siemens 802C User Manual

Start-Up 01/2002 Edition

SINUMERIK 802C

SINUMERIK 802C

Start–Up

Valid for
Control	Software Version
SINUMERIK 802C	3

01.2002 Edition

Numerical Control System 1

Installing the Control System 2

Installing the Drives

3

Start–Up

4

Update

5

Technical Appendix

6

Manual Machine

7

Index

11.02 6FC5298-6CA00-0AG3

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

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.

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.

Bestell-Nr. 6FC5597-3AA20-0BP2	Siemens–Aktiengesellschaft
Printed in the Federal Republic of Germany

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 precautions are not taken.

Warning

!indicates that loss of life, severe personal injury or substantial material damage may result if the appropriate precautions 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 precautions 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	v
6FC5 597–3AA20–0BP2 (01.02)

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

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	vii
6FC5 597–3AA20–0BP2 (01.02)

Table of Contents

notice

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

SINUMERIK 802C Control System

1

1.1Components 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:

SENC: Control component for a maximum of 3 analog axes and an analog interface for a main spindle drive (ENC = Economical Numerical Control)

SOP020: NC operator panel with graphics display and keyboard

SMCP: machine control panel

SDI/O16: 16 binary inputs/outputs each extendable to max. 64 by using 4 modules

SINUMERIK 802C	1-9
6FC5 597–3AA20–0BP2 (01.02)

SINUMERIK 802C Control System

1.1Components of the SINUMERIK 802C

OP020 MCP

INC JOG

REF

AUTO SBL

MDA

M

N

X

Y

Z

T

D

VM

+X

%

G E

7 >

8

9 +

K

Pg

-Z

+Z

F O

4 <

5

6

LA _

P

R

-X

S Q

1

2

3 =

AF U B V C W

Pg

M H

0

$

INS

%

ENCODER1ENCODER2

X10

X2003

X2005

X3

X4

MPG

IN

OUT

ERR

L+

0

0

POK

S2

1

1

DIAG

S3

2

2

3

3

4

4

5

5

D15

6

6

7

7

M

M

L+

8

8

9

9

10

10

DC24V X1

11

11

12

12

13

13

PE

14

14

15

15

M

M

M

L+

M

RS232ENCODER3SPINDLEAXIS

OPI

DI

X2004

X2006

X2

X5

X6

X7

X8

X20

ENC

DI/O

External analog drive

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

Software components

The SINUMERIK 802C comprises the following software components, which can be ordered:

SSystem software on the permanent flash memory of the ENC

–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”).

1-10	SINUMERIK 802C
	6FC5 597–3AA20–0BP2 (01.02)

SINUMERIK 802C Control System

1.1 Components of the SINUMERIK 802C

SToolbox

–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

SUpdate diskettes

–Update program with operator prompting system

–802C system software, packed, for loading and programming the SINUMERIK 802C via an update program.

User data

User data are:

SMachine data

SSetting data

STool data

SR parameters

SZero offsets

SCompensation data

SPart programs

SStandard cycles

Data saving

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	1-11
6FC5 597–3AA20–0BP2 (01.02)

SINUMERIK 802C Control System

1.2Technical data

1.2Technical data

Connected load

Table 1-1	Connected load
	Parameter	Min.		Typ.	Max.	Unit
Supply voltage		20.4			28.8	V
Ripple					3.6	Vss
Current consumption from 24 V			1			A		*
Power dissipation of ENC			15			W
Power dissipation of OP020			7			W
Power dissipation of MCP			-
Power dissipation of DI/O16			7			W		**
Start–up current					2.6	A
*	Basic configuration of ENC,			further DI/O16			connected
	OP020, MCP and DI/O16, all			will increase by 0.05 A each.
	outputs open,	**		at nominal load
	current consumption for any

Weight

Table 1-2	Weight
	Component	Weight [g]
ENC component		900 g
DI/O16 component		350 g
OP020 component		1,800 g
MCP component		1,200 g

Dimensions

Table 1-3	Component dimensions
	Component	Dimensions HxWxD [mm]
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

1-12	SINUMERIK 802C
	6FC5 597–3AA20–0BP2 (01.02)

SINUMERIK 802C Control System

1.2 Technical data

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		Transport: -40...70 °C
		Storage: –20 ... 55 °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

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.

Sfor ENC and DI/O16: IP 20

Sfor OP020 and MCP: IP 54 front

IP 00 rear

SINUMERIK 802C	1-13
6FC5 597–3AA20–0BP2 (01.02)

SINUMERIK 802C Control System

1.2Technical data

1-14	SINUMERIK 802C
	6FC5 597–3AA20–0BP2 (01.02)

Installing the Control System

2

2.1Installing and removing the SINUMERIK 802C

Warning

!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.

Approach

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.

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	2-15
6FC5 597–3AA20–0BP2 (01.02)

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

Installing the Control System

2.1Installing and removing the SINUMERIK 802C

Mounting dimensions

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

8			250						170
142
										300
										SubD
142			A
			F
	8		234						154	45
										8
										80
	Mounting	4,8
								482	40
										120
32,5			ENCODER1	ENCODER2			X10	X2003	X2005
								IN	OUT
			X3	X4			MPG		L+
	ERR
								0	0
	POK							1	1
	DIAG							2	2
								3	3
								4	4
								5	5
								6	6
57,2								7	7	125
								9	9
								M	M
									L+
								8	8
								10	10
	DC24V X1							11	11
								12	12
								13	13
20	L+							14	14
	M							15	15
	L+							M	M
	M	RS232	ENCODER3	SPINDLE	AXIS	OPI	DI
		X2	X5	X6	X7	X8	X20	X2004	X2006
		200						80
15
									40

Fig. 2-1 Mounting dimensions for SINUMERIK 802C

SINUMERIK 802C	2-17
6FC5 597–3AA20–0BP2 (01.02)

Installing the Control System

2.2Interfaces and cables

2.2Interfaces and cables

Position of the interfaces and front panel elements

		ECU					DI/O16
		ENCODER1 ENCODER2				X10	X2003	X2005
		X3	X4			MPG	IN	OUT
ERR								L+
							0	0
POK	S2						1	1
DIAG	S3						2	2
							3	3
							4	4
							5	5
	D15						6	6
							7	7
							M	M
								L+
							8	8
							9	9
							10	10
DC24V X1							11	11
							12	12
							13	13
PE							14	14
							15	15
M
							M	M
L+
M	RS232	ENCODER3	SPINDLE	AXIS	OPI	DI	X2004	X2006
	X2	X5	X6	X7	X8	X20

Fig. 2-2 User interfaces

	MCP	OP020
	Rear	Rear
	X1202	CFL
	X1201
		LCDsignal
	X1001 X1002 X1009	connector

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

2-18	SINUMERIK 802C
	6FC5 597–3AA20–0BP2 (01.02)

Installing the Control System

2.2 Interfaces and cables

Interfaces

ENC

SX1 power supply terminals (DC24V)

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

SX2 RS232 interface (V24)

9–pin sub–D plug connector

SX3 to X5 measuring system interfaces (ENCODER)

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

SX6 spindle interface (SPINDLE)

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

SX7 drive interface (AXIS)

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

SX8 operator terminal interface (OPI)

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

SX10 handwheel interface (MPG)

10–pin front connector for connecting the handwheels

SX20 digital inputs (DI)

10–pin front connector for connecting the NC READY relay

DI/O

SX2003 and X2004

10–pin front connector for connecting digital inputs

SX2005 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	2-19
6FC5 597–3AA20–0BP2 (01.02)

Installing the Control System

2.2Interfaces 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	X1		L+
			M	Wire (1.0...2.5)
ECU
								Machine
				RS232				Control
	X2							Panel
RS232				Op. Panel
						1)
OPI						flat or round
	X8			X1009	X1002X1001	cable	1)	X1202X1201
AXIS	X7			ANALOG DRIVE
						ANALOG MOTOR
				SPINDLE
				DRIVE
SPINDLE	X6
ENCODER					SPINDLE MOTOR
	–X5					ENCODER
ENCODER
	X3
MPG	X10			Hand Wheels
DI	X20			NC READY
DI/O16	X2003	X2004	IN					Sensor
								1...16
IN 0..7				Wire (0.14...1.5)
			M
IN 8..15
		X2006	L+
OUT0..7	X2005		OUT	Wire (0.14...1.5)				Actor
OUT8..15
			M					1...16
								M	P24	M P24
								Power Supply

Fig. 2-4 SINUMERIK 802C connection diagram

1) Ribbon cable (included in scope of supply)

2-20	SINUMERIK 802C
	6FC5 597–3AA20–0BP2 (01.02)

Installing the Control System

2.3 Connecting the individual components

2.3Connecting 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.

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

2.3.1Connecting 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	2-21
6FC5 597–3AA20–0BP2 (01.02)

Installing the Control System

2.3Connecting the individual components

Table 2-1		Pin assignment of connector X8
						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	25	13
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	14	1
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

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
						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	25	13
6	OPD3		I	19	OPCP1_N	I
7	OPCP1		I	20	OPCP2_N	I
8	OPCP2		I	21	OPS_N	I	14
9	OPS		I	22	OPTXD_N	O		1
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

2-22	SINUMERIK 802C
	6FC5 597–3AA20–0BP2 (01.02)

		Installing the Control System
	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

2.3.2Connecting 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	2-23
6FC5 597–3AA20–0BP2 (01.02)

Installing the Control System

2.3Connecting 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

1X axis

2Y axis

3Z axis

4Spindle

2-24	SINUMERIK 802C
	6FC5 597–3AA20–0BP2 (01.02)

Installing the Control System

2.3 Connecting the individual components

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

		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
34	18	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
50	33	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.

SSWn (SETPOINT)

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

SSn (REFERENCE SIGNAL)

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

SRFn (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	2-25
6FC5 597–3AA20–0BP2 (01.02)

Installing the Control System

2.3Connecting 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

2.3.3Connecting 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	15	8
4	P5_MS			VO	12	B_N	I
5				VO	13	B	I	9	1
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
Signal level
RS422
Signal type
VO			Voltage output (supply)
I			5V input (5V signal)

2-26	SINUMERIK 802C
	6FC5 597–3AA20–0BP2 (01.02)

Installing the Control System

2.3 Connecting the individual components

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
	signalsOutput signals:
	Track A as true and negated signal (Ua1,				)
				Ua1
	Track B as true and negated signal (Ua2,				)
				Ua2
	Zero signal N as true and negated signal
	(Ua0,		)
		Ua0
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:

Table 2-8	Maximum cable lengths depending on the encoder power supply
Supply Voltage		Tolerance			Current Consumption		Max. Cable 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 2-9	Maximum cable lengths depending on the transmission frequency
Encoder Type					Frequency		Max. Cable Length
incremental			1 MHz			10 m
			500 kHz			35 m

2.3.4Configuration 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	2-27
6FC5 597–3AA20–0BP2 (01.02)

Installing the Control System

2.3Connecting the individual components

Table 2-10 Pin assignment of connector X2

						X8
	Pin	Name	Type	Pin	Name	Type
	1			6	DSR	I		1
	2	RxD	I	7	RTS	O	6
	3	TxD	O	8	CTS	I	9	5
	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
	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	Name	25–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

2-28	SINUMERIK 802C
	6FC5 597–3AA20–0BP2 (01.02)

Installing the Control System

2.3 Connecting the individual components

2.3.5Connecting 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	1
	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

Signal names

A1, A1_N

B1, B1_N

A2, A2_N

B2, B2_N

P5_MS

M

Signal level

RS422

Signal type

VO

I

Handwheels

Track A, true and negated (handwheel 1) Track B, true and negated (handwheel 1) Track A, true and negated (handwheel 2) Track B, true and negated (handwheel 2) 5.2 V supply voltage for handwheels Supply ground

Voltage output

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	2-29
6FC5 597–3AA20–0BP2 (01.02)

Installing the Control System

2.3Connecting the individual components

Max. output frequency:	500 kHz
Phase offset between
tracks A and B:	90° "30°
Supply:	5 V, max. 250 mA

2.3.6Connecting 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	11
13	reserved	DI
14	reserved	DI
15	reserved	DI
16	reserved	DI
17	reserved	DI
18	reserved	DI	20
19	reserved	VI
20	reserved	VI
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	SINUMERIK 802C
	6FC5 597–3AA20–0BP2 (01.02)