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SINUMERIK 810DSoftware Version 4
Manual 10.2000 Edition
Configuring CCU1/CCU2
Manufacturer/Service Documentation
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User Documentation
SINUMERIK
840D/810D/FM-NC
SINUMERIK
Overview of SINUMERIK 840D/840Di/810D/FM-NC Documentation (10.00)
Brochure CatalogOrdering InfoNC 60 *)
Description ofFunctionsDrive Functions *)
Description ofFunctions
Basic Machine*) Extended Functions Special Functions
SINUMERIK
611D840D/810D
SINUMERIK
840D/840Di/810DFM-NC
Accessories
CatalogAccessoriesNC-Z
SINUMERIKSIROTECSIMODRIVE
840D/840Di810D/
FMNC
Lists *)Installation &Startup Guide*)
FM-NC 810D 840D/611D MMC/HMI
SINUMERIK
840D
Description ofFunctionsDigitizing
611D
SINUMERIK
SINUMERIK
840D/810D/FM-NC
Configuring KitMMC100/101
ConfiguringSyntax
Development Kit
SINUMERIK
840D/810D/FM-NC
Screen KitMMC100/101SW Update andConfiguration
SINUMERIK
840D/840Di/810D/FM-NC
SINUMERIK
840D/840Di/810D
OperatorComponents(HW) *)
840D/840Di/810D/FM-NC
Description ofFunctionsSINUMERIKSafetyIntegrated
SINUMERIKSIMODRIVE
SINUMERIK
840D/840Di/810D/FM-NC
611, Motors
SIMODRIVE
DOC ON CD*)The SINUMERIK System
General Documentation
Electronic Documentation
Manufacturer/Service Documentation
Manufacturer/Service Documentation
SINUMERIK
840D/810D/FM-NC
SINUMERIK
840D/810D
User Documentation
DiagnosticsGuide *)
Operators Guide HT 6 (+ 840Di) HPU Unit Operator Panel
AutoTurn Short Guide Programming (1) Setup (2)
SINUMERIK
840D/840Di/810D/
FM-NC
Program. Guide Short Guide Fundamentals*) Advanced *) Cycles Measuring Cycles
Description ofFunctions
ManualTurn ShopMill
Description ofFunctionsSynchronizedActions
840D/810D
SINUMERIK
Operators Guide ManualTurn Short Guide ManualTurn ShopMill Short GuideShopMill
840D/810D
Manufacturer/Service Documentation
SINUMERIK
840D/810D
Desc. of Functions Computer Link Tool Data
Information System
*)These documents are a minimum requirement for the control
Operators Guide Short Guide Operators Guide*)
SINUMERIK
840D/840Di/810D/
FM-NC
Configuring(HW)*)
FM-NC 810D 840D
SINUMERIK
SINUMERIK
840D/840Di/810D
SINUMERIK
840D/810D/FM-NC
Description ofFunctionsOperator InterfaceOP 030
Description ofFunctionsToolManagement
SINUMERIKSIMODRIVE
SINUMERIKSIMODRIVE
SINUMERIKSIMODRIVE
SINUMERIKSIMODRIVE
SINUMERIKSIMODRIVE
840D611D
840D611D
Description ofFunctionsLinear Motor
Description ofFunctions
Hydraulics Module Analog Module
SINUMERIKSIMODRIVESIROTEC
EMCGuidelines
Manufacturer/Service Documentation
SINUMERIK
Description ofFunctionsISO Dialects forSINUMERIK
840D/840Di/810D
SINUMERIK
Description ofFunctionsCAM IntegrationDNC NT-2000
SINUMERIK
Manual(HW + Installationand Start-up)
840Di
SINUMERIK
System Overview
840Di
840D/840Di/810D/
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Valid for
Control Software version
SINUMERIK 810D 4SINUMERIK 810DE (export version) 4Drive
SIMODRIVE 611D 5
10.00 Edition
SINUMERIK 810DSoftware Version 4
Configuring CCU1/CCU2
Manual
System Overview 1
Connection Conditions 2
Design and Assembly 3
Description 4
Axis Extension 5
I/O Modules 6
NCU Terminal Block 7
DMP Compact Modules 8
Servicing and Maintenance 9
Abbreviations A
References B
EC Declaration ofConformity C
Index
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SINUMERIKDocumentation
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 Remarkscolumn.
Status code in the Remarks column:
A New documentation.. . . . .B Unrevised reprint with new Order No.. . . . .C Revised edition with new status.. . . . .
If factual changes have been made on the page since the last edition,this is indicated by a new edition coding in the header on that page.
Edition Order No. Remarks12.95 6FC5 297-1AD10-0BP0 A
07.96 6FC5 297-1AD10-0BP1 C08.97 6FC5 297-2AD10-0BP0 C12.98 6FC5 297-3AD10-0BP0 C08.99 6FC5 297-3AD10-0BP1 C04.00 6FC5 297-3AD10-0BP2 C10.00 6FC5 297-4AD10-0BP0 C
This manual is included in the documentation on CD-ROM (DOCONCD)Edition Order No. Remarks10.00 6FC5 298-6CA00-0BG0 C
TrademarksSIMATIC, SIMATIC HMI, SIMATIC NET, SIROTEC, SINUMERIKand SIMODRIVEare trademarks ofSiemens. Other product names used in this documentation may be trademarks which, if used by third par-ties, could infringe the rights of their owners.
Further information is available on the Internet under:http://www.ad.siemens.de/sinumerik
This publication was produced with Interleaf V 7
The reproduction, transmission or use of this document or itscontents is not permitted without express written authority. Offenderswill be liable for damages. All rights, including rights created by patentgrant or registration of a utility model or design, are reserved.
Siemens AG 19952000. All rights reserved.
Other functions not described in this documentation might beexecutable in the control. This does not, however, represent anobligation to supply such functions with a new control or whenservicing.
We have checked that the contents of this document correspond tothe hardware and software described. Nonetheless, differences mightexist and therefore we cannot guarantee that they are completelyidentical. The information contained in this document is, however,reviewed regularly and any necessary changes will be included in thenext edition. We welcome suggestions for improvement.
Subject to changes without prior notice.
Siemens AktiengesellschaftOrder No. 6FC5 297-4AD10-0BP0Printed in the Federal Republic of Germany
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Preface
The SINUMERIK documentation is organized on 3 levels: General documentation
User documentation
Manufacturer/service documentation
For more detailed information on SINUMERIK 810D publications and other pub-lications covering all SINUMERIK controls, please contact your local Siemensoffice.
You will also require the followingReferences: /PJU/ SIMODRIVE Planning Guide
This manual provides you with the relevant information required to set up a SI-NUMERIK 810D control system and perform maintenance and servicing proce-dures.
Configuring engineers, electricians and fitters
Servicing and operating personnel
The following safety notices are devised to protect your personal safety on theone hand and, on the other, to protect the product described or the connectedequipment and machines against damage.
!Warning
Hazardous voltages are present in this electrical equipment during operation.
Hazardous voltage is still present for at least 5 minutes in the DC link of allSIMODRIVE modules after all voltage sources have been disconnected.See Instruction Manual.
Persons who are not qualified should not be allowed to handle the
equipment/system. Non-compliance with safety notices and warnings can resultin severe personal injury or damage to property. Only appropriately qualifiedpersonnelwho are trained to install, assemble, start up or operate the productshould be allowed to handle this equipment/system.
Structure ofdocumentation
About the manual
Who is the manualintended for?
Safety notices
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If you need to carry out measurements or checks when the equipment is live,please observe the guidelines and instructions given in accident preventionregulation VBG 4.0, in particular 8 Acceptable deviations when working onlive parts. Appropriate electrical tools must be used.
!Danger
This symbol in the document indicates that death, severe physical injury orsubstantial property damagewillresult if proper precautions are not taken.
!Warning
This symbol in the document indicates that death, severe physical injury orsubstantial property damagemayresult if proper precautions are not taken.
!Caution
This symbol appears in the document indicating that minor physical injury orproperty damage canresult if proper precautions are not taken.
Caution
This symbol (without a warning triangle) indicates that properly damage canresult if proper precautions are not taken.
Notice
This symbol indicates that an undesired event can occur if the correspondingnote is not observed.
!Important
This symbol appears in the documentation to draw special attention to an im-portant point.
Note
This symbol appears in the documentation to draw your attention to a relatedtopic.
Further notes
Manual Configuring SINUMERIK 810D
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!Warning
Repairs to equipment supplied by us may only be carried out by SIEMENSCustomer Servicepersonnel or by repair centers authorized bySIEMENS. Only items contained in the spare parts list may be used toreplace parts or components.
Always interrupt the power supply before you open the device.
Emergency tripping devices as stipulated in EN 60204 IEC 204 (VDE 0113)must remain operative in all operating modes of the automation equipment.Resetting the emergency tripping device must not result in any uncontrolledor undefined restart of the equipment.
Wherever faults occurring in the automation equipment can lead to sub-stantial damage or even grievous bodily injury, i.e. are potential dangerousfaults, additional external precautions must be taken or facilities must beprovided ensuring or enforcing safe operation even when a fault occurs(e.g. independent limit switches, mechanical interlocks, etc.).
!Caution
Install power supply and signal cables in such a way as to prevent inductiveand capacitive interference voltages from affecting the automationfunctions.
!Warning
Perfect and safe operation of this equipment assumes professional transport,
storage, mounting and installation as well as careful operator control andservicing.
Failure to observe safety notices can result in severe personal injury or sub-stantial property damage.
Warning
Printed circuit boards contain components which can be destroyed by electro-static discharge. Before you touch a PCB, make sure that your own body hasbeen electrostatically discharged. The simplest way of doing this is to touch aconductive, earthed object immediately beforehand (e.g. bare metal part of a
switchboard, protective earth contact of a socket outlet).
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ElectroStatic Discharge Sensitive Boards
!Important
Handling ESDS boards:
When handling components which can be destroyed by electrostatic dis-charge, make sure that personnel, the workstation and packaging are wellgrounded.
As a general rule, electronic boards should only be touched when abso-lutely necessary. Do not touch the boards in such a way that your handscome into contact with pins or printed conductors.
You may only touch ESDS components if
you are continuously grounded via an ESDS bracelet,
you are wearing ESDS shoes or ESDS shoe grounding strips in con-junction with an ESDS floor surface.
Boards may only be placed on conductive surfaces (desk with ESDS sur-face, conductive ESDS foam rubber, ESDS packing bag, ESDS transportcontainers).
Boards may not be brought close to data terminals, monitors or televisionsets (a minimum of 10 cm should be kept between the board and thescreen).
Boards may not be allowed to come into contact with electrically insulatingmaterials such as plastic films, insulating table tops or clothing made of syn-thetic fibers.
Measurements may be taken on the boards only if
the measuring instrument is properly earthed (e.g. equipment groundingconductor), or
before measuring with a potential-free measuring instrument, the probeis briefly discharged (e.g. touch the unpainted metal parts of the controlhousing).
The device may be used only for the applications specified in the manual andonly in conjunction with external equipment and components recommended orauthorized by SIEMENS.
If you should encounter problems in using this Manual or have any other quer-ies, please contact the responsible department named on the query sheet at theback of the document.
ESDS instructions
Proper use
Further assistance
Manual Configuring SINUMERIK 810D
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1 System Overview 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 System configuration 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Markings and labels 1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Connection Conditions 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Ambient conditions 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.1 Electromagnetic compatibility (EMC) 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.2 Ambient climatic and mechanical conditions in operation 2-23. . . . . . . . . .2.1.3 Shipment and storage conditions 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.4 Stressing by pollutant contamination 2-25. . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.5 Power supply 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.6 Earthing concept 2-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.7 RI suppression measures 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.8 Protective separation 2-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.9 Technical data of individual components 2-31. . . . . . . . . . . . . . . . . . . . . . . .2.1.10 MPI connecting cable 2-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 MPI/OPI networking rules 2-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Design and Assembly of the 810D Control 3-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Design of the SINUMERIK 810D 3-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Installing the SINUMERIK 810D 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.1 Conversion for external cooling, 2-axis CCU box (SW 5 and later) 3-40. .
3.3 Mains infeed (NE) 3-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Description of the SINUMERIK 810D 4-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Components of the SINUMERIK 810D 4-43. . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Interfaces on the SINUMERIK 810D 4-45. . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.1 Overview of interfaces on CCU1/CCU2 4-45. . . . . . . . . . . . . . . . . . . . . . . . .4.2.2 Description of interfaces on the CCU1/CCU2 4-47. . . . . . . . . . . . . . . . . . . .4.2.3 Cable distributor 4-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Measuring system 4-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.1 Assignments between measuring systems and motor
connections 4-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.2 Interpretable encoder systems 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.3 Measuring channels, indirect and direct measuring system 4-60. . . . . . . .4.4 Integrated power sections: 3-axis CCU box 4-65. . . . . . . . . . . . . . . . . . . . . .
4.5 Integrated power sections: 2-axis CCU box 4-67. . . . . . . . . . . . . . . . . . . . . .
4.6 PLC module 4-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7 PCMCIA card (memory card) 4-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8 CCU1: 6th axis (SW 3.2 and later) 4-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
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5 Axis Extension 5-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Plug-in axis extension unit 5-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Axis extension with SIMODRIVE 611D control module 5-74. . . . . . . . . . . .
6 I/O Modules 6-77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Single I/O module (EFP) 6-77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 DSB with 5 incoming supplies for drive module 6-85. . . . . . . . . . . . . . . . . .
7 NCU Terminal Block 7-103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 DMP Compact Modules 8-109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 DMP compact module 16 I (6FC5 111-0CA01-0AA0) 8-109. . . . . . . . . . . . .
8.2 DMP compact module 16 O (6FC5 111-0CA02-0AA1) 8-111. . . . . . . . . . . .
8.3 DMP compact module 8 O (6FC5 111-0CA03-0AA1) 8-113. . . . . . . . . . . . .
8.4 DMP compact module 1 I analog (6FC5 111-0CA04-0AA0) 8-115. . . . . . . .8.5 DMP compact module 1 I NC analog
(6FC5 211-0AA10-0AA0) 8-118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6 DMP compact module 1 O analog (6FC5 111-0CA05-0AA0) 8-121. . . . . . .
9 Servicing and Maintenance 9-123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1 Safety Notices 9-123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 Battery replacement (6FC5 247-0AA18-0AA0,GWE-570 665 000 101) 9-124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A Abbreviations A-127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B References B-129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C EC Declaration of Conformity C-141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index Index-145
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System Overview
1.1 System configuration
A complete SINUMERIK 810D system comprises various individualcomponents. These are listed below.
A description of the components marked with 1)can be found in:References: /BH/, Operator Components Manual
Table 1-1 810D components in maximum configuration (excluding motors)
Component Order no. Description
Mains Supply (MS) See References:/PJ2/ SIMODRIVE Plan-ning Guide
Mains Supply for the electronic equipment and drives. As eitheropen-loop control (OI 5 kW28 kW) or closed-loop control as aninfeed/regenerative feedback module, 16 kW120 kW and over; filtermodules as option.
SINUMERIK 810D CCU box
(3 axes)
CCU box(2 axes)
6FC5447-0AA00-0AA0
6FC5447-0AA01-0AA1
Subrack for holding the CCU1/2 with 3 integrated power modules: 1 x18/36A (FDD) or 24/32A (MSD) and 2 x 6/12A (FDD), internal coolingonlySubrack for holding the CCU1/2 with 2 integrated power modules: 2 x9/18/A (FDD), internal or external cooling
CCU (Compact Control Unit)
6FC5 410-0AA00-0AA0CCU1/21
Contents of CPU in 810D:NCK, PLC AS 314, communications functions, standard digital
closed-loop control CCU 2 (CompactControl Unit)
6FC5 410-0AX02-1AA0CCU1/22
Contents of CPU in 810D:NCK, PLC AS 315, communications functions, standard digitalclosed-loop control
Additional features: 8 MB DRAM, 2 MB SRAM Handling with 5 axes 2nd channel with 5 axes Connection for HPU
CCU 1 (Compact Control Unit)
6FC5 410-0AX01-0AA0 Contents of CPU in 810D:NCK, PLC AS 314, communications functions, standard digitalclosed-loop controlAdditional features:
8MB DRAM, 2 MB SRAM Connection for HPU
Operator panel 1) Display, keyboard and 810D operationMMC module1) Operator panel computer (integrated in operator panel),
MMC 103 with hard disk MMC 100.2 without hard disk
Machine controlpanel1)
SIEMENS MCP or interface for customer MCP, V_03_01_01 orhigher
ISA adapter1) Allows AT modules to be operated in conjunction with the MMC 103module (integrated in the operator panel)
Full CNCkeyboard1)
Full keyboard can be connected to the MMC module
Components
1 System Overview
1
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SINUMERIK 810D Manual Configuring HW (PHC) 10.00 Edition
Component DescriptionOrder no.
Memory card(PCMCIA)
Slot for PCMCIA card on the CCU1/2,PCMCIA card for software upgrades and SW 3.xCCU1/2 system software is stored on an internal Flash Eprom forSW versions < 3.1
Floppy disk unit1) Rack-mounting unit for connection to the MMC moduleCable distributor 6FX2 006-1BA01 Connection of two handwheels and two probes to the CCU1/2/2 RC
Cable References:/Z/, Accessories Catalog NC Z
Plug-in axisextension unit
6FC5 412-0FA10-0AA0 For mounting in a SIMODRIVE 611 power module (1- or 2-axis),References:/PJ/, SIMODRIVE 611 Planning Guide
SIMATICcomponents
References:/S7H/, Manual
Single I/O module(EFP)
6FC5 411-0AA00-0AA0 PLC I/O module with 64 inputs and 32 short-circuit-proof outputs
NCU terminalblock1)
6FC5 211-0AA00-0AA0 High-speed digital and analog NC I/O devices on the SINUMERIK810D drive bus
Hand-held unit(HHU)1)
6FX2 007-1AC.. Handheld unit withhandwheel, EMERGENCY STOP button, keyswitch, override, enab-
ling switches, display, user-assignable keysConnection via MPI bus and cable distributor
Handheld program-ming unit (HPU)1)
6FX2 007-1AC.. Handheld programming unit (HPU) with Keyboard + travel key block, Enabling switches, LCD display (240 x 64 pixels) with LED brightness control,
LED background lighting, EMERGENCY STOP button, V.24 interface,
Connection via X103 with 15-way SUB D plug with ribbon cable link
Distribution box1) 6FX2 006-1BC00 For linking the handheld unit to the MPI bus. Connection for EMER-GENCY STOP circuit, enabling switches, handwheel, 24 V DC
Mini hand-heldunit1)
6FX2 006-1BG00 Mini handheld unit for setting up and operating simple machines inthe JobShop sector or similar applications.
Suitable for use with 810D, 840C, 840D and FM-NC.Distribution board(DSB, seeSection 6.2)
6FM8 180-1AA00-0AA0 Distribution board consisting of one single I/O module (EFP; 64 inputs, 32 outputs), one basic module (24 outputs) and one drive module (5 outputs)
A description of the components marked with 1)can be found in:References: /BH/, Operator Components Manual
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MCP
Floppy diskunit
Operator panel
Plug-inaxis extensionunit
I/RF MSD FDD
Handwheel (2x)
Measurement(2x) *)Cable
distributor
Single I/Omodule
810D
3x
Motor encoder cable
Terminal block
1FT6 / 1FK6 /1PHmotors
Distribution box
Motor cable
QWERTYkeyboard
5x
UE
or
1x 1x
MPIcable
SIMATICIM cable
611powermodule
Encoder lead, directmeasuring system
Direct measuring system(e.g. at X416)
Distributionboard
Step7-300
Handheldunit
Handheld programming unit
HHU or HPU or Mini HHU
14
15
14
*) One measurement input can be replaced by a 3rd handwheel
Fig. 1-1 SINUMERIK 810D system
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X3
Floppy1)
X4X6
X10
MCP
Powersupply
PG740 programming device
Cable distributor
QWERTY
MPI bus lead
MPI cable
X20
Operator panelMMC
ISA adapter
(rear view)
X8
X9
1) X8/X9 on MMC 101/102 only
X8: Parallel interface 1)
Distribution box
HHU
Handwheel HHU
X4
X1
X2
X5
X7: COM2 interfaceX6: COM1 interfaceX5: VGA interface
X7 X5
CCU1/2/2-H
MPI bus lead 2
3
4
1
5
6
Handwheel
Sensor
(with MMC 103
HPU
16
or
Shield
(rear view)
in this diagram)
Fig. 1-2 SINUMERIK 810D connection configuration for the MPI bus, HPU and cable distributor
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CCU1/2
IM
SIMATIC S7-300 I/Os
PS SMs
X2
SIMATIC S7-300 IM connecting cable 8
8
9 9
Shielded connecting cable
Single I/O module (EFP)
Terminal block
Drive bus lead 7
Do not exceed maximum configuration !!1)
1)
8
Terminator
Distributionboard (DSB)
EFP EFP
Fig. 1-3 SINUMERIK 810D connection configuration for PLC I/Os and NCU terminal block
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The following connecting leads are used on the SINUMERIK 810D
Table 1-2 Connecting cables for the SINUMERIK 810D
No. Order no. Designation
1 6FX2 0024EA010 1) MPI bus lead from operator panel to MCP and CCU1/2
2 6ES7 901-0BF00-0AA0 MPI bus lead from distribution box (HHU) to CCU1/2
3 6FX2 0024AA2110 1) Connecting lead from distribution box to cable distributor on theCCU1/2 (for handwheel pulses from HHU)
4 Included in the scope of sup-ply of the PG740
MPI bus lead to PG
5 6FX2 002-4AA41-1AB0 Sensor connecting lead to cable distributor, length: 5 m
6 6FX2 0024AA2110 1) Connecting lead for electronic handwheel to cable distributor onCCU1/2
7 6FX2 002-1CB01-1AB0 Drive bus lead (1 m) to connecting up the NCU terminal block
8 6ES7 368300AA0 1) Connecting lead for Step7-300 I/Os (IM361 or single I/O module)
9 6FC5 411-0AA80-0AA0 Shielded connecting lead for single-tier installation with several singleI/O modules
10 6FC5 412-0FA80-0AA0 Cable set for external SIMODRIVE 611 closed-loop control; forconnection of device and drive buses
11 6FX2003-0DA00-0AA0 Terminator for drive bus (only when a drive bus is used)
12 1) Ribbon cable to terminal strip converter
13 2) Motor encoder cable incremental absolute
146FX2002-2CG00-1AA06FX2002-2CH00-1AA0
Cable for connecting direct measuring systems to the CCU1/2 incremental absolute
15 2) Power leads for motor
16 1) Ribbon cable from HPU to distribution box
Each cable has its own number.You can find these numbers (1 to 16) in the above diagrams.
1) For length code, see References: /Z/ Catalog NC Z
2) see References: /PJ2/SIMODRIVE Planning Guide
There are 4 possible variants:
HPU without MMC/MCP
MMC + MCP MPI bus lead with cable no. 1
MMC MPI bus lead with cable no. 2
MCP MPI bus lead with cable no. 2
Connectingleads
MMC, MCP andHPU
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The SINUMERIK 810D can be expanded up to five drives (see below forSW 3.1) by an axis extension feature. There are two possible expansionmethods, i.e.
either a plug-in axis extension unit and SIMODRIVE 611 power
module connected at the axis extension terminalor SIMODRIVE 611D closed-loop control plug-in unit with
SIMODRIVE 611 power module connected to the drivebus/unit bus (see Fig. 1-4)
The appropriate axis expansion method is primarily determined by the numberof measuring channels required.
Plug-in axis extension units are used whenever a maximum of six measuringchannels are needed on the SINUMERIK 810D. The unit is plugged into aSIMODRIVE 611 power module. Plug-in axis extension units are designed for1-axis and 2-axis power modules. The plug-in unit is supplied with all necessaryribbon cables.
If an application requires more than the six standard measuring channels on theSINUMERIK 810D, further channels can be connected by installingSIMODRIVE 611 closed-loop control units in the SIMODRIVE 611 power mod-ules (connected via drive bus with drive bus terminator). When 611D closed-loop control modules are used, it may be necessary to connect theNCU terminal block to the free drive bus connector on the 611D control.
SIMODRIVE
810D Powersection
Mains Supply(I/RF or OI)
SIEMENS
611D closed-loop control unitDevice bus
Cable set 10
Drive bus
Busterminator
Fig. 1-4 Axis extension on a SINUMERIK 810D with SIMODRIVE 611D closed-loopcontrol
Axis extensionfeature on 810D
Plug-in axisextension unit
Axis extension viaclosed-loopcontrol units
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Axis extension units can be connected to 1-axis or 2-axis power modules.2-axis power modules are suitable for both axes and spindles. Power modulesmust always be installed on the right of the SINUMERIK 810D modules.
With SW version 3.1 and earlier, it is not possible to combine the two methodsof axis extension. The number of drives is limited to five.With SW 3.2 and later, the number of axes is limited to 6. In this case, the 6thaxis is a combination.
Configurations from 1 to 5 drives can be obtained by many combinations. If thespindle is to be operated on the internal power module, then it must be con-nected to the 24A/32A power section (A1).
Table 1-3 Possible combinations for 15 drives on the SINUMERIK 810D
Number of drives Internal drives1 x 18/36A (FDD) or 24/32A (MSD)
2 x 6/12A
Drives providedby axis extension
1 1 0
0 1
2 2 0
1 1
0 2
3 3 0
2 1
1 2
0 3
4 3 1
2 21 3
5 3 2
2 3
Mains Supply:55 kW (07.99 and later: 120 kW).
The DC link busbar on the 810D has an effective load capability of 120 A(07.99 and later: 200 A).
The ribbon cable on the plug-in axis extension unit is long enough for amodule width of 100 mm (07.99 and later: 150 mm).
The length of the cable set for the plug-in axis expansion with 611D closed-loop control unit is:62 mm for the drive bus and 150 mm for the device bus.
Power modules
Combinations
Restrictions
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1.2 Markings and labels
If you have any technical queries or require servicing assistance, pleasehave all the rating plate data available when you contact your local Siemens
sales office.One of the following labels will be attached to the components and modules:
Example: Component number: 570 573.9001.00Product version: B (last cross)
A B
Example: Component name: OP 031
MLFB (order number):6FC5203-0BA10-0AA0Component number: GE.570 038.9001.00
Example: Component name: CCU1MLFB: 6FC5410-0AA00-0AA0Component number: GE.570039.9001.01
Example: Component name: SINUMERIK 810DPower section module 2x15A+1x50AMLFB: 6FC5447-0AA00-0AA0Product status: A (last cross)
SINUMERIK 810D
Power section module
2x15A + 1x50A
6FC5 447-0AA00-0AA0
Screen printing onPCBs
OP, MMC, HD, ISA
adapter, PCMCIA
CCU1 plug-in unit
CCU box
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Warning
Printed circuit boards contain components which can be destroyed by electro-static discharge. Before you touch a PCB, make sure that your own body hasbeen electrostatically discharged. To discharge your body, touch a conductive,grounded object (e.g. the unpainted metal parts of the switching cabinet,ground contact of outlet).
ESDS symbol
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Connection Conditions
2.1 Ambient conditions
The 810D numerical control system is checked for compliance with the ambientconditions listed below. Fault-free operation can be guaranteed only if
these ambient conditions are satisfied in operation and duringtransportation,
original components and spare parts are used. This applies in particular tothe use of specified cables and connectors,
the equipment is installed correctly to specification.
The system must not be started up until conformity with the standards specifiedin Directive 89/392/EEC has been verified.
References: /EMC/, Description
The relevant connection conditions must be satisfied in the overall plantinstallation. If you require further support and advice, please contact yourSiemens sales partner.
Compliance withconnection
conditions
Additionalinformation
Support andadvice
2 Connection Conditions
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2.1.1 Electromagnetic compatibility (EMC)
Applicable standards: EN 55011, EN 55022 (with limit value class B only)
Table 2-1 Limit values of emitted interference
Limit value according to
Cable-conducted RI suppression Limit value class A for industrialapplications
Interference radiation Limit value class A for industrialapplications
To information about satisfying limit value class B (residential areas), pleasecontact your local Siemens sales office.
Note
The operator must assess the interference radiation in relation to the wholeplant. Special attention must be paid to cabling.For support and advice, please contact your Siemens sales partner.
Applicable standards: ENV 50140, ENV 50141, ENV 50204, EN 61000-4-8,EN 61000-4-2, EN 61000-4-4
Table 2-2 Extract defining interference immunity according to EN 50082-2
Limit value
Cable-conducted
interference(power supply and signalleads via coupling networksor clamp)EN 61000-4-4
Test voltage: 2 kV
Static discharge(via air gap)EN 61000-4-2
Test voltage onuser interface: 12 kV
Test voltage on device: 4 kV (contact)
Test voltage on device: 8 kV (air)Test duration: 10 discharges
at 1 discharge/s
Radiated radio
frequency fieldsEN 50140
Test field strength: 10V/m
Frequency: 801000 MHz
For a complete list of limit values to be applied, please refer to Generic NormEN 50082-2.
Note
The emitted interference and interference immunity are determined by thewhole plant. As a result, the control system must be installed in the overall plantin compliance with the EMC Directive and the appendix containing theDeclaration of Conformity.
Emittedinterference
Interferenceimmunity
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2.1.2 Ambient climatic and mechanical conditions in
operation
IEC 68-2-1, IEC 68-2-2, IEC 68-2-3, EN 60721
If the specified values cannot be guaranteed, then a heat exchanger orair-conditioning unit must be provided.
Table 2-3 Ambient climatic conditions
Temperature range Lower limit temperature See Section 2.1.9
Upper limit temperature See Section 2.1.9
Permissible change in
relative air humidityEN 60721-3-3, Class 3K5
Within 1 minute max. 0.1 %
Condensation Not permissible
Temperature change Within 1 minute max. 0.2 K
Within three minutes 1 K
Air pressure At site altitudes of up to1500 m above s. l. Atgreater altitudes the upperlimit temperature must bereduced by 3.5C/500m.
860 hPa to 1080 hPa
Table 2-4 Ambient mechanical conditions
Vibrational stressing(to IEC 68-2-6)
Frequency range1058 Hz
betw. 58500 Hz
Const. deflection0.075 mmAmpl. of acceleration9.8 m/s2
Shock stressing(Test Group E, test Ea acc.to IEC 68, Part 2-27)
Acceleration 15 g
Acceleration for screenunits
2 g
Duration of nominal shock 11 ms / 30 ms for drives
Acceleration for drive
components
0.5 g
Applicablestandards
Ambientclimaticconditions
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2.1.3 Shipment and storage conditions
IEC 68-2-1, IEC 68-2-2, IEC 68-2-3
The following data apply to modules in original packaging:
Table 2-5 Climatic conditions
Temperature range Lower limit temperature See Section 2.1.9
Upper limit temperature See Section 2.1.9
Dewpoint temperature tdand relative air humidity U
Annual average U = 75%, td = 17C
On 30 days (24 hours) inthe year (days distributedover annual period)
U = 95%, td = 24C
On 30 days (24 hours) inthe year (days distributedover annual period)
U = 85%, td = 20C
CondensationThe following cases canapply simultaneously asregards condensation:
Rare, brief, slight
Max. period ofcondensation
3 hours
Frequency of condensation Annual average:3 / max.: 10
Briefest sequence ofcondensation cycles
1 day
Temperature change Within one hour 20 K
Air pressure The specified valuescorrespond to a shipmentaltitude of 3265 m above s.l.
660 hPa to 1080 hPa
Table 2-6 Mechanical conditions for shipment in original packaging
Vibrational stressing
(acc. to IEC 68-2-6)Frequency range59 Hz
betw. 9500 Hz
Const. deflection3.5 mmAmpl. of acceleration10 m/s2
Backup batteries must always be transported in their original packaging. Nospecial approval needs to be obtained to transport backup batteries. The lithiumcontent is approximately 300 mg.
Note: The backup battery belongs to Dangerous Materials Class 9 according toair freight haulage regulations.
!Warning
Improper handling of backup batteries can cause them to ignite, explode orcombust!
Applicable
standards
Modules inoriginal packaging
Transport ofbackup batteries
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The following regulations must be adhered to:Backup batteries must not be
charged
heated up or burned
drilled into or crushed
manipulated in any other way, either mechanically or electrically!
The hard disk unit on the MMC is fitted with shock absorbers. Nevertheless, thefollowing rules must be applied when handling the unit:
!Important
The hard disk unit
must always be transported in its original packaging, must not be thrown or subjected to other shocks,
and must not be removed from the mechanical casing in which it issupplied.
The disk support springs must not be adjusted!
2.1.4 Stressing by pollutant contamination
DIN 40046, Parts 36 and 37
Table 2-7 Gases which may impair operation
Sulphur dioxide (SO2)Test conditions: Severity 10 cm3/m30.3 cm3/m3
Temperature 25 C2 C
Relative air humidity 75%5%
Test duration 4 days
Hydrogen sulfide (H2S)
Test conditions: Severity 1 cm3/m30.3 cm3/m3
Temperature 25 C2 C
Relative air humidity 75%5%
Test duration 4 days
If the control is to be operated in areas where its function may be impaired bydust, it must be installed in a cubicle with a heat exchanger or with adequatecooling air supply.
Rules for handlingbackup batteries
Rules for handlingthe MMC 103
Applicablestandards
Dust which mayimpair operation
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2.1.5 Power supply
810D and SIMODRIVE components are supplied via the device bus and the DClink busbar from the SIMODRIVE mains supply module. No provision is made
for connecting a supply voltage in any other way and any attempt to do so coulddamage the equipment.
For information about electrical connection conditions of mains supply modulesas well as typical circuits, technical data and setting options, please refer to
References: /PJ2/ SIMODRIVE Planning Guide
The 810D is integrated as a compact module into the SIMODRIVE modulenetwork (power supply or mains supply module, feed modules, main spindlemodules). The power supply is connected via the device bus. The total powermust be calculated for the total module network. This must not exceed thepower supplied by the power supply module. To facilitate the power calculation,
each module has 2 weighting factors that specify the power requirement of themodule (electronics points EP and control points AP). These must be entered inthe table below in order to form the product weighting factor number ofmodules. The sum of the products must not be greater than specified on thedata sheet of the power supply module.
Note
The data of the SIMODRIVE components can be found inReferences: /PJ1/, Planning Guide.For assistance in configuring the 611D/611A system, useful information can befound inReferences: /SP/, SimoPro V5.x configuration program.
The version which also supports the SINUMERIK 810D is available fromapproximately 10.96 (to be notified via PRODOK). The SimoPro program canrun under MS WINDOWS (3.1 and later) on any IBM-compatible PC.
The EP and AP points for the power section modules are valid only incombination with the SINUMERIK 810D (axis extension). When SIMODRIVE611D modules with plug-in closed-loop control are used, the EP and AP pointsfrom Catalog NC60.1 apply.
Table 2-8 EP and AP points for 810D components
Component Electronics points(EP)
Control points (AP)
810D 2 4.5
EnDat encoder 0 0.3
Power section module 50A 0.6 0.5
Power sectionmodule > 50A 80A 0.75 1.0
Power sectionmodule > 80A, 120A 1.5 1.5
611D module MSD or FDD See Catalog NC 60.1 See Catalog NC 60.1
Mains connection810D / SIMODRIVE
Connection andpower losscalculations forthe 810D
Configuring the810D powerconsumption
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Table 2-9 Example of how to calculate the supply power 4 axes / 1 spindle for 810D
Electronics points (EP) Control points (AP)
Module Weightingfactor for
single module
Number ofmodules
Product Weightingfactor for
single module
Number ofmodules
Product
810D 2 1 2 4.5 1 4.5
EnDat encoder 0 2 0 0.3 2 0.6
LTM 50A 0.6 1 0.6 0.5 1 0.5
LTM 80A 0.75 1 0.75 1 1 1
Sum ofproducts
3.35 Sum ofproducts
6.6
With16 kW I/RF unit 7.5 With16 kW I/RF unit 16.50
MMC, MCP and I/Os require an external 24 V DC supply.
!Warning
The DC supply is always referred to ground and must not be generated bymeans of an autotransformer.
In order to ensure safe electrical separation of the user interface, the DCsupply must be protectively separated. See Section 2.1.8.
Table 2-10 Requirements of the DC supply
Rated voltage acc. to IEC 65A (Co) 22-I
Voltage range (mean value)
Voltage ripple at rated voltageand rated current peak/peak
Runup time after Power ON
24 V DC
20.4 V DC to 28.8 V DC
3.6 V
any
Harmonic content acc. to DIN VDE 0160 10%
Transient overvoltages Magnitude of overvoltage
Period of overvoltage
Recovery time Events per hour
35 V
500 ms
50 s
10
Brief voltage dips Period of voltage dips
Recovery time
Events per hour
5 ms
10 s
10
Power supply forMMC/MCP/I/Os
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2.1.6 Earthing concept
The 810D system consists of a number of individual components, each ofwhich complies with the EMC and safety regulations in its own right.
CCU box and SIMODRIVE components are bolted to a metallic cubicle wall. Itmust be possible to create a low-impedance contact around the bolts betweenthe CCU box and the cubicle wall. Insulating paint must be removed whereverpossible. The contact point must be kept free of corrosion.The electronics grounds of the modules must be interconnected via the deviceand drive buses and taken to terminal X131 on the mains infeed module aswell.
References: /EMV/, EMC Guidelines
Operator panel
PA PA
Powerelectronics
Machine base
Earthing bar
Central earthing bar
PAM
E
PA
Driveelectronics
CCU
PE in motor cable
Machine
control panel
PLC I/Os
PA
MB
MB: Shielded signal cable with ground reference
PA: Equipotential bondingconductor
PE: PE conductorS: Mains connection
M: MotorE: Encoder
MMC
PA
NCU terminalblock
PA
Distribution
box
Cross-sections (mm2) 10
Mains connection S PE minimum
S 16
16 < S 35S > 35
S
16S / 2
Large-area conductive connectionwith earthed housing
Equipotential bonding conductor (30cm)to earthed housing, A=10mm2
Fig. 2-1 Earthing concept
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2.1.7 RI suppression measures
In addition to the protective earthing of the plant components in accordance withVDE, special supplementary measures for ensuring reliable, fault-free operation
of the installation must be implemented. These measures include shieldedsignal cables, special equipotential bonding and ground connections.
To ensure reliable, fault-free operation of the plant, the cables specified inindividual circuit diagrams must be used (shield connected at both ends).
Note
If external devices are connected (printers, programming devices, etc.), it ispermissible to use standard cables with shield connection at one end.
However, external devices of this type must not be connected to the control
system in normal operation. If it is impossible to avoid using them in operation,their cable shields must be connected at both ends. The external device mustalso be connected to the control system via an equipotential bonding conductor.
Line filters for RI suppression according to CE Standard, see
References: /PJ2/ SIMODRIVE 611D Planning Guide
Definition:
Signal cables (e.g.)
Data cables (MPI, sensor cables, etc.)
Binary inputs and outputs
Emergency Stop cables
Motor and power cables
Load cables (e.g.)
Low-voltage supply cables (230 V AC, +24 V DC etc.)
Supply cables for contactors (primary and secondary circuits)
References: /EMV/, EMC Guidelines
The following EMC measures must be implemented to ensure the greatestpossible interference immunity of the overall installation (control system,power section, machine).
The largest possible clearance must be left between signal and load cables.
Signal and load cables may cross one another (if possible, at an angle of90), but must never be laid in close proximity to one another or parallel.
Shieldedsignal cables
Filter modules
Cabledefinitions
Assemblyguidelines
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Only cables supplied by SIEMENS may be used as the signal cables fromand to the NC or PLC.
Signal cables must not be laid close to strong permanentmagnetic fields(e.g. motors and transformers).
If signal cables cannot be effectively separated from interference sources,they must be installed in shielding cable ducts (metal).
The distance (interference coupling surface) between the following cablesmust be as short as possible:
Signal cable and signal cable
Signal cable and associated equipotential bonding conductor
Equipotential bonding conductor and accompanying PE conductor.
!
Important
For further information about suppression measures and connecting shieldedcables, please see
References: /EMV/, EMC Guidelines
2.1.8 Protective separation
User interfaces and interfaces for servicing, start-up and maintenance form partof the overall system.
The term UI refers to all interfaces which are freely accessible to the machineoperator, i.e. for which no tools or ancillary equipment are required. These userinterfaces are designed in accordance with EN 60204-1 and DIN VDE 0160 tobe protectively separated.
These interfaces are provided solely for servicing, maintenance and start-uppurposes. They are notprotectively separated.
Table 2-11 Service interfaces
Component Interface designation Function
810D CCU module X341, X342, X351, X352 DAC test sockets for analogsignals
Userinterfaces (UI)
Interfaces forservicing/Start-up/Maintenance
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2.1.9 Technical data of individual components
Table 2-12 Mechanical data and temperature ranges
Component
DimensionsWidth x height x
depth in mm
Weight approx.in g
Degree ofprotection to
DIN 40050
Temperature rangesOperation or
storage/transportin C
CCU box3 axes2 axes
150 x 490 x 268Internal cooling
Internal and externalcooling
9800
IP 20
0...55
20...60
CCU (Compact Con-trol Unit)
150 x 307 x 220
1600
Front panel:IP 20
0...55
20...60
Single I/O module(EFP)
50 x 374 x 153
1700
IP 20
0...55
20...60
NCU terminal block
257 x 89.4 x 36.1
500
IP 00
0...55
20...60
Distribution board(DSB)
150 x 440 x 268
1700
IP 20
0...55
40...70
Table 2-13 Electrical data
ComponentsLine voltageand tolerance
Max. power loss atrated voltage
Max. currentProtect. classDIN VDE 0160
CCU box
3 axes2 axes Approx. 350 WInternal/external/total69/ 111 / 180 W
See table 2-9 1
CCU Power supply via SIMO-DRIVE 611 mains supply(I/RF or OI module).Power may not be suppliedby other devices.
Approx. 25 W See Table 2-9 1
Single I/O module(EFP)
24 V for logics supply,24 V for load supply,
0.3 A12 A
1
NCU terminal block 24 V for logics supply, loadsupply direct to the DMPmodule
0.5 A 1
Distribution board
(DSB)
24 V for logics supply
24 V for load supply
30.2 W
30 W
1 A
2 A
1
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2.1.10 MPI connecting cable
MPI connecting cables are available in different lengths. They can be used tomake the following connections:
CCU to operator panel
Operator panel to MCP
PLC (S7) to PG740
CCU to handheld unit via distribution box
You can use the MPI connecting cable to link one node to the next by insertingthe MPI connector on the outgoing cable in the MPI connector of the incomingcable.
Switch on the terminating resistor in the MPI connector of the first and lastnodes. Switch off the resistors on all other nodes.
O
N
Terminating resistorOff On
O
N
46 46
55
Fig. 2-2 MPI connector
References: /Z/, Accessories and Equipment for Special-PurposeMachines
Cables withswitchableterminatingresistor
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2.2 MPI/OPI networking rules
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2.2 MPI/OPI networking rules
The following basic rules governing network installations must be observed:
1. The bus line must be terminated at both ends. To do this, switch on the ter-minating resistor in the MPI connector on the first and last nodes and allothers off.
Note
Only two terminators may be switched on.
Bus terminating resistors are integral components of the HHU and HPU.
2. At least1 terminator must be supplied with a 5V voltage.
This supply can be provided by connecting the MPI connector with activeterminating resistor to a unit that is switched on.
Note
The NC unit is best suited for this purpose.
3. Spur lines (supply cable from bus segment to node) should be kept as shortas possible.
Note
Unused spur lines should be removed if possible.
4. Each MPI node must be connected up first, and then activated.If you wish to disconnect a node, you must deactivate the link firstand thenremove the connector.
5. One HHU and one HPU or two HHUs or two HPUs can be connected toeach bus segment. Nobus terminators may be inserted in the distributionboxes of an HHU or HPU.If necessary, an intermediate repeater can be inserted to connect more thanone HHU/HPU to a bus segment.
6. The following cable lengths for MPI or OPI for standard application withoutrepeater must not be exceeded:
MPI (187.5 kbaud): Max. cable length in total 1000 m
OPI (1.5 Mbaud): Max. cable length in total 200 m
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2 Connection Conditions
Notes
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Design and Assembly of the 810D Control
3.1 Design of the SINUMERIK 810D
The SINUMERIK 810D comprises three components:
CCU module 3-axis CCU box 2-axis CCU box
Fig. 3-1 Components of the SINUMERIK 810D
1. CCU module (Compact Control Unit).
2. 3-axis CCU box (metal casing with 3 integrated power sections for holdingthe CCU module) with internal cooling
3. 2-axis CCU box with external and internal cooling (metal casing with2 integrated power sections for holding the CCU module).Delivery state: Internal cooling.Conversion: Unscrew mounting bracket using a screwdriver (Torx for M6)and mount the 4 grounding springs (see assembly instructions)
3 Design and Assembly
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3.2 Installing the SINUMERIK 810D
You will need the following tools to install the SINUMERIK 810D: Screwdriver for slotted screw sizes 0 and 1
Screwdriver for Torx screws M4 and M5
The CCU box must be installed directly on the right of the SIMODRIVE mainssupply module.
The CCU box is installed on the right of the mains supply module. It should bemounted by means of 4 M5 screws.
1. Remove the plastic cover over the DC link busbars. To do this, loosen it byinserting a flat screwdriver in the recess on the top edge and then fold itdown forwards.
2. Using two M4 screws, connect the DC link bars of the mains supply unit andthe CCU box and, if applicable, the next module.Check that all DC link connecting screws are correctly positioned.
3. Replace the cover so that the plastic lugs are resting in the correct recessesand then close the DC link by swinging the cover backwards until the latchon the top engages correctly.
SIMODRIVE
810D Power sectionMains Supply(I/RF or OI)
SIEMENS
Plug-in axis extension unit
Fig. 3-2 Plug-in axis extension unit with SIMODRIVE 611 power modules
Preparations forassembly
Position withinthe overall system
Installing the
CCU box
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Installation sequence:
1. Connect up the battery on the CCU module
2. Place the CCU module on the guide rails in the CCU box and secure
You must tighten the slotted screws (1) (see Fig. 3-3) in order to guaranteevibration resistance and compliance with EMC regulations.
DC-linkbusbars
1
1
CCU CCU box
PE conductor terminal
Battery
Fig. 3-3 Assembling the SINUMERIK 810D
Installing the CCU
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Please observe the following points when installing the SINUMERIK 810D:
1. Approx. 80 mm of free space for cooling air at top and bottom
2. The shields of the motor cables must be connected once the shielding plateis installed, see Section 2.1.6.
3. The equipotential bonding conductor must be connected on each motor
4. Extra mounting depth is needed to fit connectors.
5. The specified screw tightening torque must be observed.
6. All the screws on the DC-link busbars must be tightened.
The shielding plate is attached to the bottom of the 2-axis CCU box by means of3 screws; for 2-axis CCU box, see Fig. Mounting the shielding plate). Theshielding plate is supplied with the box. The tube clip for the shield connection isincluded in the scope of supply of the pre-assembled SIEMENS motor connect-ing cable.
480
443
150
10025
466
Additional connection option forshield support M5x10
Please observe thefollowing tightening
torques for moduleassembly screws !!M3 : 0.8 NmM4 : 1.8 NmM5 : 3 NmM6 : 6 Nm
80
Free spacefor coolingair 80 mm
Shielding plate
80Free space for cooling air 80 mm130
288
Equipotential bonding terminal
120
A3 A2 A1
Motor terminal
Fig. 3-4 Dimension drawing of 3-axis CCU box
Assembly info
Mounting theshielding plate
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80
80
24.8 0.2 100 0.2149.5 0.2
6
0.1
466
0.3
480
8
0.190
100 0.2150
24.7 0.2
130
120
1107757232
289
20
443
(included in the scope of supply of ourpre-assembled Siemens motor cable)
X
Free space for cooling air
Free space for cooling air
M3
M4
Tube clampfor shield
e.g. made by Rasmussen GmbHD63461 MaintalP. O. Box 1149Tel.:++49-6181-403-0Fax: ++49-6181-403-210
Caution! The shield support
does not provide for cable strain relief
X
Shielding plate
Screw M2.5x8
5)
Heat sink
Seal
Combiscrew M5x10
Shield connecting busMLFB: 6SN1162-0FA00-0AA0
Support point for cable shields(e.g. control lead for function terminals)
Please observe thefollowing tighteningtorques for moduleassembly screws !!M3 : 0.8 NmM4 : 1.8 NmM5 : 3 NmM6 : 6 Nm
Fig. 3-5 Dimension drawing of 2-axis CCU box
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Shielding plate assembly
Fig. 3-6 2-axis CCU box: Shielding plate assembly
3.2.1 Conversion for external cooling, 2-axis CCU box (SW 5 and later)
Conversion for external cooling
Fit the grounding springs(packed in flat bag)
Undo M6 screws
and remove bracket
Fit the grounding springs(packed in flat bag)
Undo M6 screwsand remove bracket
Fig. 3-7 2-axis CCU box: Conversion for external cooling
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Motor cables
Option for fitting plug-inconnector for motorbrake
Shielding plate
Equipotentialbondingterminal
Equipotentialbonding terminal
Tube clamp
A3A2A1
Connector type for connection*motor brake:
PHNIXType: MSTB 2.5/2-STF-5.08-BD1-2SOOrder No.: 1863 631Type: MVSTBU 2.5/2-GFB-5.08Order No.: 1788 347
*included in scope of supplyof SIEMENS motor cable
Shield terminal
Fig. 3-8 Connection of motor and encoder cables (3-axis CCU box)
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3.3 Mains Supply (MS)
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3.3 Mains Supply (MS)
Mains Supply (MS) are available as a closed-loop-control infeed/regenerativefeedback module or as an open-loop-control infeed module (OI). They supply
the required operating voltages and power for the relevant system in a variety ofrating classes.
With I/RF modules, excess DC link current (e.g. during braking) can be returnedto the system. OI modules discharge the braking energy via a pulsed resistor.
The OI module is installed as the first module on the left in the driveconfiguration.
Line filters must be fitted to ensure compliance with EMC regulations stipulatedby the CE Standard.
Ready to run signal from NC and drive.Terminals 72 and 73 are closed in the error-free status.
Mains Supply: OI 5 kW, OI 10 kW, OI 28 kW,I/RF 16 kW, I/RF 36 kW, I/RF 55 kW(from 07.99: 120 kW)
SIMODRIVE filter modules or commutating reactor
Note
The mains supply and filter modules/reactors are described in the PlanningGuide 6SN1 197-0AA00 (setting options, technical data, typical circuits).
!Warning
Hazardous voltage is still present for at least 5 minutes after all voltage sourceshave been disconnected.
Terminals72, 73, 74
Permissiblemodules
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Description of the SINUMERIK 810D
4.1 Components of the SINUMERIK 810D
The SINUMERIK 810D is designed to be compatible with the modular SIMO-DRIVE 611 digital product range. The SINUMERIK 810D is operated on theSIMODRIVE 611 mains supply module (OI or I/RF modules).
Basic housing with fan for holding the CCU1/2 module with 3 integrated power
sections, 1x18A/36A (FDD) or 24A/32A (MSD) and 2x6A/12A (FDD), and a slotfor the CCU1/2 module (internal cooling).
Basic housing with fan for holding the CCU1/2 module with 2 integrated powersections, 9A/18A (FDD), and a slot for the CCU1/2 module (internal and exter-nal cooling).
The CCU (Compact Control Unit) module on the SINUMERIK 810D performs allCNC, PLC, communications and closed-loop control tasks. It has 6 measuringchannels and can digitally control up to 5 drives (5 x FDD or 4 x FDD and 1 xMSD). Each drive requires its own measuring channel for the motor measuringsystem. If there are any measuring channels left spare on the basic unit afterconnection of the drives, these can be freely assigned as direct measuringchannels, e.g. for the spindle.
Additional measuring channels can be provided by means of a 611D closed-loop control module (1- or 2-axis closed-loop control unit) with or without a directmeasuring system (DMS). In this case, the drive is controlled by the 611D mod-ule. Any unused measuring channels can be assigned freely by the user.
SW 2.x and earlier:The system software for the SINUMERIK 810D is stored on an internal FlashEPROM and included in the standard scope of supply. The PCMCIA card needonly be used when the software is upgraded.
SW 3 and later:
The NC card containing the system software must be left in the appropriate
slot during operation.In addition to SW upgrades, the PCMCIA card can also be used as a storagemedium for series start-up processes; seeReferences:/IAC/ 810D Installation and Start-Up Guide
With SW 3.2 and later, the CCU1 is capable of operating a 6th axis,see Section 4.8.
3-axis CCU box
2-axis CCU box(02.99 and later)
CCU1 / CCU2module
PCMCIA card(NC card)
6th axis(SW 3.2 and later)
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The closed-loop control is identical to the 611D standard closed-loop controlwith the following restrictions:
No star/delta switchover
No operation under V/Hz control
No speed setpoint filter switching via PLC
No parking axis
No variable signalling functions
No torque feedforward control, weight compensation
Speed controller I component cannot be switched
Only one power and one torque limit
Closed-loopcontrol
Restrictions
vis--vis 611Dstandardclosed-loopcontrol
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4.2 Interfaces on the SINUMERIK 810D
4.2.1 Overview of interfaces on CCU1/CCU2
The interfaces on the CCU1/CCU2 modules are as follows:
Optical encoders (max. 6 measuring systems for voltage raw signal encod-ers, 1VPP, incremental/absolute with EnDat interface)
3 axis extension terminals for up to 3 ext. power sections
Drive bus for axis extension with 611D modules and connection of NCU ter-minal block
PCMCIA slot
Onboard backup battery
Connection for cable distributor (handwheel, sensor)
MPI interface for operator panel, programming device, ...
PLC I/O device bus (P/K bus)
Option: PROFIBUS DP on the CCU2 with SW 3 and later
Ext. group pulse enable for all 5 drives
Starting lockout terminals AS1, AS2
BERO input for ext. zero marker (spindle)
Indicators for error, status, booting
Operator elements for start-up, general reset and reset
3 test sockets for diagnostics
Device bus connection
Note
On 1FK6 motors with optical encoders, optimum torque utilization is supportedby automatic identification processes. In this case, travel motions of
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Location of interfaces, control and display elements
Reserved
PLC I/O deviceconnection(P bus)
MPI interface
I/O deviceinterface(cable dis-tributor)
Various error andstatus LEDs(H1/H2)
7-segmentdisplay (H3)
RESET button(S1)
PLC start-upswitch (S4)
NCK start-upswitch (S3)
SIMODRIVE611D drive bus
PCMCIA slot
Device bus interfaceX151
Axis
extensionconnectionX304X306
Test sockets
Measuringsystem con-nectionX411X416
Terminal blockX431
Profibus DP on CCU2(from 06.99)
Fig. 4-1 SINUMERIK 810D, location of interfaces for control and display elements
Overview
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4.2.2 Description of interfaces on the CCU1/CCU2
PROFIBUS-DP interface
Connector name: X102Connector type: 9-way subminiature D socket connectorMax. cable length: 200 mSpecial features: Electrical (safety) isolation
12 MB
Table 4-1 Pin assignment of connector X102
X102
Pin Name Type Pin Name Type
1 Not assigned 6 VP VO
2 M24ext VO 7 P24ext VO3 RS_PROFIBUSDP B 8 XRS_PROFIBUSDP B
4 RTSAS_PROFIBUSDP O 9 RTSPG_PROFIBUSDP I
5 DGND VO
Signal names
XRS_PROFIBUSDP,RS_PROFIBUSDP Differential RS485 data PROFIBUSDPRTSAS_PROFIBUSDP Request to Send AS PROFIBUSDPRTSPG_PROFIBUSDP Request to Send PG PROFIBUSDPDGND Signal ground, floatingVP +5V, floating
P24ext, M24ext 24V supply voltage
Signal type
B BidirectionalO OutputVO Voltage OutputI Input
P bus (PLC I/O bus)
Connection of S7300 I/Os, single I/O module and distribution board
Connector name: X111Connector type: 25-way subminiature D socket connectorMax. cable length: 10 mSpecial features: Non-floating, no safety isolation
Reserved
I/O device interface (cable distributor for handwheel and sensor)
X102(from 06.99,CCU2 only)
X111
X113/X114
X121
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Connector name: X121Connector type: 37-way subminiature D plug connectorMax. cable length: 25 m for all functionsSpecial features: Non-floating handwheels
For pin assignments, see Section 4.2.3. Cable distributor.
MPI interface (187.5 Kbaud)
Connector name: X122Connector type: 9-way subminiature D socket connectorMax. cable length: 200 m
Table 4-2 Pin assignments of connector X122
X122
Pin Name Type Pin Name Type
1 Not assigned 6 P5EXT VO2 M24EXT VO 7 P24EXT VO
3 RS_BTSS B 8 XRS_BTSS B
4 ORTSAS_BTSS O 9 IRTSPG_BTSS I
5 M5EXT VO
Signal names
RS_BTSS, XRS_BTSS Differential RS485 data K bus from PLCORTSAS_BTSS Request to Send PLC
K bus from PLCIRTSPG_BTSS Request to Send programming device
K bus from PLCM5EXT Ground 5VP5EXT 5 VP24EXT 24VM24EXT Ground 24V
Signal type
B BidirectionalO OutputVO Voltage OutputI Input
SIMODRIVE 611D drive bus interface and I/O extensionConnector name: X130Connector type: 36-way Micro RibbonMax. cable length: 10 mSpecial features: Non-floating, no safety isolation
Reserved
Device bus interface (power supply)
X122
X130
X131
X151
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Connector name: X151Connector type: 34-way ribbon cable connector, plug connector
Connection for plug-in axis extension unit
Connector name: X304, X305, X306Connector type: 20-way ribbon cable connector, plug connector
Test sockets for the output of 3 analog signals. Measured values are as-signed to the sockets via a software function.
Connector name: X341, X342, X351, X352Connector type: Test socket 2 mm
Table 4-3 Assignment of test sockets X341 to X352
Test socket Location on CCU Meaning Range
X351
DAC 1 05V
X352
DAC 2 05V
X341
DAC 3 05V
X342
Ground for all DACs
6-way measuring system connection for indirect and direct position
sensing
Connector name: X411X416Connector type: 25-way subminiature D plug connectorSignals on a gray background are not required with direct measuring systems.
Table 4-4 Pin assignment of measuring system connection X411X416
X411X416
Pin Name Type Pin Name Type
1 PENC1/2 VO 14 PENC1/2
2 M M 15 ENCDATi B
3 APi I 16 M4 ANi I 17 RPi I
5 M V 18 RNi I
6 BPi I 19 CPi I
7 BNi I 20 CNi I
8 M V 21 DPi I
9 Not assigned 22 DNi I
10 ENCCLK O 23 XENCDATi B
11 Not assigned 24 M V
X304, X305, X306
X341, X342,X351, X352
X411X416
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Table 4-4 Pin assignment of measuring system connection X411X416
X411X416
12 XENCCLK O 25 THMOTCOM I
13 THMOTi I
Signal names
PENC1/2 Encoder power supply (PENC1: X411X413, PENC2:X414X416)
APi Incremental signal AANi Incremental signal ABPi Incremental signal BBNi Incremental signal BCPi Incremental signal C (not with direct measuring system)CNi Incremental signal C (not with direct measuring system)DPi Incremental sign D (not with direct measuring system)DNi Incremental signal D (not with direct measuring system)
RPi Incremental signal RRNi Incremental signal RENCCLK Clock signalXENCCLK Clock signalENCDATi Data signalXENCDATi Data signalTHMOTi Motor temperature (not with direct measuring system)THMOTCOM Motor temperature (not with direct measuring system)
Signal type
B BidirectionalO InputO OutputVO Voltage OutputV VoltageM Logic reference potential ground
Note
The encoder power supply is not stabilized which means no remote/sensemode. As a result, the encoder cable length is limited.
EQN 1325: 18 m
ERN 1387: 25 m
External encoder with power
consumption 300 mA: 18 m
Terminal block for the connection of starting lockout, pulse enable (all
drives) and external zero marker (BERO)
X431
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Table 4-5 Terminal signals drive X431
Terminal Function Cross-section
AS1 Starting lockout relay (checkback at term.663) 1.5 mm2
AS2 Starting lockout relay (checkback at term.663) 1.5 mm2
663 Pulse enable for all drives (FDD and MSD). Terminal 663switches the Starting lockout relay. When it opens, thecontrol pulses are disabled and the drive torque is cut off.
1.5 mm2
9 Enabling potential +24 V, reference terminal is term. 19 1.5 mm2
B Input for external zero marker (BERO) 1.5 mm2
19 Reference ground for enabling potential 1.5 mm2
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The layout of the control and display elements on the module front panel can beseen in Fig. 4-1.
Table 4-6 Control and display elements on the CCU module
Desig-nation
Type Meaning
RESET(S1)
ButtonInitiates a HW RESET to reset the control system and drivesfollowed by rebooting.
S3Rotaryswitch
NCK start-up switchPosition 0: Normal operationPosition 1: NCK general resetPosition 2: NCK SW update from memory cardPositions 3...7: Reserved
S4Rotaryswitch
PLC mode selector switchPosition 0: PLC-RUNPosition 1: PLC-RUN-PPosition 2: PLC-STOP
Position 3: MRES
LEDs(left-handrow)
Green LED
Red LED
Red LED
Yellow LED
+5V: Lights up when the supply voltage is withintolerance range.
NF: Lights up if the NCK or PLC watchdog has beentriggered
SF: Lights up in response to drive faults. Goes out after asystem powerup in an error-free state.
CB: Lights up if data are being transferredvia the MPI interface.
LEDs(right-handrow)
Green LEDRed LEDRed LED
Yellow LEDYellow LED
PR: PLC-RUN statePS: PLC-STOP statePF: Lights up with PLC errorPFO: PLC-FORCE state: No function (lights up briefly during
Reset).
H3 7-segmentSoftware-backed output of test anddiagnostic signals
DAC 1
DAC 3
DAC 2
Ground
Fig. 4-2 DAC test sockets on the CCU1/2 modules
Control anddisplay elements
DAC test sockets
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4.2.3 Cable distributor
Interface X121 of the CCU1/CCU2 is split in the cable distributor into
two connections for differential handwheel,
two connections for measuring pulse input,
in a maximum of seven individual cables.
Max. 2 cables for handwheel6FX20024AA210
90
bottom
topMax. 2 cables for sensor6FX2002-4AA41-0
7
1
Fig. 4-3 Cable distributor
The cable distributor (37-way) consists of a connector jacket (SINUMERIK
design) for a 37-way subminiature D plug connector with enlarged interior.Seven cable inputs are located on the rear side of the jacket. Cables must beconnected to these as specified in Table 4-8.
Attach the cable to connectors X1 to X10 in the open cable distributor and placethe cable in the cable entry. The exposed shielding sheaths must be bondedover a large conductive area with the metallic contact surfaces, as shown in Fig.4-4. Insert the top terminal clamp in such a way that the teeth are facing theteeth in the bottom clamp and then secure the top half of the connector jacket.
Cable distributor(I/O deviceinterface)X121
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The cable shields are thereby compressed and contacted between the contactsurfaces of the contact springs. When you attach the distributor to the frontpanel of the CCU, the shield potential is directed via the contact springs in thedistributor.
The DIP-FIX switches inside the cable distributor 6FX 2006-1BA01 must be setas follows:
Table 4-7 Setting the DIP-FIX switches (S1...S6) in the cable distributor
Switch S1 S2 S3 S4 S5 S6
opened x x x x
closed x x
X1 X2 X4 X5 X6 X7 X8 X9 X10X3
X11
Cable guides
Terminal clamp
Contact surfaces
Connectors X1...X10
S3S4S5 S1S2
Subminiature D socketconnector
S6
1 2 3 4 5 6 7
Fig. 4-4 Location of interfaces on cable distributor
Table 4-8 Connector assignments
Connector no. Cable run I/O devices
X1 1X2
1(top)
1st handwheel
X3
X42 2nd handwheel
X5 3 2nd sensor
X6
X74 Reserved
X8 5 Reserved
Location of
interfaces
Connectors X1-X10
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Table 4-8 Connector assignments
Connector no. I/O devicesCable run
X9 6 Reserved
X107
(bottom) 1st sensor
Connector designation: X1...X10Connector type: DU-BOX plug connectors
Table 4-9 Terminal assignment, cable distributor
Pin no.37-wayconnec-
tor
Signalname
DU-BOXconnector
No./pin
Cable run Cable order no.6FX20024AA
Core color I/O device Terminal
9
10
MEPUS 0
MEPUC 0
X10/2X10/1X10/4X10/3
7 410
rdogbnbk
Shield
1st sensor
1st sensor
+24V signal
Referencesignal
1202
21
X9/2X9/1X9/4X9/3
6 410 Reserved
3224
23
X8/2X8/1X8/4X8/3
5 410 Reserved
5246
257
268
27
X7/2X7/1X7/4X7/3X6/2X6/1X6/4X6/3
4 210 Reserved
28
29
MEPUS 1
MEPUC 1
X5/2X5/1X5/4X5/3
3 410
rdogbnbk
Shield
2nd sensor
2nd sensor
+24V signal
Referencesignal
Terminal
assignment
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Table 4-9 Terminal assignment, cable distributor
Pin no.37-wayconnec-
tor
TerminalI/O deviceCore color
Cable order no.6FX20024AA
Cable runDU-BOXconnector
No./pinSignalname
1130123113321433
MPG1 AMPG1 AMPG1 5VMPG1 0VMPG1 5VMPG1 0VMPG1 BMPG1 B
X4/2X4/1X4/4X4/3X3/2X3/1X3/4X3/3
2 210
rdogbnbkgnyevtbu
Shield
2nd handwheel
6FC9320-5DB
AA
5 V0 V5 V0 VBB
1534163517
361837
MPG0 AMPG0 AMPG0 5V
MPG0 0VMPG0 5V
MPG0 0VMPG0 BMPG0 B
X2/2X2/1X2/4X2/3X1/2
X1/1X1/4X1/3
1 210
rdogbnbkgn
yevtbu
Shield
1st handwheel
6FC9320-5DB
AA
5 V0 V5 V
0 VBB
MPG0/1 5 V Supply voltage for handwheel 0/1, 5 V 1)
MPG0/1 0V Supply voltage for handwheel 0/1, 0 VMPG0/1 A/A Differential handwheel input 0/1 A/AMPG0/1 B/B Differential handwheel input 0/1 B/BMEPUS 0/1 Measuring pulse signal 0/1MEPUC 0/1 Measuring pulse common (reference ground) 0/1
1) total of max. 1 A, i.e. max. 500 mA per handwheel
Signal names
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4.3 Measuring system
4.3.1 Assignments between measuring systems and motor
connections
There is a fixed assignment between