Sinumerik 801

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
Start-Up
Built-In PLC Application 3
Setting Up 4
Technical Manual
Services, Diagnosis & Data 5
Saving
Accessories 6
Technical Appendix 7
Valid for
Control system
SINUMERIK 801
11. 2005 Edition

®
SINUMERIK Documentation
Key to editions
The editions listed below have been published prior to the current edition.
The column headed “Note” lists the amended sections, with reference to the previous edition.
Marking of edition in the “Note” column:
A ... ... New documentation.

B ... ... Unchanged reprint with new order number.
C ... ... Revised edition of new issue.
Edition Order No. Note
2005.11 A5E00702069 A
Trademarks
® ® ® ® ® ®
SIMATIC , SIMATIC HMI , SIMATIC NET , SIMODRIVE , SINUMERIK , and SIMOTION are registered
trademarks of SIEMENS AG.
Other names in this publication might be trademarks whose use by a third party for his own purposes may violate
the registered holder.
Copyright Siemens AG 2005. All right reserved Exclusion of liability
The reproduction, transmission or use of this document or its con- We have checked that the contents of this document correspond to
tents is not permitted without express written authority. Offenders the hardware and software described. Nonetheless, differences
will be liable for damages. All rights, including rights created by might exist and we cannot therefore guarantee that they are com-
patent grant or registration of a utility model, are reserved. pletely identical. The information contained in this document is re-
viewed regularly and any necessary changes will be included in the
next edition. We welcome suggestions for improvement.
© 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 I
Start-Up
Table of Contents
Table of Contents
1. SINUMERIK 801 Control System…………………………………………………………………………… 1-1
1.1 System Overview …………………………………………………… 1-1
1.2 CNC Operator Panel ……………………………………………… ………… 1-3
1.3 Position of the Interfaces………………………………………………………………………………… 1-5
1.4 Technical Data ………………………………………………………………………………… 1-6
2. Installation and Start-Up ………………………………………………………………………… 2-1

2.1 Cabinet, Power Supply and Grounding …………………………………………………… … 2-1
2.2 Installing and Cabling ……………………………………………………………………………… 2-4
2.2.1 Installing the control system ……………………………………………………………………… 2-4
2.2.2 Cabling …………………………………………………………………………………………… 2-11
2.2.2.1 Connecting with the stepper drives ………………………………………………………………… 2-11
2.2.2.2 Connecting with the servo drives (example) ……………………………………………………… 2-12
2.3 Interfaces and Cables ……………………………………………………………………………… 2-15
2.3.1 Power supply for CNC – X1 ……………………………………………………………… 2-16
2.3.2 RS232 interface - X2 (RS232) …………………………………………………………… 2-16
2.3.3 Spindle encoder interface - X3 (SPINDLE)…………………………………………………… 2-17
2.3.4 Feed drive interface – X4 (AXIS)…………………………………………………………………… 2-18
2.3.5 Handwheel & extension keys connection - X10 (MPG) ……………………………………… 2-19
2.3.6 BERO input interface - X20 (BERO)…………………………………………………………………… 2-19
2.3.7 Digital inputs/outputs - X100 (DIN0) & X101 (DIN1), X200 (DOUT0) & X201 (DOUT1)… 2-20
2.3.8 Connecting cables for SINUMERIK 801 ……………………………………………………… 2-22
2.4 Installing and Starting-Up the Drive Modules …………………………………………… 2-26
2.4.1 Connecting the STEPDRIVE C/C+ drive modules ………… …………………………………… 2-26
2.4.2 Connecting the servo drive modules ………… …………………………………… 2-26
3. Built-In PLC Application …………………………………………………………………………………… 3-1

3.1 Input/Output Configuration …………………………………………………………………… 3-4
3.2 Definition of User Keys ………………………………………………………………… 3-6
3.3 PLC Machine Data ……………………………………………………………………………… 3-9
3.4 Fixed PLC Alarms………………………………………………………………………………………… 3-16
4. Setting Up …………………………………………………………………………………… 4-1

4.1 Setting Up NC Parameters ………………………………………………………………… 4-6
4.2 Starting Up the Dynamic Characteristic of the Axes ……………………………………………… 4-9
4.3 Starting Up Reference Points ……………………………………………………………… 4-9
4.4 Software Limit Switch and Backlash Compensation…………………………………………… 4-14
4.5 Rotation Monitoring ………………………………………………………………………… 4-16
4.6 Leadscrew Error Compensation …………………………………………………………… 4-17
4.7 Starting Up the Spindle ……………………………………………………………………… 4-17
5. Services, Diagnosis & Data Saving ………………………………………………………… 5-1

5.1 Services …………………………………………………………………………………………… 5-2
5.2 Diagnosis …………………………………………………………………………………………… 5-2
5.3 Data Saving …………………………………………………………………………………………… 5-6
5.3.1 Internal data saving …………………………………………………………………………………… 5-6
5.3.2 External data saving …………………………………………………………………………………… 5-6
5.3.3 Important Notice …………………………………………………………………………………… 5-9
6. Accessories ……………………………………………………………………………… 6-1
7. Techncial Appendix …………………………………………………………………………………………7-1

7.1 List of Machine Data ………………………………………………………………………………………7-1
SINUMERIK 801 III

Start-Up
SINUMERIK 801 Control System 1
1.1 System Overview
General The SINUMERIK 801 is a highly integrated, high-performance and

economic numerical control system, which can be extensively applied to
economic CNC turning machines. It can control 2 feed axes and 1 spindle.
Control signals output to feed axes include digital pulse, direction and
enable signals, control signals output to the spindle include analog voltage
and enable. The SINUMERIK 801 can thus be used to control feed axes
for stepper drives, and servo drives with digital pulse interfaces. Either
servo spindle or variable frequency spindle can be controlled via the
SINUMERIK 801. This documentation gives descriptions for configuring
the SINUMERIK 801 with stepper drives/servo drives.
System components The SINUMERIK 801 control system is a compact CNC unit. It consists of the
following components:
h CNC
A compact CNC with an integrated 6″ LCD, full NC keys and MCP area;
h Stepper drives and stepper motors
1) Stepper drives STEPDRIVE C/C+;
2) Five-phase hybrid stepper motors
h Cables
1) Signal cables for connecting CNC to drives;
2) Cables for connecting drives to motors;
3) Signal cable for connecting spindle encoder to CNC;
4) RS232 cable for connecting CNC to a PC;
5) Signal cable for connecting CNC to an electronic handwheel.
z One spindle encoder
z One electronic handwheel
z Possible configurations by users: servo motors (with digital pulse
interfaces) and servo motors.
SINUMERIK 801 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
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 1-3

Start-Up
Acknowledge alarm Delete key (backspace)
SPACE (INSERT) Vertical menu
ENTER / input key Shift key
Numerical keys (with shift for Alphanumeric keys (with shift for
… alternative assignment) … 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 Spindle override minus (with LED)
externally (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
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 1-5

Start-Up
1.3 Position of the Interfaces
General Interfaces of the control system are positioned in the rear of the CNC system,
see Fig. 1-3 below.
Interfaces Interfaces of the SINUMERIK 801 control system are shown as below:
Fig. 1-3 Position of SINUMERIK 801 interfaces
Notice
See Section 2.3 “Interfaces and Cables” for detailed description of each
interface.
1-6 SINUMERIK 801

Start-Up
1.4 Technical Data
Connected load Table 1–1 Connected load

Parameter Min. Typ. Max. Unit
Supply voltage 20.4 24 28.8 V
Ripple 3.6 Vss
Current consumption from 24 V 2 A
Power dissipation of CNC 48 W
Start-up current 4 A
Note: The 24V DC voltage must be generated as a functional extra-low voltage
with safe electrical isolation (to EN60204-1, Section 6.4, PELV).
Weight Table 1–2 Weight

Component Weight [g]
CNC 2120 circa
Dimensions Table 1–3 Component dimensions

Component Dimensions LxWxD [mm]
CNC 400 x 250 x 57.6
Environmental operating conditions

Table 1–4 Environmental operating conditions
Parameter
Temperature range 0….55°C (for box)；
(horizontal mounting and
convection) 0….45°C (for display surface)
Permissible relative humidity 5…95% without condensation
Air pressure 860 ... 1,060 hPa
The operating conditions refer to EN60204-1.
Installation in a housing (e.g. cubicle) is absolutely necessary for operation.
Transport and storage conditions

Table 1–5 Transport and storage conditions
Parameter
Temperature range -20 ... 60°C
Permissible relative air humidity 5 ... 95 % without condensation
Air pressure 700 ... 1,060hPa
Transport height –1,000 ... 3,000m
Free fall in transport package ≤0.5m
Protection class
Class of protection I according to IEC 529
The control must be equipped with a grounding conductor terminal.
Protection against ingress of solid foreign bodies and water according to ICE
529:
For CNC system: Front: IP54 Rear: IP20
SINUMERIK 801 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/IEC60204-1：2000 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

安装调试手册
Start-Up
U V W
380VAC 220VAC 220VAC
24V
L L+ L+ L
220/24 DC
Power CNC PC
1) Supply 0V
M M
0V
0V
PE N PE PE N PE
4) 3) 2,3) 3) 3) 3)
3)
PE PE rails
Fig. 2-1 Connecting the control transformer
Notes (for Fig. 2-1):
1) Two phases of U，V，W that are not used by the drive transformer;
2) Connections can not be made until PE rails are found well grounded.
3) In order to ensure a good grounding, the cross-sectional area of PE rails
shall be not less than 6mm2.
Notice
The control transformer will not be provided by Siemens. Customer may
order it from other sources.
Drive transformer Use a separate drive transformer in the cabinet to supply the 85VAC power
supply for stepper drives. Connections with the drive transformer are shown
in Fig. 2-2.
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 U，V，W that are not used by the control transformer;
2) In order to ensure a good grounding, the cross-sectional area of PE rails

shall be not less than 6mm2.
Notice
When AC servo drives are used, please connect cables as per requirements
concerned.
24VDC power supply

The SINUMERIK 801 CNC is supplied by a 24V DC power supply, which
enables the control system to run in order under the voltage range of
24V-15% ... +20%. The excellent quality of the DC power supply is critical for
the stable operation of the control system. You’re recommend to select
Siemens 24VDC stabilized power supply (order number: 6EP1333-3BA00). If
a DC power supply other than Siemens is used, please detect the output
waveform generated when the power supply is switched off.
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
CNC
0VDC
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!
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 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
1) Free space necessary for heat

dissipation
2) Holes reserved for plastic clips
with screws
Fig. 2-6 CNC outline dimensions
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) Horizontal installation
90 (100*) >100 176 (180*) >50

(>150*)
71 (73*)
> 80
12 34
7
PE rails
286 (305.6*)
307 (327*)
(>100*)
> 80
Changed installation angle
Install with M5 screws, spacers and spring washers 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)
Dimensions and tolerance Wt.
Model Key
D D1 D2 D3 D4 D5 L L1 L2 L3 L4 h h1 A B C (kg)
6FC5
C3X1
548-0AB03- 92 9f6 10 60f7 107 6.6 162 34 14 20 26 3 7 93 62.5 R10 3
4
0AA0
6FC5
10X4 C5X2
548-0AB06- 110 16f6 17 56f7 127 8.5 186.5 34 25 32 37 2 12.5 112 65.0 5.6
5° 5
0AA0
6FC5
10X4 C5X2
548-0AB09- 110 16f6 17 56f7 127 8.5 216.5 34 25 32 37 2 12.5 112 65.0 7.2
5° 5
0AA0
6FC5
10X4 C5X2
548-0AB12- 110 16f6 17 56f7 127 8.5 248.5 34 25 32 37 2 12.5 112 65.0 8.6
5° 5
0AA0
6FC5
17h 10X4 C5X2
548-0AB18- 130 16f6 100f7 155 10.5 239.0 34 32 36 43 3 15.0 132 90.0 13.0
7 5° 5
0AA0
6FC5
17h 10X4 C5X2
548-0AB25- 130 16f6 100f7 155 10.5 263.5 34 32 36 43 3 15.0 132 90.0 15.0
7 5° 5
0AA0
When installing the stepper motor, its radial load shall stay within the data
range listed below:
SINUMERIK 801 2-9

Start-Up
Start-Up
Motor data
Speed 600 rev/min 300 rev/min
Radial load
Shoulder distance 20 mm 20 mm
Max. radial load 950 N 1150 N
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 5 4 8 -0 A B 1 2 -0 A A 0
6FC5 5 4 8 -0 A B 0 9 -0 A A 0
1 2 ,0 0
6FC5 5 4 8 -0 A B 0 6 -0 A A 0
6FC5 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 1 ,0 0 F r e q u e n c y [K H z ] 1 0 ,0 0 1 0 0 ,0 0
6 60 S P E E D [R P M ] 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
Cable overview Connect the STEPDRIVE C/C+ drive modules, the stepper motors and the
SINUMERIK 801 control system as shown in the connection diagram 2-12.
For the cables required, please refer to the diagram below.
X1
X2
X4
X3
X10
X20
X101
X100
X201
X200
Fig. 2-12 Overview of cables
SINUMERIK 801 2-11

Start-Up
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 X-AXIS
P1N X-PLUS2
D1
PANASONIC
X-SIGN1 AC SERVO DRIVE
D1N
X-SIGN2
24V_GND
Co
nn
24V
ec
Axis/Spindle
E1
ti o
E1
n
Signal cable:
ca
E1N E1N
X4
ble
6FX6002-5AA52-1..0 GS
24Vdc -
CN2 power +
P2
Y-AXIS
Y-PLUS1
P2N Y-PLUS2
D2
Y-SIGN1
D2N
Y-SIGN2 X5
PANASONIC ADAPTOR
E2
E1
E2N
E1N
SINUMERIK GS
801 CNC
CN3
Z-AXIS
C on
nec
PANASONIC
tion
AC SERVO DRIVE
c ab
le
3
BERO
4
X20
Wi
re
( fo
Wi
CN4
rB
re
e ro
(fo r
10
1)
Be
ro
2)
M24
X5
HMX
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 J5
P1N X_PLUS2
D1
GOLDEN AGE
X_SIGN1 AC SERVO DRIVE
D1N
X_SIGN2
+24V_GND
Co
nn
+24V
ec
Axis/Spindle
E1
ti o
X_E1
n
Signal cable:
ca
E1N X_E1N
X4
ble
6FX6002-5AA52-1..0
24Vdc -
J2 power +
P2 J6
Y_PLUS1
P2N Y_PLUS2
D2
Y_SIGN1
D2N
Y_SIGN2 XS3
GOLDEN AGE ADAPTOR

E2
Y_E1
E2N
Y_E1N
SINUMERIK
801 CNC
J3
J7
C on
nec
GOLDEN AGE
tion
AC SERVO DRIVE
c ab
le
3
BERO
4
X20
Wi
re
( fo
Wi
J4
rB
re
e ro
(fo r
10
1)
Be
ro
2)
M24
XS3
HMX
HMY
Fig. 2-14 Connecting with the servo drives (SINUMERIK 801+ Golden Age Adaptor + Golden Age
Servo Drives)
SINUMERIK 801 2-13

Start-Up
Start-Up
2.3 Interfaces and Cables
Position of the See Fig. 2-15 for interface positions.

interfaces
Fig. 2-15 Rear of CNC System
2-14 SINUMERIK 801

Start-Up
Start-Up
2.3.1 Power supply for CNC - X1
General The 24V DC load power supply unit required for supplying CNC is connected
to 3-pin screw-type terminal block.
Table 2-2 The load power supply for CNC (X1)
Terminal Signal Description
1 PE Protective earth
2 M 0V
3 P24 DC24 V
2.3.2 RS232 interface - X2 (RS232)
General When external PC/PG is required to make data communication (WINPCIN)

with the SINUMERIK 801, use RS232 plug connector (9 pin SUB-D).
Table 2-3 RS232 interface X2
Pin Name Type Pin Name Type
1 n.c. 6 DSR I 1
6
2 RxD I 7 RTS O
3 TxD O 8 CTS I 9 5
4 DTR O 9 n.c.
5 M VO
Signal description:
RxD Receive Data
TxD Transmit Data
RTS Request to send
CTS Clear to send
DTR Data Terminal Ready
DSR Data Set Ready
M Ground (0V)
Signal level RS232
Signal type
I Input
O Output
VO Voltage output
Cable for WinPCIN Table 2-4 Cable for WinPCIN: Pin assignment of the Sub-D connector
9-Pin (801) Name 25-Pin (PC)
1 Shield 1
2 RxD 2
3 TxD 3
4 DTR 6
5 M 7
6 DSR 20
SINUMERIK 801 2-15
Start-Up
Start-Up
7 RTS 5
8 CTS 4
9
or
9-Pin (801) Name 9-Pin (PC)
1 Shield 1
2 RxD 3
3 TxD 2
4 DTR 6
5 M 5
6 DSR 4
7 RTS 8
8 CTS 7
9
SINUMERIK 801 PC SINUMERIK 801 PC

9PIN SUB-D (socket) 9 PIN SUB-D (fsocket) 9 PIN SUB-D (socket) 25 PIN SUB-D (plug)
2 2
0.1 mm 0.1 mm
RxD 2 3 TxD RxD 2 2 RxD
TxD 3 2 RxD TxD 3 3 TxD
DTR 4 6 DSR DTR 4 6 DSR
0V 5 5 0V 0V 5 7 0V
DSR 6 4 DTR DSR 6 20 DTR
RTS 7 8 CTS RTS 7 5 CTS
CTS 8 7 RTS CTS 8 4 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) 9 P IN S U B -D (s o c k e t)
2
0 .1 m m
R xD 2 2 R xD
T xD 3 3 T xD
DTR 4 4 DTR
D SR 6 6 DSR
0V 5 5 0V
RTS 7 7 RTS
CTS 8 8 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 )
0 .1 m m 2
R xD 2 3 R xD
T xD 3 2 T xD
DTR 4 20 DTR
DSR 6 6 DSR
0V 5 7 0V
RTS 7 4 RTS
CTS 8 5 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)
0 .1 m m 2
R xD 2 2 R xD
T xD 3 3 TxD
DTR 4 4 DTR
DSR 6 6 DSR
0V 5 5 0V
RTS 7 7 RTS
CTS 8 8 CTS
X1
Fig.2-19 Connecting diagram 3 (with SINUMERIK 801)
Notes:
(1) X1 and X2 indicated in Fig. 2-17～2-19 refer to interfaces of RS232
adapter itself. In which, X1 is for connecting RM232 adapter and
SINUMERIK 801, X2 is for connecting RS232 adapter and PC serial
port.
(2) SIEMENS can provide the connecting cable (9PIN to 9PIN SUB-D),
the order number (MLFB number): 6FX8002-1AA01-1..0.
(3) The maximum baudrate for RS232 adapter is 9600 and the
maximum length of each connecting cable for PC and SINUMERIK
801 shall be no more than 15m.
Notice:
In order to ensure the common grounding between SINUMERIK 801 CNC and
! PC, use only shielded cable and make sure that the shield is connected to the
metal or metal plated connector casing on both ends of the cable.
Connect and disconnect cables between CNC and PC under power-off
conditions only;
We recommend you to use a RS232 terminal adapter (order number:
6FX2003-0DS00).
SINUMERIK 801 2-17

Start-Up
Start-Up
2.3.3 Spindle encoder interface – X3 (SPINDLE)
General The spindle encoder interface (X3) of the SINUMERIK 801 is a 15-pin SUB-D
socket connector.
Table 2-5 Spindle encoder interface X3
Pin Signal Type Pin Signal Type
1 n.c. 9 M VO
2 n.c. 10 Z I
3 n.c. 11 Z_N I
4 P5_MS VO 12 B_N I
5 n.c. 13 B I
6 P5_MS VO 14 A_N I
7 M VO 15 A I
8 n.c.
Signal Description
A; A_N Channel A
B; B_N Channel B
Z; Z_N Zero Reference Mark
P5_MS +5,2V Supply Voltage
M Ground
Signal level: RS422
Signal type
VO Voltage output (supply)
I 5V input (5V signal)
Connectable encoder types

Incremental 5 V encoders can be connected directly.
Characteristics The encoders must meet the following requirements:

Transmission method: Differential transmission with 5 V square-wave signals
Output signals: Track A as true and negated signal (Ua1, 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
tracks A and B: 90º ± 30º
Current consumption: max. 300 mA
2-18 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
Max. Cable
Supply Voltage Tolerance Current Consumption
Length
5 V DC 4.75 V ... 5.25 V < 300 mA 25 m
5 V DC 4.75 V ... 5.25 V < 220 mA 35 m
Table 2–7 Maximum cable lengths depending on the transmission frequency

Encoder Type Frequency Max. Cable Length
incremental 1 MHz 10 m
500 kHz 35 m
SINUMERIK 801 2-19

Start-Up
Start-Up
2.3.4 Feed drive interface - X4 (AXIS)
General The feed drive interface X4 of the SINUMERIK 801 is a 25-pin SUB-D plug
connector.
Table 2-8 Feed drive interface X4
1 PULS1 O 14 PULS1_N O
2 DIR1 O 15 DIR1_N O
3 ENABLE1 O 16 ENABLE1_N O
4 PULS2 O 17 PULS2_N O
5 DIR2 18 DIR2_N O
6 ENABLE2 O 19 ENABLE2_N O
7 n.c. 20 n.c.
8 n.c. 21 n.c.
9 n.c. 22 n.c.
10 SE4_1 K 23 SE4_2 K
11 n.c. 24 n.c.
12 AO4 AO 25 AGND4 AO
13 M
Signal Description
Stepper Interface
PULS[1 … 2], PULS[1 … 2]_N Stepper Clock
DIR[1 … 2], DIR[1 … 2]_N Stepper Revolution Direction
EN[1 … 2], EN[1 … 2]_N Stepper Enable

M Ground (not to be connected when using
differential signals)
Analog 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
AO Analog output
O Output
K Switch signal
2-20 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 Min Max Unit
Voltage range –10.5 10.5 V
Output current –3 3 mA
Relay contact
Table 2–10 Electrical parameters of the relay contacts
Parameter Max. Unit
Switching voltage 50 V
Switching current 1 A
Switching power 30 VA
Cable length: max. 35 m
SINUMERIK 801 2-21

Start-Up
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
1 A I 6 M5 VO
2 /A I 7 Reset DI
3 B I 8 CycSta DI
4 /B I 9 CycSto DI
5 P5 VO 10 M24 VI
Signal (handwheel) Description

A Channel A, true, handwheel
/A Complement Channel A, negated, handwheel
B Channel B, true, handwheel
/B Complement Channel B, negated handwheel
P5 Power supply, 5.2V
M5 5.2 V supply ground for handwheel
Signal level (handwheel)

RS422
Signal type (handwheel)

VO Voltage output
I Input (5 V signal)
Handwheel One electronic handwheel can be connected which must meet the following
requirements:
Transmission method: 5 V square-wave (TTL level or RS422)
Signals: 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
Phase offset between
tracks A and B: 90º ± 30º
Supply: 5 V, max. 250 mA
Reset Reset key

CycSta Cycle Start key
CycSto Cycle Stop key
M24 24V supply ground
2-22 SINUMERIK 801

Start-Up
Start-Up
Signal level (extension keys) RS422
Signal type (extension keys)

VI Voltage input
DI Input (24V signal)
SINUMERIK 801 2-23

Start-Up
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
1 NCRDY_K1 K 6 n.c.
2 NCRDY_K2 K 7 n.c.
3 BERO1 DI 8 n.c.
4 BERO2 DI 9 n.c.
5 n.c. 10 M24 VI
Signal Description
NCRDY_K[1 … 2] NC-READY-Relay-Contact, max. current is 2A at
150VDC or 125VAC)
BERO[1 … 2] BERO-Input for axis 1 ... 2
M24 Reference potential for digital input
Signal type
K Switching contact
DI Digital input
VI Voltage input
2 BERO inputs These inputs are 24V PNP-switching. Switches or non-contact sensors, e.g.
inductive proximity switches(BERO) can be connected.
They can be used as switches for reference points, for example:
BERO1 – X axis
BERO2 – Z axis
Table 2-13 Electrical parameters of the digital inputs
Parameter Value Unit Note
“1” signal, voltage range 11 …30 V
“1” signal, current consumption 6 …15 mA
“0” signal, voltage range -3 …5 V Or input open
Signal delay 0Æ1 15 us
Signal delay 1Æ0 150 us
Notice
When AC servo drives are used, BERO can be input as zero mark signals.
However, be careful that here BERO refers to 24V pulse input.
NC–READY output Readiness in the form of a relay contact (NO); must be integrated into the
EMERGENCY STOP circuit.
2-24 SINUMERIK 801

Start-Up
Start-Up
Table 2–14 Electrical parameters of the NCREADY relay contact

Parameter Max. Unit
DC switching voltage 50 V
Switching current 1 A
Switching power 30 VA
Pin number of
Relay X20
NC_RDY 1
2
1P5
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 2-25

Start-Up
Start-Up
2.3.7 Digital inputs/outputs X100 (DIN0)～X101 (DIN1), X200 (DOUT0) ... X201
(DOUT1)
General There are 16 digital inputs and 12 digital outputs in all. Connector designation:
10 pin Mini-Combicon plug connector.
Table 2-15 Pin assignment for connectors X100～X101

X100 X101
Pin Signal Pin Signal
Signal type Signal type
1 n.c. 1 n.c.
2 Limit X+ DI 2 T1 DI
3 Limit X- DI 3 T2 DI
4 Ref. X DI 4 T3 DI
5 Limit Z+ DI 5 T4 DI
6 Limit Z- DI 6 T5 DI
7 Ref. Z DI 7 T6 DI
8 FootPed DI 8 User in1 DI
9 E-Stop DI 9 User in2 DI
10 M24 VI 10 M24 VI
* In the list above, high signal level refers to 15 …30 VDC, current drain 2 …
15 mA and low level -3 … 5 VDC.
Signal type
VI Voltage input
DI Input (24 V signal)
Table 2–16 Electrical parameters of the digital inputs

“1” signal, voltage range 15 ... 30 V
“1” signal, current consumption 2 ... 15 mA
“0” signal, voltage range –3 ... 5 V Or input open
Signal delay 0 Æ 1 0.5 ... 3 ms
Signal delay 1 Æ 0 0.5 ... 3 ms
Notice
See Section 3.2 “ Input/Output Configuration” for definitions of X100 ... X101
input signals.
2-26 SINUMERIK 801

Start-Up
Start-Up
Table 2-17 Pin assignment for connectors X200～X201

X200 X201
Pin Signal Pin Signal
Signal type Signal type
1 P24 VI 1 P24 VI
2 S-CW DO 2 User out1 DO
3 S-CCW DO 3 User out2 DO
4 T-CW DO 4 User out3 DO
5 T-CCW DO 5 User out4 DO
6 Cooling DO 6 n.c.
7 Lubric DO 7 n.c.
8 S-Brake DO 8 n.c.
9 Chuck DO 9 n.c.
10 M24 VI 10 M24 VI
* In this list, high signal level refers to the 24VDC, current leakage less than
2mA with a simultaneity factor of 0.5.
Signal type
VI Voltage input
DO Digital output (24 V signal)
Table 2–18 Electrical parameters of the digital outputs

“1” signal, nominal voltage 24 V
Voltage drop max. 28.8 V
“1” signal, output current 0.5 A Simultaneity factor
0.5 per 12 outputs
“0” signal, leakage current max. 2 mA
Notice
See Section 3.2 “Input/Output Configuration” for definitions of X200 ... X201
output signals.
SINUMERIK 801 2-27

Start-Up
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
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
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 E1
connector E1N
X axis
P2
P2N
D2
D2N Z axis
E2
E2N
SE1
SE2
AO Spindle
AON
On CNC side: ＋
On drive side: System interface
X4 interface
Fig. 2-23 Setpoint cable for SINUMERIK 801
SINUMERIK 801 2-29

Start-Up
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 Drive of axis 2

yellow
A A
white
A A
blue
B B
white
B B
green
C C
white
black
C C
white
D D
brown D D
white
E E
E E
PE PE
CURR.1 CURR.1
CURR.2 CURR.2
RES. RES.
DIR. DIR.
Power cable RDY RDY
TMP TMP
SINUMERIK 801 FLT FLT
DIS DIS
Signal cable
X4
P1 +PULS P3 +PULS
P1N -PULS P3N -PULS
D1 +DIR D3 +DIR
D1N -DIR D3N -DIR
E1 +ENA E3 +ENA
E1N -ENA E3N -ENA
RDY RDY
ZPH ZPH
24Vdc + +24V +24V
Power Supply
- 24V GND 24V GND
PE PE
380/85 VAC - Transformer
L
380VAC
N L L
N N
PE PE 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 If the transformer possesses a shielded winding, this should be
connected with low inductivity to PE.
z Ground the transformer on the secondary side.
Connecting the motor-end cables

z To connect the cables, remove the terminal box cover (3 screws).
z Use the cable with the order no. 6FX6 002–5AA51–1..0
z On the drive end, connect the cable shield to the housing such that an
electrical connection is provided via the appropriate strain relief clamp
and clamp the braided shield to PE.
z On the motor side, braid the shield, provided it with a cable shoe and
clamp it to the grounding screw.
Pulse interface
z To connect the drive pulse interface to the SINUMERIK 801, use the
preassembled cable, order no.6FX6 002–5AA52–1..0.
z On the drive side, connect the cable shield to the housing such that an
electrical connection is provided via the appropriate strain relief clamp.
24V signal interface

z To evaluate the 24 V high–side signals “Zero Phase” (ZPH) and/or “Drive
ready” (RDY) in the CNC, then connect a 24 V voltage (PELV) to the +24
V and 24 V GND terminals.
Driving system design
When a driving system for machine tools is configured with stepper drives, pay
attention to following requirements:
1. Design the driving system according to the frequency – torque
characteristics of the stepper motors (see Fig. 2-11: Frequency – torque
characteristics of the stepper motors). The characteristic feature of the
stepper motors depends on the frequency-torque characteristics. The
motor will have a larger output torque while running at a low speed or a
smaller one while at a high speed (and also a high power dissipation and
SINUMERIK 801 2-31
Start-Up
Start-Up
temperature boost during this period).

1) The resolution (displacement per step of the stepper motor)
depends on mechanical data:
Resolution＝leadscrew pitch/steps per revolution × reduction ratio
2) Calculate the max. motor speed according to the max. axis speed,
then the corresponding output torque of the stepper motor
according to the frequency – torque characteristics:
Motor speed＝axis speed/leadscrew pitch/reduction ratio
2. Each axis must be configured with one BERO proximity switch (PNP
normal open, viz. 24Vdc level output) for generating zero marks for
reference point approach.
Notice
The quality of BERO proximity switches will have influences on the resolution
! of reference points. It’s recommended to use high quality switches;
Make the clearance between end face of the proximity switch used for tesing
and the object under test as short as possible.
Do not use conventional contact stroke switches as proximity switches for zero
mark signals (because of the bigger signal jitters).
Reference point approach configuration

Since the stepper motors cannot generate zero marks required by the encoder,
the SINUMERIK 801 can take two configurations for approaching reference
points as: double-switch mode and single-switch mode.
Double-switch mode:
There is one reference cam in the axis and one BERO (inductive proximity
switch) at the leadscrew (one pluse is generated per revolution of the
leadscrew). Connect the reference cam to the inputs of DI （X100） (see
Chapter 3:”Built-In PLC Application for detailed description) while BERO to
connector X20 of the control system.
Machine body
BERO
Leadscrew Reference cam

Signal to X20 Object under test
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 Signal output to X20 Bero
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 When stepper motors is connected with a leadscrew directly:
SINUMERIK 801 2-33

Start-Up
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
接近开关（带LED）
BERO (with LED)
Leadscrew
丝杠
连接至X20接口
To X20 interface
Stepper motor
步进电机
齿轮二
Gear 2
Gear 1
齿轮一
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
ON LEDs
CURR.1
CURR.2 RDY
RES. TMP
FLT
DIR DIS
Motor Type CURR 1 CURR 2 Phase Curr Stepper Driver
3.5 Nm OFF OFF 1.35 A

6 Nm OFF OFF 1.35 A
STEPDRIVE C
9 Nm OFF ON 2.00 A
12 Nm ON ON 2.55 A
18 Nm OFF ON 3.6 A
STEPDRIVE C+
25 Nm ON ON 5.00 A
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 2-35

Start-Up
Start-Up
Table 2-19 LED alarms
LED
Meaning Remedy
Name Color
RDY green the only LED Drive ready If the motor does not rotate, it can
that is lit have the following causes:
- No pulses are output by the
control system.
- Pulse frequency too high
(motor is “out of step”)
- Motor load too large or
sluggish
DIS yellow the only LED Drive ready; motor not powered Activate ENABLE signal via CNC
that is lit
FLT red is lit There is one of the following Measure 85 V operating voltage
errors: Check cable connections
- Overvoltage or undervoltage
- Short-circuit between the
motor phases
- Short-circuit between motor
phase and ground
TMP red is lit Overtemperature in the drive Drive defective; replace
all No LED is lit No operating voltage Check cable connections
Selection of the drive

transformer
Configure the stepper motors in different torques with a drive transformer
(380VA C->85VAC) that has a suitable power.
Table 2-20 Reference table for power ratings of differnt transformers*
No. of Power of
MLFB (Order No.) of
motor Torque (Nm) transformer
Motor
axes (KVA)
6FC5 548-0AB03-0AA0 1 3.5 0.3
6FC5 548-0AB06-0AA0 1 6 0.403
6FC5 548-0AB09-0AA0 1 9 0.612
6FC5 1 12 0.7
548-0AB012-0AA0
6FC5 1 18 1.368
548-0AB018-0AA0
6FC5 1 25 1.420
548-0AB025-0AA0
*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 3
Important ! After the connection of individual components, the related functions in PLC
application (emergency stop, hardware limit switch) must be commissioned
first. Only after the afore-said safety functions are commissioned without error,
you may start NC parameters.
SINUMERIK 801 3-1

Start-Up
Built-In PLC Application
3.1 Input/Output Configuration
Input signals description

Table 3-1 Input signals description
Description of Input Signals
X100 DIN0
Pin# Signal Input # Signal Description

1 n.c Not defined
2 Limit X+ I0.0 Hardware limit X+ (normally closed)
3 Limit X- I0.1 Hardware limit X- (normally closed)
4 Ref. X I0.2 X reference cam
5 Limit Z+ I0.3 Hardware limit Z+ (normally closed)
6 Limit Z- I0.4 Hardware limit Z- (normally closed)
7 Ref. Z I0.5 Z reference cam
8 FootPed I0.6 Foot pedal
9 E-Stop I0.7 Emergency Stop key (normally closed)
10 M24 24V ground
X101 DIN1

1 n.c. Not defined
2 T1 I1.0 Tool sensor T1
3 T2 I1.1 Tool sensor T2 Active low when HED
4 T3 I1.2 Tool sensor T3 approximates to the
magnet, otherwise
5 T4 I1.3 Tool sensor T4 active high (see below
for wiring diagram)
8 User in1 I1.6 User input 1
9 User in2 I1.7 User input 2
10 M24 24V ground
3-2 SINUMERIK 801

Start-Up
2
Tool sensor T1
3
Tool sensor T2
Digital input X101

Active low
4
when HED
Tool sensor T3 approximates
5 to the magnet,
Tool sensor T4 otherwise ＋
6 active high 24VDC
Tool sensor T5 Power Supply
7
Tool sensor T6 －
8
User input 1
9
User input 2
10
Output signals description

Table 3-2 Output signals description
Description of Output Signals
X200 DOUT0

1 P24 24V power supply
Direction and enable of unipolar spindle or
2 S-CW Q0.0 contactor-controlled spindle (see MD30134
description)
Direction and enable of unipolar spindle or
3 S-CCW Q0.1 contactor-controlled spindle (see MD30134
description)
4 T-CW Q0.2 Turret CW
5 T-CCW Q0.3 Turret CCW
6 Cooling Q0.4 Coolant control
7 Lubrica Q0.5 Lubrication control
8 S-Brake Q0.6 Spindle control
9 Chuck Q0.7 Chuck clamping control
10 M24 24V ground
X201 DOUT1

1 P24 24V power supply
SINUMERIK 801 3-3
Start-Up
2 User out1 Q1.0 User output 1

6 n.c. Not defined
7 n.c. Not defined
8 n.c. Not defined
9 n.c. Not defined
10 M24 24V ground
Note:
User inputs/outputs
a） User in1（I1.6）＝0 ――>User out1(Q1.0)=0
User in1（I1.6）＝1 ――>User out1(Q1.0)=1
b） User in2（I1.7）＝0 ――>User out2(Q1.1)=0
User in2（I1.7）＝1 ――>User out2(Q1.1)=1
c） The output values of User out3 and 4 are defined by M functions

Use out3(Q1.3) User out4(Q1.2)
M20 0 0
M21 0 1
M22 1 0
M23 1 1
3-4 SINUMERIK 801

Start-Up
3.2 Definition of User Keys
User
Keys
Override keys Traverse keys
Fig. 3-1 User keys on MCP area
SINUMERIK 801 3-5

Start-Up
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

1）Feedrate override plus key with LED
The feedrate override will be increased by a set increment when pressing
the key once until reaching 120％;
LED is lit when the feedrate override is more than 100%, and flashes when
it reaches 120%;
3-6 SINUMERIK 801
Start-Up
2）Feedrate override 100% key

Keep pressing this key for 1.5 seconds, the feedrate override will be
changed into 100% directly.
3）Feedrate override minus key with LED
The feedrate override will be decreased by a set increment when pressing
Keep pressing this key for 1.5 seconds, the feedrate override will be
LED is lit when the feedrate override is between 0 ... 100%, and flashes
when it’s lowered to 0%;
4）Spindle speed override plus key with LED
The spindle override will be increased by a set increment when pressing
LED is lit when the spindle override is more than 100%, and flashes when
it reaches 120%;
5）Spindle override 100% key
Keep pressing this key for 1.5 seconds, the spindle override will be
6）Spindle override minus key with LED
The spindle override will be decreased by a set increment when pressing
Keep pressing this key for 1.5 seconds, the spindle override will be
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 3-7

Start-Up
3.3 PLC Machine Data
Definition of MD14512
Table 3-4 MD14512
MD14512 USER_DATA_HEX
Machine data PLC machine data - Hex
INDEX Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
[0] Reserved
[1] Reserved
[2] Reserved
[3] Reserved
PLC application configuration

[4] Toolholder Clamp & Lubrication
control unclamp
inactive inactive inactive
[5] Reserved
Technology Setting
[6] Z axis X axis Spindle Auto
rotation rotation brake lubrication
monitoring monitoring active once when
active active power on
[7] Reserved
Notes:
1) If you don’t want to use PLC to activate toolholder control, clamp/umclamp or lubrication functions,
set MD14512 [4] to proper bit to deactivate corresponding function.
2) You may set MD14512[6] to desired bit to activate corresponding function.
Caution
!
PLC machine data reserved by the control system must not be changed!
Definition of MD14510
Table 3-5 MD14510
MD14510
Machine Data PLC Machine Date—Integer
Index
14510[0] Reserved
14510[1] Reserved
3-8 SINUMERIK 801
Start-Up
Definition: Interval of track lubrication

14510[2] Unit: 1 minute
Range: 5～300 minutes
Definition: Duration of lubrication
14510[3] Unit: 0.1 second
Range: 10～200 (1～20 seconds)
Definition: Number of positions on the turret
14510[4] Unit: -
Range: 4 or 6
Definition: Monitor time (turret change abort if destination tool not
found within specified time)
14510[5] Unit: 0.1second
Range: 30～200 (3～20 seconds)
Definition: Turret clamping time
Range: 5～30 (0.5～3 seconds)
Definition: Braking time of external brake mechanism of a
contactor controlled spindle
Range: 5～200 (0.5～20 seconds)
SINUMERIK 801 3-9

Start-Up
3.4 Fixed PLC Alarms
Definition of fixed PLC alarms
Table 3-6 Definition of fixed PLC alarms
Alarm # Alarm Description
700008 Turret # wrongly defined, MD14510[4] (4/6)
700009 Turret clamping time undefined, check MD14510[6]
700010 Turret monitoring time undefined, check MD14510[5]
700011 Spindle brake time out range, check MD14510[7]
700021 Spindle/feed axis start impossible while unclamped
Unclamping impossible while spindle run or NC start enabled in

700022
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
3-10 SINUMERIK 801

Start-Up
Setting Up 4
4.1 Setting Up NC Parameters
System configuration
The system configuration for SINUMERIK 801 is a turning variant, i.e.: X axis
is set as the 1st axis, Z axis the 2nd and spindle the 3rd. Technology settings
are also for turning machining.
Notice
NC parameters can not be changed unless the Machine Manufacturer
password (“Evening”) has been input.
Parameterization Parameter settings for SINUMERIK 801 are given in following tables. In which,
IPR refers to pulses per motor revolution, RPM revolutions per minute and I
the number of pulses.
SINUMERIK 801：
Input
MD Designation Unit Axis Description
value
30130 CTRLOUT_T - X，Z 2 Output type of
setpoint (setpoint
YPE branch): the setpoint
signals are output to
connector X4
30240 ENC_TYPE - X，Z 3 Type of actual value
acquisition (actual
position value)
(encoder no.):
3: Encoder for
stepper motor
34200 ENC_REF_M - X，Z 2* or Type of position
measuring system:
ODE 4* 2: BERO
4: Bero with two
edges
34210 ENC_REF_ - X，Z 0 or Reference state
1 0: Function “Record
STATE reference point”
inactive
1: Function “Record
reference point”
activated
SINUMERIK 801 5-1
Start-Up
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:

Input
value
31020 ENC_RESOL IPR X, Z 1000 Encoder
markings per
revolution
(encoder no.)
31400 STEP_RESOL IPR X, Z 1000 Steps per
stepping motor
revolution
Mechanical parameters for the driving system:
Input
value
31030 LEADSCREW_ mm X, Z 5 Pitch of
leadscrew
PITCH
31050 DRIVE_AX_RATIO - X, Z 40 Denominator
load gearbox
_DENUM[0 ... 5] (control
parameter No.)
31060 DRIVE_AX_RATIO - X, Z 50 Numerator load
gearbox (control
_NUMERA[0 … 5] parameter set
No.)
Note:
After determining the mechanical parameters, set the axis speed. For
stepper motors, the motor speed shall be determined according to its
frequency-torque characteristics: motor speed ＝ axis speed/leadscrew
pitch/reduction ratio.
5-2 SINUMERIK 801

Start-Up
Setting Up
Example
value
32000 MAX_ AX_VELO mm/Min X，Z 4800 Maximum axis
velocity
32010 JOG_ VELO_ mm/Min X，Z 4800 Rapid traverse
in JOG mode
RAPID
32020 JOG_ VELO mm/Min X，Z 3000 JOG axis
velocity
32260 RATED_VELO RPM X，Z 1200 Rated motor
speed (setpoint
branch)
36200 AX_VELO_LIMIT mm/Min X，Z 5280 Threshold value
for velocity
monitoring
After the above parameters have been set, SINUMERIK 801 will
automatically determine the frequency when being powered on:
20rev./sec.×1000 pulses/rev.＝20000pulses/sec., and MD31350 is set as
follows:
Example
value
31350 FREQ_STEP_LIMIT Hz X，Z 20000 Stepping rate at
maximum velocity
Setting the encoder limit frequency according to MD31350:

Example
value
36300 ENC_FREQ_LIMIT Hz X，Z 22000 Encoder limit
frequency
Note:
The max. output frequency of SINUMERIK 801 can reach 500000Hz.
SINUMERIK 801 5-3

Start-Up
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.
MD35230 reduced acceleration factor: value

Velocity Vmax
40% ... 95%
MD35220 speed for reduced acceleration: values from

80% …20%
MD32300 max. axis acceleration

Time
Table 4-1 Parameterization

Input
value
35220 ACCEL_REDUC - X，Z 1 ... 0 Speed for reduced
acceleration:
TION_SPEED_ max. speed * percent,
POINT values valid from 0.8 ... 0.2.
35230 ACCEL_ - X，Z 0 ... 1 Factor of reduced
acceleration:
REDUCTION_ max. acceleration *
FACTOR percent, values valid from
0.4 ... 0.95.
32300 MAX_AX_ACCEL m/s2 X，Z 1 The max. axis acceleration
(default value)
5-4 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
Start RK
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
Start RK
Reference cam
BERO—pulse
Without reference cam

RV
VM
VP
Start
RK
BERO—pulse
SINUMERIK 801 5-5

Start-Up
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
Example
value
34000 REFP_CAM_ - X, Z 1 Axis with reference
point cam
IS_ACTIVE
34010 REFP_CAM_ - X, Z 0/1 Approach
reference point in:
DIR_IS_ 0- plus direction; 1-
MINUS minus direction
34020 REFP_VELO_ mm/Min X, Z 2000 Reference point

approach velocity
SEARCH_
CAM
34040 REFP_VELO_ mm/Min X, Z 300 Creep speed
(encoder no.)
SEARCH_
MARKER
34050 REFP_SEAR - X, Z 0/1 BERO pulse is:
0-ouside BERO;
CH_MARKER 1-inside BERO
_REVERSE
34060 REFP_MAX_ mm X, Z 200 Maximum distance
to reference mark.
MARKER_ Max. distance to 2
DIST reference marks
for distance–coded
measuring
systems.
34070 REFP_VELO_ mm/Min X, Z 200 Reference point
positioning velocity
POS
34080 REFP_MOVE mm X, Z -2 Reference point
distance/target
5-6 SINUMERIK 801
Start-Up
Setting Up
_DIST point for

distance-coded
system (with
direction)
34100 REFP_SET_ mm X, Z 29.4 Reference point
value/irrelevant to
POS distance-coded
system
SINUMERIK 801 5-7

Start-Up
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:
Example
value
36100 POS_LIMIT_MINUS mm X, Z -1 1st software limit
switch minus
36110 POS_LIMIT_PLUS mm X, Z 200 1st software limit
switch plus
Backlash compensation
Test the backlash and make backlash compensations:
Example
value
32450 BACKLASH mm X, Z 0.024 Backlash
5-8 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.
Example
value
31100 BERO_CYCLE IPR X，Z 1250 Steps for monitoring
rotation
31110 BERO_EDGE_ I X，Z 500 Step tolerance for
TOL monitoring rotation
Notes:
The step tolerance of the stepper motors shall include positional difference
between both edges of BERO and follow-up error resulted at the maximum
traversing speed. The interrelations are given as below:
Steps for monitoring rotation = steps per revolution of the step motor/reduction
ratio
Steps corresponding to follow-up error = steps × follow-up error at the max.
speed/pitch of leadscrew
SINUMERIK 801 5-9

Start-Up
Setting Up
4.6 Leadscrew Error Compensation
General When starting up a machine tool, you may make leadscrew error
compensations to enhance the machining precision. Herein below gives an
example to show you how to make a leadscrew error compensation.
A maximum of 64 compensation intermediate points can be set for each axis
of the SINUMERIK 801. Machine tool builders may set desired number of
compensation intermediate points based on actual needs.
Example Set the Z axis as the compensation axis, the starting compensation point as
100mm(absolute coordinate)，clearance for compensation 100mm and end
point for compensation 1200mm (absolute coordinate).
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

($AA_ENC_COMP_MAX)
Measuring clearance error
($AA_ENC_COMP_STEP) Compensation value at point 5
100 200 300 1200 Axis position
0 1 2 3 4 5 10
Interpolation point Linear interpolation between two points 11 (k)
($AA_ENC_COMP_MIN)
Min. coordinate point－correpsonding to $AA_ENC_COMP[0, 0, AX2]
Table 4-1 Compensation principle
Caution
! After setting up this MD, the control system will reassign the memory when
next power-up and user data including part program, fixed cycles and tool
parameter will be cleared. So, prior to this data setting, unload user data into a
PC.
2nd step: Transfer the leadscrew error compensation file into the computer
using the WINPCIN tool integreated into the control sytem. You may enter
compensation values with following two methods:
1st method:
1) Load the leadscrew pitch error compensation array into the computer via
SINUMERIK 801;
2) Edit this file on computer and write the error values measured into
corresponding positions in the array;
3) Transfer the file into SINUMERIK 801 from the computer.
nd
2 method:
1) Transfer this compesation array into the computer via SINUMERIK 801;
5-10 SINUMERIK 801
Start-Up
Setting Up
2) Edit this file on computer and change the file header into a machining
program, then transfer to SINUMERIK 801;
3) Use the Edit function of the SINUMERIK 801 to input compensation
values on the operator panel directly;
4) Start running this program (and compensation values will be input into
the control system)
1ST Method 2nd Method Remarks
%_N_COMPLETE_EEC_ %_N_BUCHANG_MPF File header
INI ；$PATH=/_N_MPF_DIR
$AA_ENC_COMP $AA_ENC_COMP[0，0，AX2]= 0.0
[0，0，AX2]= 0.0
$AA_ENC_COMP $AA_ENC_COMP[0 ， 1 ， AX2]=
[0，1，AX2]= 0.020 0.020
[0，2，AX2]= 0.015 0.015
[0，3，AX2]= 0.014 0.014
[0，4，AX2]= 0.011 0.011 Corresponding
$AA_ENC_COMP $AA_ENC_COMP[0 ， 5 ， AX2]= min. position
[0，5，AX2]= 0.009 0.009

Compensation
value array
[0，6，AX2]= 0.004 0.004
$AA_ENC_COMP $AA_ENC_COMP[0 ， 7 ，
[0，7，AX2]=-0.010 AX2]=-0.010
Corresponding
$AA_ENC_COMP $AA_ENC_COMP[0 ， 8 ， max. position
[0，8，AX2]=-0.013 AX2]=-0.013
[0，9，AX2]=-0.015 AX2]=-0.015
[0，10，AX2]=-0.009 AX2]=-0.009
[0，11，AX2]=-0.004 AX2]=-0.004
… …
$AA_ENC_COMP $AA_ENC_COMP[0，63，AX2]
[0，63，AX2]
$AA_ENC_COMP_STEP $AA_ENC_COMP_STEP[0 ， Measuring
clearance (mm)
[0，AX2]=100.0 AX2]=100.0
$AA_ENC_COMP_MIN $AA_ENC_COMP_MIN[0 ， AX2] Min. position
(abs.)
[0，AX2] =100.0 =100.0
$AA_ENC_COMP_MAX $AA_ENC_COMP_MAX[0 ， AX2] Max. position
(abs.)
[0，AX2] =1200.0 =1200.0
$AA_ENC_COMP_IS_MO $AA_ENC_COMP_IS_MODULO[0， (for rotating axis)
SINUMERIK 801 5-11

Start-Up
Setting Up
DULO AX2]=0
[0，AX2]=0
M17 M02 End of the file
3rd step：Enable the leadscrew error compensation function through set MD

Example
value
32700 ENC_COMP_ENA - X，Z 0 Compensation
inactive
BLE Compensation
1
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.
Input
value
30130 CTRLOUT_TYPE - Spindle 0 No analog output
30130 CTRLOUT_TYPE - Spindle 1 ±10VDC analog
output
Set the machine spindle outputs as unipolar/bipolar setpoint output.

Input
value
30134 IS_UNIPOLAR_ - Spindle 0 Setpoint output is
OUTPUT bipolar
30134 IS_UNIPOLAR_ - Spindle 1* Setpoint output is
OUTPUT unipolar
30134 IS_UNIPOLAR_ - Spindle 2* Setpoint output is
OUTPUT unipolar，Q0.0 and
Q0.1 can not be
recalled by PLC;
* When MD30134 =1: Q0.0＝Servo enable;
Q0.1＝ Spindle CCW
MD30134 =2: Q0.0＝Sevo enable, spindle CW;
Q0.1＝Servo enable, spindle CCW
If the spindle has no encoder feedback, set MD30200 = 0.

Input
value
30200 NUM_ENCS - Spindle 0 Spindle without
encoder
When producing a thread, configure the spindle with an encoder:

Input
value
30240 ENC_TYPE - Spindle 2 Spindle with
measuring system
SINUMERIK 801 5-13
Start-Up
Setting Up
Set spindle MDs as listed below:

Input
value
31020 ENC_RESOL IPR Spindle 1024 Encoder markings
per revolution
(encoder no.)
32260 RATED_VELO RP Spindle 3000 Rated motor speed
M (setpoint branch)
36200 AX_VELO_ RP Spindle 3300 Threshold value for
LIMIT[ 0 ... 5 ] M velocity monitoring
Determine the encoder limit frequency:

Spindle speed 3000 rev/min = 50rev/s;
Encoder limit frequency 50 rev/s×1024 pulses/rev = 51200 pulses/s
Fill in weighted machine data:

Input
value
36300 MA_ ENC_ FREQ_ Hz Spindle 55000 Encoder limit
LIMIT frequency
For anolog spindle with gear changes:

MD Designation Unit Axis Input value Description
35010 GEAR_STEP_ - Spindle 1 Gear change
CHANGE_ possible.
ENABLE Spindle has
several gear
steps
35110 GEAR_STEP_ RPM Spindle Speed Maximum
MAX_VELO[ 0， [i] speed for
gear
1 ... 5 ]
change(gear
stage no.):
0 ... 5
35130 GEAR_STEP_ RPM Spindle Speed Maximum
MAX_VELOLIMI [i] speed of gear
T[ 0，1 ... 5 ] stag(gear
stage no.):
0 ... 5
36200 AX_VELO_ RPM Spindle Speed Threshold
LIMIT[ 0，1 ... 5 ] [i] value for
velocity
monitoring
(control
parameter set
no.): 0 ... 5
31050 DRIVE_AX_ - Spindle Denominator Denominator
RATIO_ [i] load gearbox
DENUM[0，1 ... (control
parameter
5-14 SINUMERIK 801
Start-Up
Setting Up
5] no.): 0 ... 5
31060 DRIVE_AX_ - Spindle Numerator Numerator
RATIO_ [i] load gearbox
NUMERA[0，1 ... (control
parameter set
5]
no.): 0 ... 5
Notice
A maxium of 5 spindle gear stages can be provided. Assigning the same
parameters to the index [0] and [1] makes gear changes (i=1 ... 5) active only
by setting corresponding interface signals via PLC application.
Programming notice
Pay attention to the following instructions when programming machining

programs:
1) When mm/Min is used as the unit of measurement for the feedrate F,
activate G94; Programming example: N10 G94 G01 Z100 F100
2) When mm/Rev is used as the unit of measurement for the feedrate F,
activate G95; mm/Rev. Programming example: N10 G95 G01 Z100 F1
3) For contactor-controlled spindle, when producing a thread with G33,
program spindle speed S within the actual spindle speed range;
4) When programming a thread cutting, program thread run-in and run-out
paths;
5) The result of a thread lead value multiplied by spindle speed shall be
less than the maximum setpoint speed of Z axis.
Programming example
N10 G91 G94 F100 S350 M4 ； actual spindle speed 350
N20 G01 Z-0.5 ； thread run-in
N30 G33 Z-100 K2 SF=0 ； K - thread lead; SF；SF – Infeed angle for
thread cutting
N40 G01 Z-0.5 ； thread run-out
N50 X50
SINUMERIK 801 5-15

Start-Up
Services, Diagnosis and Data Saving 5
5.1 Services
Functionality You can use the RS232 interface of the CNC to output data to an external
data storage medium or to read in them from there. RS232 interface
parameters have been fixed by the control system and cannot be changed.
File types Files including various data, programs and parameters can be read in/out of
RS232 interface with specified access authorization.
File type has been fixed as : RS232 text Baudrate: 9600
RS232 text file screen is shown as below:
Fig. 5-1 RS232 text file screen

For machine tool builders, after the password assigned to them is entered,
following screen appears:
SINUMERIK 801 5-1

Start-Up
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
Fig.5-4
SINUMERIK 801 5-3

Start-Up
5.2 Diagnosis
Functionality In the “Diagnosis” operating area, machine manufactuere may optimize the
drives with an oscillograph function.
Selecting the Diagnosis softkey will open the Diagnosis main screen.
Fig.5-5 Diagnosis main screen
Selecting the “Service display” from the screen above to branch to another
softkey level.
Fig. 5-6
Notice
Machine manufacturer may select the “Servo trace” softkey on the screen of
Fig. 5-6 to branch to the corresponding “Servo trace” main screen. However,
before entering this main screen, machine manufacturer password must first
be input. Otherwise, system will prompt “Access Denied!”
5-4 SINUMERIK 801

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

representation of the velocity setpoint. The velocity setpoint corresponds to
the ± 10V interface.
The start of recording can be linked with various criteria which permit
recording in parallel to internal conditions of the control system. The setting
needed for this option must be carried out in the “Select Signal” function.
The following functions can be used to analyze the result:
z Change scaling of abscissa and ordinate,
z Measure value by means of a horizontal or vertical marker,
z Measure the abscissa and ordinate values as a difference between two
marker positions.
Fig. 5–7 The “Servo Trace” main screen
The heading of the diagram contains the current graduation of abscissa and
ordinate, the current measured positions and the difference values of the
markers.
The displayed diagram can be moved within the visible screen area by means
of the cursor keys.
Graduation Graduation
of abscissa of ordinate
Difference
display
of Markers
Current
Initial values
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 5-5

Start-Up
Fig. 5–9 Signal selection

z Selecting the axis: The axis is selected in the Axis toggle field.
z Signal type:
Velocity setpoint
Actual position value of measuring system 1
Following error
z Determining the measuring time: The measuring time is entered in ms
directly in the “Measuring Time” input field.
z Determining trigger time to or after
With input values < 0, recording starts by the set time prior to the trigger event,
and with values > 0 accordingly after the trigger event, whereby the following
conditions must be observed:
Trigger time + measuring time ≥ 0.
z Selecting the trigger condition: Position the cursor on the Trigger
Condition field and select the condition using the toggle key.
— No trigger, i.e. the measuring starts immediately after pressing the Start
softkey.
— Negative edge.
— Exact stop fine reached.
— Exact stop coarse reached.
z Determining the trigger threshold: The threshold is entered directly in the

Threshold input field. It acts only for the trigger conditions “Positive edge”
and “Negative edge”.
Press “Marker” key to branch to another softkey level, in which the horizontal
or vertical marker can be switched on or off. The markers are displayed in the
status bar.
The markers are moved in steps of one increment by means of the cursor
keys. Larger step widths can be set in the input fields. The value specifies
the number of raster units per <SHIFT> + cursor movement by which the
marker is to be moved.
If a marker reaches the margin of the diagram, the next raster in horizontal or
vertical direction is automatically pulled down.
5-6 SINUMERIK 801

Start-Up
Fig. 5–10 Setting the markers

The markers can also be used to determine the differences in the horizontal or
vertical direction. To this aim, position the marker on the start point and press
either the Fix H - Mark. or the Fix T- Mark. softkey. The difference between the
start point and the current marker position is now displayed in the status bar.
The softkey labeling changes to “Free H - Mark” or “Free T - Mark”.
Pressing the Help key softkey calls explanations with regard to the displayed
values on the screen.
Pressing the Start softkey starts recording. The softkey labeling changes to
Stop. The note “Recording active” is displayed.
When the measuring time is elapsed, the softkey labeling changes to Start.
Pressing the Stop softkey aborts the current measuring. The softkey labeling
changes to Start.
Pressing “Zoom Time +”/”Zoom Time - ” enables the scaling changes in the
following steps:
1, 2, 5, 10, 20, 50, 100, 200, 500, 1,000 ms/div.
Pressing “Zoom V +”/”Zoom V -” enables the horizontal scaling changes in the

following steps:
0.01, 0.05, 0.1, 0.5, 1, 5, 10, 50, 100, 500, 1,000, 5,000 unit/ div
Pressing the Auto Scaling key calculates the vertical scaling from the peak
values.
SINUMERIK 801 5-7

Start-Up
5.3 Data Saving
5.3.1 Internal Data Saving
Data saving After all MD has been started up, the password must be closed so as to save
data and call the data again rapidly next time.
Operating sequence:
D iagnostics S ta rt-u p Sav e data
Save machine data, set data, machining data, leadscrw error compensation
data, etc. in the permanent memory. Recall them again via Start-up switch
position 3 or by selecting menu “Power-up with saved data”.
Notice
If the fuction “record reference point” has been executed (with MD34210),
do approach reference point again after system power up with saved data!
5.3.2 External Data Saving
Purpose In case of any product fault and subsequent maintenance, the machine tool
builder / end user is requested to fill in the Warranty Card – SINUMERIK 801
delivered in the package so that the setting data can be recovered
immediately by Siemens after product has been replaced or maintained.
Hereinbelow is relevant data sheet described in the Warranty Card.
1. Machine Data
Data Definition Unit OEM Value
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.)
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 -
5-8 SINUMERIK 801
Start-Up

X-axis Z-axis Spin.
[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
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
32260 Rated motor speed (setpoint rpm
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 mm/Min
34080 Reference point distance
34100 Reference point value/irrelevant for mm
distance-coded system
35110 Maximum speed for gear change rpm
SINUMERIK 801 5-9

Start-Up

X-axis Z-axis Spin.
[1] [1]
35130 Maximum speed of gear change [1] rpm
[1]
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
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
X-axis Z-axis
$AA_ENC_COMP[0,0,AX1]= $AA_ENC_COMP[0,0,AX2]=
$AA_ENC_COMP_STEP[0,AX1]= $AA_ENC_COMP_STEP[0,AX2]=
$AA_ENC_COMP_MIN[0,AX1]= $AA_ENC_COMP_MIN[0,AX2]=
$AA_ENC_COMP_MAX[0,AX1]= $AA_ENC_COMP_MAX[0,AX2]=
2．PLC Parameter
MD14512 PLC data（Binary） MD PLC data
Bit Bit Bit Bit Bit Bit Bit Bit
14510 （integer）
7 6 5 4 3 2 1 0
14512[4] 14510[2]
14512[6] 14510[3]
14510[4]
14510[5]
14510[6]
14510[7]
5.3.3 Important Notice
Important Pay attention to following notices prior to the delivery of machine tools by
machine manufacturers:
1) Password
Some functions of the the control system are protected by password.
The control system has preset one password (“Evening”) for machine
manufacturers. If no password is entered by the machine manufacturer,
only tool offset, tool wear, zero offset, R parameter and part program edit
5-4 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 5-11

Start-Up
Be sure to make data backup after the machine has been started up and
ready for delivery. Data backup includes internal data saving and external
data saving. With external data saving, machine data, leadscrew error
compensation data, tool data can be loaded into a PC.
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 6-1

Start-Up
Technical Appendix
Technical Appendix 7
7.1 List of Machine Data
Data type BOOLEAN Machine data bit (1 or 0)

BYTE Integer values (from – 128 to 127)
DOUBLE Real and integer values
(from ± 2.23 x 10–308 to ± 1.79 x 10308)
DWORD Integer values (from – 2.147 x 109 to 2.147 x 109 )
STRING Character string (max. 16 characters) consisting of
upper–case letters with digits and underscore
UNSIGNED WORD Integer values (from 0 to 65535)
SIGNED WORD Integer values (from – 32768 to 32767)
UNSIGNED DWORD Integer values (from 0 to 4294967295)
SIGNED DWORD Integer values (from – 2147483648 to 2147483647)
WORD Hex values (from 0000 to FFFF)
DWORD Hex values (from 00000000 to FFFFFFFF)
FLOAT DWORD Real values (from ±1.18 x 10–38 to ± 3.4 x 1038)
Activation conditions
PO(Power On) Data active when system power on;
RE(Reset) Data active whey system is reset
CF(Configuration) Active when “Data Active” soft menu is enabled;
IM(Immediate) Immediately active
7-1 SINUMERIK 801

Start-Up
Technical Appendix
Data format
Number MD Name Reference
Unit Name, Miscellaneous Activated
HW / Standard value Minimum value Maximum value Data type
function
General machine data

10240 SCALING_SYSTEM_IS_METRIC
– Basic system metric POWER ON
_always 1 *** *** BOOLEAN
14510 USER_DATA_INT [n]

kB User data (INT) 0 ... 31 POWER ON
– – 0 – DWORD
14512 USER_DATA_BIN [n]

kB User data (Binary) 0 ... 31 POWER ON
– 0 0 0xFF DWORD
Axis-specific machine data

30130 CTRLOUT_TYPE
– Output type of setpoint (setpoint branch): 0 POWER ON
_always 0 0 2 BYTE
30134 IS_UNIPOLAR_OUTPUT[0]
– Setpoint output is unipolar : 0 POWER ON
_always 0 0 2 BYTE
30200 NUM_ENCS
– Number of encoders (spindle with or without encoder) RESTART
1 0 1 BYTE
30240 ENC_TYPE
– Type of actual value acquisition (actual position value) POWER ON
(encoder no.)
0: Simulation
2: Square–wave generator, standard encoder
(pulse multiplication)
3: Encoder for stepper motor
_always 0, 0 0 4 BYTE
30350 SIMU_AX_VDI_OUTPUT
– Output of axis signals with simulation axes POWER ON
30600 FIX_POINT_POS
SINUMERIK 801 7-2

Start-Up
Technical Appendix
mm, Fixed–value positions of axis with G75 (position no.) POWER ON

degrees
_always 0.0 – – DOUBLE
31000 ENC_IS_LINEAR
– Direct measuring system (linear scale) (encoder no.) POWER ON
31010 ENC_GRID_POINT_DIST
mm Division period for linear scales (encoder no.) POWER ON
_always 0.01 0.0 plus DOUBLE
31020 ENC_RESOL
– Encoder markings per revolution (encoder no.) POWER ON
_always 2048 0.0 plus DWORD
31030 LEADSCREW_PITCH
mm Pitch of leadscrew POWER ON
31040 ENC_IS_DIRECT
– Encoder mounted directly to the machine (encoder no:) POWER ON
31050 DRIVE_AX_RATIO_DENOM
– Denominator load gearbox (control parameter no.): 0 ... 5 POWER ON
_always 1, 1, 1, 1, 1, 1 1 2147000000 DWORD
31060 DRIVE_AX_RATIO_NUMERA
– Numerator load gearbox (control parameter set no.): 0 ... POWER ON
5
_always 1, 1, 1, 1, 1, 1 1 2147000000 DWORD
31070 DRIVE_ENC_RATIO_DENOM
– Denominator resolver gearbox (encoder no.) POWER ON
_always 1 1 2147000000 DWORD
31080 DRIVE_ENC_RATIO_NUMERA
– Numerator resolver gearbox (encoder no.) POWER ON
_always 1 1 2147000000 DWORD
31090 JOG_INCR_WEIGHT
mm, Evaluation of an increment with INC/handwheel RESET
degrees
31100 BERO_CYCLE
– Steps for monitoring rotation POWER ON
2000 10 10000000 DWORD
7-1 SINUMERIK 801

Start-Up
Technical Appendix
31110 BERO_EDGE_TOL
– Step tolerance for monitoring rotation POWER ON
50 10 10000000 DWORD
31350 FREQ_STEP_LIMIT
– Stepping rate at maximum velocity NEW CONF
Hz 250000 0.1 4000000 DOUBLE
31400 STEP_RESOL
– Steps per stepper motor revolution POWER ON
1000 0 plus DWORD
31500 AXIS_NUMBER_FOR_MONITORING
– Display setpoint of this axis for servicing POWER ON
0 0 4 DWORD
32000 MAX_AX_VELO
mm/min, Maximum axis velocity NEW CONF
rev/min
_always 10000. 0.0 plus DOUBLE
32010 JOG_VELO_RAPID
mm/min, Rapid treverse in jog mode RESET
rev/min
32020 JOG_VELO
mm/min, Jog axis velocity RESET
rev/min
32070 CORR_VELO
% Axis velocity for handwheel override, ext. ZO, cont. RESET
dressing, distance control
_always 50 0.0 plus DWORD
32100 AX_MOTION_DIR
– Traversing direction (not control direction) POWER ON
_always 1 –1 1 DWORD
32110 ENC_FEEDBACK_POL
– Sign actual value (control direction) (encoder no.) POWER ON
32200 POSCTRL_GAIN
1000/min Servo gain factor (control parameter set no.): 0 ... 5 NEW CONF
_always (2,5; 2,5; 2,5; 1), ... 0.0 plus DOUBLE
32260 RATED_VELO
rev/min Rated motor speed (setpoint branch): 0 NEW CONF
_always 3000 0.0 plus DOUBLE
SINUMERIK 801 7-2

Start-Up
Technical Appendix
32300 MAX_AX_ACCEL
mm/s^2, Axis acceleration NEW CONF
rev/s^2
_always 1 0 *** DOUBLE
32420 JOG_AND_POS_JERK_ENABLE
- Enable axial jerk limitation NEW CONF
32430 JOG_AND_POS_,AX_JERK
- Axial jerk NEW CONF
_always 1000 (mm/s^3) 10 -9 *** DOUBLE
2777,77
(degrees/s^3)
32450 BACKLASH
mm Backlash NEW CONF
_always 0.000 * * DOUBLE
32700 ENC_COMP_ENABLE
– Interpolatory compensation (encoder no.): 0,1 POWER ON
32900 DYN_MATCH_ENABLE
– Dynamic response adaptation NEW_CONF
0 0 1 BYTE
32910 DYN_MATCH_TIME
– Time constant of dynamic adaption (control parameter set NEW_CONF
no): 0 ... 5
0 0.0 plus DOUBLE
32920 AC_FILTER_TIME
s Smoothing factor time constant for adaptive control POWER ON
33050 LUBRICATION_DIST
mm, Traversing distance for lubrication from PLC NEW CONF
deg.
34000 REFP_CAM_IS_ACTIVE
– Axis with reference point cam RESET
34010 REFP_CAM_DIR_IS_MINUS
– Approach reference point in minus direction RESET
34020 REFP_VELO_SEARCH_CAM
mm/min, Reference point approach velocity RESET
rev/min
7-1 SINUMERIK 801
Start-Up
Technical Appendix
34030 REFP_MAX_CAM_DIST
mm, Maximum distance to reference cam RESET
deg.
34040 REFP_VELO_SEARCH_MARKER
mm/min, Creep speed (encoder no.) RESET
rev/min
34050 REFP_SEARCH_MARKER_REVERSE
– Direction reversal to reference cams (encoder no.) RESET
34060 REFP_MAX_MARKER_DIST
mm, Maximum distance to reference mark. Max. distance to 2 RESET
deg. reference marks for distance–coded measuring systems.
34070 REFP_VELO_POS
mm/min, Reference point positioning velocity RESET
rev/min
34080 REFP_MOVE_DIST
mm, Reference point distance/target point for distance–coded RESET
deg. system
_always –2.0 – – DOUBLE
34090 REFP_MOVE_DIST_CORR
mm, Reference point offset/absolute offset distance–coded POWER ON
deg.
_always 0.0 – – DOUBLE
34092 REFP_CAM_SHIFT
mm, Electr. cam offset of incremental measuring systems with RESET
deg. equidistant zero marks
34100 REFP_SET_POS
mm, Reference point value/irrelevant for distance–coded RESET
deg. system: 0 ... 3
_always 0., 0., 0., 0. – – DOUBLE
34110 REFP_CYCLE_NR
– Sequence of axes in channel–specific referencing RESET
–1: No obligatory reference point for NC Start
0: No channel–specific reference–point approach
1–15: Sequence in channel–specific reference point
approach
SINUMERIK 801 7-2

Start-Up
Technical Appendix
34200 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)
_always 1 0 6 BYTE
34210 ENC_REFP_STATE
– 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.
_always 0 1 2 DWORD
35010 GEAR_STEP_CHANGE_ENABLE
– Gear change possible. Spindle has several gear steps POWER ON
35040 SPIND_ACTIVE_AFTER_RESET
– Own spindle reset POWER ON
35100 SPIND_VELO_LIMIT
rev/min Maximum spindle speed POWER ON
35110 GEAR_STEP_MAX_VELO
rev/min Maximum speed for gear change (gear stage no.): 0..5 NEW CONF
_always 500, 500, 1000, 0.0 plus DOUBLE
2000, 4000, 8000
35120 GEAR_STEP_MIN_VELO
rev/min Minimum speed for gear change (gear stage no.): 0..5 NEW CONF
_always 50, 50, 400, 800, 0.0 plus DOUBLE
1500, 3000
35130 GEAR_STEP_MAX_VELO_LIMIT
rev/min Maximum speed of gear stage (gear stage no.): 0 ... 5 NEW
CONF
_always 500, 500, 1000, 2000, 0.0 plus DOUBLE
4000, 8000
35140 GEAR_STEP_MIN_VELO_LIMIT
rev/min Minimum speed of gearsetp (gear stage no.): 0 ... 5 NEW CONF
7-1 SINUMERIK 801

Start-Up
Technical Appendix
_always 5, 5,10, 20, 40, 80 0.0 plus DOUBLE
35150 SPIND_DES_VELO_TOL
Factor Spindle speed tolerance RESET
_always 0.1 0.0 1.0 DOUBLE
35160 SPIND_EXTERN_VELO_LIMIT
rev/min Spindle speed limitation from PLC NEW CONF
35200 GEAR_STEP_SPEEDCTRL_ACCEL
rev/s^2 Acceleration in speed control mode [gear stage no.]: 0 ... NEW CONF
5
_always 30, 30, 25, 20, 15, 10 2 *** DOUBLE
35210 GEAR_STEP_POSCTRL_ACCEL
rev/s^2 Acceleration in position control mode (gear stage no.): NEW CONF
1 ... 5
_always 30, 30, 25, 20, 15, 10 2 *** DOUBLE
35220 ACCEL_REDUCTION_SPEED_POINT
Factor Speed for reduced acceleration RESET
35230 ACCEL_REDUCTION_FACTOR
Factor Reduced acceleration RESET
35240 ACCEL_TYPE_DRIVE
– Type of acceleration RESET
0 0 1 BOOLEAN
35300 SPIND_POSCTRL_VELO
rev/min Position control switch–on speed NEW CONF
35350 SPIND_POSITIONING_DIR
– Direction of rotation when positioning RESET
_always 3 3 4 BYTE
35400 SPIND_OSCILL_DES_VELO
rev/min Reciprocation speed NEW CONF
35410 SPIND_OSCILL_ACCEL
rev/s^2 Acceleration during reciprocating NEW CONF
_always 16 2 *** DOUBLE
35430 SPIND_OSCILL_START_DIR
- Starting direction during reciprocation RESET
0-2: As last direction of rotation (zero-speed
SINUMERIK 801 7-2

Start-Up
Technical Appendix
M3)
3: M3 direction
4: M4 direction
_always 0 0 4 BYTE
35440 SPIND_OSCILL_TIME_CW
s Reciprocation time for M3 direction NEW CONF
35450 SPIND_OSCILL_TIME_CCW
s Reciprocation time for M4 direction NEW CONF
35500 SPIND_ON_SPEED_AT_IPO_START
- Feed enable for spindle in setp. Range RESET
_always 1 0 2 BYTE
35510 SPIND_STOPPED_AT_IPO_START
– Feedrate enable for spindle stopped RESET
36000 STOP_LIMIT_COARSE
mm, Exact positioning coarse NEW CONF
deg.
36010 STOP_LIMIT_FINE
mm, Exact positioning fine NEW CONF
deg.
36020 POSITIONING_TIME
s Delay exact positioning fine NEW CONF
36030 STANDSTILL_POS_TOL
mm, Zero–speed tolerance NEW CONF
deg.
0.2 0.0 plus DOUBLE
36040 STANDSTILL_DELAY_TIME
s Delay zero–speed monitoring NEW CONF
36050 CLAMP_POS_TOL
mm, Clamping tolerance NEW CONF
deg.
36060 STANDSTILL_VELO_TOL
mm/min, Maximum velocity/speed “axis/spindle stopped” NEW CONF
7-1 SINUMERIK 801
Start-Up
Technical Appendix
rev/min
_always 5 (0.014) 0.0 plus DOUBLE
36100 POS_LIMIT_MINUS
mm, 1st software limit switch minus RESET
deg.
_always –100000000 – – DOUBLE
36110 POS_LIMIT_PLUS
mm, 1st software limit switch plus RESET
deg.
_always 100000000 – – DOUBLE
36120 POS_LIMIT_MINUS2
mm, 2nd software limit switch minus RESET
deg.
_always –100000000 – – DOUBLE
36130 POS_LIMIT_PLUS2
mm, 2nd software limit switch plus RESET
deg.
_always 100000000 – – DOUBLE
36200 AX_VELO_LIMIT
mm/min, Threshold value for velocity monitoring NEW CONF
rev/min (control parameter set no.): 0 ... 5
_always 11500., 11500., 0.0 plus DOUBLE
11500., 11500., ...
36300 ENC_FREQ_LIMIT
Hz Encoder limit frequency POWER ON
_always 300000 0 plus DOUBLE
36302 ENC_FREQ_LIMIT_LOW
% Encoder limit frequency at which encoder is switched on NEW CONF
again. (Hysteresis)
_always 99.9 0 100 DOUBLE
36310 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
_always 0, 0 0.0 plus DWORD
36400 CONTOUR_TOL
mm, Contour monitoring tolerance band NEW CONF
deg.
_always 1.0 *** *** DOUBLE
36500 ENC_CHANGE_TOL
SINUMERIK 801 7-2

Start-Up
Technical Appendix
mm, deg Portion of distance for backlash working NEW CONF

_always 0,1 0.0 plus DOUBLE
36610 AX_EMERGENCY_STOP_TIME
s Duration of the deceleration ramp for error states NEW CONF
36620 SERVO_DISABLE_DELAY_TIME
s Cutout delay servo enable NEW CONF
36700 DRIFT_ENABLE
– Automatic drift compensation NEW CONF
36710 DRIFT_LIMIT
% Drift limit value for automatic drift compensation NEW CONF
36720 DRIFT_VALUE
% Drift basic value NEW CONF
_always 0.0 DOUBLE
38000 MM_ENC_COMP_MAX_POINTS
– Number of intermediate points for interpolatory POWER ON
compensation (SRAM)
_always 0, 0 0 5000 DWORD
Setting data
41110 JOG_SET_VELO
mm/min Axis speed for JOG Immediately
41200 JOG_SPIND_SET_VELO
rev/min Speed for spindle JOG mode Immediately
43210 SPIND_MIN_VELO_G25
rev/min Progr. spindle speed limitation G25 Immediately
43220 SPIND_MAX_VELO_G26
rev/min Progr. spindle speed limitation G26 Immediately
43230 SPIND_MAX_VELO_LIMS
rev/min Spindle speed limitation with G96 Immediately
7-1 SINUMERIK 801

Start-Up
Technical Appendix
52011 STOP_CUTCOM_STORE
Alarm response for TRC and feedforward stop Immediately
– 1 0 1 BOOLEAN
SINUMERIK 801 7-2

Start-Up
Technical Appendix
SINUMERIK 801
Start-Up
Techncial Manual
Order No: A5E00702069
Edition: 2005.11
7-1 SINUMERIK 801

Start-Up
A5E00702069

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Start-Up 11/2005 Edition

User Documentation: Operation and Programming

Technical Documentation: Start-Up

User Documentation: Diagnostics Guide

SINUMERIK 801 Control System 1

11. 2005 Edition

Marking of edition in the “Note” column:

A ... ... New documentation.

Edition Order No. Note

Copyright Siemens AG 2005. All right reserved Exclusion of liability

© Siemens AG, 2005

Siemens-Aktiengesellschaft. SINUMERIK 801

Proper use Please observe the following:

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

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

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

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

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

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

SINUMERIK 801 III

1.1 System Overview

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

SINUMERIK 801 1-1

SINUMERIK 801 system

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

1-2 SINUMERIK 801

1.2 CNC Operator Panel

Layout of the CNC operator panel

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

Recall key Cursor DOWN (with shift: page down)

Softkey Cursor LEFT

Area switchover key Cursor RIGHT

ETC key Selection key/toggle key

SINUMERIK 801 1-3

Acknowledge alarm Delete key (backspace)

SPACE (INSERT) Vertical menu

ENTER / input key Shift key

MCP (Machine Control Panel) area

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

MANUAL DATA (with LED) SPINDLE STOP

Increment (with LED) SPINDLE START RIGHT

1-4 SINUMERIK 801

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)

SINUMERIK 801 1-5

1.3 Position of the Interfaces

Fig. 1-3 Position of SINUMERIK 801 interfaces

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1.4 Technical Data

90 (100) >100 176 (180) >50