SINUMERIK 801 Control System 1
Installation and Start-Up 2
Built-In PLC Application 3
Setting Up 45
Saving
Accessories 6
T echnical Appendix 7
SINUMERIKDocumentation
®
Key to editions
The editions listed below have been published prior to the current edition.
The column headed “Note” lists the amended sections, with reference to the previous edition.
Marking of edition in the “Note” column:
A ... ... New documentation.
B ... ... Unchanged reprint with new order number.
C ... ... Revised edition of new issue.
Edition Order No. Note
2005.11 A5E00702069 A
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®
, 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.
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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.
Siemens-Aktiengesellschaft.
Exclusion of liability
We have checked that the contents of this document correspond to
the hardware and software described. Nonetheless, differences
might exist and we cannot therefore guarantee that they are 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.
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
!
This product must be transported, stored and installed as intended, and
SINUMERIK 801 I
Start-Up
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.
maintained and operated with care to ensure that it functions correctly and
safely.
7.1 List of Machine Data ………………………………………………………………………………………7-1
…………………………………………………………………………… 1-1
+
drive modules ………… …………………………………… 2-26
drive modules ………… …………………………………… 2-26
SINUMERIK 801 III
Start-Up
SINUMERIK 801 Control System1
1.1 System Overview
General The SINUMERIK 801 is a highly integrated, high-performance and
economic numerical control system, which can be extensively applied to
economic CNC turning machines. It can control 2 feed axes and 1 spindle.
Control signals output to feed axes include digital pulse, direction and
enable signals, control signals output to the spindle include analog voltage
and enable. The SINUMERIK 801 can thus be used to control feed axes
for stepper drives, and servo drives with digital pulse interfaces. Either
servo spindle or variable frequency spindle can be controlled via the
SINUMERIK 801. This documentation gives descriptions for configuring
the SINUMERIK 801 with stepper drives/servo drives.
System components The SINUMERIK 801 control system is a compact CNC unit. It consists of the
following components:
h CNC
A compact CNC with an integrated 6″ LCD, full NC keys and MCP area;
hStepper drives and stepper motors
+
1) Stepper drives STEPDRIVE C/C
2) Five-phase hybrid stepper motors
h Cables
1) Signal cables for connecting CNC to drives;
2) Cables for connecting drives to motors;
3) Signal cable for connecting spindle encoder to CNC;
4) RS232 cable for connecting CNC to a PC;
5) Signal cable for connecting CNC to an electronic handwheel.
z One spindle encoder
z One electronic handwheel
z Possible configurations by users: servo motors (with digital pulse
interfaces) and servo motors.
;
SINUMERIK 801 1-1
Start-Up
SINUMERIK 801 Control System
SINUMERIK 801 system
Fig.1-1 SINUMERIK 801 system overview(CNC + 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
Recall key
Softkey
Area switchover key
Cursor UP (with shift: page up)
Cursor DOWN (with shift: page down)
Cursor LEFT
Cursor RIGHT
ETC key
SINUMERIK 801 1-3
Start-Up
Selection key/toggle key
SINUMERIK 801 Control System
Acknowledge alarm
SPACE (INSERT)
ENTER / input key
Numerical keys (with shift for
…
Notice See”Operation & Programming” for the use of NC keys.
Alphanumeric keys (with shift for
alternative assignment)
Spindle override 100%
Spindle override minus (with LED)
Chuck unclamping (with LED)
Manual tool change (with LED)
Manual lubrication (with LED)
Manual coolant (with LED)
AUTOMATIC (with LED)
SINGLE BLOCK (with LED)
MANUAL DATA (with LED)
Increment (with LED)
X axis, plus direction
X axis, minus direction
Z axis, plus direction
Z axis, minus direction
RAPID TRAVERSE OVERLAY
SPINDLE START LEFT
Counterclockwise direction
SPINDLE STOP
SPINDLE START RIGHT
Clockwise direction
1-4 SINUMERIK 801
Start-Up
SINUMERIK 801 Control System
JOG (with LED)
REFERENCE POINT (with LED)
Feedrate override plus (with LED)
Feedrate override 100%
Feedrate override minus (with LED)
Spindle override plus (with LED)
RESET
NC STOP
NC START
LED POK (Power OK), green
LED ERR (Error), red
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 1-5
Start-Up
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.
InterfacesInterfaces 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 Weight [g]
CNC 2120 circa
Dimensions Table 1–3 Component dimensions
Component Dimensions LxWxD [mm]
CNC 400 x 250 x 57.6
Environmental operating conditions
Table 1–4 Environmental operating conditions
Parameter
Temperature range
(horizontal mounting and
convection)
Permissible relative humidity 5…95% without condensation
Air pressure 860 ... 1,060 hPa
0….55°C (for box);
0….45°C (for display surface)
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 5 ... 95 % without condensation
Air pressure 700 ... 1,060hPa
Transport height –1,000 ... 3,000m
Free fall in transport package
-20 ... 60°C
≤0.5m
Protection class
Class of protection I according to IEC 529
The control must be equipped with a grounding conductor terminal.
Protection against ingress of solid foreign bodies and water according to ICE
529:
For CNC system: Front: IP54 Rear: IP20
SINUMERIK 801 1-7
Start-Up
Installation and Start-Up 2
2.1 Cabinet, Power supply and Grounding
Requirements for
cabinet Machine tool builders need to pay attention to following requirements for a
cabinet:
1) Furnish the cabinet with a cooling or ventilation device; When using an
electric fan to cool the cabinet, mount a dust gauze at the air inlet of the
cabinet;
2) Mount all cabinet components on an unpainted galvanized metal plate;
3) Protection class for cabinet: IP54;
4) Grounding as per China national standard
GB/T5226.1-2002/IEC60204-1
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.
:
2000 Safety of machinery - Electrical
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
安装调试手册
Start-Up
U V W
380VAC
1)
PE
220VAC
0V
L
L+
220/24 DC
Power
Supply
M
PE
N
24V
0V
L+
CNC
M
PE
220VAC
0V
L
PC
PE
N
3)
3)
PE
4)
3)3)3)
2,3)
PE rails
Fig. 2-1 Connecting the control transformer
Notes (for Fig. 2-1):
1) Two phases of U,V,W that are not used by the drive transformer;
2) Connections can not be made until PE rails are found well grounded.
3) In order to ensure a good grounding, the cross-sectional area of PE rails
shall be not less than 6mm
2
.
Notice
The control transformer will not be provided by Siemens. Customer may
order it from other sources.
Drive transformerUse 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
W
W
Syst
24V mi
Start-Up
Notes (for Fig. 2-2):
1)Two phases of U,V,W that are not used by the control transformer;
2) In order to ensure a good grounding, the cross-sectional area of PE rails
shall be not less than 6mm
2
.
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.
aveform of Siemens PS
aveform of non-Siemens PS
em operating
volt:
n.
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.
KA1SA2SA1
24VDC
KA1
0VDC
KA1
24VDC
0VDC
CNC
Fig. 2-4 Power on/off sequence of the power supply
Note:
SINUMERIK 801 2-3
Start-Up
Start-Up
1) All input signals must be level signals, i.e. level “0” (-3 ... 5VDC) and
level “1” (11 ... 30VDC). Both suspended and high resistance signals are
level “0”.
2-4 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!
GeneralAs 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 2-5
Start-Up
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
Fig. 2-6 CNC outline dimensions
1)Free space necessary for heat
dissipation
2)Holes reserved for plastic clips
with screws
SINUMERIK 801 2-7
Start-Up
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.
Vertical installation (recommended)
90 (100*)
3412
> 80
(>150*)
>100
7
Horizontal installation
176 (180*)
71 (73*)
>50
PE rails
307 (327*)
286 (305.6*)
> 80
(>100*)
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)