siemens 840D User Manual

SINUMERIK 840D

Configuring the NCU

Manual

System Overview 1

Connection Conditions 2

Structure and Installation 3

Description of the NCU 4

I/O Modules 5

Terminal Block 6

Valid for

Control

SINUMERIK 840D SINUMERIK 840DE (export version) SINUMERIK 840D powerline SINUMERIK 840DE powerline

DMP Compact Modules 7

Maintenance and Service 8

Abbreviations A

Index

Drive

SIMODRIVE 611 digital

03/2006 Edition

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

06.94 6FC5297-0AC10-0BP0 A

08.94 6FC5297-0AC10-0BP1 C

02.95 6FC5297-2AC10-0BP0 C

04.95 6FC5297-2AC10-0BP1 C

09.95 6FC5297-3AA01-0BP0 Description of differences

03.96 6FC5297-3AC10-0BP0 C

08.97 6FC5297-4AC10-0BP0 C

12.97 6FC5297-4AC10-0BP1 C

12.98 6FC5297-5AC10-0BP0 C

08.99 6FC5297-5AC10-0BP1 C

04.00 6FC5297-5AC10-0BP2 C

10.00 6FC5297-6AC10-0BP0 C

09.01 6FC5297-6AC10-0BP1 C

11.02 6FC5297-6AC10-0BP2 C

11.03 6FC5297-6AC10-0BP3 C

12.04 6FC5297-7AC10-0BP0 C

03.06 6FC5297-7AC10-0BP1 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 Further information is available in the Internet under: http://www.siemens.com/motioncontrol

This publication was produced with Interleaf V 7.

©

Copyright

Order No. 6FC5297-7AC10-0BP1 Printed in German

Siemens AG, 2006.

executable in the control. However, no claim can be made regarding

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. However, the information contained in this

document is reviewed regularly and any necessary changes included

in subsequent editions. We welcome suggestions for improvement.

Subject to change without prior notice.

Siemens AG

Preface

SINUMERIK Documentation

Target group

Benefits

The SINUMERIK documentation is subdivided into 3 parts:

 General Documentation

 User documentation

 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

This documentation is intended for:

and menu item “Support”.

 Project engineers, electricians and installers

 Maintenance and service personnel

The information in this manual enables installation of the SINUMERIK 840D Numerical Control and measures for maintenance and service to be carried out.

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

03.06

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:

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

Questions about the manual

SINUMERIK Internet address

EC Conformity Declaration

Safety information

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:

 In the Internet:

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

under the product/order no. 15257461

 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 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

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

Proper 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.

Startup 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

03.06

Danger notes

!

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 lines 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, bare metal parts of control cabinet or the protective ground contact of a socket outlet).

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Preface

ESDS information

!

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.

Additional notes

!

 Measurements on modules are allowed only if

– the measuring instrument is properly earthed (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.

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Preface

03.06

Notes

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SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

System Overview

1.1 System configuration

1

Introduction

NCU

Battery and fan slide-in module

Infeed/Regenerative feedback module Feed DriveMain Spindle DriveNCU box

Fig. 1-1 Central control units SINUMERIK 840D

A numeric control is modular in design. The central control units of an 840D system are shown in Fig. 1-1:

I/R FDMSD

Round cable to the NCU terminal block

Device bus

The subject of this document is the NCU, the central processing unit of the 840D controller. It contains the NC-CPU and the PLC-CPU.

The NCU has the following tasks:

 Execute the NC program  Maintain communication with the peripherals.

Note

When using I/O devices, ensure that they are suitable for industrial use!

The NCU is installed in a housing called the NCU box. This housing also contains a power supply and a fan subassembly.

1-11

Ä

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1.1 System configuration

03.06

Connection configuration

MPI bus

for PCU / MCP (see Fig. 1-3)

2x sensor

2x handwheel

The NCU can communicate with the peripheral components via numerous interfaces. These are shown in Fig. 1-2 with their connections to the NCU and explained in more detail in Table 1-1:

NCU

–X102

–X101

PROFIBUS DP I/Os

Reserved for service

–X111

–X112

–X122

or

Cable distribut or

SIMODRIVE components

–X121

X130B

X130A

*)

PG / PC, e.g. Field PG

IN OUT

X20 X21

NCU terminal block

MPI cable

4x digit. input 4x digit. output

IM

SIMATIC S7-300

X2

: Optional

*) MPI cable or MPI PG cable

Fig. 1-2 SINUMERIK 840D system overview

–X172

Mini-

handheld unit

Memory card (PCMCIA)

Handheld unit

Type B-MPI

X1 X2

Distribution box

or

X4

X3

Handheld terminal

HT 6

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03.06

1 System Overview

1.1 System configuration

Table 1-1 Components of the 840D

Component

NCU Central processing unit of 840D Cable distributor

 Connection of up to 2 probes

Description

 Connection of up to 2 handwheels  Connection of up to 4 digital inputs and outputs  24V supply for connection to MPI connector

SIMODRIVE components

NCU terminal block High-speed NC I/Os

References: /PJU/, Configuration Manual Converters

 Analog I/Os  Digital I/Os

Memory card (PCMCIA)

 Contains the system program  Can be plugged into the NCU

Distribution box

 For linking the handheld unit/handheld terminal to the

MPI bus

 Connection for EMERGENCY STOP circuit, enable

keys, handwheel, 24 V DC Mini-handheld unit see 1) Handheld unit 1)

 Connect handheld unit/handheld terminal via MPI  Handwheel, EMERGENCY STOP button, key-actuated

switch, override, agreement buttons, display, unas-

signed keys Handheld Terminal HT 6 1) see 1)

The components marked with 1) are described in:

References: /BH/, Operator Components Manual

Note

If additional SIMODRIVE monitoring modules are used, they must be switched at the same time as the infeed unit. In a multi-tier configuration, all the infeed supply units must be connected simultaneously. For cable, see Reference: Catalog NC 60, MOTION-CONNECT cables and

connections

1-13

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1.1 System configuration

03.06

PCU–MCP configuration

3.5” Floppy Disk Drive

3.5” floppy disk drive, USB

VGA monitor

Fig. 1-3 shows an OP 012-PCU 50 combination. It is connected to the NCU via the MPI bus (see Fig. 1-2).

Rear side

Ethernet

Operator panel front OP 012PCU 50

SIEMENS

* TEMP* POWER

Machine control panel

SINUMERIK

X20 (rear side)

MPI bus

for NCU (see Fig.

1-2)

USB (mouse/keyboard/ USB device)

Printer

PS/2 mouse

Fig. 1-3 Components of the OP 012-PCU 50 configuration

All the components, except for the printer, mouse and monitor are described in:

Reference: /BH/, Operating Components Manual

USB mouse Full CNC keyboard USB

Full CNC keyboard PS/2

Optional

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1.1 System configuration

SW – HW

The following tables show the possible combinations of software and hardware:

combinations

Table 1-2 Software - hardware combination options for NCU 5xx.3 to SW 6.4

NCU system software

Designation Order No. 561.3 571.3 572.3 573.3

NCU system software 2 axes on PC card, Export 840DE

NCU system software 6 axes on PC card, Export 840DE

NCU system software 12 axes on PC card

 Standard 840D  Export 840DE

NCU system software 12 axes on PC card, standard 840D incl. software version-specific additional functions

NCU system software 31 axes on PC card

 Standard 840D  Export 840DE

NCU system software 31 axes on PC card, standard 840D incl. software version-specific additional functions

 combination possible; – combination not possible

6FC5250-PX10-AH   – –

6FC5250-BX10-AH –  – –

6FC5250-BX30-AH 6FC5250-BY30-AH

6FC5270-BX30-AH – –  

6FC5250-AX30-AH 6FC5250-AY30-AH

6FC5270-AX30-AH 6FC5270-AX31-AH 6FC5270-AX32-AH

NCU hardware

–



–



–



–



– –  

 

Table 1-3 Combination possibilities for software and hardware for NCU 5xx.4 and NCU 5xx.5, SW 6.5 or higher

NCU hard-

ware

561.4/.5 max. 2 out of 2 axes,

571.4/.5 max. 2 out of 2 axes,

572.4/.5 max. 2 out of 2 axes, max. 6 out of 31 axes, max. 12 out of 31 axes, max. 31 out of 31 axes,

573.4/.5 max. 2 out of 2 axes,

*) for SW 7.2 or higher: max. 4 channels

2 axes 6 axes 12 axes 31 axes

max. 2 channels

max. 2 out of 2 axes,

max. 2 channels

max. 6 out of 31 axes,

max. 2 channels

max. 6 out of 31 axes,

max. 2 channels

NCU system software

max. 2 out of 2 axes,

max. 2 channels

max. 6 out of 31 axes,

max. 2 channels

max. 2 channels *)

max. 12 out of 31 axes,

max. 2 channels *)

max. 2 out of 2 axes,

max. 2 channels

max. 6 out of 31 axes,

max. 2 channels

max. 10 channels

max. 31 out of 31 axes,

max. 10 channels

1-15

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1.2 Labels and stickers

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:

03.06

PCBs with screen printing

NCU

NCU 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: NCU 573.4

MLFB: 6FC5357-0BB34-0AE0 Component number: GWE-570038963520 Version F (printed)

Example: Component name: NCU box

MLFB: 6FC5247-0AA00-0AA2 Component number: GWE-570038901611 Version H (printed)

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1.3 Non-Siemens keyboards

1 S

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1.3 Non-Siemens keyboards

Standard PC keyboard

When standard PC keyboards are used, ensure that they have a CE symbol and correspond to industrial requirements. Otherwise, there may be problems with the PC keyboard.

If you encounter problems, contact the relevant regional office.



1-17

1 System Overview

1.3 Non-Siemens keyboards

Notes

03.06

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SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

Connection Conditions

2.1 Secondary electrical conditions

2

Compliance with the connection conditions

!

Assistance and support

The controller is tested for compliance with the environmental 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.

2-19

2 Connection Conditions

2.1 Secondary 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.

 User interfaces must be powered via a DC power supply with safe isolation

to 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 Configuration Guideline.

03.06

Table 2-1 Requirements of the DC power supply

Rated voltage

In accordance with EN 61131–2

 Voltage range (mean value)  Voltage ripple peak-to-peak  Booting time at POWER ON

Non-cyclic overvoltage

 Duration

 Recovery time

 Events per hour

Transient voltage interruptions

 Idle time

 Recovery time

 Events per hour

24 VDC

20.4 VDC to 28.8 VDC

5% (unfiltered 6-pulse rectification)

Any value

 35 V

 500 ms

 50 s

 10

 3 ms

 10 s

 10

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2.1.2 Safe isolation to EN 61800–5–1

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

2 Connection Conditions

2.1 Secondary electrical conditions

End user interfaces (UI)

Interfaces for servicing, startup 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, start-up 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). Although these adapters are not included in the Siemens scope of delivery, you can buy these parts from your local dealer, who will be happy to advise you.

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 a UI, please make sure that the UI has basic insulation for at least 230 V AC.

2-21

2 Connection Conditions

2.1 Secondary electrical conditions

3ph 400 V AC

N

03.06

Housing/shield

1

2

3

840D / 611 digital

G

4

10

Basic insulation Safety isolation

Fig. 2-1 Safe isolation to EN 61800–5–1

Fig. 2-1 shows the various electrical potentials of the 840D/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 NCU to the PCU or HHU with 230 V AC basic insulation.

5. Non-floating signal connection between NCU 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.

MSTT/MCP

4

Distribution box

5

8

PCU

11

4

HHU/ HT 6

4

6

Person

11

S7-300 I/Os

10

24 V

7

11

Terminal

G

Motor

9

block

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SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

2.1.3 Grounding concept

The SINUMERIK 840D 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:

 NCU 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

The NCU box is a 50 mm wide cassette that is integrated into the infeed/regenerative feedback (I/RF) unit, FSD and MSD.

The individual modules are attached to a metal cabinet panel by means of screws. Make sure that near the screws a low-impedance contact of the NCU box with the cabinet wall can be made. Insulating paints at the contact point must be removed. The electronic grounding points of the modules are interconnected via the device and drive bus and at the same time conducted to the X131 terminal of the I/RF 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 Connection Conditions

2.1 Secondary electrical conditions

2-23

2 Connection Conditions

2.1 Secondary electrical conditions

03.06

Operator panel front

SL

Grounding bar

PCU/ TCU

– Ground (frame) –

S7-300 peripherals

IM 361

/single I/O module

PA

Central ground connection conductor/protective conductor

Machine control panel

SL

Gating

NCU

MB

PA

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

PA: Equipotential bonding conductor SL: Protective conductor

electronics

SL in the motor cable

MB

G

Machine bed

Line supply conn. S

S v 16 16 v S v 35 S w 35

Power electronics

Cross-sections (mm2)

w10

Distribu– tion box

SL

Terminal block

SL

SL minimum

S 16 S/2

Fig. 2-2 Grounding concept

References: /EMC/ 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.).

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SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

2 Connection Conditions

2.1 Secondary 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 (example)

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

– EMERGENCY OFF lines

 Load cables (example)

– 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 dis-

tance 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 NCU.

 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 (interference injection area) between the following lines must

be kept to a minimum:

– Signal line and electrical circuit signal line (twisted)

– Signal line 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: /EMC/ EMC Configuring Guidelines

2-25

2 Connection Conditions

2.2 Climatic and mechanical environmental conditions

03.06

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 2-2 Ambient climatic conditions per EN 60721–3–1/–3–2,

Temperature range –40 ... 70 °C –25 ... 55 °C Temperature change < 18 K < 18 K Within one hour Relative humidity 10 to 95% 10 to 95% Permissible change

in relative humidity

class 1K3/2K4

Transport Bearings

max 0.1 % max 0.1 % Within 1 minute

Table 2-3 Test limits for mechanical environmental conditions

Vibration

to EN 60068–2–6

Shock resistance

to EN 60068–2–27

g  9.81 m/s

2 (acceleration due to gravity)

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

2-26

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

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 authorization is required to ship 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 Chapter 8.1.

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 2-4 Climatic environmental conditions to EN 60721–3–3, Class 3K3

Temperature range Temperature change max. 0.5 K Within 1 minute Relative humidity 5 to 90 % Permissible change in the

relative air humidity Moisture condensation

and ice formation Dripping water, spray,

splash water, water jets Supply air Without caustic gases, dusts and oils Air 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 to 55 °C

max. 0.1% Within 1 minute

Not permitted

level

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

2-27

2 Connection Conditions

2.2 Climatic and mechanical environmental conditions

Mechanical environmental conditions

Table 2-5 Test limits for mechanical environmental conditions

03.06

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/s

2 (acceleration due to gravity)

Frequency range 10 to 58 Hz Constant deflection 0.075 mm Acceleration amplitude 58 to 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

Note

The dust precipitate must be removed at appropriate time intervals.

Radio interference

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

Table 2-6 Limit values for radio interference in industrial environments

Limit class as per EN 61000–6–4

Conducted radio interference A (industry) Interference radiation 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 class B (residential areas) is required, please contact your local Siemens office or sales representative.

2-28

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

2.3 MPI/OPI network rules

2 Connection Conditions

2.3 MPI/OPI network rules

Use

Network installations

The following devices can be interconnected across the MPI bus:

 NCU

 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 Fig. 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.

Note

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

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

Note

Unused spurs 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.

2-29

2 Connection Conditions

2.3 MPI/OPI network rules

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

03.06

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 Oper-

ating 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



2-30

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

Structure and Installation

3.1 Structure of the SINUMERIK 840D

3

SINUMERIK 840D

The SINUMERIK 840D consists of two components:

1. NCU box (sheet metal housing with a combined battery/fan slide-in module) for housing the NCU module.

2. NCU module (Numeric Control Unit)

NCU box

NCU module

Fig. 3-1 Components of the SINUMERIK 840D

3-31

3 Structure and Installation

3.2 Installation of the SINUMERIK 840D

03.06

Preparing for installation

Assembly of the NCU box

You need the following tool to assembly the SINUMERIK 840D:

 Screwdriver for slot-head screws sizes 0 and 1

 Screwdriver for Torx screws M4 and M5

Note

The NCU is exclusively intended for installation in ESD-protected zones. The ESD interference immunity limits relevant to CE compliance can only be achieved by installation in a cabinet. Make contact only while taking suitable ESD protective measures (see ESD information in the preface).

The NCU box is installed between the SIMODRIVE power supply and the first SIMODRIVE drive module. To secure the NCU box, two M5 screws are recommended.

3-32

SIEMENS

SIMODRIVE

Power supply (I/R or OI)

Fig. 3-2 Position of the NCU in the overall configuration

Danger

!

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

NCU MSD

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

FD

03.06

Mounting the DC link busbar

3 Structure and Installation

3.2 Installation of the SINUMERIK 840D

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

2. Remove the DC link busbars at the module to the right of the NCU box.

3. Now mount the DC link busbars from the accessory kit of the NCU box between the power module and the first drive module. Use the screws located on the modules (observe tightening torque, M4: 1.8 Nm, M5: 3 Nm).

4. 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.

Inserting the NCU

The NCU module is secured when it clicks into the NCU box.

In order to guarantee the vibration resistance, both slotted screws (1) must be tightened (see Fig. 3-3).

The battery/fan module is delivered completely assembled with the NCU box.

NCU box

NCU module

1

Memory card

Fig. 3-3 Installation of the NCU module in the NCU box

1

Battery/fan slide-in module

End-to-end DC link busbars

PE conductor connection

3-33

3 Structure and Installation

3.2 Installation of the SINUMERIK 840D

03.06

Maintaining distances

130

Certain distances must be maintained with regard to cable routing and open ventilation when mounting the NCU box.

49.6

Space for exhaust air

100443

24.8

466

480

127

A

23

Space for supply air

208

20

100

24.8

A

Fig. 3-4 NCU cassette for Sinumerik 840D, dimensional drawing and installation instructions

8

3-34

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

3 Structure and Installation

3.2 Installation of the SINUMERIK 840D

80

60

100

80

Cooling clearance

Variant 1 Variant 2

288

60

100

Cooling clearance

20

Cooling clearance

Fig. 3-5 Cable routing and ventilation space when mounting modules

Mounting the link module

For installation, it is recommended that the front plate at the link module be removed and then reattached after the installation.

60

20

100

60

100

200

Cooling clearance



3-35

3 Structure and Installation

3.2 Installation of the SINUMERIK 840D

Notes

03.06

3-36

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

Description of the NCU

4.1 Components

4

Configuration

The components of the SINUMERIK 840D are compatible with the module series SIMODRIVE 611D. The 840D is operated with the power supply of SIMODRIVE 611 and the SIMODRIVE 611D drive modules.

NCU module

The NCU module (Numeric Control Unit) is the CPU of the SINUMERIK 840D. It takes over all the CNC, PLC and communication tasks. It is available in various performance variants:

Table 4-1 Components from the NCU 5xx.3 series:

NCU

561.3 6FC5356-0BB11-

561.3 6FC5356-0BB13-

571.3 6FC5357-0BB11-

571.3 6FC5357-0BB13-

572.3 6FC5357-0BB22-

572.3 6FC5357-0BB23-

573.3 6FC5357-0BB33-

Order no. (MLFB) Processor CNC user

0AE1

0AA1

0AE1

0AA1

0AE0

0AA0/1

0AE2

0AE3

0AA0/1

Intel 486 DX4 100 MHz

Celeron 400 MHz

Intel 486 DX4 100 MHz

Celeron 400 MHz

AMD K6-2 233 MHz

Celeron 400 MHz

Pentium III 500 MHz

Celeron 650 MHz

memory

min. / max.

0.25/1.5 MB PLC 315-2DP 96 / 288 KB Type 1 No

0.5/2.5 MB *) PLC 315-2DP 96 / 288 KB Type 3 No

0.25/1.5 MB PLC 315-2DP 96 / 288 KB Type 1 No

0.5/2.5 MB *) PLC 315-2DP 96 / 288 KB Type 3 No

0.25/1.5 MB PLC 315-2DP 96 / 288 KB Type 2 No

0.5/2.5 MB *) PLC 315-2DP 96 / 288 KB Type 3 No

2.5/2.5 MB *) PLC 315-2DP 96 / 288 KB Type 3 Yes

2.5/2.5 MB *) PLC 315-2DP 96 / 288 KB Type 3 No

PLC PLC

memory

min. / max.

Front

plate

Fan box

*) With technological cycles and measuring cycles, max. 1.5 MB available for users. With ShopMill/ShopTurn 1.2 MB available to users in the basic configuration and no other CNC user memory options are possible.

4-37

4 Description of the NCU

4.1 Components

Table 4-2 Components from the NCU 5xx.4 series:

03.06

NCU

561.4 6FC5356-0BB12-

561.4 6FC5356-0BB14-

571.4 6FC5357-0BB12-

571.4 6FC5357-0BB14-

572.4 6FC5357-0BB23-

572.4 6FC5357-0BB24-

573.4 6FC5357-0BB34-

*) With technological cycles and measuring cycles, max. 1.5 MB available for users. With ShopMill/ShopTurn 1.2 MB available to users in the basic configuration and no other CNC user memory options are possible.

Order no. (MLFB) Processor CNC user

0AE0

0AA0

0AE0

0AA0

0AE0

0AA0

0AE0

0AE1

0AA0

AMD K6-2 233 MHz

Celeron 400 MHz

AMD K6-2 233 MHz

Celeron 400 MHz

AMD K6-2 233 MHz

Celeron 400 MHz

Pentium III 500 MHz

Celeron 650 MHz

memory

min. / max.

0.5/2.5 MB *) PLC 314C-2DP 96 / 480 KB Type 2 No

0.5/3 MB *) PLC 314C-2DP 96 / 480 KB Type 3 No

0.5/2.5 MB *) PLC 314C-2DP 96 / 480 KB Type 2 No

0.5/3 MB *) PLC 314C-2DP 96 / 480 KB Type 3 No

0.5/2.5 MB *) PLC 314C-2DP 96 / 480 KB Type 2 No

0.5/3 MB *) PLC 314C-2DP 96 / 480 KB Type 3 No

2.5/2.5 MB *) PLC 314C-2DP 96 / 480 KB Type 3 Ye s

2.5/2.5 MB *) PLC 314C-2DP 96 / 480 KB Type 3 No

2.5/3 MB *) PLC 314C-2DP 96 / 480 KB Type 3 No

PLC PLC

memory

min. / max.

Front

plate

Fan box

Table 4-3 Components from the NCU 5xx.5 series:

NCU

561.5 6FC5356-0BB15-

571.5 6FC5357-0BB15-

572.5 6FC5357-0BB25-

573.5 6FC5357-0BB35-

**) Available to the user in the basic configuration:

Order no. (MLFB) Processor CNC user

0AA0

0AE0

0AA0

– with technological cycles and measuring cycles max. 1.5 MB – with ShopMill/ShopTurn 1.2 MB

Celeron 400 MHz

Celeron 650 MHz

Pentium III 933 MHz

memory

min. / max.

3 **) / 6 MB PLC 317-2DP 128 / 768 KB Type 3 No

Features of the NCU modules:

 Standard PCMCIA card

 4 High-speed NC inputs and 4 rapid NC outputs

 2 Measuring pulse inputs

PLC PLC

memory

min. / max.

Front panel

Fan box

4-38

 2 Handwheel inputs

 Voltage and temperature monitoring

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

p

4 Descri

4.1 Components

tion of the NCU

NCU box

Fan box

PLC module

COM module

187.5 kBd/1.5 MBd

The NCU box is the module rack of the NCU module and consists of:

 NC rack assembly with cable distributor

 Battery/fan slide-in module

 Sheet metal housing with integrated guide bars for accommodating the

NCU and the fan/battery slide-in modules and power supply unit

Order number: 6FC5247-0AA00-0AA3

The fan box is absolutely required for the 573.3 (Pentium III) and 573.4 (Pentium III) NCUs. Mount the fan box to the NCU box if necessary.

Order number: 6FC5247-0AA30-0AA0

As a submodule of the NCU, the PLC module supports machine monitoring and represents a PLC-CPU that is compatible to the S7-300 family of products. Via the P bus, three external lines can be connected for every eight S7-300 peripheral modules.

Reference: Installation manual for setting up the S7-300: CPU

The COM module is a submodule of the NCU. It is used for communication with the PCU and peripherals.

Driver module

187.5 kBd/1.5 MBd

PCMCIA card

The driver module is a submodule of the NCU (...-...-0AEx). It forms the interface to the operator panel front, to the programming device, to the decentralized peripherals and to S7-300 peripherals.

The NCU contains a plug-in unit for standard PCMCIA cards (PC card or NC card), via which all flash cards of type II up to 8 MB storage capacity can be operated.

The PCMCIA card serves as a bulk memory for the NC system software (NC card).

In addition to the software upgrade, the PCMCIA card can also be used for series start-up; see

References: /IAD/ Commissioning Manual 840D

Caution

Plugging the PCMCIA card in and out while energized will cause data to be lost!

4-39

4 Descri

p

tion of the NCU

4.1 Components

03.06

Link module (option for NCU 573.3/4/5)

The link module is a submodule of the NCU 573.3/4/5. If it is plugged in, you can reach the interface via the front plate of the NCU (above X122).

The module allows synchronization and an additional data exchange between several NCU 573.3/4/5 in a group.

Order No.: 6FC5212-0AA01-1AA0

96.5

+0.4

2.4

–1.4

16.8

163.3

Link cable

37.4

Fig. 4-1 Link submodule

Standard Profibus cable

4-40

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

4.2 Mounting

4.2.1 NCU box without a fan box

4 Description of the NCU

4.2 Mounting

NCU mounting board

316

Driver

module

COM

module

PLC

module

480

443

MEMORY CARD

Cable distributor

Battery/fan slide-in module

Power supply unit

198 208

265

Sheet metal housing

Fig. 4-2 Example: complete NCU box without a fan box with NCU 561.3

50

4-41

4 Descri

p

tion of the NCU

4.2 Mounting

4.2.2 NCU box with a fan box

316

Link submodule

03.06

Cut-out for link module

Cable distributor

Battery/fan slide-in module

Power supply unit

Fan box

198 208

136

265

480

510

443

Sheet metal housing

MEMORY CARD

50

Fig. 4-3 Example: complete NCU box with fan box and NCU 573.3 (Pentium III)

An alarm is issued if a fan fails.Monitoring the

fans

4-42

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

p

Mounting the fan box

4 Descri

1. Slide the back of the fan box into the locking mechanism on the NCU box.

Fan box

tion of the NCU

4.2 Mounting



Replacement

2. Push the front section into the guide until the spring locks.

Guide



For replacing the fan box

1. Apply pressure to the locking spring on the front section of the fan box and

2. Slide the fan box downward.

4-43

4 Description of the NCU

4.2 Mounting

03.06



Fan box



Warning

!

 Only trained personnel may replace a fan box. The regulations for handling

electrostatic sensitive devices must be observed.

 Completely switch off the system. Check that it is safely isolated from the

supply and safeguard against unauthorized switch-on.

4-44

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

p

4.3 NCU module interfaces

4 Descri

4.3 NCU module interfaces

tion of the NCU

Brief description of the interfaces

The NCU module has the following interfaces:

 Operating panel front interface X101 (MPI 1.5 MBaud, floating)

 PROFIBUS DP X102 interface

 SIMATIC S7 I/O bus X111 (P/C bus)

 Link interface (option for NCU 573.3/4/5)

 Connection for handwheel, sensor, NC-I/O X121 (cable distributor)

 Interface for programming device X122 (MPI 187.5 KBaud, non-isolated)

 SIMODRIVE 611D interface X130A (611D module and NCU terminal block)

 Device bus connection X172

 PCMCIA slot X173

 Displays for faults, status, start-up

 Operating elements for start-up, general reset, reset

4-45

4 Descri

p

tion of the NCU

4.3 NCU module interfaces

03.06

Interfaces, Operator Controls and Displays

For component assignments, see Section 4.1

–X101

–X102

Operator panel front interface

PROFIBUS DP interface

Reserved for service

–X112

–X122

 +5V

 PR

 NF

 PS

 CF

 PF

 CB

 CP

RESET

 PFO

 −

NMI

–X121 –X111

S3

S4

SIMATIC interface

PG-MPI interface I/O interface

(cable distributor) Various error and status LEDs

(H1/H2)

7-segment display (H3) NMI button (S2)

RESET button (S1) NCK start-up switch

PLC start-up switch

X130B

–X172

Fig. 4-4 Front plate type 1

X130A

MEMORY CARD

SIMODRIVE 611D interface

Reserved

Device bus interface

PCMCIA slot (X173)

4-46

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

4 Description of the NCU

4.3 NCU module interfaces

–X101

–X121 –X111

–X122

 +5V

 NF

 CF

 CB

 CP

RESET

–X102

–X103

 PR

 PS

 PF

 PFO

 T

Operator panel front interface PROFIBUS DP Interface

Reserved

SIMATIC interface

PG-MPI interface I/O interface

(cable distributor) Various error and status LEDs

(H1/H2)

7-segment display (H3)

–X172

Fig. 4-5 Front plate type 2

S3

S4

X130A

MEMORY CARD

RESET button (S1) NCK start-up switch

PLC start-up switch

SIMODRIVE 611D interface

Device bus interface

PCMCIA slot (X173)

4-47

4 Description of the NCU

4.3 NCU module interfaces

03.06

–X101

–X121 –X111

 POK

 NF

 CF

 CB

 CP

–X102

–X122

 PR

 PS

 PF

 PFO

 DP

RESET

NMI

S3

S4

Operator panel front interface

PROFIBUS DP Interface

Slot for link module (blank plate)

SIMATIC interface

PG-MPI interface I/O interface

(cable distributor) Various error and status LEDs

(H1/H2)

RESET button (S1)

7-segment display (H3)

NMI button (S2) NCK start-up switch

PLC start-up switch

X130B

–X172

Fig. 4-6 Front plate type 3

X130A

MEMORY CARD

SIMODRIVE 611D interface

Reserved

Device bus interface

PCMCIA slot (X173)

4-48

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

p

4 Descri

tion of the NCU

4.3 NCU module interfaces

X101

Operator panel front interface (MPI)

Connector name: X101 Connector type: 9-pole sub D socket connector Maximum cable length: 200 m Special features: Isolation (safe isolation)

Table 4-4 Pin assignments on connector X101

X101

Pin Name Type Pin Name Type

1 Not assigned 6 2P5 VO 2 Not assigned 7 Not assigned 3 RS_OPI B 8 XRS_OPI B 4 RTSAS_BTSS O 9 RTSPG_BTSS I 5 2M VO

Signal names

XRS_BTSS, RS_BTSS differential RS485 data – BTSS RTSAS_BTSS Request to Send AS – BTSS RTSPG_BTSS Request to Send PG – BTSS 2M Signal Ground, isolated 2P5 + 5 V, isolated P24ext, M24ext 24 V supply voltage

Signal type

B Bidirectional O Output VO Voltage Output I Input

X102

PROFIBUS DP interface

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

1.5 MBaud

Table 4-5 X102 pin assignments

X102

Pin Name Type Pin Name Type

1 Not assigned 6 VP VO 2 M24ext *) VO 7 P24ext *) VO 3 RS_PROFIBUSDP B 8 XRS_PROFIBUSDP B 4 RTSAS_PROFIBUSDP O 9 RTSPG_PROFIBUSDP I 5 DGND VO

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

4-49

4 Description of the NCU

4.3 NCU module interfaces

Signal names

XRS_PROFIBUSDP, RS_PROFIBUSDP Differential RS485 data – PROFIBUSDP RTSAS_PROFIBUSDP Request to Send AS – PROFIBUSDP RTSPG_PROFIBUSDP Request to Send PG – PROFIBUSDP DGND Signal Ground, isolated VP + 5 V, isolated P24ext, M24ext 24 V supply voltage

Signal type

B Bidirectional O Output VO Voltage Output I Input

03.06

X111

X112

(only NCUs with front plate type 1)

SIMATIC interface

Connector name: X111 Connector type: 25-pole sub D socket connector Maximum cable length: 10 m Special features: Non-isolated (basic isolation)

Serial interface RS232 (reserved for service)

Connector name: X112 Connector type: 9-pole sub D male connector Maximum cable length: 10 m Special features: Non-isolated (no safe isolation)

Table 4-6 X112 pin assignments

X112

Pin Name Type Pin Name Type

1 Not assigned 6 Not assigned 2 RxD I 7 RTS O 3 TxD O 8 CTS I 4 Not assigned 9 Not assigned 5 G VO

4-50

Signal names

RxD Receive Data TxD Transmit Data RTS Request to Send CTS Clear to Send M Ground

Signal type

O Output I Input VO Voltage Output

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

p

4 Descri

tion of the NCU

4.3 NCU module interfaces

Only NCU 573.3/4/5 with link module

Link module interface

Connector name: None Connector type: 9-pole sub D socket connector Maximum cable length: 100 m

Table 4-7 Pin assignment of plug X112 at the link module

X112

Pin Name Type Pin Name Type

1 Not assigned 6 VP VO 2 Not assigned 7 Not assigned 3 RS_LINK B 8 XRS_LINK B 4 Not assigned 9 Not assigned 5 DGND VO

Signal names

XRS_LINK, RS_LINK Differential RS485 data – LINK

XRS_CLKCY; RS_CLKCY Differential RS485 data – CLKCY

DGND Signal Ground, isolated VP +5 V, isolated

Signal type

B Bidirectional O Output VO Voltage Output I Input

4-51

4 Descri

p

tion of the NCU

4.3 NCU module interfaces

03.06

X121

I/O interface (cable distributor)

Connector name: X121 Connector type: 37-pole sub D male connector Maximum cable length: 25 m for all functions Special features: Isolation for binary inputs/

outputs, handwheels non-isolated

Table 4-8 X121 pin assignments

X121

Pin Name Type Pin Name Type

1 M24EXT VI 20 P24EXT VI 2 M24EXT VI 21 P24EXT VI 3 OUTPUT 1 O 22 OUTPUT 3 O 4 OUTPUT 0 O 23 OUTPUT 2 O 5 INPUT 3 I 24 MEXT VI 6 INPUT 2 I 25 MEXT VI 7 INPUT 1 I 26 MEXT VI 8 INPUT 0 I 27 MEXT VI

9 MEPUS 0 I 28 MEPUS 1 I 10 MEPUC 0 I 29 MEPUC 1 I 11 MPG1 XA I 30 MPG1 A I 12 MPG1 5 V VO 31 MPG1 0 V VO 13 MPG1 5 V VO 32 MPG1 0 V VO 14 MPG1 XB I 33 MPG1 B I 15 MPG0 XA I 34 MPG0 A I 16 MPG0 5 V VO 35 MPG0 0 V VO 17 MPG0 5 V VO 36 MPG0 0 V VO 18 MPG0 XB I 37 MPG0 B I 19 Not assigned

Signal names

MPG 0/1 5V supply voltage handwheel 0/1. 5 V, max. 500 mA

1)

MPG 0/1 0V supply voltage handwheel 0/1.0 V MPG 0/1 A/XA differential handwheel input 0/1, A/XA MPG 0/1 B/XB differential handwheel input 0/1, B/XB MEPUS 0/1 measuring pulse signal 0/1

2)

MEPUC 0/1 measuring pulse common (reference ground) 0/1 INPUT [0...3] binary NC input 0...3

2)

MEXT external ground (reference ground for binary NC inputs) OUTPUT [0...3] binary NC output 0...3

3)

M24EXT external 24 V infeed (–) for binary NC outputs P24EXT external 24 V infeed (+) for binary NC outputs

1)

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

2)

High level: rated value 24 V, limits 15 ...30 V / 2 mA...15 mA Low level: rated vale 0 V or open, limits –3...5 V

3)

The binary outputs are short-circuit proof. Max. switching current per output: 500 mA (coincidence factor 100%). For an inductive load, an external protective circuit is required for unloading the inductivity

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SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

p

Signal type

O Output VO Voltage Output I Input VI Voltage Input

4 Descri

tion of the NCU

4.3 NCU module interfaces

X122

PG-MPI interface

Connector name: X122 Connector type: 9-pole sub D socket connector Maximum cable length: 200 m Special features: Non-isolated (no safe isolation)

Table 4-9 X122 pin assignments

X122

Pin Name Type Pin Name Type

1 Not assigned 6 P5 VO 2 M24EXT *) VO 7 P24EXT *) VO 3 RS_KP B 8 XRS_KP B 4 RTSAS_KP O 9 RTSPG_KP I 5 G VO

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

Signal names

RS_KP, XRS_KP Differential RS485 data – C bus from PLC RTSAS_KP Request to Send AS – C bus from PLC RTSPG_KP Request to Send PG – C bus from PLC M Ground P5 5 V

Signal type

B Bidirectional O Output VO Voltage Output I Input

X130A

SIMODRIVE 611D interface

Connector name: X130A Connector type: 2x36-pole Micro Ribbon Maximum cable length: 10 m Special features: Non-isolated (no safe isolation)

4-53

4 Descri

p

tion of the NCU

4.3 NCU module interfaces

03.06

X172

Device bus interface

Connector name: X172 Connector type: 2x17-pole ribbon cable connector, male

Table 4-10 X172 pin assignments

X172

Pin Name Type Pin Name Type

1 HF1 VI 18 P27 VI

2 HF2 VI 19 M27 VI

3 HF1 VI 20 G VI

4 HF2 VI 21 Not assigned

5 Not assigned 22 G VI

6 Not assigned 23 Not assigned

7 Not assigned 24 G VI

8 Not assigned 25 Not assigned

9 P15 VI 26 G VI 10 Not assigned 27 Not assigned 11 P15 VI 28 Not assigned 12 Not assigned 29 Not assigned 13 N15 VI 30 Not assigned 14 Not assigned 31 SIM_RDY OC 15 N15 VI 32 Not assigned 16 I2T_TMP OC 33 Not assigned 17 Not assigned 34 Not assigned

X173

Signal names

HF 1, 2 Voltage supply " 57 V, 20 kHz P15 + 15 V M Ground P27 + 27 V fan supply M27 Reference ground to P27 N15 – 15 V I2T_TMP I

2

t advance warning (NC-specific: fan/temperature alarm)

SIM_RDY Drive and NC operationally ready

Signal type

OC Open Collector VI Voltage Input

PCMCIA slot

Connector name: X173 Connector type: 68-pole PCMCIA card connector, male

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SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

p

Operator controls and displays

Table 4-11 Operator controls and displays

4 Descri

tion of the NCU

4.3 NCU module interfaces

Designation

RESET (S1) Button Triggering a hardware reset to reset the control and drive followed by a

NMI (S2) Button Triggering an NMI request at the processor S3 Rotary switch NCK-startup switch

S4 Rotary switch PLC-mode switch

H1 (left row) LED Illuminates if ...

H2 (right row) LED Illuminates, ...

Type Meaning Fea-

complete restart.

Position 0: normal mode Position 1: startup position Positions 2 to 7: reserved

Position 0: PLC–RUN Position 1: PLC–RUN–P Position 2: PLC–STOP Position 3: MRES

+5V/POK: ... supply voltage is in tolerance range. NF: ... NCK-Watchdog has activated and during the

startup phase.

CF: ... COM-Watchdog has activated. CB: ... data transfer takes place via BTSS. CP: ... data transfer takes place via PG MPI interface.

For NCUs with the MLFB ...-...-0AA0, the following applies:

NCU-internal voltage monitoring has switched off the power supply (retentive) of the module if ... POK : Off NF : On CF/CB/CP : undefined H2 : undefined

Therefore, ensure that the recovery time after shutdown (re-activation via power ON) is at least 10 s, because otherwise the voltage monitoring can be activated.

PR: ... if PLC-status = RUN PS: ... if PLC-status = STOP PF: ... + PR + PS + PFO: if PLC Watchdog has activated. PFO: ... if PLC status = FORCE

1)

T/DP

: PLC-DP-status:

– LED is off:

DP is not configured or DP is configured, all slaves are found.

– LED is flashing:

DP is configured, at least one slave is missing.

– LED illuminates:

error (e.g. bus short-circuit, no token circulation)

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

ture

green red

red yellow yellow

green red red yellow yellow

1)

On the SIMATIC CPU 315-2DP, the LED is called “BUSF”.

4-55

4 Descri

p

tion of the NCU

4.4 Cable distributor (distributor box)

03.06

Cable distributor (I/O interface)

The cable distributor splits the X121 interface of the NCU into

 two connections of differential handwheel,  two connections of meas. pulse input,  four connections of binary NC input,  four connections of binary NC output and  single connection 24 V/M24

using max. seven single cables. To supply the binary NC outputs, an external 24 V supply is possible at the cable distributor.

ext

Cable 6FX2002-4AA21-0

Cable 6FX2002-4AA41-0

90

Fig. 4-7 Cable distributor

The cable distributor (37-pole) consists of connector housing (SINUMERIK version) for a 37-pole sub D connector with an enlarged interior. The rear contains seven cable inputs where the cables must be attached as shown in Table 4-14.

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 free stripped shield jackets have a large conductive connection to the metallic contact areas as shown in the Figure showing the position of the interfaces of the cable distributor (see below).

4-56

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

p

4 Descri

tion of the NCU

4.4 Cable distributor (distributor box)

Insert 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. Securing to the front panel of the NCU routes the shield potential via the contact springs of the cable distributor.

Status table for switches S1...S5 (Order No. 6FX 2006-1BA00)

The DIP FIX switches in the cable distributor must be set as follows:

Table 4-12 Setting the DIP-FIX switches in the cable distributor (S1...S5)

Location of interfaces

Switch

Open x x x x x Closed

S1 S2 S3 S4 S5

Status table for switches S1...S6 (Order No. 6FX 2006-1BA01)

The DIP FIX switches in the cable distributor must be set as follows:

Table 4-13 Setting the DIP-FIX switches in the cable distributor (S1...S6)

Switch

Open x x x x Closed x x

S1 S2 S3 S4 S5 S6

Cable inlets

Terminal caps

Contact surfaces

X1 X2 X4 X5 X6 X7 X8

X3

S5 S6

X11

1) Not for Order No. 6FX 2006-1BA00

Fig. 4-8 Position of the interfaces of the cable distributor

1)

X9 X10

S1S2 S3S4

Plug-in connectors X1...X10

Sub-D female connector

S1 to S6:

Closed

Open

4-57

1

1. Hand wheel

2

2. Hand wheel

4

4 bi

4 Descri

p

tion of the NCU

4.4 Cable distributor (distributor box)

Connector assignments

Table 4-14 Connector assignments

03.06

Connector coding

Connector No.

X1 X2 X3 X4 X5 3 2. Probe X6 X7 X8 5 4 binary outputs X9 6 Supply for 4 binary outputs

X10

Cable No. Peripherals

1

(top)

nary inputs

7

(bottom)

1. Probe

= coding pin

= no coding pin

Viewing direction: from behind toward the cable distributor

Pin 1

Fig. 4-9 Position of the coding pins

Note

When assembling the cable distributor, make absolutely sure that the supplied insulating washer is installed correctly and the coding pins are installed.

4-58

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

p

4 Descri

tion of the NCU

4.4 Cable distributor (distributor box)

Pin assignment

Table 4-15 Cable distributor pin assignment

Pin no. 37-pin

connec-

tor

9

10

1

20

2

21

3

22

4

23

5

24

6

25

7

26

8

27

28

29

Signal

name

–

MEPUS 0

–

MEPUC 0

M24EXT P24EXT M24EXT P24EXT

OUTPUT 1 OUTPUT 3 OUTPUT 0 OUTPUT 2

INPUT 3 MEXT INPUT 2 MEXT INPUT 1 MEXT INPUT 0 MEXT

–

MEPUS 1

–

MEPUC 1

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

Cable No. Cable Order

No.

6FX2002-4AA

7 41–0

6 41–0

5 41–0

4 21–0

3 41–0

Core color I/Os Terminal

rd or br

bk

shield

rd or br

bk

shield

rd or br

bk

shield

rd or br

bk

gn

ye

vio

bl

shield

rd or br

bk

shield

1. Probe

Supply

of the 4 binary

outputs

4 binary

outputs

4 binary

inputs

2. Probe

Signal

+24 V

Reference-

signal 0 V

Ground

24 V

Ground

24 V

2. Output

4. Output

1. Output

3. Output

4. input ground

3. Input

ground

2. Input

ground

1. Input

ground

Signal

+ 24 V

Reference

signal 0 V

11 30 12 31 13 32 14 33

15 34 16 35 17 36 18 37

MPG1 XA MPG1 A MPG1 5V MPG1 0V MPG1 5V MPG1 0V MPG1 XB MPG1 B

MPG0 XA MPG0 A

MPG0 5V MPG0 0V

MPG0 5V MPG0 0V MPG0 XB MPG0 B

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

2 21–0

1 21–0

rd or br

bk

gn

ye

vio

bl

shield

rd or br

bk

gn

ye

vio

bl

shield

2. Handwheel

6FC9320-5DB

1. Handwheel

6FC9320-5DB

Signal names

MPG 0/1 5V supply voltage handwheel 0/1. 5 V

1)

MPG 0/1 0V supply voltage handwheel 0/1.0 V MPG 0/1 A/XA differential handwheel input 0/1, A/XA MPG 0/1 B/XB differential handwheel input 0/1, B/XB

XA

A 5 V 0 V 5 V 0 V XB

B

XA

A 5 V 0 V 5 V 0 V XB

B

4-59

4 Description of the NCU

4.5 Technical data

MEPUS 0/1 measuring pulse signal 0/1 MEPUC 0/1 measuring pulse common (reference ground) 0/1 INPUT [0...3] binary NC input 0...3 MEXT external ground (reference ground for binary NC inputs) OUTPUT [0...3] binary NC output 0...3 M24EXT external 24 V infeed (–) for binary NC outputs P24EXT external 24 V infeed (+) for binary NC outputs

1)

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

2)

High level: rated value 24 V, limits 15 ..30 V / 2 mA...15 mA Low level: rated vale 0 V or open, limits –3...5 V

3)

The binary outputs are short-circuit proof. Max. switching current per output: 500 mA (coincidence factor 100%). For an inductive load, an external protective circuit is required for unloading

the inductivity

4.5 Technical data

Table 4-16 General technical data

03.06

2)

3)

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 ambient conditions

Transport (in transport packaging)

Bearings 1M2 according to EN 60721–3–1

IP20 (with NCU box)

or IPXXB

2M2 according to EN 60721–3–2

IP00 (without NCU box)

4-60

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

571.4

p

Table 4-17 Electrical and mechanical data of the individual components

4 Descri

tion of the NCU

4.5 Technical data

Component

NCU 561.3

571.3

NCU 561.4

572.3/.4

NCU 573.3/.4 Pentium III 500 MHz 45 50 x 316 x 207 1.05

NCU 561.5

571.5 NCU 572.5 Celeron 650 MHz 36 50 x 316 x 207 0.72 NCU 573.5 Pentium III 933 MHz 40 50 x 316 x 207 0.72 NCU box – – Without fan box: 50 x 480 x 265

Fan box – – 50 x 47 x 136 0.14

Intel 486 DX4 33 50 x 316 x 115 0.68 Celeron 400 MHz 32 50 x 316 x 207 0.72 AMD K6-2 36 50 x 316 x 115 0.68

Celeron 400 MHz 32 50 x 316 x 207 0.72

Celeron 650 MHz 36 50 x 316 x 207 0.72 Celeron 400 MHz 32 50 x 316 x 207 0.72

CPU Power loss *)

in W

*) NCU with NCU box, without handwheel and I/O

Dimensions

width x height x depth in mm

With fan box: 50 x 510 x 265

Weight

in kg

3.2

Note

The NCU is supplied with power via the device bus (HF1/2) from the SIMODRIVE infeed module (see Table 4-10).



4-61

4 Description of the NCU

4.5 Technical data

Notes

03.06

4-62

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

I/O Modules

5.1 Single I/O module

5

Short description

Connection to 840D

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 connected to the SINUMERIK 840D; combinations with SIMATIC S7-300 lines are possible.

The single I/O module (connector X3 IN) is connected to the SINUMERIK 840D (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: 6FC5

411-0AA80-0AA0, length 150 mm

6ES7368-30-0AA0

OUTIN OUTIN OUTIN

X3

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

X3 X3

840D

X3 IN

X3 OUT

EFP

Fig. 5-1 Overview of connections, single I/O modules on the SINUMERIK 840D

X404 32 I

X405 32 I

X402 32 O

6ES7368-30-0AA0

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

Ribbon cable

EFP EFP EFP

SINUMERIK 840D

IM 361 or second single I/O module

Terminal strip converter

5-63

5 I/O Modules

5.1 Single I/O module

03.06

SHIELD M24 P24Logic

SHIELD M24 P24Power

360

374

Cooling clearance 50 mm

70

Space for front connector

25

Fig. 5-2 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

2

least 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.

5-64

Cooling clearance 50 mm

135

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

I

l

2–1

Technical data

5 I/O Modules

5.1 Single I/O module

Table 5-1 Technical data of the single I/O module

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

Current consumption – LOGIC

Power loss – LOGIC

Inputs

Outputs

Overtemperature protection block-specific shutdown Coincidence factor

Total of all nominal currents within each group of 0.5 A

Degree of protection IP20 or IPXXB Weight 1.7 kg

– Nominal value – Perm. range – Ripple – Polarity reversal protection – Fuse-protection

– POWER

Number of inputs Signal level for signal “0” Signal level for signal “1” Isolation

nput current 1-signa Input current 0-signal Delay time T Delay time T Noise immunity (DIN 57847) Cable length terminal block

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

Switching frequency

Noise immunity (DIN 57847) Cable length terminal block

PHL PLH

DC 24 V

18.5 ... 30.2 V

3.6 V ss yes LOGIC: 1 A/250 V POWER: no type: 0.3 A , max. 1 A max. 12 A type: 7.2 W, max. 30.2 W max: 362 W

64 digital inputs –3 V to + 5 V + 15 V to +30 V yes (optocoupler)

5 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%

5-65

5 I/O Modules

5.1 Single I/O module

03.06

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 mm

SHIELD (pin 3)

X1

Table 5-2 X1 pin assignment

Pin Name Type

3 SHIELD 2 M24 VI 1 P24 Logic VI

M24 (Pin 2) P24Logic (pin 1)

2

).

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.

Connection of the load power supply

The 24 V DC load power supply is connected to X5 via a 3-way angled Phoenix

2

screw terminal connector (2.5 mm

X5

Table 5-3 Assignment of connector X5

Pin Name Type

3 SHIELD 2 M24 VI 1 P24 Power VI

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

).

X5 POWER power supply

Signal names

P24 Power +24 V electronics load power supply external M24 Electronics load power supply ground external

Signal type

VI Voltage Input

5-66

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

5 I/O Modules

5.1 Single I/O module

Connection of the inputs/outputs

Meanings of the LEDs

X402 outputs 0–31

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

6FC9302-2AL (2 A) Terminal strip converter with LED green: 6FC9302-2AD Assignment of the ribbon cable is compatible with the I/O modules (logic modules) of the SINUMERIK 840D.

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-pole 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

assigned

OUT0ȱ0ȳ

OUT0ȱ2ȳ

OUT0ȱ4ȳ

OUT0ȱ6ȳ

OUT1ȱ0ȳ

OUT1ȱ2ȳ

OUT1ȱ4ȳ

OUT1ȱ6ȳ

OUT2ȱ0ȳ

OUT2ȱ2ȳ

OUT2ȱ4ȳ

OUT2ȱ6ȳ

OUT3ȱ0ȳ

OUT3ȱ2ȳ

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

2 Not

assigned

OUT0ȱ1ȳ

OUT0ȱ3ȳ

OUT0ȱ5ȳ

OUT0ȱ7ȳ

OUT1ȱ1ȳ

OUT1ȱ3ȳ

OUT1ȱ5ȳ

OUT1ȱ7ȳ

OUT2ȱ1ȳ

OUT2ȱ3ȳ

OUT2ȱ5ȳ

OUT2ȱ7ȳ

OUT3ȱ1ȳ

OUT3ȱ3ȳ

O

5-67

5 I/O Modules

5.1 Single I/O module

03.06

X404 inputs 0 to 31

31

33

OUT3ȱ4ȳ

OUT3ȱ6ȳ

O 32

O 34

OUT3ȱ5ȳ

OUT3ȱ7ȳ

Signal names

OUTi[j] Output j of output byte i

Signal type

O Output

Connecting inputs 0 to 31

Connector name: X404 INPUT 0–31 Connector type: 34-pole 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

O

I

5-68

Signal names

INPi[j] Input j of input byte i

Signal type

I Input

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

5 I/O Modules

5.1 Single I/O module

X405 inputs 32 to 63

Connecting inputs 32 to 63

Connector name: X405 INPUT 32–63 Connector type: 34-pole 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 840D 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

5-69

5 I/O Modules

5.1 Single I/O module

03.06

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 start-up. Parameterization is not required.

In HW-Config, it is possible to treat the 840D I/Os as the equivalent arrangement of S7-300 modules.

Chain 1

X111

I/O bus

Chain 2

SINUMERIK 840D with integrated PLC

EFP

Fig. 5-3 SINUMERIK 840D with 3 I/O chains (max. configuration)

Chain 3

EFP



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SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

Terminal Block

6.1 NCU terminal block 6FC5211-0AA00-0AA0

6

X20: Interface with the drive bus

2

2.5 mm 24 V

321

4

1234 5678

100

0 V

PE conductor connection

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

X21: Interface with the next NCU terminal block

X9: Terminal external 24 V logic power supply

DMP compact module slots

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

237 257

Shielding plate

74,4

Fig. 6-1 Front view of NCU terminal block

Mounting

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.

6-71

6 Terminal Block

6.1 NCU terminal block 6FC5211-0AA00-0AA0

03.06

Connection to the drive bus

!

Connection PROFIBUS DP terminal block

Drive bus max. length 10 m

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.

Up to 2 NCU terminal blocks can be connected

Device bus

SIEMENS

SIMODRIVE

I/R

Fig. 6-2 Connection of terminal block to 840D

Terminator

Protective conductor

NCU MSD FD

The termination connector must be plugged into slot X21 on the last NCU terminal block.

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. 6-1.

Termination connector

Round cable

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03.06

6 Terminal Block

6.1 NCU terminal block 6FC5211-0AA00-0AA0

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 fine stranded cable with a cross-section of at least 10 mm

No more than 8 DMP compact modules can be connected per NCU terminal block.

Module type Max.

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 ana-

log IN

DMP compact module 1A analog 4 Analog output 14 bits

2

and a length of at least < 30 cm, if possible.

number

4 High-speed analog input 75 ms, 12

Distinction

bits

Maximum number of components in all terminal blocks of a controller:

Peripherals Number

Digital inputs 32

Digital outputs 32

Analog inputs 8

Analog outputs 8

Important

!

No more than 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.

6-73

6 Terminal Block

6.1 NCU terminal block 6FC5211-0AA00-0AA0

03.06

Monitoring

 +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

Error Acquisition Effect

Undervoltage (< 4.75 V)

Ambient temperature Temperature sensor Status signal to NC,

Sign of life NCU Cyclic signaling Disabling of the NC outputs, LED

Watchdog Timing Disabling of the NC outputs, LED

Hardware combination Hardware configura-

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

Limit monitor Disabling of the NC outputs, LED

tion

(green) off

screen display

(red) on

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

Power supply

DC 24 V (20.4 V DC to 28.8 V DC) Connector designation: X9

2

Connector type: 4-pole terminal block, 2.5 mm

Table 6-1 X9 pin assignments

Terminal

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 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

X20/X21

X Drive bus interface

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

6 Terminal Block

6.1 NCU terminal block 6FC5211-0AA00-0AA0

X11–X18

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

Table 6-2 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



6-75

6 Terminal Block

6.1 NCU terminal block 6FC5211-0AA00-0AA0

Notes

03.06

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SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

DMP Compact Modules

7

Mounting

The following dimensions must be observed when mounting:

Table 7-1 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

7.1 DMP compact module 16E 6FC5111-0CA01-0AA0

The DMP compact module 16E is an encapsulated module. It can be plugged into a slot of the (PROFIBUS DP or NCU) terminal block as a plug-in module.

1.5

0 V

Status LEDs

Labeling strips

Fixing screw

X3

0

. .

7

0

. .

7

LOW byte

HIGH byte

X1

PG765

X3

43210

Inputs IN 7 ... IN 0 HIGH byte

X2

Fig. 7-1 Front view and side view of a DMP compact module 16E

Inputs IN 0 ... IN 7 LOW byte

01234 567GP

1.5

0 V

X2

7-77

7 DMP Compact Modules

7.1 DMP compact module 16E 6FC5111-0CA01-0AA0

03.06

Interfaces

Display elements

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

 Two 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 inputs and the load power supply.

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

mer.

 The 24 V terminal P (24 V) is not used

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

LEDs lit: Input on.

Table 7-2 Technical data DMP compact module 16 I

Number of 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 Maximum 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 – For signal “0”

– For signal “1” +13 V to +33 V

LH

HL

16 digital inputs

24 V DC –3 to +5 V

tpLH = type 1 ms tpHL = type 1 ms

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SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

7 DMP Compact Modules

7.2 DMP compact module 16 A 6FC5111-0CA02-0AA1

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

24 V

DC 1.5

LOAD

0 V

Status LEDs

Labeling strips

Fastening screw

X3

0

. .

7 0

. .

7

LOW byte

HIGH byte

X1

PG76 5

X3

43210

Outputs OUT 7 ... OUT 0 HIGH byte

Interfaces

Display elements

X2

Outputs OUT 0 ... OUT 7 LOW byte

0 1234 567GP

0 V

24 V

DC 1.5

LOAD

X2

Fig. 7-2 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 custo-

mer.

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 7-3 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

7-79

7 DMP Compact Modules

7.2 DMP compact module 16 A 6FC5111-0CA02-0AA1

Table 7-3 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 Yes Power loss at 30 V max. 3.8 W Operating frequency for

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

load, higher values are permissible for lower loads)

Derated loading at 55 C (relative to the total of the rated currents of all outputs)

Delay time for tp Delay time for tp Length for cables Maximum 30 m Weight About 160 g

LH

HL

03.06

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: a retentive shutdown until the output is energized again by the PLC user program). When an output is short-circuited, the three additional outputs of the corresponding half byte can also be shutdown. In normal mode, with currents of < 0.7 A, no opposing effect occurs.

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.

7-80

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03.06

7 DMP Compact Modules

7.3 DMP compact module 8 A (6FC5111-0CA03-0AA1)

The DMP compact module 8O is an encapsulated module. It can be plugged into a slot of the (PROFIBUS DP or NCU) terminal block as a plug-in module.

24 V

DC 2.5

LOAD

Status LEDs

Labeling strips

X3

0 V

765

PG

X3

0

. .

7

4

Outputs OUT 7 ... OUT 4

Interfaces

Fixing screw

X2

X1

Outputs OUT 0 ... OUT 3

X2

PG3

210

0 V

24 V

DC 2.5

LOAD

Fig. 7-3 Front view and side view of a DMP compact module 8A

Terminal P G 7/3 6/2 5/1 4/0

X3 24 V 0 V OUT 7 OUT 6 OUT 5 OUT 4 X2 24 V 0 V OUT 3 OUT 2 OUT 1 OUT 0

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

 6-pole terminals X3 and X2 (Phoenix, type MSTB2.5/6-ST-5.08 GRAY Order

No. for X3 :18 28 647 and for X2: 18 28 168) for connecting the 8 outputs and the load power supply.

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

mer.

Display elements

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

LEDs lit: Output on

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7 DMP Compact Modules

7.3 DMP compact module 8 A (6FC5111-0CA03-0AA1)

Table 7-4 Technical data of DMP compact module 8O

03.06

Number of outputs Galvanic isolation Ye s Power supply V

Signal level of the outputs (typically)

Output load for signal “1” (rated value)

Short-circuit protection Yes Power loss at 30 V max. 3.1 W Operating frequency for

Derated loading at 55 C (relative to the total of the rated currents of all outputs)

Delay time for tp Delay time for tp Length for cables Maximum 30 m Weight About 145 g

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

– Ohmic load 2000 mA – Lamp load 25 W – Inductive load 2000 mA

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

load, higher values are permissible for lower loads)

LH

HL

8 digital outputs

–80 mV

load

2 Hz

50%

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

4 outputs each are powered by a power supply. For each group of 4 outputs (outputs 0 to 3 and 4 to 7), the total of the output currents must not be greater than 4 A. (This corresponds to a coincidence factor of 50 % if each output is under full load). All 8 outputs can be loaded simultaneously with 1 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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03.06

7 DMP Compact Modules

7.4 DMP compact module 1I analog 6FC5 111-0CA04-0AA0

The DMP compact module 1I analog is an encapsulated module. It can be plugged into a slot of the (PROFIBUS DP or NCU) terminal block as a plug-in module. The conversion time is a max. of 60 ms in the rated range and a max. of 80 ms in the overshoot range.

M2M1

P2P1

24 V DC

X3

2.5

0 V

Connection terminals

Interfaces

Status LED

Labeling strips

Fastening screw

Fig. 7-4 Front view and side view of a DMP compact module 1E analog

POWER SUPPLY

O.K.

ANALOG IN

X1

2,5

X2

S1

6..1

S2

1

3 21 2

Terminal:

6, 1 Shield 2 Curr. source for PT100 3 Analog input In+ 4 Analog input In– 5 Ground

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

 4x terminal X3 (Phoenix, Type MSTB2.5/4-ST-5.08 GREY, Order No. for X3:

18 48 407) for connecting the power supply for the analog part and 6x terminal X2 (Phoenix, Type MSTB2.5/6-ST-5.08 GREY, Order No. for X2: 17 87

076) for connecting the analog input.

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

mer.

Display elements

Jumpering

1 LED as a status display for the power supply.

LED lit: Internal power supply OK

S1: Setting of the measurement range

1–2 closed: +10 V 1–3 closed: +500 mV

S2: Setting the line frequency

closed: for 50 Hz systems open: for 60 Hz systems

7-83

7 DMP Compact Modules

7.4 DMP compact module 1I analog 6FC5 111-0CA04-0AA0

03.06

Example circuits

Analog voltage measurement

X2

S6M5–4+

X2

S6M5–4+3S

Fig. 7-5 Example circuits for DMP compact module 1I analog

S

3

1

2

Differential input (common-mode

UU

disturbances are suppressed)

Measurement with PT100

I

1

2

PT100 with 4-wire connection

S6M5–4+

S6M5–4+3I2S

X2

3

S 1

2

1

PT100 with 2-wire connection

Unipolar (default)

Note

If the power source is not required, it must be short-circuited.

Table 7-5 Technical data DMP compact module 1I analog

Number of inputs Galvanic isolation Ye s Power supply V

Input voltage – Rated range

Input resistance 40 kΩ or 1 MΩ Power consumption (24 V) 45 mA I

for PT100 2.5 mA

const

Connection of signal generators See below Digital representation of the input signal 12 bits + sign Error message on overrange

(" 20 V; "1 V) Basic error limits

Operational limits (0 C to 60 C)

Length of cables (shielded) max. 30 m Weight about 150 g

LOAD

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

– Overshoot range

1 analog input

"10 V or "500 mV+ "20 V or "1 V

Yes

"0.2%

"0.5%

7-84

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03.06

7 DMP Compact Modules

7.4 DMP compact module 1I analog 6FC5 111-0CA04-0AA0

The DMP compact module 1I analog is used to input and digitize an analog voltage value. This voltage value is measured by an isolated differential input.

In conjunction with the installed constant current source (2.5 mA), it is possible to connect PT100 resistance thermometers.

Conversion time

The conversion time depends on the level of the input voltage. Input voltage in the dimensioning range ––> conversion time < 60 ms input voltage in the overshoot range ––> conversion time < 80 ms The integration time is included in the conversion time, which determines the noise suppression: S 2 closed––> Integration time 20 ms 50 Hz noise suppression. S 2 open ––> Integration time 16 2/3 ms 60 Hz noise suppression.

Table 7-6 Digital analog value representation for DMP compact module 1E analog

Input word

76543210 76543 210 10V range 500 mV

Significance

Digital value 00000000 00001 000 0.005 V 0.24 mV

VZ 2112102928272625242322212000RPF

01111111 11111 000 19.995 V 999.76 mV

01000000 00001 000 10.005 V 500.24 mV 01000000 00000 000 10 V 500 mV 00111111 11111 000 9.995 V 499.76 mV

00000000 00000 000 0 V 0 mV 11111111 11111 000 –0.005 V –0.24 mV

11000000 00001 000 –9.995 V –499.76 mV 11000000 00000 000 –10 V –500 mV 10111111 11111 000 –10.005 V –500.24 mV

10000000 00001 000 –19.995 V – 999.76 mV

IB m IB m+1 Analog input voltage

range

: : : :

0 = Always 0 OR= Overflow bit, input voltage is greater than 20 V or 1 V (double input

range)

PF = Power supply failure of the analog part

7-85

7 DMP Compact Modules

7.5 DMP compact module 1E NC analog

7.5 DMP compact module 1E NC analog 6FC5211-0AA10-0AA0

The DMP compact module 1E NC analog is an encapsulated high-speed analog input module with 75ms access time. It can be plugged into a slot of the NCU terminal block as a plug-in module. The DMP compact module 1E NC analog serves for inputting and digitizing an analog voltage value. This voltage value is measured by an isolated differential input.

24 V DC

X3

03.06

M2M1

P2P1

2.5

0 V

Connection terminals

Interfaces

Status LED

Labeling strips

Fastening screw

Fig. 7-6 Front view and side view of a DMP compact module 1E NC analog

POWER SUPPLY

O.K.

ANALOG IN

X1

2.5

X2

6..1

1

3 21 2

Terminal:

6, 1 Shield 2 Ground 3 Analog input In+ 4 Analog input In– 5 Ground

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

 4x terminal X3 (Phoenix, Type MSTB2.5/4-ST-5.08 GREY, Order No. for X3:

18 48 407) for connecting the power supply for the analog part and 6x terminal X2 (Phoenix, Type MSTB2.5/6-ST-5.08 GREY, Order No. for X2: 17 87

076) for connecting the analog input.

Display elements

Analog-value representation

7-86

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

mer.

1 LED as a status display for the power supply. LED lit: internal power supply OK.

The converter result is available to the user as two’s complement. The resolution is 4.88 mV for one bit. The duration for a converter cycle (from triggering of conversion to the time at which the result can be read out) is max. 75 µs.

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

7.5 DMP compact module 1E NC analog

Table 7-7 Digital analog value representation for DMP compact module 1I NC analog

7 DMP Compact Modules

Input word

76543210 7654 3210 Range +/– 10 V

Significance

Digital value 00000000 0000 0000 0 V

VZ 21029282726252423222120000PF

01111111 1111 0000 9.995 V

00000000 0001 0000 0.005 V

11111111 1111 0000 –0.005 V

10000000 0001 0000 –9.995 V 10000000 0000 0000 –10 V

IB m IB m+1 Analog input voltage

: : :

0 = always 0, PF=failure of the power supply of the analog part

Example circuits

X2

S6M5–4+

Analog voltage measurement

X2

GG

S

3

1

2

S6M5–4+

3

2

S 1

Differential input (common-mode

UU

disturbances are suppressed)

Fig. 7-7 Example circuits for DMP compact module 1I NC analog

Table 7-8 Technical data DMP compact module 1I NC analog

Number of inputs Galvanic isolation Ye s Power supply V

Input voltage – Rated range Input resistance 100 kΩ Power consumption (24 V) 85 mA Connection of signal generators See below Digital representation of the input signal 11 bits + sign Total error over temperature range 0 to 55 C including zero

error Length of cables (shielded) Max. 30 m Weight Approx. 160 g

LOAD

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

1 analog input

"10 V

"0.6 %

Unipolar (default)

7-87

s

7 DMP Compact Modules

7.6 DMP compact module 1A analog

7.6 DMP compact module 1A analog 6FC5111-0CA05-0AA0

The DMP compact module 1A analog is an encapsulated module. It can be plugged into a slot of the (PROFIBUS DP or NCU) terminal block as a plug-in module.

03.06

Interfaces

P1 P2 M1 M2

24 V DC

X3

Status LED

Labeling strips

Fastening screw

Fig. 7-8 Front view and side view of a DMP compact module 1A analog

POWER SUPPLY

O.K.

ANALOG OUT

X1

X2

2.5

1.5

0 V

Connection terminal

1234

Terminal:

1, 4 ... Shield 2 ... Analog output Out+ 3 ... Analog output Out–

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

 4x terminal X3 (Phoenix, Type MC1.5/4-ST-3.81, Order No. for X3: 1828126)

for connecting the power supply for the analog part and X2 (Phoenix, Type MSTB2.5/4-ST-5.08 GREY, Order No. for X2: 18 40 942) for connecting the analog output.

Conversion time

Display elements

7-88

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

mer.

The pure conversion time is a max. of 10 µs. Because the analog signal is smoothed by an RC element, its time constant determines the total conversion time:

 Product version A: 100 µs

 As of product version B: 330 µs

1 LED as a status display for the power supply.

LED lit: internal power supply OK

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

03.06

tage

cance

SG 2122112102928272

6

25242322212

0

7 DMP Compact Modules

7.6 DMP compact module 1A analog

Table 7-9 Technical data DMP compact module 1A analog

Number of outputs

1 analog output Galvanic isolation Ye s Power supply V

LOAD

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

Power consumption (24 V) 60 mA Output voltage – Rated range

Output current

Load resistance at voltage outputs Min.

"10 V DC

"3 mA

3.3 kΩ

Digital representation of the input signal 13 bits + sign Short-circuit protection Yes Length of cables (shielded) Max. 30 m Weight About 140 g

Table 7-10 Digital analog value representation DMP compact module 1A analog

Output word

Significance

QB m QB m+1

76543210

12

11

10

9

8

7

6

765432

5

4

3

2

1

0

10

always 0

Analog

output vol-

01111111 111111 00 +9.9988 V

tage

Digital value

00000000 000001 00 +1.22 mV 00000000 000000 00 0 V

11111111 111111 00 –1.22 mV

10000000 000000 00 –10 V



7-89

7 DMP Compact Modules

7.6 DMP compact module 1A analog

Notes

03.06

7-90

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

Maintenance and Service

8.1 Battery and fan replacement

8

4

3

1) Battery

2) Red cable (polarity +)

3) Latch

4) Fan

Fig. 8-1 Battery/fan slide-in module

Danger

!

Do not attempt to reactivate discharged batteries with heat or by any other means. The batteries must not be recharged because this could cause leakage and/or explosion.

Non-compliance can cause injury to people or damage to property.

1

+

2

8-91

8 Service and Maintenance

8.1 Battery and fan replacement

The NCU features battery-backed SRAMs and clock modules. The NCU monitors the backup voltage. The battery must be replaced within 6 weeks of a monitoring response. The battery/fan slide-in module in the NCU box can only be changed after switching off the controller. The data is backed up for a period of approx. 15 minutes.

03.06

Backup time

Replacement of the battery/fan slide-in module

The service life of the batteries used is at least 3 years.

The battery/fan subassembly is located under the DC link busbars (see Fig 3-3). The slide-in module is replaced in its entirety.

Order number of the battery/fan slide-in unit: 6FC5247-0AA06-0AA0

1. Switch off the control.

2. Pull out the slide-in module. There is a latch (3) on the lower side of the slide-in module, see Fig. 8-1. Press this latch (3) up and pull the slide-in module forwards and out at the same time.

3. Install the new slide-in module. (within 15 minutes)

4. Switch the controller on again, the battery alarm should now be off.



8-92

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

Abbreviations

AC Alternating Current

A

C Bus CE CNC COM CPU DC DE DMIO DP EFP EGB EMC ESD FD HHU HMI

Communication Bus

Communauté Européenne – European Community

Computerized Numerical Control

Communication Module

Central Processor Unit

Direct Current

Automation System

Distributed Machine Peripherals (I/Os)

Distributed I/Os

Single I/O Module

Electrostatic Sensitive Device

Electromagnetic Compatibility

Electro Static Discharge

Feed Drive

Handheld Unit

Human Machine Interface: Operator function of SINUMERIK for operation, programming and simulation.

HW-Config

I/O bus I/R IM IM address ISA LED LFT MCP MLFB (Order no.) MPI

SIMATIC S7 Tool for configuring and parameterizing S7 hardware within an S7 project

Peripherals Bus

Infeed/regenerative feedback module

Interface Module: SIMATIC S7-300 interface module

Interface Module Address

Industry Standard Architecture

Light Emitting Diode

Handheld Terminal

Machine Control Panel

Machine-Readable Product Designation (order no.)

Multi Point Interface: Multi-point serial interface

A-93

A Abbreviations

03.06

MSD NC NCK

NCU NE NMI OI OP OPI PCMCIA PCU

PG PLC PROFIBUS PS RAM

Main Spindle Drive

Numerical Control

Numerical Control Kernel: NC kernel with block preparation, traversing range, etc.

Numerical Control Unit – Hardware Unit of the NCK

Mains Supply

Non Maskable Interrupt

Unstabilized power supply

Operator Panel: Operator panel front

Operator Panel Interface

Personal Computer Memory Card International Association

Personal Computer Unit: NC controller component which allows the operator to communicate with the machine and vice versa.

Programming device

Programmable Logic Control

Process Field Bus: Serial data bus

Power Supply: SIMATIC S7-300 power supply

Random Access Memory: Program memory that can be read and written to

SRAM UI VGA

Static RAM: Static memory (battery-backed)

End User Interface

Video Graphics Adapter



A-94

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

Index

A

Abbreviations, A-93 Assembly of the NCU box, 3-32

B

Backup battery, transport, 2-27 Backup time, battery, 8-92 Battery replacement, 8-91 Battery/fan slide-in module, 8-92

C

Cable distributor

Connector assignments, 4-58 Set up and connection, 4-56

Status table for S1–S6, 4-57 Cable routing, 3-35 Climatic environmental conditions, 2-26

Operation, 2-27, 2-28

Transport and storage, 2-26 COM module, 4-39 Connection assignment, cable distributor, 4-59 Connector coding, 4-58 Constraints, electric, 2-19 Conversion time

DMP compact module 1A analog, 7-88

DMP compact module 1I analog, 7-83, 7-85 Cooling clearance, 3-35

D

DC power supplies, 2-20 Description of the NCU, 4-37 Device bus interface, X172, 4-54 Distribution box, 4-56 DMP compact module 8O, 7-81 DMP compact module 16I, 7-77 DMP compact module 16O, 7-79 DMP compact module 1A analog, 7-88 DMP compact module 1I analog, 7-83 DMP compact module 1I, NC analog, 7-86 DMP compact modules, 6-73, 7-77 Driver module, 4-39 Dust, that can adversely affect function, 2-28

F

Fan box

Mounting, 4-39 Replacement, 4-43

Function-impairing gases, 2-28

G

Gases, function-impairing, 2-28 Grounding concept, 2-23

I

I/O interface (cable distributor), X121, 4-52 I/O modules, 5-63 Installation of the SINUMERIK 840D, 3-32 Installing the NCU module, 3-33

L

L2-DP interface, X102, 4-49 Link module interface, X112, 4-51 Link submodule, 4-40

M

Maintaining distances, 3-34 Mechanical environmental conditions

Operation, 2-28

Transport and storage, 2-26 Mounting the DC link busbar, 3-33 MPI/OPI network rules, 2-29

N

NCU, description, 4-37 NCU box, 4-39 NCU box with a fan box, dimensions, 4-42 NCU box without a fan box, dimensions, 4-41 NCU module, 4-37 NCU module interfaces, 4-45 NCU switch positions, meaning, 4-55 NCU terminal block, 6-71

Index-95

03.06

Noise immunity of the complete system, 2-25 Non-Siemens keyboards, 1-17

O

Operating conditions, 2-27 Operator controls and displays, meaning, 4-55 Operator panel interface (MPI), X101, 4-49

P

PCMCIA card, 4-39 PCMCIA slot, X173, 4-54 PCU-MCP configuration, 1-14 PG-MPI interface, X122, 4-53 PLC module, 4-39 Power supply, 2-20

R

Radio interference, 2-28 Replacing the fan, 8-91 RI suppression measures, 2-24 RS232 serial interface, X112, 4-50

S

Safety isolation, 2-21 Secondary electrical conditions, 2-19 Shielded signal cables, 2-24 SIMATIC interface, X111, 4-50 SIMODRIVE 611D interface, X130A, 4-53

Single I/O, address space, 5-69 Single I/O module

Connection, 5-63

Dimension drawing, 5-64

Electronics power supply, 5-66

EMC, 5-64

Inputs/outputs, 5-67

LED, 5-67

Load power supply, 5-66

Technical data, 5-65

X402, 5-67

X404, 5-68

X405, 5-69 Software and hardware combinations, 1-15 Storage conditions, 2-26 Structure of the SINUMERIK 840D, 3-31 System configuration, 1-11

T

Transport conditions, 2-26 Type plate, 1-16

X

X101, 4-49 X102, 4-49 X111, 4-50 X112, 4-50 X121, 4-52 X122, 4-53 X130A, 4-53 X172, 4-54 X173, 4-54

Index-96

SINUMERIK 840D Configuring Manual NCU (PHD) – 03.06 Edition

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03.06 Edition

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siemens 840D User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Configuring the NCU

Preface

Contents

System Overview

1.1 System configuration

1.2 Labels and stickers

1.3 Non-Siemens keyboards

Connection Conditions

2.1 Secondary 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 MPI/OPI network rules

Structure and Installation

3.1 Structure of the SINUMERIK 840D

3.2 Installation of the SINUMERIK 840D

Description of the NCU

4.1 Components

4.2.1 NCU box without a fan box

4.2 Mounting

4.2.2 NCU box with a fan box

4.3 NCU module interfaces

4.4 Cable distributor (distributor box)

4.5 Technical data

I/O Modules

5.1 Single I/O module

Terminal Block

6.1 NCU terminal block 6FC5211-0AA00-0AA0

DMP Compact Modules

7.1 DMP compact module 16E 6FC5111-0CA01-0AA0

7.2 DMP compact module 16 A 6FC5111-0CA02-0AA1

7.3 DMP compact module 8 A (6FC5111-0CA03-0AA1)

7.4 DMP compact module 1I analog 6FC5 111-0CA04-0AA0

7.5 DMP compact module 1E NC analog 6FC5211-0AA10-0AA0

7.6 DMP compact module 1A analog 6FC5111-0CA05-0AA0

Maintenance and Service

8.1 Battery and fan replacement

Abbreviations

Index