manual_configuring_810d.pdf

5/17/2018 Manual_Configuring_810D.pdf

1/149

SINUMERIK 810DSoftware Version 4

Manual 10.2000 Edition

Configuring CCU1/CCU2

Manufacturer/Service Documentation


2/149

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



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


ManualTurn ShopMill

Description ofFunctionsSynchronizedActions

840D/810D

SINUMERIK

Operators Guide ManualTurn Short Guide ManualTurn ShopMill Short GuideShopMill

840D/810D


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


Hydraulics Module Analog Module

SINUMERIKSIMODRIVESIROTEC

EMCGuidelines


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/


3/149

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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vSiemens AG 2000. All rights reserved.SINUMERIK 810D Manual Configuring HW (PHC) 10.00 Edition

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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SINUMERIK 810D Manual Configuring HW (PHC) 10.00 Edition

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

Preface

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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).


Preface


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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


Preface

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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

10.00 Manual Configuring SINUMERIK 810D

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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1-11Siemens AG 2000. All rights reserved.SINUMERIK 810D Manual Configuring HW (PHC) 10.00 Edition

System Overview


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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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

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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

1 System Overview


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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

1 System Overview


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2.1 Ambient conditions

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Connection 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

2


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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

2 Connection Conditions 10.00


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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

2 Connection Conditions12.98


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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)


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


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


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


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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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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Notes

04.00


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3.1 Design of the SINUMERIK 810D

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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

3

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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

3 Design and Assembly 07.96


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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)



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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4.1 Components of the SINUMERIK 810D

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Description 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)

4 Description of the SINUMERIK 810D

4

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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

4 Description of the SINUMERIK 810D 08.99


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4.2 Interfaces on the SINUMERIK 810D

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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

4 Description of the SINUMERIK 810D04.00


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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


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


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

4 Description of the SINUMERIK 810D04.00


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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

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4.3 Measuring system

4.3.1 Assignments between measuring systems and motor

connections

There is a fixed assignment between

manual_configuring_810d.pdf

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