siemens 802D User Manual

The Control System 1

Installing the

SINUMERIK 802D
SINUMERIK 802D base line

Commissioning Manual

Control System

Commissioning 3

Starting up the Spindle 4

Starting up the PLC 5

Series Machine Start−up
Data Backup

Software Update 7

2

6

Valid for

Control system Software version

SINUMERIK 802D 2
SINUMERIK 802D base line 1

802D Machine and
Setting Data

802D base line
Machine and Setting Data

8

9

Start−up ISO mode 10

08/2005 Edition

Safety information

This Manual contains information which you should carefully observe to ensure your own personal safety
and the prevention of material damage. The notices are highlighted by a warning triangle and, depending on
the degree of hazard, represented as shown below:

Danger

!

indicates that death or severe personal injury will result if proper precautions are not taken.

Warning

!

indicates that death or severe personal injury can result if proper precautions are not taken.

Caution

!

with a warning triangle indicates that minor personal injury can result if proper precautions are not taken.

Caution

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

Attention

indicates that an undesired event or status can occur if the appropriate note is not observed.

If several hazards of different degrees occur, the hazard with the highest degree must always be given prefe­rence. If a warning note with a warning triangle warns of personal injury, the same warning note can also
contain a warning of material damage.

Qualified personnel

Start−up and operation of the device/equipment/system in question must only be performed using this docu­mentation. The start−up and operation of a device/system must only be performed by qualified personnel.
Qualified personnel as referred to in the safety guidelines in this documentation are those who are authori­zed to start up, ground and label units, systems and circuits in accordance with the relevant safety stan­dards.

Proper use

Please note the following:

Warning

!

The device must only be used for the applications described in the Catalog and only in combination with the
equipment, components and devices of other manufacturers as far as this is recommended or permitted by
Siemens. It is assumed that this product be transported, stored and installed as intended and maintained
and operated with care to ensure that the product functions correctly and properly.

Trademarks

All designations marked with the copyright notice ® are registered trademarks of Siemens AG. Other names
in this publication might be trademarks whose use by a third party for its own purposes may violate the rights
of the registered holder.

Disclaimer of liability

Although we have checked the contents of this publication for agreement with the hardware and software
described, since differences cannot be totally ruled out. Nonetheless, differences might exist and therefore
we cannot guarantee that they are completely identical. The information given in this publication is reviewed
at regular intervals and any corrections that might be necessary are made in the subsequent editions.

Siemens AG
Automation and Drives
Postfach 4848
90437 NÜRNBERG
GERMANY

Copyright (E ) Siemens AG 2005.
6FC5697−2AA00−1BP5

Siemens AG 2005
Subject to change without prior notice.

Preface

SINUMERIK Documentation
The SINUMERIK Documentation is organized in 3 levels:

S General Documentation:
S User Documentation
S Manufacturer/Service Documentation:

For detailed information regarding further publications about SINUMERIK 802D, as well as
for publications that apply for all SINUMERIK control systems (e.g. Universal Interface, Mea­suring Cycles...), please contact your Siemens branch office.

A monthly overview of publications with specification of the available languages can be found
on the Internet at:

http://www.siemens.com/motioncontrol

Follow the menu items ”Support”/”Technical Documentation”/”Overview of Publications”.
The Internet edition of DOConCD − DOConWEB − can be found at:

http://www.automation.siemens.com/doconweb

Addressees of the documentation

Standard scope

Hotline

The present documentation is aimed at the machine tool manufacturer. This publication pro­vides detailed information required for the machine tool manufacturer to start up the SINU­MERIK 802D control system.

The present Instruction Manual describes the functionality of the standard scope. Any
amendments made by the machine manufacturer are documented by the machine manufac­turer.

Other functions not described in this documentation can possibly also be performed on the
control system. However, the customer is not entitled to demand these functions when the
new equipment is supplied or servicing is carried out.

If you have any questions, do not hesitate to call our hotline:

A&D Technical Support
Tel.: +49 (0) 180 / 5050 − 222
Fax: +49 (0) 180 / 5050 − 223
Internet: http://www.siemens.de/automation/support−request

If you have any questions (suggestions, corrections) regarding the Documentation, please
send a fax to the following number or an e−mail to the following address:

Fax: [phone] / 98 − 63315
E−mail: [e-mail]

Fax form: see return fax form at the end of this publication

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition
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Preface

Internet address

http://www.siemens.com/motioncontrol

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Contents

1 The SINUMERIK 802D Control System 1-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

1.2 Technical specifications 1-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

2.2 Interfaces and lines 2-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Connecting the individual components 2-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.1 Connecting the keyboard 2-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.2 Connecting handwheels to the PCU 2-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.3 Terminal configuration of the RS232 interface (COM1) on the PCU 2-30 . . . . . . . . . . . . . . . . . . .

2.3.4 Connecting the I/Os to PP 72/48 2-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.5 Connecting the ADI4 module 2-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 Connecting the SIMODRIVE 611U drive unit 2-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 Connecting the Profibus 2-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6 Grounding 2-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7 Power supply of PCU (X8) and PP 72/48 (X1) 2-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8 Displays on the PCU 2-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9 Displays on the PP 72/48 2-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents

3 Commissioning 3-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 General 3-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.1 Access levels 3-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.2 Structure of machine data (MD) and setting data (SD) 3-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Turning on and booting the control system 3-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Language setting 3-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 Setting the technology 3-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 Entering the machine data 3-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 Setting the Profibus address 3-49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 Starting up the PLC 3-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 Starting up the axes/spindle 3-52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8.1 Setpoint/actual value assignment 3-52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8.2 Default settings for the axis machine data for the feed axes 3-54 . . . . . . . . . . . . . . . . . . . . . . . . .

3.8.3 Connecting a direct measuring system 3-55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8.4 Default settings for the axis machine data for the spindle 3-59 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9 Completing the start−up 3-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 Service display for the axis drive behavior 3-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Starting up the Spindle 4-61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Digital spindle drive with spindle actual−value encoder integrated into the motor 4-63 . . . . . . . .

4.2 Digital spindle drive with spindle actual−value encoder (TTL)

mounted directly on the motor 4-64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Digital spindle drive with the encoder integrated into the motor,

gearbox and external zero mark via BERO 4-65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Digital spindle without external encoder 4-67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Contents

4.4.1 Parameterization using the Drive Configuration Wizard 4-67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.2 Parameterization using the Expert List 4-67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.3 Adapting the machine data in the control system 4-68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Digital spindle without encoder with external TTL encoder 4-69 . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.1 Parameterization using the Expert List 4-69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.2 Adapting the machine data in the control system 4-70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 Analog spindle (via 611 U(E)) with with spindle actual−value encoder mounted directly on the motor . . . . . .

4-71

4.7 Analog axis/spindle with TTL encoder via ADI4 4-74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 Digital axis/spindle with direct measuring system (TTL) via ADI4 4-76 . . . . . . . . . . . . . . . . . . . . .

5 Starting up the PLC 5-79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Commissioning the PLC 5-80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Start−up modes of the PLC 5-80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 PLC alarms 5-82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.1 General PLC alarms 5-83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.2 User alarms 5-83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 PLC programming 5-85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.1 Command overview 5-87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.2 Explanation of the stack operations 5-89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.3 Program organization 5-96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.4 Data organization 5-96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.5 Interface to the control system 5-96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.6 Testing and monitoring your program 5-97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 PLC applications ”Download/Upload/Copy/Compare” 5-98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 User interface 5-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Series Machine Start−Upand Data Backup 6-101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Series machine start−up 6-101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Data backup 6-104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.1 Internal data backup 6-104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.2 External data backup via V24 6-104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.3 External data backup via NC card 6-105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Formatting an NC card 6-107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 Data backup in case of backlight failure 6-108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Software Update via NC card 7-109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Machine and Setting Data 802D 8-111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 List of machine data 8-112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.1 Display machine data 8-112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.2 General machine data 8-117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.3 Channel−specific machine data 8-120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.4 Axis−specific machine data 8-127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 Setting data 8-137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 Machine and Setting Data 802D base line 9-141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1 List of machine data 9-142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1.1 Display machine data 9-142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1.2 General machine data 9-147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1.3 Channel−specific machine data 9-148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1.4 Axis−specific machine data 9-151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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9.2 Setting data 9-160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Start−Up ISO Mode (with 802D only) 10-163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1 1. Setup 10-163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1.1 Turning variant 10-163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1.2 Milling variant 10-164 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2 Machine data 10-164 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2.1 Decimal point programming 10-164 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2.2 Linear path control at rapid traverse rate G00 10-164 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2.3 Spindle positioning M19 10-165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2.4 Blueprint programming (for the turning technology only) 10-165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2.5 Tool compensation (for the turning technology only) 10-165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.3 Functions 10-166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents

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Contents

Platz für Notizen

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The SINUMERIK 802D Control System

1.1 Components of the SINUMERIK 802D

Hardware components

S PCU (Panel Control Unit): Component of the control system for max. 4 axes and one

spindle, with graphical display, softkey menu and NC card slot

S KB (keyboard): horizontal or vertical design
S MCP: Machine control panel
S PP 72/48 (Profibus I/Os): 72 digital inputs, 48 digital outputs
S ADI4 (analog drive interface for 4 axes)
S Drive module

− SIMODRIVE 611UE closed−loop control module

− PROFIBUS DP option module

Software components

1

S System software on the permanent flash memory of the PCU

− Boot software
starts the system

− Human Machine Interface (HMI)
realizes all operator functions

− NCK software (NC Kernel)
realizes all NC functions. It controls one ”NC channel ” with up to 5 axes (2 of them
can be configured as spindles).

− Programmable Logic Control (PLC)
executes the integrated PLC user program cyclically.

S Toolbox

− Setup files for turning and milling

− Configuration file for transformations with turning

− Cycle package for turning and milling

− WINPCIN transfer program for transferring user data and programs between PC and

NC

− Reloadable languages

− Text manager

− PLC user library

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition
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1-9

The SINUMERIK 802D Control System

1.1 Components of the SINUMERIK 802D

− SimoCom U Parameterization and Commissioning Tool for Drives

− SIMODRIVE 611 UE Firmware

− PLC 802 Programming Tool

Note

Please always observe the readme file supplied with the ”Toolbox”. It provides up−to−date
information.

User data

The user data include:

S Machine data
S Setting data
S Tool data
S R parameters
S Work offsets
S Offset data
S Part programs
S Standard cycles
S PLC user program
S PLC alarms

Note

After turning off or in case of power failure, changed user data are stored for at least 50 h.
Thereafter, they can be lost if they are not permanently stored by appropriate operator ac­tions (see Section 6.2.1)

1-10

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition

6FC5 697−2AA00−1BP5

The SINUMERIK 802D Control System

1.1 Components of the SINUMERIK 802D

PCU

(control system)

KB (operator panel)

Machine control panel
(MCP)

JOG Ref Point

[VAR]

Auto Single Block

MDA

Spindle CCW

Spindle CWSpindle CW

Rapid

Reset Cycle STOP

Cycle START

PROCESS FIELD BUS

SIMODRIVE
611UE closed−loop control
module

PROFIBUS DP
option module

Fig. 1-1 Hardware components of the SINUMERIK 802D

PP 72/48

(input/output module)

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition
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1-11

The SINUMERIK 802D Control System

1.2 Technical specifications

1.2 Technical specifications

Connected loads

Table 1-1 Connected loads

Weight

Parameters

Supply voltage 20.4 28.8 V
Ripple 3.6 Vss
24 V current consumption 1 A *
Power dissipation of the PCU including KB

Power dissipation of the MCP
Power dissipation of the PP 72/48

Starting current, total 2.6 A

* Basic configuration from PCU, KB, MCP and PP 72/48;

all outputs open

** with nominal load

Table 1-2 Weight

Component

PCU 4.9 kg
KB 1.7 kg
MCP 1.5 kg
PP 72/48 1.2 kg

min. typ. max. Unit

50
<5

11

Weight

W
W
W

**

Dimensions

Table 1-3 Dimensions of the individual components

Component

PCU 310 x 330 x 85
KB, horizontal design 310 x 175 x 32
KB, vertical design 172 x 330 x 32
MCP 170 x 330 x 128

PP 72/48 194 x 325 x 35

Dimensions WxHxD [mm]

1-12

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6FC5 697−2AA00−1BP5

Ambient conditions during operation

Table 1-4 Ambient conditions during operation

Parameters

Temperature range 0...50 °C
Permissible relative humidity 5...95 %, not condensing
Air pressure 700...1,060 hPa

The conditions during operation comply with IEC 1131-2.
The control system is to be intended for installation in a housing (e.g. cubicle).

Transport and storage conditions

Table 1-5 Transport and storage conditions

Parameter

Temperature range -20...60 °C
Permissible relative humidity 5...95 %, not condensing
Air pressure 700...1,060 hPa
Transport height -1,000...3,000 m
Free fall in transport package v 1,200 mm (PP 72/48 v 1,000 mm)

The SINUMERIK 802D Control System

1.2 Technical specifications

Protective quality and degree of protection

Class of protection I to IEC 536.
No connection to protective−conductor terminal is required.
Protection from foreign matter and penetrating water to IEC 529.
S For the PCU : IP 65 (front)

IP 00 (rear)

S For the keyboard : IP 65 (front)

IP 00 (rear)

S For the MCP : IP 54 (front)

IP 00 (rear)

S PP 72/48 IP 00

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1-13

The SINUMERIK 802D Control System

1.2 Technical specifications

PP 72/48

Table 1-6 Digital inputs

Parameter

U

H

I

at U

in

H

U

L

I

at U

in

L

min typ max Unit

15 24 30 V

2 15 mA

−30 0 +5 V

not defi-

15 mA

ned

Signal delay caused by the hardware 0.5 3 ms

A voltage of 24V for controlling the digital inputs is provided at pin 2 of the interfaces X111,
X222 and X333.

Max. current on pin 2 I

Table 1-7 Digital outputs (high−side driver)

Parameter

U

H

I

at UH and 100% simultaneity factor 250 mA

out

U

L

I

out

Signal delay caused by the hardware 0.5 ms
Switching rate for the ohmic load 100 Hz
Switching rate for the inductive load (free−wheeling

diode required)

at U

(leakage current) 50 400 µA

L

out

=0.5A

min typ max Unit

Vcc − 3V V

cc

Output open

2 Hz

V

Switching rate for the lamp load 11 Hz

The 24V voltage for the digital outputs must be connected to all 4 pins 47, 48, 49, 50.
Max. 1A may flow per supply pin.

1-14

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition

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Installing the Control System

2.1 Installing and removing the SINUMERIK 802D

Warning

!

Procedure

Before installing the control system, make absolutely sure that the system is disconnected
form the mains and deenergized!

The modules contain electrostatic sensitive devices.
When handling the modules, make sure that neither p.c.boards, nor components are
touched by persons not grounded with ESD protection.

1. Install the PCU, the keyboard (KB) and the machine control panel (MCP).

Attention! The maximum permissible torque for tightening the fastening screws
is 1.8 Nm and must not be exceeded.

2

2. Install the PP 72/48.

3. Installing the drive compound (see SIMODRIVE 611 UE Documentation)

4. Establish the connection between PCU and keyboard, as well as between MCP and PP
72/48.

5. Establish the PROFIBUS connection between PCU, PP 72/48 and SIMODRIVE 611 UE.

Removing the control system

To remove the control system, proceed in the reverse order.

Warning

!

Mounting dimensions

Before removing the control system, make absolutely sure that the system is disconnected
form the mains and deenergized!

Note

When installing the control components, observe the dimensions specified in the diagrams
below. These drilling patterns constitute the basis for preparing the mounting holes. The di­mensions are binding.

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition
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2-15

Installing the Control System

2.1 Installing and removing the SINUMERIK 802D

7

8.2

70

35

50

90_

ø (X8)4.5

5

A-A

309.4

302.2

295.6

154.7

13.8

7.2

0

15

Required clearance

15

13

20

A

A

50

Required clearance

20

13

330

321

Fig. 2-1 PCU mounting dimensions

2-16

161.2

0

9

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition

6FC5 697−2AA00−1BP5

Installing the Control System

2.1 Installing and removing the SINUMERIK 802D

Panel cutout

Panel cutout

Z

0.5

+3

2

+0.3

302

1)
M4

295

281.8

Z

2)

281.8

2)

5

1.6

5

140.9

+0.3

285

312

286.6

Fig. 2-2 Drilling pattern for the PCU

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition
6FC5 697−2AA00−1BP5

152.2

0

1) M4 rivet−down, insert nut or M4 extruded hole (8x)

2) Drill holes for fixing the position ø 5.2 mm (2x)

2-17

Installing the Control System

2.1 Installing and removing the SINUMERIK 802D

128

68.7

A

33

263

330

34

170

A

90_

ø (X6)4.5

17.2

Fig. 2-3 Mounting dimensions for the machine control panel (MCP)

19

9 152.2 159.8

8 154

2-18

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition

6FC5 697−2AA00−1BP5

Installing the Control System

2.1 Installing and removing the SINUMERIK 802D

>= 2

147
140

6xM4 1)

0
7

301

290

141.2

Fig. 2-4 Drilling pattern for the machine control panel (MCP)

0

11

1) M4 rivet−down, insert nut or M4 extruded hole

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition
6FC5 697−2AA00−1BP5

2-19

Installing the Control System

2.1 Installing and removing the SINUMERIK 802D

86.1

172.2

0

7.7

24

1)

330

320

Ground screw M5

10

Connection socket

0

2)

Note:

1) This dimension should be added to the height of the connector (15mm),

that is (24+15)=39 mm.

2) Location pins (2xø4.7)

20 290 20

172.2

165

158.8

13.4

7.2
0

330

321

161.2

9

15 142.2 15

0

Fig. 2-5 Mounting dimensions for the keyboard (vertical layout for installation alongside the PCU)

2)

2-20

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition

6FC5 697−2AA00−1BP5

Installing the Control System

2.1 Installing and removing the SINUMERIK 802D

0.5

2

+3

2)

ø5(2x)

303.5

302.5

295

Up

3)

143.7

M4(6x)

1)

7.5

0

8.5

0

0.3

73

145.7

146

151.9

Fig. 2-6 Drilling pattern for the keyboard (vertical layout for installation alongside the PCU)

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition
6FC5 697−2AA00−1BP5

1) M4 rivet−down, insert nut or M4 extruded hole

2) Drill holes for fixing the position ø5 mm (2x)

3) Observe the cut direction.

2-21

Installing the Control System

2.1 Installing and removing the SINUMERIK 802D

7.2

302.2

309.4

175

0

7.724

87.5

0

Connection socket

2)

Ground screw M5

Note:

1) This dimension should be added to the height of the connector (15mm),

that is (24+15) 39 mm.

2) Location pins (2xø4.7)

1)

309.4

295.6

154.7

13.8

14515

0

175

169

15

2)

15 279.4 15

0

6

Fig. 2-7 Mounting dimensions for the keyboard (horizontal layout for installation beneath the PCU)

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition

2-22

6FC5 697−2AA00−1BP5

Installing the Control System

2.1 Installing and removing the SINUMERIK 802D

0.5

+3

2

2)

1)

M4(6x)

ø5(2x)

290

285

283.4

142.5

1.6

0

00

5

0

5

158

153

76.5

000

Fig. 2-8 Drilling pattern for the keyboard (horizontal layout for installation beneath the PCU)

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition
6FC5 697−2AA00−1BP5

Location holes ø5 mm

2) Drill holes for fixing the position (2x)

1) M4 rivet−down, insert nut or M4 extruded hole (6x)

2-23

Installing the Control System

2.1 Installing and removing the SINUMERIK 802D

194

325

10.5

306

6.5

10

35

10170

Fig. 2-9 Mounting dimensions for the PP 72/48

2-24

35

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition

6FC5 697−2AA00−1BP5

2.2 Interfaces and lines

Position of the interfaces, operator controls and displays on the PCU

Installing the Control System

2.2 Interfaces and lines

Fig. 2-10 User interface on the PCU

S 24V DC Power supply connection (X8)

3−pin screw terminal connection for connecting the 24 V load power supply

S Profibus (X4)

B

B (side view)

24V DC

A

M5ground terminal

M5ground terminal

A

Jumper

9−pin D-Sub socket connector for connecting Profibus

S COM1 RS232 interface (X6)

9−pin D-Sub connector
The COM2 port does not have any function.

S Handweels 1 to 3 (X14/X15/X16)

15−pin D-Sub connector for connecting the handwheels

S Keyboard Keyboard connection (X10)

6−pin mini−DIN

S Reset button
S Jumper X311
S 4 LEDs for error and status displays (behind the front hatch)

Interface on the keyboard

S Keyboard connection

6−pin mini−DIN

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2-25

Installing the Control System

2.2 Interfaces and lines

Position of the interfaces, displays and operator controls on the PP 72/48

OVERTEMP

POWER

X2

X1

X333 X222

Fig. 2-11 User interfaces on the PP 72/48

S X1 Power supply connection (24 V DC)

3−pin screw terminal connection for connecting the 24 V load power supply

S X2 Profibus

9−pin D-Sub socket connector for connecting Profibus

RESET

EXCHANGE

READY

S1

X111

X2

X1

S X111, X222 and X333

50−pin ribbon−cable connector for connecting the digital inputs/outputs

S 4 LEDs on the PP 72/48 for status displays
S S1 DIL switches for setting the PROFIBUS address (see Section 3.6)

2-26

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6FC5 697−2AA00−1BP5

Interfaces on the MCP

Installing the Control System

2.2 Interfaces and lines

X1202

X1201

Fig. 2-12 User interfaces on the MCP

S X1201 and X1202

50−pin ribbon−cable connector for connection to PP 72/48

Interconnecting cables

The individual components are connected as shown in the Connection Diagram in Fig. 2-13.
For the cable designations and connector types, please refer to the SINUMERIK 802D Cata­log.

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition
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2-27

Installing the Control System

2.2 Interfaces and lines

Power supply
24 V DC

PCU

X8

Profibus (X4)

COM 1 (X6)

Handwheel1 (X14)

Handwheel 2 (X15)

Handwheel 3 (X16)

Keyboard (X10)

PROCESS FIELD BUS

RS232

Handwheels

KB

CNC keyboard

PP 72/48

X111

X1

X2

X1

X2

SIMODRIVE 611U

Fig. 2-13 Connection Diagram of the SINUMERIK 802D

X222
X333

X111
X222
X333

X423

X1201X1202

Machine I/Os

MCP

2-28

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition

6FC5 697−2AA00−1BP5

2.3 Connecting the individual components

PinSi

l

t

Si

l

t

2.3 Connecting the individual components

Note

Always use shielded lines only; make sure that the shield is connected to the metallic or
metalized connector housing on the side of the control system.

1. Connect the lines to the components as shown in Fig. 2-13.

2. Lock the D-Sub connector using the fastening screws and install the strain reliefs.

The cable sets offered as accessories provide maximum interference immunity.

2.3.1 Connecting the keyboard

To connect the keyboard to the PCU, use the supplied cable. Insert the angular connector
into the keyboard.

2.3.2 Connecting handwheels to the PCU

Installing the Control System

Connector designation: HANDWHEEL1 (X14)

HANDWHEEL2 (X15)
HANDWHEEL3 (X16)

Connector type: 15−pin D−Sub socket connector
Max. cable length 3 m

Table 2-1 Pin assignment of the socket connectors X14, X15, X16

X14, X15, X16

gna
1 1P5 V 9 1P5 V
2 1 M V 10 N.C.
3 A 11 1 M V
4 A 12 N.C.
5 N.C. 13 N.C.
6 B 14 N.C.
7 B 15 N.C.
8 N.C.

yp.Pin

gna

yp.

Signal names

A A pulse
A

Inverted A pulse
B B pulse
B

Inverted B pulse
1P5 5V power supply
1M Ground

8

1

915

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2-29

Installing the Control System

2.3 Connecting the individual components

Signal type

V Voltage output

Handwheels

Three electronic handwheels can be connected; these must meet the following
requirements:

Transmission technique: 5 V square wave signals (TTL level or RS422)
Signals: Track A as true and negated signal (U

Track B as true and negated signal (U

, Ua1)

a1

, Ua2)

a2

Max. output frequency: 500 kHz
Phase shift

of the A tracks to B: 90° "30°
Power supply: 5 V, max. 250 mA

2.3.3 Terminal configuration of the RS232 interface (COM1) on the PCU

RS232 interface COM1

Connector designation: COM1 (X6)
Connector type: 9−pin D−Sub plug connector
Max. cable length 15 m

Table 2-2 Pin assignment of the COM1 socket connector (X6)

COM1 (X6)

Pin Name typ. Pin Name typ.

1 DCD I 6 DSR I
2 RXD I 7 RTS O
3 TXD O 8 CTS I
4 DTR O 9 RI I
5 1 M V

15

69

2-30

Signal description:

DCD Data Carrier Detect
RxD Receive Data V24
TxD Transmit Data V24
RTS Request To Send
CTS Clear To Send
DTR Data Terminal Ready
DSR Data Send Ready
RI Ring Indicator
1M Signal Ground

SINUMERIK 802D, 802D bl Start−up (IBN), 08/05 Edition

6FC5 697−2AA00−1BP5