System Overview 1 Connection Conditions 2 Design and Installation 3 Description 4 Axis Expansion 5 I/O Modules 6 NCU Terminal Block 7 DMP Compact Modules 8 Maintenance and Service 9 Abbreviations A SINUMERIK 810D Configuration CCU Equipment Manual Valid for Index Control SINUMERIK 810D powerline SINUMERIK 810DE powerline Edition 03/2006
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 12.95 07.96 08.97 12.98 08.99 04.00 10.00 12.01 03.02 11.02 03.05 03.06 Order No.
Preface SINUMERIK Documentation The SINUMERIK documentation is subdivided into 3 parts: S General Documentation S User documentation S Manufacturer/Service documentation A list of documents with the respective available languages is updated on a monthly basis and is available on the Internet at: http://www.siemens.com/motioncontrol Select “Support” → “Technical Documentation → “Overview of Documents”. The Internet version of the DOConCD (DOConWEB) is available at: http://www.automation.siemens.
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Preface ! ! Warning indicates that death or serious injury may result if proper precautions are not taken. Caution with a safety alert symbol, indicates that minor personal injury may result if proper precautions are not taken. Caution without a safety alert symbol, indicates that property damage can result if proper precautions are not taken. Notice indicates that an undesirable event or state may arise if the relevant notes are not observed.
Preface Danger notices ! Should it be necessary to test or take measurements on live equipment, then the specifications and procedures defined in Accident Prevention Regulation of the Berufsgenossenschaft BGV A3 (German employer’s liability insurance association) must be adhered to, in particular § 8 “Permissible deviations when working with live components”. Suitable electric tools should be used. Danger Operating electrical equipment has parts and components that are at hazardous voltage levels.
Preface ESD notices ! Electrostatically Sensitive Devices Important Handling of modules containing devices sensitive to electrostatic discharge: When handling components which can be destroyed by electrostatic discharge, it must be ensured that personnel, the workstation and packaging are well grounded. Generally, electronic modules must not be touched unless work has to be carried out on them. Only touch electronic modules after you have grounded yourself.
Preface Notes viii Copyright © Siemens AG 2006 SINUMERIK 810D Equipment Manual Configuration CCU (PHC) – 03/2006 Edition
Contents 1 2 3 4 System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 1.1 SINUMERIK 810D powerline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 1.2 System configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 1.3 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Axis expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77 5.1 Axis expansion plug-in unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77 5.2 Axis expansion with SIMODRIVE 611D control plug-in unit . . . . . . . . 5-80 I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83 6.1 Single I/O module . . . . . . . . . . . . . .
1 System Overview 1.1 SINUMERIK 810D powerline Since 03.2002 SINUMERIK 810D powerline and SINUMERIK 810DE powerline have been available. The following powerline module with improved performance is now available: Table 1-1 powerline module for SINUMERIK 810D/810DE Module Description CCU3 with additional pulse interface and 2 machining channels CCU3.
1 System Overview 1.2 System configuration 1.2 System configuration Components Table 1-2 A fully equipped SINUMERIK 810D consists of different components. These are listed below. Components of the 810D in the maximum configuration (without motors) Component Mains supply module (MS) MLFB Description See References: /PJU/ Configuration Manual Converters Power supply module for powering the electronics and drives.
1 System Overview 1.2 System configuration Component MLFB Description Handheld terminal (HT 6) 1) 6FC5403-0AA10-0AA0 Handheld unit combining the functions of operator panel front and MCP, with – Display, – Keyboard, enabling buttons, EMERGENCY STOP and override button – RS 232 C interface for archiving programs and data – Connection via cables and distributors to SINUMERIK 810D/840Di/840D and FM357-2H Distributor box 1) 6FX2006-1BC00 For linking the hand-held unit to the MPI bus.
1 System Overview 1.2 System configuration Diskette unit ÄÄ ÄÄ Handheld unit PCU * POWER Handheld unit or mini handheld unit or HT 6 SINUMERIK * TEMP Operator panel front HT 6 MPI cable MCP 17 QWERTY keyboard 16 Distributor box Cable distributor Encoder cable direct measuring system Measurement (2x) *) 14 Handwheel (2x) OI or I/R MSD 810D FSD FSD (CCU3) 14 Axis expansion plug-in unit 15 Motor cable 1x Motor encoder cable Direct measuring system (e.g. on the X416) Fig.
1 System Overview 1.
1 System Overview 1.2 System configuration SIMATIC S7-300 I/O X2 PS IM SMs SIMATIC S7-300 IM connecting cable 8 8 –X416 –X415 –X414 –X121 –X413 –X412 –X411 CCU3 –X102 1) –X130 –X307 –X431 MEMORY CARD –X122 –X111 Single I/O module 8 Connecting cable shielded –X305 –X304 –X306 Drive bus cable 7 9 Terminal block Single I/O module Terminator Fig.
1 System Overview 1.2 System configuration Connecting cables Table 1-3 The following connecting cables are used for the SINUMERIK 810D Connecting cables for SINUMERIK 810D No.
1 System Overview 1.2 System configuration Axis expansion on 810D On the SINUMERIK 810D, the number of axes can be expanded to six axes, including spindles. There are two possibilities: either Connect axis expansion plug-in unit and SIMODRIVE 611 power module at axis expansion interface, or Connect SIMODRIVE 611D control plug-in unit with SIMODRIVE 611 power module on drive bus/device bus.
1 System Overview 1.
1 System Overview 1.2 System configuration CCU 3 with 3 axis CCU box or 2 axis CCU box plus 2 axis power module to the right of CCU 1 axis power module to the right of CCU 1 axis power module to the left of CCU { 25 A Fig. 1-5 X305 X304 X306 internal/ external X307 CCU 3 6x encoder connection If an external power module is connected to connector -X307, then the 3rd internal power module will be switched to the external power module.
1 System Overview 1.3 Labels 1.3 Labels In case of technical queries or service, please quote all data on the rating plate to the local SIEMENS office responsible for your equipment. One of the following labels is attached to the components and modules: PCBs with screen printing Example: Component number: 570 573.9001.00 Product version: B (last cross) SIEMENS A B C D E 570 573.9001.00 CCU3.4 module CCU3.4 CCU box Example: Component name: CCU3.
1 System Overview 1.
Connection Conditions 2.1 2 Supplementary electrical conditions Compliance with the connection conditions The controller is tested for compliance with the ambient conditions specified below. Fault-free operation is only ensured if: These environmental conditions are maintained when storing, transporting and operating the equipment. Original components and spare parts are used. This applies in particular to the use of specified cables and plug connectors.
2 Connection Conditions 2.1 Supplementary electrical conditions 2.1.1 Power supply Demands on DC power supplies Warning ! The DC power supply is always referenced to ground and must be generated by a safety transformer. Final user interfaces are powered via a DC power supply with protective separation per EN 61800-5-1. In the case of supply cables > 10 m, protective elements must be fitted at the device input in order to protect against lightning (surge voltage).
2 Connection Conditions 2.1 Supplementary electrical conditions Table 2-2 EP and CP points for 810D components Component Electronics points (EP) Control points (CP) 2 4.5 810D EnDat encoder 0 0.3 Power module 50 A 0.6 0.5 Power module > 50 A 80 A 0.75 1.0 Power module > 80 A, 120 A 1.5 1.
2 Connection Conditions 2.1 Supplementary electrical conditions 2.1.2 Safe isolation to EN 61800-5-1 The complete system includes end user interfaces (UIs) and interfaces for servicing, commissioning and maintenance. End user interfaces (UI) UIs are all the interfaces that are freely accessible to the machine operator without the need for tools or aids. These user interfaces are designed with safe isolation to EN 61800-5-1.
2 Connection Conditions 2.1 Supplementary electrical conditions 3 x 400 V AC N Housing/shield 8 MSTT/MCP PCU 1 4 11 24V 4 4 2 M (GND) 11 HHU/ HT 6 3 Distributor box 5 4 7 6 810D/611 digital 9 S7-300 I/Os 10 ÎÎÎ Machine 10 M (GND) 5 Basic insulation Fig. 2-1 Person 11 Terminal block Protective separation Protective separation as per EN 61800-5-1 Fig. 2-1 shows the potential balance of the 810D/611D/S7-300 system. Legend: 1.
2 Connection Conditions 2.1 Supplementary electrical conditions 2.1.3 Grounding Concept The SINUMERIK 810D system consists of a number of individual components, each of which must comply with the appropriate EMC and safety standards.
2 Connection Conditions 2.
2 Connection Conditions 2.1 Supplementary electrical conditions These external devices may not be connected to the control during normal operation. However, if the system cannot be operated without them, then the cable shields must be connected at both ends. Furthermore, the external device must be connected to the control via an equipotential bonding cable. Cable definitions Definition: Signal cables (e.g.) – Data cables (MPI, sensor cables, etc.
2 Connection Conditions 2.2 Climatic and mechanical environmental conditions 2.2 Climatic and mechanical environmental conditions Test standards Vibration load: Shock load: Climate: EN 60068-2-6 EN 60068-2-27 EN 60068-2-1/EN 60068-2-2/EN 60068-2-14 EN 60068-2-30/EN 60068-2-31/EN 60068-2-32/ EN 60068-2-33/EN 60068-2-34 Requirement standards Long-term storage: Transport: Stationary operation: EN 60721-3-1 EN 60721-3-2 EN 60721-3-3 2.2.
2 Connection Conditions 2.2 Climatic and mechanical environmental conditions Shipment of backup batteries Backup batteries must only be transported in the original packaging. No special approval is needed for transporting backup batteries. The lithium content is approximately 300 mg. Note The backup battery is classified as a hazardous substance, Class 9, in accordance with the relevant air-freight transportation regulations.
2 Connection Conditions 2.2 Climatic and mechanical environmental conditions Mechanical environmental conditions Table 2-8 Test limits for mechanical environmental conditions Vibration t EN 60068 to 60068-2-6 26 Shock resistance t EN 60068 to 60068-2-27 2 27 Frequency range 10 ... 58 Hz Constant deflection 0.075 mm Acceleration amplitude 58 ... 200 Hz: 1g Acceleration 5g Duration of nominal shock 30 ms Number of nominal shocks 18 shocks Shock form Half-sine g 9.
2 Connection Conditions 2.3 Technical data of the individual components 2.
2 Connection Conditions 2.4 MPI/OPI network rules 2.4 MPI/OPI network rules Application The following devices can be interconnected across the MPI bus: CCU PCU HT 6 HHU MSTT/MCP The MPI interconnecting cables are available in different lengths. Network installations When installing a network, observe the following basic rules: 1. The MPI connection can be routed from one user to the next by plugging the MPI connector of the outgoing cable onto the MPI connector of the incoming cable. 2.
2 Connection Conditions 2.4 MPI/OPI network rules Another possibility is two identical components, provided they have different node addresses. For setting the addresses (also see corresponding component section): – HHU: Via DIP switch or display (see “Handheld unit” section), – For HT 6, by adapting the address before commissioning (refer to Operating Components “Handheld Terminal HT 6”).
Design and Installation of the 810D 3.1 3 Structure of the SINUMERIK 810D The SINUMERIK 810D consists of two components: CCU3 module Fig. 3-1 3-axis CCU box 2-axis CCU box Components of the SINUMERIK 810D 1. CCU module (Compact Control Unit) 2. 3-axis CCU box (sheet-metal housing with 3 integrated power modules for fitting the CCU module) with internal heat dissipation or 3.
3 Design and Installation of the 810D 3.2 Assembly of the SINUMERIK 810D Open equipment 3.2 These modules are open equipment. This means they may only be installed in housings, cabinets, or in electrical equipment rooms that can only be entered or accessed with a key or tool. Housings, cabinets, or electrical equipment rooms may only be accessed by trained or authorized personnel. An external fire protection casing is required.
3 Design and Installation of the 810D 3.2 Assembly of the SINUMERIK 810D Axis expansion plug-in unit, left Axis expansion plug-in unit SIEMENS SIMODRIVE Power supply (I/R or OI) Fig. 3-2 LDC 810D (CCU3) LDC Overall assembly SINUMERIK 810D with SIMODRIVE 611 power module Installation of the CCU Sequence: 1. Connect the battery on the CCU module 2.
3 Design and Installation of the 810D 3.2 Assembly of the SINUMERIK 810D CCU box CCU3 1 –X307 Battery DC link rails 1 PE conductor connection Fig. 3-3 Assembly of the SINUMERIK 810D Installation instructions Pay attention to the following when installing the SINUMERIK 810D: 1. Cooling clearance top and bottom, approx. 100 mm 2. The shields of the motor cables must be connected after mounting the shield sheet, see section 2.1.3. 3.
3 Design and Installation of the 810D 3.2 Assembly of the SINUMERIK 810D Mounting the shielding plate The metal sheet is mounted on the 3-axis CCU box with the 3 screws on the underside (2-axis CCU box, see figure Mounting the shielding plate). The shielding plate is supplied in the box. The tube clip for connecting the shield is contained in the scope of supply of the ready-assembled SIEMENS motor cable. 466 480 The tightening torque must be complied with when mounting modules!! M3: 0.8 Nm M4 : 1.
3 Design and Installation of the 810D 3.2 Assembly of the SINUMERIK 810D 149.5 0.2 100 0.2 Dichtung 130 100 Heat sink Kühlkörper The tightening torque must be complied with when mounting modules!! M3: 0.8 Nm M4 : 1.8 Nm M5 : 3 Nm M6 : 6 Nm 443 466 + 480 0.3 24.8 0.2 Cooling clearance Lüftungsfreiraum Seal M3 57 20 8 100 M4 24.85 90 0.2 77 100 0.
3 Design and Installation of the 810D 3.2 Assembly of the SINUMERIK 810D Mounting the shielding plate Montage Schirmblech Fig. 3-6 3.2.
3 Design and Installation of the 810D 3.2 Assembly of the SINUMERIK 810D A1 A2 A3 Equipotential bonding terminal Equipotential bonding terminal Á Á Á ÁÁÁ ÁÁ Motor cables Attachment point for motor brake plug connection Shielding plate Tube clip Shield connection Type of plug connection* Motor brake: PHOENIX Type: MSTB 2.5/2-STF-5.08-BD1-2SO Order No.: 1863 631 Type: MVSTBU 2.5/2-GFB-5.08 Order No.: 1788 347 *Included with SIEMENS motor cable Fig.
3 Design and Installation of the 810D 3.3 Power supply 3.3 Power supply Power supplies are available as a stabilized infeed/regenerative feedback module (I/R module) and as an open-loop control infeed module (OI) The provide the necessary operating voltages and the necessary power for the system in different power ranges. The I/R modules can feed excess DC link energy (e.g. in braking operation) back into the network. OI modules dissipate the braking energy in a pulsed resistor.
3 Design and Installation of the 810D 3.
Description of the SINUMERIK 810D 4.1 Components of the SINUMERIK 810D 4.1.1 Overview 4 The structure of the SINUMERIK 810D is compatible with the SIMODRIVE 611 digital module series. The SINUMERIK 810D is operated with the SIMODRIVE 611 power supply modules (OI or I/R modules). 3-axis CCU box Basic housing with fans for fitting the CCU module with three integrated power modules 1x18A/36A (FSD) or 24A/32A (MSD) and 2x6A/12A (FSD) and slot for CCU module (internal heat dissipation).
4 Description of the SINUMERIK 810D 4.1 Components of the SINUMERIK 810D PCMCIA card (NC card) The NC card with the system software must remain inserted during operation. Note For a software upgrade, the export software can be copied onto the internal flash EPROM.
4 Description of the SINUMERIK 810D 4.1 Components of the SINUMERIK 810D Drive functions of SIMODRIVE 611D Table 4-1 The following table shows drive functions and values, which differ from module to module. Function differences for SIMODRIVE 611 digital Function Standard 2 1-axis 2-axis (FSD only) Performance 1 1-axis Performance 2 (2-axis) CCU3/CCU3.
4 Description of the SINUMERIK 810D 4.2 Interfaces 4.2 Interfaces 4.2.1 Overview Brief description The modules have the following interfaces: Optical encoder (up to six measuring systems for unconditioned voltage signal encoder, 1 Vpp, incremental/absolute with EnDat interface ) Three axis expansion connections for up to three ext.
4 Description of the SINUMERIK 810D 4.2 Interfaces Table 4-2 Overview of hardware interfaces Closed-loop Cl dl control NCK/PLC Miscellaneous Interface CCU Pulse interfaces (6 axes) 4 **) Optical encoder 6 DAC test sockets Yes BERO input Yes Terminals (AS1, AS2, 663, 9,19) Yes PBus/KBus Yes MPI interface Yes Drive bus (611D interface) Yes Connection for diff.
4 Description of the SINUMERIK 810D 4.2 Interfaces 4.2.2 Description of the interfaces, operating and display elements Overview Location of the interfaces, operating and display elements I/O interface (cable distributor) Meas.
4 Description of the SINUMERIK 810D 4.
4 Description of the SINUMERIK 810D 4.
4 Description of the SINUMERIK 810D 4.
4 Description of the SINUMERIK 810D 4.
4 Description of the SINUMERIK 810D 4.
4 Description of the SINUMERIK 810D 4.2 Interfaces X431 Terminal block for connection of starting lockout, pulse release (all drives) and external zero mark (BERO) Connector name: Connector type: Table 4-9 X431 6-pole Combicon terminal (Phoenix connector), for 1.
4 Description of the SINUMERIK 810D 4.2 Interfaces Operating and display elements Fig. 4-1 shows the position of the operating and display elements on the front panel. Table 4-10 Operating and display elements on the CCU module Description Type Meaning RESET (S1) Button Triggering a hardware reset to reset the control and drive followed by a complete restart.
4 Description of the SINUMERIK 810D 4.2 Interfaces 4.2.3 Cable distributor Cable distributor (I/O interface) X121 The cable distributor splits the X121 interface of the CCU into two connections of differential handwheel, two connections of meas. pulse input, in max. seven single cables. 90 max. 2 cables handwheel 6FX2002-4AA21-0 max. 2 cables for probe 6FX2002-4AA41-0 top 1 7 bottom Fig.
4 Description of the SINUMERIK 810D 4.2 Interfaces The DIP-FIX switches inside the cable distributor 6FX 2006-1BA01 must be set as follows: Table 4-11 Setting the DIP-FIX switches (S1 to S6) in the cable distributor Switches Open S1 S2 S3 S4 x x x x S5 S6 x x Closed Location of interfaces 1 2 3 4 5 6 7 Cable inlets Terminal caps Contact surfaces X1 X2 X3 X4 X5 X6 X7 X8 X9 Plug-in connectors X1...X10 X10 D-Sub female connector S2 S4 S1 S3 S5 S6 X11 Fig.
4 Description of the SINUMERIK 810D 4.2 Interfaces Pin assignment Table 4-13 Pin no. 37-pole connector 9 10 Connector designation: Connector type: X1...X10 DU-BOX plug connectors Cable distributor pin assignment Signal name – MEPUS 0 – MEPUC 0 DU BOX connector no./pin Cable routing X10/2 X10/1 X10/4 X10/3 7 Cable Order No.
4 Description of the SINUMERIK 810D 4.3 Measuring system 4.3 Measuring system 4.3.1 Assignment of measuring systems and motor connection Motor measuring system and motor connection A certain motor connection is permanently assigned to each measuring system M1 -X411 M2 -X412 M3 -X413 M4 -X414 M5 -X415 M6 -X416 OI or I/R MSD 810D CCU3 A1 FSD FSD A2 Motor 6 Motor 3 Motor 1 Motor 2 Motor 4 Fig.
4 Description of the SINUMERIK 810D 4.3 Measuring system 4.3.2 Encoder systems that can be evaluated Incremental measuring systems Incremental systems with two 90-degree offset sinusoidal voltages signals A, B and a reference mark R. E.g. ERN 1387 (motor measuring system) Transfer: Differential signals A, A; B, B and R, R Amplitude A – A typ. 1 Vpp Amplitude B – B typ. 1 Vpp Amplitude R – R typ. 0.5 Vpp...1 Vpp Power supply: 5 V ±5 % Maximum supply current: 300 mA Max.
4 Description of the SINUMERIK 810D 4.3 Measuring system Absolute (EnDat) measuring systems Single-turn, multi-turn, and linear absolute measuring systems with two 90_ offset sinusoidal voltage signals A, B, and EnDat interface, e.g. multi-turn encoder EQN 1325, single-turn encoder ECN 1313 or linear absolute measurement system LC181. Transfer incremental signals: Differential signals A, A and B, B Amplitude A – A typ. 1 Vpp Amplitude B – B typ.
4 Description of the SINUMERIK 810D 4.3 Measuring system 4.3.3 Measuring channels, indirect and direct measuring system Measuring channels for SINUMERIK 810D The six measuring channels on the SINUMERIK 810D can be used both for indirect and for direct position sensing. A free measuring channel can, for example, be used for a direct spindle measuring system. Additional measuring channels can be obtained by using a 611D standard control module with/without direct measuring system.
4 Description of the SINUMERIK 810D 4.3 Measuring system Indirect position (motor rotor position) and motor speed sensing FSD 1 M: Max. possible measuring steps G: Accuracy of the encoder system Incremental X411 M = 128 x Z per 360 degr. mech. Z...Increments Z = 2048 SINUMERIK 810D CCU module Motor 1 6 G = 0.006 deg. Incremental and multiturn absolute EnDat 7 X411 SINUMERIK 810D CCU module M = 128 x Z per 360 degr. mech. Z...Increments Z = 2048 G = 0.006 deg.
4 Description of the SINUMERIK 810D 4.3 Measuring system Direct measuring system FSD The motor measurement system is used for sensing the motor position. A second measuring system, e.g. a scale, can be used for load-side position sensing if necessary. Incremental encoders, distance-coded incremental encoders, or EnDat absolute value encoders can be used (voltage signals). Direct position sensing with free CCU measuring channel M: Max.
4 Description of the SINUMERIK 810D 4.3 Measuring system Indirect measuring system MSD The motor measuring system is also used for position sensing. An encoder system is available: optical/incremental (1PH motor) Indirect position (motor rotor position) and motor speed sensing MSD 1 X411 M: Max. possible measuring steps G: Accuracy of the encoder system Incremental Z...Increments Z = 2048 SINUMERIK 810D CCU module Motor *) 1 Incremental X130 SINUMERIK 810D CCU module Fig.
4 Description of the SINUMERIK 810D 4.3 Measuring system Direct measuring system MSD The motor measurement system is used for sensing the motor position. A second measuring system, e.g. a rotary transducer, can be used for load-side position sensing if necessary. In the case of SINUMERIK 810D only encoders with voltage signals can be used. M: Max.
4 Description of the SINUMERIK 810D 4.4 Integrated power modules: 3-axis CCU box 4.
4 Description of the SINUMERIK 810D 4.4 Integrated power modules: 3-axis CCU box Permissible duty cycles FSD For use as FSD power module (A1 – A3) I Imax In 0.2 s Imax = Peak current In = Rated current Fig. 4-12 t 10 s Peak current duty cycle with previous load for FSD I Imax In Imax = Peak current In = Rated current Fig. 4-13 Permissible duty cycles FSD 4s t 10 s Peak current duty cycle without previous load for FSD For MSD power module only with 24A/32A I Imax IS6 In 0.
4 Description of the SINUMERIK 810D 4.4 Integrated power modules: 3-axis CCU box I Imax IS6 In 0.7xIn 10 s 60 s t Imax = Peak current In = Rated current Fig. 4-15 Coincidence factor S6 duty cycle with previous load for MSD The power modules A2 and A3 may only be operated in simultaneous continuous duty at 63 % of their rated current on average. No coincidence restrictions apply to A1.
4 Description of the SINUMERIK 810D 4.5 Integrated power modules: 2-axis CCU box 4.5 Integrated power modules: 2-axis CCU box Description On the SINUMERIK 810D, 2 integrated power modules are fitted on one heat sink in the 2-axis CCU box: Power module for 9A/18A (FSD) Heat sink temperature sensor The 2-axis CCU box can be mounted with internal or external heat dissipation.
4 Description of the SINUMERIK 810D 4.6 PLC module Permissible duty cycles FSD For use as FSD power module (A1 – A2) I Imax In 0.2 s Imax = Peak current In = Rated current Fig. 4-16 t 10 s Peak current duty cycle with previous load for FSD I Imax In Imax = Peak current In = Rated current Fig. 4-17 t 10 s Peak current duty cycle without previous load for FSD References: 4.
4 Description of the SINUMERIK 810D 4.7 PCMCIA card (memory card) 4.7 PCMCIA card (memory card) The CCU contains a plug-in unit for standard PC cards with which all type II flash cards with up to 8 Mbytes storage capacity can be operated. Recommendation: Use Siemens PC cards. The PCMCIA card is used for software upgrading or for standard software.
5 Axis Expansion 5.1 Axis expansion plug-in unit Application The axis expansion plug-in unit is installed in a SIMODRIVE 611 power module and then connected to the X304-X306 axis expansion terminal of the SINUMERIK 810D. The plug-in unit is designed for 1-axis and 2-axis power modules. There is also an axis expansion plug-in unit left with terminals for connectors X307 (CCU) und X301 (expansion plug-in unit) at the same height.
5 Axis Expansion 5.1 Axis expansion plug-in unit Note On LT modules more than 50 mm wide and a permanently mounted device bus, the free end of the device bus must be fixed to the 34-pole device bus connector on the module. Axis expansion plug-in unit Fig. 5-2 Connecting the ribbon cable connector 5-78 SIMODRIVE 611 power module Mounting the axis expansion plug-in unit in the power module The axis expansion plug-in module has two connectors X301 and X302.
5 Axis Expansion 5.1 Axis expansion plug-in unit Table 5-1 Connection of the ribbon cable connector to the axis expansion plug-in unit Ribbon cable connector 1-axis power module 2-axis power module X301 1st axis 1st axis X302 Unassigned 2nd axis Installation 1. Bring in and connect the ribbon cable for connector X301 through the slot in the front panel with the notch facing forward. 2. If applicable, also attach the ribbon cable for connector X302 accordingly (for 2nd axis).
5 Axis Expansion 5.2 Axis expansion with SIMODRIVE 611D control plug-in unit 5.2 Axis expansion with SIMODRIVE 611D control plug-in unit Application Axis expansion with SIMODRIVE 611D control plug-in unit is only used if the number of measuring channels of the SINUMERIK 810D is insufficient, or higher performance is required. Mounting The SIMODRIVE 611D module must be inserted as the first module to the right of the SINUMERIK 810D.
5 Axis Expansion 5.2 Axis expansion with SIMODRIVE 611D control plug-in unit Note For EMC-compliant assembly, shielded motor cables must be used in conjunction with the shielding contact plates available for SIMODRIVE power modules; see References: /PJU/, Configuration Manual Converters /EMV/, EMC Configuring Guidelines Cable set for axis expansion For connection of the SIMODRIVE 611D control plug-in unit that is located immediately to the right of the 810D.
5 Axis Expansion 5.
6 I/O Modules 6.1 Single I/O module Brief description The single I/O module has 64 inputs and 32 short-circuit-proof outputs (isolated). Each output can be loaded with 0.5 A. The coincidence factor is 75 %. Up to three single I/O modules can be attached to the SINUMERIK 810D; combinations with SIMATIC S7-300 chains are possible. Connection to 810D The single I/O module (connector X3 IN) is connected to the SINUMERIK 810D (connector X111). The max. cable length is 10 m.
6 I/O Modules 6.1 Single I/O module Cooling clearance 50 mm 70 SHIELD M24Lo. P24Logic Space for front connector 374 360 SHIELD M24Po P24Power Cooling clearance 50 mm 25 Fig. 6-2 Dimension drawing of single I/O module EMC measures 6-84 135 25 The single I/O module has an equipotential bonding terminal. To conduct interference currents away, a low-resistance finely stranded bonding conductor to the ground bus is required (see subsection 2.1.3) with a cross-section of at least 10 mm2.
6 I/O Modules 6.1 Single I/O module Technical data Table 6-1 Technical data of the single I/O module Power supply for LOGIC (X1) and POWER (X5) – rated value – perm. range – ripple – polarity reversal protection – fuse-protection – LOGIC – POWER – LOGIC – POWER 24 V DC 18.5 ... 30.2 V 3.6 Vpp yes LOGIC: 1 A/250 V POWER: no Type: 0.3 A, max. 1 A max: 12 A Type: 7.2 VA, max. 30.2 VA max.
6 I/O Modules 6.1 Single I/O module Connection of the electronics power supply The 24 V DC power supply is connected to X1 via a 3-way angled Phoenix screw terminal connector (2.5 mm2).
6 I/O Modules 6.1 Single I/O module Connection of the inputs/outputs The inputs/outputs are connected via ribbon cables (max. 3 m length). The following 34-way terminal strip converters can be used for this purpose: see References: Catalog NCZ Terminal strip converter without LED: 6FC9302-2AA Terminal strip converter with LED red: 6FC9302-2AB (0.
6 I/O Modules 6.1 Single I/O module Signal names OUTi[j] Output j of output byte i Signal type O X404 Inputs 0 to 31 Output Connecting inputs 0 to 31 Connector name: Connector type: of the ribbon cable: 1 Not assigned 3 INP0ȱ0ȳ 5 X404 INPUT 0–31 34-way DIN ribbon cable connection length Max.
6 I/O Modules 6.
6 I/O Modules 6.1 Single I/O module X3 IN X404 X405 X406 X3 OUT 32 inputs 0 to 31 32 inputs 32 to 63 32 outputs 0 to 31 This results in the following address space: 1. Input range Input byte (chain number *32) to (chain number *32) +7, i.e. from input byte 32 to input byte 39 for operation in chain 1 2. Output range Output byte (chain number *32) +8 to (chain number *32) +11, i.e. from output byte 40 to output byte 44 for operation in chain 1 Only one I/O module is possible per chain.
7 NCU Terminal Block 6FC5211-0AA00-0AA0 X20: Interface with the drive bus X21: Interface with the next NCU terminal block 2.5mm2 24V 0V 4 3 21 Shielding plate X9: Terminal external 24 V logic power supply DMP compact module slots 100 1 PE conductor connection 2 3 4 5 6 7 8 74.4 Status LED green: 5V OK Status LED yellow: Internal fault terminal block Status LED red: External fault (drive bus interface) 237 257 Depth: 40 mm or 130 mm (with DMP compact module) Fig.
7 NCU Terminal Block Connection to the drive bus ! The terminal block is connected to connector X20 on the drive bus of the last drive module via round cables. These cables are available in different lengths. (cable lengths 1, 2, 5, and 10 m). Up to 2 terminal blocks can be operated (in accordance with the available NCK addresses for rapid analog and digital I/Os). The round cables are also used in conjunction with individual terminal blocks.
7 NCU Terminal Block EMC measures The PE conductor connection is also used to conduct interference currents away from: the shields of the DMP casing, the DMP compact plug-in modules, the 24 V logic power supply. To ensure that these interference suppression measures are effective, there must be a low-resistance connection between the shielding plate and ground potential.
7 NCU Terminal Block Monitoring functions +5 V monitoring Temperature monitoring 60 C "3 C Configuration monitoring Sign-of-life monitoring (watchdog) of the microcontroller Sign-of-life monitoring of the NC Fault Acquisition Effect Undervoltage (< 4.
7 NCU Terminal Block X20/X21 X X11–X18 Drive bus interface Connector name: Connector type: Special features: Caution: Module connector Connector name: Connector type: Table 7-2 X20 (IN) X21 (OUT) 36-pole micro ribbon Non-isolated, no protective separation Max. length of the drive bus is 10 m X11 ... X18 (slots 1 ... 8) 30-pole male connector ELCO Microleaf Technical data of the NCU terminal block Mechanical data Dimensions Weight Height Width Depth 100 mm 257 mm 40 mm Approx. 0.
7 NCU Terminal Block Notes 7-96 Copyright © Siemens AG 2006 SINUMERIK 810D Equipment Manual Configuration CCU (PHC) – 03/2006 Edition
8 DMP Compact Modules Mounting The following dimensions must be observed when mounting: Table 8-1 Dimensions of the DMP compact modules Width 25 mm Height 90 mm 115 mm with plugged in connecting plugs 130 mm with terminal block 8.1 Depth 108 mm Degree of protection IP20 or IPXXB DMP compact module 16I (6FC5111-0CA01-0AA0) The DMP compact module 16I is an encapsulated module. It can be plugged into a slot of the NCU terminal block as a plug-in module.
8 DMP Compact Modules 8.1 DMP compact module 16I (6FC5111-0CA01-0AA0) Interfaces A 30-pole connector X1 for connection to the NCU terminal block. Two 10x terminals X2 and X3 (Phoenix, Type MC1.5/10-ST-3.81 GREY, order no. for X3 and X2: 18 28 171) for connecting the 16 inputs and the load power supply. The terminals are pluggable and can be mechanically coded by the customer. The 24 V terminal P is not used Display elements 16 LEDs as a status display for the logical states of the inputs.
8 DMP Compact Modules 8.2 DMP compact module 16O (6FC5111-0CA02-0AA2) 8.2 DMP compact module 16O (6FC5111-0CA02-0AA2) The DMP compact module 16O is an encapsulated module. It can be plugged into a slot of the NCU terminal block as a plug-in module. 24 VLOAD DC 1.5 0V X3 X3 Status LEDs Labeling strips 0 . . 7 LOW byte 0 . . 7 HIGH byte Fixing screw Outputs OUT 0 ... OUT 7 LOW byte M = GND Interfaces P M 7 6 5 4 3 2 1 0 0 1 2 3 4 5 6 7 M P X2 X1 X2 Fig. 8-2 Outputs OUT 7 ...
8 DMP Compact Modules 8.2 DMP compact module 16O (6FC5111-0CA02-0AA2) Table 8-3 Technical data of DMP compact module 16O Output load for signal “1” (rated value) – Ohmic load – Lamp load – Inductive load 500 mA 5W 500 mA Short-circuit protection Yes Power loss at 30 V Max. 3.
8 DMP Compact Modules 8.3 DMP compact module 8O (6FC5111-0CA03-0AA2) 8.3 DMP compact module 8O (6FC5111-0CA03-0AA2) The DMP compact module 8O is an encapsulated module. It can be plugged into a slot of the NCU terminal block as a plug-in module. 24 VLOAD DC 2.5 0V X3 Status LEDs X3 P M7 6 5 4 X2 0 1 2 3 MP Outputs OUT 7 ... OUT 4 0 . . 7 Labeling strips X1 Fixing screw X2 Outputs OUT 0 ... OUT 3 0V 24 VLOAD DC 2.5 M = GND Fig.
8 DMP Compact Modules 8.3 DMP compact module 8O (6FC5111-0CA03-0AA2) Table 8-4 Technical data of DMP compact module 8O Number of outputs 8 digital outputs Galvanic isolation Yes Power supply VLOAD – Rated value – Perm. range – Ripple 24 V DC 20.4 V to 28.8 V 3.6 Vpp Signal level of the outputs (typically) – For signal “0” – For signal “1” Open Vload –80 mV Output load for signal “1” (rated value) – Ohmic load – Lamp load – Inductive load Short-circuit protection Yes Power loss at 30 V Max. 3.
8 DMP Compact Modules 8.4 DMP compact module 1I analog (6FC5111-0CA04-0AA0) 8.4 DMP compact module 1I analog (6FC5111-0CA04-0AA0) The DMP compact module 1I analog is an encapsulated module. It can be plugged into a slot of the NCU terminal block as a plug-in module. (Maximum of 4 modules per terminal block) The conversion time is a max. of 60 ms in the rated range and a max. of 80 ms in the overshoot range. P1 P2 M1 M2 24 V DC 2.
8 DMP Compact Modules 8.4 DMP compact module 1I analog (6FC5111-0CA04-0AA0) Analog value representation The DMP compact module 1I analog is used to input and digitize an analog voltage value. This voltage value is measured by an isolated differential input. In conjunction with the installed constant current source (2.5 mA), it is possible to connect PT100 resistance thermometers. Conversion time Table 8-5 The conversion time depends on the level of the input voltage.
8 DMP Compact Modules 8.4 DMP compact module 1I analog (6FC5111-0CA04-0AA0) Example circuits Analog voltage measurement X2 S 6 X2 M – + S 5 4 3 2 1 M – + S 5 4 3 2 1 Differential input (common-mode disturbances are suppressed) Measurement with PT100 U S 6 S 6 X2 M – + I S 5 4 3 2 1 S 6 U Unipolar (default) X2 M – + I S 5 4 3 2 1 PT100 with 2-wire connection PT100 with 4-wire connection Fig.
8 DMP Compact Modules 8.5 DMP compact module 1I NC analog (6FC5211-0AA10-0AA0) 8.5 DMP compact module 1I NC analog (6FC5211-0AA10-0AA0) The DMP compact module 1I NC analog is an encapsulated rapid analog input module with 75 ms access time. It can be plugged into a slot of the NCU terminal block as a plug-in module (maximum 4 modules per terminal block). P1 P2 M1 M2 24 V DC 2.
8 DMP Compact Modules 8.5 DMP compact module 1I NC analog (6FC5211-0AA10-0AA0) Analog value representation The DMP compact module 1I NC analog is used to input and digitize an analog voltage value. This voltage value is measured by an isolated differential input. The converter result is available to the user in the form of two’s complement. The resolution is 4.88 mV for one bit. The duration for a converter cycle (from triggering of conversion to the time at which the result can be read out) is max.
8 DMP Compact Modules 8.5 DMP compact module 1I NC analog (6FC5211-0AA10-0AA0) Table 8-8 Technical data DMP compact module 1I NC analog Number of inputs 1 analog input Galvanic isolation Yes Power supply VLOAD – Rated value – Perm. range – Ripple 24 V DC 20.4 V to 28.8 V 3.
8 DMP Compact Modules 8.6 DMP compact module 1O analog (6FC5111-0CA05-0AA0) 8.6 DMP compact module 1O analog (6FC5111-0CA05-0AA0) The DMP compact module 1O analog is an encapsulated module. It can be plugged into a slot of the NCU terminal block as a plug-in module. (Maximum 4 modules per terminal block) P1 P2 M1 M2 24 V DC 0V X3 Status LEDs 1.5 Connecting terminals POWER SUPPLY OK Labeling strips ANALOG OUT Fixing screw X1 4 3 2 1 X2 2.5 Fig. 8-8 Interfaces Terminal: 1, 4 ...
8 DMP Compact Modules 8.6 DMP compact module 1O analog (6FC5111-0CA05-0AA0) Table 8-9 Digital analog value representation DMP compact module 1O analog Output word QB m Significance 7 6 5 4 3 2 1 0 SG 212 211 210 29 28 27 26 Analog output voltage QB m+1 7 6 5 4 3 2 25 24 23 22 21 20 1 0 always 0 Digital value 0 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 +9.9988 V 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 +1.
9 Maintenance and Service 9.1 Battery replacement (6FC5247-0AA18-0AA0) Battery Fig. 9-1 ! CCU module: Location of battery Danger Do not attempt to reactivate discharged batteries with heat or by any other means. The batteries must not be recharged because this could cause leakage and/or explosion. Non-compliance can cause injury to people or damage to property.
9 Maintenance and Service 9.1 Battery replacement (6FC5247-0AA18-0AA0) The CCU module features battery-backed SRAMs and clock modules. The back-up voltage is monitored by the control and a monitoring signal is output. The battery must be replaced within 6 weeks of the monitoring responding. The battery can be replaced after the controller has been switched off without any loss of data, as data is retained for approximately 15 minutes.
Abbreviations A AC Alternating Current AT Advanced Technology C-bus Communication Bus CCU Compact Control Unit CE Communauté Européenne – European Community CNC Computerized Numerical Control COM Communication module CPU Central Processor Unit DC Direct Current DMP Distributed Machine Peripherals (I/Os) DP Distributed I/Os DRAM Dynamic RAM: Dynamic memory (volatile) EMC Electromagnetic Compatibility EnDat Absolute encoder interface, Heidenhain ESD Electrostatic Sensitive Devic
A Abbreviations LED Light Emitting Diode MCP Machine Control Panel MLFB Machine-Readable Product Designation (order no.) MPI Multi Point Interface: Multi-point serial interface MS Mains Supply MSD Main Spindle Drive NC Numerical Control NCK Numerical Control Kernel: NC kernel with block preparation, traversing range, etc.
B Index Numbers D 2-axis CCU box, 4-74 3-axis CCU box, 4-71 Backup battery, transportation, 2-32 Battery replacement, 9-111 DAC measuring sockets, 4-59 DC power supplies, 2-24 Device bus, X151, 4-56 Dimension drawing 2-axis CCU box, 3-42 3-axis CCU box, 3-41 Display elements, 4-59 DMP compact module, 8-97 16I, 8-97 16O, 8-99 1I analog, 8-103 1I, NC analog, 8-106 1O analog, 8-109 8O, 8-101 Drive bus, X130, 4-56 Drive functions of SIMODRIVE 611D, 4-49 Dust that can adversely affect function, 2-33 Duty c
B Index I N I/O interface, X121, 4-54 Installation altitude, 4-71, 4-74 Interface configuration, for MPI bus, HHU, HT 6, 1-15 with PLC I/Os and NCU terminal block, 1-16 Interfaces, 4-50 Description, 4-52 NCU terminal block, 7-91 DMP compact modules, 7-93 EMC measures, 7-93 Monitoring, 7-94 Power supply, 7-94 Terminal, 7-92 Terminator, 7-92 X11-X18, 7-95 X20/X21, 7-95 Noise immunity of the complete system, 2-30 K K-bus, X111, 4-53 O Operating conditions, 2-32 Operator controls, 4-59 L L2-DP interface,
B Index S T Sensor systems, 4-64 Service, 9-111 Shielded signal cables, 2-29 Shielding plate, mounting, 3-41 Siemens PC card, 4-76 Signal curve of incremental encoders, 4-64 Single I/O, address space, 6-89 Single I/O module, 6-83 Dimension drawing, 6-84 Electronics power supply, 6-86 EMC, 6-84 Inputs/outputs, 6-87 LED, 6-87 Load power supply, 6-86 Technical data, 6-85 Terminal, 6-83 X402, 6-87 X404, 6-88 X405, 6-89 Storage conditions, 2-31 Structure of the SINUMERIK 810D, 3-37 Supplementary conditions, e
B Index Notes B-118 Copyright © Siemens AG 2006 SINUMERIK 810D Equipment Manual Configuration CCU (PHC) – 03/2006 Edition
To SIEMENS AG A&D MC MS Postfach 3180 Suggestions D–91050 Erlangen SINUMERIK 810D Configuration CCU Corrections For publication/manual: Phone: +49 (0) 180 5050 – 222 [Hotline] Fax: +49 (0) 9131 98 – 63315 [Documentation] mailto:motioncontrol.docu@siemens.com Equipment Manual From Order No.: Edition: Name Company/Dept.
Documentation overview SINUMERIK 840D/840Di/810D (03/2006) General documentation SINUMERIK Brochure SINUMERIK 840D 840Di 810D Catalog NC 60 *) Safety integrated Safety Integrated Application Manual User documentation SINUMERIK 840D 840Di 810D Operating Manual – HMI Embedded *) – ShopMill – ShopTurn – HT6 SINUMERIK 840D sl 840D 840Di sl 840Di 810D Operating Manual – HMI Advanced *) – Operation compact SINUMERIK 840D sl 840D 840Di sl 840Di 810D SINUMERIK 840D sl 840D 840Di sl 840Di 810D Programmin
