Siemens Sinumerik 801, Technical Manual

Page 1: ...Start Up 11 2005 Edition sinumerik SIEMENS SINUMERIK 801 ...

Page 2: ...SINUMERIK 801 Document Structure User Documentation Operation and Programming User Documentation Diagnostics Guide Technical Documentation Start Up Turning Turning Turning ...

Page 3: ... 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 ...

Page 4: ...stered holder Copyright Siemens AG 2005 All right reserved 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 correspo...

Page 5: ...t 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...

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Page 7: ...tal 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 ...

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Page 9: ...an 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 Fiv...

Page 10: ...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 ...

Page 11: ... 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 ...

Page 12: ...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 L...

Page 13: ...lus 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 ...

Page 14: ...rfaces 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 ...

Page 15: ...ng 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 Pa...

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Page 17: ...ring 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 transforme...

Page 18: ...tions 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 wi...

Page 19: ...er 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 ...

Page 20: ...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 ...

Page 21: ... 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 i...

Page 22: ...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 ...

Page 23: ...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 ...

Page 24: ...ring 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 ...

Page 25: ...the stepper motors see Fig 2 9 Dimensions and tolerance Model D D1 D2 D3 D4 D5 L L1 L2 L3 L4 h 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 2 12 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 2 12 5 112 65 0 10X4 5 C5X2 5 7 2 6FC5 548...

Page 26: ... 6 0 0 0 S P E E D R P M 2 4 0 0 2 6 0 0 2 2 0 0 2 0 0 0 1 8 0 0 1 6 0 0 2 8 0 0 6 F C 5 5 4 8 0 A B 2 5 0 A A 0 6 F C 5 5 4 8 0 A B 1 8 0 A A 0 6 F C 5 5 4 8 0 A B 1 2 0 A A 0 6 F C 5 5 4 8 0 A B 0 9 0 A A 0 6 F C 5 5 4 8 0 A B 0 6 0 A A 0 6 F C 5 5 4 8 0 A B 0 3 0 A A 0 Fig 2 11 Frequency torque characteristics of the stepper motors 20 mm Radial load Motor data Speed Shoulder distance Max radial...

Page 27: ...er 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 X10 X20 X100 X201 X200 X4 X2 X101 Fig 2 12 Overview of cables ...

Page 28: ...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 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 C o n n e c t i o n c a b l e X20 BERO Axis Spindle M24 24Vdc power PANASONIC AC SERVO DRIVE W i r e f o r B e r o 1 C o n n e c t io n c a b le W i r e f o r B e r...

Page 29: ... AC SERVO DRIVE GOLDEN AGE ADAPTOR Signal cable 6FX6002 5AA52 1 0 D1 P1 P1N D1N E1 E1N P2 P2N D2 D2N E2 E2N C o n n e c t i o n c a b l e X20 BERO Axis Spindle M24 24Vdc power GOLDEN AGE AC SERVO DRIVE W i r e f o r B e r o 1 C o n n e c t io n c a b le W i r e f o r B e r o 2 J2 J3 J5 J6 J7 J4 Fig 2 14 Connecting with the servo drives SINUMERIK 801 Golden Age Adaptor Golden Age Servo Drives ...

Page 30: ...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 ...

Page 31: ...ommunication 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...

Page 32: ...NUMERIK 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 R S232 adapter 9 P IN S U B D socket PC 9 P IN S U B D ...

Page 33: ...icated 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...

Page 34: ... 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 negate...

Page 35: ... 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...

Page 36: ...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 Spindle Interface AO4 Analog Command Value AGND4 Analog Ground ...

Page 37: ...d 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 Parame...

Page 38: ...nnel 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 handwheel 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 Tra...

Page 39: ...Start Up SINUMERIK 801 2 23 Start Up Signal level extension keys RS422 Signal type extension keys VI Voltage input DI Input 24V signal ...

Page 40: ...tal 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 ...

Page 41: ...DY 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 ...

Page 42: ...it 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 ...

Page 43: ...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 V 1 signal output current 0 5 A Simultaneity factor 0 5 per 12 out...

Page 44: ... inputs outputs see Fig 2 22 and 2 23 below 2 3 4 9 10 1 Pin number of X100 X101 Optic isolated P24 P24 M24 Fig 2 21 Connection of digital inputs 24V stabilized power supply Driver 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 ...

Page 45: ...en 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 ...

Page 46: ...R 1 CURR 2 RES DIR PULS PULS DIR DIR ENA ENA RDY ZPH 24V 24V GND PE L N PE A A B B C C D D E 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 g...

Page 47: ...mp 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 s...

Page 48: ...se 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 referenc...

Page 49: ...O 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 ...

Page 50: ...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 Leadscrew Gear 2 Gear 1 Stepper motor BERO with LED To X20 interface Leadscrew BERO with LED To X20 interface Stepper motor Coupling joint ...

Page 51: ...en 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 LED...

Page 52: ... 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 tran...

Page 53: ...ortant 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 ...

Page 54: ...are 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 Too...

Page 55: ...pindle 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 s...

Page 56: ...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 ...

Page 57: ...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 Traverse keys User Keys ...

Page 58: ...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 wh...

Page 59: ... 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 ...

Page 60: ... 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...

Page 61: ...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...

Page 62: ...ned 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 700...

Page 63: ...n 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 fo...

Page 64: ...t 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...

Page 65: ...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 M...

Page 66: ...urves 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...

Page 67: ...e 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 cam MD34050 REFP_SEARCH_MA...

Page 68: ... REFP_CAM_ IS_ACTIVE X Z 1 Axis with reference point cam 34010 REFP_CAM_ DIR_IS_ MINUS X Z 0 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 Z 0 1 BERO pulse is 0 ouside BERO 1 inside BERO 34060 RE...

Page 69: ...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 ...

Page 70: ...oach 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 ...

Page 71: ...alue 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 revo...

Page 72: ...nsation 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 2 3 4 5 10 100 200 300 11 k 1200 Axis position AA_ENC_COMP_STEP Interpolation point Table 4 1 Compensation principle Caution A...

Page 73: ...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 0...

Page 74: ...A 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 ena...

Page 75: ...pindle 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 Se...

Page 76: ... 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 35...

Page 77: ...drate 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 T...

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Page 79: ...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 e...

Page 80: ...n 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 ...

Page 81: ...Services Diagnosis and Data Saving SINUMERIK 801 5 3 Start Up Fig 5 4 ...

Page 82: ...l 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 Otherwis...

Page 83: ...easure 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 ar...

Page 84: ...ield 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 ano...

Page 85: ...lls 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 scalin...

Page 86: ... 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 Warra...

Page 87: ...ntrol 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...

Page 88: ...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 ...

Page 89: ...AX 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...

Page 90: ... 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 ...

Page 91: ...ause 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 pres...

Page 92: ... 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...

Page 93: ...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 genera...

Page 94: ...1040 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 g...

Page 95: ...OG_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_...

Page 96: ...0 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...

Page 97: ... 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 equid...

Page 98: ...ved 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 ...

Page 99: ...5220 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 ...

Page 100: ...ndle 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 ...

Page 101: ...or 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 mar...

Page 102: ...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...

Page 103: ...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 ...

Page 104: ...Technical Appendix 7 1 SINUMERIK 801 Start Up SINUMERIK 801 Start Up Techncial Manual Order No A5E00702069 Edition 2005 11 ...

Page 105: ...A5E00702069 ...