Siemens SINUMERIK 840DE, SINUMERIK 840D, SINUMERIK 840DE powerline, SINUMERIK 840D powerline, SIMODRIVE 611 digital User Manual

RGB ELEKTRONIKA AGACIAK CIACIEK

SPÓŁKA JAWNA

Jana Dlugosza 2-6 Street

51-162 Wrocław

Poland

biuro@rgbelektronika.pl

+48 71 325 15 05

www.rgbautomatyka.pl

www.rgbelektronika.pl

DATASHEET

www.rgbautomatyka.pl

www.rgbelektronika.pl

OTHER SYMBOLS:

6FC5247-0AA00-0AA1

6FC52470AA000AA1, 6FC52470AA00 0AA1, 6FC52470AA00-0AA1, 6FC5247 0AA000AA1, 6FC5247 0AA00 0AA1, 6FC5247 0AA00-0AA1, 6FC5247-0AA000AA1, 6FC5247-0AA00 0AA1, 6FC5247-0AA00-0AA1

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

Drive

SIMODRIVE 611 digital

03/2006 Edition

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

DMP Compact Modules 7

Maintenance and Service 8

Abbreviations A

Index

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.

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

This publication was produced with Interleaf V 7.

Siemens AG, 2006.

Other functions not described in this documentation might be 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

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

iii

Preface

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

and menu item “Support”.

This documentation is intended for:

 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.

This documentation only describes the functionality of the standard version. Extensions or changes made by the machine tool manufacturer are docu- mented by the machine tool manufacturer. Other functions not described in this documentation might be executable in the control. This does not, however, rep- resent an obligation to supply such functions with an initial delivery or when ser- vicing.

For the sake of simplicity, this documentation does not contain all detailed infor- mation 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

SINUMERIK Documentation

Target group

Benefits

Standard version

Technical Support

03.06

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

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

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.

Questions about the manual

SINUMERIK Internet address

EC Conformity Declaration

Safety information

Preface

03.06

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.

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 prac- tices 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.

Qualified personnel

Proper use

Preface

03.06

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

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 as- sociation) 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).

Danger notes

Preface

03.06

vii

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.

 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.

ESDS information

Additional notes

Preface

03.06

viii

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

Preface

Notes

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. . . . . . . . . .

Contents

03.06

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

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

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

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

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

1-11

System Overview

1.1 System configuration

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

Battery and fan slide-in module

Infeed/Regenerative feedback module Feed DriveMain Spindle DriveNCU box

Round cable to the NCU terminal block

NCU

Device bus

I/R FDMSD

Fig. 1-1 Central control units SINUMERIK 840D

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 con- tains a power supply and a fan subassembly.

Introduction

03.06

1.1 System configuration

1-12

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

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

NCU terminal block

IN OUT

X20 X21

Distribution box

SIMATIC S7-300

Handheld unit

Type B-MPI

2x sensor

2x handwheel

PG / PC, e.g. Field PG

–X102

–X112

–X111

–X121

X130B

X130A

–X172

–X101

NCU

–X122

Cable distribut or

PROFIBUS DP I/Os

Reserved for service

X1 X2

: Optional

MPI cable

SIMODRIVE components

MPI bus

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

*) MPI cable or MPI PG cable

Memory card (PCMCIA)

Handheld terminal

HT 6

Mini-

handheld unit

4x digit. input 4x digit. output

Fig. 1-2 SINUMERIK 840D system overview

Connection configuration

1 S

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03.06

1.1 System configuration

1-13

Table 1-1 Components of the 840D

Component

Description

NCU Central processing unit of 840D Cable distributor

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

SIMODRIVE components

References: /PJU/, Configuration Manual Converters

NCU terminal block High-speed NC I/Os

 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 System Overview

03.06

1.1 System configuration

1-14

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

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

Operator panel front OP 012PCU 50

Full CNC keyboard PS/2

3.5” Floppy Disk Drive

PS/2 mouse

VGA monitor

Printer

Machine control panel

X20 (rear side)

MPI bus

Ethernet

for NCU (see Fig.

1-2)

Rear side

Optional

USB (mouse/keyboard/ USB device)

* TEMP* POWER

SIEMENS

SINUMERIK

USB mouse Full CNC keyboard USB

3.5” floppy disk drive, USB

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

PCU–MCP configuration

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03.06

1.1 System configuration

1-15

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

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

NCU system software

NCU hardware

Designation Order No. 561.3 571.3 572.3 573.3

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

6FC5250-PX10-AH   – –

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

6FC5250-BX10-AH –  – –

NCU system software 12 axes on PC card

 Standard 840D  Export 840DE

6FC5250-BX30-AH 6FC5250-BY30-AH

– –





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

6FC5270-BX30-AH – –  

NCU system software 31 axes on PC card

 Standard 840D  Export 840DE

6FC5250-AX30-AH 6FC5250-AY30-AH

– –





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

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

– –  

 combination possible; – combination not possible

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

NCU hard-

NCU system software

ware

2 axes 6 axes 12 axes 31 axes

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

max. 2 channels

max. 2 out of 2 axes,

max. 2 channels

max. 2 out of 2 axes,

max. 2 channels

max. 2 out of 2 axes,

max. 2 channels

571.4/.5 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

max. 6 out of 31 axes,

max. 2 channels

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,

max. 2 channels

max. 2 channels *)

max. 10 channels

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

max. 2 channels

max. 6 out of 31 axes,

max. 2 channels

max. 12 out of 31 axes,

max. 2 channels *)

max. 31 out of 31 axes,

max. 10 channels

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

SW – HW combinations

1 S

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03.06

1.2 Labels and stickers

1-16

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

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:

Example: Component number: 570 573.9001.00

Product version: B (last cross)

570 573.9001.00

SIEMENS

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)

PCBs with screen printing

NCU

NCU box

1 S

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03.06

1.3 Non-Siemens keyboards

1-17

1.3 Non-Siemens keyboards

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.



Standard PC keyboard

1 S

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03.06

1.3 Non-Siemens keyboards

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

1 System Overview

Notes

2-19

Connection Conditions

2.1 Secondary electrical conditions

The controller is tested for compliance with the environmental conditions speci- fied 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 sys- tem. Please contact your local Siemens office or representative for any assis- tance.

Compliance with the connection conditions

Assistance and support

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

2.1.1 Power supply

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.

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

24 VDC

20.4 VDC to 28.8 VDC

5% (unfiltered 6-pulse rectification)

Any value

Non-cyclic overvoltage

 Duration

 Recovery time

 Events per hour

 35 V

 500 ms

 50 s

 10

Transient voltage interruptions

 Idle time

 Recovery time

 Events per hour

 3 ms

 10 s

 10

Demands on DC power supplies

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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.

UIs are all the interfaces that are freely accessible to the machine operator wi- thout 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.

End user interfaces (UI)

Interfaces for servicing, startup and maintenance

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

Basic insulation Safety isolation

3ph 400 V AC

Housing/shield

840D / 611 digital

S7-300 I/Os

MSTT/MCP

PCU

24 V

Person

Terminal block

Motor

HHU/ HT 6

Distribution box

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

Fig. 2-1 shows the various electrical potentials of the 840D/611D/S7-300 sys- tem. 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 sepa- rated 24 V DC supply.

8. 24 V DC power supply unit for external devices and for the machine adapta- tion control according to applicable standards in the form of a PELV (Protec- tive 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 isola- tion with respect to the line supply voltage or that there are two basic insula- tion levels, for 230 V AC each.

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

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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/regen- erative 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 intercon- nected 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 con- nected in connector X1.

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

Operator panel front

Power electronics

Machine bed

Grounding bar

Central ground connection conductor/protective conductor

Gating electronics

NCU

SL in the motor cable

Machine control panel

S7-300 peripherals /single I/O module

MB: Shielded signal cable with reference ground

PA: Equipotential bonding conductor SL: Protective conductor

M: Motor G: Encoders

– Ground (frame) –

Terminal block

Distribu– tion box

Cross-sections (mm2)

w10

Line supply conn. S

SL minimum

S v 16 16 v S v 35 S w 35

S 16 S/2

IM 361

PCU/ TCU

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 precau- tions must be taken to ensure safe, fault-free operation of the system. These measures include shielded signal cables, special equipotential bonding, isola- tion, and shielding measures.

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.).

Shielded signal cables

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These external devices may not be connected to the control during normal op- eration. 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.

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 care- fully 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

Cable definitions

Rules for routing cables

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2.2 Climatic and mechanical environmental conditions

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

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

The following specifications apply to components in transport packaging:

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

class 1K3/2K4

Transport Bearings

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

max 0.1 % max 0.1 % Within 1 minute

Table 2-3 Test limits for mechanical environmental conditions

Vibration

Frequency range 5 to 9 Hz

to EN 60068–2–6

Constant deflection 7.5 mm Acceleration amplitude 9 to 200 Hz: 2g

Shock resistance

Acceleration 30g

to EN 60068–2–27

Duration of nominal shock 6 ms Number of nominal shocks 18 shocks Shock form Half-sine

g  9.81 m/s

2 (acceleration due to gravity)

Test standards

Requirement standards

Components in original packaging

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Backup batteries must only be transported in the original packaging. No special authorization is required to ship backup batteries. The lithium content is approxi- mately 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

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

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

Temperature range

0 to 55 °C

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

relative air humidity

max. 0.1% Within 1 minute

Moisture condensation and ice formation

Not permitted

Dripping water, spray, splash water, water jets

Not permitted

Supply air Without caustic gases, dusts and oils Air pressure 1060 to 920 kPa 0 to 1000 meters above mean sea

level

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

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

Shipment of backup batteries

Climatic environmental conditions

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Table 2-5 Test limits for mechanical environmental conditions

Vibration

Frequency range 10 to 58 Hz

to EN 60068–2–6

Constant deflection 0.075 mm Acceleration amplitude 58 to 200 Hz: 1g

Shock resistance

Acceleration 5g

to EN 60068–2–27

Duration of nominal shock 30 ms Number of nominal shocks 18 shocks Shock form Half-sine

g  9.81 m/s

2 (acceleration due to gravity)

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

When working in areas where gases, dust and oils may be hazardous to func- tionality, the controller must be operated in a control cabinet with a heat exchan- ger 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.

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.

Mechanical environmental conditions

Gases that can adversely affect the function

Dust that can adversely affect the function

Radio interference

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