SINUMERIK 802S base line

The SINUMERIK for an easy entry into the CNC world

April 2010
SINUMERIK
Answers for industry.
Siemens AG 2010
SINUMERIK 802S base line 2
SINUMERIK 802S base line
System overview
Overview
The combination of SINUMERIK 802S base line with the SINAMICS V60 servo drive and 1FL5 servo motors
provides a perfect solution for the cost-effective, simple implementation of control tasks for machine tools.
SINUMERIK 802S base line
SINUMERIK 802S base line, the CNC from Siemens for applica-
tions in the lower performance class is ideally suited for
turning and milling machines with up to 3 axes and a spindle.
Its key characteristics are:
Extremely easy operation and programming
Maintenance-free
Compact design
The SINUMERIK 802S base line is dimensioned for a maximum
of three feed axes and one spindle. The feed axes are linked to
the SINAMICS V60 servo drives via a pulse/direction interface.
The spindle drive is controlled by means of an analog interface
(10 V). All control components, including the machine
control panel and input/output module, are integrated in the
operator panel. The integrated PLC for perfect adaptation to
the machine tool is programmed by a PC tool using Ladder
Diagram (LAD) notation. The programming tool is included in
the scope of supply.
SINAMICS V60 drive system with 1FL5 servo motors
The Controlled Power Modules (CPM60.1) of the SINAMICS
V60 drive system are specially designed to control feed axes in
simple machine tool applications. The CPM60.1 are designed
for operation in combination with 1FL5 servo motors.
SINAMICS V60 CPM60.1 modules and 1FL5 servo motors in
combination with the preconfigured cables provide a ready-
to-run drive system for the SINUMERIK 802S base line.
The CNC sends setpoints over the reliable pulse/direction
interface to the drive. The drive converts these setpoints to
the motor in form of a closed loop control.
The use of the pulse/direction interface in conjunction with
the servo motor combines the simplicity of a stepper drive
control and the performance of the servo drive providing the
best combination for this power range.
SINUMERIK 802S base line SINAMICS V60-CPM60.1 1FL5 servo motors
Siemens AG 2010
SINUMERIK 802S base line 3
SINUMERIK 802S base line
The perfect CNC for simple applications
The perfect control system for the entry level:
Easy to operate and program
Tools and workpieces can be set up quickly and easily
Programming with cycle and contour support.
The CNC system for a broad range of applications:
Controls up to 3 axes and 1 spindle
Complete, compact-sized unit
Maintenance-free, because no batteries or fans are
required
Easy connection to the SINAMICS V60 by means of pulse/di-
rection interface (feed axes) or 10 V analog interface
(spindle)
Standard solution with worldwide service support for
numerous different applications.
The SINUMERIK 802S base line offers you many benefits:
Easy CNC programming in DIN 66025
Easy tool measurement by scratching
Contour elements for graphical programming
Cycle support for complex applications
Compensation of leadscrew errors, backlash and measur-
ing system errors for accurate machining results.
Turning cycles:
Grooving
Undercutting
Stock removal
Thread cutting
Drilling, end facing
Deep-hole drilling
Tapping with compensating chuck/rigid tapping
Boring
Milling cycles:
Deep-hole drilling
Thread cutting with/without compensating chuck
Series of holes circle
Series of holes straight line
Drilling, countersinking
Milling of pockets, grooves and circular pockets
Further features:
Execution from external source can process even
large CNC programs over the RS 232 C (V.24) interface
Manual machine a turning machine can also be operated
as a conventional (cycles) machine.
Teach-in function (optional) program input by means of
handwheels or direction keys
Extremely robust thanks to compact design
High-performance PLC for perfect adaptation to the
machine tool (compatible with SIMATIC S7-200)
SINUMERIK 802S base line
1)

1)
Emergency OFF button not included in scope of supply.
Siemens AG 2010
SINUMERIK 802S base line 4
SINUMERIK 802S base line
Contour element programming
Programming
Program input according to DIN 66025
High-level language elements and R parameters for modu-
lar and efficient programming
Graphical programming with contour elements
Integrated turning and milling cycles with graphical screen
Teach-in function (optional) for program input by means of
handwheels or direction keys
Tool offsets
Tool management
15 tools and 30 cutting edges
Tool length compensation
2D tool radius compensation
Measuring cycles for simple workpiece and tool
measurements
PLC programming
PLC
Integrated high-speed PLC based on SIMATIC S7-200
Up to 4000 instructions
Programming with Ladder Diagram notation (LAD)
User-friendly programming tool supplied with the control
system.
Programming tool supports Englisch and German
Siemens AG 2010
SINUMERIK 802S base line 5
Integration
Pulse/direction interface
Legend:
Spindle drive
(not in scope of supply)
Feed drives
1FL5 motor
6FX2002-3AD02-...
10 V
SINAMICS V60 CPM60.1
SINUMERIK 802S base line
Configuration example for a milling machine
Benefits
3 servo axes (pulse/direction interface,
5 V difference signals) and 1 spindle (10 V)
8" LCD flat panel display (monochrome)
256 KB of part program memory
Handwheel function (max. 2 handwheels)
Serial interface RS 232 C
Operator panel front rated for IP65 protection degree
12 customer keys with LED for free assignment and
labeling by user
48 integrated digital inputs and 16 integrated digital
outputs
Extension module with 16 digital inputs and 16 digital
outputs (max. 2 modules)
Emergency stop button can be integrated in the panel
PLC with LAD (Ladder Diagram) programming
Look Ahead function for smooth CNC program
execution
Up to 15 tools, 30 cutting edges
Pocket calculator function
Teach-in (optional)
Servo trace tool for drive diagnostics
User interface with 11 languages (English, Chinese
simplified, Czech, French, German, Hungarian, Italian,
Polish, Russian, Spanish and Turkish)
2 languages switchable online without restart
6FX8002-1AA01-....
6FX8002-2BB01-....
6FX2002-3AD02-....
RS 232 C
X2
X6
X10
X7
X20
X100 ... X105
X200/X201
X2004/X2003
X2006/X2005
X1
6FX8002-2CD01-....
DI
DO
SINUMERIK
802S
base line
Adapter
module
Digital I/O
module
16I/16O
Frequency
converter for
spindle drive
Handwheel
4 BEROs
24 V DC
Order No.
Pre-assembled cable
25 m for handwheel signals
Setpoint cable
Power supply
24 V DC
Wire (1.0 to 2.0 mm
2
)
Incremental
encoder for spindle
(TTL) RS 422
6FX2001-2...
Wire (0.14 to 1.5 mm
2
)
Wire (0.14 to 1.5 mm
2
)
48 digital inputs
24 V DC
Wire (0.14 to 1.5 mm
2
)
16 digital
outputs
24 V DC
Wire (0.14 to 1.5 mm
2
)
16 digital inputs
24 V DC
Wire (0.14 to 1.5 mm
2
)
16 digital
outputs
24 V DC
SlNAMlCS V60
CPM60.1
Connection overview for SINUMERIK 802S base line
SINAMICS V60 CPM60.1
Siemens AG 2010
SINAMICS V60 servo drive / 1FL5 servo motor 6
SINAMICS V60 servo drive / 1FL5 servo motor
SINAMICS V60 servo drive
The SINAMICS V60 CPM60.1 servo drive is specially designed
to control the feed axes in simple machine tool applications.
The system is designed primarily for applications where
cost effectiveness is the primary consideration. The key
performance data of the drive are aligned to perfectly fit to the
SINUMERIK 802S base line offering a perfect system solution.
Compact module with integrated infeed, inverter and
closed-loop position control for one feed axis
4 versions with output currents of 4 A, 6 A, 7 A and 10 A
Pulse/direction setpoint interface (5 V difference signals) to
the higher-level control system
No cooling fans needed thanks to large heat sink made of
die-cast aluminum
Commissioning and configuring without PC-based tools
Very simple commissioning using keys/7-segment display
200 % overload capability
Supply voltage 220 V to 240 V 3 AC
Preconfigured motor data stored in the drive (no commis-
sioning required)
CE certified
1FL5 servo motor
The 1FL5 servo motor is optimized for operation with the
SINAMICS V60 servo drive and provides the dynamic perfor-
mance required by machine tools.
4 motor types with 4 Nm, 6 Nm, 7.7 Nm and 10 Nm
Rated speed of 2000 rpm
Integrated TTL encoder with 2500 PPR
(13-bit resolution through electronic multiplication of the
CPM60.1 module)
Degree of protection IP54, natural cooling
Optional holding brake
Rugged connector design with solderable connectors
Pre-assembled cables of 5 m or 10 m in length
SINAMICS V60 and 1FL5 servo motors combine to provide a
perfectly coordinated axis package. The components are
generally delivered in a bundle (drive, motor and cables) for
one axis (axis package). in order to simplify the engineering
and ordering processes.
The pre-assembled motor/drive combination ensures quick
and easy commissioning. The rugged design offers an
optimum combination of functionality and the necessary
technology.
SINAMICS V60 CPM60.1 1FL5 servo motor
Siemens AG 2010
SINAMICS V60 CPM60.1 servo drive 7
SINAMICS V60 CPM60.1 servo drive
Technical data
1)
Minimum distances: 25 mm between drive modules,
100 mm from other control cabinet components.
CPM60.1 Controlled Power Module
Type 6SL3210-5CC14-0... 6SL3210-5CC16-0... 6SL3210-5CC17-0... 6SL3210-5CC21-0...
Product name CPM60.1 Controlled Power Module
Input voltage 220 ... 240 V -15 %/+10 % 3 AC
Input frequency 50 60 Hz 10 %
Infeed Non-stabilized
Electronics power supply 24 V DC -15 %/+20 %
24 V DC supply 0.8 A (1.4 A) combined with motors without brake (with brake)
Input voltage
pulse/direction interface
Rated value 5 V DC
Frequency range 333 kHz
Cooling Natural cooling
Ambient temperature
Storage/transport -20 ... 80 C
In operation 0 ... 45 C without derating,
> 45 ... 55 C derating to 70 %
Air humidity < 95 %
Site altitude Up ... 1000 m without derating,
> 1000 ... 2000 m derating to 80 %
Conductor cross-section, max. 2.5 mm
2
Connectable motors 1FL5
Degree of protection IP20
Encoder evaluation TTL encoder with 2500 PPR (13 bit resolution through electronic multiplication)
Output current
Rated current I
rated
4 A 6 A 7 A 10 A
Peak current I
max
8 A 12 A 14 A 20 A
Rated power P
rated
0.8 kW 1.2 kW 1.4 kW 2 kW
Power loss 36 W 47 W 54 W 70 W
Cooling air required 0.005 m
3
/s 0.005 m
3
/s 0.005 m
3
/s 0.005 m
3
/s
Sound pressure level L
pA
(1 m) < 45 dB < 45 dB < 45 dB < 45 dB
Dimensions
1)
Width 106 mm 106 mm 106 mm 123 mm
Height 226 mm 226 mm 226 mm 226 mm
Depth 200 mm 200 mm 200 mm 200 mm
Weight 2.63 kg 2.63 kg 2.63 kg 3.44 kg
Certification CE
Siemens AG 2010
1FL5 servo motors 8
1FL5 servo motors
Technical data
Dimensions
1FL5 servo motors
Type
1FL5060-... 1FL5062-... 1FL5064-... 1FL5066-...
Product name 1FL5 servo motor
Rated speed 2000 rpm
Encoder TTL encoder with 2500 PPR
Type of construction in
accordance with EN 60034-7
(IEC 60034-7)
IM B5 (IM V1, IM V3)
Degree of protection in accor-
dance with EN 60034-5
(IEC 60034-5)
IP65
Cooling Natural cooling
Shaft end in accordance with
DIN 748-3 (IEC 60072-1)
Plain shaft
Paint finish Black
Insulation of the stator winding
in accordance with EN 600034-1 (IEC
60034-1)
Temperature class 130 (B)
Ambient temperature
Storage/transport -20 ... 80 C
In operation 0 ... 45 C without derating, > 45 ... 55 C derating to 70 %
Torque
Rated torque M
rated
4 Nm 6 Nm 7.7 Nm 10 Nm
Torque max. M
max

(converter)
8 Nm 12 Nm 15.4 Nm 20 Nm
Rated power 0.8 kW 1.2 kW 1.5 kW 2.0 kW
Moment of inertia 11,01 10
-4
kgm
2
15,44 10
-4
kgm
2
20,17 10
-4
kgm
2
25,95 10
-4
kgm
2
Dimensions
Edge dimension 130 mm 130 mm 130 mm 130 mm
Length (without/with brake) 221/263 mm 239/281 mm 253/295 mm 277/319 mm
Weight (without/with brake) 6/8.6 kg 7.6/10.2 kg 8.6/11.2 kg 10.6/13.2 kg
Certification CE
4
5

2
B
A
12 3
0
20
50
G_NC01_XX_00428

2
2

2
5

1
1
0

8
5

145
4x9
1
1
2
6
130
Motor
variants
Nm
A
without brake
(with brake)
mm
B
mm
4 163 (205) 80
6 181 (223) 98
7.7 195 (237) 112
10 219 (261) 136
PPR = pulses per revolution
Siemens AG 2010
Ordering data 9
Ordering data
Ordering data for SINUMERIK 802S base line
Ordering data spare parts
1)
For length codes, refer to Catalog NC 61 2010
Ordering data for axis package
Integration
Description Order No.
SINUMERIK 802S base line basic package
consisting of:
Operator panel control incl. machine control
panel, I/Os 48/16 DI/O, Toolbox (CD)
6FC5500-0AA00-1AA0
Setpoint cable for SINUMERIK 802S base line
- Control of up to 3 CPM60.1 modules
- Control of an analog spindle
- Length maximum 35 m
6FX2002-3AD02-.
1)

Emergency stop button
on the operator panel
Actuating element
Contact block
3SB3000-1HA20
3SB3400-0A
Adapter module with assembly material
For a single expansion of the inputs/outputs
with 16I/16O digital I/O module
6FC5511-0CB00-0AA0
SINUMERIK 802S/802C digital
I/O module, 16I/16O
6FC5511-0CA00-0AA0
SINUMERIK 802 option
Teach-in single-user license (label)
6FC5571-0AA01-0BF0
Electronic handwheel 6FC9320-5DC01
1)
Description Order No.
SINAMICS V60 CPM60.1 - 4 A 6SL3210-5CC14-0UA0
SINAMICS V60 CPM60.1 - 6 A 6SL3210-5CC16-0UA0
SINAMICS V60 CPM60.1 - 7 A 6SL3210-5CC17-0UA0
SINAMICS V60 CPM60.1 - 10 A 6SL3210-5CC21-0UA0
1FL5 servo motor - 4 Nm - without holding
brake
1FL5060-0AC21-0AG0
1FL5 servo motor - 4 Nm - with holding brake 1FL5060-0AC21-0AH0
1FL5 servo motor - 6 Nm - without holding
brake
1FL5062-0AC21-0AG0
1FL5 servo motor - 6 Nm - with holding brake 1FL5062-0AC21-0AH0
1FL5 servo motor - 7.7 Nm -
without holding brake
1FL5064-0AC21-0AG0
1FL5 servo motor - 7.7 Nm - with holding brake 1FL5064-0AC21-0AH0
1FL5 servo motor - 10 Nm - without holding
brake
1FL5066-0AC21-0AG0
1FL5 servo motor - 10 Nm - with holding brake 1FL5066-0AC21-0AH0
Signal cable for 1FL5 servo motor - 5 m 6FX6002-2LE00-1AF0
Signal cable for 1FL5 servo motor - 10 m 6FX6002-2LE00-1BA0
Power cable for 1FL5 servo motor - 5 m 6FX6002-5LE00-1AF0
Power cable for 1FL5 servo motor - 10 m 6FX6002-5LE00-1BA0
Brake cable for 1FL5 servo motor - 5 m 6FX6002-2BR00-1AF0
Brake cable for 1FL5 servo motor - 10 m 6FX6002-2BR00-1BA0
1FL5 CPM60.1 Axis kit
4 Nm 4 A
6FC5548-0AF02- 7 7 7 0
6 Nm 6 A
6FC5548-0AF03- 7 7 7 0
7.7 Nm 7 A 6FC5548-0AF04- 7 7 7 0
10 Nm 10 A
6FC5548-0AF05- 7 7 7 0
1FL5 servo motor:
Without holding brake 0
With holding brake 1
Cable length:
5 m A F
10 m B A
6FX2002-3AD02-....
X5
X7
SINAMICS V60
CPM60.1
35 m
SINUMERIK 802S
base line
X4
L1 / L2 / L3
U / V / W
X6
X3
Enable pulses
24 V DC power
supply
230 V AC main
supply
TTL encoder in
1FL5 motor
Included in the axis package
5 m or 10 m
1FL5 motor
Included in the axis package
5 m or 10 m
Brake in
1FL5 motor
Included in the axis package
5 m or 10 m
Order No.
Pre-assembled cable
Connection overview of SINAMICS V60 drive system
Siemens AG 2010
The information provided in this brochure contains descriptions
or characteristics of performance which in case of actual use
do not always apply as described or which may change as a result
of further development of the products.
An obligation to provide the respective characteristics shall
only exist if expressly agreed in the terms of contract.
Availability and technical specifications are subject to change
without prior notice.
All product designations may be trademarks or product names
of Siemens AG or supplier companies whose use by third parties
for their own purposes could violate the rights of the owners. www.siemens.com/sinumerik
Subject to change without prior notice
Order No.: 6ZB5411-0CB02-0BA0
3P.8222.03.02 / Dispo 09400
BS 0410 5.0 SB 10 En
Printed in Germany
Siemens AG 2010
Siemens AG
Industry Sector
Drive Technologies Division
Motion Control Systems
Postfach 31 80
91050 ERLANGEN
GERMANY
Further information
SINUMERIK 802S base line
www.siemens.com/sinumerik802
Service & Support
support.automation.siemens.com
Industry Mall
www.siemens.com/industrymall
Documentation
www.automation.siemens.com/doconweb
Siemens AG 2010