810d Configuration PDF
810d Configuration PDF
810d Configuration PDF
Connection Conditions 2
I/O Modules 6
Abbreviations A
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.
A . . . . . New documentation.
B . . . . . Unrevised reprint with new order no.
C . . . . . Revised edition with new status.
Trademarks
All product names mentioned may be trademarks or product designations of Siemens AG or their suppliers,
whose use by third parties for their own purposes may infringe the rights of the trademark owners.
Benefits The information in this manual enables installation of the SINUMERIK 810D
Numerical Control and measures for maintenance and service.
Standard version This documentation only describes the functionality of the standard version.
Extensions or changes made by the machine tool manufacturer are documen-
ted by the machine tool manufacturer. Other functions not described in this
documentation might be executable in the control. This does not, however,
represent an obligation to supply such functions with an initial delivery or when
servicing.
For the sake of simplicity, this documentation does not contain all detailed infor-
mation about all types of the product and cannot cover every conceivable case
of installation, operation, or maintenance.
Technical Support If you have any questions about the control, please contact the hotline:
Europe and Africa time zone
A&D Technical Support
Tel.: +49 (0) 180 / 5050 222
Fax: +49 (0) 180 / 5050-223
Internet: http://www.siemens.com/automation/support-request
E-Mail: mailto:adsupport@siemens.com
Note
Country-specific telephone numbers for technical support are provided under
the following internet address:
Enter http://www.siemens.com/automation/service&support
Questions about For questions on the documentation (suggestions, corrections), please send a
the manual fax or e-mail to the following address:
Fax: +49 (0) 9131 / 98 – 63315
E-Mail: mailto:motioncontrol.docu@siemens.com
Fax form: see the reply form at the end of the brochure
SINUMERIK http://www.siemens.com/sinumerik
Internet address
Safety instructions This manual contains information which you should observe in order to ensure
your own personal safety, as well to avoid material damage. Notices which are
relevant to your own personal safety are highlighted by a safety alert symbol;
notices which are relevant only to equipment and property damage have no
safety alert symbol. The warnings appear in decreasing order of risk as given
below.
Danger
! indicates that death or serious injury will result if proper precautions are not
taken.
Warning
! indicates that death or serious injury may result if proper precautions are not
taken.
Caution
! with a safety alert symbol, indicates that minor personal injury may result if
proper precautions are not taken.
Caution
without a safety alert symbol, indicates that property damage can result if
proper precautions are not taken.
Notice
indicates that an undesirable event or state may arise if the relevant notes are
not observed.
If several hazards of different degrees occur, the hazard with the highest degree
must always be given priority. If a warning note with a warning triangle warns of
personal injury, the same warning note can also contain a warning of material
damage.
Warning
! The equipment may only be used for single purpose applications explicitly
described in the catalog and in the technical description and it may only be
used along with third-party devices and components recommended by
Siemens. To ensure trouble-free and safe operation of the product, it must be
transported, stored and installed as intended and maintained and operated with
care.
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.
After disconnecting all the supply voltages, a hazardous voltage will be present
in the DC link of all SIMODRIVE modules for another 5 minutes!
See Operating Guide
Danger
! Repairs to devices that have been supplied by our company must only be
carried out by SIEMENS Customer Service or by repair centers
authorized by SIEMENS. When replacing parts or components, only use
those parts that are included in the spare parts list.
Before opening the equipment, always ensure that the power is off.
EMERGENCY STOP devices complying with EN 60204 (VDE 0113 Part 1)
must remain effective in all automation equipment modes. Resetting the
EMERGENCY STOP device must not cause an uncontrolled or undefined
restart.
Warning
! Connecting cables and signal cables should be installed so that inductive and
capacitive interference does not in any way impair the automation functions.
Warning
The modules contain electrostatically sensitive devices. Discharge yourself of
electrostatic energy before touching the components. The easiest way to do
this is to touch a conductive, grounded object immediately beforehand (for
example, the bare metal part of control cabinet or the protective ground contact
of a socket outlet).
Important
! Handling of modules containing devices sensitive to electrostatic discharge:
Other information
Important
! This notice indicates important facts that must be taken into consideration.
Note
This note contains additional important information.
Notes
Since 03.2002
Module Description
CCU3 with additional pulse interface and 2 machining channels
CCU3.4 like CCU3, but with increased NC performance and PLC 314C-2DP
Note
SINUMERIK 810D powerline and SINUMERIK 810DE powerline are delivered
with software version 6.
Earlier software versions of SINUMERIK 810D cannot be run on
SINUMERIK 810D powerline and SINUMERIK 810DE powerline.
Table 1-2 Components of the 810D in the maximum configuration (without motors)
NCU terminal block 1) 6FC5211-0AA00-0AA0 Rapid digital and analog NC I/Os on the drive bus of the
SINUMERIK 810D
Handheld unit 1) 6FX2007-1AC.. Handheld unit with handwheel, EMERGENCY STOP button, key-
switch, override, enabling buttons, display, free keys, connection
via MPI bus and cable distributor
ÄÄ
PCU Handheld
unit HT 6
ÄÄ
MPI
cable
MCP 17 16
Cable
distributor
Encoder cable
direct
measuring system
Measurement (2x) *)
14
Handwheel (2x)
OI
or
I/R MSD 810D FSD FSD
(CCU3)
14
Axis
expansion Axis Terminal block
plug-in expansion
15 plug-in
unit SIMATIC
unit
IM cable
Motor cable 1x 2x 2x 1x
Motor encoder 5x 611
cable power
module
Single
SIMATIC
I/O module
Direct measuring Profibus I/O
system Motors
(e.g. on the X416) e.g. 1FNx, 1FEx, 1FKx *) One measurement input can be replaced by a 3rd handwheel
Fig. 1-1 System of the SINUMERIK 810D, for example, the CCU3
QWERTY Floppy/interface
Connection on left side of housing
PCU50
(right side of
COM1/RS232/PLC housing)
COM2 MPI/DP
MCP
X20
(Rear view)
HHU or HT 6
ÄÄ
ÄÄ Distributor box
X1 X5
16 X2
Handwheel
Shield
–X102
–X122
4
MPI cable
Fig. 1-2 Interface configuration of the SINUMERIK 810D for the MPI bus, HHU, HT 6 and cable distributor
X2
PS IM SMs
8
SIMATIC S7-300 IM connecting cable
CCU3
–X411
–X412
–X413
–X121
8
–X414
–X415
–X416
–X102
1)
–X431
MEMORY CARD
–X307
–X130
–X306
–X305 –X304 Connecting cable shielded
Terminal block
Terminator
1) Pay attention to maximum configuration !!
Fig. 1-3 Interface configuration of the SINUMERIK 810D for PLC I/Os and NCU terminal block
Connecting The following connecting cables are used for the SINUMERIK 810D
cables
Table 1-3 Connecting cables for SINUMERIK 810D
Axis expansion on On the SINUMERIK 810D, the number of axes can be expanded to six axes,
810D 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.
Axis expansion The axis expansion plug-in units are used whenever no more than six measur-
plug-in unit ing channels are required for the SINUMERIK 810D. This plug-in unit is plugged
into a SIMODRIVE 611 power module. The axis expansion plug-in units are
designed for 1-axis and 2-axis power modules. The ribbon cables are part of the
plug-in unit.
Axis expansion If the six measuring channels of the SINUMERIK 810D are insufficient,
control SIMODRIVE 611 controller plug-ins must be inserted into the SIMODRIVE 611
plug-in unit power modules to connect further measuring systems (connection via drive bus
with drive bus terminator). If 611D control modules are used, it may be neces-
sary to connect the NCU terminal block to the free drive bus connector of the
611D control.
See Chapter 5, Axis expansion
Power modules The CCU can control up to 6 axes onboard. For this purpose there is a new
expansion plug-in in addition to the existing axis expansion plug-in modules.
All power modules of the 611D series can be connected as external power
modules for axis expansion.
CCU 3
6x encoder
connection {
If no external power module is
internal/ connected on connector -X307
external (internal/external pulse interface 3rd
X307
Fig. 1-4 First way of operating 6 axes on CCU3 with internal 3 axis CCU box
{
CCU 3
6x encoder
connection
If an external power module
is connected to connector
-X307, then the 3rd internal
power module will be
internal/ switched to the external
external power module. On a 3-axis
X307
cannot be used.
25 A 25 A
Fig. 1-5 Second way of operating 6 axes on CCU 3 with 2 axis CCU box
Restrictions
Power supply: 120 kW.
The DC link busbar of the 810D is capable of an effective load of 200 A.
The length of the ribbon cable of the axis expansion plug-in unit left for con-
necting the SIMODRIVE 611 power module is 300 mm.
The length of the ribbon cable of the axis expansion plug-in unit right is suffi-
cient for a module width of 150 mm.
The length of the cable set for the axis expansion with 611D control plug-in
unit is:
62 mm for the drive bus and 150 mm for the device bus.
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:
SIEMENS A B C D E
570 573.9001.00
SINUMERIK 810D
Power module 2x15A + 1x50A
6FC5 447-0AA00-0AA1
Made in Germany
A B C
Notes
Compliance with The controller is tested for compliance with the ambient conditions specified
the connection below. Fault-free operation is only ensured if:
conditions
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.
Danger
! The equipment may not be commissioned until it has been clearly identified
that the machine in which the controller is installed is in full conformance with
the specifications in EC Machinery Directive 98/37/EC.
Assistance and The connection conditions must be carefully maintained for the complete
support system. Please contact your local Siemens office or representative for any
assistance.
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.
Restoration time 50 s
Restoration time 10 s
Events per hour 10
Configuration The EP and CP points for the power modules only apply in conjunction with the
810D power SINUMERIK 810D (axis expansion). The EP and CP points from Catalog NC 60
consumption apply when SIMODRIVE 611D modules with control plug-in units are used.
Table 2-3 Example of calculation of the supply power for 4 axes/1 spindle for 810D
The complete system includes end user interfaces (UIs) and interfaces for
servicing, commissioning and maintenance.
End user UIs are all the interfaces that are freely accessible to the machine operator
interfaces (UI) without the need for tools or aids. These user interfaces are designed with safe
isolation to EN 61800-5-1.
Interfaces for
servicing,
commissioning
and maintenance
Danger
! The interfaces for servicing, commissioning and maintenance purposes are
provided without safe isolation.
Danger
! Safe isolation can only be ensured if the system configuration specified below
is strictly adhered to. When mounting additional components (e.g. S7-300 FM,
IP) with an end user interface, please make sure that the end user interface
has a basic insulation for at least 230 V AC.
3 x 400 V AC
Housing/shield 8
MSTT/MCP
1 PCU
4 11 24V M (GND)
4 4
2 11
3 HHU/
HT 6
ÎÎÎ
Distributor box 4 6 7
5
810D/611 digital Machine
9
10 S7-300 I/Os
10
M (GND)
11
5 Person Terminal
block
Fig. 2-1 shows the potential balance of the 810D/611D/S7-300 system. Legend:
1. Floating power supply of the SIMODRIVE electronics unit with 230 V AC
basic insulation.
2. Floating transistor triggers for the three-phase rectifier bridge with 230 V AC
basic insulation.
3. Floating transistor triggers for each axis of the three-phase inverter bridge
with 230 V AC basic insulation.
4. Floating signal connection from the CCU to the PCU or HHU/HT 6 with
230 V AC basic insulation.
5. Non-floating signal line between CCU and I/O devices.
6. Non-floating end user interface with protective separation for 230 VAC
through interfaces 1 to 4 and 7.
7. Protectively separated 5 V DC power supply, fed from a protectively separa-
ted 24 V DC supply.
8. 24 V DC power supply unit for external devices and for the machine adapta-
tion control according to applicable standards in the form of a PELV (Protec-
tive Extra Low Voltage) circuit featuring safe isolation.
9. Floating interfaces to the machine (not accessible to the end user).
10. Floating signal interfaces directly accessible to the end user (e.g. V.24). For
these interfaces, you must always make sure that there is either safe isola-
tion with respect to the line supply voltage or that there are two basic insula-
tion levels, for 230 V AC each.
11. 5 V DC power supply with basic insulation, fed from a safely-isolated
24 V DC supply.
CCU box
Machine control panel MCP
Keyboard
Operator panels (operator panel front + PCU/TCU)
NCU terminal block
Distributor box and handheld unit
S7-300 I/O with IM 361 interface module
Single I/O module
CCU box and SIMODRIVE components are fixed to a metal cabinet plate with
screws. Make sure that near the screws a low-impedance contact of the CCU
box with the cabinet panel can be made. Insulating varnishes must be removed
where possible. The connection must be kept free of corrosion.
The electronics grounds of the modules are interconnected via the unit and con-
trol bus and also routed to terminal X151 of the NE module.
The ground and module ground M should be connected at the power supply
terminal of the IM 361. Further, for the EFP, “SHIELD” and “M24” must be con-
nected in connector X1.
ÏÏÏ
ÏÏÏ Gating Power Distributor
ÏÏÏ
electronics electronics box
CCU
SL
Operator PCU/ Machine
panel front TCU control panel
MB
Grounding bar
MB: Shielded signal cable with reference ground
M: Motor
Central ground connection G: Encoder
conductor/protective
PA: Equipotential bonding conductor
conductor Cross-sections (mm2)
SL: Protective conductor w10
Line supply connection S SL minimum
S v 16 S
16 < S v 35 16
S > 35
S/2
These external devices may not be connected to the control during normal ope-
ration. 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 Definition:
definitions
Signal cables (e.g.)
– Data cables (MPI, sensor cables, etc.)
– Binary inputs and outputs
– Emergency Stop cables
Rules for routing In order to achieve the best possible noise immunity of the complete system
cables (control, power module, machine), the following EMC measures must be care-
fully observed:
Signal cables and load cables must be routed at the greatest possible
distance from one another.
If necessary, signal and load cables may cross one another (if possible, at
an angle of 90°), but must never be laid close or parallel to one another.
Signal cables may not be routed close to strong external magnetic fields
(e.g. motors and transformers).
If signal lines cannot be routed a sufficient distance away from other cables,
they must be installed in grounded cable ducts (metal).
Important
! For further notes on interference suppression measures and the connection of
shielded cables, please refer to
References: /EMV/, EMC Configuring Guidelines.
Transportation Storage
Ambient temperature –40 ... 70 °C –25 ... 55 °C
range
Rate of temperature <18 K <18 K Within one hour
change
Relative humidity 10 ... 95 % 10 ... 95 %
Permissible change max 0.1 % max 0.1 % Within 1 minute
in relative air humi-
dity
Shipment of Backup batteries must only be transported in the original packaging. No special
backup batteries 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.
Danger
! Incorrect handling of backup batteries can lead to a risk of ignition, explosion
and combustion. The stipulations of EN 60086-4, in particular regarding
avoidance of mechanical or electrical tampering of any kind, must be complied
with.
Climatic If the specified values cannot be maintained, then a heat exchanger or air con-
environmental ditioner must be provided.
conditions
Table 2-7 Climatic environmental conditions to EN 60721-3-3, Class 3K3
Mechanical
environmental
conditions
Table 2-8 Test limits for mechanical environmental conditions
Dust that can When working in areas where gases, dust and oils may be hazardous to func-
adversely tionality, the controller must be operated in a control cabinet with a heat exchan-
affect the function ger or with suitable supply air.
Maximum permissible dust contents in the air circulating in the cabinet:
– Suspended solids 0.2 mg/m3
– Deposits 1.5 mg/m2/h
Note
The dust precipitate must be removed at appropriate time intervals.
Table 2-9 Limit values for radio interference suppression in industrial environments
Note
The user must consider interference radiation for the complete system.
Particular attention should be paid to cabling. Please contact your sales
representative for assistance and support.
If compliance with limit value class B (residential areas) is required, please
contact your local Siemens office or representative.
Security
Protection class I (protective conductor) as per EN 61800-5-1
Degree of protection IP20 or IPXXB
per EN 60529
Approvals CE / cULus
Degree of contamination 2
Cooling Open circuit ventilation
Mechanical environmental conditions
Transport 2M2 according to EN 60721-3-2
(in transport packaging)
Storage 1M2 according to EN 60721-3-1
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
Table 2-11
ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
Mechanical data
Weight
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
Dimensions
Component in kg
width x height x depth in mm
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
(approx.)
CCU box 150 x 490 x 268
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
CCU
3 axes
ÁÁÁÁÁ
2 axes
Internal heat dissipation
Internal and external heat dissipation
150 x 307 x 220
11.3
11.4
1.6
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ
Single I/O module
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
NCU terminal block
50 x 374 x 153
257 x 100 x 40
1.7
0.5
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.
Note
Only two inserted terminating resistors are permitted.
In the case of the HHU/HT 6, bus terminating resistors are permanently
integrated in the device.
Notice
The CCU must be located at the end of the connection.
Note
Unused stubs must be removed.
46 46
OFF On
O O
N N
55
Terminating resistor
Open equipment 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 pro-
tection casing is required.
Preparing for You require the following tool to assemble the SINUMERIK 810D:
installation
Screwdriver for slot-head screws sizes 0 and 1
Screwdriver for Torx screws M4 and M5
Position in the The CCU box must be installed to the right of the SIMODRIVE power supply
overall assembly module. It is possible to mount a further power module to the left of the box.
Installation of the The CCU box is fitted to the right of the power supply. 4 M5 screws are recom-
CCU box mended for fixing.
1. Remove the plastic cover over the DC link bars by loosening it with a flat
screwdriver in the gap on the top and then folding it forward and down.
2. With two M4 Torx screws, connect the DC link bars of the power supply unit
and CCU box and possibly the next module also.
Ensure that all the DC link connecting screws are securely fastened.
3. Place the cover into the matching cut-outs with the plastic lugs facing down-
ward and close the DC link by folding the cover backward until the topside
latch clicks.
SIEMENS
SIMODRIVE
Fig. 3-2 Overall assembly SINUMERIK 810D with SIMODRIVE 611 power module
Battery
–X307
DC link
rails
PE conductor connection
Installation Pay attention to the following when installing the SINUMERIK 810D:
instructions
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. The equipotential bonding conductor must be connected for each motor.
4. Additional mounting depth is required for mounting the connector.
5. The tightening torque of the screws must be complied with.
6. The screws of the DC link busbars must all be tightened.
Mounting the The metal sheet is mounted on the 3-axis CCU box with the 3 screws on the
shielding plate underside (2-axis CCU box, see figure Mounting the shielding plate). The shiel-
ding plate is supplied in the box. The tube clip for connecting the shield is con-
tained in the scope of supply of the ready-assembled SIEMENS motor cable.
100
130 Cooling clearance 100 mm
The tightening
torque must be
complied with
when mounting
modules!!
443
466
480
M3: 0.8 Nm
M4 : 1.8 Nm
M5 : 3 Nm
M6 : 6 Nm
Motor connection
A3 A2 A1
Cooling
100
clearance
120
100 mm
25 100
150
288
Equipotential bonding terminal
Shielding plate
100
The tightening torque
must be complied
with when mounting
modules!!
0.3
M3: 0.8 Nm
480
+ M4 : 1.8 Nm
466
M5 : 3 Nm
M6 : 6 Nm
443
M3
M4
100
57
20
8
24.85
90 0.2
77 110
View without
100 0.2 protective cover
Darstellung ohne 232
Abdeckblech
150
289
Tube clip
for shield Cooling clearance
Schlauchschelle für Schirm Lüftungsfreiraum Shielding plate
(included in the scope of supply of our Schirmblech
preassembled Siemens motor cable) Notice: Place shielded cables
entering the control cabinet as close
(im Lieferumfang unserer konfektionierten as possible to the cabinet! Screw M2.5x8
Siemens Motoranschlussleitung enthalten) Achtung: Geschirmte Leitungen Schraube M2.5x8
beim Eintritt in den Schaltschrank
e.g. made by Rasmussen GmbH kürzmöglichst am Schrank auflegen!
D–63461 Maintal
Postfach 1149 Attention! The shield attachment
Phone: 06181-403-0 is not for strain relief
Fax: 06181-403-210 Achtung! Die Schirmauflage
ist keine Zugentlastung
Loosen M6 screws
and remove bracket
Schrauben M6 lösen
und Winkel abnehemen
Fig. 3-7 2-axis CCU box: Alteration for external heat dissipation
A1 A2 A3
Equipotential
bonding terminal
Attachment point for
ÁÁ ÁÁÁÁ
motor brake plug
connection
ÁÁ
Equipotential
bonding Shielding plate
terminal
Tube clip
Shield connection
Motor cables 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
Fig. 3-8 Terminal for motor and encoder cables (3-axis CCU box)
Permissible
modules Power supply module: OI 5 kW, OI 10 kW, OI 28 kW,
I/R 16 kW, I/R 36 kW, I/R 55 kW; I/R 80 kW;
I/R 120 kW
Note
The power supply and filter modules/reactors are described in the
Configuration Manual Converters SIMODRIVE 611 digital (settings, technical
data, circuit suggestions).
Danger
! A hazardous voltage will be present for a further 5 minutes after the system has
been shut down.
Notes
4.1.1 Overview
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).
2-axis CCU box Basic housing with fan for fitting the CCU module with two integrated power
modules 9A/18A (FSD) and slot for CCU module (internal and external heat
dissipation).
CCU The CCU module (Compact Control Unit) of the SINUMERIK 810D performs all
module CNC, PLC, communication, and closed-loop control tasks. The CCU has 6
measuring channels. Each drive requires one measuring channel for the motor
measuring system. If measuring channels of the basic unit are left over, they
can be assigned freely as direct measuring channels, e.g. for the spindle.
Additional measuring channels are obtained by using a 611D closed-loop con-
trol module (1- or 2-axis control module) with or without a direct measuring
system (DMS). The 611D closed-loop control module performs closed-loop con-
trol of the drive. The unused measuring channels can be freely assigned.
PCMCIA card The NC card with the system software must remain inserted during
(NC card) operation.
Note
For a software upgrade, the export software can be copied onto the internal
flash EPROM.
In addition to the software upgrade, the PCMCIA card can also be used for
series commissioning; see
References: /IAC/, Commissioning Manual 810D
Closed-loop The closed-loop control complies with the 611D standard control with the
control following restrictions as compared with SINUMERIK 840D:
5-axis transformation
Safety integrated
Analog axis
Hydraulic drives
Drive-independent stop/retract
3D clearance control
Drive functions of The following table shows drive functions and values, which differ from module
SIMODRIVE 611D to module.
4.2 Interfaces
4.2.1 Overview
Interface CCU
Pulse interfaces (6 axes) 4 **)
Optical encoder 6
Closed-loop
Cl dl DAC test sockets Yes
control
BERO input Yes
Terminals (AS1, AS2, 663, 9,19) Yes
PBus/KBus Yes
MPI interface Yes
Drive bus (611D interface) Yes
NCK/PLC Connection for diff. handwheel Yes
Two measuring pulse inputs Yes
PCMCIA interface Yes
PROFIBUS DP Yes
Miscella- Electronic PS (backplane) Yes
neous
I/O interface
Meas. system (cable
terminals distributor)
X411-X416
P-bus/K-bus
interface
Profibus DP
Terminal
MPI interface block
Measuring 611D drive
sockets bus (master)
Various error
and status LEDs
(H1/H2) PCMCIA
-X431
+5V PR
slot
NF PS
AS1
Pulse interface SF PF AS2
CB PF0
(axis 3) external – -
663
9
7-segment B
display 19
NCK
RESET button
commissioning
switch (S3)
PLC
commissioning
Pulse
switch (S4)
interfaces
(axes 4 - 6)
Device bus
interface X151
Fig. 4-1 SINUMERIK 810D with CCU 3, position of the interfaces, operating and display elements
X102
Pin Name Type Pin Name Type
1 Not assigned 6 P5EXT VO
2 M24EXT *) VO 7 P24EXT *) VO
3 RS_L2DP B 8 XRS_L2DP B
4 ORTSAS_L2DP O 9 IRTSPG_L2DP I
5 M5EXT VO
X111 P-bus/K-bus
Connection of S7-300 I/O and single I/O module
Connector name: X111
Connector type: 25-pole D-Sub socket connector
Maximum cable length: 10 m
Special features: non-isolated (no safe isolation)
X111
Pin Name Type Pin Name Type
1 RS_ALARM_N I 14 RS_ALARM I
2 IM_ADR0_N O 15 IM_ADR0 O
3 IM_ADR1_N O 16 IM_ADR1 O
4 IM_ADR2_N O 17 IM_ADR2 O
5 M (GND) VO 18 K<2> O
6 KBUS_B_N B 19 KBUS_B B
7 RS_OD_N O 20 RS_OD O
8 RS_DIDO_N B 21 RS_DIDO B
9 RS_CLK_N O 22 RS_CLK O
10 RS_COM_N O 23 RS_COM O
11 RS_LAT_N O 24 RS_LAT O
12 RS_READY_N O 25 RS_READY I
13 Not assigned –
Signal names
RS_ALARM, RS_ALARM_N
IM_ADRi, IM_ADRi_N P-bus line number
KBUS_B, KBUS_B_N
RS_OD, RS_OD_N
RS_DIDO, RS_DIDO_N P-bus data
RS_CLK, RS_CLK_N P-bus cycle
RS_COM, RS_COM_N P-bus command
RS_LAT, RS_LAT_N
RS_READY, RS_READY_N P-bus ready signal
Signal names
PENC1 P5 power handwheel 1
PENC2 P5 power handwheel 2
MPGi_B Meas. pulse encoder (handwheel encoder) track B (i ={1..0})
MPGi_*B Meas. pulse encoder (handwheel encoder) track B inverted
(i ={1..0})
MPGi_A Meas. pulse encoder (handwheel encoder) track A (i ={1..0})
MPGi_*A Meas. pulse encoder (handwheel encoder) track A inverted
(i ={1..0})
MEPUCi Meas. pulse
MEPUSi Meas. pulse
X122
Pin Name Type Pin Name Type
1 Not assigned – 6 P5EXT VO
2 M24EXT VO 7 P24EXT VO
3 RS B 8 XRS B
4 ORTSAS O 9 IRTSPG I
5 M5EXT VO
Signal names
Analogous to X102 (table 4-3)
X341, X342, Measuring sockets for output of 3 analog signals. The measuring values
X351, X352 that are output are assigned in the software.
Connector name: X341, X342, X351, X352
Connector type: Measuring socket 2 mm
X341 DAC 3 0 – 5V
X342 Ground for all DACs
X411-X416 6 x measuring system connection for indirect and direct position sensing
Connector name: X411-X416
Connector type: 25-pole, D-Sub male connector
Signals with a gray background are not required for a direct measuring system.
X411-X416
Pin Name Type Pin Name Type
1 PENC1/2 VO 14 PENC1/2 VO
2 M (GND) V 15 ENCDATi B
3 APi I 16 M (GND) V
4 ANi I 17 RPi I
5 M (GND) V 18 RNi I
6 BPi I 19 CPi I
7 BNi I 20 CNi I
8 M (GND) V 21 DPi I
9 Not assigned – 22 DNi I
10 ENCCLK O 23 XENCDATi B
11 Not assigned – 24 M (GND) V
12 XENCCLK O 25 THMOTCOM I
13 THMOTi I
Signals with a gray background are not assigned when connecting direct measuring
systems.
Signal names
<Signal name>i means signal of the measuring system i with i = 1, ..., 6
PENC1/2 Encoder power supply
(PENC1: X411-X413, PENC2: X414-X416)
APi Incremental signal A BPi Incremental signal B
ANi Incremental signal A BNi Incremental signal B
ENCCLK BMI clock signal RPi Incremental signal R
XENCCLK BMI clock signal RNi Incremental signal R
THMOTi Motor temperature CPi Incremental signal C
ENCDATi BMI data signal CNi Incremental signal C
XENCDATi BMI data signal
DPi Incremental signal D
DNi Incremental signal D (not for direct meas. system)
XBMIDAT BMI data signal
THMOTCOM Motor temperature
Note
The encoder power supply is not stabilized; that means: no remote/sense
operation. This limits the encoder cable length.
EQN 1325: 18 m
ERN 1387: 25 m
Non-Siemens encoder with power consumption 300 mA: 18 m
X431 Terminal block for connection of starting lockout, pulse release (all drives)
and external zero mark (BERO)
Connector name: X431
Connector type: 6-pole Combicon terminal (Phoenix
connector), for 1.5 mm2 conductor cross-section
Signal names
AS1 Feedback drive enable (NC)
AS2 Feedback drive enable (NC)
T663 Control SH relay
BERO BERO input
EN+ Enable voltage (+24 V)
EN– Enable voltage (24 V reference)
Note
The “starting lockout” relay is operated with terminal 663. If opened, the control
pulses are blocked and the motors are switched torque-free.
Operating and Fig. 4-1 shows the position of the operating and display elements on the front
display elements panel.
Descrip-
Type Meaning
tion
RESET Triggering a hardware reset to reset the control and drive
Button
(S1) followed by a complete restart.
NCK commissioning switch
Position 0: Normal operation
Rotary
S3 Position 1: Clear and reset NCK
switch
Position 2: Software update NCK of memory card
Position 3...7: not used
PLC mode switch
Position 0: PLC-RUN
Rotary
S4 Position 1: PLC-RUN-P
switch
Position 2: PLC-STOP
Position 3: MRES
green LED +5V: lit when the supply voltage is within the tolerance
range.
red LED NF: lit if the NCK or PLC watchdog
has responded
LEDs
red LED SF: lit in the event of drive error. No longer lit following
(left row)
system power up in the fault-free condition.
yellow LED CB: lit when data transmission is in progress
via the MPI interface.
yellow LED P24: lit on failure of the 24V power supply
green LED PR: PLC-RUN state
LEDs red LED PS: PLC-STOP state
(right red LED PF: lit on PLC error
row) yellow LED PFO: PLC-FORCE state
yellow LED RST: lit briefly on reset.
H3 7 segment Software-assisted output of test and diagnostics messages
DAC measuring
sockets
DAC 1 DAC 2
DAC 3 Ground
Cable distributor The cable distributor splits the X121 interface of the CCU into
(I/O interface) two connections of differential handwheel,
X121
two connections of meas. pulse input,
in max. seven single cables.
90
bottom
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 S1 S2 S3 S4 S5 S6
Open x x x x
Closed x x
Location of
interfaces
1 2 3 4 5 6 7 Cable inlets
Terminal caps
Contact surfaces
Plug-in connectors
X1 X2 X3 X4 X5 X6 X7 X8 X9 X10
X1...X10
X11
Connector X1-X10
Table 4-12 Connector assignments
Motor measuring A certain motor connection is permanently assigned to each measuring system
system and
motor connection
M1 M2 M3
-X411 -X412 -X413
M4
-X414
M5
-X415
M6
-X416
OI
or
A1 A2
Motor 3 Motor 6
Motor 1 Motor 2
Motor 4 Motor 5
Incremental Incremental systems with two 90-degree offset sinusoidal voltages signals A, B
measuring and a reference mark R.
systems 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. encoder signal frequency
that can be evaluated: 350 kHz
Note
For the above frequency, the signal amplitude must be 60 % of the typical
amplitude and the deviation of the phase offset from the ideal 90 between
track A and B must be 30.
Pay attention to the frequency characteristic of the encoder signals.
A–A 0.5 V
0
90 el.
360 el.
B–B 0.5 V
Uniqueness range
R–R
Absolute (EnDat) Single-turn, multi-turn, and linear absolute measuring systems with two
measuring 90_ offset sinusoidal voltage signals A, B, and EnDat interface,
systems 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. 1 Vpp
Transfer serial signals: Differential signals
Data, Data and Clock, Clock
Level: acc. to EIA 485
Power supply: 5 V ±5 %
Maximum supply current: 300 mA
Max. encoder signal frequency
that can be evaluated: 350 kHz
Note
For the above frequency, the signal amplitude must be 60 % of the typical
amplitude and the deviation of the phase offset from the ideal 90 between
track A and B must be 30.
Pay attention to the frequency characteristic of the encoder signals.
A–A
0
90 el.
360 el.
B–B
Fig. 4-7 Signal curve for incremental tracks for a clockwise rotation
Measuring The six measuring channels on the SINUMERIK 810D can be used both for
channels for indirect and for direct position sensing. A free measuring channel can, for exam-
SINUMERIK 810D ple, be used for a direct spindle measuring system. Additional measuring chan-
nels can be obtained by using a 611D standard control module with/without di-
rect measuring system.
Connecting The following connecting cables are used for the SINUMERIK 810D:
cables
Indirect The motor measuring system is also used for position sensing.
measuring system
Two encoder systems are available:
FSD
Incremental encoder
Absolute encoder
Indirect position (motor rotor position) and motor speed sensing M: Max. possible measuring steps
G: Accuracy of the encoder
FSD system
1 Incremental
X411 M = 128 x Z per 360 degr. mech.
multiturn absolute:
4096 revolutions
Fig. 4-8 Indirect position sensing with digital closed-loop control FSD
Direct The motor measurement system is used for sensing the motor position. A se-
measuring system cond measuring system, e.g. a scale, can be used for load-side position
FSD sensing if necessary.
Incremental encoders, distance-coded incremental encoders, or EnDat absolute
value encoders can be used (voltage signals).
X416
SINUMERIK 810D G is a function of the accuracy of the
Motor load-side encoder system.
CCU module
*)
Incremental
Voltage signals motor position 2 or 3
4 or 5
Voltage signals and Incremental
EnDat absolute motor position
Fig. 4-9 Direct position sensing with digital closed-loop control FSD
*) e.g. 1FK7
Indirect The motor measuring system is also used for position sensing.
measuring system
An encoder system is available:
MSD
optical/incremental (1PH motor)
1
Incremental M = 128 x Z per 360 degr. mech.
X411
Fig. 4-10 Indirect position sensing with digital closed-loop control MSD
*) e.g. 1PH7
Direct The motor measurement system is used for sensing the motor position. A se-
measuring system cond measuring system, e.g. a rotary transducer, can be used for load-side
MSD position sensing if necessary.
In the case of SINUMERIK 810D only encoders with voltage signals can be
used.
Direct position sensing with free CCU measuring channel M: Max. possible measuring steps
MSD G: Accuracy of the encoder
system
Spindle measuring system
1 incremental M = 128 per encoder signal
X411 Motor measuring period or lattice pitch
system incremental
X416
SINUMERIK 810D
G is a function of the accuracy of the
optional encoder system.
CCU module
Motor *)
2
Voltage signals
Motor *)
4
Motor *)
BERO
*) e.g. 1PH7
Description On the SINUMERIK 810D, three integrated power modules are fitted on one
heat sink in the 3-axis CCU box:
Note
The spindle can only be used on “A1” on the integrated power module.
Current derating All the technical details apply for ambient temperatures up to max. 40 C. At
as a function of ambient temperatures > 40, linear current derating is necessary, as in the case
the ambient of the OI power supply. At maximum ambient temperature 55 C: Current
temperature derating to 60 % of the 40 C value.
Current derating All power ratings apply up to an installation altitude of 1000 m. At an installation
as a function of altitude of > 1000 m, the load currents must be reduced according to the
the installation derating factor.
altitude The diagram is given in Subsection 4.3.3 Installation altitude
References: /PJU/, Configuration Manual Converters
I
Imax
In
0.2 s
Fig. 4-12 Peak current duty cycle with previous load for FSD
I
Imax
In
4s
Fig. 4-13 Peak current duty cycle without previous load for FSD
I
Imax
IS6
In
4 min
0.7xIn
t
10 min
I
Imax
IS6
In
10 s
0.7xIn
t
60 s
Coincidence factor The power modules A2 and A3 may only be operated in simultaneous con-
tinuous duty at 63 % of their rated current on average. No coincidence restric-
tions apply to A1.
Description On the SINUMERIK 810D, 2 integrated power modules are fitted on one heat
sink in the 2-axis CCU box:
Note
The 3rd drive number “A3” can be used for an axis in “Axis expansion plug-in
unit left”.
Current derating All the technical details apply for ambient temperatures up to max. 40 C. At
as a function of ambient temperatures > 40, linear current derating is necessary, as in the case
the ambient of the OI power supply. At maximum ambient temperature 55 C: Current
temperature derating to 60 % of the 40 C value.
Current derating All power ratings apply up to an installation altitude of 1000 m. At an installation
as a function of altitude > 1000 m, the load currents must be derated according to the diagram
the installation for the OI power supply.
altitude The diagram is given in Subsection 4.3.3 Installation altitude
References: /PJU/, Configuration Manual Converters
In
0.2 s
Fig. 4-16 Peak current duty cycle with previous load for FSD
I
Imax
In
4s
Fig. 4-17 Peak current duty cycle without previous load for FSD
PLC module The PLC module represents a PLC-CPU that is compatible with the S7-300
product range. Via the PK bus X111, three external chains with eight S7-300 I/O
modules each can be connected. It is also possible to connect up three single
I/O modules. Mixing IM 361s and single I/O modules is permissible.
The PCMCIA card is used for software upgrading or for standard software.
In addition to the software upgrade, the PC card can also be used for series
commissioning; see
References: /IAC/, Commissioning Manual 810D
The PCMCIA card with the system software must remain inserted during
operation.
Caution
Inserting and removing the PCMCIA card while energized will cause data to be
lost!
Application The axis expansion plug-in unit is installed in a SIMODRIVE 611 power mo-
dule 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.
SIEMENS
SIMODRIVE
Fig. 5-1 Axis expansion plug-in unit, left and right, for the SINUMERIK 810D with
SIMODRIVE 611 power modules
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.
Fig. 5-2 Mounting the axis expansion plug-in unit in the power module
Connecting The axis expansion plug-in module has two connectors X301 and X302.
the ribbon cable Connector X301 must be connected to a 1-axis power module when used. If a
connector 2-axis power module is used, connector X301 must be assigned to the first axis
and connectors X302, to the second axis.
Table 5-1 Connection of the ribbon cable connector to the axis expansion plug-in
unit
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).
Front panel
Notch
X302
Ribbon cable
3. After plugging in the axis expansion plug-in unit and connecting to the CCU,
you should push the excess cable length in the space provided for that pur-
pose under the sheet-metal cover of the axis expansion 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. If DC link busbars are connected, all screws must be
tightened firmly (comply with tightening torque, see figure 3-4).
Connection A special set of cables is required to connect the SIMODRIVE 611D control
module. This cable set contains the connection with the drive bus and another
device bus cable.
SIEMENS
SIMODRIVE
Fig. 5-4 Axis expansion for SINUMERIK 810D with the SIMODRIVE 611D module
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 For connection of the SIMODRIVE 611D control plug-in unit that is located
expansion immediately to the right of the 810D.
62
54 105
Fig. 5-5 Cable set for axis expansion with SIMODRIVE 611D module
Table 5-2 Recommendation for length selection of the drive bus cable
Notes
Connection The single I/O module (connector X3 IN) is connected to the SINUMERIK 810D
to 810D (connector X111). The max. cable length is 10 m. Two cable variants are availa-
ble for the connection from one single I/O module to the next:
X111 ÏÏÏ
ÏÏÏ
IN OUT ÏÏÏ
ÏÏÏ
IN OUT ÏÏÏ
ÏÏÏ
IN OUT
ÏÏÏ
ÏÏÏ ÏÏÏ
ÏÏÏ ÏÏÏ
ÏÏÏ
ÏÏÏ ÏÏÏ ÏÏÏ
Single Single Single
ÏÏ
module module
ÏÏ
ÏÏ
6ES7368-30-0AA0 SINUMERIK 810D
X3 IN
ÏÏ
ÏÏ
X3 OUT
6ES7368-30-0AA0
6FC5411-0AA80-0AA0, length 150mm
IM 361 or second single I/O module
ÏÏ
Single Ribbon cable
X405 Terminal strip converter
I/O
ÏÏ
32 I
module
ÏÏ
Ribbon cable
X405 Terminal strip converter
ÏÏ
32 I
Ribbon cable
ÏÏ
X402
Terminal strip converter
32 O
Fig. 6-1 Overview of terminals, single I/O modules on the SINUMERIK 810D
Cooling clearance 50 mm 70
SHIELD
M24Lo.
P24Logic
Space for
front
connector
SHIELD
M24Po
P24Power
360
374
Cooling clearance 50 mm
25 25 135
EMC measures The single I/O module has an equipotential bonding terminal. To conduct inter-
ference 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. The connection must be as short as possible. When the PE and inter-
ference conductors are in common, the PE conductor rules in EN 61800-5-1
must be followed.
Technical data
Table 6-1 Technical data of the single I/O module
Connection of the The 24 V DC power supply is connected to X1 via a 3-way angled Phoenix
electronics screw terminal connector (2.5 mm2).
power supply
SHIELD (pin 3)
X1 M24 (pin 2)
P24Logic (pin 1)
Signal names
P24 Logic + 24 V electronics power supply external
M24 Electronics power supply ground external
Signal type
VI Voltage Input
Note
SHIELD and M24 must be bridged.
Connecting the The 24 V DC load power supply is connected to X5 via a 3-way angled Phoenix
load power supply screw terminal connector (2.5 mm2).
SHIELD (pin 3)
M24 Power (pin 2)
P24 Power (pin 1)
Signal names
P24 Power + 24 V load power supply external
M24 Load power supply ground external
Signal type
VI Voltage Input
Connection of the The inputs/outputs are connected via ribbon cables (max. 3 m length). The
inputs/outputs 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 (0.5A)
6FC9302-2AL (2 A)
Terminal strip converter with LED green: 6FC9302-2BB01
Assignment of the ribbon cable is compatible with the I/O modules (logic
modules) of the SINUMERIK 810.
Meaning The module status of the single I/O module is indicated via two LEDs.
of the LEDs
LED green: 5 V Power OK
LED red: Group error
Note
The outputs must be protected externally against voltage surges by inductive
loads. (free-wheeling diodes, RC elements, . . .)
1 Not 2 Not
assigned assigned
3 OUT0ȱ0ȳ O 4 OUT0ȱ1ȳ O
5 OUT0ȱ2ȳ O 6 OUT0ȱ3ȳ O
7 OUT0ȱ4ȳ O 8 OUT0ȱ5ȳ O
9 OUT0ȱ6ȳ O 10 OUT0ȱ7ȳ O
11 OUT1ȱ0ȳ O 12 OUT1ȱ1ȳ O
13 OUT1ȱ2ȳ O 14 OUT1ȱ3ȳ O
15 OUT1ȱ4ȳ O 16 OUT1ȱ5ȳ O
17 OUT1ȱ6ȳ O 18 OUT1ȱ7ȳ O
19 OUT2ȱ0ȳ O 20 OUT2ȱ1ȳ O
21 OUT2ȱ2ȳ O 22 OUT2ȱ3ȳ O
23 OUT2ȱ4ȳ O 24 OUT2ȱ5ȳ O
25 OUT2ȱ6ȳ O 26 OUT2ȱ7ȳ O
27 OUT3ȱ0ȳ O 28 OUT3ȱ1ȳ O
29 OUT3ȱ2ȳ O 30 OUT3ȱ3ȳ O
31 OUT3ȱ4ȳ O 32 OUT3ȱ5ȳ O
33 OUT3ȱ6ȳ O 34 OUT3ȱ7ȳ O
Signal names
OUTi[j] Output j of output byte i
Signal type
O Output
1 Not 2 Not
assigned assigned
3 INP0ȱ0ȳ I 4 INP0ȱ1ȳ I
5 INP0ȱ2ȳ I 6 INP0ȱ3ȳ I
7 INP0ȱ4ȳ I 8 INP0ȱ5ȳ I
9 INP0ȱ6ȳ I 10 INP0ȱ7ȳ I
11 INP1ȱ0ȳ I 12 INP1ȱ1ȳ I
13 INP1ȱ2ȳ I 14 INP1ȱ3ȳ I
15 INP1ȱ4ȳ I 16 INP1ȱ5ȳ I
17 INP1ȱ6ȳ I 18 INP1ȱ7ȳ I
19 INP2ȱ0ȳ I 20 INP2ȱ1ȳ I
21 INP2ȱ2ȳ I 22 INP2ȱ3ȳ I
23 INP2ȱ4ȳ I 24 INP2ȱ5ȳ I
25 INP2ȱ6ȳ I 26 INP2ȱ7ȳ I
27 INP3ȱ0ȳ I 28 INP3ȱ1ȳ I
29 INP3ȱ2ȳ I 30 INP3ȱ3ȳ I
31 INP3ȱ4ȳ I 32 INP3ȱ5ȳ I
33 INP3ȱ6ȳ I 34 INP3ȱ7ȳ I
Signal names
INPi[j] Input j of input byte i
Signal type
I Input
1 Not 2 Not
assigned assigned
3 INP4ȱ0ȳ I 4 INP4ȱ1ȳ I
5 INP4ȱ2ȳ I 6 INP4ȱ3ȳ I
7 INP4ȱ4ȳ I 8 INP4ȱ5ȳ I
9 INP4ȱ6ȳ I 10 INP4ȱ7ȳ I
11 INP5ȱ0ȳ I 12 INP5ȱ1ȳ I
13 INP5ȱ2ȳ I 14 INP5ȱ3ȳ I
15 INP5ȱ4ȳ I 16 INP5ȱ5ȳ I
17 INP5ȱ6ȳ I 18 INP5ȱ7ȳ I
19 INP6ȱ0ȳ I 20 INP6ȱ1ȳ I
21 INP6ȱ2ȳ I 22 INP6ȱ3ȳ I
23 INP6ȱ4ȳ I 24 INP6ȱ5ȳ I
25 INP6ȱ6ȳ I 26 INP6ȱ7ȳ I
27 INP7ȱ0ȳ I 28 INP7ȱ1ȳ I
29 INP7ȱ2ȳ I 30 INP7ȱ3ȳ I
31 INP7ȱ4ȳ I 32 INP7ȱ5ȳ I
33 INP7ȱ6ȳ I 34 INP7ȱ7ȳ I
Signal names
INPi[j] Input j of input byte i
Signal type
I Input
Address space From the PLC’s viewpoint, the 810D single I/O is equivalent to a S7-300 I/O
chain with the following configuration:
X3 IN X3 OUT
32 inputs 0 to 31
X404
32 inputs 32 to 63
X405
32 outputs 0 to 31
X406
Chain 1
Chain 3
SINUMERIK 810D
with
integrated PLC
Single I/O
module
Single I/O
module
Single I/O
module
2.5mm2
0V 24V
4 3 21 Shielding plate
X9: Terminal external 24 V logic power supply
Mounting In order to ensure optimum heat dissipation of the DMP compact module, the
terminal block should be secured horizontally, so that the modules can be
suspended vertically.
Connection to the The terminal block is connected to connector X20 on the drive bus of the last
drive bus 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.
Important
! Please make sure that the total length of the cable connections does not
exceed 10 m.
611 control
plug-in unit Up to 2 NCU terminal
blocks can be connected
Termination
connector
Drive bus max.
SIEMENS length 10 m
SIMODRIVE
Note:
If there are EMC problems, attach the shield of
Power supply 810D LDC
the drive bus cable to the drive module (above).
(I/R or OI)
Terminator The drive bus terminator must be plugged into slot X21 on the last NCU terminal
block.
PE conductor When the PE and interference conductors are in common, the PE conductor
rules in EN 61800-5-1 must be followed. PE conductor connection, see fig. 7-1.
EMC measures The PE conductor connection is also used to conduct interference currents
away from:
DMP compact A maximum of 8 DMP compact modules can be connected per NCU terminal
modules block.
Peripherals Number
Digital inputs 32
Digital outputs 32
Analog inputs 8
Analog outputs 8
Important
! A maximum of 4 analog outputs and 4 analog inputs can be plugged in at the
same time for each NCU terminal block.
Caution
! After the load supply voltage for the DMP compact modules has been switched
off during operation, the outputs do not reliably reestablish through-connection
when the load supply voltage is switched on again. If switch-off during
operation cannot be avoided, the DMP outputs have to be reset via the PLC
program when the load supply voltage is switched off. The outputs are set
again after the voltage has been switched on again.
Monitoring +5 V monitoring
functions
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 Limit monitor Disabling of the NC outputs,
(< 4.75 V) LED (green) off
Ambient temperature Temperature sensor Status signal to NC,
screen display
Sign of life CCU Cyclic signaling Disabling of the NC outputs,
LED (red) on
Watchdog Time acquisition Disabling of the NC outputs,
LED (red) on
Hardware combination Hardware Disabling of the NC outputs,
configuration LED (red, yellow) on,
status signal to NC
The digital and analog ouputs are switched to a safe state (0 V at the output)
with the XOUTDS signal in the event of disturbances or faults in the CCU, the
microcontroller, and power failure.
X9
Pin Name Type
1 P24 ext VI
2 P24 ext VI
3 M24 ext VI
4 M24 ext VI
Note
Pins 1 and 2 or 3 and 4 are bridged in a group on the module.
Signal names
P24 ext +24 V power supply external
M24 ext Power supply ground external
Signal type
VI Voltage Input
X20/X21
X Drive bus interface
Connector name: X20 (IN) X21 (OUT)
Connector type: 36-pole micro ribbon
Special features: Non-isolated, no protective separation
Caution: Max. length of the drive bus is 10 m
Mechanical data
Dimensions Height Width Depth
100 mm 257 mm 40 mm
Weight Approx. 0.5 kg
Ambient conditions
Degree of protection IP20 or IPXXB
Power consumption (24 V)
During operation 150 –500 mA
Notes
Width 25 mm
Height 90 mm
115 mm with plugged in connecting plugs
130 mm with terminal block
Depth 108 mm
Degree of IP20 or IPXXB
protection
Inputs
1,5 IN 7 ... IN 0
0V HIGH byte
X3 X3 P M 7 6 5 4 3 2 1 0
Status
LEDs 0
. LOW byte
.
7
Labeling 0
strips . HIGH byte
.
7
Fixing X1
screw
X2 0 1 2 3 4 5 6 7 M P X2
Inputs
IN 0 ... IN 7 0V
M = GND LOW byte 1,5
Fig. 8-1 Front view and side view of a DMP compact module 16I
Display elements 16 LEDs as a status display for the logical states of the inputs.
LEDs lit: Input on.
Outputs
24 VLOAD DC 1.5 OUT 7 ... OUT 0
HIGH byte
0V
X3 X3 P M 7 6 5 4 3 2 1 0
Status
LEDs 0
. LOW byte
.
7
0
Labeling
strips . HIGH byte
.
7
Fixing X1
screw
X2 0 1 2 3 4 5 6 7 M P X2
Outputs
OUT 0 ... OUT 7 0V
M = GND LOW byte 24 VLOAD DC 1.5
Fig. 8-2 Front view and side view of a DMP compact module 16A
Display elements 16 LEDs as a status display for the logical states of the outputs.
As from product version B, the LEDs go out when the load voltage fails.
LEDs lit: Output on.
Important
! As of version C, a new output driver is used for the DMP compact module 16A.
The following behavior is to be observed:
In the event of a fault triggered by overcurrent or short-circuit, the outputs
automatically reconnect after the fault has been rectified. (previously: latching
disable until the output is reactivated by the PLC user program).
If one output is short-circuited, the three other outputs of the same half-byte can
also be disabled. In normal operation with currents < 0.7 A, there is no mutual
influence.
8 outputs each are powered by a power supply. For each group of 8 outputs
(2 x outputs 0 ... 7), the total of the output currents must not be greater than 2 A.
(This corresponds to a coincidence factor of 50 % if each output is under full
load). All 16 outputs can be loaded simultaneously with 0.25 A for example.
Important
! If inductive loads are used, switching voltage peaks must be limited by external
free-wheeling diodes or RC connections.
24 VLOAD DC 2.5
0V Outputs
OUT 7 ... OUT 4
X3 X3 P M7 6 5 4
Status
LEDs 0
.
.
7
Labeling
strips
Fixing X1
screw
X2 X2 0 1 2 3 MP
Outputs
OUT 0 ... OUT 3
0V
24 VLOAD DC 2.5
M = GND
Fig. 8-3 Front view and side view of a DMP compact module 8A
Display elements 8 LEDs as a status display for the logical states of the outputs. As from product
version B, the LEDs go out when the load voltage fails.
LEDs lit: Output on
Important
! As of product version B, a new output driver is used for the DMP compact
module 8O. It behaves as follows:
In the event of a fault triggered by overcurrent or short-circuit, the outputs
automatically reconnect after the fault has been rectified.
4 outputs each are powered by a power supply. For each group of 4 outputs
(outputs 0 to 3 and 4 to 7), the total of the output currents must not be greater
than 4 A. (This corresponds to a coincidence factor of 50 % if each output is
under full load). All 8 outputs can be loaded simultaneously with 1 A for
example.
Important
! If inductive loads are used, switching voltage peaks must be limited by external
free-wheeling diodes or RC connections.
P1 P2 M1 M2
2.5
24 V DC 0V
X3 Connecting terminals
Status POWER
LEDs SUPPLY
OK
Labeling
strips
ANALOG S1
Fixing IN X1 S2
screw
1 1
3 2 2
X2 6 . . 1
Terminal:
6, 1 Shield
2 Current source PT100
2.5
3 Analog input In+
4 Analog input In–
5 Ground
Fig. 8-4 Front view and side view of a DMP compact module 1E analog
Analog value The DMP compact module 1I analog is used to input and digitize an analog
representation 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 The conversion time depends on the level of the input voltage.
Input voltage in the dimensioning range ––> conversion time < 60 ms.
Input voltage in the overshoot range ––> conversion time < 80 ms.
The integration time is included in the conversion time, which determines the
noise suppression:
S 2 closed––> Integration time 20 ms 50 Hz noise suppression.
S 2 open––> Integration time 16 2/3 ms 60 Hz noise suppression.
Table 8-5 Digital analog value representation for DMP compact module 1I analog
7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 10 V range 500 mV
range
SG 211 210 29 28 27 26 25 24 23 22 21 20 0 0R PF
Significance
0 1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 19.995 V 999.76 mV
: : : :
0 1 0 0 0 0 0 0 0 0 0 0 1 0 0 0 10.005 V 500.24 mV
0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 10 V 500 mV
0 0 1 1 1 1 1 1 1 1 1 1 1 0 0 0 9.995 V 499.76 mV
: : : :
Digital value 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0.005 V 0.24 mV
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0V 0 mV
1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 –0.005 V –0.24 mV
: : : :
1 1 0 0 0 0 0 0 0 0 0 0 1 0 0 0 –9.995 V –499.76 mV
1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 –10 V –500 mV
1 0 1 1 1 1 1 1 1 1 1 1 1 0 0 0 –10.005 V –500.24 mV
: : : :
1 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 –19.995 V –999.76 mV
0 = always 0
OR= Overflow bit, input voltage is greater than 20 V or 1 V (double input
range)
PF = Power supply failure of the analog part
Example
Analog voltage measurement
circuits
X2 X2
S M – + S S M – + S
6 5 4 3 2 1 6 5 4 3 2 1
Differential input
(common-mode Unipolar
U U (default)
disturbances are
suppressed)
Measurement with PT100
X2 X2
S M – + I S S M – + I S
6 5 4 3 2 1 6 5 4 3 2 1
PT100 with
PT100 with 2-wire
4-wire connection connection
Note
If the power source is not required, it must be short-circuited.
P1 P2 M1 M2
2.5
24 V DC 0V
X3 Connecting terminals
Status POWER
LEDs SUPPLY
OK
Labeling
strips
ANALOG S1
Fixing IN X1 S2
screw
1 1
3 2 2
X2 6 . . 1
Terminal:
6, 1 Shield
2 Ground
2,5
3 Analog input In+
4 Analog input In–
5 Ground
Fig. 8-6 Front view and side view of a DMP compact module 1E NC analog
Analog value The DMP compact module 1I NC analog is used to input and digitize an analog
representation 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.
75 ms.
Table 8-7 Digital analog value representation for DMP compact module 1I NC analog
7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 Range +/– 10 V
SG 210 29 28 27 26 25 24 23 22 21 20 0 0 0 PF
Significance
0 1 1 1 1 1 1 1 1 1 1 1 0 0 0 0 9.995 V
: : :
0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0.005 V
Digital value 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0V
1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 0 –0.005 V
: : :
1 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 –9.995 V
1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 –10 V
0 = always 0
PF = Power supply failure of the analog part
Example
Analog voltage measurement
circuits
X2 X2
S M – + M S S M – + M S
6 5 4 3 2 1 6 5 4 3 2 1
Differential input
(common-mode Unipolar
U U (default)
disturbances are
suppressed)
M = GND
P1 P2 M1 M2 1.5
24 V DC 0V
X3 Connecting terminals
Status POWER
LEDs SUPPLY
OK
Labeling
strips
ANALOG
Fixing OUT X1
screw
4 3 2 1
X2
Terminal:
1, 4 ... Shield
2 ... Analog output Out+
2.5 3 ... Analog output Out–
Fig. 8-8 Front view and side view of a DMP compact module 1A analog
Conversion time The pure conversion time is a max. of 10 µs. Because the analog signal is
smoothed by an RC element, its time constant determines the total conversion
time:
Table 8-9 Digital analog value representation DMP compact module 1O analog
Output Analog
word QB m QB m+1 output
voltage
Signifi- 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
cance SG 212 211 210 29 28 27 26 25 24 23 22 21 20 always
0
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 +1.22 mV
Digital 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0V
value
1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 –1.22 mV
1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 –10 V
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.
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.
Backup time The service life of the batteries used is a minimum of 3 years.
The battery must be removed before the module is put into storage.
Replacement of The battery is located on the CCU module (see figure 9-1). Before removing the
the battery on the CCU module, please comply with the ESD measures in the Preface and the
CCU module transportation and storage conditions specified in section 2.2.1 of this manual.
1. Switch off the control.
2. Follow the ESD rules!
3. Remove all connectors, first labeling them if necessary.
4. Loosen the 4 fixing screws of the CCU module and pull it out.
5. Remove the battery and pull out the battery connector. Data backup is
ensured for about 15 min by a capacitor.
6. Connect the new battery (ensuring correct polarity) and press it into its
holder.
7. Reinsert the CCU module and screw it tight.
8. Plug in all connectors correctly.
AT Advanced Technology
DC Direct Current
DP Distributed I/Os
HT Handheld Terminal
MS Mains Supply
NC Numerical Control
NCK Numerical Control Kernel: NC kernel with block preparation, traversing range,
etc.
OP Operator Panel
PCU Personal Computer Unit: NC controller component which allows the operator to
communicate with the machine and vice versa.
PG Programming device
RAM Random Access Memory: Program memory that can be read and written to.
C E
Cable distributor, 4-60 Encoder cables, terminal, 3-44
Connector, 4-61
DIP FIX switches, 4-61
Location of the ports, 4-61
Pin assignments, 4-62
F
Cable set for 611D control plug-in unit, 5-81 Function-impairing gases, 2-33
CCU
Interfaces, 4-51
Mounting, 3-39
Operating and display elements, 4-59
G
CCU box, installation, 3-38 Gases, function-impairing, 2-33
Climatic environmental conditions, 2-31 General view of the 810D, 1-14
Operation, 2-32, 2-33 Grounding concept, 2-28
Transport and storage, 2-31
Coincidence factor, 4-73
Combinations, 1-18
Components of the SINUMERIK 810D, 1-12, 4-47
H
Connecting cables, 1-17 Heat sink temperature sensor, 4-71
Conversion time
DMP compact module 1I analog, 8-103, 8-104
DMP compact module 1O analog, 8-109
Current derating, 4-71, 4-74
I N
I/O interface, X121, 4-54 NCU terminal block, 7-91
Installation altitude, 4-71, 4-74 DMP compact modules, 7-93
Interface configuration, EMC measures, 7-93
for MPI bus, HHU, HT 6, 1-15 Monitoring, 7-94
with PLC I/Os and NCU terminal block, 1-16 Power supply, 7-94
Interfaces, 4-50 Terminal, 7-92
Description, 4-52 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
L Operator controls, 4-59
L2-DP interface, X102, 4-53
Labeling, 1-21
Labels, 1-21
Location of the ports, 4-52
P
P-bus, X111, 4-53
PCMCIA card (memory card), 4-76
PLC module, 4-75
M PLCCPU, 4-75
Maintenance, 9-111 Position sensing
Measuring channels, 4-66 direct, FSD, 4-68
Measuring system, 4-63 direct, MSD, 4-70
direct, 4-66 indirect, FSD, 4-67
direct, FSD, 4-68 indirect, MSD, 4-69
direct, MSD, 4-70 Power consumption, 2-24
indirect, 4-66 Power modules, 1-18
indirect, FSD, 4-66 Power modules, integrated
indirect, MSD, 4-69 2-axis CCU box, 4-74
Measuring systems 3-axis CCU box, 4-71
Absolute (EnDat), 4-65 Power supply, 2-24
Connecting cables, 4-66 Power supply module, 3-45
Incremental, 4-64 powerline modules, SINUMERIK 810D/810DE,
Mechanical data, 2-34 1-11
Mechanical environmental conditions Protective separation, 2-26
Operation, 2-33 Pulse interface (axis 3), 4-56
Transport and storage, 2-31
Motor cables, terminal, 3-44
Motor connection, 4-63
Motor measuring system, 4-63
R
Mounting the shielding plate, 2-axis CCU box, Radio interference, 2-33
3-43 RI suppression measures, 2-29
MPI interface, X122, 4-55 Ribbon cable, 5-79
MPI/OPI network rules, 2-35 Connector, 5-78
S T
Sensor systems, 4-64 Technical data of the individual components, 2-34
Service, 9-111 Terminal block, X431, 4-58
Shielded signal cables, 2-29 Transport conditions, 2-31
Shielding plate, mounting, 3-41
Siemens PC card, 4-76
Signal curve of incremental encoders, 4-64
Single I/O, address space, 6-89
X
Single I/O module, 6-83 X102, 4-53
Dimension drawing, 6-84 X111, 4-53
Electronics power supply, 6-86 X121, 4-54
EMC, 6-84 X122, 4-55
Inputs/outputs, 6-87 X130, 4-56
LED, 6-87 X151, 4-56
Load power supply, 6-86 X304, X305, X306, 4-56
Technical data, 6-85 X307, 4-56
Terminal, 6-83 X341, X342, X351, X352, 4-56
X402, 6-87 X411-X416, 4-56
X404, 6-88 X431, 4-58
X405, 6-89
Storage conditions, 2-31
Structure of the SINUMERIK 810D, 3-37
Supplementary conditions, electrical, 2-23
Supplementary electrical conditions, 2-23
System configuration, 1-12
Notes
Telephone: /
Fax: /
Safety
SINUMERIK SINUMERIK integrated
840D
840Di
810D
User documentation
Operating Manual Operating Manual Programming Manual Programming Manual Diagnostics System overview
– HMI Embedded *) – HMI Advanced *) – Fundamentals *) – Cycles Manual *)
– ShopMill – Operation compact – Job planning *) – Measuring cycles
– ShopTurn – Programming compact
– HT6 – Lists of system variables
– ISO Turning/Milling
Manufacturer/service documentation
Manufacturer/service documentation
Function Manual Function Manual Function Manual Function Manual Configuration MCIS
– Fundamentals *) – Drive functions – Remote diagnostics Safety Integrated –Operator interface – Computer Link
– Expansion functions. – Tool management – @Event OP030 – Tool Data Information
– Special functions – Hydraulic module –HMI Embedded – NC Data Management
– Synchronous actions – Analog module – NC Data Transfer
– ISO dialects – Tool Data Communication
– EMC guidelines
Electronic Documentation
SINUMERIK
SIMODRIVE
Motors
DOCONCD *)
DOCONWEB
*) Recommended minimum scope of documentation