Start-Up 11/2005 Edition sinumerik SIEMENS SINUMERIK 801 SINUMERIK 801 Document Structure User Documentation: Operation and Programming Turning Technical Documentation: Start-Up Turning User Documentation: Diagnostics Guide Turning SINUMERIK 801 SINUMERIK 801 Control System 1 Installation and Start-Up 2 Built-In PLC Application 3 Setting Up 4 Services, Diagnosis & Data Saving 5 Accessories 6 Technical Appendix 7 Start-Up Technical Manual Valid for Control system SINUMERIK 801 11. 2005 Edition SINUMERIK (R) 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 ... ... B ... ... C ... ... New documentation. Unchanged reprint with new order number. Revised edition of new issue. Edition 2005.11 Order No. A5E00702069 Note A Trademarks (R) (R) (R) (R) (R) (R) 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. Copyright Siemens AG 2005. All right reserved Exclusion of liability The reproduction, transmission or use of this document or its contents 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. 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 completely identical. The information contained in this document is reviewed regularly and any necessary changes will be included in the next edition. We welcome suggestions for improvement. (c) Siemens AG, 2005 Subject to technical changes without notice. Siemens-Aktiengesellschaft. SINUMERIK 801 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. SINUMERIK 801 Start-Up I Table of Contents Table of Contents 1. SINUMERIK 801 Control System....................................................................................... 1-1 1.1 1.2 1.3 1.4 2. Built-In PLC Application ................................................................................................ 3-1 3.1 3.2 3.3 3.4 4. 7. ................................................................................................ 4-1 Setting Up NC Parameters ........................................................................... 4-6 Starting Up the Dynamic Characteristic of the Axes ...................................................... 4-9 Starting Up Reference Points ........................................................................ 4-9 Software Limit Switch and Backlash Compensation................................................... 4-14 Rotation Monitoring .................................................................................... 4-16 Leadscrew Error Compensation ..................................................................... 4-17 Starting Up the Spindle ................................................................................. 4-17 .................................................................. Services ......................................................................................................... Diagnosis ......................................................................................................... Data Saving ......................................................................................................... Internal data saving ................................................................................................ External data saving ................................................................................................ Important Notice ................................................................................................ 5-1 5-2 5-2 5-6 5-6 5-6 5-9 .......................................................................................... 6-1 Services, Diagnosis & Data Saving 5.1 5.2 5.3 5.3.1 5.3.2 5.3.3 6. Input/Output Configuration .............................................................................. 3-4 Definition of User Keys ........................................................................... 3-6 PLC Machine Data .......................................................................................... 3-9 Fixed PLC Alarms...................................................................................................... 3-16 Setting Up 4.1 4.2 4.3 4.4 4.5 4.6 4.7 5. .................................................................................... 2-1 Cabinet, Power Supply and Grounding ............................................................ ... 2-1 Installing and Cabling .......................................................................................... 2-4 Installing the control system ................................................................................. 2-4 Cabling ......................................................................................................... 2-11 Connecting with the stepper drives ........................................................................... 2-11 Connecting with the servo drives (example) ............................................................... 2-12 Interfaces and Cables .......................................................................................... 2-15 Power supply for CNC - X1 ........................................................................ 2-16 RS232 interface - X2 (RS232) ..................................................................... 2-16 Spindle encoder interface - X3 (SPINDLE)............................................................ 2-17 Feed drive interface - X4 (AXIS).............................................................................. 2-18 Handwheel & extension keys connection - X10 (MPG) ............................................. 2-19 BERO input interface - X20 (BERO).............................................................................. 2-19 Digital inputs/outputs - X100 (DIN0) & X101 (DIN1), X200 (DOUT0) & X201 (DOUT1)... 2-20 Connecting cables for SINUMERIK 801 ............................................................... 2-22 Installing and Starting-Up the Drive Modules ................................................... 2-26 Connecting the STEPDRIVE C/C+ drive modules ............ .......................................... 2-26 ............ .......................................... 2-26 Connecting the servo drive modules Installation and Start-Up 2.1 2.2 2.2.1 2.2.2 2.2.2.1 2.2.2.2 2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6 2.3.7 2.3.8 2.4 2.4.1 2.4.2 3. System Overview ............................................................ 1-1 CNC Operator Panel ...................................................... ............ 1-3 Position of the Interfaces............................................................................................. 1-5 Technical Data ............................................................................................. 1-6 Accessories ......................................................................................................7-1 List of Machine Data ...................................................................................................7-1 Techncial Appendix 7.1 SINUMERIK 801 Start-Up III SINUMERIK 801 Control System 1.1 1 System Overview 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. General 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. SINUMERIK 801 Start-Up z One spindle encoder z One electronic handwheel z Possible configurations by users: servo motors (with digital pulse interfaces) and servo motors. 1-1 SINUMERIK 801 Control System SINUMERIK 801 system Fig.1-1 SINUMERIK 801 system overviewCNC + stepper drives + stepper motors 1-2 SINUMERIK 801 Start-Up SINUMERIK 801 Control System 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. LCD NC keys 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 SINUMERIK 801 Start-Up 1-3 SINUMERIK 801 Control System ... 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 (Machine 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 1-4 SINUMERIK 801 Start-Up SINUMERIK 801 Control System 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 Start-Up 1-5 SINUMERIK 801 Control System 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. 1-6 SINUMERIK 801 Start-Up SINUMERIK 801 Control System 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 CNC Dimensions Weight [g] 2120 circa Table 1-3 Component dimensions Component CNC Dimensions LxWxD [mm] 400 x 250 x 57.6 Environmental operating conditions Table 1-4 Environmental operating conditions Parameter Temperature range (horizontal mounting and convection) Permissible relative humidity Air pressure 0....55C (for box) 0....45C (for display surface) 5...95% without condensation 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 Permissible relative air humidity Air pressure Transport height Free fall in transport package -20 ... 60C 5 ... 95 % without condensation 700 ... 1,060hPa -1,000 ... 3,000m 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 SINUMERIK 801 Start-Up Rear: IP20 1-7 Installation and Start-Up 2.1 2 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/IEC60204-12000 Safety of machinery - Electrical equipment of machines - Part II: General requirements; 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. SINUMERIK 801 2-1 Start-Up U V W 380VAC 220VAC 1) M 4) 0V PC CNC M 0V 0V 3) L L+ L+ 220/24 DC Power Supply PE 220VAC 24V L N PE 2,3) N PE 3) PE 3) 3) 3) PE rails PE Fig. 2-1 Connecting the control transformer Notes (for Fig. 2-1): 1) Two phases of UVW 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. PE rails Fig. 2-2 Connecting the drive transformer 2-2 SINUMERIK 801 Start-Up Start-Up Notes (for Fig. 2-2): 1) Two phases of UVW 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. Waveform of Siemens PS Waveform of non-Siemens PS System operating volt: 24V min. 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. SA1 SA2 KA1 24VDC 0VDC KA1 KA1 24VDC 0VDC CNC Fig. 2-4 Power on/off sequence of the power supply Note: SINUMERIK 801 Start-Up 2-3 Start-Up 1) 2-4 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". SINUMERIK 801 Start-Up 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. SINUMERIK 801 Start-Up 2-5 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. 2-6 SINUMERIK 801 Start-Up Start-Up Mounting Dimensions 2) SINUMERIK 801 1) 2) Free space necessary for heat dissipation Holes reserved for plastic clips with screws Fig. 2-6 CNC outline dimensions SINUMERIK 801 Start-Up 2-7 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. Horizontal installation Vertical installation (recommended) > 80 (>150*) 90 (100*) 176 (180*) >100 >50 71 (73*) 34 7 12 307 (327*) > 80 (>100*) 286 (305.6*) PE rails Install with M5 screws, spacers and spring washers Changed installation angle Without forced cooling Fig. 2-8 Mounting dimensions for stepper drives 2-8 SINUMERIK 801 Start-Up 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) Model 6FC5 548-0AB030AA0 6FC5 548-0AB060AA0 6FC5 548-0AB090AA0 6FC5 548-0AB120AA0 6FC5 548-0AB180AA0 6FC5 548-0AB250AA0 Dimensions and tolerance L L1 L2 L3 D D1 D2 D3 D4 D5 92 9f6 10 60f7 107 6.6 162 34 14 110 16f6 17 56f7 127 8.5 186.5 34 110 16f6 17 56f7 127 8.5 216.5 110 16f6 17 56f7 127 8.5 130 16f6 17h 7 100f7 155 130 16f6 17h 7 100f7 155 Key Wt. (kg) R10 C3X1 4 3 65.0 10X4 5 C5X2 5 5.6 112 65.0 10X4 5 C5X2 5 7.2 12.5 112 65.0 10X4 5 C5X2 5 8.6 3 15.0 132 90.0 10X4 5 C5X2 5 13.0 3 15.0 132 90.0 10X4 5 C5X2 5 15.0 L4 h h1 A B C 20 26 3 7 93 62.5 25 32 37 2 12.5 112 34 25 32 37 2 12.5 248.5 34 25 32 37 2 10.5 239.0 34 32 36 43 10.5 263.5 34 32 36 43 When installing the stepper motor, its radial load shall stay within the data range listed below: SINUMERIK 801 Start-Up 2-9 Start-Up Motor data Speed 600 rev/min 300 rev/min 20 mm Shoulder distance 20 mm 950 N 1150 N Max. radial load Radial load 20 mm Fig. 2-10 Radial load of the stepper motor Frequency - torque characteristics of the stepper motors 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 2 6 ,0 0 2 4 ,0 0 2 2 ,0 0 2 0 ,0 0 1 8 ,0 0 1 6 ,0 0 1 4 ,0 0 6FC5 6FC5 6FC5 6FC5 1 2 ,0 0 5 4 8 -0 A B 1 2 -0 A A 0 5 4 8 -0 A B 0 9 -0 A A 0 5 4 8 -0 A B 0 6 -0 A A 0 5 4 8 -0 A B 0 3 -0 A A 0 1 0 ,0 0 8 ,0 0 6 ,0 0 4 ,0 0 2 ,0 0 0 ,0 0 0 ,1 0 6 1 ,0 0 60 F r e q u e n c y [K H z ] S P E E D [R P M ] 1 0 ,0 0 1 0 0 ,0 0 600 6000 Fig. 2-11 Frequency - torque characteristics of the stepper motors 2-10 SINUMERIK 801 Start-Up Start-Up 2.2.2 Cabling 2.2.2.1 Connecting with the stepper drives 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. X200 X201 X100 X101 X20 X10 X3 X4 X2 X1 Cable overview Fig. 2-12 Overview of cables SINUMERIK 801 Start-Up 2-11 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. CN1 P1 X-PLUS1 P1N X-PLUS2 D1 X-SIGN1 D1N X-SIGN2 X-AXIS PANASONIC AC SERVO DRIVE nn E1N ble E1 E1N ca Signal cable: n X4 24V E1 ti o ec Axis/Spindle Co 24V_GND GS 6FX6002-5AA52-1..0 CN2 Y-PLUS1 Y-PLUS2 D2 Y-SIGN1 D2N Y-SIGN2 E2 E1 E2N E1N GS X5 Z-AXIS C on tion nec PANASONIC AC SERVO DRIVE c ab le 3 4 24Vdc power + re Wi BERO X20 CN3 PANASONIC ADAPTOR SINUMERIK 801 CNC P2 P2N Y-AXIS ( fo ( re e ro rB Wi CN4 Be 1) fo r 10 ro 2) M24 HMX X5 HMY Fig. 2-13 Connecting with the servo drives (SINUMERIK 801+ Panasonic Adaptor + Panasonic Servo Drives) 2-12 SINUMERIK 801 Start-Up Start-Up J1 P1 X_PLUS1 P1N X_PLUS2 D1 X_SIGN1 D1N X_SIGN2 J5 GOLDEN AGE AC SERVO DRIVE nn X_E1N ble X_E1 E1N ca Signal cable: n X4 +24V E1 ti o ec Axis/Spindle Co +24V_GND 6FX6002-5AA52-1..0 J2 Y_PLUS1 Y_PLUS2 D2 Y_SIGN1 D2N Y_SIGN2 E2 Y_E1 E2N Y_E1N SINUMERIK 801 CNC J7 C on tion nec GOLDEN AGE AC SERVO DRIVE c ab le 3 4 XS3 re Wi BERO X20 J3 J6 GOLDEN AGE ADAPTOR P2 P2N 24Vdc power + ( fo ( re e ro rB Wi Be 1) fo r 10 J4 ro 2) M24 HMX XS3 HMY Fig. 2-14 Connecting with the servo drives (SINUMERIK 801+ Golden Age Adaptor + Golden Age Servo Drives) SINUMERIK 801 Start-Up 2-13 Start-Up 2.3 Interfaces and Cables Position of the interfaces See Fig. 2-15 for interface positions. Fig. 2-15 Rear of CNC System 2-14 SINUMERIK 801 Start-Up Start-Up 2.3.1 Power supply for CNC - X1 The 24V DC load power supply unit required for supplying CNC is connected to 3-pin screw-type terminal block. General Table 2-2 The load power supply for CNC (X1) Terminal 1 2 3 2.3.2 Signal PE M P24 Description Protective earth 0V DC24 V 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 1 2 3 4 5 Name n.c. RxD TxD DTR M Type I O O VO Pin 6 7 8 9 Name DSR RTS CTS n.c. Type I O I 6 1 9 5 Signal description: RxD Receive Data TxD Transmit Data RTS CTS Request to send Clear to send DTR Data Terminal Ready DSR Data Set Ready M Ground (0V) Signal level RS232 Signal type Cable for WinPCIN I Input O Output VO Voltage output Table 2-4 Cable for WinPCIN: Pin assignment of the Sub-D connector 9-Pin (801) 1 2 3 4 5 6 SINUMERIK 801 Start-Up Name Shield RxD TxD DTR M DSR 25-Pin (PC) 1 2 3 6 7 20 2-15 Start-Up 7 8 9 RTS CTS 5 4 or 9-Pin (801) 1 2 3 4 5 6 7 8 9 Name 9-Pin (PC) 1 3 2 6 5 4 8 7 Shield RxD TxD DTR M DSR RTS CTS SINUMERIK 801 PC SINUMERIK 801 9PIN SUB-D (socket) 9 PIN SUB-D (fsocket) 9 PIN SUB-D (socket) RxD TxD DTR 0V DSR RTS CTS 2 3 4 5 6 7 8 0.1 mm 2 3 2 6 5 4 8 7 TxD RxD DSR 0V DTR CTS RTS RxD TxD DTR 0V DSR RTS CTS 2 3 4 5 6 7 8 PC 0.1 mm 25 PIN SUB-D (plug) 2 2 3 6 7 20 5 4 RxD TxD DSR 0V DTR CTS RTS 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 S 2 3 2 a d a p te r PC 9 P IN S U B -D (s o c k e t) R xD T xD DTR D SR 0V RTS CTS 2 3 4 6 5 7 8 9 P IN S U B -D (s o c k e t) 0 .1 m m 2 2 3 4 6 5 7 8 R xD T xD DTR DSR 0V RTS CTS X2 Fig. 2-17 Connecting diagram 1 (with 9 PIN SUB-D connector of PC Serial Port 2-16 SINUMERIK 801 Start-Up Start-Up R S 2 3 2 a d a p te r PC 9 P IN S U B -D (s o c k e t) 2 5 P IN S U B -D (p lu g ) R xD T xD DTR DSR 0V RTS CTS 2 3 4 6 5 7 8 0 .1 m m 2 3 2 20 6 7 4 5 R xD T xD DTR DSR 0V RTS CTS 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 R S 2 3 2 a d a p te r S IN U M E R IK 8 0 1 9 P IN S U B -D (s o c k e t) 9 P IN S U B -D (s o c k e t) R xD T xD DTR DSR 0V RTS CTS 2 3 4 6 5 7 8 0 .1 m m 2 2 3 4 6 5 7 8 R xD TxD DTR DSR 0V RTS CTS X1 Fig.2-19 Connecting diagram 3 (with SINUMERIK 801) Notes: (1) X1 and X2 indicated in Fig. 2-172-19 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). SINUMERIK 801 Start-Up 2-17 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 1 Type Pin Signal Type n.c. 9 M VO 2 n.c. 10 Z I 3 n.c. 11 Z_N I 4 P5_MS 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. VO Signal A; A_N B; B_N Z; Z_N P5_MS M Signal level: Description Channel A Channel B Zero Reference Mark +5,2V Supply Voltage Ground RS422 Signal type VO I Voltage output (supply) 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, U a1 ) Track B as true and negated signal (Ua2, U a 2 ) Zero signal N as true and negated signal (Ua0, U a 0 ) Max. output frequency: 1.5 MHz Phase offset between 2-18 tracks A and B: 90 30 Current consumption: max. 300 mA SINUMERIK 801 Start-Up 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 5 V DC 5 V DC 4.75 V ... 5.25 V 4.75 V ... 5.25 V < 300 mA < 220 mA Max. Cable Length 25 m 35 m Table 2-7 Maximum cable lengths depending on the transmission frequency Encoder Type incremental SINUMERIK 801 Start-Up Frequency 1 MHz 500 kHz Max. Cable Length 10 m 35 m 2-19 Start-Up 2.3.4 General Feed drive interface - X4 (AXIS) 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 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 23 SE4_2 11 n.c. 24 n.c. 12 AO4 25 AGND4 13 M O K AO Signal K AO 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 SE4_1, SE4_2 Servo Enable Relay Contact Signal level: +/-10V for Analog Outputs RS422 for Stepper Signals Signal type 2-20 AO Analog output O Output K Switch signal SINUMERIK 801 Start-Up 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 Voltage range Output current Min -10.5 -3 Max 10.5 3 Unit V mA Relay contact Table 2-10 Electrical parameters of the relay contacts Parameter Switching voltage Switching current Switching power Cable length: SINUMERIK 801 Start-Up Max. 50 1 30 Unit V A VA max. 35 m 2-21 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 /A B Channel A, true, handwheel Complement Channel A, negated, handwheel Channel B, true, handwheel /B Complement Channel B, negated handwheel P5 M5 Power supply, 5.2V 5.2 V supply ground for handwheel Signal level (handwheel) RS422 Signal type (handwheel) VO I Handwheel Voltage output Input (5 V signal) 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, U a1 ) Track B as true and negated signal (Ua2, U a 2 ) Max. output frequency: 500 kHz 2-22 Phase offset between tracks A and B: 90 30 Supply: 5 V, max. 250 mA Reset Reset key CycSta Cycle Start key CycSto Cycle Stop key M24 24V supply ground SINUMERIK 801 Start-Up Start-Up Signal level (extension keys) RS422 Signal type (extension keys) SINUMERIK 801 Start-Up VI Voltage input DI Input (24V signal) 2-23 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 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 Signal NCRDY_K[1 ... 2] Type VI Description 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 2 BERO inputs K Switching contact DI Digital input VI Voltage input 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 "1" signal, voltage range "1" signal, current consumption "0" signal, voltage range Signal delay 0AE1 Signal delay 1AE0 Value 11 ...30 6 ...15 -3 ...5 15 150 Unit V mA V us us Note Or input open 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 2-24 Readiness in the form of a relay contact (NO); must be integrated into the EMERGENCY STOP circuit. SINUMERIK 801 Start-Up Start-Up Table 2-14 Electrical parameters of the NCREADY relay contact Parameter DC switching voltage Switching current Switching power Max. Unit 50 1 30 V A VA Pin number of X20 Relay NC_RDY 1P5 1 2 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. SINUMERIK 801 Start-Up 2-25 Start-Up 2.3.7 General Digital inputs/outputs X100 (DIN0)X101 (DIN1), X200 (DOUT0) ... X201 (DOUT1) 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 X100X101 Pin Signal 1 2 3 4 5 6 7 8 9 10 n.c. Limit X+ Limit XRef. X Limit Z+ Limit ZRef. Z FootPed E-Stop M24 X100 Signal type DI DI DI DI DI DI DI DI VI Pin Signal 1 2 3 4 5 6 7 8 9 10 n.c. T1 T2 T3 T4 T5 T6 User in1 User in2 M24 X101 Signal type DI DI DI DI DI DI DI DI 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 DI Voltage input Input (24 V signal) Table 2-16 Electrical parameters of the digital inputs Parameter "1" signal, voltage range "1" signal, current consumption "0" signal, voltage range Signal delay 0 AE 1 Signal delay 1 AE 0 Value 15 ... 30 2 ... 15 -3 ... 5 0.5 ... 3 0.5 ... 3 Unit V mA V ms ms Note Or input open Notice See Section 3.2 " Input/Output Configuration" for definitions of X100 ... X101 input signals. 2-26 SINUMERIK 801 Start-Up Start-Up Table 2-17 Pin assignment for connectors X200X201 Pin Signal 1 2 3 4 5 6 7 8 9 10 P24 S-CW S-CCW T-CW T-CCW Cooling Lubric S-Brake Chuck M24 X200 Signal type VI DO DO DO DO DO DO DO DO VI Pin Signal 1 2 3 4 5 6 7 8 9 10 P24 User out1 User out2 User out3 User out4 n.c. n.c. n.c. n.c. M24 X201 Signal type VI DO DO DO DO 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 DO Voltage input Digital output (24 V signal) Table 2-18 Electrical parameters of the digital outputs Parameter "1" signal, nominal voltage Voltage drop "1" signal, output current Value 24 max. 28.8 0.5 V V A Unit "0" signal, leakage current max. 2 mA Note Simultaneity factor 0.5 per 12 outputs Notice See Section 3.2 "Input/Output Configuration" for definitions of X200 ... X201 output signals. SINUMERIK 801 Start-Up 2-27 Start-Up Connections of digital inputs/outputs For the connections of digital inputs/outputs, see Fig. 2-22 and 2-23 below. Pin number of X100---X101 1 Optic-isolated 2 3 4 9 P24 10 P24 M24 Fig. 2-21 Connection of digital inputs Pin number of X200,X201 1 P24 +24V 0V +24V stabilized power supply Optic-isolated 2 Relay Driver Driver 3 Driver 9 10 M24 M Fig. 2-22 Connection of digital outputs 2-28 SINUMERIK 801 Start-Up 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. P1 P1N D1 D1N 25-pin SUB-D connector E1 E1N X axis P2 P2N D2 D2N Z axis E2 E2N SE1 SE2 AO AON On CNC side: X4 interface On drive side: Spindle System interface Fig. 2-23 Setpoint cable for SINUMERIK 801 SINUMERIK 801 Start-Up 2-29 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: Drive of axis 1 yellow white blue white green white black white brown white Power cable SINUMERIK 801 X4 Drive of axis 2 A A B B C C D D E E PE CURR.1 CURR.2 RES. DIR. CURR.1 CURR.2 RES. DIR. RDY TMP FLT DIS RDY TMP FLT DIS Signal cable P1 P1N D1 D1N E1 E1N 24Vdc Power Supply L A A B B C C D D E E PE + - 380/85 VAC - Transformer 380VAC N PE +PULS -PULS +DIR -DIR +ENA -ENA RDY ZPH +24V 24V GND PE P3 P3N D3 D3N E3 E3N +PULS -PULS +DIR -DIR +ENA -ENA RDY ZPH +24V 24V GND PE L N PE L N PE Motor Note: The drive and motor must be well grounded via the shield connections. wh. blk. wh. br. wh. wh. blk. wh. br. wh. Fig. 2-24 Overview of cables 2-30 SINUMERIK 801 Start-Up 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 z If the transformer possesses a shielded winding, this should be connected with low inductivity to PE. 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 z To connect the drive pulse interface to the SINUMERIK 801, use the preassembled cable, order no.6FX6 002-5AA52-1..0. 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. SINUMERIK 801 Start-Up 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 2-31 Start-Up temperature boost during this period). 1) The resolution (displacement per step of the stepper motor) depends on mechanical data: Resolutionleadscrew pitch/steps per revolution x 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 speedaxis 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. Machine body BERO Signal to X20 Object under test Leadscrew 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. 2-32 SINUMERIK 801 Start-Up Start-Up Single-switch mode (without reference cam, MD34000=0) There is one BERO in the axis. Machine body Object under test Leadscrew Bero 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. V V Threshold Level Threshold Level Rising Edge Falling Edge Threshold Level Falling Edge Ref. Point Ref. Point t t Fig. 2-27 BERO sampling methods Mechanical installation of the proximity switches Follow Fig. 2-28 & 2-29 to complete the mechanical installation of BERO under double-switch mode. z SINUMERIK 801 Start-Up When stepper motors is connected with a leadscrew directly: 2-33 Start-Up Stepper motor Leadscrew Coupling joint BERO (with LED) To X20 interface Fig.2-28 Installing the BERO - 1 z If there are reduction gears between the stepper motor and proximity switch BERO (with LED) LED Leadscrew To X20 interface X20 Stepper motor Gear 2 Gear 1 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: 2-34 SINUMERIK 801 Start-Up Start-Up DIR switch LEDs ON CURR.1 CURR.2 RDY TMP FLT DIS RES. DIR Motor Type CURR 1 CURR 2 Phase Curr 3.5 Nm OFF OFF 1.35 A 6 Nm OFF OFF 1.35 A 9 Nm OFF ON 2.00 A 2.55 A 12 Nm ON ON 18 Nm OFF ON 3.6 25 Nm ON ON 5.00 A Stepper Driver STEPDRIVE C A STEPDRIVE C+ 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! SINUMERIK 801 Start-Up 2-35 Start-Up Table 2-19 LED alarms LED Meaning Name Color RDY green the only LED Drive ready that is lit DIS FLT TMP all Remedy yellow the only LED Drive ready; motor not powered that is lit 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 red is lit Overtemperature in the drive No LED is lit No operating voltage 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 Activate ENABLE signal via CNC Measure 85 V operating voltage Check cable connections Drive defective; replace 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 6FC5 548-0AB03-0AA0 6FC5 548-0AB06-0AA0 6FC5 548-0AB09-0AA0 6FC5 548-0AB012-0AA0 6FC5 548-0AB018-0AA0 6FC5 548-0AB025-0AA0 No. of motor axes 1 1 1 1 3.5 6 9 12 Power of transformer (KVA) 0.3 0.403 0.612 0.7 1 18 1.368 1 25 1.420 Torque (Nm) *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. 2-36 SINUMERIK 801 Start-Up Built-In PLC Application Important ! SINUMERIK 801 Start-Up 3 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. 3-1 Built-In PLC Application 3.1 Input/Output Configuration Input signals description Table 3-1 Input signals description Description of Input Signals X100 Pin# 3-2 DIN0 Signal Input # Signal Description 1 n.c 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 10 M24 X101 DIN1 Pin# Signal Not defined (normally closed) 24V ground 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 8 User in1 I1.6 User input 1 9 User in2 I1.7 User input 2 10 M24 Active low when HED approximates to the magnet, otherwise active high (see below for wiring diagram) 24V ground SINUMERIK 801 Start-Up Built-In PLC Application 1 2 Digital input X101 3 4 5 6 7 8 9 Tool sensor T1 Tool sensor T2 Tool sensor T3 Tool sensor T4 Tool sensor T5 Active low when HED approximates to the magnet, otherwise active high Tool sensor T6 24VDC Power Supply User input 1 User input 2 10 Output signals description Table 3-2 Output signals description Description of Output Signals X200 Pin# Signal 1 P24 2 S-CW Q0.0 3 S-CCW Q0.1 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 X201 DOUT1 Pin# Signal 1 SINUMERIK 801 Start-Up DOUT0 P24 Input # Signal Description 24V power supply Direction and enable of unipolar spindle or contactor-controlled spindle (see MD30134 description) Direction and enable of unipolar spindle or contactor-controlled spindle (see MD30134 description) 24V ground Input # Signal Description 24V power supply 3-3 Built-In PLC Application 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 in1I1.60 >User out1(Q1.0)=0 User in1I1.61 >User out1(Q1.0)=1 b User in2I1.70 >User out2(Q1.1)=0 User in2I1.71 >User out2(Q1.1)=1 c The output values of User out3 and 4 are defined by M functions 3-4 Use out3(Q1.3) User out4(Q1.2) M20 0 0 M21 0 1 M22 1 0 M23 1 1 SINUMERIK 801 Start-Up Built-In PLC Application 3.2 Definition of User Keys User Keys Override keys Traverse keys Fig. 3-1 User keys on MCP area SINUMERIK 801 Start-Up 3-5 Built-In PLC Application Definition of user keys Table 3-3 Definition of user keys Key Description 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 1Feedrate 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%; 3-6 SINUMERIK 801 Start-Up Built-In PLC Application 2Feedrate override 100% key Keep pressing this key for 1.5 seconds, the feedrate override will be changed into 100% directly. 3Feedrate 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%; 4Spindle 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%; 5Spindle override 100% key Keep pressing this key for 1.5 seconds, the spindle override will be changed into 100% directly. 6Spindle 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. SINUMERIK 801 Start-Up 3-7 Built-In PLC Application 3.3 PLC Machine Data Definition of MD14512 Table 3-4 MD14512 MD14512 Machine data INDEX Bit 7 Bit 6 USER_DATA_HEX PLC machine data - Hex Bit 4 Bit 3 Bit 2 Bit 5 [0] Reserved [1] Reserved [2] Reserved [3] Reserved [4] Bit 0 PLC application configuration Clamp & Lubrication unclamp inactive inactive Toolholder control inactive [5] [6] Bit 1 Reserved Z axis rotation monitoring active Technology Setting X axis rotation monitoring active Spindle brake active Auto lubrication once when power on Reserved [7] 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 3-8 14510[0] Reserved 14510[1] Reserved SINUMERIK 801 Start-Up Built-In PLC Application 14510[2] 14510[3] 14510[4] 14510[5] 14510[6] 14510[7] SINUMERIK 801 Start-Up Definition: Interval of track lubrication Unit: 1 minute Range: 5300 minutes Definition: Duration of lubrication Unit: 0.1 second Range: 10200 (120 seconds) Definition: Number of positions on the turret Unit: Range: 4 or 6 Definition: Monitor time (turret change abort if destination tool not found within specified time) Unit: 0.1second Range: 30200 (320 seconds) Definition: Turret clamping time Unit: 0.1 second Range: 530 (0.53 seconds) Definition: Braking time of external brake mechanism of a contactor controlled spindle Unit: 0.1 second Range: 5200 (0.520 seconds) 3-9 Built-In PLC Application 3.4 Fixed PLC Alarms Definition of fixed PLC alarms Table 3-6 Definition of fixed PLC alarms Alarm # 3-10 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 Start-Up 4 Setting Up 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 30130 CTRLOUT_T - XZ 2 YPE 30240 ENC_TYPE - XZ 3 34200 ENC_REF_M - XZ 2* or ODE 34210 ENC_REF_ STATE SINUMERIK 801 Start-Up 4* - XZ 0 or 1 Description Output type of setpoint (setpoint branch): the setpoint signals are output to connector X4 Type of actual value acquisition (actual position value) (encoder no.): 3: Encoder for stepper motor Type of position measuring system: 2: BERO 4: Bero with two edges Reference state 0: Function "Record reference point" inactive 1: Function "Record reference point" activated 5-1 Setting 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: Designation Unit Axis Input value 31020 ENC_RESOL IPR X, Z 1000 31400 STEP_RESOL IPR X, Z 1000 MD Description Encoder markings per revolution (encoder no.) Steps per stepping motor revolution Mechanical parameters for the driving system: MD 31030 Designation Unit Axis Input value LEADSCREW_ mm X, Z 5 Pitch of leadscrew - X, Z 40 - X, Z 50 Denominator load gearbox (control parameter No.) Numerator load gearbox (control parameter set No.) PITCH 31050 DRIVE_AX_RATIO _DENUM[0 ... 5] 31060 DRIVE_AX_RATIO _NUMERA[0 ... 5] Description 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. 5-2 SINUMERIK 801 Start-Up Setting Up MD Designation Unit Axis Example value 32000 MAX_ AX_VELO mm/Min XZ 4800 32010 JOG_ VELO_ mm/Min XZ 4800 mm/Min XZ 3000 RPM XZ 1200 mm/Min XZ 5280 RAPID 32020 JOG_ VELO 32260 RATED_VELO 36200 AX_VELO_LIMIT Description Maximum axis velocity Rapid traverse in JOG mode JOG axis velocity Rated motor speed (setpoint branch) 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.x1000 pulses/rev.20000pulses/sec., and MD31350 is set as follows: MD Designation Unit Axis Example value Description 31350 FREQ_STEP_LIMIT Hz XZ 20000 Stepping rate at maximum velocity Setting the encoder limit frequency according to MD31350: MD Designation Unit Axis Example value 36300 ENC_FREQ_LIMIT Hz XZ 22000 Description Encoder frequency limit Note: The max. output frequency of SINUMERIK 801 can reach 500000Hz. SINUMERIK 801 Start-Up 5-3 Setting 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 Vmax MD35230 reduced acceleration factor: value 40% ... 95% MD35220 speed for reduced acceleration: values from 80% ...20% MD32300 max. axis acceleration Time Table 4-1 Parameterization MD Designation Unit Axis Input value 35220 ACCEL_REDUC - XZ 1 ... 0 - XZ 0 ... 1 m/s2 XZ 1 TION_SPEED_ POINT 35230 ACCEL_ REDUCTION_ FACTOR 32300 5-4 MAX_AX_ACCEL Description Speed for reduced acceleration: max. speed * percent, values valid from 0.8 ... 0.2. Factor of reduced acceleration: max. acceleration * percent, values valid from 0.4 ... 0.95. The max. axis acceleration (default value) SINUMERIK 801 Start-Up Setting 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. RV VC VM VP RK Start Reference cam BERO--pulse 2) after reference cam: MD34050: REFP_SEARCH_MARKER_REVERS=1, search for BERO pulse in the same direction as the reference cam. RV VC VM VP RK Start Reference cam BERO--pulse Without reference cam RV VM VP Start BERO--pulse SINUMERIK 801 Start-Up RK 5-5 Setting Up Notes: VC - Reference point approach velocity MD34020 REFP_VELO_SEARCH_CAM VM - Creep speed MD34040 REFP_VELO_SEARCH_MARKER VP - Reference point positioning velocity MD34070 REFP_VELO_POS RV - Reference point distance/target point for distance-coded system MD34080 REFP_MOVE_DIST RK - Reference point value/irrelevant to distance-coded system MD34100 REFP_SET_POS[0] Parameterization MD Designation Unit Axis Example value Description 34000 REFP_CAM_ - X, Z 1 Axis with reference point cam - X, Z 0/1 Approach reference point in: 0- plus direction; 1minus direction mm/Min X, Z 2000 Reference point approach velocity mm/Min X, Z 300 Creep speed (encoder no.) - X, Z 0/1 BERO pulse is: 0-ouside BERO; 1-inside BERO mm X, Z 200 mm/Min X, Z 200 Maximum distance to reference mark. Max. distance to 2 reference marks for distance-coded measuring systems. Reference point positioning velocity mm X, Z -2 IS_ACTIVE 34010 REFP_CAM_ DIR_IS_ MINUS 34020 REFP_VELO_ SEARCH_ CAM 34040 REFP_VELO_ SEARCH_ MARKER 34050 REFP_SEAR CH_MARKER _REVERSE 34060 REFP_MAX_ MARKER_ DIST 34070 REFP_VELO_ POS 34080 5-6 REFP_MOVE Reference point distance/target SINUMERIK 801 Start-Up Setting Up _DIST 34100 REFP_SET_ POS SINUMERIK 801 Start-Up mm X, Z 29.4 point for distance-coded system (with direction) Reference point value/irrelevant to distance-coded system 5-7 Setting Up 4.4 Software Limit Switch and Backlash Compensation Software 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 36100 POS_LIMIT_MINUS mm X, Z Example value -1 36110 POS_LIMIT_PLUS mm X, Z 200 Description 1st software limit switch minus 1st software limit switch plus Backlash compensation Test the backlash and make backlash compensations: 5-8 MD Designation Unit Axis 32450 BACKLASH mm X, Z Example value 0.024 Description Backlash SINUMERIK 801 Start-Up Setting Up 4.5 Rotation Monitoring Rotation 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 31100 BERO_CYCLE IPR XZ Example value 1250 31110 BERO_EDGE_ TOL I XZ 500 Description Steps for monitoring rotation 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 x follow-up error at the max. speed/pitch of leadscrew SINUMERIK 801 Start-Up 5-9 Setting Up 4.6 General Leadscrew Error Compensation 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). 1st step: Determine the number of compensation intermediate points Example: Number of compensation intermediate points: 13 Error curve Compensation value Compensation curve(Linear interpolation between compensation points) Compensation values in the compensation tables Max. number of intermediate points for interpolatory compensation: MM_ENC_COMP_MAX_POINTS Max. coordinate point ($AA_ENC_COMP_MAX) Measuring clearance error Compensation value at point 5 ($AA_ENC_COMP_STEP) 100 200 300 0 1 2 1200 3 4 Interpolation point 5 Linear interpolation between two points 10 Axis position 11 (k) ($AA_ENC_COMP_MIN) Min. coordinate pointcorrepsonding to $AA_ENC_COMP[0, 0, AX2] 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: 1st 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. nd 2 method: 1) 5-10 Transfer this compesation array into the computer via SINUMERIK 801; SINUMERIK 801 Start-Up Setting 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 %_N_COMPLETE_EEC_ INI 2nd Method %_N_BUCHANG_MPF $PATH=/_N_MPF_DIR $AA_ENC_COMP $AA_ENC_COMP[00AX2]= 0.0 Remarks File header [00AX2]= 0.0 $AA_ENC_COMP[0 1 AX2]= [01AX2]= 0.020 0.020 $AA_ENC_COMP $AA_ENC_COMP[0 2 AX2]= [02AX2]= 0.015 0.015 $AA_ENC_COMP $AA_ENC_COMP[0 3 AX2]= [03AX2]= 0.014 0.014 $AA_ENC_COMP $AA_ENC_COMP[0 4 AX2]= [04AX2]= 0.011 0.011 $AA_ENC_COMP $AA_ENC_COMP[0 5 AX2]= [05AX2]= 0.009 0.009 $AA_ENC_COMP $AA_ENC_COMP[0 6 AX2]= [06AX2]= 0.004 0.004 $AA_ENC_COMP $AA_ENC_COMP[0 [07AX2]=-0.010 AX2]=-0.010 $AA_ENC_COMP $AA_ENC_COMP[0 [08AX2]=-0.013 AX2]=-0.013 $AA_ENC_COMP $AA_ENC_COMP[0 [09AX2]=-0.015 AX2]=-0.015 $AA_ENC_COMP $AA_ENC_COMP[0 [010AX2]=-0.009 AX2]=-0.009 $AA_ENC_COMP $AA_ENC_COMP[0 [011AX2]=-0.004 ... AX2]=-0.004 ... $AA_ENC_COMP $AA_ENC_COMP[063AX2] 7 8 9 10 11 Corresponding min. position Compensation value array $AA_ENC_COMP Corresponding max. position [063AX2] SINUMERIK 801 Start-Up $AA_ENC_COMP_STEP $AA_ENC_COMP_STEP[0 [0AX2]=100.0 AX2]=100.0 $AA_ENC_COMP_MIN $AA_ENC_COMP_MIN[0 AX2] [0AX2] =100.0 =100.0 $AA_ENC_COMP_MAX $AA_ENC_COMP_MAX[0 AX2] [0AX2] =1200.0 =1200.0 $AA_ENC_COMP_IS_MO $AA_ENC_COMP_IS_MODULO[0 Measuring clearance (mm) Min. position (abs.) Max. position (abs.) (for rotating axis) 5-11 Setting Up DULO AX2]=0 [0AX2]=0 M17 End of the file M02 3rd stepEnable the leadscrew error compensation function through set MD MD Designation Unit Axis Example value 32700 ENC_COMP_ENA - XZ 0 BLE 1 Description Compensation inactive 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. 5-12 SINUMERIK 801 Start-Up Setting 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 30130 30130 CTRLOUT_TYPE CTRLOUT_TYPE - Spindle Spindle Input value 0 1 Description No analog output 10VDC analog output Set the machine spindle outputs as unipolar/bipolar setpoint output. MD Designation Unit Axis 30134 IS_UNIPOLAR_ OUTPUT IS_UNIPOLAR_ OUTPUT IS_UNIPOLAR_ OUTPUT - Spindle Input value 0 - Spindle 1* - Spindle 2* 30134 30134 * When MD30134 =1: Description Setpoint output is bipolar Setpoint output is unipolar Setpoint output is unipolarQ0.0 and Q0.1 can not be recalled by PLC; Q0.0Servo enable; Q0.1 Spindle CCW MD30134 =2: Q0.0Sevo enable, spindle CW; Q0.1Servo enable, spindle CCW If the spindle has no encoder feedback, set MD30200 = 0. MD 30200 Designation NUM_ENCS Unit Axis - Spindle Input value 0 Description Spindle encoder without When producing a thread, configure the spindle with an encoder: MD 30240 SINUMERIK 801 Start-Up Designation ENC_TYPE Unit Axis - Spindle Input value 2 Description Spindle with measuring system 5-13 Setting Up Set spindle MDs as listed below: Designation Unit Axis 31020 ENC_RESOL IPR Spindle Input value 1024 32260 RATED_VELO Spindle 3000 36200 AX_VELO_ LIMIT[ 0 ... 5 ] RP M RP M Spindle 3300 MD Description Encoder markings per revolution (encoder no.) Rated motor speed (setpoint branch) Threshold value for velocity monitoring Determine the encoder limit frequency: Spindle speed 3000 rev/min = 50rev/s; Encoder limit frequency 50 rev/sx1024 pulses/rev = 51200 pulses/s Fill in weighted machine data: MD 36300 Designation MA_ ENC_ LIMIT FREQ_ Unit Axis Hz Spindle Input value 55000 Description Encoder limit frequency For anolog spindle with gear changes: MD 35010 5-14 Designation GEAR_STEP_ CHANGE_ ENABLE Unit - Axis Spindle Input value 1 Speed [i] 35110 GEAR_STEP_ MAX_VELO[ 0 1 ... 5 ] RPM Spindle 35130 GEAR_STEP_ MAX_VELOLIMI T[ 01 ... 5 ] RPM Spindle Speed [i] 36200 AX_VELO_ LIMIT[ 01 ... 5 ] RPM Spindle Speed [i] 31050 DRIVE_AX_ RATIO_ DENUM[01 ... - Spindle Denominator [i] Description Gear change possible. Spindle has several gear steps Maximum speed for gear change(gear stage no.): 0 ... 5 Maximum speed of gear stag(gear stage no.): 0 ... 5 Threshold value for velocity monitoring (control parameter set no.): 0 ... 5 Denominator load gearbox (control parameter SINUMERIK 801 Start-Up Setting Up 31060 5] DRIVE_AX_ RATIO_ NUMERA[01 ... 5] - Spindle Numerator [i] no.): 0 ... 5 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 N40 G01 Z-0.5 K - thread lead; SFSF - Infeed angle for thread cutting thread run-out N50 X50 SINUMERIK 801 Start-Up 5-15 Services, Diagnosis and Data Saving 5.1 5 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: SINUMERIK 801 Start-Up 5-1 Services, Diagnosis and Data Saving 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 5-2 SINUMERIK 801 Start-Up Services, Diagnosis and Data Saving Fig.5-4 SINUMERIK 801 Start-Up 5-3 Services, Diagnosis and Data Saving 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!" 5-4 SINUMERIK 801 Start-Up Services, Diagnosis and Data Saving 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 Difference display of Markers Initial values Current marker position 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. SINUMERIK 801 Start-Up 5-5 Services, Diagnosis and Data Saving Fig. 5-9 Signal selection z z z z Selecting the axis: The axis is selected in the Axis toggle field. Signal type: Velocity setpoint Actual position value of measuring system 1 Following error Determining the measuring time: The measuring time is entered in ms directly in the "Measuring Time" input field. 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. 5-6 SINUMERIK 801 Start-Up Services, Diagnosis and Data Saving 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. SINUMERIK 801 Start-Up 5-7 Services, Diagnosis and Data Saving 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: Sav e data S ta rt-u p D iagnostics 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 Purpose External Data Saving 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 Data Definition OEM Value Unit X-axis Z-axis Spin. Setting value: 30134 Setpoint output is unipolar - 30600 Fixed-value positions of axis with mm G75 (position no.) 31020 Encoder markings per revolution IPR (encoder no.) 5-8 31030 Pitch of leadscrew mm 31050 Denominator load gearbox (control - [0] parameter No.)[0] 31050 Denominator load gearbox (control [1] parameter No.)[1] 31060 Numerator load gearbox (control - SINUMERIK 801 Start-Up Services, Diagnosis and Data Saving Data Definition Unit OEM Value X-axis [0] parameter set No.)[0] 31060 Numerator load gearbox (control [1] parameter set No.)[1] 31100 Steps for monitoring rotation IPR 31110 Step tolerance for monitoring I Z-axis Spin. - rotation 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 Servo gain factor (control 1000/mi [0] parameter set no.) n 32200 Servo gain factor (control 1000/mi [1] parameter set no.) n Rated motor speed (setpoint rpm 32260 branch) 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 mm/Min mark 34070 Reference point positioning velocity 34080 Reference point distance 34100 Reference point value/irrelevant for mm/Min mm distance-coded system 35110 SINUMERIK 801 Start-Up Maximum speed for gear change rpm 5-9 Services, Diagnosis and Data Saving Data Definition Unit OEM Value X-axis [1] [1] 35130 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 Threshold value for velocity mm/Min [0] monitoring [0] rpm 36200 Threshold value for velocity mm/Min [1] monitoring [1] rpm 36300 Encoder limit frequency Hz Z-axis Spin. [1] Other machine data (if necessary) 32700* note: If interpolatory compensation is used, please fill in the parameters into the following table. 5-10 SINUMERIK 801 Start-Up Services, Diagnosis and Data Saving X-axis $AA_ENC_COMP[0,0,AX1]= $AA_ENC_COMP[0,1,AX1]= $AA_ENC_COMP[0,2,AX1]= $AA_ENC_COMP[0,3,AX1]= $AA_ENC_COMP[0,4,AX1]= $AA_ENC_COMP[0,5,AX1]= $AA_ENC_COMP[0,6,AX1]= $AA_ENC_COMP[0,7,AX1]= $AA_ENC_COMP[0,8,AX1]= $AA_ENC_COMP[0,9,AX1]= $AA_ENC_COMP[0,10,AX1]= $AA_ENC_COMP[0,11,AX1]= $AA_ENC_COMP[0,12,AX1]= $AA_ENC_COMP[0,13,AX1]= $AA_ENC_COMP[0,14,AX1]= $AA_ENC_COMP[0,15,AX1]= $AA_ENC_COMP_STEP[0,AX1]= $AA_ENC_COMP_MIN[0,AX1]= $AA_ENC_COMP_MAX[0,AX1]= Z-axis $AA_ENC_COMP[0,0,AX2]= $AA_ENC_COMP[0,1,AX2]= $AA_ENC_COMP[0,2,AX2]= $AA_ENC_COMP[0,3,AX2]= $AA_ENC_COMP[0,4,AX2]= $AA_ENC_COMP[0,5,AX2]= $AA_ENC_COMP[0,6,AX2]= $AA_ENC_COMP[0,7,AX2]= $AA_ENC_COMP[0,8,AX2]= $AA_ENC_COMP[0,9,AX2]= $AA_ENC_COMP[0,10,AX2]= $AA_ENC_COMP[0,11,AX2]= $AA_ENC_COMP[0,12,AX2]= $AA_ENC_COMP[0,13,AX2]= $AA_ENC_COMP[0,14,AX2]= $AA_ENC_COMP[0,15,AX2]= $AA_ENC_COMP_STEP[0,AX2]= $AA_ENC_COMP_MIN[0,AX2]= $AA_ENC_COMP_MAX[0,AX2]= 2PLC Parameter MD14512 PLC dataBinary Bit 7 14512[4] 14512[6] 5.3.3 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 MD 14510 PLC data integer 14510[2] 14510[3] 14510[4] 14510[5] 14510[6] 14510[7] Important Notice Important 5-4 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 SINUMERIK 801 Start-Up 5-11 Services, Diagnosis and Data Saving 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. 5-12 SINUMERIK 801 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. SINUMERIK 801 Start-Up 6-1 Technical Appendix 7 Technical Appendix 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) 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 Activation conditions 7-1 SINUMERIK 801 Start-Up Technical Appendix Data format Number Unit HW / function MD Name Name, Miscellaneous Standard value Minimum value Reference Activated Maximum value Data type General machine data 10240 - _always SCALING_SYSTEM_IS_METRIC Basic system metric 1 *** *** 14510 kB - USER_DATA_INT [n] User data (INT) 0 ... 31 - 0 - 14512 kB - USER_DATA_BIN [n] User data (Binary) 0 ... 31 0 0 0xFF POWER ON BOOLEAN POWER ON DWORD POWER ON DWORD Axis-specific machine data 30130 - _always CTRLOUT_TYPE Output type of setpoint (setpoint branch): 0 0 0 2 30134 - _always IS_UNIPOLAR_OUTPUT[0] Setpoint output is unipolar : 0 0 0 2 30200 - NUM_ENCS Number of encoders (spindle with or without encoder) 1 0 1 30240 - POWER ON BYTE POWER ON BYTE RESTART BYTE _always ENC_TYPE Type of actual value acquisition (actual position value) POWER ON (encoder no.) 0: Simulation 2: Square-wave generator, standard encoder (pulse multiplication) 3: Encoder for stepper motor 0, 0 0 4 30350 SIMU_AX_VDI_OUTPUT - Output of axis signals with simulation axes _always 30600 0 *** BYTE POWER ON *** BOOLEAN FIX_POINT_POS SINUMERIK 801 Start-Up 7-2 Technical Appendix mm, degrees _always Fixed-value positions of axis with G75 (position no.) 31000 - _always ENC_IS_LINEAR Direct measuring system (linear scale) (encoder no.) 0 *** *** 31010 ENC_GRID_POINT_DIST mm Division period for linear scales (encoder no.) _always 0.0 0.01 - 0.0 POWER ON - DOUBLE POWER ON BOOLEAN POWER ON plus DOUBLE 31020 - _always ENC_RESOL Encoder markings per revolution (encoder no.) 2048 0.0 plus 31030 mm _always LEADSCREW_PITCH Pitch of leadscrew 10.0 plus 31040 - _always ENC_IS_DIRECT Encoder mounted directly to the machine (encoder no:) 0 *** *** 31050 - _always DRIVE_AX_RATIO_DENOM Denominator load gearbox (control parameter no.): 0 ... 5 POWER ON 1, 1, 1, 1, 1, 1 1 2147000000 DWORD 31060 - _always DRIVE_AX_RATIO_NUMERA Numerator load gearbox (control parameter set no.): 0 ... POWER ON 5 1, 1, 1, 1, 1, 1 1 2147000000 DWORD 31070 - _always DRIVE_ENC_RATIO_DENOM Denominator resolver gearbox (encoder no.) 1 1 POWER ON 2147000000 DWORD 31080 - _always DRIVE_ENC_RATIO_NUMERA Numerator resolver gearbox (encoder no.) 1 1 POWER ON 2147000000 DWORD 31090 mm, degrees JOG_INCR_WEIGHT Evaluation of an increment with INC/handwheel 31100 - BERO_CYCLE Steps for monitoring rotation 2000 10 7-1 POWER ON DWORD POWER ON 0.0 DOUBLE POWER ON BOOLEAN RESET POWER ON 10000000 DWORD SINUMERIK 801 Start-Up Technical Appendix 31110 - BERO_EDGE_TOL Step tolerance for monitoring rotation 50 10 POWER ON 10000000 DWORD 31350 - Hz FREQ_STEP_LIMIT Stepping rate at maximum velocity 250000 0.1 NEW CONF 4000000 DOUBLE 31400 - STEP_RESOL Steps per stepper motor revolution 1000 0 plus AXIS_NUMBER_FOR_MONITORING Display setpoint of this axis for servicing 0 0 4 31500 - 32000 MAX_AX_VELO mm/min, Maximum axis velocity rev/min _always 10000. 32010 JOG_VELO_RAPID mm/min, Rapid treverse in jog mode rev/min _always 10000. 32020 JOG_VELO mm/min, Jog axis velocity rev/min _always 2000. 32070 % POWER ON DWORD POWER ON DWORD NEW CONF 0.0 plus DOUBLE RESET 0.0 plus DOUBLE RESET 0.0 plus DOUBLE _always CORR_VELO Axis velocity for handwheel override, ext. ZO, cont. RESET dressing, distance control 50 0.0 plus DWORD 32100 - _always AX_MOTION_DIR Traversing direction (not control direction) 1 -1 1 DWORD 32110 - _always ENC_FEEDBACK_POL Sign actual value (control direction) (encoder no.) 1 -1 1 POWER ON POWER ON 32200 POSCTRL_GAIN 1000/min Servo gain factor (control parameter set no.): 0 ... 5 _always (2,5; 2,5; 2,5; 1), ... 0.0 plus 32260 rev/min _always plus RATED_VELO Rated motor speed (setpoint branch): 0 3000 0.0 SINUMERIK 801 Start-Up DWORD NEW CONF DOUBLE NEW CONF DOUBLE 7-2 Technical Appendix 32300 MAX_AX_ACCEL mm/s^2, Axis acceleration rev/s^2 _always 1 NEW CONF 0 *** 32420 _always JOG_AND_POS_JERK_ENABLE Enable axial jerk limitation 0 *** 32430 _always JOG_AND_POS_,AX_JERK Axial jerk 1000 (mm/s^3) 10 -9 2777,77 (degrees/s^3) 32450 mm _always BACKLASH Backlash 0.000 32700 - _always ENC_COMP_ENABLE Interpolatory compensation (encoder no.): 0,1 0 *** *** 32900 - DYN_MATCH_ENABLE Dynamic response adaptation 0 0 1 32910 - DOUBLE NEW CONF *** BOOLEAN NEW CONF *** DOUBLE NEW CONF * * DOUBLE POWER ON BOOLEAN NEW_CONF BYTE DYN_MATCH_TIME Time constant of dynamic adaption (control parameter set NEW_CONF no): 0 ... 5 0 0.0 plus DOUBLE 32920 s _always AC_FILTER_TIME Smoothing factor time constant for adaptive control 0.0 0.0 DOUBLE 33050 mm, deg. _always LUBRICATION_DIST Traversing distance for lubrication from PLC 34000 - _always REFP_CAM_IS_ACTIVE Axis with reference point cam 1 *** *** 34010 - _always REFP_CAM_DIR_IS_MINUS Approach reference point in minus direction 0 *** *** 100000000 0.0 34020 REFP_VELO_SEARCH_CAM mm/min, Reference point approach velocity rev/min 7-1 POWER ON plus NEW CONF plus DOUBLE RESET BOOLEAN RESET BOOLEAN RESET SINUMERIK 801 Start-Up Technical Appendix _always 34030 mm, deg. _always 5000.0 0.0 plus REFP_MAX_CAM_DIST Maximum distance to reference cam 10000.0 0.0 DOUBLE RESET plus DOUBLE 34040 REFP_VELO_SEARCH_MARKER mm/min, Creep speed (encoder no.) rev/min _always 300.0 0.0 plus 34050 - _always REFP_SEARCH_MARKER_REVERSE Direction reversal to reference cams (encoder no.) 0 *** *** 34060 mm, deg. _always REFP_MAX_MARKER_DIST Maximum distance to reference mark. Max. distance to 2 RESET reference marks for distance-coded measuring systems. 20.0 0.0 plus 34070 REFP_VELO_POS mm/min, Reference point positioning velocity rev/min _always 1000.0 0.0 RESET DOUBLE RESET BOOLEAN DOUBLE RESET plus DOUBLE 34080 mm, deg. _always REFP_MOVE_DIST Reference point distance/target point for distance-coded RESET system -2.0 - - 34090 mm, deg. _always REFP_MOVE_DIST_CORR Reference point offset/absolute offset distance-coded 34092 mm, deg. _always REFP_CAM_SHIFT Electr. cam offset of incremental measuring systems with RESET equidistant zero marks 0.0 0.0 plus DOUBLE 34100 mm, deg. _always REFP_SET_POS Reference point value/irrelevant for distance-coded RESET system: 0 ... 3 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 0.0 SINUMERIK 801 Start-Up - DOUBLE POWER ON - DOUBLE RESET 7-2 Technical Appendix _always 34200 - _always 34210 - 1 -1 31 DWORD ENC_REFP_MODE Type of position measuring system POWER ON 0: No ref. point appr.; if an absolute encoder exists: REFP_SET_POS accepted 1: Zero pulse (on encoder track) 1 0 6 ENC_REFP_STATE _always 0: Function "record reference point" inactive. Reference POWER ON 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. 0 1 2 35010 - _always GEAR_STEP_CHANGE_ENABLE Gear change possible. Spindle has several gear steps 0 *** *** POWER ON 35040 - _always SPIND_ACTIVE_AFTER_RESET Own spindle reset 0 *** POWER ON *** 35100 rev/min _always SPIND_VELO_LIMIT Maximum spindle speed 10000 plus 35110 rev/min _always GEAR_STEP_MAX_VELO Maximum speed for gear change (gear stage no.): 0..5 NEW CONF 500, 500, 1000, 0.0 plus 2000, 4000, 8000 35120 rev/min _always GEAR_STEP_MIN_VELO Minimum speed for gear change (gear stage no.): 0..5 NEW CONF 50, 50, 400, 800, 0.0 plus 1500, 3000 35130 rev/min GEAR_STEP_MAX_VELO_LIMIT Maximum speed of gear stage (gear stage no.): 0 ... 5 _always 35140 rev/min 7-1 BYTE DWORD BOOLEAN BOOLEAN POWER ON 0.0 500, 500, 1000, 2000, 0.0 4000, 8000 GEAR_STEP_MIN_VELO_LIMIT Minimum speed of gearsetp (gear stage no.): 0 ... 5 DOUBLE DOUBLE DOUBLE NEW CONF plus DOUBLE NEW CONF SINUMERIK 801 Start-Up Technical Appendix _always 5, 5,10, 20, 40, 80 0.0 plus 35150 Factor _always SPIND_DES_VELO_TOL Spindle speed tolerance 0.1 0.0 1.0 35160 rev/min _always SPIND_EXTERN_VELO_LIMIT Spindle speed limitation from PLC 1000 0.0 35200 rev/s^2 GEAR_STEP_SPEEDCTRL_ACCEL Acceleration in speed control mode [gear stage no.]: 0 ... NEW CONF 5 30, 30, 25, 20, 15, 10 2 *** DOUBLE _always GEAR_STEP_POSCTRL_ACCEL Acceleration in position control mode (gear stage no.): NEW CONF 1 ... 5 30, 30, 25, 20, 15, 10 2 *** DOUBLE 35220 Factor _always ACCEL_REDUCTION_SPEED_POINT Speed for reduced acceleration 1.0 0.0 1.0 DOUBLE 35230 Factor _always ACCEL_REDUCTION_FACTOR Reduced acceleration 0.0 0.0 0.95 35240 - ACCEL_TYPE_DRIVE Type of acceleration 0 1 _always 35210 rev/s^2 DOUBLE RESET DOUBLE NEW CONF plus DOUBLE RESET RESET DOUBLE RESET 0 BOOLEAN 35300 rev/min _always SPIND_POSCTRL_VELO Position control switch-on speed 500 0.0 plus 35350 - _always SPIND_POSITIONING_DIR Direction of rotation when positioning 3 3 4 35400 rev/min _always SPIND_OSCILL_DES_VELO Reciprocation speed 500 0.0 plus 35410 rev/s^2 _always SPIND_OSCILL_ACCEL Acceleration during reciprocating 16 2 *** 35430 - SPIND_OSCILL_START_DIR Starting direction during reciprocation RESET 0-2: As last direction of rotation (zero-speed SINUMERIK 801 Start-Up NEW CONF DOUBLE RESET BYTE NEW CONF DOUBLE NEW CONF DOUBLE 7-2 Technical Appendix M3) 3: 4: _always M3 direction M4 direction 0 0 4 35440 s _always SPIND_OSCILL_TIME_CW Reciprocation time for M3 direction 1.0 0.0 plus 35450 s _always SPIND_OSCILL_TIME_CCW Reciprocation time for M4 direction 0.5 0.0 plus 35500 _always SPIND_ON_SPEED_AT_IPO_START Feed enable for spindle in setp. Range 1 0 2 35510 - _always SPIND_STOPPED_AT_IPO_START Feedrate enable for spindle stopped 0 *** *** 36000 mm, deg. _always STOP_LIMIT_COARSE Exact positioning coarse 36010 mm, deg. _always STOP_LIMIT_FINE Exact positioning fine 36020 s _always POSITIONING_TIME Delay exact positioning fine 1.0 36030 mm, deg. STANDSTILL_POS_TOL Zero-speed tolerance 0.04 0.01 0.2 NEW CONF DOUBLE NEW CONF DOUBLE RESET BYTE RESET BOOLEAN NEW CONF 0.0 plus DOUBLE NEW CONF 0.0 plus 0.0 plus DOUBLE NEW CONF DOUBLE NEW CONF 0.0 plus 36040 s _always STANDSTILL_DELAY_TIME Delay zero-speed monitoring 0.4 0.0 plus 36050 mm, deg. _always CLAMP_POS_TOL Clamping tolerance 0.5 BYTE DOUBLE NEW CONF DOUBLE NEW CONF 0.0 36060 STANDSTILL_VELO_TOL mm/min, Maximum velocity/speed "axis/spindle stopped" 7-1 plus DOUBLE NEW CONF SINUMERIK 801 Start-Up Technical Appendix rev/min _always 5 (0.014) 0.0 36100 mm, deg. _always POS_LIMIT_MINUS 1st software limit switch minus 36110 mm, deg. _always POS_LIMIT_PLUS 1st software limit switch plus 36120 mm, deg. _always POS_LIMIT_MINUS2 2nd software limit switch minus 36130 mm, deg. _always POS_LIMIT_PLUS2 2nd software limit switch plus -100000000 100000000 -100000000 100000000 plus DOUBLE RESET - - DOUBLE RESET - - - DOUBLE RESET - DOUBLE RESET - 36200 AX_VELO_LIMIT mm/min, Threshold value for velocity monitoring rev/min (control parameter set no.): 0 ... 5 _always 11500., 11500., 0.0 11500., 11500., ... - DOUBLE NEW CONF plus DOUBLE 36300 Hz _always ENC_FREQ_LIMIT Encoder limit frequency 300000 36302 % ENC_FREQ_LIMIT_LOW Encoder limit frequency at which encoder is switched on NEW CONF again. (Hysteresis) 99.9 0 100 DOUBLE ENC_ZERO_MONITORING Zero mark monitoring (encoder no.): 0,1 NEW CONF 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 0, 0 0.0 plus DWORD _always 36310 - _always POWER ON 0 36400 mm, deg. _always CONTOUR_TOL Contour monitoring tolerance band 36500 ENC_CHANGE_TOL 1.0 SINUMERIK 801 Start-Up *** plus DOUBLE NEW CONF *** DOUBLE 7-2 Technical Appendix mm, deg Portion of distance for backlash working _always 0,1 0.0 plus 36610 s _always AX_EMERGENCY_STOP_TIME Duration of the deceleration ramp for error states 0.05 0.0 plus 36620 s _always SERVO_DISABLE_DELAY_TIME Cutout delay servo enable 0.1 0.0 plus 36700 - _always DRIFT_ENABLE Automatic drift compensation 0 *** *** 36710 % _always DRIFT_LIMIT Drift limit value for automatic drift compensation 1.000 0.0 plus 36720 % _always DRIFT_VALUE Drift basic value 0.0 38000 - MM_ENC_COMP_MAX_POINTS Number of intermediate points for interpolatory compensation (SRAM) 0, 0 0 _always NEW CONF DOUBLE NEW CONF DOUBLE NEW CONF DOUBLE NEW CONF BOOLEAN NEW CONF DOUBLE NEW CONF DOUBLE POWER ON 5000 DWORD Setting data 41110 mm/min _always JOG_SET_VELO Axis speed for JOG 0.0 0.0 plus 41200 rev/min _always JOG_SPIND_SET_VELO Speed for spindle JOG mode 0.0 0.0 plus 43210 rev/min _always SPIND_MIN_VELO_G25 Progr. spindle speed limitation G25 0.0 0.0 plus 43220 rev/min _always SPIND_MAX_VELO_G26 Progr. spindle speed limitation G26 1000 0.0 plus 43230 rev/min SPIND_MAX_VELO_LIMS Spindle speed limitation with G96 7-1 Immediately DOUBLE Immediately DOUBLE Immediately DOUBLE Immediately DOUBLE Immediately SINUMERIK 801 Start-Up Technical Appendix _always 52011 - 100 0.0 STOP_CUTCOM_STORE Alarm response for TRC and feedforward stop 1 0 SINUMERIK 801 Start-Up plus DOUBLE Immediately 1 BOOLEAN 7-2 Technical Appendix SINUMERIK 801 Start-Up Techncial Manual Order No: A5E00702069 Edition: 2005.11 7-1 SINUMERIK 801 Start-Up A5E00702069