Siemens SINUMERIK 810D Instruction sheet

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Manual 11/2002 Edition
Hardware Configuration
SINUMERIK 810D

Valid for
Control Software Version
SINUMERIK 810D 3
SINUMERIK 810DE (export version) 3
SINUMERIK 810D powerline 6
SINUMERIK 810DE powerline 6
11.2002 Edition
SINUMERIK 810D
Hardware Configuration
Manual
System Overview 1
Installation Conditions 2
Design and Installation 3
Description 4
Axis Expansion 5
I/O Modules 6
NCU Terminal Block 7
DMP Compact Modules 8
Maintenance and Service 9
Abbreviations A
References B
EC Declaration of
Conformity C
Index

SINUMERIKRDocumentation
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” columns.
Status code in the “Remarks” column:
ANew documentation......
BUnrevised reprint with new order no......
CRevised edition with new status......If factual changes have been made on the page within the same
software version, this is indicated by a new edition coding in the
header on that page.
Edition Order No. Remarks
12.95 6FC5 297-1AD10-0BP0 A
07.96 6FC5 297-1AD10-0BP1 C
08.97 6FC5 297-2AD10-0BP0 C
12.98 6FC5 297-3AD10-0BP0 C
08.99 6FC5 297-3AD10-0BP1 C
04.00 6FC5 297-3AD10-0BP2 C
10.00 6FC5 297-4AD10-0BP0 C
12.01 6FC5 297-4AD10-0BP1 C
03.02 6FC5 297-6AD10-0BP0 C
11.02 6FC5 297-6AD10-0BP1 C
This manual is included in the documentation available on CD--ROM (DOCONCD)
Edition Order No. Remarks
11.02 6FC5 298-6CA00-0BG3 C
Trademarks
SIMATICr, SIMATIC HMIr, SIMATIC NETr,SIROTECr, SINUMERIKrand SIMODRIVErare registered
trademarks of Siemens AG. Other product names used in this documentation may be trademarks which, if
used by third parties, 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 V7.
The reproduction, transmission or use of this document or its
contents is not permitted without express written authority. Offenders
will be liable for damages. All rights, including rights created by patent
grant or registration of a utility model or design, are reserved.
ESiemens AG, 1995--2002. All rights reserved
Other functions not described in this documentation might be
executable in the control. However, no claim can be made regarding
the availability of these functions when the equipment is first supplied
or for service cases.
We have checked that the contents of this document correspond to
the hardware and software described. Nonetheless, differences might
exist. The information contained in this document is, however,
reviewed regularly and any necessary changes will be included in the
next edition. We welcome suggestions for improvement.
Subject to change without prior notice
Siemens Aktiengesellschaft
Order No. 6FC5 297-6AD10-0BP1
Printed in Germany

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SINUMERIK 810D Manual Hardware Configuration (PHC) -- 11.02 Edition
Preface
SINUMERIK documentation is split into three levels:
SGeneral Documentation
SUser Documentation
SManufacturer/Service Documentation.
For more detailed information on SINUMERIK 810D publications and other pu-
blications covering all the SINUMERIK controls, please contact your local SIE-
MENS office.
You will also require the following
References: /PJU/ SIMODRIVE Planning Guide
As from 12.2001,
SSINUMERIK 810D powerline and
SSINUMERIK 810DE powerline
are available with improved performance. A list of the available powerline
modules can be found in the hardware description:
References: /PHC/ Configuration Manual SINUMERIK 810D
Armed with the information contained in this manual, it is possible to install the
SINUMERIK 810D numerical control and take measures to maintain and ser-
vice it.
If you have any questions, please call the following hotline:
A&D Technical Support Phone: [phone]
Fax: [phone]
Email: [e-mail]
For questions about the documentation (suggestions for improvement, correc-
tions) please send a fax to the following number or send an email:
Fax: [phone] -- 2176
E--mail: [e-mail]
Fax form: see feedback page at the end of this publication.
Internet address http://www.ad.siemens.de/sinumerik
SProject planning engineers, electricians and fitters
SService and operating personnel.
Notes for the
reader
SINUMERIK 810D
powerline
Subject matter of
this manual
Hotline
Who is this
manual intended
for?

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The following notices are intended firstly for your personal safety and secondly
to prevent damage occurring to the products described or any connected
devices and machines.
!Warning
When operating electrical devices, it is impossible to avoid applying hazardous
voltages to certain parts of the equipment.
After all power has been cut off, there will still be dangerous voltages present in
the intermediate circuit of all SIMODRIVE modules for a further 5 minutes!
See operating instructions.
Unqualified operator action of the device/system or failure to observe the war-
ning notices may result in serious physical injury or material damage. Only
suitably qualified personnel trained in assembling, installing, activating or
operating the product, should operate this device/system.
Should measurements or tests need to be carried out on the active device, it is
important to comply with the definitions and implementation instructions of acci-
dent prevention regulation VBG 4.0, in particular § 8 ”Permissible differences
when working on active components”. Suitable electric tools should be used.
!Danger
This warning notice indicates that death, serious physical injury or considerable
material damage will occur if the relevant safety precautions are not taken.
!Warning
This warning notice indicates that death, serious physical injury or considerable
material damage may occur if the relevant safety precautions are not taken.
!Caution
This warning notice (with warning triangle) indicates that slight physical injury or
some material damage may occur if the relevant safety precautions are not
taken.
Caution
This warning notice (without a warning triangle) indicates that some material
damage may occur if the relevant safety precautions are not taken.
Danger notices
Additional notices
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Atention
This warning notice indicates that an unwelcome event or unwanted situation
may occur if the relevant notices are ignored.
!Important
This notice indicates that there is an important issue to be considered.
Note
This notice indicates that it there is a further issue to be considered.
!Warning
SRepairs to devices that have been supplied by our company must only be
carried out by SIEMENS Customer Service or by repair centers author-
ized by SIEMENS. When replacing parts or components, only use those
parts that are included in the spare parts list.
SBefore opening the device, always disconnect the power supply.
SEMERGENCY STOP devices complying with EN 60204 IEC 204 (VDE
0113) must remain effective in all automation equipment modes. Resetting
the EMERGENCY STOP device must not cause an uncontrolled or unde-
fined restart.
SAnywhere in the automation equipment where faults might cause major
material damage or even physical injury, in other words, where faults could
be dangerous, additional external precautions must be taken, or facilities
must be provided, that guarantee or enforce a safe operational state, even
when there is a fault (e.g. caused by an independent limit switch, mechani-
cal interlocks, etc.).
!Caution
SConnecting cables and signal lines should be installed so that inductive and
capacitive interference does not in any way impair the automation func-
tions.
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SINUMERIK 810D Manual Hardware Configuration (PHC) -- 11.02 Edition
!Warning
Proper transportation, expert storage, installation and mounting, as well as
careful operation and maintenance are essential for this device to operate
correctly and reliably.
If warning notices are ignored, serious physical injury or material damage may
result.
Warning
The modules contain electrostatic sensitive components. Before touching an
electronic module, the persons carrying out the work must themselves be
electrostatically discharged. The simplest way of doing this is to touch an
electrically conducting earthed object (e.g. a bare metal part of a switchboard
or a plug socket protective conductor).
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Electrostatic Sensitive Devices
!Important
Handling ESD modules:
SWhen dealing with electrostatic components, make sure that people, work-
places and packaging are well earthed!
SThe fundamental principle here is that you should only ever touch electronic
modules if this is unavoidable because work needs to be carried out. Under
no circumstances should you take hold of printed circuit boards so that you
touch component pins or printed conductors.
SYou should only ever touch the units if
-- you are permanently earthed by an ESD armband,
-- you are wearing ESD shoes or ESD shoe grounding strips in connection
with an ESD base.
SModules must only be put on conductive supports (machine table with ESD
layer, conductive ESD foam, ESD packing bag, ESD transport container).
SDo not place modules near to display units, monitors or television sets (mi-
nimum distance to screen > 10 cm).
SModules must not be brought into contact with chargeable and highly insu-
lating materials, such as plastic sheets, insulating table tops or clothing ma-
de of synthetic fibers.
SMeasurements must only be carried out on modules if
-- the measuring instrument is grounded (e.g. by protective conductors) or
-- before measuring, with an isolated measuring instrument, the measu-
ring head is briefly discharged (e.g. touching a bare metal control hou-
sing).
The device must only be put to the uses prescribed in the manual and only in
conjunction with third party devices and components recommended or appro-
ved by SIEMENS.
Should any problems or questions arise while you are using this manual, please
contact the Siemens office concerned using the form provided at the end of this
manual.
J
ESD notices
Intended use
Contact persons
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SINUMERIK 810D Manual Hardware Configuration (PHC) -- 11.02 Edition
1 System Overview 1-13....................................................
1.1 SINUMERIK 810D powerline 1-13..................................
1.2 System configuration 1-14.........................................
1.3 Labeling and adhesive labels 1-23..................................
2 Installation Conditions 2-25...............................................
2.1 Secondary electrical conditions 2-25................................
2.1.1 Electromagnetic compatibility (EMC) 2-26...........................
2.1.2 Power supply 2-27...............................................
2.1.3 Safe electrical isolation 2-29.......................................
2.1.4 Earthing concept 2-31............................................
2.1.5 RI suppression measures 2-32.....................................
2.2 Ambient climatic and mechanical conditions 2-34.....................
2.2.1 Transport and storage conditions 2-34..............................
2.2.2 Operating conditions 2-35.........................................
2.2.3 Exposure to contaminants 2-36....................................
2.3 Technical data of the individual components 2-37.....................
2.4 MPI network 2-38................................................
2.4.1 MPI interconnecting cables 2-38....................................
2.4.2 MPI network rules 2-39...........................................
3 Design and Installation of the 810D 3-41...................................
3.1 Design of the SINUMERIK 810D 3-41...............................
3.2 Installing the SINUMERIK 810D 3-42...............................
3.2.1 Modification for external cooling, 2-axis CCU box (SW 5 and higher) 3-47
3.3 Mains supply (MS) 3-49...........................................
4 Description of the SINUMERIK 810D 4-51..................................
4.1 Components of the SINUMERIK 810D 4-51..........................
4.1.1 Overview 4-51...................................................
4.2 Interfaces of the SINUMERIK 810D 4-54............................
4.2.1 Brief description 4-54.............................................
4.2.2 Hardware interfaces overview 4-55.................................
4.2.3 CCU1/CCU2: Description of the interfaces,
operating and display elements 4-56................................
4.2.4 CCU3: Description of the interfaces, operating and display elements 4-64
4.2.5 Cable distributor 4-66.............................................
4.3 Measuring system 4-69...........................................
4.3.1 Measuring system and motor connection assignments 4-69............
4.3.2 Evaluative encoder systems 4-70...................................
4.3.3 Measuring channels, indirect and direct measuring systems 4-72.......
4.4 Integrated power sections: 3-axis CCU box 4-77......................
4.5 Integrated power sections: 2-axis CCU box 4-79......................
Contents

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4.6 PLC module 4-80................................................
4.7 PCMCIA card (memory card) 4-80..................................
4.8 CCU1: 6th axis (SW 3.2 and higher) 4-81............................
5 Axis Expansion 5-83.....................................................
5.1 Axis expansion plug-in unit 5-83....................................
5.2 Axis expansion with the SIMODRIVE 611D
closed-loop control module 5-86....................................
6 I/O Modules 6-89.........................................................
6.1 Single I/O module 6-89............................................
7 NCU Terminal Block 7-97.................................................
8 DMP Compact Modules 8-103..............................................
8.1 DMP compact module 16I (6FC5 111-0CA01-0AA0) 8-103..............
8.2 DMP compact module 16O (6FC5 111-0CA02-0AA1) 8-105............
8.3 DMP compact module 8O (6FC5 111-0CA03-0AA1) 8-107.............
8.4 DMP compact module 1I analog (6FC5 111-0CA04-0AA0) 8-109.........
8.5 DMP compact module 1I NC analog (6FC5 211-0AA10-0AA0) 8-112.....
8.6 DMP compact module 1O analog (6FC5 111-0CA05-0AA0) 8-115........
9 Maintenance and Service 9-117.............................................
9.1 Warning notices 9-117.............................................
9.2 Battery replacement
(6FC5 247-0AA18-0AA0, GWE-570 665 000 101) 9-118................
A Abbreviations A-121.......................................................
B References B-123..........................................................
C EC Declaration of Conformity C-135........................................
D Index Index-139..............................................................
11.02

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SINUMERIK 810D Manual Hardware Configuration (PHC) -- 11.02 Edition
System Overview
1.1 SINUMERIK 810D powerline
As from 03.2002
SSINUMERIK 810D powerline and
SSINUMERIK 810DE powerline
are ready for delivery. The following powerline modules are now available with
enhanced performance:
Table 1-1 powerline modules for SINUMERIK 810D/810DE
Module Description
CCU3 with additional pulse interface and two machining channels
Note
The SINUMERIK 810D powerline and SINUMERIK 810DE powerline are
suppliedwithSW6.
Earlier system software versions of the SINUMERIK 810D cannot be used on
the
SINUMERIK 810D powerline or SINUMERIK 810DE powerline.
1

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SINUMERIK 810D Manual Hardware Configuration (PHC) -- 11.02 Edition
1.2 System configuration
A fully--equipped SINUMERIK 810D system consists of various individual
components. These are listed below.
Table 1-2 Components of 810D at maximum configuration (excluding motors)
Components Order No. Description
Mains supply (MS) see Reference:
/PJ2/ SIMODRIVE Plan-
ning Guide
Mains supply for supplying power to electronics and drives. Either
open--loop control (OI 5kW--28kW) or closed loop control as an
infeed/regenerative feedback module (I/RF module), 16kW--120kW
and over; optional filter modules.
SINUMERIK 810D
-- CCU box
(3 axes) 6FC5447-0AA00-0AA1 Subrack for mounting the CCU with integrated power modules: 1 x
18/36A (FDD) or 24/32A (MSD) and 2 x 6/12A (FDD), internal cooling
o
n
l
y
-- CCU box
(2 axes) 6FC5447-0AA01-0AA0 on
l
y
Subrack for mounting the CCU with integrated power modules: 2 x
9/18/A (FDD), internal or external cooling
-- CCU3 (Compact
Control Unit) 6FC5 410-0AY03-1AA0 CCU The central processing unit of the 810D contains: NCK, PLC AS 315, communication functions, standard digital
closed--loop control
Additional functions:
-- 16MB DRAM, 2MB SRAM
-- Handling with 6 axes
-- 2nd Channel with 6 axes
-- CCU2 (Compact
Control Unit) 6FC5 410-0AX02-1AA0 CCU The central processing unit of the 810D contains: NCK, PLC AS 315, communication functions, standard digital
closed--loop control
Additional functions:
-- 8MB DRAM, 2MB SRAM
-- Handling with 5 axes
-- 2nd channel with 5 axes
-- Connection for HPU
-- CCU 1 (Compact
Control Unit) 6FC5 410-0AY01-0AA0 Same as CCU with the following changes: -- Supports a full-functional sixth axis
-- Hardware/software separation: supplied with export software;
Miscellaneous functions on PCMCIA card
Operator panel front
1) Display, keyboard and operator controls for the 810D
PCU 20/50/70 1) SINUMERIK PCU (Personal Computer Unit)
Machine control
panel1) SIEMENS MCP or interface for customer MCP V_03_01_01 or higher
ISA adapter1) Allows AT modules to be used in conjunction with the PCU
Full CNC keyboard
1) Full keyboard can be connected to PCU
Memory card
(PCMCIA) Slot for PCMCIA card on CCU PCMCIA card for software updates, SW 3 and higher (not 810DE)
The system software of the CCU1/2 is stored on internal flash
EPROM for software version < 3.1
Disk drive unit 1) Rack--mounting unit for connection to the PCU
Cable distributor 6FX2 006-1BA02 Connection of two handwheels and two probes to the CCU
Cable References: /Z/, Catalog of accessories NC Z.
Axis expansion
plug--in unit, left 6FC5 412-0FA12-0AA0 CCU3 only: place between I/RF module and 810D for axis expansion when installing in a SIMODRIVE 611 D single-axis power module
References: /PJ/, SIMODRIVE 611 Planning Guide
Axis expansion
plug--in unit 6FC5 412--0FA10--0AA0 For installing in a SIMODRIVE 611 power module (1-axis or 2-axis), References: /PJ/, SIMODRIVE 611 Planning Guide
Components
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SINUMERIK 810D Manual Hardware Configuration (PHC) -- 11.02 Edition
Components DescriptionOrder No.
SIMATIC
components 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 terminal
block1) 6FC5 211-0AA00-0AA0 High-speed digital and analog NC I/Os on the SINUMERIK 810D
drive bus
Handheld unit
(HHU)1) 6FX2 007-1AC.. Handheld unit with handwheel, Emergency Stop button, keyswitch, override, enabling
switches, display, user-assignable keys,
connection via MPI bus and cable distributor
Handheld Terminal
(HT 6) 1) 6FC5 403-0AA10-0AA0 Handheld device combining the functions of the operator panel front and MCP with
-- D is p l ay,
-- Keyboard, enable key, Emergency Stop and Override button
-- RS-232 interface for archiving programs and data
-- Connection via cable and distributor to SINUMERIK 810D/840Di/
840D and FM357-2H
Distributor box1) 6FX2 006-1BC00 For connection of the handheld unit to the MPI bus Connection for
Emergency Stop circuit, enabling, handwheel, 24VDC
Mini handheld unit1) 6FX2 006-1BG00 Small handheld unit for setting up and operating simple machines in
the JobShop sector or similar applications.
Can be used with 810D, 840C, 840D and FM-NC.
Components marked with 1) are described in:
References: /BH/, Operator Components Manual.
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1.2 System configuration
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SINUMERIK 810D Manual Hardware Configuration (PHC) -- 11.02 Edition
MCP
Disk drive
unit
Operator panel front
Axis
expansion
plug-in
unit
I/RF FDD FDD
Handwheel (2x)
Measuring (2x) *)
Cable
distributor
Single
I/O module
810D
2x
Motor encoder
cable
Terminal block
Motors
e.g. 1FNx, 1FEx, 1FKx
Distributor box
Motor cable
QWERTY
keyboard
5x
OI
or
2x 1x
PCU
MPI
cable
SIMATIC
IM cable
611
power
module
Encoder lead
direct
measuring system
Direct measuring
(e.g. at X416)
SIMATIC
PROFIBUS I/Os
Handheld
unit
HHU or mini HHU or HT 6
14
15
14
*) One measuring output can be replaced by a 3rd handwheel
HT 6
16
17
(CCU3)
Axis
expansion
plug-in
unit
1x
MSD
Fig. 1-1 The SINUMERIK 810D system showing example of CCU3
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12.95 1.2 System configuration
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SINUMERIK 810D Manual Hardware Configuration (PHC) -- 11.02 Edition
17
X3
Floppy/interface
MCP
PG740 programming device
Cable distributor
QWERTY
MPI bus cable
MPI cable
X20 (rear view)
Distributor box
HHU
HHU handwheel
X4
X1
X2 X5
CCU 3
MPI bus cable 2
3
4
1
5
6
Handwheel
Probe
Shield
or HT 6
16
PCU50
(right side of
housing)
PC card
Port on the left side of the housing
PS/2 mouse
COM1/RS--232/PLC
LPT1/PRINTER VGA
24V power supply
USB
COM2
Ethernet
PCI slot PCI/ISA slot
MPI/DP
2
--X307
--X122
--X102
Fig. 1-2 SINUMERIK 810D connection configuration for the MPI bus, HHU, HPU and cable distributor
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SINUMERIK 810D Manual Hardware Configuration (PHC) -- 11.02 Edition
CCU3
IM
SIMATIC S7--300 I/Os
PS SMs
X2
SIMATIC S7-300 IM interconnecting cable
Shielded interconnecting cables
Single I/O module
Terminal block
Drive bus cable
Do not exceed maximum configuration !!
1)
1)
Terminator
Single I/O module Single I/O module
--X307 --X130
8
8
8
7 9
-- X 411
--X412 --X413--X416
--X415 --X414
--X121
--X111
--X122 --X102
--X431
Memory card
--X306--X305 --X304
Fig. 1-3 SINUMERIK 810D connection configuration for PLC I/Os and NCU terminal block
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