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

y

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

!

iv

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.

v

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).

vi

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

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

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

1)

See References: /PJU/ Configuration Manual Converters

6FC5447-0AA00-0AA1

6FC5410-0AY03-0AA2

1)

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)

1-12

1)

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

1)

(HT 6)

Distributor box

Mini Handheld Unit

1)

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

1)

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

14

QWERTY keyboard

* POWER

PCU

* TEMP

SINUMERIK

Diskette unit

Handheld unit

MPI cable

Handheld unit or mini handheld unit or HT 6

17

Distributor box

Cable distributor

Measurement (2x) *)

Handwheel (2x)

HT 6

16

OI or

I/R

14

Motor encoder cable

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

MSD

Axis expansion plug-in unit

Motor cable

810D

(CCU3)

2x

1x

5x

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

FSD FSD

Axis

611 power module

expansion plug-in unit

15

1x

2x

*) 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

1

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

or

HHU

17

Measuring probe

Cable distributor

5

6

PC card

HT 6

Distributor box

16

2

X1 X2

3

Handwheel HHU

PCU50 (right side of housing)

MCP

(Rear view)

X5

X4

X3

Handwheel

Shield

MPI bus cable

–X307

–X122

–X102

PG740 programming device

4

MPI cable

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

2

1-15

1 System Overview

1.2 System configuration

SIMATIC S7-300 I/O

X2

IM

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

8

Single I/O module

1)

8

Connecting cable shielded

8

Drive bus cable

7 9

Terminal block

Single I/O module Single I/O module

Terminator

1)

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

14

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

supply of the PG740

1)

2)

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

2)

MLFB Description

1)

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

1)

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

1)

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

1)

2)

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.

1-20

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)

E

C

D

B

SIEMENS

A

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

2

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

2

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

2-24

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

2

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

2

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

2

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

2

N

Connection Conditions

2.1 Supplementary electrical conditions

Housing/shield

1

2

3

810D/611 digital

10

M (GND)

Basic insulation Protective separation

MSTT/MCP

4

Distributor box

5

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.

8

4

11

HHU/ HT 6

5

4

6

Person

PCU

11

S7-300 I/Os

10

24V

7

11

M (GND)

9

Terminal block

Machine

2-27

2

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

2

Connection Conditions

2.1 Supplementary electrical conditions

Operator panel front

SL

Grounding bar

PCU/ TCU

– Ground (frame) –

IM 361

S7-300 peripherals/ single I/O module

PA

Central ground connection conductor/protective conductor

Machine control panel

SL

Gating

CCU

MB

PA

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

PA: Equipotential bonding conductor

SL: Protective conductor

electronics

MB

G

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

SL

Terminal block

SL

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

2

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

2

Connection Conditions

2.2 Climatic and mechanical environmental conditions

Test standards

Vibration load: EN 60068-2-6 Shock load: EN 60068-2-27 Climate: EN 60068-2-1/EN 60068-2-2/EN 60068-2-14

EN 60068-2-30/EN 60068-2-31/EN 60068-2-32/ EN 60068-2-33/EN 60068-2-34

Requirement standards

Long-term storage: EN 60721-3-1 Transport: EN 60721-3-2 Stationary operation: EN 60721-3-3

2.2.1 Transport and storage conditions

Components in original packaging

The following specifications apply to components in transport packaging:

Table 2-5 Ambient climatic conditions per EN 60721-3-1/-3-2, class 1K3/2K4

Transportation Storage

Ambient temperature range

Rate of temperature change

Relative humidity 10 ... 95 % 10 ... 95 % Permissible change

in relative air humidity

–40 ... 70 °C –25 ... 55 °C

<18 K <18 K Within one hour

max 0.1 % max 0.1 % Within 1 minute

Table 2-6 Test limits for mechanical environmental conditions

Vibration

to EN 60068-2-6

Shock resistance

to EN 60068-2-27

g  9.81 m/s2 (acceleration due to gravity)

Frequency range 5 ... 9 Hz Constant deflection 7.5 mm Acceleration amplitude 9 ... 200 Hz: 2g Acceleration 30g Duration of nominal shock 6 ms Number of nominal shocks 18 shocks Shock form Half-sine

2-31

2

Connection Conditions

2.2 Climatic and mechanical environmental conditions

Shipment of backup batteries

Backup batteries must only be transported in the original packaging. No special approval is needed for transporting backup batteries. The lithium content is approximately 300 mg.

Note

The backup battery is classified as a hazardous substance, Class 9, in accordance with the relevant air-freight transportation regulations.

Danger

!

Incorrect handling of backup batteries can lead to a risk of ignition, explosion and combustion. The stipulations of EN 60086-4, in particular regarding avoidance of mechanical or electrical tampering of any kind, must be complied with.

For more information on handling batteries, see section 9.1.

2.2.2 Operating conditions

Climatic environmental conditions

If the specified values cannot be maintained, then a heat exchanger or air conditioner must be provided.

Table 2-7 Climatic environmental conditions to EN 60721-3-3, Class 3K3

Ambient temperature range

Rate of temperature change

Relative humidity 5 ... 90 % Permissible change in the

relative air humidity Moisture condensation

and ice formation Dripping water, spray,

splash water, water jets Air inlet Without caustic gases, dusts and oils Atmospheric pressure 1060 to 920 kPa 0 to 1000 meters above mean sea

Derating At altitudes of 1000 to 4000 m above SL, the upper limit

0 ... 55 °C

max. 0.5 K Within 1 minute

Max. 0.1 % Within 1 minute

not permissible

level

temperature is to be lowered by 3.5 °C/500 m.

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

Mechanical

2

environmental conditions

Connection Conditions

2.2 Climatic and mechanical environmental conditions

Table 2-8 Test limits for mechanical environmental conditions

Gases that can adversely affect the function

Dust that can adversely affect the function

Vibration

to EN 60068-2-6

Shock resistance

to EN 60068-2-27

g  9.81 m/s2 (acceleration due to gravity)

Frequency range 10 ... 58 Hz Constant deflection 0.075 mm Acceleration amplitude 58 ... 200 Hz: 1g Acceleration 5g Duration of nominal shock 30 ms Number of nominal shocks 18 shocks Shock form Half-sine

Degree of severity 3C2 as per EN 60721-3-3

When working in areas where gases, dust and oils may be hazardous to functionality, the controller must be operated in a control cabinet with a heat exchanger or with suitable supply air.

Maximum permissible dust contents in the air circulating in the cabinet:

– Suspended solids 0.2 mg/m

3

– Deposits 1.5 mg/m2/h

Radio interference

Note

The dust precipitate must be removed at appropriate time intervals.

Relevant standards: EN 61000-6-3 and -4

Table 2-9 Limit values for radio interference suppression in industrial environments

Limit class as per EN 61000-6-4

Conducted radio interference A (Industry) Radio interference A (Industry)

Note

The user must consider interference radiation for the complete system. Particular attention should be paid to cabling. Please contact your sales representative for assistance and support.

If compliance with limit value class B (residential areas) is required, please contact your local Siemens office or representative.

2-33

Á

2

Connection Conditions

2.3 Technical data of the individual components

Table 2-10 General technical data

Security

Protection class I (protective conductor) as per EN 61800-5-1 Degree of protection

per EN 60529 Approvals CE / cULus Degree of contamination 2 Cooling Open circuit ventilation

Mechanical environmental conditions

Transport

2M2 according to EN 60721-3-2

(in transport packaging) Storage 1M2 according to EN 60721-3-1

Table 2-11 Mechanical data

IP20 or IPXXB

БББББББ

Component

CCU box

3 axes

2 axes CCU Single I/O module NCU terminal block

Table 2-12 Electrical data

Components Rated voltage

CCU box

3 axes 2 axes

CCU

Power supply via SIMODRIVE 611

power supply (I/R or OI module).

Power supply via other devices is not

permitted.

Single I/O module 24 V for logic supply,

24 V for load supply,

NCU terminal block 24 V for logic supply, load supply directly

on the DMP module

ББББББББ

width x height x depth in mm

Dimensions

150 x 490 x 268

ББББББББ

Internal heat dissipation

Internal and external heat dissipation

150 x 307 x 220

50 x 374 x 153 257 x 100 x 40

Max. power loss at

rated voltage

Approx. 350 W

internal/external/total

69/ 111 /180 W

Approx. 25 W Refer to table 2-3

Weight

in kg

ÁÁÁ

(approx.)

ÁÁÁ

11.3

11.4

1.6

1.7

0.5

Max. current

Refer to table 2-3

0.3 A 12 A

0.5 A

2-34

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

2.4 MPI/OPI network rules

2

Connection Conditions

2.4 MPI/OPI network rules

Application

Network installations

The following devices can be interconnected across the MPI bus:

 CCU

 PCU

 HT 6

 HHU

 MSTT/MCP

The MPI interconnecting cables are available in different lengths.

When installing a network, observe the following basic rules:

1. The MPI connection can be routed from one user to the next by plugging the MPI connector of the outgoing cable onto the MPI connector of the incoming cable.

2. The bus line must be terminated at both ends. To do this, enable the terminating resistor in the MPI connector of the first and last node and disable the remaining terminating resistors (see figure 2-3).

Note

 Only two inserted terminating resistors are permitted.  In the case of the HHU/HT 6, bus terminating resistors are permanently

integrated in the device.

3. At least 1 terminal must be supplied with 5 V. This is done by connecting an MPI connector with the terminating resistor connected to an energized device.

Notice

The CCU must be located at the end of the connection.

4. Stubs (feeder cable from bus segment to node) should be as short as possible.

Note

Unused stubs must be removed.

5. Every MPI node must first be connected and then activated. When disconnecting an MPI node, first deactivate the connection and then remove the connector.

6. A maximum of two of the HHU and HT 6 components can be connected for each bus segment.

2-35

2

Connection Conditions

2.4 MPI/OPI network rules

7. The following cable lengths for MPI or OPI for standard use without repeater

Another possibility is two identical components, provided they have different node addresses. For setting the addresses (also see corresponding component section):

– HHU: Via DIP switch or display (see “Handheld unit” section), – For HT 6, by adapting the address before commissioning (refer to

Operating Components “Handheld Terminal HT 6”).

No bus terminating resistors may be inserted at the distributor boxes of an HHU or HT 6 (refer to the note on item 2.)

If required, more than one HHU/HT 6 can be connected to a bus segment using intermediate repeaters.

may not be exceeded: MPI (187.5 kbaud): Max. total cable length is 1000 m OPI (1.5 Mbaud): Max. total cable length is 200 m.

46

OFF On

O N

46

O N

55

Terminating resistor

Fig. 2-3 MPI connector

Reference: Catalog IK PI – Industrial Communication for Automation

and Drives



2-36

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

Design and Installation of the 810D

3.1 Structure of the SINUMERIK 810D

The SINUMERIK 810D consists of two components:

3

CCU3 module 3-axis CCU box

2-axis CCU box

Fig. 3-1 Components of the SINUMERIK 810D

1. CCU module (Compact Control Unit)

2. 3-axis CCU box (sheet-metal housing with 3 integrated power modules for fitting the CCU module) with internal heat dissipation or

3. 2-axis CCU box with external and internal heat dissipation (sheet-metal housing with 2 integrated power modules for fitting the CCU module). As-delivered state: internal heat dissipation. Alteration: Unscrew mounting bracket with screwdriver (Torx for M6) and plug in the 4 ground springs (see Installation Guide).

3-37

3 Design and Installation of the 810D

3.2 Assembly of the SINUMERIK 810D

Open equipment

These modules are open equipment. This means they may only be installed in housings, cabinets, or in electrical equipment rooms that can only be entered or accessed with a key or tool. Housings, cabinets, or electrical equipment rooms may only be accessed by trained or authorized personnel. An external fire protection casing is required.

3.2 Assembly of the SINUMERIK 810D

Preparing for installation

Position in the overall assembly

Installation of the CCU box

You require the following tool to assemble the SINUMERIK 810D:

 Screwdriver for slot-head screws sizes 0 and 1

 Screwdriver for Torx screws M4 and M5

The CCU box must be installed to the right of the SIMODRIVE power supply module. It is possible to mount a further power module to the left of the box.

The CCU box is fitted to the right of the power supply. 4 M5 screws are recommended for fixing.

1. Remove the plastic cover over the DC link bars by loosening it with a flat screwdriver in the gap on the top and then folding it forward and down.

2. With two M4 Torx screws, connect the DC link bars of the power supply unit and CCU box and possibly the next module also. Ensure that all the DC link connecting screws are securely fastened.

3. Place the cover into the matching cut-outs with the plastic lugs facing downward and close the DC link by folding the cover backward until the topside latch clicks.

3-38

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

3 Design and Installation of the 810D

3.2 Assembly of the SINUMERIK 810D

SIEMENS

SIMODRIVE

Power supply (I/R or OI)

LDC

Axis expansion plug-in unit, left

LDC810D

(CCU3)

Axis expansion plug-in unit

Fig. 3-2 Overall assembly SINUMERIK 810D with SIMODRIVE 611 power module

Installation of the CCU

Sequence:

1. Connect the battery on the CCU module

2. Insert and fix the CCU module into the guide rails of the CCU box

To be able to ensure compliance with the EMC conditions and resistance to vibrations, it is necessary to tighten the slot-head screws (1) (see figure 3-3).

3-39

3 Design and Installation of the 810D

3.2 Assembly of the SINUMERIK 810D

–X307

CCU3

1

CCU box

Battery

DC link rails

1

Fig. 3-3 Assembly of the SINUMERIK 810D

Installation instructions

Pay attention to the following when installing the SINUMERIK 810D:

1. Cooling clearance top and bottom, approx. 100 mm

2. The shields of the motor cables must be connected after mounting the shield sheet, see section 2.1.3.

3. The equipotential bonding conductor must be connected for each motor.

4. Additional mounting depth is required for mounting the connector.

5. The tightening torque of the screws must be complied with.

6. The screws of the DC link busbars must all be tightened.

PE conductor connection

3-40

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

3 Design and Installation of the 810D

3.2 Assembly of the SINUMERIK 810D

Mounting the shielding plate

130

The metal sheet is mounted on the 3-axis CCU box with the 3 screws on the underside (2-axis CCU box, see figure Mounting the shielding plate). The shielding plate is supplied in the box. The tube clip for connecting the shield is contained in the scope of supply of the ready-assembled SIEMENS motor cable.

Additional connection option for shield connection M5x10

Cooling clearance 100 mm

The tightening torque must be complied with when mounting modules!! M3: 0.8 Nm M4 : 1.8 Nm M5 : 3 Nm M6 : 6 Nm

100

443

480

466

Motor connection

A3 A2 A1

Cooling clearance 100 mm

288

Fig. 3-4 Dimension drawing of the 3-axis CCU box

Shielding plate

100

120

10025

150

Equipotential bonding terminal

3-41

3 Design and Installation of the 810D

3.2 Assembly of the SINUMERIK 810D

24.8

 0.2

149.5

100

 0.2

M3

M4

8

+

24.85

Heat sink

0.3

466

Seal

Kühlkörper

480

100 443

Dichtung

100

20

Cooling clearance Lüftungsfreiraum

130

The tightening torque must be complied with when mounting modules!! M3: 0.8 Nm M4 : 1.8 Nm M5 : 3 Nm M6 : 6 Nm

57

90

 0.2

View without

100

 0.2

150

Tube clip for shield Schlauchschelle für Schirm

(included in the scope of supply of our preassembled Siemens motor cable)

(im Lieferumfang unserer konfektionierten Siemens Motoranschlussleitung enthalten)

e.g. made by Rasmussen GmbH D–63461 Maintal

Postfach 1149 Phone: 06181-403-0

Fax: 06181-403-210

Fig. 3-5 Dimension drawing of the 2-axis CCU box

protective cover

Darstellung ohne

Abdeckblech

Attention! The shield attachment is not for strain relief Achtung! Die Schirmauflage

ist keine Zugentlastung

77

232

289

Cooling clearance Lüftungsfreiraum

Notice: Place shielded cables entering the control cabinet as close as possible to the cabinet!

Achtung: Geschirmte Leitungen beim Eintritt in den Schaltschrank kürzmöglichst am Schrank auflegen!

110

Shielding plate Schirmblech

Screw M2.5x8 Schraube M2.5x8

3-42

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

Mounting the shielding plate

Montage Schirmblech

3 Design and Installation of the 810D

3.2 Assembly of the SINUMERIK 810D

Fig. 3-6 2-axis CCU box: Mounting the shielding plate

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

Alteration for external heat dissipation Umbau fuer externe Entwärmung

Attach ground spring (packed in flat bag) Massefedern aufstecken (in Flachbeutel verpackt)

Loosen M6 screws and remove bracket Schrauben M6 lösen und Winkel abnehemen

Attach ground spring (packed in flat bag)

Massefedern aufstecken

(in Flachbeutel verpackt)

Fig. 3-7 2-axis CCU box: Alteration for external heat dissipation

3-43

Á

3 Design and Installation of the 810D

3.2 Assembly of the SINUMERIK 810D

Equipotential bonding terminal

Motor cables

Fig. 3-8 Terminal for motor and encoder cables (3-axis CCU box)

A3A2A1

Equipotential bonding terminal

Attachment point for motor brake plug connection

Shielding plate

Tube clip

Shield connection

Type of plug connection* Motor brake:

PHOENIX Type: MSTB 2.5/2-STF-5.08-BD1-2SO Order No.: 1863 631 Type: MVSTBU 2.5/2-GFB-5.08 Order No.: 1788 347

*Included with SIEMENS motor cable

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

3.3 Power supply

Power supplies are available as a stabilized infeed/regenerative feedback module (I/R module) and as an open-loop control infeed module (OI) The provide the necessary operating voltages and the necessary power for the system in different power ranges.

The I/R modules can feed excess DC link energy (e.g. in braking operation) back into the network. OI modules dissipate the braking energy in a pulsed resistor.

The power supply module is the first module on the left in the sequence of modules.

Line filters must be used to comply with the EMC rules of the CE standard.

3 Design and Installation of the 810D

3.3 Power supply

Terminals 72, 73, 74

Permissible modules

“Ready” message from NC and drive. Terminals 72 and 73 are closed in the fault-free condition.

 Power supply module: OI 5 kW, OI 10 kW, OI 28 kW,

I/R 16 kW, I/R 36 kW, I/R 55 kW; I/R 80 kW; I/R 120 kW

 SIMODRIVE filter modules or commutation reactors

Note

The power supply and filter modules/reactors are described in the Configuration Manual Converters SIMODRIVE 611 digital (settings, technical data, circuit suggestions).

Danger

!

A hazardous voltage will be present for a further 5 minutes after the system has been shut down.



3-45

3 Design and Installation of the 810D

3.3 Power supply

Notes

3-46

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

Description of the SINUMERIK 810D

4.1 Components of the SINUMERIK 810D

4.1.1 Overview

The structure of the SINUMERIK 810D is compatible with the SIMODRIVE 611 digital module series. The SINUMERIK 810D is operated with the SIMODRIVE 611 power supply modules (OI or I/R modules).

4

3-axis CCU box

2-axis CCU box

CCU module

Basic housing with fans for fitting the CCU module with three integrated power modules 1x18A/36A (FSD) or 24A/32A (MSD) and 2x6A/12A (FSD) and slot for CCU module (internal heat dissipation).

Basic housing with fan for fitting the CCU module with two integrated power modules 9A/18A (FSD) and slot for CCU module (internal and external heat dissipation).

The CCU module (Compact Control Unit) of the SINUMERIK 810D performs all CNC, PLC, communication, and closed-loop control tasks. The CCU has 6 measuring channels. Each drive requires one measuring channel for the motor measuring system. If measuring channels of the basic unit are left over, they can be assigned freely as direct measuring channels, e.g. for the spindle.

Additional measuring channels are obtained by using a 611D closed-loop control module (1- or 2-axis control module) with or without a direct measuring system (DMS). The 611D closed-loop control module performs closed-loop control of the drive. The unused measuring channels can be freely assigned.

4-47

4 Description of the SINUMERIK 810D

4.1 Components of the SINUMERIK 810D

PCMCIA card

(NC card)

Closed-loop control

The NC card with the system software must remain inserted during operation.

Note

For a software upgrade, the export software can be copied onto the internal flash EPROM.

In addition to the software upgrade, the PCMCIA card can also be used for series commissioning; see References: /IAC/, Commissioning Manual 810D

The closed-loop control complies with the 611D standard control with the following restrictions as compared with SINUMERIK 840D:

 5-axis transformation

 Safety integrated

 Analog axis

 Hydraulic drives

 Drive-independent stop/retract

 3D clearance control

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

4 Description of the SINUMERIK 810D

4.1 Components of the SINUMERIK 810D

Drive functions of SIMODRIVE 611D

Table 4-1 Function differences for SIMODRIVE 611 digital

Function Standard 2 Performance 1 Performance 2

Disabling of pulses via NCK (safety)

Encoder limit frequency, direct measuring system

Motor data sets, expansion from 2 to 4 for MSD

Speed actual-value filter for analog 611U

i2t power module limitation

Minimum current controller cycle

The following table shows drive functions and values, which differ from module to module.

1-axis 2-axis

(FSD

only)

No No Yes Ye s

200 kHz 300 kHz 350 kHz 300 kHz

No No Yes Ye s

125 µs

1-axis 2-axis

62,5 µs

(FSD only)

125 µs

(2-axis)

62,5 µs

31,25 µs

CCU3/CCU3.4

(6-axis/810D)

1)

Standard 156.5 µs

(option 125 µs)

Minimum speed controller cycle

Minimum position controller cycles

Speed controller rise time

Rated frequency of closed speed control loop

Max. motor speed (4-pole)

Max. electrical fundamental frequency for motor

Smooth running

Pulse multiplication factor

1) As from drive software version 6.4.2 for FSD 1-axis

125 µs

2 ms 4 ms 0.5 ms 1 ms 0.5 ms 1.5 ms to 3 axes;

1.4 ms 4 ms 0.8 ms 1.4 ms 0.8 ms approx. 1.4 ms

550 Hz 160 Hz 1 kHz 550 Hz 1 kHz approx. 550 Hz for 125 µs;

0.2 µm 1.5 µm 0.1 µm 0.2 µm 0.1 µm

500 µs 62,5 µs 125 µs 62,5 µs

18000 rpm 36000 rpm 18000 rpm 42000 rpm 18000 rpm

666 Hz 1333 Hz 666 Hz 1400 Hz 666 Hz for 125 µs

128 2048 2048 128

31,25 µs

1)

Standard 312 µs

(option 125 µs)

as from 3 axes 2.5 ms

(standard 2.5 ms)

approx. 300 Hz for 312 µs

Current controller cycle

approx. 1.5 µm

4-49

4 Description of the SINUMERIK 810D

4.2 Interfaces

4.2.1 Overview

Brief description

The modules have the following interfaces:

 Optical encoder (up to six measuring systems for unconditioned voltage

signal encoder, 1 V

, incremental/absolute with EnDat interface )

pp

 Three axis expansion connections for up to three ext. power modules

 Drive bus for axis expansion with 611D modules and connection from NCU

terminal block

 PCMCIA slot

 Backup battery on board

 Connection for cable distributor (handwheel, probe)

 MPI interface for operator panel front, programming device, ...  PLC I/O bus (P/K bus)

 PROFIBUS DP

 External pulse enable common for all drives

 Start disable terminals AS1, AS2

 BERO input for ext. zero mark (spindle)

 Displays for errors, status, power up

 Operating elements for commissioning, general reset, reset

 Four measuring sockets for diagnostics

 Device bus terminal

4-50

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

control

4 Description of the SINUMERIK 810D

Table 4-2 Overview of hardware interfaces

Interface CCU

Pulse interfaces (6 axes) 4 **)

Optical encoder 6

Closed-loop

NCK/PLC

Miscella-

neous

DAC test sockets Yes

BERO input Yes

Terminals (AS1, AS2, 663, 9,19) Yes

PBus/KBus Ye s

MPI interface Ye s

Drive bus (611D interface) Ye s

Connection for diff. handwheel Yes

Two measuring pulse inputs Yes

PCMCIA interface Yes

PROFIBUS DP Yes

Electronic PS (backplane) Yes

4.2 Interfaces

**) incl. 2 spindles

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4 Description of the SINUMERIK 810D

4.2 Interfaces

4.2.2 Description of the interfaces, operating and display elements

Overview

Meas. system terminals X411-X416

Location of the interfaces, operating and display elements

I/O interface (cable distributor)

P-bus/K-bus interface

Profibus DP MPI interface

Measuring sockets Various error and status LEDs (H1/H2)

Pulse interface (axis 3) external

7-segment display

NCK commissioning switch (S3)

PLC commissioning switch (S4)

Device bus interface X151

+5V

Terminal block

611D drive bus (master)

PR

NF

PS

SF

PF

CB

PF0

–

-

AS1 AS2

663 9 B 19

-X431

PCMCIA slot

RESET button

Pulse interfaces (axes 4 - 6)

Fig. 4-1 SINUMERIK 810D with CCU 3, position of the interfaces, operating and display elements

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

4 Description of the SINUMERIK 810D

4.2 Interfaces

Signal names

Signal types

X102

The signal names in the following tables mean:

P5 Logic power supply 5 V GND Logic reference potential ground P5EXT Logic power supply 5 V isolated M5EXT Logic reference potential for P5EXT

The signal types in the following tables mean:

B Bidirectional I Input O Output V Voltage OC Open Collector

PROFIBUS DP interface

Connector name: X102 Connector type: 9-pole D-Sub socket connector Maximum cable length: 200 m Special features: isolation (safe isolation)

12 MBaud

Table 4-3 X102 pin assignments

X102

Pin Name Type Pin Name Type

1 Not assigned 6 P5EXT VO 2 M24EXT *) VO 7 P24EXT *) VO 3 RS_L2DP B 8 XRS_L2DP B 4 ORTSAS_L2DP O 9 IRTSPG_L2DP I 5 M5EXT VO

X111

*) 24 V only present if 24 V is fed to X121 (cable distributor).

Signal names

RS, XRS RS485 data ORTSAS Request to Send programmable controller IRTSPG Request to Send programming device

P-bus/K-bus Connection of S7-300 I/O and single I/O module

Connector name: X111 Connector type: 25-pole D-Sub socket connector Maximum cable length: 10 m Special features: non-isolated (no safe isolation)

4-53

4 Description of the SINUMERIK 810D

4.2 Interfaces

Table 4-4 Assignment of the P-bus/K-bus terminal X111

Pin Name Type Pin Name Type

1 RS_ALARM_N I 14 RS_ALARM I 2 IM_ADR0_N O 15 IM_ADR0 O 3 IM_ADR1_N O 16 IM_ADR1 O 4 IM_ADR2_N O 17 IM_ADR2 O 5 M (GND) VO 18 K<2> O 6 KBUS_B_N B 19 KBUS_B B 7 RS_OD_N O 20 RS_OD O 8 RS_DIDO_N B 21 RS_DIDO B

9 RS_CLK_N O 22 RS_CLK O 10 RS_COM_N O 23 RS_COM O 11 RS_LAT_N O 24 RS_LAT O 12 RS_READY_N O 25 RS_READY I 13 Not assigned –

X111

X121

Signal names

RS_ALARM, RS_ALARM_N IM_ADRi, IM_ADRi_N P-bus line number KBUS_B, KBUS_B_N RS_OD, RS_OD_N RS_DIDO, RS_DIDO_N P-bus data RS_CLK, RS_CLK_N P-bus cycle RS_COM, RS_COM_N P-bus command RS_LAT, RS_LAT_N RS_READY, RS_READY_N P-bus ready signal

I/O interface (cable distributor for handwheel and probe)

Connector name: X121 Connector type: 37-pole D-Sub male connector Maximum cable length: 25 m for all functions Special features: Handwheels non-isolated

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

4 Description of the SINUMERIK 810D

4.2 Interfaces

Table 4-5 Pin assignment of the cable distributor interface X121

X121

Pin Name Type Pin Name Type

1/2 M24_EXT VI 18 MPG0 *B I

3 OUTPUT_1 O 19 Not assigned –

4 OUTPUT_0 O 20/21 P24_EXT VI

5 INPUT_3 I 22 OUTPUT_3 O

6 INPUT_2 I 23 OUTPUT_2 O

7 INPUT_1 I 24-27 MEXT VI

8 INPUT_0 I 28 MEPUS 1 I

9 MEPUS 0 I 29 MEPUC 1 I 10 MEPUC 0 I 30 MPG1 A I 11 MPG1 *A I 31/32 M (GND) VO

12/13 PENC1 VO 33 MPG1 B I

14 MPG1 *B I 34 MPG0 A I 15 MPG0 *A I 35/36 M (GND) VO

16/17 PENC2 VO 37 MPG0 B I

X122

The terminals with a gray background are not assigned.

Signal names

PENC1 P5 power handwheel 1 PENC2 P5 power handwheel 2 MPGi_B Meas. pulse encoder (handwheel encoder) track B (i ={1..0}) MPGi_*B Meas. pulse encoder (handwheel encoder) track B inverted

(i ={1..0}) MPGi_A Meas. pulse encoder (handwheel encoder) track A (i ={1..0}) MPGi_*A Meas. pulse encoder (handwheel encoder) track A inverted

(i ={1..0}) MEPUCi Meas. pulse MEPUSi Meas. pulse

MPI interface (187.5 kBaud)

Connector name: X122 Connector type: 9-pole D-Sub socket connector Maximum cable length: 200 m

Table 4-6 X122 pin assignments

X122

Pin Name Type Pin Name Type

1 Not assigned – 6 P5EXT VO 2 M24EXT VO 7 P24EXT VO 3 RS B 8 XRS B 4 ORTSAS O 9 IRTSPG I 5 M5EXT VO

Signal names

Analogous to X102 (table 4-3)

4-55

4 Description of the SINUMERIK 810D

4.2 Interfaces

X130

X151

X304, X305, X306

X307

X341, X342, X351, X352

SIMODRIVE 611D-Drive bus interface and I/O extension

Connector name: X130 Connector type: 36-pole Micro Ribbon Maximum cable length: 10 m Special features: non-isolated (no safe isolation)

Device bus interface (power supply)

Connector name: X151 Connector type: 34-pole ribbon cable connector, male

Connection for axis expansion plug-in unit

Connector name: X304, X305, X306 Connector type: 20-pole ribbon cable connector, male

Pulse interface for axis 3

Connector name: X307 Connector type: 20-pole ribbon cable connector, male

Measuring sockets for output of 3 analog signals. The measuring values that are output are assigned in the software.

Connector name: X341, X342, X351, X352 Connector type: Measuring socket 2 mm

X411-X416

Table 4-7 Assignment of the measuring sockets X341 to X352

Measuring socket Position on the

X351

X352

X341

X342

CCU

   

   

   

   

Meaning Section

DAC 1 0– 5V

DAC 2 0– 5V

DAC 3 0 – 5V

Ground for all DACs

6 x measuring system connection for indirect and direct position sensing

Connector name: X411-X416 Connector type: 25-pole, D-Sub male connector Signals with a gray background are not required for a direct measuring system.

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

4 Description of the SINUMERIK 810D

4.2 Interfaces

Table 4-8 Assignment of the measuring system terminal X411-X416

X411-X416

Pin Name Type Pin Name Type

1 PENC1/2 VO 14 PENC1/2 VO 2 M (GND) V 15 ENCDATi B 3 APi I 16 M (GND) V 4 ANi I 17 RPi I 5 M (GND) V 18 RNi I 6 BPi I 19 CPi I 7 BNi I 20 CNi I 8 M (GND) V 21 DPi I

9 Not assigned – 22 DNi I 10 ENCCLK O 23 XENCDATi B 11 Not assigned – 24 M (GND) V 12 XENCCLK O 25 THMOTCOM I 13 THMOTi I

Signals with a gray background are not assigned when connecting direct measuring systems.

Signal names

<Signal name>i means signal of the measuring system i with i = 1, ..., 6

PENC1/2 Encoder power supply

(PENC1: X411-X413, PENC2: X414-X416) APi Incremental signal A BPi Incremental signal B ANi Incremental signal A

BNi Incremental signal B ENCCLK BMI clock signal RPi Incremental signal R XENCCLK BMI clock signal RNi Incremental signal R THMOTi Motor temperature CPi Incremental signal C ENCDATi BMI data signal CNi Incremental signal C XENCDATi BMI data signal DPi Incremental signal D DNi Incremental signal D

(not for direct meas. system) XBMIDAT BMI data signal THMOTCOM Motor temperature

Note

The encoder power supply is not stabilized; that means: no remote/sense operation. This limits the encoder cable length.

 EQN 1325:  18 m  ERN 1387:  25 m  Non-Siemens encoder with power consumption  300 mA: 18 m

4-57

4 Description of the SINUMERIK 810D

4.2 Interfaces

X431

Terminal block for connection of starting lockout, pulse release (all drives) and external zero mark (BERO)

Connector name: X431 Connector type: 6-pole Combicon terminal (Phoenix

2

connector), for 1.5 mm

Table 4-9 Terminal signals drive X431

Termi-

Signal Front panel

nal

1 EN– 19 Reference ground for enable potential V 2 BERO B Input for external zero mark (BERO) I 3 EN+ 9 Enable potential + 24 V,

4 T663 T663 Pulse enable for all drives

5 AS2 AS2 Relay starting lockout

6 AS1 AS1 Relay starting lockout

labeling

reference terminal is terminal 19

(FSD and MSD)

(feedback terminal 663)

conductor cross-section

Function Type

V

I

Signal names

AS1 Feedback drive enable (NC) AS2 Feedback drive enable (NC) T663 Control SH relay BERO BERO input EN+ Enable voltage (+24 V) EN– Enable voltage (24 V reference)

Note

The “starting lockout” relay is operated with terminal 663. If opened, the control pulses are blocked and the motors are switched torque-free.

4-58

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

4 Description of the SINUMERIK 810D

4.2 Interfaces

Operating and display elements

Fig. 4-1 shows the position of the operating and display elements on the front panel.

Table 4-10 Operating and display elements on the CCU module

Descrip-

tion

RESET (S1)

S3

S4

LEDs (left row)

LEDs (right row)

H3 7 segment Software-assisted output of test and diagnostics messages

Type Meaning

Button

Rotary switch

green LED

red LED

yellow LED

yellow LED green LED

red LED red LED yellow LED yellow LED

Triggering a hardware reset to reset the control and drive followed by a complete restart.

NCK commissioning switch Position 0: Normal operation Position 1: Clear and reset NCK Position 2: Software update NCK of memory card Position 3...7: not used

PLC mode switch Position 0: PLC-RUN Position 1: PLC-RUN-P Position 2: PLC-STOP Position 3: MRES

+5V: lit when the supply voltage is within the tolerance

range.

NF: lit if the NCK or PLC watchdog

has responded

SF: lit in the event of drive error. No longer lit following

system power up in the fault-free condition.

CB: lit when data transmission is in progress

via the MPI interface.

P24: lit on failure of the 24V power supply PR: PLC-RUN state

PS: PLC-STOP state PF: lit on PLC error PFO: PLC-FORCE state RST: lit briefly on reset.

DAC measuring sockets

DAC 1

DAC 3

Fig. 4-2 DAC measuring sockets on CCU modules

DAC 2

Ground

4-59

4 Description of the SINUMERIK 810D

4.2 Interfaces

4.2.3 Cable distributor

Cable distributor (I/O interface) X121

The cable distributor splits the X121 interface of the CCU into

 two connections of differential handwheel,  two connections of meas. pulse input,

in max. seven single cables.

90

max. 2 cables handwheel 6FX2002-4AA21-0

top

1

max. 2 cables for probe 6FX2002-4AA41-0

7

bottom

Fig. 4-3 Cable distributor

The cable distributor (37-pole) consists of connector housing (SINUMERIK version) for a 37-pole D-Sub connector with an enlarged interior. The rear contains seven cable inputs where the cables must be attached as shown in table 4-12.

Plug the cables into connectors X1 to X10 in the opened cable distributors and route the cable into the cable entry. Make sure that the shield jackets that became free have a large conductive connection to the metallic contact areas as shown in figure 4-4. Locate the upper terminal bar in such a way that its “teeth” are facing the “teeth” of the lower terminal bar and then secure the upper housing section.

This will reliably press the cable shields between the contact areas of the contact springs and contact them. Fixing to the front panel of the CCU routes the shield potential via the contact springs of the cable distributor.

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

1 2

2nd handwheel

4

R

d

Location of interfaces

4 Description of the SINUMERIK 810D

4.2 Interfaces

The DIP-FIX switches inside the cable distributor 6FX 2006-1BA01 must be set as follows:

Table 4-11 Setting the DIP-FIX switches (S1 to S6) in the cable distributor

Switches S1 S2 S3 S4 S5 S6

Open x x x x Closed x x

1 2345 67

Cable inlets

Terminal caps

Contact surfaces

Connector X1-X10

X1 X2 X4 X5 X6 X7 X8 X9 X10X3

X11

1

(top)

7

S1S2 S3S4

S5

S6

Fig. 4-4 Position of the interfaces of the cable distributor

Table 4-12 Connector assignments

Connector No. Cable routing Peripherals

X1 X2 X3 X4 X5 3 2nd measuring probe X6 X7 X8 5 Reserved X9 6 Reserved

X10

(bottom)

Plug-in connectors X1...X10

D-Sub female connector

1st handwheel

eserve

1st measuring probe

4-61

4 Description of the SINUMERIK 810D

4.2 Interfaces

Pin assignment

Table 4-13 Cable distributor pin assignment

Pin no. 37-pole

connec-

tor

9

10

1

20

2

21

3

22

4

23

5

24

6

25

7

26

8

27

28

29

11 30 12 31 13 32 14 33

15 34 16 35 17 36 18 37

Signal

name

–

MEPUS 0

–

MEPUC 0

–

MEPUS 1

–

MEPUC 1

MPG1 A MPG1 A MPG1 5V MPG1 0V MPG1 5V MPG1 0V MPG1 B MPG1 B

MPG0 A MPG0 A

MPG0 5V MPG0 0V

MPG0 5V MPG0 0V MPG0 B MPG0 B

Connector designation: X1...X10 Connector type: DU-BOX plug connectors

DU BOX

connector

no./pin

X10/2 X10/1 X10/4 X10/3

X9/2 X9/1 X9/4 X9/3

X8/2 X8/1 X8/4 X8/3

X7/2 X7/1 X7/4 X7/3 X6/2 X6/1 X6/4 X6/3

X5/2 X5/1 X5/4 X5/3

X4/2 X4/1 X4/4 X4/3 X3/2 X3/1 X3/4 X3/3

X2/2 X2/1 X2/4 X2/3 X1/2 X1/1 X1/4 X1/3

Cable

routing

Cable

Order No.

6FX2002-4AA

7 41-0

6 41-0 Reserved

5 41-0 Reserved

4 21-0 Reserved

3 41-0

2 21-0

1 21-0

Core color I/Os Terminal

rd or

bn

bk

shield

rd or

bn

bk

shield

rd or

bn

bk

gn

ye

vt

bu

shield

rd or

bn

bk

gn

ye

vt

bu

shield

1st probe

2nd probe

2nd handwheel

6FC9320-5DB

1st handwheel

6FC9320-5DB

Signal +24V

Reference

signal

Signal +24V

Reference

signal

A

A 5 V 0 V 5 V 0 V

B

A

A 5 V 0 V 5 V 0 V

B

Signal names

4-62

MPG0/1 5V Supply voltage handwheel 0/1, 5 V

1)

MPG0/1 0V Supply voltage handwheel 0/1, 0 V MPG0/1 A/A Differential handwheel input 0/1 A/A MPG0/1 B/B Differential handwheel input 0/1 B/B MEPUS 0/1 Meas. pulse signal 0/1 MEPUC 0/1 Meas. pulse common (reference ground) 0/1

1) total of max. 1 A, i.e. max. 500 mA per handwheel

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

4 Description of the SINUMERIK 810D

4.3 Measuring system

4.3.1 Assignment of measuring systems and motor connection

Motor measuring system and motor connection

A certain motor connection is permanently assigned to each measuring system

M1

-X411M2-X412M3-X413

M4

-X414

M5

-X415

M6

-X416

OI

or

FSD FSD810D CCU3

Motor 6

Motor 3

I/R

MSD

A1 A2

Motor 1 Motor 2

Motor 4 Motor 5

Fig. 4-5 Assignment of measuring system to motor connection

Table 4-14 Assignment of measuring system to motor connection or axis expansion

Connection of

measuring system

X411 A1 internal – X412 A2 internal – X413

alternatively

X414 – X304 X415 – X305 X416 – X306

Motor connection Connection of axis expansion

A3 internal

A3 external

–

X307

4-63

4 Description of the SINUMERIK 810D

4.3 Measuring system

4.3.2 Encoder systems that can be evaluated

Incremental measuring systems

Incremental systems with two 90-degree offset sinusoidal voltages signals A, B and a reference mark R. E.g. ERN 1387 (motor measuring system)

Transfer: Differential signals

; B, B and R, R

A, A

Amplitude A – A typ. 1 Vpp

Amplitude B – B

Amplitude R – R Power supply: 5 V ±5 %

Maximum supply current: 300 mA

Max. encoder signal frequency that can be evaluated: 350 kHz

Note

For the above frequency, the signal amplitude must be  60 % of the typical amplitude and the deviation of the phase offset from the ideal 90

track A and B must be   30

Pay attention to the frequency characteristic of the encoder signals.



.

typ. 1 Vpp

typ. 0.5 Vpp...1 Vpp



between

A–A

0

90 el.

B–B

0

R–R

0

Fig. 4-6 Signal curve of incremental encoders for clockwise rotation

360 el.

Uniqueness range

0.5 V

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

4 Description of the SINUMERIK 810D

4.3 Measuring system

Absolute (EnDat) measuring systems

Single-turn, multi-turn, and linear absolute measuring systems with two 90_ offset sinusoidal voltage signals A, B, and EnDat interface,

e.g. multi-turn encoder EQN 1325, single-turn encoder ECN 1313 or linear absolute measurement system LC181.

Transfer incremental signals: Differential signals

and B, B

A, A Amplitude A – A typ. 1 Vpp

Amplitude B – B

typ. 1 Vpp

Transfer serial signals: Differential signals

Data, Data

and Clock, Clock

Level: acc. to EIA 485 Power supply: 5 V ±5 %

Maximum supply current: 300 mA

Max. encoder signal frequency that can be evaluated: 350 kHz

Note

For the above frequency, the signal amplitude must be

 60 % of the typical

amplitude and the deviation of the phase offset from the ideal 90 between track A and B must be

  30

.



Pay attention to the frequency characteristic of the encoder signals.

A–A

0

90 el.

360 el.

B–B

0

Fig. 4-7 Signal curve for incremental tracks for a clockwise rotation

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4 Description of the SINUMERIK 810D

4.3 Measuring system

4.3.3 Measuring channels, indirect and direct measuring system

Measuring channels for

SINUMERIK 810D

The six measuring channels on the SINUMERIK 810D can be used both for indirect and for direct position sensing. A free measuring channel can, for example, be used for a direct spindle measuring system. Additional measuring channels can be obtained by using a 611D standard control module with/without direct measuring system.

Connecting

The following connecting cables are used for the SINUMERIK 810D:

cables

Table 4-15 Connecting cables for SINUMERIK 810D

No. MLFB Description

1 6FX2002-2CA31-10 2 6FX2002-2CG00-10

3 6FX2002-2CH00-10

4 6FX2002-2CA11-10

5 6FX2002-2AD00-10

6 6FX2002-2EQ00-10 7 6FX2002-2EQ10-10

1)

1), 2)

1)

Motor measuring system cable incremental, 25-pole connector Connecting cable for direct measuring system, 25-pole connector (for

connection to CCU only) Connecting cable for Multiturn absolute EnDat encoder, 25-pole

connector (for connection to CCU only) Connecting cable for direct measuring system, 15-pole connector (for

connection to 611D control only) Connecting cable for Multiturn absolute EnDat encoder, 15-pole

connector (for connection to 611 control only) Motor measuring system cable absolute, 25-pole connector Motor measuring system cable absolute, 25-pole connector

1)

2)

Length code, refer to Catalog NC Z

Measuring system end circular connector

Indirect measuring system FSD

A number is assigned to each cable. You will find these numbers (1-7) in the following figures.

The motor measuring system is also used for position sensing.

Two encoder systems are available:

 Incremental encoder

 Absolute encoder

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

4 Description of the SINUMERIK 810D

4.3 Measuring system

Indirect position (motor rotor position) and motor speed sensing M: Max. possible measuring steps

G: Accuracy of the encoder

system

M = 128 x Z per 360 degr. mech. Z...Increments

Z = 2048

G = 0.006 deg.

M = 128 x Z per 360 degr. mech. Z...Increments

Z = 2048

G = 0.006 deg.

X411

SINUMERIK 810D CCU module

X411

SINUMERIK 810D CCU module

FSD

1 6

1

7

Incremental

Motor

Incremental and multiturn absolute

EnDat

Motor

multiturn absolute: 4096 revolutions

Incremental/or

6

multiturn absolute

7

EnDat

Motor

M = 128 x Z per 360 degr. mech. Z...Increments

Z = 2048

G = 0.006 deg.

X130

SINUMERIK 810D CCU module

1

Axis expansion 611D control

multiturn absolute: 4096 revolutions

Fig. 4-8 Indirect position sensing with digital closed-loop control FSD

4-67

4 Description of the SINUMERIK 810D

4.3 Measuring system

Direct measuring system FSD

with free CCU measuring channel

SINUMERIK 810D CCU module

Voltage signals

SINUMERIK 810D CCU module

Voltage signals and EnDat absolute

X411

X416

Direkt position sensing for axis expansion

X130

The motor measurement system is used for sensing the motor position. A second measuring system, e.g. a scale, can be used for load-side position sensing if necessary. Incremental encoders, distance-coded incremental encoders, or EnDat absolute value encoders can be used (voltage signals).

Direct position sensing

FSD

1

Incremental motor position

with external 611D control

Axis expansion 611D control

or

32

1

Motor position incremental/absolute

Linear measuring system incremental/absolute

Motor *)

32

or

Linear measuring system incremental or incremental and absolute

Motor *)

M: Max. possible measuring steps G: Accuracy of the encoder

system

M = 128 per encoder signal period or lattice pitch

G is a function of the accuracy of the load-side encoder system.

M = 128 or 2048 for 611D convenience control per encoder signal period or lattice pitch

G is a function of the accuracy of the load-side encoder system.

Linear measuring system incremental or incremental

1

and absolute

Motor *)

or

54

X130

SINUMERIK 810D CCU module

Voltage signals and EnDat absolute

Axis expansion 611D control

Incremental motor position

Fig. 4-9 Direct position sensing with digital closed-loop control FSD

*) e.g. 1FK7

M = 128 per encoder signal period or lattice pitch

G is a function of the accuracy of the optional encoder system.

4-68

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

4 Description of the SINUMERIK 810D

4.3 Measuring system

Indirect measuring system MSD

The motor measuring system is also used for position sensing.

An encoder system is available:

 optical/incremental (1PH motor)

Indirect position (motor rotor position) and motor speed sensing

MSD

X411

SINUMERIK 810D CCU module

X130

SINUMERIK 810D CCU module

Axis expansion 611D control

1

Motor *)

1

Motor *)

Incremental

M: Max. possible measuring steps G: Accuracy of the encoder

system

M = 128 x Z per 360 degr. mech. Z...Increments

Z = 2048

G = 0.006 deg.

M = 128 x Z per 360 degr. mech. Z...Increments

Z = 2048

G = 0.006 deg.

Fig. 4-10 Indirect position sensing with digital closed-loop control MSD

*) e.g. 1PH7

4-69

4 Description of the SINUMERIK 810D

4.3 Measuring system

Direct measuring system MSD

Direct position sensing with free CCU measuring channel

SINUMERIK 810D CCU module

X411

X416

Voltage signals

X411

X431

The motor measurement system is used for sensing the motor position. A second measuring system, e.g. a rotary transducer, can be used for load-side position sensing if necessary. In the case of SINUMERIK 810D only encoders with voltage signals can be used.

M: Max. possible measuring steps

MSD

1

2

1

Motor measuring system incremental

Spindle measuring system

incremental Motor measuring system incremental

Motor *)

G: Accuracy of the encoder

system

M = 128 per encoder signal period or lattice pitch

G is a function of the accuracy of the optional encoder system.

M = 128 x Z per 360 deg. mech. Z...Increments

Z = 2048

G = 0.006 deg.

BERO

Direkt position sensing for axis expansion

with external 611D control

X130

SINUMERIK 810D CCU module

Axis expansion 611D control

X130

SINUMERIK 810D CCU module

Axis expansion 611D control

Fig. 4-11 Direct position sensing for MSD

1

4

1

Spindle measuring system incremental

Motor measuring system incremental

Motor *)

Motor measuring system incremental

Motor *)

BERO

M = 128 x Z per 360 degr. mech. Z...Increments

Z = 2048

G = 0.006 deg.

M = 128 x Z per 360 degr. mech. Z...Increments

Z = 2048

G = 0.006 deg.

4-70

*) e.g. 1PH7

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

4 Description of the SINUMERIK 810D

4.4 Integrated power modules: 3-axis CCU box

Description

Current derating as a function of the ambient temperature

On the SINUMERIK 810D, three integrated power modules are fitted on one heat sink in the 3-axis CCU box:

 Power module for 2 x 6A/12A (FSD)

 Power module for 1 x 18A/36A (FSD) or 24A/32A (MSD)

 Heat sink temperature sensor

Table 4-16 Assignment between motor connection and power module

Motor connection Power module Rated current

(sine, rms)

A1 (rear) 18A/36A (FSD) or 24 A/32A /MSD) 24 A

A2 (center) 6A/12A (only as FSD) 6 A

A3 (front) 6A/12A (only as FSD) 6 A

Note

The spindle can only be used on “A1” on the integrated power module.

All the technical details apply for ambient temperatures up to max. 40 C. At ambient temperatures > 40, linear current derating is necessary, as in the case of the OI power supply. At maximum ambient temperature 55 C: Current derating to 60 % of the 40 C value.

Current derating as a function of the installation altitude

All power ratings apply up to an installation altitude of 1000 m. At an installation altitude of > 1000 m, the load currents must be reduced according to the derating factor.

The diagram is given in Subsection 4.3.3 Installation altitude References: /PJU/, Configuration Manual Converters

4-71

4 Description of the SINUMERIK 810D

4.4 Integrated power modules: 3-axis CCU box

Permissible duty cycles FSD

For use as FSD power module (A1 – A3)

I

max

I

n

I

= Peak current

max

I

= Rated current

n

Fig. 4-12 Peak current duty cycle with previous load for FSD

I

max

I

n

I

= Peak current

max

I

= Rated current

n

0.2 s

10 s

4 s

10 s

t

Permissible duty cycles FSD

Fig. 4-13 Peak current duty cycle without previous load for FSD

For MSD power module only with 24A/32A

I

max

I

S6

I

n

0.7xI

n

I

= Peak current

max

I

= Rated current

n

Fig. 4-14 S6 duty cycle with previous load for MSD

4 min

10 min

t

4-72

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

0.7xI

I

max

S6

n

4 Description of the SINUMERIK 810D

4.4 Integrated power modules: 3-axis CCU box

I

10 s

n

Coincidence factor

60 s

I

= Peak current

max

I

= Rated current

n

Fig. 4-15 S6 duty cycle with previous load for MSD

The power modules A2 and A3 may only be operated in simultaneous continuous duty at 63 % of their rated current on average. No coincidence restrictions apply to A1.

t

4-73

4 Description of the SINUMERIK 810D

4.5 Integrated power modules: 2-axis CCU box

Description

Current derating as a function of the ambient temperature

On the SINUMERIK 810D, 2 integrated power modules are fitted on one heat sink in the 2-axis CCU box:

 Power module for 9A/18A (FSD)

 Heat sink temperature sensor

The 2-axis CCU box can be mounted with internal or external heat dissipation.

Table 4-17 Assignment between motor connection and power module

Motor connection Power module Rated current

(sine, rms)

A1 (rear) 9A/18A (only as FSD) 9 A

A2 (front) 9A/18A (only as FSD) 9 A

Note

The 3rd drive number “A3” can be used for an axis in “Axis expansion plug-in unit left”.

All the technical details apply for ambient temperatures up to max. 40 C. At ambient temperatures > 40, linear current derating is necessary, as in the case of the OI power supply. At maximum ambient temperature 55 C: Current derating to 60 % of the 40 C value.

Current derating as a function of the installation altitude

All power ratings apply up to an installation altitude of 1000 m. At an installation altitude > 1000 m, the load currents must be derated according to the diagram for the OI power supply.

The diagram is given in Subsection 4.3.3 Installation altitude References: /PJU/, Configuration Manual Converters

4-74

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

4 Description of the SINUMERIK 810D

4.6 PLC module

Permissible duty cycles FSD

For use as FSD power module (A1 – A2)

I

max

I

n

I

= Peak current

max

I

= Rated current

n

Fig. 4-16 Peak current duty cycle with previous load for FSD

I

max

I

n

I

= Peak current

max

I

= Rated current

n

Fig. 4-17 Peak current duty cycle without previous load for FSD

0.2 s

10 s

4 s

10 s

t

References: /PJU/, Configuration Manual Converters

4.6 PLC module

PLC module

The PLC module represents a PLC-CPU that is compatible with the S7-300 product range. Via the PK bus X111, three external chains with eight S7-300 I/O modules each can be connected. It is also possible to connect up three single I/O modules. Mixing IM 361s and single I/O modules is permissible.

4-75

4 Description of the SINUMERIK 810D

4.7 PCMCIA card (memory card)

The CCU contains a plug-in unit for standard PC cards with which all type II flash cards with up to 8 Mbytes storage capacity can be operated. Recommendation: Use Siemens PC cards.

 The PCMCIA card is used for software upgrading or for standard software.

 In addition to the software upgrade, the PC card can also be used for series

commissioning; see References: /IAC/, Commissioning Manual 810D

 The PCMCIA card with the system software must remain inserted during

operation.

Caution

Inserting and removing the PCMCIA card while energized will cause data to be lost!



4-76

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

Axis Expansion

5.1 Axis expansion plug-in unit

5

Application

The axis expansion plug-in unit is installed in a SIMODRIVE 611 power module and then connected to the X304-X306 axis expansion terminal of the SINUMERIK 810D. The plug-in unit is designed for 1-axis and 2-axis power modules. There is also an axis expansion plug-in unit left with terminals for connectors X307 (CCU) und X301 (expansion plug-in unit) at the same height.

Axis expansion plug-in unit, left

Axis expansion plug-in unit

SIEMENS

SIMODRIVE

Power supply (I/R or OI)

Fig. 5-1 Axis expansion plug-in unit, left and right, for the SINUMERIK 810D with

LDC

(CCU3)

SIMODRIVE 611 power modules

LDC810D

5-77

5 Axis Expansion

5.1 Axis expansion plug-in unit

Note

On LT modules more than 50 mm wide and a permanently mounted device bus, the free end of the device bus must be fixed to the 34-pole device bus connector on the module.

Axis expansion plug-in unit

SIMODRIVE 611 power module

Connecting the ribbon cable connector

5-78

Fig. 5-2 Mounting the axis expansion plug-in unit in the power module

The axis expansion plug-in module has two connectors X301 and X302. Connector X301 must be connected to a 1-axis power module when used. If a 2-axis power module is used, connector X301 must be assigned to the first axis and connectors X302, to the second axis.

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

5 Axis Expansion

5.1 Axis expansion plug-in unit

Installation

Table 5-1 Connection of the ribbon cable connector to the axis expansion plug-in

unit

Ribbon cable connector 1-axis power module 2-axis power module

X301 1st axis 1st axis X302 Unassigned 2nd axis

1. Bring in and connect the ribbon cable for connector X301 through the slot in the front panel with the notch facing forward.

2. If applicable, also attach the ribbon cable for connector X302 accordingly (for 2nd axis).

Front panel

X302

X301

Ribbon cable

Fig. 5-3 Connection of the ribbon cables to the axis expansion

Notch

301 302

Sheet-metal cover Axis expansion plug-in unit

3. After plugging in the axis expansion plug-in unit and connecting to the CCU, you should push the excess cable length in the space provided for that purpose under the sheet-metal cover of the axis expansion plug-in unit.

5-79

5 Axis Expansion

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

Application

Mounting

Connection

Axis expansion with SIMODRIVE 611D control plug-in unit is only used if the number of measuring channels of the SINUMERIK 810D is insufficient, or higher performance is required.

The SIMODRIVE 611D module must be inserted as the first module to the right of the SINUMERIK 810D. If DC link busbars are connected, all screws must be tightened firmly (comply with tightening torque, see figure 3-4).

A special set of cables is required to connect the SIMODRIVE 611D control module. This cable set contains the connection with the drive bus and another device bus cable.

Cable set: Device bus and drive bus

611D control plug-in unit

5-80

SIEMENS

SIMODRIVE

810D

(I/R or OI)

Fig. 5-4 Axis expansion for SINUMERIK 810D with the SIMODRIVE 611D module

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

(CCU3)

LDCPower supply

5 Axis Expansion

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

Note

For EMC-compliant assembly, shielded motor cables must be used in conjunction with the shielding contact plates available for SIMODRIVE power modules; see References: /PJU/, Configuration Manual Converters

/EMV/, EMC Configuring Guidelines

Cable set for axis expansion

For connection of the SIMODRIVE 611D control plug-in unit that is located immediately to the right of the 810D.

Drive bus cable

62

Device bus cable

54 105

Fig. 5-5 Cable set for axis expansion with SIMODRIVE 611D module

Table 5-2 Recommendation for length selection of the drive bus cable

Order no. Module width to be

6SN1161-1CA00-0BA1 50 Drive bus cable round

6FC5247-0AA28-0AA0 50 Device bus cable GWE: 462008006403 50 Device bus cable

6SN1161-1AA00-0BA0 <50 Device bus cable 400 mm NC60 Catalog: Select

length + 50 mm

bridged in mm

<50 Drive bus cable round

Comment

cable, shielded



5-81

5 Axis Expansion

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

Notes

5-82

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

I/O Modules

6.1 Single I/O module

6

Brief description

Connection to 810D

X111

The single I/O module has 64 inputs and 32 short-circuit-proof outputs (isolated). Each output can be loaded with 0.5 A. The coincidence factor is 75 %.

Up to three single I/O modules can be attached to the SINUMERIK 810D; combinations with SIMATIC S7-300 chains are possible.

The single I/O module (connector X3 IN) is connected to the SINUMERIK 810D (connector X111). The max. cable length is 10 m. Two cable variants are available for the connection from one single I/O module to the next:

 For single mounting: 6ES7368-30-0AA0

 For single-tier configuration with several single I/O modules:

6FC5411-0AA80-0AA0, length 150 mm.

6ES7368-30-0AA0

IN OUT IN OUT IN OUT

X3

Connecting cable shielded for single-tier configuration only 6FC5411-0AA80-0AA0, length 150 mm

X3 X3

Single

810D

X3 IN

X3 OUT

Single I/O module

Fig. 6-1 Overview of terminals, single I/O modules on the SINUMERIK 810D

X405 32 I

X402 32 O

6ES7368-30-0AA0

6ES7368-30-0AA0 6FC5411-0AA80-0AA0, length 150mm

Ribbon cable

I/O module

Single I/O module

SINUMERIK 810D

IM 361 or second single I/O module

Terminal strip converter

Single I/O module

6-83

6 I/O Modules

6.1 Single I/O module

SHIELD M24Lo. P24Logic

SHIELD M24Po P24Power

360

374

Cooling clearance 50 mm

70

Space for front connector

25

Fig. 6-2 Dimension drawing of single I/O module

EMC measures

The single I/O module has an equipotential bonding terminal. To conduct interference currents away, a low-resistance finely stranded bonding conductor to the ground bus is required (see subsection 2.1.3) with a cross-section of at least

2

10 mm

. The connection must be as short as possible. When the PE and interference conductors are in common, the PE conductor rules in EN 61800-5-1 must be followed.

6-84

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

Cooling clearance 50 mm

135

pg

,yp

Technical data

6 I/O Modules

6.1 Single I/O module

Table 6-1 Technical data of the single I/O module

Power supply for LOGIC (X1) and POWER (X5)

Current consumption – LOGIC

Power loss – LOGIC

Inputs Number of inputs

Outputs Number of outputs

Overtemperature protection Block specific Coincidence factor

Total of all rated currents each within group of 0.5 A

– rated value – perm. range – ripple – polarity reversal protection – fuse-protection

– POWER

Signal level for signal “0” Signal level for signal “1” Isolation Input current 1-signal Input current 0-signal Delay time T Delay time T Voltage strength Cable length terminal block

Signal level for signal “0” Signal level for signal “1” Isolation Short-circuit-proof Max. output current

Switching frequency

Voltage strength Cable length terminal block

PHL PLH

24 V DC

18.5 ... 30.2 V

3.6 Vpp yes LOGIC: 1 A/250 V POWER: no Type: 0.3 A, max. 1 A max: 12 A Type: 7.2 VA, max. 30.2 VA max. 362 VA

64 digital inputs –3 V to + 5 V + 15 V to + 30 V yes (optocoupler) 2 – 15 mA, type: 6 mA –9 mA to 1 mA

0.5 to 3 ms

0.5 to 3 ms 2 kV max. 3 m

32 digital outputs open U

– 0.5 V

Power

yes (optocoupler) yes resistive: 0.6 A inductive: 0.6 A Lamp: 6 W ohmic load: 100 Hz inductive load: 2 Hz Lamp load: 11 Hz 2 kV max. 3 m

75 %

6-85

6 I/O Modules

6.1 Single I/O module

Connection of the electronics power supply

The 24 V DC power supply is connected to X1 via a 3-way angled Phoenix screw terminal connector (2.5 mm2).

SHIELD (pin 3)

X1

Table 6-2 X1 pin assignment

Pin Name Type

3 SHIELD 2 M24 VI 1 P24 Logic VI

M24 (pin 2) P24Logic (pin 1)

X1 LOGIC power supply

Signal names

P24 Logic + 24 V electronics power supply external M24 Electronics power supply ground external

Signal type

VI Voltage Input

Note

SHIELD and M24 must be bridged.

Connecting the load power supply

The 24 V DC load power supply is connected to X5 via a 3-way angled Phoenix screw terminal connector (2.5 mm2).

SHIELD (pin 3) M24 Power (pin 2) P24 Power (pin 1)

Table 6-3 X5 pin assignment

X5 POWER power supply

Pin Name Type

3 SHIELD 2 M24 VI 1 P24 Power VI

Signal names

P24 Power + 24 V load power supply external M24 Load power supply ground external

Signal type

VI Voltage Input

6-86

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

6 I/O Modules

6.1 Single I/O module

Connection of the inputs/outputs

Meaning of the LEDs

X402 outputs 0-31

The inputs/outputs are connected via ribbon cables (max. 3 m length). The following 34-way terminal strip converters can be used for this purpose: see References: Catalog NCZ Terminal strip converter without LED: 6FC9302-2AA Terminal strip converter with LED red: 6FC9302-2AB (0.5A)

6FC9302-2AL (2 A) Terminal strip converter with LED green: 6FC9302-2BB01 Assignment of the ribbon cable is compatible with the I/O modules (logic modules) of the SINUMERIK 810.

The module status of the single I/O module is indicated via two LEDs.

LED green: 5 V Power OK LED red: Group error

Connecting the outputs

Connector name: X402 OUTPUT 0–31 Connector type: 34-way DIN ribbon cable connection Length of the ribbon cable: Max. 3 m to the terminal strip converter

Note

The outputs must be protected externally against voltage surges by inductive loads. (free-wheeling diodes, RC elements, . . .)

1 Not

3

5

7

9

11

13

15

17

19

21

23

25

27

29

31

33

assigned

OUT0ȱ0ȳ

OUT0ȱ2ȳ

OUT0ȱ4ȳ

OUT0ȱ6ȳ

OUT1ȱ0ȳ

OUT1ȱ2ȳ

OUT1ȱ4ȳ

OUT1ȱ6ȳ

OUT2ȱ0ȳ

OUT2ȱ2ȳ

OUT2ȱ4ȳ

OUT2ȱ6ȳ

OUT3ȱ0ȳ

OUT3ȱ2ȳ

OUT3ȱ4ȳ

OUT3ȱ6ȳ

O 4

O 6

O 8

O 10

O 12

O 14

O 16

O 18

O 20

O 22

O 24

O 26

O 28

O 30

O 32

O 34

2 Not

assigned

OUT0ȱ1ȳ

OUT0ȱ3ȳ

OUT0ȱ5ȳ

OUT0ȱ7ȳ

OUT1ȱ1ȳ

OUT1ȱ3ȳ

OUT1ȱ5ȳ

OUT1ȱ7ȳ

OUT2ȱ1ȳ

OUT2ȱ3ȳ

OUT2ȱ5ȳ

OUT2ȱ7ȳ

OUT3ȱ1ȳ

OUT3ȱ3ȳ

OUT3ȱ5ȳ

OUT3ȱ7ȳ

O

6-87

6 I/O Modules

6.1 Single I/O module

Signal names

OUTi[j] Output j of output byte i

Signal type

O Output

X404 Inputs 0 to 31

Connecting inputs 0 to 31

Connector name: X404 INPUT 0–31 Connector type: 34-way DIN ribbon cable connection length of the ribbon cable: Max. 3 m to the terminal block

1 Not

3

5

7

9

11

13

15

17

19

21

23

25

27

29

31

33

assigned

INP0ȱ0ȳ

INP0ȱ2ȳ

INP0ȱ4ȳ

INP0ȱ6ȳ

INP1ȱ0ȳ

INP1ȱ2ȳ

INP1ȱ4ȳ

INP1ȱ6ȳ

INP2ȱ0ȳ

INP2ȱ2ȳ

INP2ȱ4ȳ

INP2ȱ6ȳ

INP3ȱ0ȳ

INP3ȱ2ȳ

INP3ȱ4ȳ

INP3ȱ6ȳ

I 4

I 6

I 8

I 10

I 12

I 14

I 16

I 18

I 20

I 22

I 24

I 26

I 28

I 30

I 32

I 34

2 Not

assigned

INP0ȱ1ȳ

INP0ȱ3ȳ

INP0ȱ5ȳ

INP0ȱ7ȳ

INP1ȱ1ȳ

INP1ȱ3ȳ

INP1ȱ5ȳ

INP1ȱ7ȳ

INP2ȱ1ȳ

INP2ȱ3ȳ

INP2ȱ5ȳ

INP2ȱ7ȳ

INP3ȱ1ȳ

INP3ȱ3ȳ

INP3ȱ5ȳ

INP3ȱ7ȳ

I

6-88

Signal names

INPi[j] Input j of input byte i

Signal type

I Input

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

6 I/O Modules

6.1 Single I/O module

X405 Inputs 32 to 63

Connecting inputs 32 to 63

Connector name: X405 INPUT 32–63 Connector type: 34-way DIN ribbon cable connection length of the ribbon cable: Max 3 m to the terminal block

1 Not

3

5

7

9

11

13

15

17

19

21

23

25

27

29

31

33

assigned

INP4ȱ0ȳ

INP4ȱ2ȳ

INP4ȱ4ȳ

INP4ȱ6ȳ

INP5ȱ0ȳ

INP5ȱ2ȳ

INP5ȱ4ȳ

INP5ȱ6ȳ

INP6ȱ0ȳ

INP6ȱ2ȳ

INP6ȱ4ȳ

INP6ȱ6ȳ

INP7ȱ0ȳ

INP7ȱ2ȳ

INP7ȱ4ȳ

INP7ȱ6ȳ

I 4

I 6

I 8

I 10

I 12

I 14

I 16

I 18

I 20

I 22

I 24

I 26

I 28

I 30

I 32

I 34

2 Not

assigned

INP4ȱ1ȳ

INP4ȱ3ȳ

INP4ȱ5ȳ

INP4ȱ7ȳ

INP5ȱ1ȳ

INP5ȱ3ȳ

INP5ȱ5ȳ

INP5ȱ7ȳ

INP6ȱ1ȳ

INP6ȱ3ȳ

INP6ȱ5ȳ

INP6ȱ7ȳ

INP7ȱ1ȳ

INP7ȱ3ȳ

INP7ȱ5ȳ

INP7ȱ7ȳ

I

Address space

Signal names

INPi[j] Input j of input byte i

Signal type

I Input

From the PLC’s viewpoint, the 810D single I/O is equivalent to a S7-300 I/O chain with the following configuration:

 P-bus interface IM-R

 2 x 32-bit input module

 1 x 32-bit output module

6-89

6 I/O Modules

6.1 Single I/O module

X3 IN X3 OUT

X404

X405

X406

32 inputs 0 to 31

32 inputs 32 to 63

32 outputs 0 to 31

This results in the following address space:

1. Input range

Input byte (chain number *32) to (chain number *32) +7, i.e. from input byte 32 to input byte 39 for operation in chain 1

2. Output range

Output byte (chain number *32) +8 to (chain number *32) +11, i.e. from output byte 40 to output byte 44 for operation in chain 1

Only one I/O module is possible per chain.

The address range is assigned automatically during startup. Parameterization is not required.

In HW Config, it is possible to treat the 810D I/Os as the equivalent arrangement of S7-300 modules.

Chain 1

X111

P-bus

Chain 2

SINUMERIK 810D with integrated PLC

Single I/O module

Fig. 6-3 SINUMERIK 810D with 3 I/O chains (max. configuration)

Chain 3

Single I/O module



6-90

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

NCU Terminal Block

6FC5211-0AA00-0AA0

X20: Interface with the drive bus X21: Interface with the next NCU terminal block

2

2.5mm

4

321

24V

X9: Terminal external 24 V logic power supply

Shielding plate

0V

7

100

1234 5678

PE conductor connection

Depth: 40 mm or 130 mm (with DMP compact module)

Fig. 7-1 Front view of NCU terminal block

Mounting

Status LED green: 5V OK Status LED yellow: Internal fault terminal block Status LED red: External fault (drive bus interface)

In order to ensure optimum heat dissipation of the DMP compact module, the terminal block should be secured horizontally, so that the modules can be suspended vertically.

DMP compact module slots

74.4

237 257

7-91

7 NCU Terminal Block

Connection to the drive bus

!

The terminal block is connected to connector X20 on the drive bus of the last drive module via round cables. These cables are available in different lengths. (cable lengths 1, 2, 5, and 10 m). Up to 2 terminal blocks can be operated (in accordance with the available NCK addresses for rapid analog and digital I/Os). The round cables are also used in conjunction with individual terminal blocks.

Important

Please make sure that the total length of the cable connections does not exceed 10 m.

611 control plug-in unit

Up to 2 NCU terminal blocks can be connected

SIEMENS

SIMODRIVE

Power supply (I/R or OI)

Fig. 7-2 Connection of NCU terminal block

Terminator

810D LDC

The drive bus terminator must be plugged into slot X21 on the last NCU terminal block.

PE conductor

When the PE and interference conductors are in common, the PE conductor rules in EN 61800-5-1 must be followed. PE conductor connection, see fig. 7-1.

Termination

connector Drive bus max. length 10 m

Note: If there are EMC problems, attach the shield of the drive bus cable to the drive module (above).

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

7 NCU Terminal Block

EMC measures

DMP compact modules

The PE conductor connection is also used to conduct interference currents away from:

 the shields of the DMP casing,  the DMP compact plug-in modules,  the 24 V logic power supply.

To ensure that these interference suppression measures are effective, there must be a low-resistance connection between the shielding plate and ground potential.

The low-resistance bonding conductor should be a stranded cable with a crosssection of at least 10 mm2 and a length of less than < 30 cm, if possible.

A maximum of 8 DMP compact modules can be connected per NCU terminal block.

Module type Max.

number

DMP compact module 16 I 2 Digital inputs DMP compact module 16 O 2 Digital outputs 0,5 A DMP compact module 8 O 4 Digital outputs 2.0 A DMP compact module 1I analog 8 Analog input 13 bits DMP compact module 1I NC analog IN 4 Rapid analog input 75 ms, 12 bits DMP compact module 1O analog 4 Analog output 14 bits

Variation

Equipment in max. 2 terminal blocks of a control:

Peripherals Number

Digital inputs 32

Digital outputs 32

Analog inputs 8

Analog outputs 8

Important

!

A maximum of 4 analog outputs and 4 analog inputs can be plugged in at the same time for each NCU terminal block.

Caution

After the load supply voltage for the DMP compact modules has been switched off during operation, the outputs do not reliably reestablish through-connection when the load supply voltage is switched on again. If switch-off during operation cannot be avoided, the DMP outputs have to be reset via the PLC program when the load supply voltage is switched off. The outputs are set again after the voltage has been switched on again.

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7 NCU Terminal Block

Monitoring functions

 +5 V monitoring

 Temperature monitoring 60



C "3 C

 Configuration monitoring

 Sign-of-life monitoring (watchdog) of the microcontroller

 Sign-of-life monitoring of the NC

Fault Acquisition Effect

Undervoltage (< 4.75 V)

Ambient temperature Temperature sensor Status signal to NC,

Sign of life CCU Cyclic signaling Disabling of the NC outputs,

Watchdog Time acquisition Disabling of the NC outputs,

Hardware combination Hardware

The digital and analog ouputs are switched to a safe state (0 V at the output) with the XOUTDS signal in the event of disturbances or faults in the CCU, the microcontroller, and power failure.

Limit monitor Disabling of the NC outputs,

configuration

LED (green) off

screen display

LED (red) on

Disabling of the NC outputs, LED (red, yellow) on, status signal to NC

Power supply

DC 24 V (20.4 V DC to 28.8 V DC) Connector designation: X9 Connector type: 4-pole terminal block, 2.5 mm2 Terminal

Table 7-1 X9 pin assignments

X9

Pin Name Type

1 P24 ext VI 2 P24 ext VI 3 M24 ext VI 4 M24 ext VI

Note

Pins 1 and 2 or 3 and 4 are bridged in a group on the module.

Signal names

P24 ext +24 V power supply external M24 ext Power supply ground external

Signal type

VI Voltage Input

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

X Drive bus interface

X20/X21

Connector name: X20 (IN) X21 (OUT) Connector type: 36-pole micro ribbon Special features: Non-isolated, no protective separation Caution: Max. length of the drive bus is 10 m

7 NCU Terminal Block

X11–X18

Module connector Connector name: X11 ... X18 (slots 1 ... 8) Connector type: 30-pole male connector ELCO Microleaf

Table 7-2 Technical data of the NCU terminal block

Mechanical data

Dimensions Height Width Depth

100 mm 257 mm 40 mm

Weight Approx. 0.5 kg

Ambient conditions

Degree of protection IP20 or IPXXB Power consumption (24 V) During operation 150 –500 mA



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7 NCU Terminal Block

Notes

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

DMP Compact Modules

8

Mounting

The following dimensions must be observed when mounting:

Table 8-1 Dimensions of the DMP compact modules

Width 25 mm Height 90 mm

115 mm with plugged in connecting plugs

130 mm with terminal block Depth 108 mm Degree of

protection

IP20 or IPXXB

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

The DMP compact module 16I is an encapsulated module. It can be plugged into a slot of the NCU terminal block as a plug-in module.

1,5

0V

Status LEDs

Labeling strips

Fixing screw

X3

0

. .

7

0

. .

7

LOW byte

HIGH byte

X1

PM765

X3

43210

Inputs IN 7 ... IN 0 HIGH byte

X2

M = GND

Fig. 8-1 Front view and side view of a DMP compact module 16I

Inputs IN 0 ... IN 7 LOW byte

01234 567MP

1,5

0V

X2

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8 DMP Compact Modules

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

Interfaces

Display elements

 A 30-pole connector X1 for connection to the NCU terminal block.

 Two 10x terminals X2 and X3 (Phoenix, Type MC1.5/10-ST-3.81 GREY,

order no. for X3 and X2: 18 28 171) for connecting the 16 inputs and the load power supply.

 The terminals are pluggable and can be mechanically coded by the

customer.

 The 24 V terminal P is not used

16 LEDs as a status display for the logical states of the inputs.

LEDs lit: Input on.

Table 8-2 Technical data of DMP compact module 16I

Number of inputs 16 digital inputs Galvanic isolation Ye s Power supply V

Input voltage

Input current for signal “1” + 2 mA to + 5 mA Delay time for tp Delay time for tp Length for cables max. 30 m Weight about 125 g

LOAD

– Rated value 24 V DC – Perm. range 20.4 V to 28.8 V – Ripple 3.6 Vpp

– Rated value 24 V DC – For signal “0” –3 to +5 V – For signal “1” +13 V to +33 V

LH

HL

tpLH = type 1 ms tpHL = type 1 ms

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

8 DMP Compact Modules

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

The DMP compact module 16O is an encapsulated module. It can be plugged into a slot of the NCU terminal block as a plug-in module.

Outputs OUT 7 ... OUT 0 HIGH byte

43210

Status LEDs

Labeling strips

Fixing screw

X3

0

. .

7 0

. .

7

LOW byte

HIGH byte

X1

24 V

PM7 6 5

X3

LOAD

0V

DC 1.5

Interfaces

Display elements

M = GND

X2

Outputs OUT 0 ... OUT 7 LOW byte

0 1234 567MP

0V

24 V

DC 1.5

LOAD

X2

Fig. 8-2 Front view and side view of a DMP compact module 16A

 A 30-pole connector X1 for connection to the NCU terminal block.

 10-terminal X2 and X3 (Phoenix, Type MC1.5/10-ST-3.81 GREY, order no.

for X3 and X2: 18 28 171) for connecting the 16 outputs and the load power supply.

 The terminals are pluggable and can be mechanically coded by the

customer.

16 LEDs as a status display for the logical states of the outputs. As from product version B, the LEDs go out when the load voltage fails.

LEDs lit: Output on.

Table 8-3 Technical data of DMP compact module 16O

Number of outputs 16 digital outputs Galvanic isolation Ye s Power supply V

Signal level of the outputs (typically)

LOAD

– Rated value 24 V DC – Perm. range 20.4 V to 28.8 V – Ripple 3.6 Vpp

– For signal “0” Open – For signal “1” V

–250 mV

load

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8 DMP Compact Modules

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

Table 8-3 Technical data of DMP compact module 16O

Output load for signal “1” (rated value)

– Ohmic load 500 mA – Lamp load 5 W – Inductive load 500 mA

Short-circuit protection Ye s Power loss at 30 V Max. 3.8 W Operating frequency for

– Ohmic load 100 Hz – Lamps 11 Hz – Inductive load (for rated

current, higher values are permissible for lower currents)

Total load capability at 55 C (relative to the total rated current of all outputs)

Delay time for tp Delay time for tp Length for cables Max. 50 m Weight about 160 g

LH

HL

2 Hz

50 %

tpLH = max. 0.5 ms tpHL = max. 0.5 ms

Important

!

As of version C, a new output driver is used for the DMP compact module 16A. The following behavior is to be observed: In the event of a fault triggered by overcurrent or short-circuit, the outputs automatically reconnect after the fault has been rectified. (previously: latching disable until the output is reactivated by the PLC user program). If one output is short-circuited, the three other outputs of the same half-byte can also be disabled. In normal operation with currents < 0.7 A, there is no mutual influence.

8 outputs each are powered by a power supply. For each group of 8 outputs (2 x outputs 0 ... 7), the total of the output currents must not be greater than 2 A. (This corresponds to a coincidence factor of 50 % if each output is under full load). All 16 outputs can be loaded simultaneously with 0.25 A for example.

Important

!

If inductive loads are used, switching voltage peaks must be limited by external free-wheeling diodes or RC connections.

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

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

2.2 Climatic and mechanical environmental conditions

2.2.1 Transport and storage conditions

2.2.2 Operating conditions

2.3 Technical data of the individual components

2.4 MPI/OPI network rules

Design and Installation of the 810D

3.1 Structure of the SINUMERIK 810D

3.2 Assembly of the SINUMERIK 810D

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

3.3 Power supply

Description of the SINUMERIK 810D

4.1 Components of the SINUMERIK 810D

4.1.1 Overview

4.2 Interfaces

4.2.1 Overview

4.2.2 Description of the interfaces, operating and display elements

4.2.3 Cable distributor

4.3 Measuring system

4.3.1 Assignment of measuring systems and motor connection

4.3.2 Encoder systems that can be evaluated

4.3.3 Measuring channels, indirect and direct measuring system

4.4 Integrated power modules: 3-axis CCU box

4.5 Integrated power modules: 2-axis CCU box

4.6 PLC module

4.7 PCMCIA card (memory card)

Axis Expansion

5.1 Axis expansion plug-in unit

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

I/O Modules

6.1 Single I/O module

NCU Terminal Block

DMP Compact Modules

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

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