siemens 802C User Manual

Start-Up 01/2002 Edition

SINUMERIK 802C

Numerical Control System 1

SINUMERIK 802C

Start–Up

Installing the Control System 2

Installing the Drives 3

Start–Up 4

Update 5

Valid for

Control Software Version

SINUMERIK 802C 3

01.2002 Edition

Technical Appendix 6

Manual Machine 7

Index

3ls

SINUMERIKDocumentation

Printing history

Brief details of this edition and previous editions are listed below.
IThe status of each edition is shown by the code in the ”Remarks” column.

Status code in the “Remarks” column:

A New documentation.. . . . .

B Unrevised reprint with new Order No.. . . . .

C Revised edition with new status. . . . . .

If actual changes have been made on the page since the last edition,
this is indicated by a new edition coding in the header on the page.

Edition Order–No. Remark

04.00 6FC5597-3AA20-0BP2 A

01.02 6FC5597-3AA20-0BP2 C

This Manual is included on the documentation on CD–ROM (DOCONCD)

Edition Order–No. Remark

11.02 6FC5298-6CA00-0AG3 C

Trademarks

SIMATICr, SIMATIC HMIr, SIMATIC NETr, SIROTECr, SINUMERIKr and SIMODRIVEr are registered
trademarks of Siemens. Third parties using for their own purposes any other names in this document which
refer to trademarks might infringe upon the rights of trademark owners.

This publication was produced with Interleaf V 7
The reproduction, transmission or use of this document or its

contents is not permitted without express written authority. Offenders
will be liable for demages. All rights, including rights created by patent
grant or registration of utility model or design, are reserved.



Siemens AG 2002. All rights reserved.

Printed in the Federal Republic of Germany

Other functions not described in this documentation might be
executable in the control. This does not, however, represent an
obligation to supply such functions with a new control or when
servicing.

We have checked that the contents of this document correspond to
the hardware and software described. Nonetheless, differences might
exist and therefore we cannot guarantee that they are completely
identical. The information contained in this document is, however,
reviewed regularly and any necessary changes will be included in the
next edition. We welcome suggestions for improvement.

Subject to change without prior notice.

Siemens–AktiengesellschaftBestell-Nr. 6FC5597-3AA20-0BP2

Safety notices

!

!

!

This Manual contains notices intended to ensure your personal safety and to avoid material damage. The notices
are highlighted by a warning triangle and, depending on the degree of hazard, represented as shown below:

Danger

indicates that loss of life, severe personal injury or substantial material damage will result if the appropriate pre-
cautions are not taken.

Warning

indicates that loss of life, severe personal injury or substantial material damage may result if the appropriate pre-
cautions are not taken.

Caution

indicates that minor personal injury or material damage may result if the appropriate precautions are not taken.

Caution

without a warning triangle means that a material damage can occur if the appropriate precau-
tions are not taken.

Attention

means that an undesirede event or status can occur if the appropriate note is not observed.

Note

is used to draw your special attention to an important information on the product, the handling of the product or the
corresponding part of the documentation.

Qualified personnel

Start–up and operation of a device may only be carried out by qualified personnel. Qualified personnel as refer­red to in the safety notices provided in this Manual are persons who are authorized to start up, ground and tag
devices, systems and circuits according to the relevant safety standards.

Usage as per intended purpose

Please observe the following:

Warning

!

The device may only be used for the cases of application, as intended by the Catalog, and only in conjunction with
third–party devices and components recommended or approved by Siemens.

The proper and safe operation of the product requires transport, storage and installation according to the relevant
instructions and qualified operation and maintenance at the prescribed intervals.

SINUMERIK 802C
6FC5 597–3AA20–0BP2 (01.02)

v

Table of Contents

Table of Contents

1 SINUMERIK 802C Control System 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Components of the SINUMERIK 802C 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Technical data 1-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Installing the Control System 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Installing and removing the SINUMERIK 802C 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Interfaces and cables 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Connecting the individual components 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.1 Connecting the operator panel 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.2 Connecting the feed drives and the spindle (X7) 2-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.3 Connecting the measuring systems (X3 ... X6) 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.4 Configuration of the RS232 interface connection (X8) 2-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.5 Connecting handwheels (X10) 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.6 Connecting NCREADY (X20) 2-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.7 Connecting the digital inputs and outputs (X2003 ... X2006) 2-31. . . . . . . . . . . . . . . . . . . . . . . . .

2.4 ENC and operator panel power supply (X1) 2-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 Grounding 2-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6 LEDs and operating elements on the ENC 2-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Installing the Drives 3-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Start-Up 4-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 General 4-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.1 Access levels 4-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.2 Structure of machine data (MD) and setting data (SD) 4-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.3 Handling machine data 4-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.4 Data saving 4-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Turning on and booting the control system 4-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1 Boot messages 4-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Starting up the PLC 4-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.1 Commissioning of the PLC 4-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.2 Start–up modes of the PLC 4-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.3 PLC alarms 4-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.4 Machine control panel (MCP) layout 4-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.5 PLC programming 4-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.6 Instruction set 4-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.7 Programm organization 4-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.8 Data organization 4-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.9 Interface to the control system 4-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.10 Testing and monitoring the user program 4-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 PLC applications “Download/Upload/Copy/Compare” 4-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 User Interface 4-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 Technology Setting 4-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 Commissioning 4-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.1 Entering the general machine data 4-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.2 Starting up the axes 4-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.3 Starting up the spindle 4-85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.4 Completing the Start–Up 4-87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.5 Cycle start–up 4-88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 Series machine start-up 4-89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vi

6FC5 597–3AA20–0BP2 (01.02)

SINUMERIK 802C

Table of Contents

5 Software Update 5-91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Updating the system software using a PC/PG 5-91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Updating the system software incl. user data without using a PC/PG 5-92. . . . . . . . . . . . . . . . . .

5.3 Update errors 5-93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Technical Appendix 6-94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 List of machine and setting data 6-94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.1 Display machine data 6-94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.2 General machine data 6-96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.3 Channel-specific machine data 6-96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.4 Axis-specific machine data 6-97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.5 Setting data 6-103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 PLC user interface signals 6-105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.1 Address ranges 6-105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.2 Retentive data area 6-106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.3 NCK signals 6-107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.4 Channel signals 6-108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.5 Axis/spindle signals 6-113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.6 Signals from/to MMC 6-116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.7 Machine control panel signals (MCP signals) 6-118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.8 PLC machine data 6-119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.9 User alarm 6-120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Application note: unipolar spindle control 6-123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Manual Machine 7-125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 Hardware and software requirements for the installation 7-125. . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 Loading the software 7-126. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 Switching the user interface 7-128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4 Switching the language 7-128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5 Additional machine data 7-129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.6 Input limitations with regard to the user interface 7-129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.7 Operation without machine control panel (MCP) 7-130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8 I/O assignment in the standard PLC program 7-130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8.1 Assignment of the digital inputs: 7-130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8.2 Assignment of the digital outputs: 7-132. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.9 Default assignment of special data for the “Manual machine” 7-133. . . . . . . . . . . . . . . . . . . . . . . .

SINUMERIK 802C
6FC5 597–3AA20–0BP2 (01.02)

vii

Table of Contents

notice

viii

6FC5 597–3AA20–0BP2 (01.02)

SINUMERIK 802C

SINUMERIK 802C Control System

1.1 Components of the SINUMERIK 802C

What is SINUMERIK?

The SINUMERIK 802C is a microprocessor–controlled numerical control system for simple
machine tools with stepper motor drives .

Hardware components

It consists of the following hardware components:
S ENC: Control component for a maximum of 3 analog axes and an analog interface for a

main spindle drive (ENC = Economical Numerical Control)

S OP020: NC operator panel with graphics display and keyboard
S MCP: machine control panel
S DI/O16: 16 binary inputs/outputs each extendable to max. 64 by using 4 modules

1

SINUMERIK 802C
6FC5 597–3AA20–0BP2 (01.02)

1-9

SINUMERIK 802C Control System

1.1 Components of the SINUMERIK 802C

OP020 MCP

M

X Y Z

N

+

>

E

7

859

G

<

O

F

4

6

Q

=

S

3

2

1

$

H

0

M

VM

T D

Pg

K

_

P

RAL

W

U

BVC

FA

Pg

INS

INCJOGREF

+X

-X

MDAAUTOSBL

%

+Z-Z

%

Fig. 1-1 SINUMERIK 802C hardware components (example configuration)

Software components

The SINUMERIK 802C comprises the following software components, which can be ordered:
S System software on the permanent flash memory of the ENC

ERR
POK
DIAG

DC24V X1

ENCODER1

X4

X3

S2
S3

D15

PE

M
L+
M

RS232

SPINDLE

ENCODER3

X2

X5

X6

X10
MPG

OPI

AXIS

DI

X8

X7

X20

ENCODER2

ENC DI/O

External analog
drive

X2003 X2005

IN

0
1
2
3
4
5
6
7
M

8
9
10
11
12
13
14
15
M

X2004 X2006

OUT
L+
0
1
2
3
4
5
6
7
M
L+
8
9
10
11
12
13
14
15
M

1-10

– Boot software,

loads the remaining system software from the permanent memory into the user me­mory (DRAM) and starts the system.

– MMC software (Man Machine Communication),

implements all operating functions

– NCK software (NC Kernel)

implements all NC functions. This software controls an NC channel with a maximum of
3 movement axes and a spindle.

– PLC software (Programmable Logic Control),

executes the integrated PLC user program cyclically.

– Integrated PLC user program

intended to adjust the SINUMERIK 802C to the machine functions (see also Descrip­tion of Functions “Integrated User Program for SINUMERIK 802C”).

6FC5 597–3AA20–0BP2 (01.02)

SINUMERIK 802C

User data

SINUMERIK 802C Control System

1.1 Components of the SINUMERIK 802C

S Toolbox

– WinPCIN transfer program for a PC/PG (programming device) to transfer user data and

programs

– Text manager
– Cycle kit for loading into the control system using WinPCIN
– User program library
– Technological machine data files
– Programming tool

S Update diskettes

– Update program with operator prompting system
– 802C system software, packed, for loading and programming the

SINUMERIK 802C via an update program.

User data are:

Data saving

!

S Machine data
S Setting data
S Tool data
S R parameters
S Zero offsets
S Compensation data
S Part programs
S Standard cycles

Modified user data are saved for at least 50 h after power off or power failure. After then, they
might get lost.

Warning

To avoid data loss, the operator must carry out data saving (see Section 4.1.4).

SINUMERIK 802C
6FC5 597–3AA20–0BP2 (01.02)

1-11

SINUMERIK 802C Control System

1.2 Technical data

1.2 Technical data

Connected load

Table 1-1 Connected load

Weight

Parameter

Supply voltage 20.4 28.8 V
Ripple 3.6 Vss
Current consumption from 24 V 1 A *
Power dissipation of ENC

Power dissipation of OP020
Power dissipation of MCP
Power dissipation of DI/O16

Start–up current 2.6 A

* Basic configuration of ENC,

OP020, MCP and DI/O16, all
outputs open,
current consumption for any

Table 1-2 Weight

Component

ENC component 900 g
DI/O16 component 350 g
OP020 component 1,800 g
MCP component 1,200 g

Min. Typ. Max. Unit

15
7

­7

further DI/O16 connected
will increase by 0.05 A each.

** at nominal load

Weight [g]

W
W

W

**

Dimensions

1-12

Table 1-3 Component dimensions

Component

ENC component 125 x 200 x 118
DI/O component 125 x 80 x 118
OP020 component 300 x 250 x 50
MCP component 300 x 170 x 50

Dimensions HxWxD [mm]

6FC5 597–3AA20–0BP2 (01.02)

SINUMERIK 802C

Environmental operating conditions

Table 1-4 Environmental operating conditions

Parameter

Temperature range 0...55 °C
Permissible relative humidity 5...95 % without condensation
Air pressure 700...1,060 hPa

The operating conditions comply with IEC 1131-2.
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 T ransport: -40...70 °C

Permissible relative air humidity 5...95 % without condensation
Air pressure 700...1,060 hPa
Transport height -1,000...3,000 m
Free fall in transport package v 1,200 mm

SINUMERIK 802C Control System

1.2 Technical data

Storage: –20 ... 55 °C

Protective quality and degree of protection

Class of protection I to IEC 536.
No PE terminal required.
Foreign matter and water protection to IEC 529.

S for ENC and DI/O16: IP 20
S for OP020 and MCP: IP 54 front

IP 00 rear

SINUMERIK 802C
6FC5 597–3AA20–0BP2 (01.02)

1-13

SINUMERIK 802C Control System

1.2 Technical data

1-14

6FC5 597–3AA20–0BP2 (01.02)

SINUMERIK 802C

Installing the Control System

2.1 Installing and removing the SINUMERIK 802C

Warning

!

Approach

Before performing any installation work, always first make sure that the system is disconnec­ted from the mains!

The modules contain electrostatically sensitive devices.
It must be ensured that persons without ESD protection never touch printed circuit boards or
components when handling operator and machine control panels.

Prior to installation, the machine control panel can be provided with a spindle override switch
and an emergency stop button. If these are not required, the openings must be covered with
the supplied self–adhesive covers.

2

1. Mount the spindle override switch.

2. Install the operator panel and the machine control panel.

3. Connect the panel using ribbon cable.

4. Install the DIN rail.

5. Connect the ENC and DI/O components.

Note

If you want to connect several DI/O16 components, it may be necessary to remove the right–
hand connector from the housing.

6. Slide the components onto the DIN rail, tilt it down and screw it tight.

Removing the control system

The control components are removed as described above in the reverse order.

SINUMERIK 802C
6FC5 597–3AA20–0BP2 (01.02)

2-15

Installing the Control System

2.1 Installing and removing the SINUMERIK 802C

Warning

!

Before removing the control components, always first make sure that the system is discon­nected from the mains!

2-16

6FC5 597–3AA20–0BP2 (01.02)

SINUMERIK 802C

Mounting dimensions

The dimensions shown below are important for installing the control components:

Installing the Control System

2.1 Installing and removing the SINUMERIK 802C

142

142 8

8 234

Mounting Holes

ERR

DC24V X1

POK
DIAG

L+
M
L+
M

32,5

57,2

20

15

250

170

300

SubD

A

F

154

8

45

80

4,8

482

ENCODER2

ENCODER1

X4

X3

RS232

SPINDLE

ENCODER3

X2

X5

OPI

AXIS

X6

X8

X7

200

X2003 X2005

X10

IN

MPG

0
1
2
3
4
5
6
7
M

8
9
10
11
12
13
14
15
M

DI

X2004 X2006

X20

80

40

120

OUT
L+
0
1
2
3
4
5
6
7
M
L+

8
9
10
11
12
13
14
15
M

125

40

Fig. 2-1 Mounting dimensions for SINUMERIK 802C

SINUMERIK 802C
6FC5 597–3AA20–0BP2 (01.02)

2-17

Installing the Control System

2.2 Interfaces and cables

2.2 Interfaces and cables

Position of the interfaces and front panel elements

ERR
POK
DIAG

DC24V X1

S2
S3

D15

PE

M
L+
M

RS232

Fig. 2-2 User interfaces

MCP

Rear

X1202

X1201

X2

ECU DI/O16

ENCODER1
X3

ENCODER3

X5

ENCODER2
X4

SPINDLE
X6

AXIS
X7

X10
MPG

OPI

DI

X8

X20

X2003 X2005

X2004 X2006

OP020

Rear

IN

0
1
2
3
4
5
6
7
M

8
9
10
11
12
13
14
15
M

OUT
L+
0

1
2
3
4
5
6
7
M
L+
8
9
10
11
12
13
14
15
M

CFL

X1001 X1002 X1009

Fig. 2-3 Rear of machine control panel and operator panel

LCD- signal
connector

2-18

6FC5 597–3AA20–0BP2 (01.02)

SINUMERIK 802C

Interfaces

Installing the Control System

2.2 Interfaces and cables

ENC
S X1 power supply terminals (DC24V)

4–pin screw–type terminal block for connecting the 24 V load power supply

S X2 RS232 interface (V24)

9–pin sub–D plug connector

S X3 to X5 measuring system interfaces (ENCODER)

three 15–pin sub–D plug connectors for connecting incremental position encoders (RS422)

S X6 spindle interface (SPINDLE)

9–pin sub–D socket for connecting a spindle drive with analog interface

S X7 drive interface (AXIS)

50–pin sub–D socket connector for connecting the power sections for a maximum of four
analog drives including spindle

S X8 operator terminal interface (OPI)

25–pin D–Sub female connector for connecting the operator terminal

S X10 handwheel interface (MPG)

10–pin front connector for connecting the handwheels

S X20 digital inputs (DI)

10–pin front connector for connecting the NC READY relay

DI/O
S X2003 and X2004

10–pin front connector for connecting digital inputs

S X2005 and X2006

10–pin front connector for connecting digital outputs

LEDs

3 LEDs for fault and status displays

Operating elements

Start–up switch S

SINUMERIK 802C
6FC5 597–3AA20–0BP2 (01.02)

2-19

Installing the Control System

2.2 Interfaces and cables

Connecting cables

The components are wired up as shown in the Connection Diagram 2-4. For the cables requi­red, please refer to the diagram below.

DC24V

ECU

RS232

OPI

AXIS

SPINDLE
ENCODER

ENCODER

MPG

X1X2X8

X7X6X10

X3–X5

L+
M

Wire (1.0...2.5)

Machine

RS232

Op. Panel

Control
Panel

1)

X1201X1202

X1009

ANALOG DRIVE

X1001X1002

flat or round
cable

1)

ANALOG MOTOR

SPINDLE
DRIVE

SPINDLE MOTOR

ENCODER

Hand Wheels

DI

X20X2003

DI/O16

IN 0..7
IN 8..15

OUT0..7
OUT8..15

IN

M

X2004

L+
OUT
M

X2006

X2005

Wire (0.14...1.5)

Wire (0.14...1.5)

Fig. 2-4 SINUMERIK 802C connection diagram

1) Ribbon cable (included in scope of supply)

NC READY

Sensor

1...16

Actor

1...16

P24M

Power Supply

P24M

2-20

6FC5 597–3AA20–0BP2 (01.02)

SINUMERIK 802C

2.3 Connecting the individual components

2.3 Connecting the individual components

Connecting the components

Note

Use only shielded cable and make sure that the shield is connected to the metal or metal pla­ted connector casing on the control side. For the purpose of isolating the analog setpoint si­gnal from low–frequency interference, we recommend not to ground the shield on the drive
side.

The preassembled cable offered as accessories provides optimum protection against interfe­rence.

General procedure:

Proceed as follows to connect the individual components:

1. Connect the cables to the components as shown in Fig. 2-4.

Installing the Control System

2. Fix the sub–D connector in place using the knurled screws.

2.3.1 Connecting the operator panel

Connector pin assignment on the ENC side

Operator panel interface

Connector designation: X8

OP020

Connector type: 25–pin sub–D plug connector

SINUMERIK 802C
6FC5 597–3AA20–0BP2 (01.02)

2-21

Installing the Control System

1

2.3 Connecting the individual components

Table 2-1 Pin assignment of connector X8

Pin Signal Type Pin Signal Type
1 14 P24_OP VO
2 M_OP VO 15 OPD0_N O
3 OPD0 O 16 OPD1_N O
4 OPD1 O 17 OPD2_N O
5 OPD2 O 18 OPD3_N O
6 OPD3 O 19 OPCP1_N O
7 OPCP1 O 20 OPCP2_N O
8 OPCP2 O 21 OPS_N O
9 OPS O 22 ENRXD_N I
10 ENRXD I 23 ENTXD_N O
11 ENTXD O 24 ENRTS_N O
12 ENRTS O 25 P24_OP VO
13 M_OP VO

X8

14

14

25

13

13

1

Connector pin assignment on the OP side

Operator panel interface

Connector designation: X1009

OP020

Connector type: 25–pin sub–D plug connector

Table 2-2 Pin assignment of connector X1009

Pin Signal Type Pin Signal Type
1 14 P24_OP VI
2 M_OP VI 15 OPD0_N I
3 OPD0 I 16 OPD1_N I
4 OPD1 I 17 OPD2_N I
5 OPD2 I 18 OPD3_N I
6 OPD3 I 19 OPCP1_N I
7 OPCP1 I 20 OPCP2_N I
8 OPCP2 I 21 OPS_N I
9 OPS I 22 OPTXD_N O
10 OPTXD O 23 OPRXD_N I
11 OPRXD I 24 OPCTS_N I
12 OPCTS I 25 P24_OP VI
13 M_OP VI

X1009

14

25

13

1

2-22

6FC5 597–3AA20–0BP2 (01.02)

SINUMERIK 802C

2.3 Connecting the individual components

Signal names

OPD[0...3] LCD Data 0...3
OPCP1 LCD Latch
OPS LCD Frame
OPCP2 LCD Clock
OPRXD OP Receive Data
OPTXD OP Transmit Data
OPCTS OP Clear to Send
ENRXD ECU Receive Data
ENTXD ECU Transmit Data
ENRTS ECU Request to Send
P24_OP DC24V
M_OP Ground

Signal level

RS422 / LVDS

Signal type

VO Voltage output
VI Voltage input
O Output
I Input

Installing the Control System

2.3.2 Connecting the feed drives and the spindle (X7)

Connector pin assignment on the ENC side

Feed drive interface

Connector designation: X7

AXIS 1-4

Connector type: 50–pin sub–D plug connector

Table 2-3 Pin assignment of connector X7

X7

Pin Signal Type Pin Signal Type Pin Signal Type
1 SW1 VO 18 34 BS1 VO
2 BS2 VO 19 35 SW2 VO
3 SW3 VO 20 36 BS3 VO
4 BS4 VO 21 37 SW4 VO
5 22 38
6 23 39
7 24 40
8 25 41
9 26 42
10 27 43

SINUMERIK 802C
6FC5 597–3AA20–0BP2 (01.02)

2-23

Installing the Control System

2.3 Connecting the individual components

11 28 44
12 29 45
13 30 46
14 RF1.1 K 31 47 RF1.2 K
15 RF2.1 K 32 48 RF2.2 K
16 RF3.1 K 33 49 RF3.2 K
17 RF4.1 K 50 RF4.2 K

Signal names

SWn Setpoint
BSn Reference potential for setpoint
RFn.1, RFn.2 Servo enable contact

Signal level

RS422

Signal type

O Signal output

Axis assignment

1 X axis
2 Y axis
3 Z axis
4 Spindle

2-24

6FC5 597–3AA20–0BP2 (01.02)

SINUMERIK 802C

2.3 Connecting the individual components

Table 2-4 Cable assignment (for type 6FX2 002–3AD01)

Installing the Control System

34

18

33

50

NC Side

Cable Drive Side

PIN Core Color Signal Name PIN

14 black 1st axis 1.9
47 brown 1.65
34 red 1.4
1 orange 1.56
15 yellow 2nd axis 2.9

1

48 green 2.65
2 blue 2.14
35 purple 2.56
16 gray 3rd axis 3.9
49 pink 3.65
36 white/black 3.14

17

3 white/brown 3.56
17 white/red Spindle 4.9
50 white/orange 4.65
4 white/yellow 4.14
37 white/green 4.56

Drives with analog interface Signals

One voltage and one enable signal each is output.

S SWn (SETPOINT)

Analog voltage signal in the range "10 V to output a speed setpoint

S Sn (REFERENCE SIGNAL)

Reference potential (analog ground) for the setpoint signal, internally connected to logic ground.

S RFn (SERVO ENABLE)

Relay contact pair controlling the enable of the power section, e.g. of a SIMODRIVE drive unit
controlled via a PLC program.

Signal parameters

The setpoint is output as an analog differential signal.

Table 2-5 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

SINUMERIK 802C
6FC5 597–3AA20–0BP2 (01.02)

2-25

Installing the Control System

2.3 Connecting the individual components

Relay contact

Table 2-6 Electrical parameters of the relay contacts RFn.1 and RFn.2

Parameter Max. Unit

Switching voltage 50 V
Switching current 1 A
Switching power 30 VA

Cable length: max. 35 m

2.3.3 Connecting the measuring systems (X3 ... X6)

Pin assignment of the connector on the ENC side

Measuring system interface (incremental encoder)

Connector designation: X3 ... X6

ENCODER

Connector type: 15–pin sub–D plug connector

Table 2-7 Pin assignment of the female connector X3 ... X6

X3 ... X6

Pin Signal Type Pin Signal Type

1 9 M VO
2 10 N I
3 11 N_N I
4 P5_MS VO 12 B_N I
5 VO 13 B I
6 P5_MS VO 14 A_N I
7 M VO 15 A I
8

Signal names

A, A_N Track A (true and negated)
B, B_N Track B (true and negated)
N, N_N Zero mark (true and negated)
P5_MS +5.2 V supply
M Supply ground

15

8

9

1

2-26

Signal level

RS422

Signal type

VO Voltage output (supply)
I 5V input (5V signal)

6FC5 597–3AA20–0BP2 (01.02)

SINUMERIK 802C

Connectable encoder types

Installing the Control System

2.3 Connecting the individual components

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

Track A as true and negated signal (U

Max. output frequency: 1.5 MHz
Phase offset between
tracks A and B: 90° "30°
Current consumption: max. 300 mA

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:

signalsOutput signals:

a1

Track B as true and negated signal (U
Zero signal N as true and negated signal

, Ua0)

(U

a0

a2

, Ua1)
, Ua2)

Table 2-8 Maximum cable lengths depending on the encoder power supply

Supply Voltage

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 2-9 Maximum cable lengths depending on the transmission frequency

Encoder Type

incremental

Tolerance Current Consumption Max. Cable Length

Frequency Max. Cable Length

1 MHz 10 m
500 kHz 35 m

2.3.4 Configuration of the RS232 interface connection (X8)

Pin assignment of the connector on the ENC side

RS232 interface

Connector designation: X2

RS232

Connector type: 9–pin sub–D plug connector

SINUMERIK 802C
6FC5 597–3AA20–0BP2 (01.02)

2-27

Installing the Control System

2.3 Connecting the individual components

Table 2-10 Pin assignment of connector X2

Pin Name Type Pin Name Type
1 6 DSR I
2 RxD I 7 RTS O
3 TxD O 8 CTS I
4 DTR O 9
5 M VO

Signal description:

RxD Receive data
TxD Send data
RTS Request to send
CTS Send enable
DTR Standby output
DSR Standby input
M Ground

X8

6

9

1

5

Signal level

RS232 (+ 12 V)

Signal type

I Input
O Output
VO Voltage output

Cable for WinPCIN

Table 2-11 Cable for WinPCIN: Pin assignment of the Sub–D connector

9–Pin

1 Shield 1
2 RxD 2
3 TxD 3
4 DTR 6
5 M 7
6 DSR 20
7 RTS 5
8 CTS 4
9

Name 25–Pin

2-28

6FC5 597–3AA20–0BP2 (01.02)

SINUMERIK 802C

2.3.5 Connecting handwheels (X10)

Pin assignment of the connector on the ENC side

Handwheel interface
Connector designation: X10

MPG

Connector type: 10–pin mini-Combicon plug connector

Table 2-12 Pin assignment of connector

X10

X10

Pin Name Type
1 A1 I
2 A1_N I
3 B1 I
4 B1_N I
5 P5_MS VO
6 M5_MS VO
7 A2 I
8 A2_N I 10
9 B2 I
10 B2_N I

Installing the Control System

2.3 Connecting the individual components

1

Handwheels

Signal names

A1, A1_N Track A, true and negated (handwheel 1)
B1, B1_N Track B, true and negated (handwheel 1)
A2, A2_N Track A, true and negated (handwheel 2)
B2, B2_N Track B, true and negated (handwheel 2)
P5_MS 5.2 V supply voltage for handwheels
M Supply ground

Signal level

RS422

Signal type

VO Voltage output
I Input (5 V signal)

Two electronic handwheels 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, Ua1)

Track B as true and negated signal (Ua2, Ua2)

SINUMERIK 802C
6FC5 597–3AA20–0BP2 (01.02)

2-29

Installing the Control System

2.3 Connecting the individual components

Max. output frequency: 500 kHz
Phase offset between

tracks A and B: 90° "30°
Supply: 5 V, max. 250 mA

2.3.6 Connecting NCREADY (X20)

Pin assignment of the connector on the ENC side

BERO input interface
Connector designation: X20

DI

Connector type: 10–pin plug connector

Table 2-13Pin assignment of connector X20

X20

Pin Name Type
11 NCRDY_1 K
12 NCRDY_2 K
13 reserved DI
14 reserved DI
15 reserved DI
16 reserved DI
17 reserved DI
18 reserved DI
19 reserved VI
20 reserved VI

11

20

20

Signal names

NCRDY_1...2 NC Ready (NCREADY contacts 1...2)

Signal type

K Switching contact

NC-READY output

Readiness in the form of a relay contact (NO); must be integrated into the EMERGENCY
STOP circuit.

2-30

6FC5 597–3AA20–0BP2 (01.02)

SINUMERIK 802C