siemens 810D User Manual

SINUMERIK 810D

Configuration CCU

Equipment Manual

System Overview 1

Connection Conditions 2

Design and Installation 3

Description 4

Axis Expansion 5

I/O Modules 6

Valid for

Control

SINUMERIK 810D powerline SINUMERIK 810DE powerline

NCU Terminal Block 7

DMP Compact Modules 8

Maintenance and Service 9

Abbreviations A

Index

Edition 03/2006

SINUMERIK® Documentation

Printing history

Brief details of this edition and previous editions are listed below.

The 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. . . . . .

Edition Order No. Remarks

12.95 6FC5297–1AD10–0BP0 A

07.96 6FC5297–1AD10–0BP1 C

08.97 6FC5297–2AD10–0BP0 C

12.98 6FC5297–3AD10–0BP0 C

08.99 6FC5297–3AD10–0BP1 C

04.00 6FC5297–3AD10–0BP2 C

10.00 6FC5297–4AD10–0BP0 C

12.01 6FC5297–4AD10–0BP1 C

03.02 6FC5297–6AD10–0BP0 C

11.02 6FC5297–6AD10–0BP1 C

03.05 6FC5297–6AD10–0BP2 C

03.06 6FC5297–7AD10–0BP0 C

Trademarks

All product names mentioned may be trademarks or product designations of Siemens AG or their suppliers, whose use by third parties for their own purposes may infringe the rights of the trademark owners.

Other functions not described in this documentation might be executable in the control. However, no claim can be made regarding

Further information is available in the Internet under: http://www.siemens.com/motioncontrol

This publication was produced with Interleaf V 7.

Printed in the Federal Republic of German

the availability of these functions when the equipment is first supplied or in the event of servicing.

We have checked that the contents of this document correspond to the hardware and software described. Nevertheless, 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 printings. Suggestions for improvement are also welcome.

Subject to change without prior notice.

Siemens AktiengesellschaftOrder No. 6FC5297-7AD10-0BP0

Preface

SINUMERIK Documentation

Target group

Benefits

The SINUMERIK documentation is subdivided into 3 parts:

S General Documentation

S User documentation

S Manufacturer/Service documentation

A list of documents with the respective available languages is updated on a monthly basis and is available on the Internet at:

http://www.siemens.com/motioncontrol

Select “Support” → “Technical Documentation → “Overview of Documents”.

The Internet version of the DOConCD (DOConWEB) is available at:

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

Information on the training offerings and on FAQs (frequently asked questions) can be found in the Internet under:

http://www.siemens.com/motioncontrol and menu item “Support”.

This documentation is intended for:

S Project engineers, electricians and installers

S Maintenance and service personnel

The information in this manual enables installation of the SINUMERIK 810D Numerical Control and measures for maintenance and service.

Standard version

Technical Support

This documentation only describes the functionality of the standard version. Extensions or changes made by the machine tool manufacturer are documented by the machine tool manufacturer. 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 an initial delivery or when servicing.

For the sake of simplicity, this documentation does not contain all detailed information about all types of the product and cannot cover every conceivable case of installation, operation, or maintenance.

If you have any questions about the control, please contact the hotline:

Europe and Africa time zone

A&D Technical Support Tel.: +49 (0) 180 / 5050 222 Fax: +49 (0) 180 / 5050-223 Internet: http://www.siemens.com/automation/support-request E-Mail: mailto:adsupport@siemens.com

iii

Preface

Asia and Australia time zone

A&D Technical Support Tel.: +86 1064 719 990 Fax: +86 1064 747 474 Internet: http://www.siemens.com/automation/support-request E-Mail: mailto:adsupport@siemens.com

America time zone

A&D Technical Support Tel.: +1 423 262 2522 Fax: +1 423 262 2289 Internet: http://www.siemens.com/automation/support-request E-Mail: mailto:adsupport@siemens.com

Note

Country-specific telephone numbers for technical support are provided under the following internet address:

Enter http://www.siemens.com/automation/service&support

Questions about the manual

SINUMERIK Internet address

EC Conformity Declaration

Safety instructions

For questions on the documentation (suggestions, corrections), please send a fax or e-mail to the following address:

Fax: +49 (0) 9131 / 98 – 63315 E-Mail: mailto:motioncontrol.docu@siemens.com

Fax form: see the reply form at the end of the brochure

http://www.siemens.com/sinumerik

The EC conformity declarations on EMC are to be found at/can be obtained from:

S in the Internet:

http://www.ad.siemens.de/csinfo

under the product/order no. 15257461

S at the relevant branch office of the A&D MC group of Siemens AG.

This manual contains information which you should observe in order to ensure your own personal safety, as well to avoid material damage. Notices which are relevant to your own personal safety are highlighted by a safety alert symbol; notices which are relevant only to equipment and property damage have no safety alert symbol. The warnings appear in decreasing order of risk as given below.

Danger

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

SINUMERIK 810D Equipment Manual Configuration CCU (PHC) – 03/2006 Edition

Preface

Warning

indicates that death or serious injury may result if proper precautions are not taken.

Caution

with a safety alert symbol, indicates that minor personal injury may result if proper precautions are not taken.

Caution

without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.

Qualified personnel

Intended use

Notice

indicates that an undesirable event or state may arise if the relevant notes are not observed.

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

Commissioning and operation of the device/equipment/system in question must only be performed using this documentation. Only qualified personnel should be allowed to commission and operate the device/system. Qualified persons are defined as persons who are authorized to commission, to ground, and to tag circuits, equipment, and systems in accordance with established safety practices and standards.

Please note the following:

Warning

The equipment may only be used for single purpose applications explicitly described in the catalog and in the technical description and it may only be used along with third-party devices and components recommended by Siemens. To ensure trouble-free and safe operation of the product, it must be transported, stored and installed as intended and maintained and operated with care.

Preface

Danger notices

Should it be necessary to test or take measurements on live equipment, then the specifications and procedures defined in Accident Prevention Regulation of the Berufsgenossenschaft BGV A3 (German employer’s liability insurance association) must be adhered to, in particular § 8 “Permissible deviations when working with live components”. Suitable electric tools should be used.

Danger

Operating electrical equipment has parts and components that are at hazardous voltage levels.

After disconnecting all the supply voltages, a hazardous voltage will be present in the DC link of all SIMODRIVE modules for another 5 minutes! See Operating Guide

Danger

 Repairs to devices that have been supplied by our company must only be

carried out by SIEMENS Customer Service or by repair centers authorized by SIEMENS. When replacing parts or components, only use

those parts that are included in the spare parts list.

 Before opening the equipment, always ensure that the power is off.

 EMERGENCY STOP devices complying with EN 60204 (VDE 0113 Part 1)

must remain effective in all automation equipment modes. Resetting the EMERGENCY STOP device must not cause an uncontrolled or undefined restart.

 Anywhere in the automation equipment where faults might cause major

material damage or even physical injury, in other words, where faults could be dangerous, additional external precautions must be taken, or facilities must be provided, that guarantee or enforce a safe operational state, even when there is a fault (e.g. using an independent limit value switch, mechanical interlocks etc.)

Warning

Connecting cables and signal cables should be installed so that inductive and capacitive interference does not in any way impair the automation functions.

Warning

The modules contain electrostatically sensitive devices. Discharge yourself of electrostatic energy before touching the components. The easiest way to do this is to touch a conductive, grounded object immediately beforehand (for example, the bare metal part of control cabinet or the protective ground contact of a socket outlet).

SINUMERIK 810D Equipment Manual Configuration CCU (PHC) – 03/2006 Edition

Preface

ESD notices

Electrostatically Sensitive Devices

Important

Handling of modules containing devices sensitive to electrostatic discharge:

 When handling components which can be destroyed by electrostatic

discharge, it must be ensured that personnel, the workstation and packaging are well grounded.

 Generally, electronic modules must not be touched unless work has to be

carried out on them. Only touch electronic modules after you have grounded yourself.

 Touch components only if:

– you are constantly grounded via an ESD arm band,

– ESD-shoes or ESD-shoe grounding strips if there is an ESD floor.

 Modules may be placed only on electrically conductive surfaces (table with

ESD top, conductive ESD foam plastic, ESD packing bags, ESD transport containers).

 Keep modules away from visual display units, monitors or TV sets

(minimum distance from screen 10 cm).

 Do not bring ESD-sensitive modules into contact with chargeable and

highly-insulating materials, such as plastic, insulating table tops or clothing made of synthetic materials.

Other information

 Measurements on modules are allowed only if

– the measuring instrument is properly grounded (e.g. equipment

grounding conductor), or

– before measuring with a potential-free measuring instrument, the probe

is briefly discharged (e.g. touch the unpainted metal parts of the control housing).

Important

This notice indicates important facts that must be taken into consideration.

Note

This note contains additional important information.

vii

Preface

Notes

viii

SINUMERIK 810D Equipment Manual Configuration CCU (PHC) – 03/2006 Edition

1 System overview 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 SINUMERIK 810D powerline 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 System configuration 1-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Labels 1-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Connection Conditions 2-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Supplementary electrical conditions 2-23. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.1 Power supply 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.2 Safe isolation to EN 61800-5-1 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.3 Grounding Concept 2-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.4 RI suppression measures 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Climatic and mechanical environmental conditions 2-31. . . . . . . . . . . . . . .

2.2.1 Transport and storage conditions 2-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.2 Operating conditions 2-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Technical data of the individual components 2-34. . . . . . . . . . . . . . . . . . . . .

2.4 MPI/OPI network rules 2-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Design and Installation of the 810D 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Structure of the SINUMERIK 810D 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Assembly of the SINUMERIK 810D 3-38. . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1 Alteration for external heat dissipation, 2-axis CCU box 3-43. . . . . . . . . . .

3.3 Power supply 3-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Description of the SINUMERIK 810D 4-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Components of the SINUMERIK 810D 4-47. . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.1 Overview 4-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Interfaces 4-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1 Overview 4-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.2 Description of the interfaces, operating and display elements 4-52. . . . . .

4.2.3 Cable distributor 4-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Measuring system 4-63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.1 Assignment of measuring systems and motor connection 4-63. . . . . . . . .

4.3.2 Encoder systems that can be evaluated 4-64. . . . . . . . . . . . . . . . . . . . . . . . .

4.3.3 Measuring channels, indirect and direct measuring system 4-66. . . . . . . .

4.4 Integrated power modules: 3-axis CCU box 4-71. . . . . . . . . . . . . . . . . . . . .

4.5 Integrated power modules: 2-axis CCU box 4-74. . . . . . . . . . . . . . . . . . . . .

4.6 PLC module 4-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 PCMCIA card (memory card) 4-76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Axis expansion 5-77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Axis expansion plug-in unit 5-77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Axis expansion with SIMODRIVE 611D control plug-in unit 5-80. . . . . . . .

6 I/O Modules 6-83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Single I/O module 6-83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 NCU terminal block 7-91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 DMP compact modules 8-97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 DMP compact module 16I (6FC5111-0CA01-0AA0) 8-97. . . . . . . . . . . . . .

8.2 DMP compact module 16O (6FC5111-0CA02-0AA2) 8-99. . . . . . . . . . . . .

8.3 DMP compact module 8O (6FC5111-0CA03-0AA2) 8-101. . . . . . . . . . . . . .

8.4 DMP compact module 1I analog (6FC5111-0CA04-0AA0) 8-103. . . . . . . . .

8.5 DMP compact module 1I NC analog (6FC5211-0AA10-0AA0) 8-106. . . . . .

8.6 DMP compact module 1O analog (6FC5111-0CA05-0AA0) 8-109. . . . . . . .

9 Maintenance and Service 9-111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1 Battery replacement (6FC5247-0AA18-0AA0) 9-111. . . . . . . . . . . . . . . . . . .

A Abbreviations A-113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B Index B-115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SINUMERIK 810D Equipment Manual Configuration CCU (PHC) – 03/2006 Edition

System Overview

1.1 SINUMERIK 810D powerline

Since 03.2002

 SINUMERIK 810D powerline and

 SINUMERIK 810DE powerline

have been available. The following powerline module with improved performance is now available:

Table 1-1 powerline module for SINUMERIK 810D/810DE

Module Description

CCU3 with additional pulse interface and 2 machining channels CCU3.4 like CCU3, but with increased NC performance and PLC 314C-2DP

Note

SINUMERIK 810D powerline and SINUMERIK 810DE powerline are delivered with software version 6. Earlier software versions of SINUMERIK 810D cannot be run on SINUMERIK 810D powerline and SINUMERIK 810DE powerline.

1-11

6FC5447-0AA01-0AA0

dissi

1 System Overview

1.2 System configuration

Components

A fully equipped SINUMERIK 810D consists of different components. These are listed below.

Table 1-2 Components of the 810D in the maximum configuration (without motors)

Component MLFB Description

Mains supply module (MS)

SINUMERIK 810D – CCU box

(3 axes)

– CCU box

(2 axes)

– CCU3.4 6FC5410-0AY03-1AA0 like CCU3 but with PLC 314C-2DP – CCU3 6FC5410-0AY03-0AA1

Operator panel front PCU 20/50/70 Machine control panel ISA adapter Full CNC keyboard Memory card (PCMCIA) Slot for PCMCIA card on the CCU.

Floppy disk unit Cable distributor 6FX2006-1BA02 Connection of two handwheels and two probes to the CCU Cable References: Catalog NC Z Axis expansion

plug-in unit left

Axis expansion plug-in unit

SIMATIC components

Single I/O module 6FC5411-0AA00-0AA0 PLC I/O module with 64 inputs and 32 short-circuit-proof outputs

See References: /PJU/ Configuration Manual Converters

6FC5447-0AA00-0AA1

6FC5410-0AY03-0AA2

6FC5412-0FA12-0AA0 For installation in a SIMODRIVE 611 D power module (1-axis) for

6FC5412-0FA10-0AA0 For installation in a SIMODRIVE 611 power module (1-axis or

Power supply module for powering the electronics and drives. Either unstabilized (OI 5 kW to 28 kW) or stablized as infeed/regenerative feedback module (I/R module) as from 16 kW to 120 kW; optional filter modules.

Module racks for CCU integrated power modules: 1 x 18/36A (FSD) or 24/32A (MSD) and 2 x 6/12A (FSD), internal heat

pation only Module rack for the CCU integrated power modules: 2 x 9/18/A (FSD), internal/external heat dissipation

CPU of the 810D contains: NCK, PLC 315-2DP, communication functions, digital standard control

Additional functions: – 16 MB DRAM, 2.5 MB SRAM – Handling with 6 axes – 2nd channel with 6 axes

Display, keyboard and operation of the 810D Makes communication between operator and machine possible Operation of PLC-controlled machine functions of 810D Permits use of AT modules in conjunction with the PCU Full keyboard connectable to PCU

PCMCIA card for software update (not 810DE). Built-in unit for connection to PCU

axis expansion, place between I/R module and 810D References: /PJU/, Configuration Manual Converters

2-axis), References: /PJU/, Configuration Manual Converters

See http://www.siemens.com/automation/simatic

NCU terminal block

Handheld unit

1-12

6FC5211-0AA00-0AA0 Rapid digital and analog NC I/Os on the drive bus of the

6FX2007-1AC.. Handheld unit with handwheel, EMERGENCY STOP button, key-

SINUMERIK 810D Equipment Manual Configuration CCU (PHC) – 03/2006 Edition

SINUMERIK 810D

switch, override, enabling buttons, display, free keys, connection via MPI bus and cable distributor

Component DescriptionMLFB

Handheld terminal

(HT 6)

Distributor box

Mini Handheld Unit

6FC5403-0AA10-0AA0 Handheld unit combining the functions of operator panel front and

6FX2006-1BC00 For linking the hand-held unit to the MPI bus. Connection for

6FX2006-1BG00 Small handheld unit for setup and operation on simple machines

1 System Overview

1.2 System configuration

MCP, with – Display, – Keyboard, enabling buttons, EMERGENCY STOP and override

button – RS 232 C interface for archiving programs and data – Connection via cables and distributors to SINUMERIK

810D/840Di/840D and FM357-2H

EMERGENCY STOP circuit, enable keys, handwheel, 24 V DC

for job shop or similar applications. Use with 810D, 840C, 840D, and FM-NC possible.

The components marked with 1) are described in: References: /BH/, Operator Components Manual

1-13

1 System Overview

1.2 System configuration

Operator panel front

MCP

Encoder cable direct measuring system

QWERTY keyboard

* POWER

PCU

* TEMP

SINUMERIK

Diskette unit

Handheld unit

MPI cable

Handheld unit or mini handheld unit or HT 6

Distributor box

Cable distributor

Measurement (2x) *)

Handwheel (2x)

HT 6

OI or

I/R

Motor encoder cable

Direct measuring system (e.g. on the X416)

MSD

Axis expansion plug-in unit

Motor cable

810D

(CCU3)

Motors e.g. 1FNx, 1FEx, 1FKx

FSD FSD

Axis

611 power module

expansion plug-in unit

*) One measurement input can be replaced by a 3rd handwheel

Fig. 1-1 System of the SINUMERIK 810D, for example, the CCU3

Terminal block

SIMATIC Profibus I/O

SIMATIC IM cable

Single I/O module

1-14

SINUMERIK 810D Equipment Manual Configuration CCU (PHC) – 03/2006 Edition

1 System Overview

1.2 System configuration

PS/2 mouse

COM1/RS232/PLC

LPT1/PRINTER

MPI bus cable

QWERTY

24V power supply

COM2

VGA

CCU 3

USB

Floppy/interface

Connection on left side of housing

PCI slot PCI/ISA slot

MPI/DP

Ethernet

X20

HHU

Measuring probe

Cable distributor

PC card

HT 6

Distributor box

X1 X2

Handwheel HHU

PCU50 (right side of housing)

MCP

(Rear view)

Handwheel

Shield

MPI bus cable

–X307

–X122

–X102

PG740 programming device

MPI cable

Fig. 1-2 Interface configuration of the SINUMERIK 810D for the MPI bus, HHU, HT 6 and cable distributor

1-15

1 System Overview

1.2 System configuration

SIMATIC S7-300 I/O

PS SMs

–X307

–X411

–X414

–X306

CCU3

–X412

–X415

–X122

–X431

–X305 –X304

–X413–X416

–X102

–X130

–X121

–X111

MEMORY CARD

SIMATIC S7-300 IM connecting cable

Single I/O module

Connecting cable shielded

Drive bus cable

7 9

Terminal block

Single I/O module Single I/O module

Terminator

Pay attention to maximum configuration !!

Fig. 1-3 Interface configuration of the SINUMERIK 810D for PLC I/Os and NCU terminal block

1-16

SINUMERIK 810D Equipment Manual Configuration CCU (PHC) – 03/2006 Edition

1 System Overview

1.2 System configuration

Connecting

The following connecting cables are used for the SINUMERIK 810D

cables

Table 1-3 Connecting cables for SINUMERIK 810D

No.

1 6FX2002-4EA0-10

2 6ES7901-0BF00-0AA0 MPI bus cable from the distributor box (HHU) to the CCU 3 6FX2002-4AA21-10

4 Included in the scope of

5 6FX2002-4AA41-1AB0 Probe connection cable to cable distributor, length: 5 m 6 6FX2002-4AA21-10

7 6FX2002-1CB01-1AB0 Drive bus cable (1 m) for connection of the NCU terminal block 8 6ES7368-30-0AA0 9 6FC5411-0AA80-0AA0 Connecting cable shield for single-tier configuration with several single

10 6FC5412-0FA80-0AA0 Cable set for external SIMODRIVE 611 control, for connecting the

11 6FX2003-0DA00-0AA0 Terminator for drive bus (only if the drive bus is used) 12 13

15 16 6FX2002-1AA3-1 Round cable from HT6 to the distributor box 17

supply of the PG740

6FX2002-2CG00-1AA0 6FX2002-2CH00-1AA0

MLFB Description

MPI bus cable from the operator panel front to the MCP and to the CCU

Connecting cable from distributor box to cable distributor on the CCU (for the handwheel pulses from the HHU)

MPI bus cable to the PG

Connecting cable for the electronic handwheel to the cable distributor on the CCU

Connecting cable for the Step7-300 I/Os (IM361 or single I/O module)

I/O modules

device bus and drive bus

Ribbon cable for terminal strip converter Motor encoder cable – incremental

Cable for connection of direct measuring system to the CCU

Power cables for motor

Round cable from HHU to the distributor box

– absolute

– incremental – absolute

For length code, see Reference: Catalog NC Z

PCU 50/70, MCP and HHU/HT 6

A number is assigned to each cable. You will find these numbers (1 to 17) in the figures above.

see References: /PJU/, Configuration Manual Converters

There are 4 possible variants:

 HHU/HT 6 without PCU 50/70/MCP

 PCU 50/70/20 + MCP MPI bus cable with cable no. 1

 PCU 50/70/20 MPI bus cable with cable no. 2

 MCP MPI bus cable with cable no. 2

1-17

1 System Overview

1.2 System configuration

Axis expansion on 810D

Axis expansion plug-in unit

Axis expansion control plug-in unit

On the SINUMERIK 810D, the number of axes can be expanded to six axes, including spindles.

There are two possibilities: either Connect axis expansion plug-in unit and SIMODRIVE 611 power

module at axis expansion interface,

or Connect SIMODRIVE 611D control plug-in unit with SIMODRIVE 611

power module on drive bus/device bus.

The axis expansion plug-in units are used whenever no more than six measuring channels are required for the SINUMERIK 810D. This plug-in unit is plugged into a SIMODRIVE 611 power module. The axis expansion plug-in units are designed for 1-axis and 2-axis power modules. The ribbon cables are part of the plug-in unit.

If the six measuring channels of the SINUMERIK 810D are insufficient, SIMODRIVE 611 controller plug-ins must be inserted into the SIMODRIVE 611 power modules to connect further measuring systems (connection via drive bus with drive bus terminator). If 611D control modules are used, it may be necessary to connect the NCU terminal block to the free drive bus connector of the 611D control. See Chapter 5, Axis expansion

Power modules

Combinations

The CCU can control up to 6 axes onboard. For this purpose there is a new expansion plug-in in addition to the existing axis expansion plug-in modules.

All power modules of the 611D series can be connected as external power modules for axis expansion.

As from SW 6.3, the limitation to six drives applies.

Expansion levels 1 to 6 can be achieved by many combinations. To operate the spindle to the internal power module, connect it to the 24A/32A power module (A1).

1-18

SINUMERIK 810D Equipment Manual Configuration CCU (PHC) – 03/2006 Edition

1 System Overview

1.2 System configuration

Table 1-4 Possible combinations for 1 to 6 drives on SINUMERIK 810D

Number of

drives

3 power modules 2 power modules

1 1 1 0

2 2 2 0

3 3 – 0

4 3 – 1

5 3 – 2

6 3 – 3

Internal drives

1 x 18/36A (FSD)

*or 24/32A (MSD)

2x9/18 / 2 x 6/12A

0 0 1

1 1 1 0 0 2

2 2 1 1 1 2 0 0 3

2 2 2 1 1 3

2 2 3

2 2 4

Drives via axis

expansion

CCU 3 with 3 axis CCU box plus

2 axis power module to right of CCU 1 axis power module to right of CCU

CCU 3 6x encoder connection

internal/ external

50 A

Fig. 1-4 First way of operating 6 axes on CCU3 with internal 3 axis CCU box

{

X307

X304

X306

X305

15 A 15 A

{

3 axes 2 axes

{

1 axis

If no external power module is connected on connector -X307 (internal/external pulse interface 3rd power module) to the left of the CCU3 => CCU3 with 3 axis CCU box plus 2 axis CCU box plus 1 axis CCU box

1-19

1 System Overview

1.2 System configuration

CCU 3 6x encoder connection

internal/ external

{

X307

25 A

CCU 3 with 3 axis CCU box or 2 axis CCU box plus

2 axis power module to the right of CCU 1 axis power module to the right of CCU 1 axis power module to the left of CCU

X305

X304

X306

25 A

If an external power module is connected to connector

-X307, then the 3rd internal power module will be switched to the external power module. On a 3-axis CCU box, the 3rd internal power module A3 (6/12 A) cannot be used.

Fig. 1-5 Second way of operating 6 axes on CCU 3 with 2 axis CCU box

Restrictions

 Power supply:  120 kW.

 The DC link busbar of the 810D is capable of an effective load of 200 A.

 The length of the ribbon cable of the axis expansion plug-in unit left for con-

necting the SIMODRIVE 611 power module is 300 mm.

 The length of the ribbon cable of the axis expansion plug-in unit right is suffi-

cient for a module width of 150 mm.

 The length of the cable set for the axis expansion with 611D control plug-in

unit is: 62 mm for the drive bus and 150 mm for the device bus.

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SINUMERIK 810D Equipment Manual Configuration CCU (PHC) – 03/2006 Edition

1.3 Labels

1 System Overview

1.3 Labels

In case of technical queries or service, please quote all data on the rating plate to the local SIEMENS office responsible for your equipment.

One of the following labels is attached to the components and modules:

PCBs with screen printing

CCU3.4 module

CCU box

Example: Component number: 570 573.9001.00

Product version: B (last cross)

SIEMENS

570 573.9001.00

Example: Component name: CCU3.4

MLFB: 6FC5410-0AY03-1AA0 Component number: A5E00377496

Example: Component name: SINUMERIK 810D

Power module 2x15A+1x50A MLFB: 6FC5447-0AA00-0AA1 Product version: A (last cross)

SINUMERIK 810D Power module 2x15A + 1x50A 6FC5 447-0AA00-0AA1

A B CA5E003774966FC5410Ć0AY03Ć1AA0CCU3.4

Made in Germany

CBA



1-21

1 System Overview

1.3 Labels

Notes

1-22

SINUMERIK 810D Equipment Manual Configuration CCU (PHC) – 03/2006 Edition

Connection Conditions

2.1 Supplementary electrical conditions

Compliance with the connection conditions

Assistance and support

The controller is tested for compliance with the ambient conditions specified below. Fault-free operation is only ensured if:

 These environmental conditions are maintained when storing, transporting

and operating the equipment.

 Original components and spare parts are used. This applies in particular to

the use of specified cables and plug connectors.

 The equipment has been correctly mounted/installed.

Danger

The equipment may not be commissioned until it has been clearly identified that the machine in which the controller is installed is in full conformance with the specifications in EC Machinery Directive 98/37/EC.

The connection conditions must be carefully maintained for the complete system. Please contact your local Siemens office or representative for any assistance.

2-23

Connection Conditions

2.1 Supplementary electrical conditions

2.1.1 Power supply

Demands on DC power supplies

Warning

 The DC power supply is always referenced to ground and must be

generated by a safety transformer.

 Final user interfaces are powered via a DC power supply with protective

separation per EN 61800-5-1.

 In the case of supply cables > 10 m, protective elements must be fitted at

the device input in order to protect against lightning (surge voltage).

 The DC power supply must be connected to the ground/shield of the NC for

EMC and/or functional reasons. For EMC reasons, this connection should only be made at one point. As a rule, the connection is provided as standard in the S7-300 I/Os. If this is not the case in exceptional circumstances, the ground connection should be made to the grounding rail of the NC cabinet; also refer to /EMC/ EMC Configuring Guidelines.

Table 2-1 Requirements of the DC supply

Rated voltage In accordance with EN 61131-2

 Voltage range (average value)

 Voltage ripple peak-to-peak

 Ramp-up time at power-on

Non-cyclic overvoltages

 Duration

 Restoration time

 Events per hour

Transient voltage interruptions

 Outage time

 Restoration time

 Events per hour

Configuration 810D power consumption

The EP and CP points for the power modules only apply in conjunction with the SINUMERIK 810D (axis expansion). The EP and CP points from Catalog NC 60 apply when SIMODRIVE 611D modules with control plug-in units are used.

24 V DC

20.4 V DC to 28.8 V DC

5 % (unfiltered 6-pulse rectification)

Any

 35 V  500 ms

 50 s

 10

 3 ms

 10 s

 10

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SINUMERIK 810D Equipment Manual Configuration CCU (PHC) – 03/2006 Edition

Connection Conditions

2.1 Supplementary electrical conditions

Table 2-2 EP and CP points for 810D components

Component Electronics points (EP) Control points (CP)

810D 2 4.5 EnDat encoder 0 0.3

Power module  50 A

Power module > 50 A  80 A

Power module > 80 A,  120 A 611D module MSD or FSD See Catalog NC 60 See Catalog NC 60

Table 2-3 Example of calculation of the supply power for 4 axes/1 spindle for 810D

Electronics points (EP) Control points (CP)

Module Assessment

810D

EnDat encoder 0 2 0 0.3 2 0.6 LTM 50A 0.6 1 0.6 0.5 1 0.5 LTM 80A 0.75 1 0.75 1 1 1

factor, individual module

For I/R unit 16 kW

Number of modules

1 2 4.5 1 4.5

Total for

products

Product Assessment

3.35 Total for

 7.5

factor, individual module

For I/R unit 16 kW

0.6 0.5

0.75 1.0

1.5 1.5

Number of modules

products

Product

 16.50

6.6

2-25

Connection Conditions

2.1 Supplementary electrical conditions

2.1.2 Safe isolation to EN 61800-5-1

The complete system includes end user interfaces (UIs) and interfaces for servicing, commissioning and maintenance.

End user interfaces (UI)

Interfaces for servicing, commissioning and maintenance

UIs are all the interfaces that are freely accessible to the machine operator without the need for tools or aids. These user interfaces are designed with safe isolation to EN 61800-5-1.

Danger

The interfaces for servicing, commissioning and maintenance purposes are provided without safe isolation.

If necessary, these interfaces can be isolated safely using a supplementary adapter (insulation voltage 230 V AC). These adapters are not included in the Siemens scope of delivery. You can buy these parts from your local dealer who will help you to make the proper choice.

Table 2-4 Service interfaces

Component Interface name Function

CCU module X341, X342, X351, X352 DAC socket for analog signals

Danger

Safe isolation can only be ensured if the system configuration specified below is strictly adhered to. When mounting additional components (e.g. S7-300 FM, IP) with an end user interface, please make sure that the end user interface has a basic insulation for at least 230 V AC.

2-26

SINUMERIK 810D Equipment Manual Configuration CCU (PHC) – 03/2006 Edition

3 x 400 V AC

Connection Conditions

2.1 Supplementary electrical conditions

Housing/shield

810D/611 digital

M (GND)

Basic insulation Protective separation

MSTT/MCP

Distributor box

Fig. 2-1 Protective separation as per EN 61800-5-1

Fig. 2-1 shows the potential balance of the 810D/611D/S7-300 system. Legend:

1. Floating power supply of the SIMODRIVE electronics unit with 230 V AC basic insulation.

2. Floating transistor triggers for the three-phase rectifier bridge with 230 V AC basic insulation.

3. Floating transistor triggers for each axis of the three-phase inverter bridge with 230 V AC basic insulation.

4. Floating signal connection from the CCU to the PCU or HHU/HT 6 with 230 V AC basic insulation.

5. Non-floating signal line between CCU and I/O devices.

6. Non-floating end user interface with protective separation for 230 VAC through interfaces 1 to 4 and 7.

7. Protectively separated 5 V DC power supply, fed from a protectively separated 24 V DC supply.

8. 24 V DC power supply unit for external devices and for the machine adaptation control according to applicable standards in the form of a PELV (Protective Extra Low Voltage) circuit featuring safe isolation.

9. Floating interfaces to the machine (not accessible to the end user).

10. Floating signal interfaces directly accessible to the end user (e.g. V.24). For these interfaces, you must always make sure that there is either safe isolation with respect to the line supply voltage or that there are two basic insulation levels, for 230 V AC each.

11. 5 V DC power supply with basic insulation, fed from a safely-isolated 24 V DC supply.

HHU/ HT 6

Person

PCU

S7-300 I/Os

24V

M (GND)

Terminal block

Machine

2-27

Connection Conditions

2.1 Supplementary electrical conditions

2.1.3 Grounding Concept

The SINUMERIK 810D system consists of a number of individual components, each of which must comply with the appropriate EMC and safety standards. The individual system components are:

 CCU box

 Machine control panel MCP

 Keyboard

 Operator panels (operator panel front + PCU/TCU)

 NCU terminal block

 Distributor box and handheld unit

 S7-300 I/O with IM 361 interface module

 Single I/O module

CCU box and SIMODRIVE components are fixed to a metal cabinet plate with screws. Make sure that near the screws a low-impedance contact of the CCU box with the cabinet panel can be made. Insulating varnishes must be removed where possible. The connection must be kept free of corrosion.

The electronics grounds of the modules are interconnected via the unit and control bus and also routed to terminal X151 of the NE module.

The ground and module ground M should be connected at the power supply terminal of the IM 361. Further, for the EFP, “SHIELD” and “M24” must be connected in connector X1.

2-28

SINUMERIK 810D Equipment Manual Configuration CCU (PHC) – 03/2006 Edition

Connection Conditions

2.1 Supplementary electrical conditions

Operator panel front

Grounding bar

PCU/ TCU

– Ground (frame) –

IM 361

S7-300 peripherals/ single I/O module

Central ground connection conductor/protective conductor

Machine control panel

Gating

CCU

MB: Shielded signal cable with reference ground M: Motor G: Encoder

PA: Equipotential bonding conductor

SL: Protective conductor

electronics

Line supply connection S

Power electronics

SL in the motor cable

M (GND)

Machine bed

S v 16 16 < S v 35 S > 35

Distributor box

Terminal block

Cross-sections (mm2)

w10

SL minimum

S 16

S/2

Fig. 2-2 Grounding concept

References: /EMV/, EMC Configuring Guidelines

2.1.4 RI suppression measures

In addition to the protective grounding of system components, special precautions must be taken to ensure safe, fault-free operation of the system. These measures include shielded signal cables, special equipotential bonding, isolation, and shielding measures.

Shielded signal cables

To ensure safe, interference-free operation of the installation, it is essential to use the cables specified in the individual diagrams.

For digital signal transmission, the shield must have a conductive connection at both sides of the housing.

Exception:

Standard shielded cables grounded on only one side can be used for devices from other manufacturers (printers, programming devices, etc.).

2-29

Connection Conditions

2.1 Supplementary electrical conditions

These external devices may not be connected to the control during normal operation. However, if the system cannot be operated without them, then the cable shields must be connected at both ends. Furthermore, the external device must be connected to the control via an equipotential bonding cable.

Cable definitions

Rules for routing cables

Definition:

 Signal cables (e.g.)

– Data cables (MPI, sensor cables, etc.) – Binary inputs and outputs

– Emergency Stop cables

 Load cables (e.g.)

– Low-voltage supply cables (230 V AC, +24 V DC etc.)

– Supply cables to contactors (primary and secondary circuit)

In order to achieve the best possible noise immunity of the complete system (control, power module, machine), the following EMC measures must be carefully observed:

 Signal cables and load cables must be routed at the greatest possible

distance from one another.

 If necessary, signal and load cables may cross one another (if possible, at

an angle of 90°), but must never be laid close or parallel to one another.

 Only cables provided by the manufacturer should be used as signal cables

from and to the CCU.

 Signal cables may not be routed close to strong external magnetic fields

(e.g. motors and transformers).

 Pulse-carrying HC/HV cables must always be laid completely separately

from all other cables.

 If signal lines cannot be routed a sufficient distance away from other cables,

they must be installed in grounded cable ducts (metal).

 The clearance (surface through which interference can be coupled-in)

between the following cables must be kept to a minimum:

– Signal cable and electrical circuit signal cable (twisted)

– Signal cable and associated equipotential bonding conductor – Equipotential bonding conductor and PE conductor (routed together)

Important

For further notes on interference suppression measures and the connection of shielded cables, please refer to References: /EMV/, EMC Configuring Guidelines.

2-30

SINUMERIK 810D Equipment Manual Configuration CCU (PHC) – 03/2006 Edition

+ 90 hidden pages

siemens 810D User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Contents

System Overview

1.1 SINUMERIK 810D powerline

1.2 System configuration

1.3 Labels

Connection Conditions

2.1 Supplementary electrical conditions

2.1.1 Power supply

2.1.2 Safe isolation to EN 61800-5-1

2.1.3 Grounding Concept

2.1.4 RI suppression measures