Siemens SINUMERIK 808D User manual

Electrical Installation Manual
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SINUMERIK
SINUMERIK 808D
Electrical Installation Manual
Operating Instructions
Valid for:
SINUMERIK 808D Turning (software version: V4.4.2)
SINUMERIK 808D Milling (software version: V4.4.2)
Target group:
Electrical engineers and electrical assembly workers
12/2014
6FC5397-2EP10-0BA0
Preface
Safety instructions
1
System overview
2
Connecting
3
Technical specifications
4
Appendix
A

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 6FC5397-2EP10-0BA0
Ⓟ01/2015 Subject to change
Copyright © Siemens AG 2012.
All rights reserved
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury
will
result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury
may
result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by
personnel qualified
for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

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Operating Instructions, 12/2014, 6FC5397-2EP10-0BA0 3
Preface
SINUMERIK 808D documentation
The SINUMERIK 808D documentation consists of the following components:
●Operating Instructions
–Mechanical Installation Manual
–Electrical Installation Manual
–PLC Subroutines Manual
–Function Manual
–Parameter Manual
●Diagnostics Manual
●Commissioning Manual
●Programming and Operating Manual (Turning)
●Programming and Operating Manual (Milling)
●Manual Machine Plus (Turning)
●Online Help for Programming and Operating (Turning)
●Online Help for Programming and Operating (Milling)
●Online Help for Manual Machine Plus (Turning)
My Documentation Manager (MDM)
Under the following link you will find information to individually compile your documentation
based on the Siemens content:
www.siemens.com/mdm
Target group
This manual is intended for use by electrical engineers and electrical assembly workers.
Benefits
This manual enables the intended target groups to properly and safely connect up the
SINUMERIK 808D system.

Preface
Electrical Installation Manual
4Operating Instructions, 12/2014, 6FC5397-2EP10-0BA0
Technical support
Hotline:
[phone]
Service and Support
•China:
www.siemens.com.cn/808D
•Worldwide:
http://support.automation.siemens.com
EC Declaration of Conformity
The EC Declaration of Conformity for the EMC Directive can be found on the Internet at
http://support.automation.siemens.com.
Here, enter the number
15257461
as the search term or contact your local Siemens office.
Licensing provisions
The SINUMERIK 808D software is protected by national and international copyright laws and
agreements. Unauthorized reproduction and distribution of this software or parts thereof is
liable to prosecution. It will be prosecuted both according to criminal and civil law and may
result in severe penalties or claims for compensation.
In the SINUMERIK 808D software, open source software is used. The licensing provisions
for this software are included on the Toolbox DVD and are to be observed accordingly.

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Table of contents
Preface ................................................................................................................................................... 3
1 Safety instructions................................................................................................................................... 7
2 System overview................................................................................................................................... 11
3 Connecting ........................................................................................................................................... 15
3.1 Interface overview...................................................................................................................15
3.2 Connection Overview for SINUMERIK 808D..........................................................................17
3.3 Connecting the interfaces on the PPU....................................................................................19
3.3.1 Digital input interfaces - X100, X101, X102............................................................................19
3.3.2 Digital output interfaces - X200, X201 ....................................................................................21
3.3.3 Fast input/output - X21............................................................................................................22
3.3.4 Distributed I/O - X301, X302...................................................................................................24
3.3.5 Handwheel inputs - X10..........................................................................................................29
3.3.6 Pulse drive interfaces - X51, X52, X53 ...................................................................................30
3.3.7 Analog spindle interface - X54................................................................................................33
3.3.8 Spindle encoder interface - X60 .............................................................................................35
3.3.9 RS232 interface - X2...............................................................................................................36
3.3.10 Power supply interface - X1....................................................................................................37
3.3.11 USB interface on the front cover of the PPU ..........................................................................38
3.3.12 USB interface - X30 ................................................................................................................38
3.3.13 Battery interface......................................................................................................................39
3.3.14 Slot for the system CompactFlash Card (CF card).................................................................40
3.4 Connecting the USB interface on the MCP ............................................................................40
4 Technical specifications ........................................................................................................................ 41
4.1 Radio interference...................................................................................................................42
A Appendix............................................................................................................................................... 43
A.1 ESD Directive..........................................................................................................................43
A.1.1 What does ESD mean? ..........................................................................................................43
A.1.2 Electrostatic Discharge to Persons.........................................................................................44
A.1.3 Basic protective measures against discharge of static electricity...........................................44
A.2 Order numbers........................................................................................................................45
A.3 FAQs .......................................................................................................................................46
Index..................................................................................................................................................... 47

Table of contents
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Safety instructions
1
General
WARNING
Death or serious injury may occur.
Only qualified personnel should be allowed to work on this control system, and only after
becoming acquainted with all the safety notices regarding installing as set out in this
manual.
Failure to observe these notices contained in this manual can result in death, severe
personal injury or considerable damage to property.
Without prior authorization, you are not allowed to perform any modification on the
machine.
Identification
NOTICE
Property loss
Deliverables received should be complete and intact. Exercise caution to ensure that you
do not put a damaged device into service.
Otherwise, you may suffer property loss.
Make sure that the PPU, the MCP and the cables received correspond with the specific
package you ordered from Siemens.
Transport and storage
Note
Transport and storage should meet specified environmental conditions.

Safety instructions
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Mechanical installation
DANGER
Death or serious injury from electric shock
The equipment which is not diconnected from the mains or properly protected contains
hazardous voltage.
Such a voltage may lead to death or serious injury.
Before installing or removing the components of the control system, make sure that the
system is disconnected from the mains. In addition, do install the control system in a
distribution cabinet with an adequate protection level.
DANGER
Death or serious injury from fire or electric shock
If the equipment operates in an area subject to inflammables or combustibles, water or
corrosion hazards, it contains high risk of fire or electric shock.
The fire or electric shock may lead to death or serious injury.
Do install the control system in an area free of inflammables or combustibles, water or
corrosion hazards.
Note
When dimensioning the control cabinet, make sure that the installed components do not
exceed the permissible ambient temperature, even if the outside temperature is high.
Electrical installation
CAUTION
Damage to the control system
The high-voltage components have strong interference in 24 V DC power supply.
If the 24 V DC power supply is not isolated from high-voltage components, the control
system may be damaged.
The 24 V DC protective extra-low voltage
must
be generated as a protective extra-low
voltage with safe electrical isolation (to IEC 204-1, Section 6.4, PELV), and grounded by
with a PELV M signal connection to the central grounding point of the system.

Safety instructions
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Operating Instructions, 12/2014, 6FC5397-2EP10-0BA0 9
DANGER
Death or serious injury from electric shock
The equipment which is not disconnected from the mains contains hazardous voltage.
Such a voltage may lead to death or serious injury.
Before connecting the modules, first disconnect the equipment from the mains!
NOTICE
EMC requirements will not be met.
The unshielded or ungrounded FAST I/O cable is very sensitive to ambient electromagnetic
interference.
In this case, relevant EMC requirements will be not be met.
In order to meet IEC/CISPR requirements, the FAST I/O cable must be shielded and
grounded.
Commissioning
Note
Do not forget to back up data after completing the commissioning work.
Note
Clear the manufacturer password before the machine is delivered; otherwise, end users can
start the controller with the standard data, which can initialize the SINUMERIK 808D control
system. As a consequence, the machine will not run.
Carrying out of repairs
DANGER
Carrying out of repairs
Anywhere in the automation equipment where faults might cause physical injury or major
material damage, 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. using an independent limit value switch,
mechanical locking mechanisms, EMERGENCY STOP/EMERGENCY OFF devices).

Safety instructions
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System overview
2
System overview
The
SINUMERIK 808D
is an economical CNC solution for milling and turning machines. The
turning variant of the control system can control up to two feed axes and one spindle. If
configured with a software option for the "additional axis" function, it can additionally control
an axis that serves as either a rotary axis or a linear axis. The milling variant of the control
system can control up to three feed axes and one spindle.
The following diagram shows a system configuration example for the SINUMERIK 808D
control system:

System overview
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12 Operating Instructions, 12/2014, 6FC5397-2EP10-0BA0
Legend
Name
Order number
1) PPU141.1, turning 6FC5370-1AT00-0AA0 (English)
6FC5370-1AT00-0CA0 (Chinese)
PPU141.1, milling 6FC5370-1AM00-0AA0 (English)
6FC5370-1AM00-0CA0 (Chinese)
2) MCP 6FC5303-0AF35-0AA0 (English)
6FC5303-0AF35-0CA0 (Chinese)
3) Setpoint cable PPU141.1 to CPM60.1 6FC5548-0BA00-1AF0 (5 m)
6FC5548-0BA00-1AH0 (7 m)
6FC5548-0BA00-1BA0 (10 m)
4) SINAMICS V60 Controlled Power Module
(CPM60.1)
6SL3210-5CC14-0UA0 (4 A)
6SL3210-5CC16-0UA0 (6 A)
6SL3210-5CC17-0UA0 (7 A)
6SL3210-5CC21-0UA0 (10 A)
5) 1FL5 Motor 1FL5060-0AC21-0AA0 (4 Nm, with key,
without brake)
1FL5060-0AC21-0AG0 (4 Nm, without key,
without brake)
1FL5062-0AC21-0AA0 (6 Nm, with key,
without brake)
1FL5062-0AC21-0AG0 (6 Nm, without key,
without brake)
1FL5064-0AC21-0AA0 (7.7 Nm, with key,
without brake)
1FL5064-0AC21-0AG0 (7.7 Nm, without key,
without brake)
1FL5066-0AC21-0AA0 (10 Nm, with key,
without brake)
1FL5066-0AC21-0AG0 (10 Nm, without key,
without brake)
1FL5060-0AC21-0AB0 (4 Nm, with key,
with brake)
1FL5060-0AC21-0AH0 (4 Nm, without key,
with brake)
1FL5062-0AC21-0AB0 (6 Nm, with key,
with brake)
1FL5062-0AC21-0AH0 (6 Nm, without key,
with brake)
1FL5064-0AC21-0AB0 (7.7 Nm, with key,
with brake)
1FL5064-0AC21-0AH0 (7.7 Nm, without key,
with brake)
1FL5066-0AC21-0AB0 (10 Nm, with key,
with brake)

System overview
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Operating Instructions, 12/2014, 6FC5397-2EP10-0BA0 13
Legend
Name
Order number
1FL5066-0AC21-0AH0 (10 Nm, without key,
with brake)
6) Setpoint cable PPU141.1 to inverter or
servo spindle drive
6FC5548-0BA05-1AF0 (5 m)
6FC5548-0BA05-1AH0 (7 m)
6FC5548-0BA05-1BA0 (10 m)
7) Power cable (unshielded) 6FX6002-5LE00-1AF0 (5 m)
6FX6002-5LE00-1BA0 (10 m)
8) Brake cable (unshielded) 6FX6002-2BR00-1AF0 (5 m)
6FX6002-2BR00-1BA0 (10 m)
9) Encoder cable (shielded) 6FX6002-2LE00-1AF0 (5 m)
6FX6002-2LE00-1BA0 (10 m)
10) Inverter or servo spindle drive From Siemens or a third-party manufacturer
System structure
The structure of the SINUMERIK 808D control system is shown as follows:
●
CNC Unit
–Panel Processing Unit (PPU)
–Machine Control Panel (MCP)
–Setpoint cable to SINAMICS V60
–Setpoint cable to the spindle
●
Drive unit
–SINAMICS V60 (for controlling feed axes)
–1FL5 motor
–Power cable
–Encoder cable
–Brake cable (for motors with brake)
–Inverter or servo spindle drive (for controlling the spindle)
–Spindle motor
–Spindle encoder
●
Electronic handwheels
A maximum of two handwheels can be connected

System overview
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Connecting
3
3.1
Interface overview
Interface overview on the Panel Processing Unit (PPU)
Figure 3-1 Interface layout
Legend
Interface
Comment
Rear
①X100, X101, X102 Digital inputs
②X200, X201 Digital outputs

Connecting
3.1 Interface overview
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16 Operating Instructions, 12/2014, 6FC5397-2EP10-0BA0
Legend
Interface
Comment
③X21 FAST I/O
④X301, X302 Distributed I/O
⑤X10 Handwheel inputs
⑥X60 Spindle encoder interface
⑦X54 Analog spindle interface
⑧X2 RS232 interface
⑨X51, X52, X53 Pulse drive interfaces
⑩X30 USB interface, for connection with the MCP
⑪X1 Power supply interface, +24V DC power supply
⑫- Battery interface
⑬- Slot for the System CompactFlash Card (CF card)
Front
⑭- USB interface
Note
The rated output current of all the digital outputs is 250 mA.
Interface overview on the Machine Control Panel (MCP)
Figure 3-2 Interface layout
Legend
Interface
Comment
Rear
①X10 USB interface, for connection with the PPU

Connecting
3.2 Connection Overview for SINUMERIK 808D
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3.2
Connection Overview for SINUMERIK 808D

Connecting
3.2 Connection Overview for SINUMERIK 808D
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18 Operating Instructions, 12/2014, 6FC5397-2EP10-0BA0
Note
•The 24 V signal of X200 must be connected; otherwise, the communication between the
PPU and the drives does not function as it should.
•For the turning variant, connection to X52 is optional and depends upon whether you use
the software option "additional axis". If you desire to configure the control system to
control a rotary axis or an additional linear axis, connect X52 to a SINAMICS V60 which
connects to a servo motor.

Connecting
3.3 Connecting the interfaces on the PPU
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Operating Instructions, 12/2014, 6FC5397-2EP10-0BA0 19
3.3
Connecting the interfaces on the PPU
3.3.1
Digital input interfaces - X100, X101, X102
Type Mini Combicon 10-pin
Cable Max. length: 10 m
Max. cross-section:
One cable per connection: ≥ 0.5 mm2
Inputs Permissible level (including ripple)
High level: 18 V - 30 V
Low level: -3 V - +5 V
Table 3- 1 Pin assignment of X100 (DIN0)
Illustration
Pin
Signal
Comment
1 N.C. Not assigned
2 I0.0 Digital input
3 I0.1 Digital input
4 I0.2 Digital input
5 I0.3 Digital input
6 I0.4 Digital input
7 I0.5 Digital input
8 I0.6 Digital input
9 I0.7 Digital input
10 M External ground

Connecting
3.3 Connecting the interfaces on the PPU
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20 Operating Instructions, 12/2014, 6FC5397-2EP10-0BA0
Table 3- 2 Pin assignment of X101 (DIN1)
Interface
Pin
Signal
Comment
1 N.C. Not assigned
2 I1.0 Digital input
3 I1.1 Digital input
4 I1.2 Digital input
5 I1.3 Digital input
6 I1.4 Digital input
7 I1.5 Digital input
8 I1.6 Digital input
9 I1.7 Digital input
10 M External ground
Table 3- 3 Pin assignment of X102 (DIN2)
Interface
Pin
Signal
Comment
1
N.C.
Not assigned
2
I2.0
Digital input
3
I2.1
Digital input
4
I2.2
Digital input
5
I2.3
Digital input
6
I2.4
Digital input
7
I2.5
Digital input
8
I2.6
Digital input
9
I2.7
Digital input
10
M
External ground