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

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.

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

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.

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).

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

03.06

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.

vii

Preface

03.06

Notes

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

1 System Overview 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 System configuration 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Labels and stickers 1-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Non-Siemens keyboards 1-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Connection Conditions 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Secondary electrical conditions 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.1 Power supply 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.2 Safe isolation to EN 61800–5–1 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.3 Grounding concept 2-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.4 RI suppression measures 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Climatic and mechanical environmental conditions 2-26. . . . . . . . . . . . . . .

2.2.1 Transport and storage conditions 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.2 Operating conditions 2-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 MPI/OPI network rules 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Structure and Installation 3-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Structure of the SINUMERIK 840D 3-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Installation of the SINUMERIK 840D 3-32. . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Description of the NCU 4-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Components 4-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Mounting 4-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1 NCU box without a fan box 4-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.2 NCU box with a fan box 4-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 NCU module interfaces 4-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Cable distributor (distributor box) 4-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Technical data 4-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 I/O Modules 5-63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Single I/O module 5-63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Terminal Block 6-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 NCU terminal block 6FC5211-0AA00-0AA0 6-71. . . . . . . . . . . . . . . . . . . . . .

7 DMP Compact Modules 7-77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 DMP compact module 16E 6FC5111-0CA01-0AA0 7-77. . . . . . . . . . . . . .

7.2 DMP compact module 16 A 6FC5111-0CA02-0AA1 7-79. . . . . . . . . . . . . .

7.3 DMP compact module 8 A 6FC5111-0CA03-0AA1 7-81. . . . . . . . . . . . . . .

7.4 DMP compact module 1I analog 6FC5 111-0CA04-0AA0 7-83. . . . . . . . . .

7.5 DMP compact module 1E NC analog 6FC5211-0AA10-0AA0 7-86. . . . . .

7.6 DMP compact module 1A analog 6FC5111-0CA05-0AA0 7-88. . . . . . . . . .

8 Maintenance and Service 8-91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 Battery and fan replacement 8-91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A Abbreviations A-93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B Index Index-95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

03.06

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

System Overview

1.1 System configuration

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

1 S

stem Overview

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

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

SIMATIC S7-300

: 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

Handheld terminal

HT 6

1-12

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

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

1 S

stem Overview

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

1-14

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

03.06

1 S

stem Overview

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

1 S

stem Overview

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)

SIEMENS

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)

1-16

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

03.06

1.3 Non-Siemens keyboards

1 S

stem Overview

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

1-18

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

Connection Conditions

2.1 Secondary electrical conditions

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

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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.

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2 Connection Conditions

2.1 Secondary electrical conditions

3ph 400 V AC

03.06

Housing/shield

840D / 611 digital

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

Distribution box

PCU

HHU/ HT 6

Person

S7-300 I/Os

24 V

Terminal

Motor

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

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2 Connection Conditions

2.1 Secondary electrical conditions

03.06

Operator panel front

Grounding bar

PCU/ TCU

– Ground (frame) –

S7-300 peripherals

IM 361

/single I/O module

Central ground connection conductor/protective conductor

Machine control panel

Gating

NCU

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

PA: Equipotential bonding conductor SL: Protective conductor

electronics

SL in the motor cable

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

Terminal block

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

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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

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2 Connection Conditions

2.2 Climatic and mechanical environmental conditions

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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

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

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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.

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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

– 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.

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

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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.

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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.

OFF ON

O N

Terminating resistor

Fig. 2-3 MPI connector

Reference: Catalog IK PI – Industrial Communication for Automation

and Drives



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

+ 68 hidden pages

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