alarm Disconnection alarm of toolpost encoder
Normally-open Normally-close COOL.ALM: Normally-close/ normally-open select of pump motor overload alarm
Normally-open Normally-close HY.ALM: Normally-close/ normally-open select of hydraulic motor overload alarm
Normally-open Normally-close Normally-close/ normally-open select of chip conveyor overload alarm
Bit2 PS.ALM: 0: 1: Bit1 0: 1: Bit0 0: 1:
Normally-open Normally-close AIRP.ALM: Normally-close/ normally-open select of air pressure detect
Normally-open Normally-close HYP.ALM: Normally-close/ normally-open select of hydraulic pressure detect
Normally-open Normally-close
3004
7 T.SELE
6 CZ 0
5 M.J/A 0
4 ZXSH.I 0
10
3 WZSH.I 0
2 TUNCL.SH 0
1 SPFAN.CH 0
0 TOV.CH 0
Factory setting
Bit7 0: 1:
T.SELE:
Toolpost select
Diamond 8-station hydraulic toolpost Electrical toolpost
Bit6 0: 1:
CZ: Center drill action restriction Active Inactive Manual/auto select for electronic gear
Bit5 M.J/A: 0: 1: Bit4 0: 1: Bit3 0: 1: Manual Auto ZXSH.I: Inactive Active WZSH.I: Inactive Active
Center drill device forward /backward detect ZX.I
Tailstock forward /backward detect WZ.I
Bit2 TUNCL.SH: 0: 1: Bit1 0: 1: Bit0 0: 1: Active Inactive SPFAN.CH:
Toolpost not clamped alarm
Normally-close/ normally-open select of spindle fan overload alarm
Normally-open Normally-close TOV.CH: Normally-close/ normally-open select of toolpost overload alarm
Normally-open Normally-close
3005
1 FEED.SH
0 TCLI.CH 0
Factory setting Bit1 0: 1: Bit0 0: 1:
0 FEED.SH: Inactive Active TCLI.CH: Active Inactive
Automatic feeding select
Toolpost clamp signal TCP.I select
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PC parameter No. 1001 Pump on delay time during automatic lubricating Pump off delay time during automatic lubricating Chip conveyor on delay time during automatic chip removal Chip conveyor on delay time during automatic chip removal Max. tool change duration of toolpost External message prompt delay of axis interlock Pneumatic/hydraulic pressure detect delay Forward/retract finish of center drill device and center Spindle jog motor running time during automatic gear shift Spindle jog motor dwell time during automatic gear shift Duration from M05 output to spindle brake start Duration of spindle brake signal output S gear shift delay Chuck release/clamp duration Tailstock forward/backward duration Toolpost duration from CW stop to CCW start (electrical) Toolpost CCW clamping duration (electrical) Rotation delay after tool disk forward Indicator light lighting up time Indicator light going out time Total tools number of toolpost 25000 Parameter function explanation Factory setting
1002
1800000
1003
50000
1004 1005 1006 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 1020 1022 1023 2002
180000 5000 10000 1000 1496 1496 1496 48 1496 1496 1496 1496 96 1200 48 1496 1496 8
M codes significance of TV3.0AB-8 version PLC

M3 M4 M5 Spindle CW Spindle CCW Spindle stop
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M8 M9 M10 M11 M15 M20 M21 M22 M23 M32 M33
Pump on Pump off Clamp chuck Release chuck Feeder start Tailstock forward Tailstock backward Center forward Center backward Center hole device retract Center hole device forward Gear 1 command Gear 2 command Gear 3 command Gear 4 command
M41/S1 M42/S2 M43/S3 M44/S4
Toolpost function
1) Toolpost category selection: if PC parameter 3001.0 is set to 0, it is electrical toolpost, while
1 for gang toolpost. 2) Toolpost type selection: if PC parameter 3004.7 is set to 0, it is Diamond 8-station hydraulic toolpost, while 1 for 4-station electrical toolpost. 3) Diamond 8-station hydraulic toolpost debugging Manual tool change debugging a) Before the debugging of TV3.0AB-8 version PLC software of 983T-H CNC system, the toolpost should be moved to a safety position (with no interference with chuck and workpiece), then do the debugging in the Manual mode. b) c) d) e) PC parameter 1005 is used to set the max. tool change time for the toolpost. PC parameter 1020 is used to set the rotation delay after the tool disk forward. PC parameter 1019 is used to set the delay time for the tool disk rotation stop. After releasing the tool change key in manual tool change, it changes to next tool. If the duration from the releasing to next tool change is over the value by parameter 1005, the No.1005 alarm is shown on the screen. It may cancel the alarm by pressing RESET key. Tool change by command Prior to debugging of tool change by command, the PC parameter 2002 for tools number of toolpost should be set to 8. There is time limit to change to a specified tool number during tool change. If the tool change time is over the value by PC parameter 1005, the No.1005 alarm is
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shown on the screen. It may cancel the alarm by pressing RESET key. 4) 4-station electrical toolpost Manual tool change debugging a) Before the debugging of TV3.0AB-8 version PLC software of 983T-H CNC system, the toolpost should be moved to a safety position (with no interference with chuck and workpiece), then do the debugging in the Manual mode. b) c) d) PC parameter 1005 is used to set the max. tool change time for the toolpost. PC parameter 1018 is used to set the toolpost duration from CW stop to CCW start. PC parameter 1019 is used to set the clamping time for the toolpost CCW. After releasing the tool change key in manual tool change, it changes to next tool. If the duration from the releasing to next tool change is over the value by parameter 1005, the No.1005 alarm is shown on the screen. It may cancel the alarm by pressing RESET key. Tool change by command Prior to debugging of tool change by command, the PC parameter 2002 for tools number of toolpost should be set to 4. There is time limit to change to a specified tool number during tool change. If the tool change time is over the value by PC parameter 1005, the No.1005 alarm is shown on the screen. It may cancel the alarm by pressing RESET key. 5) As for TV3.0AB-8 version PLC, theTAA BB command for tool change can be only used in Auto and MDI modes. (TAA BBAA for tool No.BB for tool offset No., e.g. for T0101it is No.1 tool and No.1 offset.) If the commanded tool No. is over the total tools number or equal to 0, the FEED HOLD indicator on the panel lights up and No.1006 alarm will be issued. It may cancel the alarm by pressing RESET key. 6) If emergency button is pressed or power is off during the tool change, the tool not clamped alarm will be issued after system powered on, and No.1008 alarm of toolpost not clamped will be shown on the screen, and feeding axes are locked, which cant be cancelled by pressing RESET key. It should switch to Manual mode, and press TOOL CHANGE key for manual tool change, and the alarm will be cancelled after the change. 7) Tool number display The tool number displayed by the 2-digits nexie tube on operation panel is machine current tool number, while the tool number on screen is the program current tool number.
Operation panel X axis direction key adjustment (front toolpost and rear toolpost)
If the direction of panel X axis is correct in MPG mode, but not correct in Manual mode, it may
change the X axis direction by modifying PC parameter 3002.7 (X..DIR) .

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Zero return of the machine feeding axis

For this TV3.0AB-8 version PLC, it may press X , Z keys in Zero mode to make the
corresponding axis to return to reference point automatically with the direction keys automatically held on. As the reference return is finished, the zero indicator for the corresponding axis lights up. If the returning needs to be cancelled during the execution, it may press the RESET key to cancel it. The PC parameter 3002.1 and 3002.2 are used to select the zero return directions of X, Z axes respectively.
Spindle function
This TV3.0AB-8 version PLC can perform frequency conversion and servo spindle motor control,
mechanical gear shift signal output, and gear in-position detection. 1) Frequency conversion/servo spindle (no gear shift) Parameters for 0~10V control: set NC parameter 5.4=0, 9.6=1, 9.7=0 and No.120 for the
corresponding max. spindle speed of the system 10V output, No.143 for system max. speed limit, PC parameter 3002.6 is set to 0, spindle rotation direction is defined by Y0.2 and Y0.3 of I/O unit. Parameters for -10~+10V control: set NC parameter 5.4=0 9.6=0, 9.7=1, No.120 for the corresponding max. spindle speed of the system -10 or +10V output, No.143 for system max. speed limit, PC parameter 3002.6 is set to 1. Command format: M3 M4 S spindle CW S spindle CCW spindle stop
M5
2) Frequency conversion/servo spindle (with electronic automatic mechanical gear control) Parameters: Set NC parameter 37 for the spindle jog speed of automatic shift, NC
parameters 120, 121, 122, 123 for the max. speeds of the system gear 1~4 and 10V voltage output respectively; PC parameter 1011 for the spindle jog motor running time of gear shift; PC parameter 1012 for the spindle jog motor stop time of gear shift, and PC parameter 3001.5 is to 0, PC parameter 3004.5 is to 1. Note As regarding to system with automatic spindle gear shift, X40.6 for spindle zero detect signal should be connected and PC parameter 3001.2 should be set to 1. Process: To perform the gear shift in the spindle running state the system automatically stop the spindle and performs spindle jog gear shift, the jogging is stopped as the gear is in-position. If the spindle rotation direction and spindle rpm are not commanded after the gear shift, the spindle will runs as it does before. If the gear shift is performed under the spindle stop, the spindle jogs CW, then the jogging is stopped after the gear is in-position. Relevant I/O interfaces:
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X33.4(GR2.M) 0 0 1 1
X33.3(GR1.M) 0 1 0 1
Spindle gear 1 2 3 4
Y1.6: spindle gear 1 output Y1.7: spindle gear 2 output Y2.0: spindle gear 3 output Y2.1: spindle gear 4 output Command format: M41/M42/M43/M44 M03/M04 S Gear command Direction and speed command
3) Frequency conversion/servo spindle (with electronic manual mechanical gear control) Parameters: NC parameters 120, 121, 122, 123 are for the max. speeds of the system gear
1~4 and 10V voltage output respectively; PC parameter 3001.5 is set to 0, PC parameter 3004.5 is set to 0. 4Spindle with double speed motor (with mechanical gear shift) Parameters: Set NC parameter 5.4 to 1, PC parameter 1014 for S gear shift delay, PC
parameter 3001.5 to 1. Process: To perform the gear shift, the system automatically stop the spindle and outputs gear signal, it delays a time by PC parameter 1015 as the gear is in-position. And the spindle runs by the original direction and the gear commanded for the shift. If the gear commanded is the same as the current gear, the gear shift is not performed. Command format: M03/M04 S1/S2/S3 /S4
Spindle alarm
PC parameter 3001.4 is used to set spindle alarm input detection. If it is set to 1, it doesnt detect
the spindle alarm input signal; if set to 0, the No.1001 spindle alarm is shown on the screen.
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External MPG
Set PC parameter 3002.0 for MPG selection, set to 1 for external MPG, set to 0 for panel MPG.
For external MPG, axis and override selection are inactive by panel keys, which can only be selected by external MPG hand box. Refer to GSK983T Connection Manual.
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Spindle automatic chuck function
1) Command: M11 command is used to release the chuck, M10 command is used to clamp the chuck 2) Manual mode As chuck is released, by pressing the panel CHUCK RELEASE/CLAMP key, the chuck will be clamped; As chuck is clamped, by pressing the panel CHUCK RELEASE/CLAMP key, the chuck will be unclamped; Restriction: Manual chuck releasing is unallowed in the spindle running. 3) Chuck release/clamp state CHUCK RELEASE/CLAMP indicator lights up as the chuck is clamped, while indicator light goes out as chuck is unclamped. State memorizing: The chuck release/clamp is memorized by the non-volatile memory, the
chuck state is the same as that before last time power-off each time the system is powered on. 4) Internal and external chuck setting: PC parameter 3002.3 is for internal and external chuck bit, set to 1, the chuck works by internal chuck mode, set to 0, the chuck works by external chuck mode. It is active after the system is repowered as it is modified. 5 Chuck release/clamping in-position detection X35.2 and X35.3 selection: if the PC parameter 3001.6 is set to 0, this detection is inactive; if set to 1, this detection is active. If the detection is set for inactive, it should set PC parameter 1016 for timer release/clamping finish time based on the chuck action speed. If the spindle is run within the finish time, No.1021 spindle not clamped alarm will be shown on screen. 6 Pneumatic and hydraulic chuck selection: if the bit of PC parameter 3002.5 is set to 0, it uses hydraulic chuck, and the release/clamp output is held on; if set to 1, it uses pneumatic chuck, and the release/clamp output is not held on. The holding time is defined by the timer release /clamping finish time of PC parameter 1016.
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Tailstock function
1) Command: The tailstock is forwarded by M20 command, retracted by M21 command. And the tailstock
forward and backward duration is set by PC parameter 1017. 2) Manual mode As the tailstock is at the forward position, it can be retracted by pressing the panel
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TAILSTOCK FW/BK key once. As the tailstock is at the backward position, it can be advanced by pressing the panel TAILSTOCK FW/BK key once. Restriction: Manual tailstock forward/backward is unallowed in Auto mode and spindle running. 3) Tailstock forward/backward state The TAILSTOCK FW/BK key indicator lights up as tailstock is forwarding; goes out if tailstock is retracting. State memorizing: The tailstock forward/backward is memorized by the non-volatile memory,
the tailstock state is the same as that before power-off last time each time the system is powered on. 4) Tailstock forward/backward in-position detection X35.0 and X35.1 selection: if the PC parameter 3004.3 is set to 0, this detection is inactive; if set to 1, this detection is active. If the detection is set for inactive, it should set PC parameter 1017 for timer release/clamping finish time based on the tailstock forward/backward action speed. 5) If emergency stop, pneumatic or hydraulic alarm occurs during the tailstock
forwarding/retracting, the forward/backward output is stopped. Even the alarm is cancelled, the output is not restored, and it must perform the tailstock action in Manual or MDI mode, the output may be continued.
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Center function
1) Command: The center is forwarded by M22 command, retracted by M23 command. And the M code
finish time is set by PC parameter 1010. 2) Manual mode As the center is at the forward position, it can be retracted by pressing the panel CENTER FW/BK key once. As the center is at the backward position, it can be advanced by pressing the panel CENTER FW/BK key once. Restriction: Manual center forward/backward is unallowed in Auto mode and during spindle running. 3) Center forward/backward state The CENTER FW/BK key indicator lights up as center is forwarding; goes out if center is
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retracting. State memorizing: The center forward/backward is memorized by the non-volatile memory, the center state is the same as that before power off each time the system is powered on. 4) If emergency stop, pneumatic or hydraulic alarm occurs during the tailstock forwarding /retracting, the forward/backward output is stopped. Even the alarm is cancelled, the output is not restored, and it must perform the center action in Manual or MDI mode, the output may be continued.
14
Center drill device control function

1Command: The center drill device is forwarded by M33 command, retracted by M32 command. 2Center drill device state State memorizing: The center drill device forward/backward is memorized by the
non-volatile memory, the center drill device state is the same as that before power off each time the system is powered on. 3) The operation of the center drill device cant be performed during the spindle stop and the chuck release. Only under the condition of spindle running (M03 or M04) and chuck clamping the center drill device operation can be performed. If the center drill device forwarding restraining needs to be cancelled, set the PC parameter 3004.6 to 1. 4) Center drill device forward/backward in-position detection X35.4 and X35.5 selection: if the PC parameter 3004.4 is set to 0, this detection is inactive; if set to 1, this detection is active. If the detection is set for inactive, it should set PC parameter 1010 for action finish time based on the tailstock action speed. 5) If emergency stop, pneumatic or hydraulic alarm occurs during the center drill device forwarding/retracting, the forward/backward output is stopped. Even the alarm is cancelled, the output is not restored, and it must perform the tailstock action in Manual or MDI mode, the output may be continued.
15
Axes rapid move adjustment (G0 speed adjustment)

In Manual mode, press RAPID key, its indicator on panel lights up, and the rapid override can be
selected by /F0, 10/F50, 100/F100 keys; in Auto mode, the real time rapid override can also be switched over by /F25, 10/F50, 100/F100 keys.
19
RAPID
Only active in Manual and Zero modes
16
Lubrication function
1) Automatic lubrication: The PLC performs the lubrication automatically after machine power
on, shut down the lubrication pump for a while after pump runs for a short period of time. The lubrication pump ON time is set by PC parameter 1001, and the OFF time by PC parameter 1002. 2) Manual operation: Press the panel LUBRICATING key once, the lubrication pump is turned
on, (machine lubricating controlled not by automatic lubrication). If LUBRICATING key is pressed again, the manual lubricating will be stopped and the machine will get back to automatic lubrication.
17
Cooling function
1) The cooling pump can be directly operated by pressing the COOLING key on the machine
panel in any mode. Press it once for ON, then press it again for OFF; if it is turned on in Manual mode, by M09 code in Auto/MDI mode, it can be turned off. If it is turned on by M8 code in Auto or MDI mode, by pressing COOLING key or executing M09 code it can be turned off. 2) During the automatic execution of program, the cooling stops if M01 is commanded on the condition that M00, M02, M30 and optional stop are active. If the execution is to be continued, the cooling should be turned on again. 3) If safety door is opened at the state cooling ON and door interlock active, the cooling stops and its indicator blinks. After the safety door is closed, the cooling is on and the cooling indicator does not blink, and pump is started.
18 19
Overtravel release
By pressing the OVERTRAVEL key, the I/O unit Y0.5 outputs 0V.
Chip removal function

By pressing the panel CHIP REMOVAL key, it can forcely turn on and off the chip conveyor CW
rotation. Press once the conveyor is turned on, repressing the key for turning off. Under the condition of conveyor OFF, it performs the automatic interval chip removal. And the action time and stop time are set respectively by PC parameter 1003 and 1004. If the chip conveyor is needed to run reversely, switch to the Edit mode, then press the USER1 USER1 flickers, press the and FEED HOLD keys together, as the indicator of
key under the X ZERO, it can perform the conveyor CCW jogging
operation, press CHIP REMOVAL key, it can perform the conveyor CW jogging operation.
20
Spindle feed axis interlock switch on panel

In any mode, under the feed on and spindle on mode, the interlock of feed axes and spindle is
inactive. Under the feed off and spindle on mode, the interlock of feed axes is active, but spindle
20
interlock is inactive, and the message on screen shows No.2001 prompt. Under the feed off and spindle off mode, the interlock of feed axes and spindle is active, and the message on screen shows No.2002 prompt.
21
Safety door function

1) safety door selection: turn on the program switch, press the SAFETY DOOR key on the
machine panel, press it once for ON and the key indicator lights up, then press it again for OFF and the key indicator goes out. Turn off the program switch, the SAFETY DOOR key is inactive, and the safety door keeps at a state when program switch is off. 2) The safety door detection is active when the safety door is active. In Auto and MDI mode, No.1022 alarm for safety door open will be shown on the screen. This alarm does not occur in Manual mode, but occur if it switches to Manual mode from manual spindle rotation and spindle running mode. 3) As the safety door open is active, if safety door is opened in automatic running, No.1022 alarm for safety door open and No. 2004 message prompt for spindle low speed running will be shown on the screen.
22
Feeder function
1) This feeder is equipped with a PLC. The overload, under-feeding, feeding-finish signals are
provided by this feeder. And the system provides feeding enable signal. Action: Input M15 in MDI mode spindle chuck releasechuck release in-positionsystem sends feeding enable signal and spindle jog feeder feeds feeder sends feeding finish signal chuck clamping chuck is clamped in-position M15 finish 2During the feeding, if under-feeding message by feeder is received, system doesnt make alarm. Then No.1023 alarm for under-feeding will be shown on screen till the part is finished and feeding command is sent again. 3Feeding is automatically done during spindle running and system external message No.2003 for spindle not stop is shown on screen.
23
Tailstock release/clamp
1) The tailstock release or clamping operation can only be performed in Manual mode, by
pressing the panel USER1 key, it is for releasing operation, pressing it again, for clamping operation. There is no M code for this function. 2) If the tailstock is released, the machine X axis dont move as the tailstock releasing
detection switch (X38.5) is powered on. The X axis direction key indicator flickers, and spindle running, center, and tailstock actions are disabled.
21
24
Center jig release/clamp

The center jig release/clamp operation can only be performed in Manual mode. By pressing the
panel USER2 key, it is for releasing operation, pressing it again, for clamping operation. There is no M code for its function.
25
PLC version display

In Manual mode, by pressing the STOP and FEED HOLD keys together, external message
No.2010 TV version No. and toolpost type-tools number will be shown on screen, and it disappears if releasing the keys.
26
TV3.0AB-8 PLC alarm list of GSK983T-H CNC system

TV3.0AB-8 PLC alarm list Alarm No. and content Cause The emergency wires are disconnected and emergency stop button pressed Spindle alarm issued Troubleshooting 1. Check if the emergency stop switch is pressed. 2. Check if 38.4 is set to 1. 1.Check if X40.5 spindle ready signal is set to 1. 2. Check servo driver level is right. 1.Check if spindle fan alarm X33.6 normally-open or close selection 3004.1 conforms to the machine wiring circuit. 2. Check if spindle protection switch is tripped. Check if the setting by PC parameter 1005 is proper, power line of toolpost is overload, rotation direction is right. Check if the tool number input is 0 or exceeds the total number by parameter 2002. Check if toolpost encoder is disconnected, toolpost current tool No. is consistent with that by the nexie tube, if not, check tool number signal cable 48.0-48.2 connection; if it is, check parity check connection.
1000
EMERGENCY STOP
1001
SPINDLE
ALARM
1002
SPINDLE FAN ALARM
Spindle fan alarm issued
1005
CHANGE TIME OUT
Tool change overtime
1006 CUTTER NUMBER ERR
Tool number is wrong.
1007 CUTTER ENCODER ERR
Tool code wrong
22
1008 SLIDE UNCLAMP
Toolpost unclamped
1. Check if Diamond hydraulic toolpost X48.6 is powered on after tool change, if not, alarm is issued. 2. Check if 4-station electrical toolpost is clamped and if the previous tool change is not finished. 3. Alarm may be cancelled by switching to Manual mode for manual tool change. 1. Check X33.7 alarm, if normally-close, normally-open by PC parameter 3004.0 setting conforms to the machine wiring circuit. 2. Check if the toolpost motor protection switch is tripped. 1. Check X34.4 alarm, if normally-close, normally-open by PC parameter 3003.4 setting conforms to the machine wiring circuit. 2. Check if the pump motor protection switch is tripped. 1. Check X34.3 alarm, if normally-close, normally-open by PC parameter 3003.3 setting conforms to the machine wiring circuit. 2. Check if the hydraulic motor protection switch is tripped. 1. Check X34.2 alarm, if normally-close, normally-open by PC parameter 3003.2 setting conforms to the machine wiring circuit. 2. Check if the chip conveyor motor protection switch is tripped. 1. Feeder alarm X38.0 is set to 1. 2. Feeder is at fault. 1. Add lubricant. 2. Check X34.6 alarm, if normally-close, normally-open by PC parameter 3003.5 setting conforms to the machine circuit.
1009
SLIDE OVER LADO
Toolpost motor overload alarm
1011
COOLANT OVER LOAD
Pump motor overloaded
1012
HY OVERLOADING
Hydraulic motor overloaded
1013
CHIP OVERLOAD
The chip conveyor overloaded
1014
FEEDER OVERLOAD
The feeder overloaded
1017
LUB LEVEL LOW
Low lubricating oil level alarm
23
1018
HY PRESS LOW
Low hydraulic pressure alarm
1. Check X32.2 alarm, if normally-close, normally-open by PC parameter 3003.0 setting conforms to the machine wiring circuit. 2. Check if the hydraulic motor rotates CCW. 1. Check X32.4 alarm, if normally-close, normally-open by PC parameter 3003.1 setting conforms to the machine wiring circuit. 2. Check the air. 1. Check if chuck is securely clamped. 2. Check if chuck clamping signal by PC parameter 3001.6 is active. Check if 33.6 is set to 1 if 3001.6 is set to 1 for active. 1. Close the safety door. 2. Check if 33.2 is set to 1. Change for the new stock. Clamp the tailstock. Perform the machine zero return. Set the axes interlock switch to Feed and Spindle ON, then switch to other operation page, the external message may be cancelled. Set the axes interlock switch to Feed and Spindle ON, then switch to other operation page, the external message may be cancelled. Do automatic feeding in spindle running. Open safety door and spindle runs in a low speed.
1019
AIR PRESS LOW
Low air pressure alarm
1021
CHUCK UNCLAMP
Spindle chuck not securely clamped
1022 SHIELD DOOR OPENED 1023 1024 FEED STUFF END TAILSTOCK UNCLAMP
Shield door open alarm in auto running Feeder under-feeding Tailstock unclamped Machine Zero return not performed
2000 MT NOT RETURN HOME
2001
INVALID FEED
Feed axes interlock inactive
2002
INVALID SPIN&FEED
Spindle and feed axes interlock inactive
2003 2004 2010
SPINDLE NOT STOP SPINDLE LOW SPEED TV3.0AB-8 2008 08
Spindle not stopped Spindle low speed PLC version number
24
PLC version upgrade form

Version mark
Date
File name
Content This PLC version is special for China Jinan 1st machine tool factory, which is a combined version of TH-V1.2 version and TH-V1.3B-8 version, and some alarms and rearranged alarm numbers are added in it. Also automatic feeder feeding and collector control are added. New I/O unit and operation panel I/O addresses have been added in this TV3.0AB-8 version PLC for China Jinan 1st machine tool factory, and its functions are identical with that of the TH-V1.3A/B-8 version.
Designer
Remark
2008-7-15
TH-V1.3A/B-8 version PLC.ROM
TV1.3AB-8
Ye Shuhuan
Initial version
2008-8-19
TV3.0AB-8 version PLC.ROM
TV3.0AB-8
Ye Shuhuan
Initial version
25
Add: No.7, 1st . Street, Luochong North Road, Luochongwei, Guangzhou, 510165, China Website: http://www.gsk.com.cn Tel: (00) 86-20-81796410/81797922 E-mail: gsk@gsk.com.cn Fax: (00) 86-20-81993683 Aug. Oct. 2008/Edition 1
All specifications and designs are subject to change without notice. Version No.: TV3.0AB-8
2008/Printing 1

Gsk983t-h Version Tv3.0ab-8 PLC User Manual

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Gsk983t-h Version Tv3.0ab-8 PLC User Manual

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GSK983T-H Turning CNC System

TV3.0AB-8 Version PLC User Manual of GSK983T-H Turning CNC System

TV3.0AB-8 Version PLC User Manual of GSK983T-H Turning CNC System

GSK983T-H machine operation panel and relevant addresses diagnosis

POS RECORD 36.6 7.6

USER 1 36.7 7.7

SKIP 37.5 8.5

DRY 37.6 8.6

USER 2 37.7 8.7

Z 40.0 9.0 9.1 9.2 40.1 40.2

OPTIONAL STOP 40.4 9.4

MACHINE LOCK 40.5 9.4

M.S.T. LOCK 40.6 9.6

PROG RESTART 40.7 9.7

CCW 41.4 10.4

STOP 41.5 10.5

ORIENTATION 41.7 10.7

TV3.0AB-8 Version PLC User Manual of GSK983T-H Turning CNC System

LIGHT FEED HOLD CYCLE

TV3.0AB-8 Version PLC User Manual of GSK983T-H Turning CNC System

I/O interface setting of TV3.0AB-8 version PLC

SHIP.ALM HY.OV COOL.OV

TV3.0AB-8 Version PLC User Manual of GSK983T-H Turning CNC System

X38.2 X38.3 X38.4 X38.5 X38.6 X38.7 X38.COM 0V 0V +24V +24V

F.FIN ST2 ESP IT.X TL+ TLCOM 0V 0V +24V +24V

COM WZ.F WZ.B CK.UCL CK.CL ZX.F ZX.B

X35 common terminal

TV3.0AB-8 Version PLC User Manual of GSK983T-H Turning CNC System

PLC address Y3.0

Signal name T.UNCL

Signal function Tool disk release

TV3.0AB-8 Version PLC User Manual of GSK983T-H Turning CNC System

T.CL PS.CW PS.CCW DZ+.O DZ-.O WZT.O ZXZ.O CKUCL.O SLSL+

RED.L SPZD.O ERST M19.O 0V +24V

TV3.0AB-8 Version PLC User Manual of GSK983T-H Turning CNC System

Wiring for low level input active Machine side

983 system I/O unit (X1) side

Machine detection switches

Machine detection switches

TV3.0AB-8 Version PLC User Manual of GSK983T-H Turning CNC System

PC parameters of TV3.0AB-8 version PLC

MANUAL ABSOLUTE switch shield

TV3.0AB-8 Version PLC User Manual of GSK983T-H Turning CNC System

Electrical toolpost Gang toolpost

Factory setting Bit7

External Internal Automatic zero return direction of Z axis

Positive Negative Automatic zero return direction of X axis

Positive Negative MPG selection

TV3.0AB-8 Version PLC User Manual of GSK983T-H Turning CNC System

Panel External hand box

Factory setting Bit7 0: 1: Bit6 0: 1: Bit5 0: 1: Bit4 0: 1: Bit3 0: 1:

Normally-open Normally-close Normally-close/ normally-open select of chip conveyor overload alarm

Bit2 PS.ALM: 0: 1: Bit1 0: 1: Bit0 0: 1:

Normally-open Normally-close AIRP.ALM: Normally-close/ normally-open select of air pressure detect

Normally-open Normally-close HYP.ALM: Normally-close/ normally-open select of hydraulic pressure detect

TV3.0AB-8 Version PLC User Manual of GSK983T-H Turning CNC System

Diamond 8-station hydraulic toolpost Electrical toolpost

Center drill device forward /backward detect ZX.I

Tailstock forward /backward detect WZ.I

Bit2 TUNCL.SH: 0: 1: Bit1 0: 1: Bit0 0: 1: Active Inactive SPFAN.CH:

Toolpost not clamped alarm

Normally-close/ normally-open select of spindle fan overload alarm

Normally-open Normally-close TOV.CH: Normally-close/ normally-open select of toolpost overload alarm