6FX6002-1AA02-.... - Siemens

Start-Up 11/2005 Edition

sinumerik

SIEMENS

SINUMERIK 801

SINUMERIK 801 Document Structure

User Documentation: Operation and Programming

User Documentation: Diagnostics Guide

Technical Documentation: Start-Up

Turning

SINUMERIK 801 Control System 1

Installation and Start-Up 2

Built-In PLC Application 3

Setting Up 4

5

Accessories 6

Technical Appendix 7

SINUMERIK 801

Start-Up

Technical Manual

Services, Diagnosis & Data

Saving

Valid for

Control system

SINUMERIK 801

11. 2005 Edition

SINUMERIK Documentation

Key to editions

The editions listed below have been published prior to the current edition.

The column headed “Note” lists the amended sections, with reference to the previous edition.

Marking of edition in the “Note” column:

A ... ... New documentation.

B ... ... Unchanged reprint with new order number.

C ... ... Revised edition of new issue.

Edition Order No. Note

2005.11 A5E00702069 A

Trademarks

SIMATIC®, SIMATIC HMI®, SIMATIC NET®, SIMODRIVE®, SINUMERIK®, and SIMOTION® are registered

trademarks of SIEMENS AG.

Other names in this publication might be trademarks whose use by a third party for his own purposes may violate

the registered holder.

The reproduction, transmission or use of this document or its con-

tents 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, are reserved.

Exclusion of liability

We have checked that the contents of this document correspond to

the hardware and software described. Nonetheless, differences

might exist and we cannot therefore guarantee that they are com-

pletely identical. The information contained in this document is re-

viewed regularly and any necessary changes will be included in the

next edition. We welcome suggestions for improvement.

Subject to technical changes without notice.

Siemens-Aktiengesellschaft.

SINUMERIK 801

®

SINUMERIK 801 I

Start-Up

Safety notices This Manual contains notices intended to ensure your personal safety, as well

as to protect products and connected equipment against damage. Safety

notices are highlighted by a warning triangle and presented in the following

categories depending on the degree of risk involved:

Danger

Indicates an imminently hazardous situation which, if not avoided, will result in

death or serious injury or in substantial property damage.

Warning

Indicates a potentially hazardous situation which, if not avoided, could result in

death or serious injury or in substantial property damage.

Caution

Used with safety alert symbol indicates a potentially hazardous situation which,

if not avoided, may result in minor or moderate injury or in property damage.

Caution

Used without safety alert symbol indicates a potentially hazardous situation

which, if not avoided, may result in property damage.

Notice

Indicates important information relating to the product or highlights part of the

documentation for special attention.

Qualified person The unit may only be started up and operated by qualified person or persons.

Qualified personnel as referred to in the safety notices provided in this

document are those who are authorized to start up, earth and label units,

systems and circuits in accordance with relevant safety standards.

Proper use Please observe the following:

Warning

The unit may be used only for the applications described in the catalog or the

technical description, and only in combination with the equipment,

components and devices of other manufacturers as far as this is

recommended or permitted by Siemens.

This product must be transported, stored and installed as intended, and

maintained and operated with care to ensure that it functions correctly and

safely.

!

Table of Contents

SINUMERIK 801 III

Start-Up

Table of Contents

1. SINUMERIK 801 Control System…………………………………………………………………………… 1-1

1.1 System Overview …………………………………………………… 1-1

1.2 CNC Operator Panel ……………………………………………… ………… 1-3

1.3 Position of the Interfaces………………………………………………………………………………… 1-5

1.4 Technical Data ………………………………………………………………………………… 1-6

2. Installation and Start-Up ………………………………………………………………………… 2-1

2.1 Cabinet, Power Supply and Grounding …………………………………………………… … 2-1

2.2 Installing and Cabling ……………………………………………………………………………… 2-4

2.2.1 Installing the control system ……………………………………………………………………… 2-4

2.2.2 Cabling …………………………………………………………………………………………… 2-11

2.2.2.1 Connecting with the stepper drives ………………………………………………………………… 2-11

2.2.2.2 Connecting with the servo drives (example) ……………………………………………………… 2-12

2.3 Interfaces and Cables ……………………………………………………………………………… 2-15

2.3.1 Power supply for CNC – X1 ……………………………………………………………… 2-16

2.3.2 RS232 interface - X2 (RS232) …………………………………………………………… 2-16

2.3.3 Spindle encoder interface - X3 (SPINDLE)…………………………………………………… 2-17

2.3.4 Feed drive interface – X4 (AXIS)…………………………………………………………………… 2-18

2.3.5 Handwheel & extension keys connection - X10 (MPG) ……………………………………… 2-19

2.3.6 BERO input interface - X20 (BERO)…………………………………………………………………… 2-19

2.3.7 Digital inputs/outputs - X100 (DIN0) & X101 (DIN1), X200 (DOUT0) & X201 (DOUT1)… 2-20

2.3.8 Connecting cables for SINUMERIK 801 ……………………………………………………… 2-22

2.4 Installing and Starting-Up the Drive Modules …………………………………………… 2-26

2.4.1 Connecting the STEPDRIVE C/C+ drive modules ………… …………………………………… 2-26

2.4.2 Connecting the servo drive modules ………… …………………………………… 2-26

3. Built-In PLC Application …………………………………………………………………………………… 3-1

3.1 Input/Output Configuration …………………………………………………………………… 3-4

3.2 Definition of User Keys ………………………………………………………………… 3-6

3.3 PLC Machine Data ……………………………………………………………………………… 3-9

3.4 Fixed PLC Alarms………………………………………………………………………………………… 3-16

4. Setting Up …………………………………………………………………………………… 4-1

4.1 Setting Up NC Parameters ………………………………………………………………… 4-6

4.2 Starting Up the Dynamic Characteristic of the Axes ……………………………………………… 4-9

4.3 Starting Up Reference Points ……………………………………………………………… 4-9

4.4 Software Limit Switch and Backlash Compensation…………………………………………… 4-14

4.5 Rotation Monitoring ………………………………………………………………………… 4-16

4.6 Leadscrew Error Compensation …………………………………………………………… 4-17

4.7 Starting Up the Spindle ……………………………………………………………………… 4-17

5. Services, Diagnosis & Data Saving ………………………………………………………… 5-1

5.1 Services …………………………………………………………………………………………… 5-2

5.2 Diagnosis …………………………………………………………………………………………… 5-2

5.3 Data Saving …………………………………………………………………………………………… 5-6

5.3.1 Internal data saving …………………………………………………………………………………… 5-6

5.3.2 External data saving …………………………………………………………………………………… 5-6

5.3.3 Important Notice …………………………………………………………………………………… 5-9

6. Accessories ……………………………………………………………………………… 6-1

7. Techncial Appendix …………………………………………………………………………………………7-1

7.1 List of Machine Data ………………………………………………………………………………………7-1

SINUMERIK 801 1-1

Start-Up

SINUMERIK 801 Control System 1

1.1 System Overview

General The SINUMERIK 801 is a highly integrated, high-performance and

economic numerical control system, which can be extensively applied to

economic CNC turning machines. It can control 2 feed axes and 1 spindle.

Control signals output to feed axes include digital pulse, direction and

enable signals, control signals output to the spindle include analog voltage

and enable. The SINUMERIK 801 can thus be used to control feed axes

for stepper drives, and servo drives with digital pulse interfaces. Either

servo spindle or variable frequency spindle can be controlled via the

SINUMERIK 801. This documentation gives descriptions for configuring

the SINUMERIK 801 with stepper drives/servo drives.

System components The SINUMERIK 801 control system is a compact CNC unit. It consists of the

following components:

h CNC

A compact CNC with an integrated 6″ LCD, full NC keys and MCP area;

h Stepper drives and stepper motors

1) Stepper drives STEPDRIVE C/C+;

2) Five-phase hybrid stepper motors

h Cables

1) Signal cables for connecting CNC to drives;

2) Cables for connecting drives to motors;

3) Signal cable for connecting spindle encoder to CNC;

4) RS232 cable for connecting CNC to a PC;

5) Signal cable for connecting CNC to an electronic handwheel.

z One spindle encoder

z One electronic handwheel

z Possible configurations by users: servo motors (with digital pulse

interfaces) and servo motors.

SINUMERIK 801 Control System

1-2 SINUMERIK 801

Start-Up

SINUMERIK 801 system

Fig.1-1 SINUMERIK 801 system overview（CNC + stepper drives + stepper

motors）

SINUMERIK 801 Control System

SINUMERIK 801 1-3

Start-Up

1.2 CNC Operator Panel

Layout of the CNC operator panel

The SINUMERIK 801 has a compact operator panel, which can be divided into

three areas as: LCD, NC keys and MCP area.

Fig. 1-2 Layout of the CNC operator panel (front view)

Key definition

NC keyboard area

Machine area key

Cursor UP (with shift: page up)

Recall key

Cursor DOWN (with shift: page down)

Softkey

Cursor LEFT

Area switchover key

Cursor RIGHT

ETC key

Selection key/toggle key

LCD

NC keys

MCP area

SINUMERIK 801 Control System

1-4 SINUMERIK 801

Start-Up

Acknowledge alarm

Delete key (backspace)

SPACE (INSERT)

Vertical menu

ENTER / input key

Shift key

…

Numerical keys (with shift for

alternative assignment) …

Alphanumeric keys (with shift for

alternative assignment)

Notice

See”Operation & Programming” for the use of NC keys.

MCP (Ma chine Control Panel) area

Chuck clamping (with LED)

Spindle override 100％

Chuck clamping internally / Chuck clamping

externally (with LED)

Spindle override minus (with LED)

Chuck unclamping (with LED)

X axis, plus direction

Manual tool change (with LED)

X axis, minus direction

Manual lubrication (with LED)

Z axis, plus direction

Manual coolant (with LED)

Z axis, minus direction

AUTOMATIC (with LED)

RAPID TRAVERSE OVERLAY

SINGLE BLOCK (with LED)

SPINDLE START LEFT

Counterclockwise direction

MANUAL DATA (with LED)

SPINDLE STOP

Increment (with LED)

SPINDLE START RIGHT

Clockwise direction

SINUMERIK 801 Control System

SINUMERIK 801 1-5

Start-Up

JOG (with LED) RESET

REFERENCE POINT (with LED) NC STOP

Feedrate override plus (with LED) NC START

Feedrate override 100％ LED POK (Power OK), green

Feedrate override minus (with LED) LED ERR (Error), red

Spindle override plus (with LED) LED DIA (Diagnostics), yellow

Emergency Stop button (option)

Notice

See Chapter 3 “Built-in PLC Application” for detailed definitions of User Keys,

Traverse keys (+X, -X, +Z, -Z) and override keys.

SINUMERIK 801 Control System

1-6 SINUMERIK 801

Start-Up

1.3 Position of the Interfaces

General Interfaces of the control system are positioned in the rear of the CNC system,

see Fig. 1-3 below.

Interfaces Interfaces of the SINUMERIK 801 control system are shown as below:

Fig. 1-3 Position of SINUMERIK 801 interfaces

Notice

See Section 2.3 “Interfaces and Cables” for detailed description of each

interface.

SINUMERIK 801 Control System

SINUMERIK 801 1-7

Start-Up

1.4 Technical Data

Connected load Table 1–1 Connected load

Parameter Min. Typ. Max. Unit

Supply voltage 20.4 24 28.8 V

Ripple 3.6 Vss

Current consumption from 24 V 2 A

Power dissipation of CNC 48 W

Start-up current 4 A

Note: The 24V DC voltage must be generated as a functional extra-low voltage

with safe electrical isolation (to EN60204-1, Section 6.4, PELV).

Weight Table 1–2 Weight

Component Weight [g]

CNC 2120 circa

Dimensions Table 1–3 Component dimensions

Component Dimensions LxWxD [mm]

CNC 400 x 250 x 57.6

Environmental operating conditions

Table 1–4 Environmental operating conditions

Parameter

Temperature range

(horizontal mounting and

convection)

0….55°C (for box)；

0….45°C (for display surface)

Permissible relative humidity 5…95% without condensation

Air pressure 860 ... 1,060 hPa

The operating conditions refer to EN60204-1.

Installation in a housing (e.g. cubicle) is absolutely necessary for operation.

Transport and storage conditions

Table 1–5 Transport and storage conditions

Parameter

Temperature range -20 ... 60°C

Permissible relative air humidity 5 ... 95 % without condensation

Air pressure 700 ... 1,060hPa

Transport height –1,000 ... 3,000m

Free fall in transport package ≤0.5m

Protection class

Class of protection I according to IEC 529

The control must be equipped with a grounding conductor terminal.

Protection against ingress of solid foreign bodies and water according to ICE

529:

For CNC system: Front: IP54 Rear: IP20

SINUMERIK 801 2-1

安装调试手册

Installation and Start-Up 2

2.1 Cabinet, Power supply and Grounding

Requirements for

cabinet Machine tool builders need to pay attention to following requirements for a

cabinet:

1) Furnish the cabinet with a cooling or ventilation device; When using an

electric fan to cool the cabinet, mount a dust gauze at the air inlet of the

cabinet;

2) Mount all cabinet components on an unpainted galvanized metal plate;

3) Protection class for cabinet: IP54;

4) Grounding as per China national standard

GB/T5226.1-2002/IEC60204-1

：

2000 Safety of machinery - Electrical

equipment of machines – Part II: General requi rements;

5) In the case of poor field grounding, disconnect connections between PE

and neutral (M24) of DC24V power supply and have CNC ungrounded;

6) When CNC is ungrounded, it’s imperative to configure a RS232 terminal

adapter (order number: 6FX2003-0DS00) for RS232 connector to protect

the connector from being broken down;

7) When wiring up the cabinet, AC supply lines (e.g. 85VAC, 220VAC,

380VAC lines and the cable for connecting an inverter to spindle motor)

shall be routed separately from the 24VDC and signal cables;

8) If an inverter is used as spindle drive unit for the machine tool, take

adequate anti-interference measures to protect the cabinet from mains

interference and radio interference, etc;

9) Connect an isolation transformer (i.e. control transformer 380VAC

->220VAC, JBK3-400VA) to the 24VDC power supply for the control

system; Connect a separate isolation transformer to the 85VAC power

supply for stepper drives (i.e. drive transformer 380VAC ->85VAC, JBK3

series); Do not connect the primary side of both transformers to the

same phase of the 380VAC;

10) Have the control transformer ungrounded in the case of poor field

grounding, however, it’s required to connect the 220VAC power supply

for either periphery (e.g. PC/PG) to the control transformer, see Fig.

2-1.

Control transformer Use a separate control transformer in the cabinet to supply the 24VDC

power supply for CNC when Siemens stepper drives are used. Cable

connections with the control transformer are shown in Fig. 2-1.

Start-Up

2-2 SINUMERIK 801

Start-Up

U V W

380VAC 220VAC

0V

220/24 DC

Power

Supply PC

L

NPE

1)

2,3)

PE

CNC

L+

M

24V

0V

220VAC

0V

PE PE PE

L

N

L+

M

3)

3) 3) 3) 3)

PE rails

Fig. 2-1 Connecting the control transformer

Notes (for Fig. 2-1):

1) Two phases of U，V，W that are not used by the drive transformer;

2) Connections can not be made until PE rails are found well grounded.

3) In order to ensure a good grounding, the cross-sectional area of PE rails

shall be not less than 6mm2.

Notice

The control transformer will not be provided by Siemens. Customer may

order it from other sources.

Drive transformer Use a separate drive transformer in the cabinet to supply the 85VAC power

supply for stepper drives. Connections with the drive transformer are shown

in Fig. 2-2.

Fig. 2-2 Connecting the drive transformer

4)

PE rails

Start-Up

SINUMERIK 801 2-3

Start-Up

Notes (for Fig. 2-2):

1) Two phases of U，V，W that are not used by the control transformer;

2) In order to ensure a good grounding, the cross-sectional area of PE rails

shall be not less than 6mm2.

Notice

When AC servo drives are used, please connect cables as per requirements

concerned.

24VDC power supply

The SINUMERIK 801 CNC is supplied by a 24V DC power supply, which

enables the control system to run in order under the voltage range of

24V-15% ... +20%. The excellent quality of the DC power supply is critical for

the stable operation of the control system. You’re recommend to select

Siemens 24VDC stabilized power supply (order number: 6EP1333-3BA00). If

a DC power supply other than Siemens is used, please detect the output

waveform generated when the power supply is switched off.

Fig. 2-3 The power supply waveform

If the waveform as shown in the upper right figure occurs, supply the

SINUMERIK 801 in a way as indicated in the figure below and describe the

system power-on sequences in the corresponding user guide for machine

tools. Proper sequences are: switch on the mains for machine tools (to

energize 24VDC power supply and drives) first, then supply the control system

by pressing the button SA1; For switching off the control system, press SA2

first, then power off the mains for the machine tool.

0VDC

24VDC

KA1

CNC

0VDC

KA1SA2SA1

24VDC

KA1

Fig. 2-4 Power on/off sequence of the power supply

Note:

W

ave

f

orm o

f

Si

emens

PS

W

ave

f

orm o

f

non-

Si

emens

PS

S

ys

t

em opera

ti

ng

vo

lt

:

24V

m

i

n.

Start-Up

2-4 SINUMERIK 801

Start-Up

1) All input signals must be level signals, i.e. level “0” (-3 ... 5VDC) and

level “1” (11 ... 30VDC). Both suspended and high resistance signals are

level “0”.

Start-Up

SINUMERIK 801 2-5

Start-Up

2.2 Installing and cabling

2.2.1 Installing the control system

Warning：

Never install or dismantle when the control system is under power!

General As an integrated control system, the SINUMERIK 801 CNC can be installed in

the machine control station directly. Stepper drives or servo drives are

installed in the cabinet. The SINUMERIK 801 can be fixed in the station from

the rear side of the CNC with 8 black plastic clips (each of them is equipped

with one M4x16 fastening screw) specific for the control system. The

maximum allowable torque for each screw is 1.5 Nm.

Notice

Prior to the installation, the machine control panel can be provided with an

emergency stop button. If it is not required, the opening must be covered with

a self-adhesive cover delivered together with the SINUMERIK 801.

!

Start-Up

2-6 SINUMERIK 801

Start-Up

Fig.2-5 Schematic diagram for the dismounting of SINUMERIK 801 CNC

Notice

The control system is mounted as described above in the reverse order!

Mounting dimensions

See figures below for the mounting dimensions of SINUMERIK 801 CNC,

STEPDRIVE C/C+ and step motors.

Notice

When AC servo drives, servo motors are used, please refer to installation

instructions concerned for mounting dimensions.

Start-Up

SINUMERIK 801 2-7

Start-Up

Mounting Dimensions

Fig. 2-6 CNC outline dimensions

SINUMERIK 801

1) Free space necessary for heat

dissipation

2) Holes reserved for plastic clips

with screws

2)

Start-Up

2-8 SINUMERIK 801

Start-Up

Fig. 2-7 Mounting hole dimensions

Step drives To install the drive modules, proceed as follows (see vertical installation

diagram shown in Fig. 2–8):

1. Screw in the upper fastening screws M5 with spring washer and spacer.

2. Hang the module into the clips of the upper fastening bracket.

3. Screw in the lower fastening screws and tighten all screws.

34 12

7

307 (327*)

286 (305.6*)

90 (100*) >100

> 80

(>100*)

> 80

(>150*)

Vertical installation (recommended)

Install with M5 screws, spacers and spring washers

Horizontal installation

71 (73*)

176 (180*) >50

Changed installation angle

PE rails

Without forced cooling

Fig. 2-8 Mounting dimensions for stepper drives

Start-Up

SINUMERIK 801 2-9

Start-Up

Notice

Bracketed dimensions as shown in the figure above are suitable for

STEPDRIVE C+.

The modules should be installed such that a clearance of at least 10 cm is left

above, below and between the modules (dimension “a”).

The drive modules, however, can be mounted directly side by side (a>10 mm)

provided they are ventilated with an air stream greater than / equal to 1 m/s.

Do not install devices which are strongly heated during operation beneath the

drive modules!

Step motors

Fig. 2-9 Dimensions of the stepper motors (see Table 2-1)

Table 2-1 Outline dimensions of the stepper motors (see Fig. 2-9)

Dimensions and tolerance

Model D D1 D2 D3 D4 D5 L L1L2L3L4h h1 A B C Key Wt.

(kg)

6FC5

548-0AB03-

0AA0 92 9f6 10 60f7 107 6.6 162 34 14 20 26 3 7 93 62.5 R10 C3X1

4 3

6FC5

548-0AB06-

0AA0 110 16f6 17 56f7 127 8.5 186.5 34 25 32 37 212.5 112 65.0 10X4

5° C5X2

5 5.6

6FC5

548-0AB09-

0AA0 110 16f6 17 56f7 127 8.5 216.5 34 25 32 37 212.5 112 65.0 10X4

5° C5X2

5 7.2

6FC5

548-0AB12-

0AA0 110 16f6 17 56f7 127 8.5 248.5 34 25 32 37 212.5 112 65.0 10X4

5° C5X2

5 8.6

6FC5

548-0AB18-

0AA0 130 16f6 17h

7 100f7 155 10.5 239.0 34 32 36 43 315.0 132 90.0 10X4

5° C5X2

5 13.0

6FC5

548-0AB25-

0AA0 130 16f6 17h

7 100f7 155 10.5 263.5 34 32 36 43 315.0 132 90.0 10X4

5° C5X2

5 15.0

When installing the stepper motor, its radial load shall stay within the data

range listed below:

Start-Up

2-10 SINUMERIK 801

Start-Up

Fig. 2-10 Radial load of the stepper motor

Frequency – torque characteristics of the stepper motors

0,00

2,00

4,00

6,00

8,00

10,00

12,00

14,00

0,10 1,00 10,00 100,00

Frequency [K Hz]

6 60 600 6000

SPEED

[

RPM

]

24,00

26,00

22,00

20,00

18,00

16,00

28,00 6FC5 548-0AB25-0AA0

6FC5 548-0AB18-0AA0

6FC5 548-0AB12-0AA0

6FC5 548-0AB09-0AA0

6FC5 548-0AB06-0AA0

6FC5 548-0AB03-0AA0

Fig. 2-11 Frequency – torque characteristics of the stepper motors

20 mm

Radial load

Motor data

Speed

Shoulder distance

Max. radial load

20 mm

950 N

20 mm

1150 N

600 rev/min

300

r

ev/min

Start-Up

SINUMERIK 801 2-11

Start-Up

2.2.2 Cabling

2.2.2.1 Connecting with the stepper drives

Cable overview Connect the STEPDRIVE C/C+ drive modules, the stepper motors and the

SINUMERIK 801 control system as shown in the connection diagram 2-12.

For the cables required, please refer to the diagram below.

X1

X3

X10X20

X100

X201

X200 X4 X2

X101

Fig. 2-12 Overview of cables

Start-Up

2-12 SINUMERIK 801

Start-Up

2.2.2.2 Connecting with the servo drives (example)

Notice

Adaptor, servo motor, servo drive and cable for connecting the adaptor to the

servo drive are not included in the scope of supply of the SINUMERIK 801

control system.

SINUMERIK

801 CNC

X4

3

4

10

E1

E1N

CN1

X-PLUS1

X-PLUS2

X-SIGN1

X-SIGN2

24V_GND

24V

Y-PLUS1

Y-PLUS2

Y-SIGN1

Y-SIGN2

E1

E1N

CN2

CN3

CN4

HMX

HMY

X-AXIS

Y-AXIS

Z-AXIS

X5

PANASONIC

AC SERVO DRIVE

PANASONIC ADAPTOR

Signal cable:

6FX6002-5AA52-1..0

D1

P1

P1N

D1N

E1

E1N

P2

P2N

D2

D2N

E2

E2N

Connection cable

X20

BERO Axis/Spindle

M24

24Vdc -

power +

PANASONIC

AC SERVO DRIVE

Wire (for Bero 1)

Connection cable

Wire (for Bero 2)

GS

Fig. 2-13 Connecting with the servo drives (SINUMERIK 801+ Panasonic Adaptor + Panasonic Servo

Drives)

Start-Up

SINUMERIK 801 2-13

Start-Up

SINUMERIK

801 CNC

X4

3

4

10

X_E1

X_E1N

J1

X_PLUS1

X_PLUS2

X_SIGN1

X_SIGN2

+24V_GND

+24V

Y_PLUS1

Y_PLUS2

Y_SIGN1

Y_SIGN2

Y_E1

Y_E1N

HMX

HMY

XS3

GOLDEN AGE

AC SERVO DRIVE

GOLDEN AGE ADAPTOR

Signal cable:

6FX6002-5AA52-1..0

D1

P1

P1N

D1N

E1

E1N

P2

P2N

D2

D2N

E2

E2N

Connection cable

X20

BERO Axis/Spindle

M24

24Vdc -

power +

GOLDEN AGE

AC SERVO DRIVE

Wire (for Bero 1)

Connection cable

Wire (for Bero 2)

J2

J3

J5

J6

J7

J4

Fig. 2-14 Connecting with the servo drives (SINUMERIK 801+ Golden Age Adaptor + Golden Age

Servo Drives)

Start-Up

2-14 SINUMERIK 801

Start-Up

2.3 Interfaces and Cables

Position of the See Fig. 2-15 for interface positions.

interfaces

Fig. 2-15 Rear of CNC System

Start-Up

SINUMERIK 801 2-15

Start-Up

2.3.1 Power supply for CNC - X1

General The 24V DC load power supply unit required for supplying CNC is connected

to 3-pin screw-type terminal block.

Table 2-2 The load power supply for CNC (X1)

Terminal Signal Description

1 PE Protective earth

2 M 0V

3 P24 DC24 V

2.3.2 RS232 interface - X2 (RS232)

General When external PC/PG is required to make data communication (WINPCIN)

with the SINUMERIK 801, use RS232 plug connector (9 pin SUB-D).

Table 2-3 RS232 interface X2

Pin Name Type Pin Name Type

1 n.c. 6 DSR I

2 RxD I 7 RTS O

3 TxD O 8 CTS I

4 DTR O 9 n.c.

5 M VO

1

5

6

9

Signal description:

RxD Receive Data

TxD Transmit Data

RTS Request to send

CTS Clear to send

DTR Data Terminal Ready

DSR Data Set Ready

M Ground (0V)

Signal level RS232

Signal type

I Input

O Output

VO Voltage output

Cable for WinPCIN Table 2-4 Cable for WinPCIN: Pin assignment of the Sub-D connector

9-Pin (801) Name 25-Pin (PC)

1 Shield 1

2 RxD 2

3 TxD 3

4 DTR 6

5 M 7

6 DSR 20

Start-Up

2-16 SINUMERIK 801

Start-Up

7 RTS 5

8 CTS 4

9

or

9-Pin (801) Name 9-Pin (PC)

1 Shield 1

2 RxD 3

3 TxD 2

4 DTR 6

5 M 5

6 DSR 4

7 RTS 8

8 CTS 7

9

SINUMERIK 801

9PIN SUB-D (socket)

RxD 2

TxD 3

DTR 4

0 V 5

DSR 6

TxD3

RxD2

DSR6

0 V5

DTR4

0.1 mm 2

RTS 7 CTS8

CTS 8 RTS7

RxD 2

TxD 3

DTR 4

0 V 5

DSR 6

RxD 2

TxD 3

DSR 6

0 V 7

DTR 20

0.1 mm

2

RTS 7CTS 5

CTS 8RTS 4

PC

9 PIN SUB-D (fsocket)

SINUMERIK 801

9 PIN SUB-D (socket)

PC

25 PIN SUB-D (plug)

Fig. 2-16 Communication connector RS232(X2)

RS232 terminal adapter

When CNC stays ungrounded, a RS232 adapter must be used to protect RS232

connector from being broken down. The use and wiring method of the RS232

adapter is shown as below:

(1) The connecting diagram between the RS232 adapter and PC

RS232 adapter

9 PIN SUB-D (socket)

PC

9 PIN SUB-D (socket)

RxD 2

TxD 3

DTR 4

DSR 6

0V 5

RxD 2

TxD 3

DTR 4

DSR6

0V 5

0.1 mm2

RTS 7 RTS 7

CTS 8 CTS 8

X2

Fig. 2-17 Connecting diagram 1 (with 9 PIN SUB-D connector of PC

Serial Port

Start-Up

SINUMERIK 801 2-17

Start-Up

RS232 adapter

9PIN SUB-D (socket)

PC

25 PIN SUB-D (plug)

RxD 2

TxD 3

DTR 4

DSR 6

0V 5

RxD 3

TxD 2

DTR 20

DSR6

0V 7

RTS 7 RTS 4

CTS 8 CTS 5

0.1 mm

2

X2

Fig. 2-18 Connecting diagram 2 (with 25PIN SUB-D connector of PC Serial

Port)

(2) The connecting diagram between the RS232 adapter and SINUMERIK

801

RS232 adapter

9 PIN SUB-D (socket)

SINUMERIK 801

9 PIN SUB-D (socket)

RxD 2

TxD 3

DTR 4

DSR 6

0V 5

RxD 2

TxD 3

DTR 4

DSR6

0V 5

0.1 mm

2

RTS 7 RTS 7

CTS 8 CTS 8

X1

Fig.2-19 Connecting diagram 3 (with SINUMERIK 801)

Notes:

(1) X1 and X2 indicated in Fig. 2-17～2-19 refer to interfaces of RS232

adapter itself. In which, X1 is for connecting RM232 adapter and

SINUMERIK 801, X2 is for connecting RS232 adapter and PC serial

port.

(2) SIEMENS can provide the connecting cable (9PIN to 9PIN SUB-D),

the order number (MLFB number): 6FX8002-1AA01-1..0.

(3) The maximum baudrate for RS232 adapter is 9600 and the

maximum length of each connecting cable for PC and SINUMERIK

801 shall be no more than 15m.

Notice:

In order to ensure the common grounding between SINUMERIK 801 CNC and

PC, use only shielded cable and make sure that the shield is connected to the

metal or metal plated connector casing on both ends of the cable.

Connect and disconnect cables between CNC and PC under power-off

conditions only;

We recommend you to use a RS232 terminal adapter (order number:

6FX2003-0DS00).

!

Start-Up

2-18 SINUMERIK 801

Start-Up

2.3.3 Spindle encoder interface – X3 (SPINDLE)

General The spindle encoder interface (X3) of the SINUMERIK 801 is a 15-pin SUB-D

socket connector.

Table 2-5 Spindle encoder interface X3

Pin Signal Type Pin Signal Type

1 n.c. 9 M VO

2 n.c. 10 Z I

3 n.c. 11 Z_N I

4 P5_MS

VO 12 B_N I

5 n.c. 13 B I

6 P5_MS VO 14 A_N I

7 M VO 15 A I

8 n.c.

Signal Description

A; A_N Channel A

B; B_N Channel B

Z; Z_N Zero Reference Mark

P5_MS +5,2V Supply Voltage

M Ground

Signal level: RS422

Signal type

VO Voltage output (supply)

I 5V input (5V signal)

Connectable encoder types

Incremental 5 V encoders can be connected directly.

Characteristics The encoders must meet the following requirements:

Transmission method: Differential transmission with 5 V square-wave signals

Output signals: Track A as true and negated signal (Ua1, Ua1)

Track B as true and negated signal (Ua2, Ua2)

Zero signal N as true and negated signal (Ua0, Ua0)

Max. output frequency: 1.5 MHz

Phase offset between

tracks A and B: 90º ± 30º

Current consumption: max. 300 mA

Start-Up

SINUMERIK 801 2-19

Start-Up

Cable lengths The maximum cable length depends on the specifications of the encoder

power supply and on the transmission frequency.

To provide fault-free operation, make sure that the following values are not

exceeded when using preassembled interconnecting cables from SIEMENS:

Table 2–6 Maximum cable lengths depending on the encoder power supply

Supply Voltage Tolerance Current Consumption Max. Cable

Length

5 V DC 4.75 V ... 5.25 V < 300 mA 25 m

5 V DC 4.75 V ... 5.25 V < 220 mA 35 m

Table 2–7 Maximum cable lengths depending on the transmission frequency

Encoder Type Frequency Max. Cable Length

1 MHz 10 m incremental

500 kHz 35 m

Start-Up

2-20 SINUMERIK 801

Start-Up

2.3.4 Feed drive interface - X4 (AXIS)

General The feed drive interface X4 of the SINUMERIK 801 is a 25-pin SUB-D plug

connector.

Table 2-8 Feed drive interface X4

Pin Signal Type Pin Signal Type

1 PULS1 O 14 PULS1_N O

2 DIR1 O 15 DIR1_N O

3 ENABLE1 O 16 ENABLE1_N O

4 PULS2 O 17 PULS2_N O

5 DIR2 18 DIR2_N O

6 ENABLE2 O 19 ENABLE2_N O

7 n.c. 20 n.c.

8 n.c. 21 n.c.

9 n.c. 22 n.c.

10 SE4_1 K 23 SE4_2 K

11 n.c. 24 n.c.

12 AO4 AO 25 AGND4 AO

13 M

Signal Description

Stepper Interface

PULS[1 … 2], PULS[1 … 2]_N Stepper Clock

DIR[1 … 2], DIR[1 … 2]_N Stepper Revolution Direction

EN[1 … 2], EN[1 … 2]_N Stepper Enable

M Ground (not to be connected when using

differential signals)

Analog Spin dle Interface

AO4 Analog Command Value

AGND4 Analog Ground

SE4_1, SE4_2 Servo Enable Relay Contact

Signal level: +/-10V for Analog Outputs

RS422 for Stepper Signals

Signal type

AO Analog output

O Output

K Switch signal

Start-Up

SINUMERIK 801 2-21

Start-Up

Drives with analog interface

Signals:

A voltage and an enable signal are output.

z AO4 (SETPOINT)

Analog voltage signal in the range ± 10 V to output a speed setpoint

z AGND4 (REFERENCE SIGNAL)

Reference potential (analog ground) for the setpoint signal, internally

connected to logic ground.

z SE4 (SERVO ENABLE)

Relay contact pair controlling the enable of the power section.

Signal parameters

The setpoint is output as an analog differential signal.

Table 2–9 Electrical parameters of the signal outputs for step-switching drives

Parameter Min Max Unit

Voltage range –10.5 10.5 V

Output current –3 3 mA

Relay contact

Table 2–10 Electrical parameters of the relay contacts

Parameter Max. Unit

Switching voltage 50 V

Switching current 1 A

Switching power 30 VA

Cable length: max. 35 m

Start-Up

2-22 SINUMERIK 801

Start-Up

2.3.5 Handwheel & Extension Keys interface - X10 (MPG)

General One handwheel can be connected externally via the handwheel & extension

keys interface X10 (10-pin mini–Combicon plug connector) .

Table 2-11 Handwheel & extension keys interface X10

Pin Signal Type Pin Signal Type

1 A I 6 M5 VO

2 /A I 7 Reset DI

3 B I 8 CycSta DI

4 /B I 9 CycSto DI

5 P5 VO 10 M24 VI

Signal (handwheel) Description

A Channel A, true, handwheel

/A Complement Channel A, negated, handwheel

B Channel B, true, handwheel

/B Complement Channel B, negated handwheel

P5 Power supply, 5.2V

M5 5.2 V supply ground for handwheel

Signal level (handwheel)

RS422

Signal type (hand wheel)

VO Voltage output

I Input (5 V signal)

Handwheel One electronic handwheel can be connected which must meet the following

requirements:

Transmission method: 5 V square-wave (TTL level or RS422)

Signals: Track A as true and negated signal (Ua1, Ua1)

Track B as true and negated signal (Ua2, Ua2)

Max. output frequency: 500 kHz

Phase offset between

tracks A and B: 90º ± 30º

Supply: 5 V, max. 250 mA

Reset Reset key

CycSta Cycle Start key

CycSto Cycle Stop key

M24 24V supply ground

Start-Up

SINUMERIK 801 2-23

Start-Up

Signal level (extension keys) RS422

Signal type (extension keys)

VI Voltage input

DI Input (24V signal)

Start-Up

2-24 SINUMERIK 801

Start-Up

2.3.6 BERO input interface - X20 (BERO)

General Two proximity switches (BERO) can be connected via a 10 pin Mini-Combicon

plug connector X20.

Table 2-12 BERO input interface X20

Pin Signal Type Pin Signal Type

1 NCRDY_K1 K 6 n.c.

2 NCRDY_K2 K 7 n.c.

3 BERO1 DI 8 n.c.

4 BERO2 DI 9 n.c.

5 n.c. 10 M24 VI

Signal Description

NCRDY_K[1 … 2] NC-READY-Relay-Contact, max. current is 2A at

150VDC or 125VAC)

BERO[1 … 2] BERO-Input for axis 1 ... 2

M24 Reference potential for digital input

Signal type

K Switching contact

DI Digital input

VI Voltage input

2 BERO inputs These inputs are 24V PNP-switching. Switches or non-contact sensors, e.g.

inductive proximity switches(BERO) can be connected.

They can be used as switches for reference points, for example:

BERO1 – X axis

BERO2 – Z axis

Table 2-13 Electrical parameters of the digital inputs

Parameter Value Unit Note

“1” signal, voltage range 11 …30 V

“1” signal, current consumption 6 …15 mA

“0” signal, voltage range -3 …5 V Or input open

Signal delay 0Æ1 15 us

Signal delay 1Æ0 150 us

Notice

When AC servo drives are used, BERO can be input as zero mark signals.

However, be careful that here BERO refers to 24V pulse input.

NC–READY output Readiness in the form of a relay contact (NO); must be integrated into the

EMERGENCY STOP circuit.

Start-Up

SINUMERIK 801 2-25

Start-Up

Table 2–14 Electrical parameters of the NCREADY relay contact

Parameter Max. Unit

DC switching voltage 50 V

Switching current 1 A

Switching power 30 VA

2

1

Pin number of

X20

1P5

NC_RDY

Relay

Fig. 2-20 NC-READY output

The NCREADY is an internal relay of NC. It will open when NC is not ready,

and close after NC is ready for operation.

Start-Up

2-26 SINUMERIK 801

Start-Up

2.3.7 Digital inputs/outputs X100 (DIN0)～X101 (DIN1), X200 (DOUT0) ... X201

(DOUT1)

General There are 16 digital inputs and 12 digital outputs in all. Connector designation:

10 pin Mini-Combicon plug connector.

Table 2-15 Pin assignment for connectors X100～X101

Pin Signal X100

Signal type Pin Signal X101

Signal type

1 n.c. 1 n.c.

2 Limit X+ DI 2 T1 DI

3 Limit X- DI 3 T2 DI

4 Ref. X DI 4 T3 DI

5 Limit Z+ DI 5 T4 DI

6 Limit Z- DI 6 T5 DI

7 Ref. Z DI 7 T6 DI

8 FootPed DI 8 User in1 DI

9 E-Stop DI 9 User in2 DI

10 M24 VI 10 M24 VI

* In the list above, high signal level refers to 15 …30 VDC, current drain 2 …

15 mA and low level -3 … 5 VDC.

Signal type

VI Voltage input

DI Input (24 V signal)

Table 2–16 Electrical parameters of the digital inputs

Parameter Value Unit Note

“1” signal, voltage range 15 ... 30 V

“1” signal, current consumption 2 ... 15 mA

“0” signal, voltage range –3 ... 5 V Or input open

Signal delay 0 Æ 1 0.5 ... 3 ms

Signal delay 1 Æ 0 0.5 ... 3 ms

Notice

See Section 3.2 “ Input/Output Configuration” for definitions of X100 ... X101

input signals.

Start-Up

SINUMERIK 801 2-27

Start-Up

Table 2-17 Pin assignment for connectors X200～X201

Pin Signal X200

Signal type Pin Signal X201

Signal type

1 P24 VI 1 P24 VI

2 S-CW DO 2 User out1 DO

3 S-CCW DO 3 User out2 DO

4 T-CW DO 4 User out3 DO

5 T-CCW DO 5 User out4 DO

6 Cooling DO 6 n.c.

7 Lubric DO 7 n.c.

8 S-Brake DO 8 n.c.

9 Chuck DO 9 n.c.

10 M24 VI 10 M24 VI

* In this list, high signal level refers to the 24VDC, current leakage less than

2mA with a simultaneity factor of 0.5.

Signal type

VI Voltage input

DO Digital output (24 V signal)

Table 2–18 Electrical parameters of the digital outputs

Parameter Value Unit Note

“1” signal, nominal voltage

Voltage drop

24

max. 28.8

V

“1” signal, output current 0.5 A Simultaneity factor

0.5 per 12 outputs

“0” signal, leakage current max. 2 mA

Notice

See Section 3.2 “Input/Output Configuration” for definitions of X200 ... X201

output signals.

Start-Up

2-28 SINUMERIK 801

Start-Up

Connections of digital

inputs/outputs

For the connections of digital inputs/outputs, see Fig. 2-22 and 2-23 below.

2

3

4

9

10

1

Pin number of

X100---X101

Optic-isolated

P24

M24

Fig. 2-21 Connection of digital inputs

+24V stabilized power supply

Driver

2

3

9

M

P24

1

Pin number of X200

,

X201

+24V 0V

Relay

Driver

10 M24

Optic-isolated

Fig. 2-22 Connection of digital outputs

Start-Up

SINUMERIK 801 2-29

Start-Up

2.3.8 Connecting cables for SINUMERIK 801

General The connecting diagram of the setpoint cable between CNC and the drive is

given in the figure below. The MLFB (order no.) of the said cable is

6FX6002-5AA52-1..0 with RS422 differential signals.

SE1

SE2

AO

AON

25-pin SUB-D

connector

On CNC side:

X4 interface

Z axis

On drive side:＋System interface

P2

P2N

D2

D2N

E2

E2N

Spindle

X axis

P1

P1N

D1

D1N

E1

E1N

Fig. 2-23 Setpoint cable for SINUMERIK 801

Start-Up

2-30 SINUMERIK 801

Start-Up

2.4 Installing and Starting-Up the Drive Modules

2.4.1 Connecting the STEPDRIVE C/C+ drive modules

Cable overview Connect the STEPDRIVE C/C+, the stepper motors and the SINUMERIK 801

control system as shown in Figure 2-24:

wh. blk. wh. br. wh.

A

B

C

D

E

PE

RDY

TMP

FLT

DIS

CURR.1

CURR.2

RES.

DIR.

+PULS

-PULS

+DIR

-DIR

+ENA

-ENA

RDY

ZPH

+24V

24V GND

PE

L

N

PE

A

B

C

D

E

PE

RDY

TMP

FLT

DIS

CURR.1

CURR.2

RES.

DIR.

+PULS

-PULS

+DIR

-DIR

+ENA

-ENA

RDY

ZPH

+24V

24V GND

PE

L

N

PE

Drive of axis 1

Signal cable

SINUMERIK 801

X4

Power cable

yellow

P1

P1N

D1

D1N

E1

E1N

P3

P3N

D3

D3N

E3

E3N

Motor

380VAC

L

N

PE

380/85 VAC - Transformer

+

-

24Vdc

Power Supply

Note:

The drive and motor must

be well grounded via the

shield connections.

Drive of axis 2

white

blue

white

green

white

black

white

brown

white

Fig. 2-24 Overview of cables

Start-Up

SINUMERIK 801 2-31

Start-Up

Warning

Prior to performing connection work, always first make sure that the supply

voltage is switched off.

With the supply voltage switched off, hazardous voltages are present at the

mains and motor connections. Under no circumstances may these connection

be touched in the ON condition; otherwise, loss of life or severe personal

injury could be the consequence.

Mains connection

z The device must be connected via an external fuse.

Fuse: K6A for 1 axis

K10A for max. 2 axes

z If the transformer possesses a shielded winding, this should be

connected with low inductivity to PE.

z Ground the transformer on the secondary side.

Connecting the motor-end cables

z To connect the cables, remove the terminal box cover (3 screws).

z Use the cable with the order no. 6FX6 002–5AA51–1..0

z On the drive end, connect the cable shield to the housing such that an

electrical connection is provided via the appropriate strain relief clamp

and clamp the braided shield to PE.

z On the motor side, braid the shield, provided it with a cable shoe and

clamp it to the grounding screw.

Pulse interface

z To connect the drive pulse interface to the SINUMERIK 801, use the

preassembled cable, order no.6FX6 002–5AA52–1..0.

z On the drive side, connect the cable shield to the housing such that an

electrical connection is provided via the appropriate strain relief clamp.

24V signal interface

z To evaluate the 24 V high–side signals “Zero Phase” (ZPH) and/or “Drive

ready” (RDY) in the CNC, then connect a 24 V voltage (PELV) to the +24

V and 24 V GND terminals.

Driving system design

When a driving system for machine tools is configured with stepper drives, pay

attention to following requirements:

1. Design the driving system according to the frequency – torque

characteristics of the stepper motors (see Fig. 2-11: Frequency – torque

characteristics of the stepper motors). The characteristic feature of the

stepper motors depends on the frequency-torque characteristics. The

motor will have a larger output torque while running at a low speed or a

smaller one while at a high speed (and also a high power dissipation and

!

Start-Up

2-32 SINUMERIK 801

Start-Up

temperature boost during this period).

1) The resolution (displacement per step of the stepper motor)

depends on mechanical data:

Resolution＝leadscrew pitch/steps per revolution × reduction ratio

2) Calculate the max. motor speed according to the max. axis speed,

then the corresponding output torque of the stepper motor

according to the frequency – torque characteristics:

Motor speed＝axis speed/leadscrew pitch/reduction ratio

2. Each axis must be configured with one BERO proximity switch (PNP

normal open, viz. 24Vdc level output) for generating zero marks for

reference point approach.

Notice

The quality of BERO proximity switches will have influences on the resolution

of reference points. It’s recommended to use high quality switches;

Make the clearance between end face of the proximity switch used for tesing

and the object under test as short as possible.

Do not use conventional contact stroke switches as proximity switches for zero

mark signals (because of the bigger signal jitters).

Reference point approach configuration

Since the stepper motors cannot generate zero marks required by the encoder,

the SINUMERIK 801 can take two configurations for approaching reference

points as: double-switch mode and single-switch mode.

Double-switch mode:

There is one reference cam in the axis and one BERO (inductive proximity

switch) at the leadscrew (one pluse is generated per revolution of the

leadscrew). Connect the reference cam to the inputs of DI （X100） (see

Chapter 3:”Built-In PLC Application for detailed description) while BERO to

connector X20 of the control system.

Leadscrew

BERO

Signal to X20

Machine body

Object under test Reference cam

Signal to PLC input

Fig. 2-25 Configuration 1 for reference point approaching: double-switch mode

This mode enables high speed search for the reference cam, then for BERO at

a lower speed. With this mode, reference points can be approached rapidly

and more precisely. In addition, BERO can also be used for monitoring

revolutions.

!

Start-Up

SINUMERIK 801 2-33

Start-Up

Single-switch mode (without reference cam, MD34000=0)：

There is one BERO in the axis.

Machine body

Leadscrew Bero

Object under test

Signal output to X20

Fig. 2-26 Configuration 2 for reference point approaching: single-switch mode

With this mode, only one speed for referece point approaching can be set.

Precision of reference point approach is relevant to the quality of BERO and

the speed set for approaching reference points.

BERO sampling methods

No matter which configuration is taken, the control system can use two ways

to sample BERO when approaching the reference point:

1) Sample the rising edge of BERO and take the effective level of the rising

edge as the reference mark;

2) Move the axis onwards, record the distance traversed after this

reference mark and sample the falling edge of BERO. After samping the

falling edge, the control system will auto-calculate the middle point

between both edges and use this point as the reference point for the

axis.

t

Threshold Level Rising Edge Falling Edg e

Ref. Point

V V

t

Threshold Level

Threshold Level Falling Edge

Ref. Point

Fig. 2-27 BERO sampling methods

Mechanical inst allation of the proximity switches

Follow Fig. 2-28 & 2-29 to complete the mechanical installation of BERO under

double-switch mode.

z When stepper motors is connected with a leadscrew directly:

Start-Up

2-34 SINUMERIK 801

Start-Up

Fig.2-28 Installing the BERO – 1

z If there are reduction gears between the stepper motor and proximity

switch

丝杠

齿轮二

齿轮一

接近开关（带LED）

步进电机

连接至X20接口

Fig. 2-29 Installing the BERO - 2

Drive current settings

Use stepper drives to actuate stepper motors of different torques. When

starting up the drive system, set the drive current according to the torque of

the motor used. See figure below for current settings:

L

ea

d

screw

G

ear

2

G

ear

1

St

eppe

r

mo

t

o

r

BERO

(

w

i

th

LED)

T

o

X20

i

n

t

er

f

ace

L

ea

d

screw

BERO

(

w

ith

LED)

T

o

X20

i

n

t

er

f

ace

St

eppe

r

mo

t

o

r

C

oup

li

ng

j

o

i

n

t

Start-Up

SINUMERIK 801 2-35

Start-Up

Fig. 2-30 Drive current settings

Warning

If the current set is too large for the motor, the motor might be damaged due to

overtemperature.

Start-up sequence

1. Connect the mains voltage and - if necessary - also the 24 V supply

voltage.

2. Check the DIS LED.

3. Activate the ENABLE signal via the control system (power-up the control

system).

The yellow DIS LED goes out and the green RDY LED is lit. The drive is ready,

the motor is powered.

If the PULSE signal is provided by the control system with pulses, then motor

will rotate in the direction of rotation specified by the DIR signal.

Notice

The DIR switch can be used to adapt the direction of rotation to the mechanics

of the machine. Never actuate the switch when the drive is powered!

CURR.1

CURR.2

RES.

DIR

ON

RDY

TMP

FLT

DIS

LEDs

DIR

switch

Motor Type CURR 1 CURR 2 Phase Cur

r

3.5 Nm

9 Nm

12 Nm

OFF

1.35

A

2.00

A

1.35

A

2.55

A

OFF

ON ON

ON

6 Nm

18 Nm

25 Nm OFF

ON

3.6

A

5.00 A

STEPDRIVE C

STEPDRIVE C+

Stepper Driver

!

Start-Up

2-36 SINUMERIK 801

Start-Up

Table 2-19 LED alarms

LED

Name Color Meaning Remedy

RDY green the only LED

that is lit

Drive ready If the motor does not rotate, it can

have the following causes:

- No pulses are output by the

control system.

- Pulse frequency too high

(motor is “out of step”)

- Motor load too large or

sluggish

DIS yellow the only LED

that is lit

Drive ready; motor not powered Activate ENABLE signal via CNC

FLT red is lit There is one of the following

errors:

- Overvoltage or undervoltage

- Short-circuit between the

motor phases

- Short-circuit between motor

phase and ground

Measure 85 V operating voltage

Check cable connections

TMP red is lit Overtemperature in the drive Drive defective; replace

all No LED is lit No operating voltage Check cable connections

Selection of the drive

transformer

Configure the stepper motors in different torques with a drive transformer

(380VA C->85VAC) that has a suitable power.

Table 2-20 Reference table for power ratings of differnt transformers*

MLFB (Order No.) of

Motor

No. of

motor

axes

Torque (Nm)

Power of

transformer

(KVA)

6FC5 548-0AB03-0AA0 1 3.5 0.3

6FC5 548-0AB06-0AA0 1 6 0.403

6FC5 548-0AB09-0AA0 1 9 0.612

6FC5

548-0AB012-0AA0

1 12 0.7

6FC5

548-0AB018-0AA0

1 18 1.368

6FC5

548-0AB025-0AA0

1 25 1.420

*Select the drive transformer based on this table and the simultaneity factor of

the machine coordinates (coefficient recommended: 1.0).

2.4.2 Connecting the servo drive modules

Please refer to relevant technical instructions for the connection with servo

drive.

SINUMERIK 801 3-1

Start-Up

Built-In PLC Application 3

Important ! After the connection of individual components, the related functions in PLC

application (emergency stop, hardware limit switch) must be commissioned

first. Only after the afore-said safety functions are commissioned without error,

you may start NC parameters.

Built-In PLC Application

3-2 SINUMERIK 801

Start-Up

3.1 Input/Output Configuration

Input signals description

Table 3-1 Input signals description

Description of Input Signals

X100 DIN0

Pin# Signal Input # Signal Description

1 n.c Not defined

2 Limit X+ I0.0 Hardware limit X+ (normally closed)

3 Limit X- I0.1 Hardware limit X- (normally closed)

4 Ref. X I0.2 X reference cam

5 Limit Z+ I0.3 Hardware limit Z+ (normally closed)

6 Limit Z- I0.4 Hardware limit Z- (normally closed)

7 Ref. Z I0.5 Z reference cam

8 FootPed I0.6 Foot pedal

9 E-Stop I0.7 Emergency Stop key (normally closed)

10 M24 24V ground

X101 DIN1

Pin# Signal Input # Signal Description

1 n.c. Not defined

2 T1 I1.0 Tool sensor T1

3 T2 I1.1 Tool sensor T2

4 T3 I1.2 Tool sensor T3

5 T4 I1.3 Tool sensor T4

6 T5 I1.4 Tool sensor T5

7 T6 I1.5 Tool sensor T6

A

ctive low when HED

approximates to the

magnet, otherwise

active high (see below

for wiring diagram)

8 User in1 I1.6 User input 1

9 User in2 I1.7 User input 2

10 M24 24V ground

Built-In PLC Application

SINUMERIK 801 3-3

Start-Up

Output signals description

Table 3-2 Output signals description

Description of Output Signals

X200 DOUT0

Pin# Signal Input # Signal Description

1 P24 24V power supply

2 S-CW Q0.0

Direction and enable of unipolar spindle or

contactor-controlled spindle (see MD30134

description)

3 S-CCW Q0.1

Direction and enable of unipolar spindle or

contactor-controlled spindle (see MD30134

description)

4 T-CW Q0.2 Turret CW

5 T-CCW Q0.3 Turret CCW

6 Cooling Q0.4 Coolant control

7 Lubrica Q0.5 Lubrication control

8 S-Brake Q0.6 Spindle control

9 Chuck Q0.7 Chuck clamping control

10 M24 24V ground

X201 DOUT1

Pin# Signal Input # Signal Description

1 P24 24V power supply

Digital input X101

Tool sensor T1

Tool sensor T2

Tool sensor T3

Tool sensor T4

Tool sensor T5

Tool sensor T6

User input 1

User input 2

A

ctive low

when HED

approximates

to the magnet,

otherwise

active high 24VDC

Power Supply

＋

－

1

2

3

4

5

6

7

8

9

10

Built-In PLC Application

3-4 SINUMERIK 801

Start-Up

2 User out1

Q1.0 User output 1

3 User out2

Q1.1 User output 2

4 User out3

Q1.2 User output 3

5 User out4

Q1.3 User output 4

6 n.c. Not defined

7 n.c. Not defined

8 n.c. Not defined

9 n.c. Not defined

10 M24 24V ground

Note:

User inputs/outputs

a） User in1（I1.6）＝0 ――>User out1(Q1.0)=0

User in1（I1.6）＝1 ――>User out1(Q1.0)=1

b） User in2（I1.7）＝0 ――>User out2(Q1.1)=0

User in2（I1.7）＝1 ――>User out2(Q1.1)=1

c） The output values of User out3 and 4 are defined by M functions

Use out3(Q1.3) User out4(Q1.2)

M20 0 0

M21 0 1

M22 1 0

M23 1 1

Built-In PLC Application

SINUMERIK 801 3-5

Start-Up

3.2 Definition of User Keys

Fig. 3-1 User keys on MCP area

Override keys Trav erse keys

User

Keys

Built-In PLC Application

3-6 SINUMERIK 801

Start-Up

Definition of user keys

Table 3-3 Definition of user keys

Key Des cription of User Keys

Chuck clamping

Chuck clamping internally/externally

Chuck unclamping

Manual tool change

Manual lubrication start or stop

Manual coolant on or off

LED Description

Chuck clamped (LED lit)

Chuck clamped internally (LED goes out) /externally (LED lit)

Chuck unclamped (LED lit)

Tool changing (LED lit)

Lubricating (LED lit)

Cooling (LED lit)

Definiton of traverse keys

X axis, plus direction

X axis, minus direction

Z axis, plus direction

Z axis, minus direction

RAPID TRAVERSE OVERLAY

Definition of override keys

1）Feedrate override plus key with LED

The feedrate override will be increased by a set increment when pressing

the key once until reaching 120％;

LED is lit when the feedrate override is more than 100%, and flashes when

it reaches 120%;

Built-In PLC Application

SINUMERIK 801 3-7

Start-Up

2）Feedrate override 100% key

Keep pressing this key for 1.5 seconds, the feedrate override will be

changed into 100% directly.

3）Feedrate override minus key with LED

The feedrate override will be decreased by a set increment when pressing

the key once until reaching 0％;

Keep pressing this key for 1.5 seconds, the feedrate override will be

changed into 0% directly.

LED is lit when the feedrate override is between 0 ... 100%, and flashes

when it’s lowered to 0%;

4）Spindle speed override plus key with LED

The spindle override will be increased by a set increment when pressing

the key once until reaching 120％;

LED is lit when the spindle override is more than 100%, and flashes when

it reaches 120%;

5）Spindle override 100% key

Keep pressing this key for 1.5 seconds, the spindle override will be

changed into 100% directly.

6）Spindle override minus key with LED

The spindle override will be decreased by a set increment when pressing

the key once until reaching 50％;

Keep pressing this key for 1.5 seconds, the spindle override will be

changed into 50% directly.

LED is lit when the spindle override is between 50 ... 100%, and flashes

when it’s lowered to 50%.

Notice

The feedrate override can be adjusted by settable incremens as: 0％, 1%,

2%, 4%, 6%, 8%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 75%, 80%, 85%,

90%, 95%, 100%, 105%, 110%, 115%, 120％.

The spindle override can be adjusted by settable increments as 50％, 55%,

60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 105%, 110%, 115%,

120％.

Built-In PLC Application

3-8 SINUMERIK 801

Start-Up

3.3 PLC Machine Data

Definition of MD14512

Table 3-4 MD14512

MD14512

Machine data USER_DATA_HEX

PLC machine data - Hex

INDEX Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

[0]

Reserved

[1]

Reserved

[2]

Reserved

[3]

Reserved

PLC application configuration

[4] Toolholder

control

Clamp &

unclamp

Lubrication

inactive inactive inactive

[5]

Reserved

Technology Setting

[6] Z axis

rotation

monitoring

active

X axis

rotation

monitoring

active

Spindle

brake

active

Auto

lubrication

once when

power on

[7]

Reserved

Notes:

1) If you don’t want to use PLC to activate toolholder control, clamp/umclamp or lubrication functions,

set MD14512 [4] to proper bit to deactivate corresponding function.

2) You may set MD14512[6] to desired bit to activate corresponding function.

Caution

PLC machine data reserved by the control system must not be changed!

Definition of MD14510

Table 3-5 MD14510

MD14510

Machine Data PLC Machine Date—Integer

Index

14510[0] Reserved

14510[1] Reserved

!

Built-In PLC Application

SINUMERIK 801 3-9

Start-Up

14510[2]

Definition: Interval of track lubrication

Unit: 1 minute

Range: 5～300 minutes

14510[3]

Definition: Duration of lubrication

Unit: 0.1 second

Range: 10～200 (1～20 seconds)

14510[4]

Definition: Number of positions on the turret

Unit: -

Range: 4 or 6

14510[5]

Definition: Monitor time (turret change abort if destination tool not

found within specified time)

Unit: 0.1second

Range: 30～200 (3～20 seconds)

14510[6]

Definition: Turret clamping time

Unit: 0.1 second

Range: 5～30 (0.5～3 seconds)

14510[7]

Definition: Braking time of external brake mechanism of a

contactor controlled spindle

Unit: 0.1 second

Range: 5～200 (0.5～20 seconds)

Built-In PLC Application

3-10 SINUMERIK 801

Start-Up

3.4 Fixed PLC Alarms

Definition of fixed PLC alarms

Table 3-6 Definition of fixed PLC alarms

Alarm # Alarm Description

700008 Turret # wrongly defined, MD14510[4] (4/6)

700009 Turret clamping time undefined, check MD14510[6]

700010 Turret monitoring time undefined, check MD14510[5]

700011 Spindle brake time out range, check MD14510[7]

700021 Spindle/feed axis start impossible while unclamped

700022 Unclamping impossible while spindle run or NC start enabled in

AUTO or MDA mode

700023 Programmed tool #. > Max. turret on turret#

700024 Tool not found, monitoring time up

700025 No position signals from turret

700027 Approach ref. point again after rot. monitoring

SINUMERIK 801 5-1

Start-Up

Setting Up 4

4.1 Setting Up NC Parameters

System configuration

The system configuration for SINUMERIK 801 is a turning variant, i.e.: X axis

is set as the 1st axis, Z axis the 2nd and spindle the 3rd. Technology settings

are also for turning machining.

Notice

NC parameters can not be changed unless the Machine Manufacturer

password (“Evening”) has been input.

Parameterization Parameter settings for SINUMERIK 801 are given in following tables. In which,

IPR refers to pulses per motor revolution, RPM revolutions per minute and I

the number of pulses.

SINUMERIK 801：

MD Designation Unit Axis

Input

value Description

30130 CTRLOUT_T

YPE

- X，Z 2 Output type of

setpoint (setpoint

branch): the setpoint

signals are output to

connector X4

30240 ENC_TYPE - X，Z 3 Type of actual value

acquisition (actual

position value)

(encoder no.):

3: Encoder for

stepper motor

34200 ENC_REF_M

ODE

- X，Z 2* or

4*

Type of position

measuring system:

2: BERO

4: Bero with two

edges

34210 ENC_REF_

STATE

- X，Z 0 or

1

Reference state

0: Function “Record

reference point”

inactive

1: Function “Record

reference point”

activated

Setting Up

5-2 SINUMERIK 801

Start-Up

* 2: single-edge evaluation, for locking the reference point in the rising edge of

the proximity switch; 4: double-edge evaluation, for locking the referece point

in the intermediate point between rising and falling eges.

Notice

Even if the function “record reference point” has been activated, reference

point must be approached again under following circustances, otherwise

collision might be resulted!

1. After system power up with saved data

a） After machine operator selects on the operator panel to “power up with

saved data” (corresponding alarm# 004062).

b） System will be powered up automatically with saved data after it has been

dead for a long period and battery for internal data savings run out of

power. (corresponding alarm# 004065)

2. After system power-off, the actual position of the axis concerned has

been moved out of maintenance or other reasons.

Parameterization for stepper motors:

MD Designation Unit Axis

Input

value Description

31020 ENC_RESOL IPR X, Z 1000 Encoder

markings per

revolution

(encoder no.)

31400 STEP_RESOL IPR X, Z 1000 Steps per

stepping motor

revolution

Mechanical parameters for the driving system:

MD Designation Unit Axis

Input

value Description

31030 LEADSCREW_

PITCH

mm X, Z 5 Pitch of

leadscrew

31050 DRIVE_AX_RATIO

_DENUM[0 ... 5]

- X, Z 40 Denominator

load gearbox

(control

parameter No.)

31060 DRIVE_AX_RATIO

_NUMERA[0 … 5]

- X, Z 50 Numerator load

gearbox (control

parameter set

No.)

Note:

After determining the mechanical parameters, set the axis speed. For

stepper motors, the motor speed shall be determined according to its

frequency-torque characteristics: motor speed ＝axis speed/leadscrew

pitch/reduction ratio.

Setting Up

SINUMERIK 801 5-3

Start-Up

MD Designation Unit Axis Example

value Description

32000 MAX_ AX_VELO mm/Min X，Z 4800 Maximum axis

velocity

32010 JOG_ VELO_

RAPID

mm/Min X，Z 4800 Rapid traverse

in JOG mode

32020 JOG_ VELO mm/Min X，Z 3000 JOG axis

velocity

32260 RATED_VELO RPM X，Z 1200 Rated motor

speed (setpoint

branch)

36200 AX_VELO_LIMIT mm/Min X，Z 5280 Threshold value

for velocity

monitoring

After the above parameters have been set, SINUMERIK 801 will

automatically determine the frequency when being powered on:

20rev./sec.×1000 pulses/rev.＝20000pulses/sec., and MD31350 is set as

follows:

MD Designation Unit Axis Example

value Description

31350 FREQ_STEP_LIMIT Hz X，Z 20000 Stepping rate at

maximum velocity

Setting the encoder limit frequency according to MD31350:

MD Designation Unit Axis

Example

value Description

36300 ENC_FREQ_LIMIT Hz X，Z 22000 Encoder limit

frequency

Note:

The max. output frequency of SINUMERIK 801 can reach 500000Hz.

Setting Up

5-4 SINUMERIK 801

Start-Up

4.2 Starting Up the Dynamic Characteristic of the Axes

General For SINUMERIK 801, the dynamic characteristic of the axes can be started-up

through machine data settings.

SINUMERIK 801 Test the dynamic characteristic of the axes in JOG mode, set the max.

velocity of each axis and select suitable acceleration curves.

Velocity

Time

Vmax

MD32300 max. axis acceleration

MD35230 reduced acceleration factor: value

40% ... 95%

MD35220 speed for reduced acceleration: values from

80% …20%

Table 4-1 Parameterization

MD Designation Unit Axis Input

value Description

35220 ACCEL_REDUC

TION_SPEED_

POINT

- X，Z 1 ... 0 Speed for reduced

acceleration:

max. speed * percent,

values valid from 0.8 ... 0.2.

35230 ACCEL_

REDUCTION_

FACTOR

- X，Z 0 ... 1 Factor of reduced

acceleration:

max. acceleration *

percent, values valid from

0.4 ... 0.95.

32300 MAX_AX_ACCEL m/s2X，Z 1 The max. axis acceleration

(default value)

Setting Up

SINUMERIK 801 5-5

Start-Up

4.3 Starting Up Reference Points

General Many functions of the SINUMERIK 801are built on reference points, e.g.,

AUTO and MDA modes can only be activated after the machine has

approached the reference points; the backlash compensation and leadscrew

error compensation can not be enabled until reference points have been

approached. Therefore, reference points shall first be approached prior to the

normal operation of the control system.

With Reference Cam

BERO pulse refers to proximity switch signals. The BERO pulse can be

1) before reference cam:

MD34050: REFP_SEARCH_MARKER_REVERS=0, search for BERO pulse

in a direction reversal to the reference cam.

Reference cam

RV

Start RK

BERO—pulse

VC

VM

VP

2) after reference c am:

MD34050: REFP_SEARCH_MARKER_REVERS=1, search for BERO pulse in

the same direction as the reference cam.

VC

Reference cam

VP

VM

RV

Start RK

BERO—pulse

Without reference cam

R

V

Start

RK

BERO—

p

ulse

VP

VM

Setting Up

5-6 SINUMERIK 801

Start-Up

Notes:

V

C – Reference point approach velocity

MD34020： REFP_VELO_SEARCH_CAM

V

M – Creep speed

MD34040： REFP_VELO_SEARCH_MARKER

V

P – Reference point positioning velocity

MD34070： REFP_VELO_POS

R

V - Reference point distance/target point for distance–coded system

MD34080： REFP_MOVE_DIST

R

K – Reference point value/irrelevant to distance-coded system

MD34100： REFP_SET_POS[0]

Parameterization

MD Designation Unit Axis Example

value Description

34000 REFP_CAM_

IS_ACTIVE

- X, Z1

Axis with reference

point cam

34010 REFP_CAM_

DIR_IS_

MINUS

- X, Z0/1

Approach

reference point in:

0- plus direction; 1-

minus direction

34020 REFP_VELO_

SEARCH_

CAM

mm/Min X, Z 2000 Reference point

approach velocity

34040 REFP_VELO_

SEARCH_

MARKER

mm/Min X, Z 300 Creep speed

(encoder no.)

34050 REFP_SEAR

CH_MARKER

_REVERSE

- X, Z0/1

BERO pulse is:

0-ouside BERO;

1-inside BERO

34060 REFP_MAX_

MARKER_

DIST

mm X, Z 200 Maximum distance

to reference mark.

Max. distance to 2

reference marks

for distance–coded

measuring

systems.

34070 REFP_VELO_

POS

mm/Min X, Z 200 Reference point

positioning velocity

34080 REFP_MOVE mm X, Z-2

Reference point

distance/target

Setting Up

SINUMERIK 801 5-7

Start-Up

_DIST point for

distance-coded

system (with

direction)

34100 REFP_SET_

POS

mm X, Z 29.4 Reference point

value/irrelevant to

distance-coded

system

Setting Up

5-8 SINUMERIK 801

Start-Up

4.4 Software Limit Switch and Backlash Compensation

Sof tware limit switch settings

Set the software limit switche after starting up the reference point approach

function and determining the referece point positions:

MD Designation Unit Axis

Example

value Description

36100 POS_LIMIT_MINUS mm X, Z -1 1st software limit

switch minus

36110 POS_LIMIT_PLUS mm X, Z 200 1st software limit

switch plus

Backlash compensation

Test the backlash and make backlash compensations:

MD Designation Unit Axis Example

value Description

32450 BACKLASH mm X, Z 0.024 Backlash

Setting Up

SINUMERIK 801 5-9

Start-Up

4.5 Rotation Monitoring

Rot ation monitoring

If the double switch mode is used for reference point approaching, (see

Section 4.3 “Starting Up Reference Points”), monitor the output pulse of the

stepper motors with BERO pulse generated with each rotation of the

leadscrew.

MD Designation Unit Axis

Example

value Description

31100 BERO_CYCLE IPR X，Z 1250 Steps for monitoring

rotation

31110 BERO_EDGE_

TOL

I X，Z 500 Step tolerance for

monitoring rotation

Notes:

The step tolerance of the stepper motors shall include positional difference

between both edges of BERO and follow-up error resulted at the maximum

traversing speed. The interrelations are given as below:

Steps for monitoring rotation = steps per revolution of the step motor/reduction

ratio

Steps corresponding to follow-up error = steps × follow-up error at the max.

speed/pitch of leadscrew

Setting Up

5-10 SINUMERIK 801

Start-Up

4.6 Leadscrew Error Compensation

General When starting up a machine tool, you may make leadscrew error

compensations to enhance the machining precision. Herein below gives an

example to show you how to make a leadscrew error compensation.

A maximum of 64 compensation intermediate points can be set for each axis

of the SINUMERIK 801. Machine tool builders may set desired number of

compensation intermediate points based on actual needs.

Example Set the Z axis as the compensation axis, the starting compensation point as

100mm(absolute coordinate)，clearance for compensation 100mm and end

point for compensation 1200mm (absolute coordinate).

1

st step: Determine the number of compensation intermediate points

Example:

Number of compensation intermediate points: 13

Error curve

0

Compensation curve(Linear interpolation between compensation points)

Compensation values in the compensation tables

Max. coordinate point

($AA_ENC_COMP_MAX)

Compensation value at point 5

Measuring clearance error

Min. coordinate point－correpsonding to $AA_ENC_COMP[0, 0, AX2]

($AA_ENC_COMP_MIN)

Linear interpolation between two points

Max. number of intermediate points for interpolatory compensation:

MM_ENC_COMP_MAX_POINTS

Compensation value

1 2345 10

100 200 300

11 (k)

1200 Axis position

($AA_ENC_COMP_STEP)

Interpolation point

Table 4-1 Compensation principle

Caution

After setting up this MD, the control system will reassign the memory when

next power-up and user data including part program, fixed cycles and tool

parameter will be cleared. So, prior to this data setting, unload user data into a

PC.

2nd step: Transfer the leadscrew error compensation file into the computer

using the WINPCIN tool integreated into the control sytem. You may enter

compensation values with following two methods:

1

st method:

1) Load the leadscrew pitch error compensation array into the computer via

SINUMERIK 801;

2) Edit this file on computer and write the error values measured into

corresponding positions in the array;

3) Transfer the file into SINUMERIK 801 from the computer.

2nd method:

1) Transfer this compesation array into the computer via SINUMERIK 801;

!

Setting Up

SINUMERIK 801 5-11

Start-Up

2) Edit this file on computer and change the file header into a machining

program, then transfer to SINUMERIK 801;

3) Use the Edit function of the SINUMERIK 801 to input compensation

values on the operator panel directly;

4) Start running this program (and compensation values will be input into

the control system)

1ST Method 2nd Method Remarks

%_N_COMPLETE_EEC_

INI

%_N_BUCHANG_MPF

；$PATH=/_N_MPF_DIR

File header

$AA_ENC_COMP

[0，0，AX2]= 0.0

$AA_ENC_COMP[0，0，AX2]= 0.0

$AA_ENC_COMP

[0，1，AX2]= 0.020

$AA_ENC_COMP[0 ， 1 ， AX2]=

0.020

$AA_ENC_COMP

[0，2，AX2]= 0.015

$AA_ENC_COMP[0 ， 2 ， AX2]=

0.015

$AA_ENC_COMP

[0，3，AX2]= 0.014

$AA_ENC_COMP[0 ， 3 ， AX2]=

0.014

$AA_ENC_COMP

[0，4，AX2]= 0.011

$AA_ENC_COMP[0 ， 4 ， AX2]=

0.011

$AA_ENC_COMP

[0，5，AX2]= 0.009

$AA_ENC_COMP[0 ， 5 ， AX2]=

0.009

$AA_ENC_COMP

[0，6，AX2]= 0.004

$AA_ENC_COMP[0 ， 6 ， AX2]=

0.004

$AA_ENC_COMP

[0，7，AX2]=-0.010

$AA_ENC_COMP[0 ， 7 ，

AX2]=-0.010

$AA_ENC_COMP

[0，8，AX2]=-0.013

$AA_ENC_COMP[0 ， 8 ，

AX2]=-0.013

$AA_ENC_COMP

[0，9，AX2]=-0.015

$AA_ENC_COMP[0 ， 9 ，

AX2]=-0.015

$AA_ENC_COMP

[0，10，AX2]=-0.009

$AA_ENC_COMP[0 ， 10 ，

AX2]=-0.009

$AA_ENC_COMP

[0，11，AX2]=-0.004

$AA_ENC_COMP[0 ， 11 ，

AX2]=-0.004

… …

$AA_ENC_COMP

[0，63，AX2]

$AA_ENC_COMP[0，63，AX2]

Corresponding

min. position

Corresponding

max. position

Compensation

value array

$AA_ENC_COMP_STEP

[0，AX2]=100.0

$AA_ENC_COMP_STEP[0 ，

AX2]=100.0

Measuring

clearance (mm)

$AA_ENC_COMP_MIN

[0，AX2] =100.0

$AA_ENC_COMP_MIN[0 ， AX2]

=100.0

Min. position

(abs.)

$AA_ENC_COMP_MAX

[0，AX2] =1200.0

$AA_ENC_COMP_MAX[0 ， AX2]

=1200.0

Max. position

(abs.)

$AA_ENC_COMP_IS_MO $AA_ENC_COMP_IS_MODULO[0， (for rotating axis)

Setting Up

5-12 SINUMERIK 801

Start-Up

DULO

[0，AX2]=0

AX2]=0

M17 M02 End of the file

3rd step：Enable the leadscrew error compensation function through set MD

MD Designation Unit Axis

Example

value Description

0 Compensation

inactive

32700 ENC_COMP_ENA

BLE

- X，Z

1 Compensation

active

Notice

When MD32700=1, the internal compensation value file in SINUMERIK 801

goes into the write protection automatically. To change a compensation value ,

first amend the compensation file and set MD32700=0 for entering the desired

value into SINUMERIK 801. Finally, reset MD32700=1.

4th step: Power on the system again.

Notice

The leadscrew error compensation will not be enabled until reference points

have been approached.

Setting Up

SINUMERIK 801 5-13

Start-Up

4.7 Starting Up the Spindle

General Spindle can come in two types: contactor-controlled spindle and analog

spindle. For analog spindle, through setting up the spindle, the machine tool

can have various functions such as thread machining, constant cutting speed,

programming spindle speed limit, etc.

Parameterization

If an AC motor and inverter or a servo spindle is used, when machining a

thread or programming it based on the feedrate per revolution, set

MD30130 = 1.

MD Designation Unit Axis

Input

value Description

30130 CTRLOUT_TYPE - Spindle 0 No analog output

30130 CTRLOUT_TYPE - Spindle 1 ±10VDC analog

output

Set the machine spindle outputs as unipolar/bipolar setpoint output.

MD Designation Unit Axis

Input

value Description

30134 IS_UNIPOLAR_

OUTPUT

- Spindle 0 Setpoint output is

bipolar

30134 IS_UNIPOLAR_

OUTPUT

- Spindle 1* Setpoint output is

unipolar

30134 IS_UNIPOLAR_

OUTPUT

- Spindle 2* Setpoint output is

unipolar，Q0.0 and

Q0.1 can not be

recalled by PLC;

* When MD30134 =1: Q0.0＝Servo enable;

Q0.1＝ Spindle CCW

MD30134 =2: Q0.0＝Sevo enable, spindle CW;

Q0.1＝Servo enable, spindle CCW

If the spindle has no encoder feedback, set MD30200 = 0.

MD Designation Unit Axis

Input

value Description

30200 NUM_ENCS - Spindle 0 Spindle without

encoder

When producing a thread, configure the spindle with an encoder:

MD Designation Unit Axis

Input

value Description

30240 ENC_TYPE - Spindle 2 Spindle with

measuring system

Setting Up

5-14 SINUMERIK 801

Start-Up

Set spindle MDs as listed below:

MD Designation Unit Axis

Input

value Description

31020 ENC_RESOL IPR Spindle 1024 Encoder markings

per revolution

(encoder no.)

32260 RATED_VELO RP

M

Spindle 3000 Rated motor speed

(setpoint branch)

36200 AX_VELO_

LIMIT[ 0 ... 5 ]

RP

M

Spindle 3300 Threshold value for

velocity monitoring

Determine the encoder limit frequency:

Spindle speed 3000 rev/min = 50rev/s;

Encoder limit frequency 50 rev/s×1024 pulses/rev = 51200 pulses/s

Fill in weighted machine data:

MD Designation Unit Axis

Input

value Description

36300 MA_ ENC_ FREQ_

LIMIT

Hz Spindle 55000 Encoder limit

frequency

For anolog spindle with gear changes:

MD Designation Unit Axis Input value Description

35010 GEAR_STEP_

CHANGE_

ENABLE

- Spindle 1 Gear change

possible.

Spindle has

several gear

steps

35110 GEAR_STEP_

MAX_VELO[ 0，

1 ... 5 ]

RPM Spindle Speed

[i]

Maximum

speed for

gear

change(gear

stage no.):

0 ... 5

35130 GEAR_STEP_

MAX_VELOLIMI

T[ 0，1 ... 5 ]

RPM Spindle Speed

[i]

Maximum

speed of gear

stag(gear

stage no.):

0 ... 5

36200 AX_VELO_

LIMIT[ 0，1 ... 5 ]

RPM Spindle Speed

[i]

Threshold

value for

velocity

monitoring

(control

parameter set

no.): 0 ... 5

31050 DRIVE_AX_

RATIO_

DENUM[0，1 ...

- Spindle Denominator

[i]

Denominator

load gearbox

(control

parameter

Setting Up

SINUMERIK 801 5-15

Start-Up

5] no.): 0 ... 5

31060 DRIVE_AX_

RATIO_

NUMERA[0，1 ...

5]

- Spindle Numerator

[i]

Numerator

load gearbox

(control

parameter set

no.): 0 ... 5

Notice

A maxium of 5 spindle gear stages can be provided. Assigning the same

parameters to the index [0] and [1] makes gear changes (i=1 ... 5) active only

by setting corresponding interface signals via PLC application.

Programming notice

Pay attention to the following instructions when programming machining

programs:

1) When mm/Min is used as the unit of measurement for the feedrate F,

activate G94; Programming example: N10 G94 G01 Z100 F100

2) When mm/Rev is used as the unit of measurement for the feedrate F,

activate G95; mm/Rev. Programming example: N10 G95 G01 Z100 F1

3) For contactor-controlled spindle, when producing a thread with G33,

program spindle speed S within the actual spindle speed range;

4) When programming a thread cutting, program thread run-in and run-out

paths;

5) The result of a thread lead value multiplied by spindle speed shall be

less than the maximum setpoint speed of Z axis.

Programming example

N10 G91 G94 F100 S350 M4 ； actual spindle speed 350

N20 G01 Z-0.5 ； thread run-in

N30 G33 Z-100 K2 SF=0 ； K - thread lead; SF；SF – Infeed angle for

thread cutting

N40 G01 Z-0.5 ； thread run-out

N50 X50

SINUMERIK 801 5-1

Start-Up

Services, Diagnosis and Data Saving 5

5.1 Services

Functionality You can use the RS232 interface of the CNC to output data to an external

data storage medium or to read in them from there. RS232 interface

parameters have been fixed by the control system and cannot be changed.

File types Files including various data, programs and parameters can be read in/out of

RS232 interface with specified access authorization.

File type has been fixed as : RS232 text Baudrate: 9600

RS232 text file screen is shown as below:

Fig. 5-1 RS232 text file screen

For machine tool builders, after the password assigned to them is entered,

following screen appears:

Services, Diagnosis and Data Saving

5-2 SINUMERIK 801

Start-Up

Fig. 5-2 RS232 text file screen (after entering machine tool

manufacturer-specific password)

In this screen, pressing softkey “show” can display “Main/Sub part

programs…” or “Data…” and therefore execute corresponding data transfers.

Communication tool The RS232 communication tool WinPCIN shall be loaded onto the PC (you may

download corresponding tool on website at www.ad.siemens.com.cn/download/)

and baudrate be set as 9600. For detailed information about baudrate setting

and softeware tool version, see Fig. 5-3 and 5-4 below.

Fig. 5-3

Services, Diagnosis and Data Saving

SINUMERIK 801 5-3

Start-Up

Fig.5-4

Services, Diagnosis and Data Saving

5-4 SINUMERIK 801

Start-Up

5.2 Diagnosis

Functionality In the “Diagnosis” operating area, machine manufactuere may optimize the

drives with an oscillograph function.

Selecting the Diagnosis softkey will open the Diagnosis main screen.

Fig.5-5 Diagnosis main screen

Selecting the “Service display” from the screen above to branch to another

softkey level.

Fig. 5-6

Notice

Machine manufacturer may select the “Servo trace” softkey on the screen of

Fig. 5-6 to branch to the corresponding “Servo trace” main screen. However,

before entering this main screen, machine manufacturer password must first

be input. Otherwise, system will prompt “Access Denied!”

Services, Diagnosis and Data Saving

SINUMERIK 801 5-5

Start-Up

To optimize the drives, an oscillograph function is provided for graphical

representation of the velocity setpoint. The velocity setpoint corresponds to

the ± 10V interface.

The start of recording can be linked with various criteria which permit

recording in parallel to internal conditions of the control system. The setting

needed for this option must be carried out in the “Select Signal” function.

The following functions can be used to analyze the result:

z Change scaling of abscissa and ordinate,

z Measure value by means of a horizontal or vertical marker,

z Measure the abscissa and ordinate values as a difference between two

marker positions.

Fig. 5–7 The “Servo Trace” main screen

The heading of the diagram contains the current graduation of abscissa and

ordinate, the current measured positions and the difference values of the

markers.

The displayed diagram can be moved within the visible screen area by means

of the cursor keys.

Graduation

of abscissa

Graduation

of ordinate

Initial values Current

marker

position

Difference

display

of Markers

Fig. 5-8 Meaning of the fields

Press the softkey “Select Signal” to select the axis to be measured, the

measuring time, threshold value, pre-trigger/post-trigger time and trigger

conditions. The signal settings are fixed.

Services, Diagnosis and Data Saving

5-6 SINUMERIK 801

Start-Up

Fig. 5–9 Signal selection

z Selecting the axis: The axis is selected in the Axis toggle field.

z Signal type:

Velocity setpoint

Actual position value of measuring system 1

Following error

z Determining the measuring time: The measuring time is entered in ms

directly in the “Measuring Time” input field.

z Determining trigger time to or after

With input values < 0, recording starts by the set time prior to the trigger event,

and with values > 0 accordingly after the trigger event, whereby the following

conditions must be observed:

Trigger time + measuring time ≥ 0.

z Selecting the trigger condition: Position the cursor on the Trigger

Condition field and select the condition using the toggle key.

— No trigger, i.e. the measuring starts immediately after pressing the Start

softkey.

— Negative edge.

— Exact stop fine reached.

— Exact stop coarse reached.

z Determining the trigger threshold: The threshold is entered directly in the

Threshold input field. It acts only for the trigger conditions “Positive edge”

and “Negative edge”.

Press “Marker” key to branch to another softkey level, in which the horizontal

or vertical marker can be switched on or off. The markers are displayed in the

status bar.

The markers are moved in steps of one increment by means of the cursor

keys. Larger step widths can be set in the input fields. The value specifies

the number of raster units per <SHIFT> + cursor movement by which the

marker is to be moved.

If a marker reaches the margin of the diagram, the next raster in horizontal or

vertical direction is automatically pulled down.

Services, Diagnosis and Data Saving

SINUMERIK 801 5-7

Start-Up

Fig. 5–10 Setting the markers

The markers can also be used to determine the differences in the horizontal or

vertical direction. To this aim, position the marker on the start point and press

either the Fix H - Mark. or the Fix T- Mark. softkey. The difference between the

start point and the current marker position is now displayed in the status bar.

The softkey labeling changes to “Free H - Mark” or “Free T - Mark”.

Pressing the Help key softkey calls explanations with regard to the displayed

values on the screen.

Pressing the Start softkey starts recording. The softkey labeling changes to

Stop. The note “Recording active” is displayed.

When the measuring time is elapsed, the softkey labeling changes to Start.

Pressing the Stop softkey aborts the current measuring. The softkey labeling

changes to Start.

Pressing “Zoom Time +”/”Zoom Time - ” enables the scaling changes in the

following steps:

1, 2, 5, 10, 20, 50, 100, 200, 500, 1,000 ms/div.

Pressing “Zoom V +”/”Zoom V -” enables the horizontal scaling changes in the

following steps:

0.01, 0.05, 0.1, 0.5, 1, 5, 10, 50, 100, 500, 1,000, 5,000 unit/ div

Pressing the Auto Scaling key calculates the vertical scaling from the peak

values.

Services, Diagnosis and Data Saving

5-8 SINUMERIK 801

Start-Up

5.3 Data Saving

5.3.1 Internal Data Saving

Data saving After all MD has been started up, the password must be closed so as to save

data and call the data again rapidly next time.

Operating sequence:

Diagnostics Start-up Save data

Save machine data, set data, machining data, leadscrw error compensation

data, etc. in the permanent memory. Recall them again via Start-up switch

position 3 or by selecting menu “Power-up with saved data”.

Notice

If the fuction “record reference point” has been executed (with MD34210),

do approach reference point again after system power up with saved data!

5.3.2 External Data Saving

Purpose In case of any product fault and subsequent maintenance, the machine tool

builder / end user is requested to fill in the Warranty Card – SINUMERIK 801

delivered in the package so that the setting data can be recovered

immediately by Siemens after product has been replaced or maintained.

Hereinbelow is relevant data sheet described in the Warranty Card.

1. Machine Data

OEM Value

Data Definition Unit

X-axis Z-axis Spin.

Setting value:

30134 Setpoint output is unipolar -

30600 Fixed-value positions of axis with

G75 (position no.)

mm

31020 Encoder markings per revolution

(encoder no.)

IPR

31030 Pitch of leadscrew mm

31050

[0]

Denominator load gearbox (control

parameter No.)[0]

-

31050

[1]

Denominator load gearbox (control

parameter No.)[1]

-

31060 Numerator load gearbox (control -

Services, Diagnosis and Data Saving

SINUMERIK 801 5-9

Start-Up

OEM Value Data Definition Unit

X-axis Z-axis Spin.

[0] parameter set No.)[0]

31060

[1]

Numerator load gearbox (control

parameter set No.)[1]

-

31100 Steps for monitoring rotation IPR

31110 Step tolerance for monitoring

rotation

I

31350 Stepping rate at maximum velocity Hz

31400 Steps per stepping motor revolution IPR

32000 Maximum axis velocity mm/Min

rpm

32010 Rapid traverse in jog mode mm/Min

rpm

32020 Jog axis velocity mm/Min

rpm

32100 Traversing direction (not control

direction)

-

32110 Sign actual value (control direction) -

32200

[0]

Servo gain factor (control

parameter set no.)

1000/mi

n

32200

[1]

Servo gain factor (control

parameter set no.)

1000/mi

n

32260 Rated motor speed (setpoint

branch)

rpm

32300 Axis acceleration m/s2

32450 Backlash mm

32700

*

Interpolatory compensation

(encoder no.)

-

34000 Axis with reference point cam -

34010 Approach reference point in minus

direction

-

34020 Reference point approach velocity mm/Min

34040 Creep speed (encoder no.) mm/Min

34060 Maximum distance to reference

mark

mm/Min

34070 Reference point positioning velocity mm/Min

34080 Reference point distance

34100 Reference point value/irrelevant for

distance-coded system

mm

35110 Maximum speed for gear change rpm

Services, Diagnosis and Data Saving

5-10 SINUMERIK 801

Start-Up

OEM Value Data Definition Unit

X-axis Z-axis Spin.

[1] [1]

35130

[1]

Maximum speed of gear change [1] rpm

35150 Spindle speed tolerance -

36100 1st software limit switch minus mm

36110 1st software limit switch plus mm

36200

[0]

Threshold value for velocity

monitoring [0]

mm/Min

rpm

36200

[1]

Threshold value for velocity

monitoring [1]

mm/Min

rpm

36300 Encoder limit frequency Hz

Other machine data (if necessary)

32700* note: If interpolatory compensation is used, please fill in the parameters into

the following table.

Services, Diagnosis and Data Saving

SINUMERIK 801 5-11

Start-Up

X-axis Z-axis

$AA_ENC_COMP[0,0,AX1]= $AA_ENC_COMP[0,0,AX2]=

$AA_ENC_COMP[0,1,AX1]= $AA_ENC_COMP[0,1,AX2]=

$AA_ENC_COMP[0,2,AX1]= $AA_ENC_COMP[0,2,AX2]=

$AA_ENC_COMP[0,3,AX1]= $AA_ENC_COMP[0,3,AX2]=

$AA_ENC_COMP[0,4,AX1]= $AA_ENC_COMP[0,4,AX2]=

$AA_ENC_COMP[0,5,AX1]= $AA_ENC_COMP[0,5,AX2]=

$AA_ENC_COMP[0,6,AX1]= $AA_ENC_COMP[0,6,AX2]=

$AA_ENC_COMP[0,7,AX1]= $AA_ENC_COMP[0,7,AX2]=

$AA_ENC_COMP[0,8,AX1]= $AA_ENC_COMP[0,8,AX2]=

$AA_ENC_COMP[0,9,AX1]= $AA_ENC_COMP[0,9,AX2]=

$AA_ENC_COMP[0,10,AX1]= $AA_ENC_COMP[0,10,AX2]=

$AA_ENC_COMP[0,11,AX1]= $AA_ENC_COMP[0,11,AX2]=

$AA_ENC_COMP[0,12,AX1]= $AA_ENC_COMP[0,12,AX2]=

$AA_ENC_COMP[0,13,AX1]= $AA_ENC_COMP[0,13,AX2]=

$AA_ENC_COMP[0,14,AX1]= $AA_ENC_COMP[0,14,AX2]=

$AA_ENC_COMP[0,15,AX1]= $AA_ENC_COMP[0,15,AX2]=

$AA_ENC_COMP_STEP[0,AX1]= $AA_ENC_COMP_STEP[0,AX2]=

$AA_ENC_COMP_MIN[0,AX1]= $AA_ENC_COMP_MIN[0,AX2]=

$AA_ENC_COMP_MAX[0,AX1]= $AA_ENC_COMP_MAX[0,AX2]=

2．PLC Parameter

PLC data（Binary）

MD14512

Bit

7

Bit

6

Bit

5

Bit

4

Bit

3

Bit

2

Bit

1

Bit

0

MD

14510 PLC data

（integer）

14512[4] 14510[2]

14512[6] 14510[3]

14510[4]

14510[5]

14510[6]

14510[7]

5.3.3 Important Notice

Important Pay attention to following notices prior to the delivery of machine tools by

machine manufacturers:

1) Password

Some functions of the the control system are protected by password.

The control system has preset one password (“Evening”) for machine

manufacturers. If no password is entered by the machine manufacturer,

only tool offset, tool wear, zero offset, R parameter and part program edit

can be changed. If the password is entered, still machine data

modification, data transfer and servo trace functions will be made

possible.

The password input by the machine manufacturer before system

power-off will be cancelled by the control system after control power-off.

Next time after power-on again, the password shall be input again by the

machine manufacturer when necessary. Change of password by the

machine manufacturer is allowed.

2） Data backup

5-4

Services, Diagnosis and Data Saving

5-12 SINUMERIK 801

Start-Up

Be sure to make data backup after the machine has been started up and

ready for delivery. Data backup includes internal data saving and external

data saving. With external data saving, machine data, leadscrew error

compensation data, tool data can be loaded into a PC.

SINUMERIK 801 6-1

Start-Up

Accessories 6

General For the more convenient use of SINUMERIK 801, some accessories are also

delivered together with the control system such as fuse, emergency stop cover,

etc.

Fuse SINUMERIK 801 uses glass-tube fuse made by WICKMANN company, its

model and specification are : 5x20mm, No.196, 4A, 250V.

If the fuse is broken, please first find out the cause, eliminate the trouble and

then replace it with delivered spare fuse.

Cover for Emergency Stop Button

The delivered control system has a reserved mounting hole for emergency

stop button. If customer does not intend to use this button, he may attach the

delivered cover for emergency stop button to the hole after the protective film

on the cover has been removed so as to make the operator more presentable.

When mounting the cover, please first detach the adhesive film on the surface

of the cover, then direct the cover to the center of the hole and attach it to the

hole.

Technical Appendix

7-1 SINUMERIK 801

Start-Up

Technical Appendix 7

7.1 List of Machine Data

Data type BOOLEAN Machine data bit (1 or 0)

BYTE Integer values (from – 128 to 127)

DOUBLE Real and integer values

(from ± 2.23 x 10–308 to ± 1.79 x 10308)

DWORD Integer values (from – 2.147 x 109 to 2.147 x 109 )

STRING Character string (max. 16 characters) consisting of

upper–case letters with digits and underscore

UNSIGNED WORD Integer values (from 0 to 65535)

SIGNED WORD Integer values (from – 32768 to 32767)

UNSIGNED DWORD Integer values (from 0 to 4294967295)

SIGNED DWORD Integer values (from – 2147483648 to 2147483647)

WORD Hex values (from 0000 to FFFF)

DWORD Hex values (from 00000000 to FFFFFFFF)

FLOAT DWORD Real values (from ±1.18 x 10–38 to ± 3.4 x 1038)

Activation conditions

PO(Power On) Data active when system power on;

RE(Reset) Data active whey system is reset

CF(Configuration) Active when “Data Active” soft menu is enabled;

IM(Immediate) Immediately active

Technical Appendix

SINUMERIK 801 7-2

Start-Up

Data format

Number MD Name Reference

Unit Name, Miscellaneous Activated

HW /

function

Standard value Minimum value Maximum value Data type

General machine data

10240 SCALING_SYSTEM_IS_METRIC

– Basic system metric POWER ON

_always 1 *** *** BOOLEAN

14510 USER_DATA_INT [n]

kB User data (INT) 0 ... 31 POWER ON

– – 0 – DWORD

14512 USER_DATA_BIN [n]

kB User data (Binary) 0 ... 31 POWER ON

– 0 0 0xFF DWORD

Axis-specific machine data

30130 CTRLOUT_TYPE

– Output type of setpoint (setpoint branch): 0 POWER ON

_always 0 0 2 BYTE

30134 IS_UNIPOLAR_OUTPUT[0]

– Setpoint output is unipolar : 0 POWER ON

_always 0 0 2 BYTE

30200 NUM_ENCS

– Number of encoders (spindle with or without encoder) RESTART

1 0 1 BYTE

30240 ENC_TYPE

– Type of actual value acquisition (actual position value)

(encoder no.)

0: Simulation

2: Square–wave generator, standard encoder

(pulse multiplication)

3: Encoder for stepper motor

POWER ON

_always 0, 0 0 4 BYTE

30350 SIMU_AX_VDI_OUTPUT

– Output of axis signals with simulation axes POWER ON

_always 0 *** *** BOOLEAN

30600 FIX_POINT_POS

Technical Appendix

7-1 SINUMERIK 801

Start-Up

mm,

degrees

Fixed–value positions of axis with G75 (position no.) POWER ON

_always 0.0 – – DOUBLE

31000 ENC_IS_LINEAR

– Direct measuring system (linear scale) (encoder no.) POWER ON

_always 0 *** ***

BOOLEAN

31010 ENC_GRID_POINT_DIST

mm Division period for linear scales (encoder no.) POWER ON

_always 0.01 0.0 plus DOUBLE

31020 ENC_RESOL

– Encoder markings per revolution (encoder no.) POWER ON

_always 2048 0.0 plus DWORD

31030 LEADSCREW_PITCH

mm Pitch of leadscrew POWER ON

_always 10.0 0.0 plus DOUBLE

31040 ENC_IS_DIRECT

– Encoder mounted directly to the machine (encoder no:) POWER ON

_always 0 *** ***

BOOLEAN

31050 DRIVE_AX_RATIO_DENOM

– Denominator load gearbox (control parameter no.): 0 ... 5 POWER ON

_always 1, 1, 1, 1, 1, 1 1 2147000000 DWORD

31060 DRIVE_AX_RATIO_NUMERA

– Numerator load gearbox (control parameter set no.): 0 ...

5

POWER ON

_always 1, 1, 1, 1, 1, 1 1 2147000000 DWORD

31070 DRIVE_ENC_RATIO_DENOM

– Denominator resolver gearbox (encoder no.) POWER ON

_always 1 1 2147000000 DWORD

31080 DRIVE_ENC_RATIO_NUMERA

– Numerator resolver gearbox (encoder no.) POWER ON

_always 1 1 2147000000 DWORD

31090 JOG_INCR_WEIGHT

mm,

degrees

Evaluation of an increment with INC/handwheel RESET

31100 BERO_CYCLE

– Steps for monitoring rotation POWER ON

2000 10 10000000 DWORD

Technical Appendix

SINUMERIK 801 7-2

Start-Up

31110 BERO_EDGE_TOL

– Step tolerance for monitoring rotation POWER ON

50 10 10000000 DWORD

31350 FREQ_STEP_LIMIT

– Stepping rate at maximum velocity NEW CONF

Hz 250000 0.1 4000000 DOUBLE

31400 STEP_RESOL

– Steps per stepper motor revolution POWER ON

1000 0 plus DWORD

31500 AXIS_NUMBER_FOR_MONITORING

– Display setpoint of this axis for servicing POWER ON

0 0 4 DWORD

32000 MAX_AX_VELO

mm/min,

rev/min

Maximum axis velocity NEW CONF

_always 10000. 0.0 plus DOUBLE

32010 JOG_VELO_RAPID

mm/min,

rev/min

Rapid treverse in jog mode RESET

_always 10000. 0.0 plus DOUBLE

32020 JOG_VELO

mm/min,

rev/min

Jog axis velocity RESET

_always 2000. 0.0 plus DOUBLE

32070 CORR_VELO

% Axis velocity for handwheel override, ext. ZO, cont.

dressing, distance control

RESET

_always 50 0.0 plus DWORD

32100 AX_MOTION_DIR

– Traversing direction (not control direction) POWER ON

_always 1 –1 1 DWORD

32110 ENC_FEEDBACK_POL

– Sign actual value (control direction) (encoder no.) POWER ON

_always 1 –1 1 DWORD

32200 POSCTRL_GAIN

1000/min Servo gain factor (control parameter set no.): 0 ... 5 NEW CONF

_always (2,5; 2,5; 2,5; 1), ... 0.0 plus DOUBLE

32260 RATED_VELO

rev/min Rated motor speed (setpoint branch): 0 NEW CONF

_always 3000 0.0 plus DOUBLE

Technical Appendix

7-1 SINUMERIK 801

Start-Up

32300 MAX_AX_ACCEL

mm/s^2,

rev/s^2

Axis acceleration NEW CONF

_always 1 0 *** DOUBLE

32420 JOG_AND_POS_JERK_ENABLE

- Enable axial jerk limitation NEW CONF

_always 0 *** ***

BOOLEAN

32430 JOG_AND_POS_,AX_JERK

- Axial jerk NEW CONF

_always 1000 (mm/s^3)

2777,77

(degrees/s^3)

10 -9 *** DOUBLE

32450 BACKLASH

mm Backlash NEW CONF

_always 0.000 * * DOUBLE

32700 ENC_COMP_ENABLE

– Interpolatory compensation (encoder no.): 0,1 POWER ON

_always 0 *** ***

BOOLEAN

32900 DYN_MATCH_ENABLE

– Dynamic response adaptation

NEW_CONF

0 0 1 BYTE

32910 DYN_MATCH_TIME

– Time constant of dynamic adaption (control parameter set

no): 0 ... 5

NEW_CONF

0 0.0 plus DOUBLE

32920 AC_FILTER_TIME

s Smoothing factor time constant for adaptive control POWER ON

_always 0.0 0.0 plus DOUBLE

33050 LUBRICATION_DIST

mm,

deg.

Traversing distance for lubrication from PLC NEW CONF

_always 100000000 0.0 plus DOUBLE

34000 REFP_CAM_IS_ACTIVE

– Axis with reference point cam RESET

_always 1 *** ***

BOOLEAN

34010 REFP_CAM_DIR_IS_MINUS

– Approach reference point in minus direction RESET

_always 0 *** ***

BOOLEAN

34020 REFP_VELO_SEARCH_CAM

mm/min,

rev/min

Reference point approach velocity RESET

Technical Appendix

SINUMERIK 801 7-2

Start-Up

_always 5000.0 0.0 plus DOUBLE

34030 REFP_MAX_CAM_DIST

mm,

deg.

Maximum distance to reference cam RESET

_always 10000.0 0.0 plus DOUBLE

34040 REFP_VELO_SEARCH_MARKER

mm/min,

rev/min

Creep speed (encoder no.) RESET

_always 300.0 0.0 plus DOUBLE

34050 REFP_SEARCH_MARKER_REVERSE

– Direction reversal to reference cams (encoder no.) RESET

_always 0 *** ***

BOOLEAN

34060 REFP_MAX_MARKER_DIST

mm,

deg.

Maximum distance to reference mark. Max. distance to 2

reference marks for distance–coded measuring systems.

RESET

_always 20.0 0.0 plus DOUBLE

34070 REFP_VELO_POS

mm/min,

rev/min

Reference point positioning velocity RESET

_always 1000.0 0.0 plus DOUBLE

34080 REFP_MOVE_DIST

mm,

deg.

Reference point distance/target point for distance–coded

system

RESET

_always –2.0 – – DOUBLE

34090 REFP_MOVE_DIST_CORR

mm,

deg.

Reference point offset/absolute offset distance–coded POWER ON

_always 0.0 – – DOUBLE

34092 REFP_CAM_SHIFT

mm,

deg.

Electr. cam offset of incremental measuring systems with

equidistant zero marks

RESET

_always 0.0 0.0 plus DOUBLE

34100 REFP_SET_POS

mm,

deg.

Reference point value/irrelevant for distance–coded

system: 0 ... 3

RESET

_always 0., 0., 0., 0. – – DOUBLE

34110 REFP_CYCLE_NR

– Sequence of axes in channel–specific referencing

–1: No obligatory reference point for NC Start

0: No channel–specific reference–point approach

1–15: Sequence in channel–specific reference point

approach

RESET

Technical Appendix

7-1 SINUMERIK 801

Start-Up

_always 1 –1 31 DWORD

34200 ENC_REFP_MODE

– Type of position measuring system

0: No ref. point appr.; if an absolute encoder exists:

REFP_SET_POS accepted

1: Zero pulse (on encoder track)

POWER ON

_always 1 0 6 BYTE

34210 ENC_REFP_STATE

– 0: Function “record reference point” inactive. Reference

point must be approached again next time when

normal system power-up.

1: Fucntion “record refrence point” activated. After

reference point has been approached, this machine

data is changed to 2 automatically. If the reference

point has been saved before power-off, next time

when power up, system will record position and

reference point of that axis saved, so no reference

point approach is required.

POWER ON

_always 0 1 2

DWORD

35010 GEAR_STEP_CHANGE_ENABLE

– Gear change possible. Spindle has several gear steps POWER ON

_always 0 *** ***

BOOLEAN

35040 SPIND_ACTIVE_AFTER_RESET

– Own spindle reset POWER ON

_always 0 *** ***

BOOLEAN

35100 SPIND_VELO_LIMIT

rev/min Maximum spindle speed POWER ON

_always 10000 0.0 plus DOUBLE

35110 GEAR_STEP_MAX_VELO

rev/min Maximum speed for gear change (gear stage no.): 0..5 NEW CONF

_always 500, 500, 1000,

2000, 4000, 8000

0.0 plus DOUBLE

35120 GEAR_STEP_MIN_VELO

rev/min Minimum speed for gear change (gear stage no.): 0..5 NEW CONF

_always 50, 50, 400, 800,

1500, 3000

0.0 plus DOUBLE

35130 GEAR_STEP_MAX_VELO_LIMIT

rev/min Maximum speed of gear stage (gear stage no.): 0 ... 5 NEW

CONF

_always 500, 500, 1000, 2000,

4000, 8000

0.0 plus DOUBLE

35140 GEAR_STEP_MIN_VELO_LIMIT

rev/min Minimum speed of gearsetp (gear stage no.): 0 ... 5 NEW CONF

Technical Appendix

SINUMERIK 801 7-2

Start-Up

_always 5, 5,10, 20, 40, 80 0.0 plus DOUBLE

35150 SPIND_DES_VELO_TOL

Factor Spindle speed tolerance RESET

_always 0.1 0.0 1.0 DOUBLE

35160 SPIND_EXTERN_VELO_LIMIT

rev/min Spindle speed limitation from PLC NEW CONF

_always 1000 0.0 plus DOUBLE

35200 GEAR_STEP_SPEEDCTRL_ACCEL

rev/s^2 Acceleration in speed control mode [gear stage no.]: 0 ...

5

NEW CONF

_always 30, 30, 25, 20, 15, 10 2 *** DOUBLE

35210 GEAR_STEP_POSCTRL_ACCEL

rev/s^2 Acceleration in position control mode (gear stage no.):

1 ... 5

NEW CONF

_always 30, 30, 25, 20, 15, 10 2 *** DOUBLE

35220 ACCEL_REDUCTION_SPEED_POINT

Factor Speed for reduced acceleration RESET

_always 1.0 0.0 1.0 DOUBLE

35230 ACCEL_REDUCTION_FACTOR

Factor Reduced acceleration RESET

_always 0.0 0.0 0.95 DOUBLE

35240 ACCEL_TYPE_DRIVE

– Type of acceleration RESET

0 0 1

BOOLEAN

35300 SPIND_POSCTRL_VELO

rev/min Position control switch–on speed NEW CONF

_always 500 0.0 plus DOUBLE

35350 SPIND_POSITIONING_DIR

– Direction of rotation when positioning RESET

_always 3 3 4 BYTE

35400 SPIND_OSCILL_DES_VELO

rev/min Reciprocation speed NEW CONF

_always 500 0.0 plus DOUBLE

35410 SPIND_OSCILL_ACCEL

rev/s^2 Acceleration during reciprocating NEW CONF

_always 16 2 *** DOUBLE

35430 SPIND_OSCILL_START_DIR

- Starting direction during reciprocation

0-2: As last direction of rotation (zero-speed

RESET

Technical Appendix

7-1 SINUMERIK 801

Start-Up

M3)

3: M3 direction

4: M4 direction

_always 0 0 4 BYTE

35440 SPIND_OSCILL_TIME_CW

s Reciprocation time for M3 direction NEW CONF

_always 1.0 0.0 plus DOUBLE

35450 SPIND_OSCILL_TIME_CCW

s Reciprocation time for M4 direction NEW CONF

_always 0.5 0.0 plus DOUBLE

35500 SPIND_ON_SPEED_AT_IPO_START

- Feed enable for spindle in setp. Range RESET

_always 1 0 2 BYTE

35510 SPIND_STOPPED_AT_IPO_START

– Feedrate enable for spindle stopped RESET

_always 0 *** ***

BOOLEAN

36000 STOP_LIMIT_COARSE

mm,

deg.

Exact positioning coarse NEW CONF

_always 0.04 0.0 plus DOUBLE

36010 STOP_LIMIT_FINE

mm,

deg.

Exact positioning fine NEW CONF

_always 0.01 0.0 plus DOUBLE

36020 POSITIONING_TIME

s Delay exact positioning fine NEW CONF

_always 1.0 0.0 plus DOUBLE

36030 STANDSTILL_POS_TOL

mm,

deg.

Zero–speed tolerance NEW CONF

0.2 0.0 plus DOUBLE

36040 STANDSTILL_DELAY_TIME

s Delay zero–speed monitoring NEW CONF

_always 0.4 0.0 plus DOUBLE

36050 CLAMP_POS_TOL

mm,

deg.

Clamping tolerance NEW CONF

_always 0.5 0.0 plus DOUBLE

36060 STANDSTILL_VELO_TOL

mm/min, Maximum velocity/speed “axis/spindle stopped” NEW CONF

Technical Appendix

SINUMERIK 801 7-2

Start-Up

rev/min

_always 5 (0.014) 0.0 plus DOUBLE

36100 POS_LIMIT_MINUS

mm,

deg.

1st software limit switch minus RESET

_always –100000000 – – DOUBLE

36110 POS_LIMIT_PLUS

mm,

deg.

1st software limit switch plus RESET

_always 100000000 – – DOUBLE

36120 POS_LIMIT_MINUS2

mm,

deg.

2nd software limit switch minus RESET

_always –100000000 – – DOUBLE

36130 POS_LIMIT_PLUS2

mm,

deg.

2nd software limit switch plus RESET

_always 100000000 – – DOUBLE

36200 AX_VELO_LIMIT

mm/min,

rev/min

Threshold value for velocity monitoring

(control parameter set no.): 0 ... 5

NEW CONF

_always 11500., 11500.,

11500., 11500., ...

0.0 plus DOUBLE

36300 ENC_FREQ_LIMIT

Hz Encoder limit frequency POWER ON

_always 300000 0 plus DOUBLE

36302 ENC_FREQ_LIMIT_LOW

% Encoder limit frequency at which encoder is switched on

again. (Hysteresis)

NEW CONF

_always 99.9 0 100 DOUBLE

36310 ENC_ZERO_MONITORING

– Zero mark monitoring (encoder no.): 0,1

0: Zero mark monitoring off, encoder HW monitoring on

1–99, >100: Number of recognized zero mark errors

during monitoring

100: Zero mark monitoring off, encoder HW monitoring off

NEW CONF

_always 0, 0 0.0 plus DWORD

36400 CONTOUR_TOL

mm,

deg.

Contour monitoring tolerance band NEW CONF

_always 1.0 *** *** DOUBLE

36500 ENC_CHANGE_TOL

Technical Appendix

7-1 SINUMERIK 801

Start-Up

mm, deg Portion of distance for backlash working NEW CONF

_always 0,1 0.0 plus DOUBLE

36610 AX_EMERGENCY_STOP_TIME

s Duration of the deceleration ramp for error states NEW CONF

_always 0.05 0.0 plus DOUBLE

36620 SERVO_DISABLE_DELAY_TIME

s Cutout delay servo enable NEW CONF

_always 0.1 0.0 plus DOUBLE

36700 DRIFT_ENABLE

– Automatic drift compensation NEW CONF

_always 0 *** ***

BOOLEAN

36710 DRIFT_LIMIT

% Drift limit value for automatic drift compensation NEW CONF

_always 1.000 0.0 plus DOUBLE

36720 DRIFT_VALUE

% Drift basic value NEW CONF

_always 0.0 DOUBLE

38000 MM_ENC_COMP_MAX_POINTS

– Number of intermediate points for interpolatory

compensation (SRAM)

POWER ON

_always 0, 0 0 5000 DWORD

Setting data

41110 JOG_SET_VELO

mm/min Axis speed for JOG Immediately

_always 0.0 0.0 plus DOUBLE

41200 JOG_SPIND_SET_VELO

rev/min Speed for spindle JOG mode Immediately

_always 0.0 0.0 plus DOUBLE

43210 SPIND_MIN_VELO_G25

rev/min Progr. spindle speed limitation G25 Immediately

_always 0.0 0.0 plus DOUBLE

43220 SPIND_MAX_VELO_G26

rev/min Progr. spindle speed limitation G26 Immediately

_always 1000 0.0 plus DOUBLE

43230 SPIND_MAX_VELO_LIMS

rev/min Spindle speed limitation with G96 Immediately

Technical Appendix

SINUMERIK 801 7-2

Start-Up

_always 100 0.0 plus DOUBLE

52011 STOP_CUTCOM_STORE

Alarm response for TRC and feedforward stop Immediately

– 1 0 1

BOOLEAN

Technical Appendix

7-1 SINUMERIK 801

Start-Up

SINUMERIK 801

Start-Up

Techncial Manual

Order No: A5E00702069

Edition: 2005.11

A5E00702069