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    Guidelines for machine configuration 3,___________________ 11,___________________ 21,___________________ 63,___________________ 83,___________________ 97,___________________ 219,___________________ 239,___________________ 295,___________________ 301,___________________ 307,___________________ ...

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    Legal information 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, ...

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    Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 3 Preface SINUMERIK Documentation The SINUMERIK documentation is organized in 3 parts: ● General documentation ● User documentation ● Manufacturer/service documentation You can obtain further information...

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    Preface Guidelines for machine configuration 4 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Standard version This documentation also mentions components that have not been released for use with SINUMERIK 840D sl. The NC61 catalog is binding for the permitted combinations. Technical Suppo...

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    Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5 Table of contents Preface ...................................................................................................................................................... 3,3 1 System overview.........

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    Table of contents Guidelines for machine configuration 6 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 3 Communication within the system............................................................................................................ 63,63 3.1 Communication overview..............

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    Table of contents Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 7 5.4.2.5 Active Line Module X24 24 V Terminal Adapter........... 130,.............................................................130 5.4.2.6 X200-X202 DRIVE-CLiQ interfaces..................

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    Table of contents Guidelines for machine configuration 8 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.8.6 Overcurrent protection .............................................................................................................. 177,177 5.8.7 Line formation ...................

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    Table of contents Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 9 7.5 Circuit Manual Group =3................................................................................................... 259,.........259 7.6 Circuit Manual Group =4...................

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    Table of contents Guidelines for machine configuration 10 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1

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    Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 11 System overview 11.1 Application General system characteristics and areas of application SINUMERIK 840D sl is a digital complete system integrated in the SINAMICS S120 drive system and supplemented by the S...

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    System overview 1.2 System configuration Guidelines for machine configuration 12 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 1.2 System configuration The heart of the SINUMERIK 840D sl is the Numerical Control Unit (NCU). It combines NCK, HMI, PLC, closed-loop control and communication ta...

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    System overview 1.3 Variants Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 13 ● Programming device ● SINAMICS S120 drive system with feed and main spindle motors, such as – 1FT/1FK/1FN/1FW6/1FE1/2SP1 synchronous motors – 1PH/1PM asynchronous moto...

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    System overview 1.4 SINAMICS S120 components Guidelines for machine configuration 14 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 ● The NCU 730.x is recommended for maximum dynamics and accuracy in mold making applications or the high-speed cutting sector. ● Since it has the highest PL...

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    System overview 1.4 SINAMICS S120 components Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 15 New system architecture with central control unit Electronically-coordinated single drives solve your drive task together. Overlaid controllers control the driv...

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    System overview 1.5 SINAMICS S120 / SINUMERIK 840D sl Component Overview Guidelines for machine configuration 16 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 1.5 SINAMICS S120 / SINUMERIK 840D sl Component Overview The following overview contains the SINAMICS S120 and SINUMERIK components ...

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    System overview 1.5 SINAMICS S120 / SINUMERIK 840D sl Component Overview Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 17 The following power components are offered: ● Line-side power components, such as fuses, contactors, chokes and filters for switch...

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    System overview 1.6 User interface software (HMI software) Guidelines for machine configuration 18 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Motor Modules They make the energy from the DC link available at an adjusted voltage and with variable frequency. This is used to operate the conn...

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    System overview 1.6 User interface software (HMI software) Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 19 Switching between operator panels When an Ethernet switch is used, you can switch between embedded HMI (available on NCU) and HMI-Advanced (availa...

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    System overview 1.6 User interface software (HMI software) Guidelines for machine configuration 20 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1

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    Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 21 Structure of the drive group 22.1 Structure 2.1.1 Drive group structure The individual components, such as Control Unit and power units, can be attached directly to each other without any separation. The sp...

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    Structure of the drive group 2.1 Structure Guidelines for machine configuration 22 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 2-1 Removal of the DC link bridge The DC link bridges must be removed by loosening the M4 screws. DANGER The DC link bridge must not be removed for powe...

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    Structure of the drive group 2.1 Structure Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 23 2.1.2 Single row layout All required components, such as Control Unit and power units are arranged in a row. The drive group is constructed depending on the avail...

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    Structure of the drive group 2.1 Structure Guidelines for machine configuration 24 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 2.1.3 Two-row / multi-row construction The components of the SINAMICS system can also be constructed as two or more rows. As previously described above, the limit...

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    Structure of the drive group 2.1 Structure Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 25 DC link adapters are used to forward the DC link. Cross-sections of 35 mm² to 95 mm², max. 200 A, can be connected to the connection terminals. The wiring outs...

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    Structure of the drive group 2.1 Structure Guidelines for machine configuration 26 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 2.1.4 Center infeed (single row construction) for 16 to 120 kW Line Modules Another variant of the DC link supply is the center infeed. For the 16 to 120 kW Line ...

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    Structure of the drive group 2.2 Layout of the Components Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 27 2.1.5 Direct installation of a CU-/NCU-/NX module on the Line Module The Line Modules permit the docking of a CU320-/ NCU-/ NX component using the ...

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    Structure of the drive group 2.2 Layout of the Components Guidelines for machine configuration 28 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Fastening Possibilities Figure 2-6 Main NCU-NX fastening types Table 2- 1 Fastening possibilities for NCU 710 and NX NCU 710 NX NCU 710+NXs A (di...

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    Structure of the drive group 2.2 Layout of the Components Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 29 2.2.2 Layout of the NX for single row construction integrated in the power unit group If NX components are present, they should be added between th...

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    Structure of the drive group 2.3 Current Carrying Capacity of the DC Link Busbar Guidelines for machine configuration 30 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 2.3 Current Carrying Capacity of the DC Link Busbar The current carrying capacity of the DC link busbar must be observed for...

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    Structure of the drive group 2.3 Current Carrying Capacity of the DC Link Busbar Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 31 Example 1: Connection of several Motor Modules with different current carrying capacity of the DC link busbar to a Line Modu...

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    Structure of the drive group 2.4 Shield Connection Guidelines for machine configuration 32 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Example 2: Connection of several Motor Modules with the same current carrying capacity of the DC link busbar to a Line Module with center infeed. Figure...

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    Structure of the drive group 2.4 Shield Connection Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 33 2.4.1 SINAMICS Components Dimension Drawings (Internal Air Cooling) Figure 2-11 Dimension drawing of shield connecting plate on a 100 mm component with i...

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    Structure of the drive group 2.4 Shield Connection Guidelines for machine configuration 34 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 2-12 Dimension drawing of shield connecting plate on a 150 mm component with internal air cooling, all dimensions in mm and (inches)

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    Structure of the drive group 2.4 Shield Connection Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 35 Figure 2-13 Dimension drawing of shield connecting plate on a 200 mm component with internal air cooling, all dimensions in mm and (inches)

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    Structure of the drive group 2.4 Shield Connection Guidelines for machine configuration 36 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 2-14 Dimension drawing of shield connecting plate on a 300 mm component with internal air cooling, all dimensions in mm and (inches)

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    Structure of the drive group 2.4 Shield Connection Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 37 2.4.2 SINAMICS Components Dimension Drawings (External Air Cooling) Figure 2-15 Dimension drawing of shield connecting plate on a 100 mm component with e...

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    Structure of the drive group 2.4 Shield Connection Guidelines for machine configuration 38 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 2-16 Dimension drawing of shield connecting plate on a 150 mm component with external air cooling, all dimensions in mm and (inches)

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    Structure of the drive group 2.4 Shield Connection Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 39 Figure 2-17 Dimension drawing of shield connecting plate on a 200 mm component with external air cooling, all dimensions in mm and (inches)

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    Structure of the drive group 2.4 Shield Connection Guidelines for machine configuration 40 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 2-18 Dimension drawing of shield connecting plate on a 300 mm component with external air cooling, all dimensions in mm and (inches) 2.4.3 Shield ...

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    Structure of the drive group 2.5 Note for the installation clearance for the connection cables Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 41 Preassembled cable on a 100 mm component Preassembled cable on a 200 mm component 2.5 Note for the installat...

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    Structure of the drive group 2.5 Note for the installation clearance for the connection cables Guidelines for machine configuration 42 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 2.5.2 Clearance of the Power Components The installation clearance is defined by ● Ventilation clearance ●...

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    Structure of the drive group 2.6 Heat Dissipation of the Control Cabinet Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 43 2.6 Heat Dissipation of the Control Cabinet 2.6.1 Ventilation Clearances of the SINUMERIK Components Table 2- 4 Ventilation clearanc...

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    Structure of the drive group 2.6 Heat Dissipation of the Control Cabinet Guidelines for machine configuration 44 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Table 2- 5 Ventilation clearances above and below the components Component Order number Clearance [mm] CU320/CU320-2 DP 6SL3040-0MA0...

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    Structure of the drive group 2.6 Heat Dissipation of the Control Cabinet Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 45 Figure 2-20 Clearances for booksize drive line-up with internal air cooling

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    Structure of the drive group 2.6 Heat Dissipation of the Control Cabinet Guidelines for machine configuration 46 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 2-21 Clearances for booksize drive line-up with external air cooling

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    Structure of the drive group 2.6 Heat Dissipation of the Control Cabinet Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 47 Figure 2-22 Spray protection for external cooling

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    Structure of the drive group 2.6 Heat Dissipation of the Control Cabinet Guidelines for machine configuration 48 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 2-23 Cooling clearances for 300 mm components with mounted equipment fan

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    Structure of the drive group 2.6 Heat Dissipation of the Control Cabinet Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 49 Figure 2-24 Cooling clearances, rail-mounted modules (e.g. VSM, SMC, TM, DMC)

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    Structure of the drive group 2.6 Heat Dissipation of the Control Cabinet Guidelines for machine configuration 50 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 2.6.3 General information on ventilation The SINAMICS equipment is ventilated separately by means of integrated fans and is in some ...

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    Structure of the drive group 2.6 Heat Dissipation of the Control Cabinet Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 51 Figure 2-25 Examples of cabinet ventilation CAUTION The air guidance and arrangement of the cooling equipment must be chosen in s...

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    Structure of the drive group 2.6 Heat Dissipation of the Control Cabinet Guidelines for machine configuration 52 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 2.6.4 Power Loss of the SINUMERIK Components The following power losses apply to operation with rated power: Table 2- 6 List of powe...

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    Structure of the drive group 2.6 Heat Dissipation of the Control Cabinet Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 53 2.6.6 Power loss for Control Units, Sensor Modules, and other system components Table 2- 7 Overview of power loss during rated opera...

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    Structure of the drive group 2.6 Heat Dissipation of the Control Cabinet Guidelines for machine configuration 54 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 2.6.7 Power loss for line filters and line reactors Table 2- 8 Overview of power loss during rated operation for line filters and li...

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    Structure of the drive group 2.6 Heat Dissipation of the Control Cabinet Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 55 Unit Power loss Line reactors for Smart Line Modules 5 kW W 62 10 kW W 116 16 kW W 110 36 kW W 170 Line reactors for Basic Line Mod...

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    Structure of the drive group 2.6 Heat Dissipation of the Control Cabinet Guidelines for machine configuration 56 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Unit Power loss 60 A W 615,2 85 A W 786 132 A W 1270,4 200 A W 2070,4 Single Motor Modules Booksize Compact 3 A W 68 1) 5 A W 98 1)...

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    Structure of the drive group 2.6 Heat Dissipation of the Control Cabinet Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 57 2.6.9 Power loss for power units with external air cooling Table 2- 10 Overview of power loss at rated operation for power units wit...

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    Structure of the drive group 2.6 Heat Dissipation of the Control Cabinet Guidelines for machine configuration 58 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 2.6.10 Power loss for power units with cold plate With cold-plate cooling, only part of the power loss remains in the cabinet. The t...

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    Structure of the drive group 2.6 Heat Dissipation of the Control Cabinet Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 59 Unit Internal power loss 1) External power loss Total power loss Double Motor Modules Booksize Compact 2x1.7 A W 42 (20,4 + 21,6) 7...

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    Structure of the drive group 2.6 Heat Dissipation of the Control Cabinet Guidelines for machine configuration 60 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 2.6.12 Electronics losses of power units Table 2- 13 Electronics losses for power units with internal/external air cooling Component...

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    Structure of the drive group 2.6 Heat Dissipation of the Control Cabinet Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 61 Table 2- 14 Electronics losses for power units with cold plate Component Cold plate Power loss [W] 3 A 15,6 5 A 15,6 9 A 15,6 18 A 1...

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    Structure of the drive group 2.6 Heat Dissipation of the Control Cabinet Guidelines for machine configuration 62 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 2.6.13 Dimensioning Climate Control Equipment Cabinet manufacturers provide calculation programs for selecting climate control equip...

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    Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 63 Communication within the system 33.1 Communication overview Figure 3-1 Example based on the SINUMERIK 840D sl network configuration Note The significance of items ① to ⑤ is explained on the pages tha...

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    Communication within the system 3.1 Communication overview Guidelines for machine configuration 64 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 ① (NCU) ● IP assignment of the server ● The ports need to be activated if VNC and HMI/Step7 are to be used (SW2.4.xxx and higher): /user/sys...

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    Communication within the system 3.1 Communication overview Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 65 ③ (PG/PC) On the system network (X120): On the service network (X127):  TCP/IP Internet protocol – properties – general – Set fixed IP...

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    Communication within the system 3.1 Communication overview Guidelines for machine configuration 66 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 ⑤ (machine control panel – Industrial Ethernet) Note The Service menu (Backup/Restore) is only available for an analog monitor, TCU OP, or P...

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    Communication within the system 3.2 X122 and X132 Interface Overview Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 67 3.2 X122 and X132 Interface Overview X122 and X132 interfaces for NCU 7x0 Figure 3-2 X122 and X132 interfaces for NCU 7x0 Note The NX...

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    Communication within the system 3.2 X122 and X132 Interface Overview Guidelines for machine configuration 68 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 X122 and X132 block diagram for NCU 7x0 + 24 VMM Figure 3-3 X122 and X132 block diagram for NCU 7x0

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    Communication within the system 3.3 NCU 7x0 and NX1x Terminal Assignment Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 69 X122 block diagram for NX1x Figure 3-4 NX1x block diagram 3.3 NCU 7x0 and NX1x Terminal Assignment Introduction When the drive wiza...

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    Communication within the system 3.3 NCU 7x0 and NX1x Terminal Assignment Guidelines for machine configuration 70 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Terminal assignment X122 (NCU 7x0) Pin no. Function Assignment recommendation BICO source/sink Macro number (up to SW 2.5) ON/OFF ...

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    Communication within the system 3.3 NCU 7x0 and NX1x Terminal Assignment Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 71 Terminal assignment X132 (for NCU 7x0) Pin no. Function Assignment recommendation BICO source/sink Macro number 1 Input Digital in...

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    Communication within the system 3.3 NCU 7x0 and NX1x Terminal Assignment Guidelines for machine configuration 72 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Terminal assignment X122 (NX 10/15) Pin no. Function Assignment recommendation BICO source/sink Macro number 1 Input1) "Infeed...

  • Page 73

    Communication within the system 3.4 Power Supply Interface Variants Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 73 3.4 Power Supply Interface Variants 3.4.1 Ways of connecting the line supply A distinction is made between: ● Direct operation of the ...

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    Communication within the system 3.4 Power Supply Interface Variants Guidelines for machine configuration 74 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Note Line connection of motors In combination with the drive system, the motors are generally approved for operation on TN and TT syste...

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    Communication within the system 3.4 Power Supply Interface Variants Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 75 3.4.3 Operation of the line connection components via an autotransformer An autotransformer can be used to adapt the voltage in the range...

  • Page 76

    Communication within the system 3.4 Power Supply Interface Variants Guidelines for machine configuration 76 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 3-7 Autotransformer 3.4.4 Operation of the line connection components via an isolating transformer The isolating transformer conv...

  • Page 77

    Communication within the system 3.4 Power Supply Interface Variants Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 77 ● The installation altitude is higher than 2000 m above sea level. ● A line filter should be used in a line supply system that is not...

  • Page 78

    Communication within the system 3.4 Power Supply Interface Variants Guidelines for machine configuration 78 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 3.4.5 Residual-current operated circuit breakers (RCD) Residual-current operated circuit breakers (RCD) can be used in addition to the ov...

  • Page 79

    Communication within the system 3.4 Power Supply Interface Variants Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 79 Figure 3-9 Connecting a residual-current operated circuit breaker Recommendation SIEMENS selectively switching AC/DC-sensitive residual-...

  • Page 80

    Communication within the system 3.4 Power Supply Interface Variants Guidelines for machine configuration 80 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 3.4.6 Residual-current monitors (RCM) Used in conjunction with appropriate circuit breakers, residual-current monitors (RCMs) provide fir...

  • Page 81

    Communication within the system 3.4 Power Supply Interface Variants Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 81 PE Figure 3-10 Connecting a residual-current monitor Recommendation ● Bender AC/DC-sensitive residual-current monitor RCMA471LY, with m...

  • Page 82

    Communication within the system 3.4 Power Supply Interface Variants Guidelines for machine configuration 82 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1

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    Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 83 Safety Integrated 4 WARNING The following chapter describes the uses of the "Safety Integrated" functionality. The detailed knowledge of the "Safety Integrated sl Function Manual" (FBS...

  • Page 84

    Safety Integrated 4.1 SINAMICS Safety Integrated Guidelines for machine configuration 84 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Both terminals must be simultaneously energized, otherwise a fault will be issued. Note For the secure control of the safety functions using terminals, an...

  • Page 85

    Safety Integrated 4.1 SINAMICS Safety Integrated Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 85 M Figure 4-2 Safe standstill terminals; control, e.g. with the fail safe output of the ET200S Grouping drives If the function is to be simultaneously initia...

  • Page 86

    Safety Integrated 4.1 SINAMICS Safety Integrated Guidelines for machine configuration 86 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Example: Terminal grouping for safe standstill (SH) The "Safe standstill" function should be able to be selected/deselected separately for group 1...

  • Page 87

    Safety Integrated 4.1 SINAMICS Safety Integrated Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 87 MM Figure 4-4 Safe standstill terminals grouping; control, e.g. with the fail safe output of the ET200S

  • Page 88

    Safety Integrated 4.1 SINAMICS Safety Integrated Guidelines for machine configuration 88 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Enabling the safe standstill (SH) function The safe standstill (SH) function is enabled using the following parameters: p9601.0 SH using terminals on the C...

  • Page 89

    Safety Integrated 4.1 SINAMICS Safety Integrated Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 89 4.1.2 Safe Brake Control (SBC) Description The Safe Brake Control (SBC) is used to control the holding brakes that operate using the quiescent current princ...

  • Page 90

    Safety Integrated 4.2 SINUMERIK Safety Integrated Guidelines for machine configuration 90 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 4.2 SINUMERIK Safety Integrated 4.2.1 Fundamentals Functions SINUMERIK Safety Integrated can use not only "Safe standstill (SH)" and "Safe b...

  • Page 91

    Safety Integrated 4.2 SINUMERIK Safety Integrated Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 91 Signal assignment and significance Part of the signal assignment and significance for the PROFIsafe modules is explained in the following section: 4/8 F-DI...

  • Page 92

    Safety Integrated 4.2 SINUMERIK Safety Integrated Guidelines for machine configuration 92 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Signal state channel 1 = "1" and channel 5 = "1": Protective door closed and interlocked. Signal state channel 1 = "0" and ch...

  • Page 93

    Safety Integrated 4.2 SINUMERIK Safety Integrated Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 93 Figure 4-7 Signal assignment electronics module, 4F-DO, 24 VDC_2 A, PROFIsafe Meaning and use of the individual signals Valve unit 1 F-DO terminal 1,2 (ch...

  • Page 94

    Safety Integrated 4.2 SINUMERIK Safety Integrated Guidelines for machine configuration 94 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Signal state channel 2 = "1" Valve in the flow position Not assigned [F-DO terminal 13.14 (channel 3 P/M)] Power module PM-E F This module combin...

  • Page 95

    Safety Integrated 4.2 SINUMERIK Safety Integrated Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 95 Not assigned [PM-E F terminal 11,12 or channel 15,16 (channel 2 P/M)] Shutdown of the power supply for the following external standard DO module (terminal ...

  • Page 96

    Safety Integrated 4.2 SINUMERIK Safety Integrated Guidelines for machine configuration 96 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 4-9 Signal assignment, power module PM-D F 24 V DC PROFIsafe, fail-safe motor starter Significance and use of the individual signals: No (external)...

  • Page 97

    Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 97 Connection of the Components 55.1 Line Contactor Control The line contactor is used for the electrical isolation of the drive group and the DC link from the energy supply system. When selecting a line cont...

  • Page 98

    Connection of the Components 5.1 Line Contactor Control Guidelines for machine configuration 98 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 ● Enable pulse (EP): A deactivation of the line contactor may only be made when the enable pulse (EP) signal has been removed previously (t ≥ 10 ...

  • Page 99

    Connection of the Components 5.1 Line Contactor Control Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 99 Note If the line contactor should also be safely disconnected (safety), the control must be integrated in an existing safety control. This is the o...

  • Page 100

    Connection of the Components 5.1 Line Contactor Control Guidelines for machine configuration 100 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.1.3 Line Contactor Control Commissioning using an Example Assumption: ● Line contactor control uses a digital output of the Control Unit (DI/DO ...

  • Page 101

    Connection of the Components 5.1 Line Contactor Control Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 101 Function diagram overview ● 8934 missing enables, line contactor control Parameter overview ● r0863.1 CO/BO: Drive coupling status word/contro...

  • Page 102

    Connection of the Components 5.2 Active Interface Module (AIM) Guidelines for machine configuration 102 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.2 Active Interface Module (AIM) 5.2.1 Safety information NOTICE Active Interface Modules must only be operated if the option "Line f...

  • Page 103

    Connection of the Components 5.2 Active Interface Module (AIM) Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 103 5.2.2 Description Active Interface Modules are line-side interfaces for the Active Line Modules. They contain the following functional units...

  • Page 104

    Connection of the Components 5.2 Active Interface Module (AIM) Guidelines for machine configuration 104 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.2.3 Operating an Active Interface Module on an isolated-neutral network (IT system) Operating an Active Interface Module on an isolated-neu...

  • Page 105

    Connection of the Components 5.2 Active Interface Module (AIM) Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 105 5.2.5 Electronics power supply X124 Table 5- 1 Terminal block X124 Terminal Function Technical specifications + Electronics power supply + E...

  • Page 106

    Connection of the Components 5.2 Active Interface Module (AIM) Guidelines for machine configuration 106 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.2.7 Line/power connection Table 5- 3 Type of connection Terminals Designations Line supply connection (line supply) L1, L2, L3 Load connect...

  • Page 107

    Connection of the Components 5.2 Active Interface Module (AIM) Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 107 5.2.8 Overview When establishing a shield connection, please use an appropriate plate at the base of the component (36 kW and above). Figur...

  • Page 108

    Connection of the Components 5.2 Active Interface Module (AIM) Guidelines for machine configuration 108 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 5-5 Interface description: Active Interface Module 36 kW

  • Page 109

    Connection of the Components 5.2 Active Interface Module (AIM) Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 109 Figure 5-6 Interface description: Active Interface Module 55 kW

  • Page 110

    Connection of the Components 5.2 Active Interface Module (AIM) Guidelines for machine configuration 110 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 5-7 Interface description: Active Interface Module 80 kW and 120 kW

  • Page 111

    Connection of the Components 5.3 HFD reactors for Active Line Modules Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 111 5.2.9 Connection example L3 L2 L1 X21 4 3 2 1 U1 V1 W1DO CU + M + Temp- TempT1 T2 4 3 2 1 - - + + U2V2W2PEPE PEFan offext.24 V Figure...

  • Page 112

    Connection of the Components 5.3 HFD reactors for Active Line Modules Guidelines for machine configuration 112 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 CAUTION The surfaces of the line reactors can become extremely hot. To prevent adjacent components from suffering damage due to these...

  • Page 113

    Connection of the Components 5.3 HFD reactors for Active Line Modules Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 113 5.3.2 Combining line reactors and line filters Figure 5-9 Options for combining line reactors and line filters

  • Page 114

    Connection of the Components 5.3 HFD reactors for Active Line Modules Guidelines for machine configuration 114 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.3.3 Description The HFD reactor must be used to connect regulated infeed/regenerative feedback components (Line Modules) to the netw...

  • Page 115

    Connection of the Components 5.3 HFD reactors for Active Line Modules Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 115 5.3.5 Overview Figure 5-10 HFD line reactor 16 kW Figure 5-11 HFD line reactor 36 kW

  • Page 116

    Connection of the Components 5.3 HFD reactors for Active Line Modules Guidelines for machine configuration 116 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 5-12 HFD line reactor 55 kW Figure 5-13 HFD line reactor 80 kW

  • Page 117

    Connection of the Components 5.3 HFD reactors for Active Line Modules Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 117 Figure 5-14 HFD line reactor 120 kW 5.3.6 Technical data Table 5- 5 Technical data for HFD line reactors Unit 6SL3000–0DE21-6AAx...

  • Page 118

    Connection of the Components 5.3 HFD reactors for Active Line Modules Guidelines for machine configuration 118 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.3.7 Dimension drawings Figure 5-15 Dimension drawing of HFD line reactor 16 kW, all dimensions in mm and (inches)

  • Page 119

    Connection of the Components 5.3 HFD reactors for Active Line Modules Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 119 Figure 5-16 Dimension drawing of HFD line reactor 36 kW, all dimensions in mm and (inches)

  • Page 120

    Connection of the Components 5.3 HFD reactors for Active Line Modules Guidelines for machine configuration 120 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 5-17 Dimension drawing of HFD line reactor 55 kW, all dimensions in mm and (inches)

  • Page 121

    Connection of the Components 5.3 HFD reactors for Active Line Modules Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 121 Figure 5-18 Dimension drawing of HFD line reactor 80 kW, all dimensions in mm and (inches)

  • Page 122

    Connection of the Components 5.3 HFD reactors for Active Line Modules Guidelines for machine configuration 122 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 5-19 Dimension drawing of HFD line reactor 120 kW, all dimensions in mm and (inches)

  • Page 123

    Connection of the Components 5.4 Line Modules Interfaces Description Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 123 5.4 Line Modules Interfaces Description 5.4.1 Line Modules Overview The Line Module is used to connect the drive group to the energy su...

  • Page 124

    Connection of the Components 5.4 Line Modules Interfaces Description Guidelines for machine configuration 124 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Active Line Module The self-managed infeed/regenerative unit with booth converter creates an increased controlled DC link voltage. This...

  • Page 125

    Connection of the Components 5.4 Line Modules Interfaces Description Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 125 CAUTION As soon as the energy supply is present at the infeed terminals (-X1:U1/V1/W1) of the Active Line Module, the DC link will be ...

  • Page 126

    Connection of the Components 5.4 Line Modules Interfaces Description Guidelines for machine configuration 126 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.4.2 Active Line Modules with Internal Air Cooling 5.4.2.1 Overview Figure 5-20 Active Line Module with internal air cooling (example...

  • Page 127

    Connection of the Components 5.4 Line Modules Interfaces Description Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 127 5.4.2.2 Connection example PEPEPE Figure 5-21 Example connection of Active Line Module

  • Page 128

    Connection of the Components 5.4 Line Modules Interfaces Description Guidelines for machine configuration 128 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Note If you are using a VSM10 Voltage Sensing Module, the leading opening contact can be omitted. 5.4.2.3 X1 line connection Table 5...

  • Page 129

    Connection of the Components 5.4 Line Modules Interfaces Description Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 129 5.4.2.4 Active Line Module X21 EP Terminals Table 5- 10 X21 terminal block Terminal Designation Technical specifications 1 Reserved, d...

  • Page 130

    Connection of the Components 5.4 Line Modules Interfaces Description Guidelines for machine configuration 130 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 WARNING For operation, ground must be attached to the -X21:3 24 VDC terminals and the -X21:4 terminals. For cancelation, a pulse supp...

  • Page 131

    Connection of the Components 5.4 Line Modules Interfaces Description Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 131 PIN Signal name Technical specifications Blanking plate for DRIVE-CLiQ interfaces included in the scope of delivery; blanking plate (...

  • Page 132

    Connection of the Components 5.4 Line Modules Interfaces Description Guidelines for machine configuration 132 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.4.2.9 Meaning of the LEDs on the active line module Table 5- 14 Meaning of the LEDs on the Line Module LED Color Status Description -...

  • Page 133

    Connection of the Components 5.4 Line Modules Interfaces Description Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 133 5.4.3 Smart Line Modules (5 kW und 10 kW) with internal air cooling 5.4.3.1 Overview Figure 5-22 Smart Line Modules 5 kW and 10 kW wit...

  • Page 134

    Connection of the Components 5.4 Line Modules Interfaces Description Guidelines for machine configuration 134 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 5-23 Smart Line Module with internal air cooling (16 kW)

  • Page 135

    Connection of the Components 5.4 Line Modules Interfaces Description Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 135 Figure 5-24 Smart Line Module with internal air cooling (36 kW)

  • Page 136

    Connection of the Components 5.4 Line Modules Interfaces Description Guidelines for machine configuration 136 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.4.3.2 Connection example Figure 5-25 Smart Line Module connection example

  • Page 137

    Connection of the Components 5.4 Line Modules Interfaces Description Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 137 5.4.3.3 X1 line connection Table 5- 15 Terminal strip X1 of Smart Line Modules 5 kW and 10 kW Terminal Technical specifications U1 V1 ...

  • Page 138

    Connection of the Components 5.4 Line Modules Interfaces Description Guidelines for machine configuration 138 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.4.3.4 X21 terminals: smart line module The Smart Line Module (5/10 kW) is controlled using the -X21, -X22 terminal block. A connectio...

  • Page 139

    Connection of the Components 5.4 Line Modules Interfaces Description Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 139 Terminal Name Technical specifications 3 DI: Enable pulses EP +24 V EnablePulses Enable EP control input: The activation is achieved...

  • Page 140

    Connection of the Components 5.4 Line Modules Interfaces Description Guidelines for machine configuration 140 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.4.3.5 X22 terminals: smart line module Table 5- 19 Terminal block X22 Terminal Designation Technical specifications 1 24 V power sup...

  • Page 141

    Connection of the Components 5.4 Line Modules Interfaces Description Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 141 5.4.3.6 X24 24 V terminal adapter Table 5- 20 Terminal block X24 Terminal Designation Technical specifications + 24 V power supply 2...

  • Page 142

    Connection of the Components 5.4 Line Modules Interfaces Description Guidelines for machine configuration 142 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.4.3.9 Meaning of the LEDs on the Smart Line Module Table 5- 22 Meaning of the LEDs on the Smart Line Module LED Color State Descripti...

  • Page 143

    Connection of the Components 5.5 Motor Modules Interface Description Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 143 5.5 Motor Modules Interface Description 5.5.1 Overview Figure 5-26 Double Motor Module, booksize format, with internal cooling

  • Page 144

    Connection of the Components 5.5 Motor Modules Interface Description Guidelines for machine configuration 144 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.5.2 Connection examples Figure 5-27 Connection example of Motor Modules 3 A to 30 A and Double Motor Modules 3 A to 18 A

  • Page 145

    Connection of the Components 5.5 Motor Modules Interface Description Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 145 Figure 5-28 Example connection of Single Motor Modules 45 A to 200 A 5.5.3 Motor/brake connection Table 5- 23 Terminal strip X1/X2 Mot...

  • Page 146

    Connection of the Components 5.5 Motor Modules Interface Description Guidelines for machine configuration 146 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Table 5- 24 Terminal strip Single Motor Module 45 A to 200 A Terminals Technical specifications U2 V2 W2 45 A to 60 A: Threaded bolt ...

  • Page 147

    Connection of the Components 5.5 Motor Modules Interface Description Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 147 5.5.4 X21/X22 EP Terminals / Motor Module Temperature Sensor Connection Note The Motor Module is controlled using the -X21, -X22 term...

  • Page 148

    Connection of the Components 5.5 Motor Modules Interface Description Guidelines for machine configuration 148 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 The "Safe standstill (SH)" function is used in a fault situation or in conjunction with a machine function for the safe disco...

  • Page 149

    Connection of the Components 5.5 Motor Modules Interface Description Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 149 5.5.5 X200-X203 DRIVE-CLiQ interface Table 5- 26 DRIVE-CLiQ interface X200-X202: Single Motor Module DRIVE-CLiQ interface X200-X203: Do...

  • Page 150

    Connection of the Components 5.6 DRIVE-CLiQ topologies Guidelines for machine configuration 150 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 WARNING Hazardous DC link voltages may be present at any time regardless of the status of the "DC link" LED. The warning information on ...

  • Page 151

    Connection of the Components 5.6 DRIVE-CLiQ topologies Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 151 Actual topology The actual topology is the actual DRIVE-CLiQ wiring harness. When the drive system components are started up, the actual topology is ...

  • Page 152

    Connection of the Components 5.6 DRIVE-CLiQ topologies Guidelines for machine configuration 152 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 ● p9906/p9908 = 2 component type ● p9906/p9908 = 3 component class (e.g. Sensor Module or Motor Module) Figure 5-29 Topology of the SINUMERIK dr...

  • Page 153

    Connection of the Components 5.6 DRIVE-CLiQ topologies Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 153 Rules for wiring DRIVE-CLiQ The following rules must be observed when wiring DRIVE-CLiQ (the SINAMICS S120 Function Manual contains additional rules...

  • Page 154

    Connection of the Components 5.6 DRIVE-CLiQ topologies Guidelines for machine configuration 154 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 ● When a unit in chassis format is connected to a DRIVE-CLiQ line, the smallest current controller sampling time must be at least 250 µs. Example...

  • Page 155

    Connection of the Components 5.6 DRIVE-CLiQ topologies Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 155 Table 5- 29 VSM connection Component VSM connection Active Line Module booksize X202 Active Line Module chassis X402 The SINAMICS S120 Function Manua...

  • Page 156

    Connection of the Components 5.6 DRIVE-CLiQ topologies Guidelines for machine configuration 156 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.6.3 NX10/15 wiring NX10/15 components can be connected to the control unit via DRIVE-CLiQ. The following rules apply to wiring of the NX10/15: ● ...

  • Page 157

    Connection of the Components 5.6 DRIVE-CLiQ topologies Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 157 Figure 5-31 NX10/15 topology Additional references For information on commissioning NX components, please refer to the "IBN CNC: NCK, PLC, Driv...

  • Page 158

    Connection of the Components 5.6 DRIVE-CLiQ topologies Guidelines for machine configuration 158 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.6.4 Connectable DRIVE-CLiQ components Components As a rule, all SINAMICS components approved for SINUMERIK can be connected using the DRIVE-CLiQ i...

  • Page 159

    Connection of the Components 5.7 DRIVE-CLiQ Hub Modules (DMC20, DME20) Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 159 5.7 DRIVE-CLiQ Hub Modules (DMC20, DME20) 5.7.1 DMC20 5.7.1.1 Description The DMC20 DRIVE-CLiQ Hub Module is used to implement a star...

  • Page 160

    Connection of the Components 5.7 DRIVE-CLiQ Hub Modules (DMC20, DME20) Guidelines for machine configuration 160 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.7.1.2 Overview Figure 5-32 Interface description of the DMC20 5.7.1.3 DRIVE-CLiQ interface Table 5- 32 DRIVE-CLiQ interfaces X500...

  • Page 161

    Connection of the Components 5.7 DRIVE-CLiQ Hub Modules (DMC20, DME20) Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 161 Pin Signal name Technical specifications A + (24 V) Power supply B M (0 V) Electronics ground Type: RJ45 plus socket Blanking plate ...

  • Page 162

    Connection of the Components 5.7 DRIVE-CLiQ Hub Modules (DMC20, DME20) Guidelines for machine configuration 162 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.7.1.5 Significance of the LED on the DMC20 Table 5- 34 Significance of the LED on the DMC20 LED Color Status Description - Off Elec...

  • Page 163

    Connection of the Components 5.7 DRIVE-CLiQ Hub Modules (DMC20, DME20) Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 163 5.7.1.6 Dimension drawing 150891052811135501:2 Figure 5-33 Dimension drawing of the DMC20 5.7.1.7 Technical data Table 5- 35 Technica...

  • Page 164

    Connection of the Components 5.7 DRIVE-CLiQ Hub Modules (DMC20, DME20) Guidelines for machine configuration 164 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.7.2 DME20 5.7.2.1 Description The DRIVE-CLiQ Hub Module External DME20 is used to implement star-shaped distribution of a DRIVE-CLi...

  • Page 165

    Connection of the Components 5.7 DRIVE-CLiQ Hub Modules (DMC20, DME20) Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 165 5.7.2.3 Overview Figure 5-34 Interface overview: DME20 5.7.2.4 Electronics power supply X524 Table 5- 36 X524 socket for the electro...

  • Page 166

    Connection of the Components 5.7 DRIVE-CLiQ Hub Modules (DMC20, DME20) Guidelines for machine configuration 166 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Note The maximum cable length for the P24 supply of the DME20 is 100 m. 5.7.2.5 DRIVE-CLiQ interface Table 5- 37 DRIVE-CLiQ inter...

  • Page 167

    Connection of the Components 5.7 DRIVE-CLiQ Hub Modules (DMC20, DME20) Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 167 5.7.2.6 Cable lengths Table 5- 38 Cable length of P24 supply cable: Connected consumers 1) 1 2 3 4 5 Cross section 0.34 mm² 75...

  • Page 168

    Connection of the Components 5.7 DRIVE-CLiQ Hub Modules (DMC20, DME20) Guidelines for machine configuration 168 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Pin assignment of the cable Table 5- 40 Connection to X524 electronics power supply Pin Designation Technical specifications 1 (brow...

  • Page 169

    Connection of the Components 5.7 DRIVE-CLiQ Hub Modules (DMC20, DME20) Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 169 5.7.2.8 Dimension drawing Figure 5-35 Dimension drawing: DME20

  • Page 170

    Connection of the Components 5.7 DRIVE-CLiQ Hub Modules (DMC20, DME20) Guidelines for machine configuration 170 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.7.2.9 Installation Figure 5-36 DME20 installation Installation 1. Place the hole drilling template on the contact surface. 2. The ...

  • Page 171

    Connection of the Components 5.8 Electronics Power Supply Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 171 5.7.2.10 Technical data Table 5- 41 Technical data of the DME20 Unit Value Electronics power supply Voltage Current (without DRIVE-CLiQ node) VD...

  • Page 172

    Connection of the Components 5.8 Electronics Power Supply Guidelines for machine configuration 172 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 The operation of motors with integrated holding brake requires a regulated DC power supply. The power is supplied from the internal 24 V busbars. ...

  • Page 173

    Connection of the Components 5.8 Electronics Power Supply Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 173 Table 5- 44 Overview of 24 VDC current consumption Component Typical current consumption [ADC] NCU 7x0 (without load at the digital outputs) 2.1 ...

  • Page 174

    Connection of the Components 5.8 Electronics Power Supply Guidelines for machine configuration 174 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Component Typical current consumption [ADC] Sensor Modules External SME 20 0.19 SME 25 0.19 SME 120 0.24 SME 125 0.24 Additional system components...

  • Page 175

    Connection of the Components 5.8 Electronics Power Supply Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 175 5.8.5 Assignment of the power supply to other components For Smart/Active Line Module, Motor Module and for the NX component, the supply voltage i...

  • Page 176

    Connection of the Components 5.8 Electronics Power Supply Guidelines for machine configuration 176 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 5-37 24 V terminal adapter on the booksize module, front cover open The 24 V busbar is used to pass the 24 VDC power between the individua...

  • Page 177

    Connection of the Components 5.8 Electronics Power Supply Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 177 Figure 5-38 Electronic power supply infed more than once For all other components, such as Control Unit or Sensor Module, the electronic power su...

  • Page 178

    Connection of the Components 5.8 Electronics Power Supply Guidelines for machine configuration 178 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Secondary side For the protection of the secondary side, particular attention must be paid to: ● Loading due to loads, possibly the simultaneit...

  • Page 179

    Connection of the Components 5.8 Electronics Power Supply Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 179 Table 5- 46 Types of circuit breaker depending on conductor cross-section and temperature Conductor cross-section Max. value up to 40 °C Max. val...

  • Page 180

    Connection of the Components 5.8 Electronics Power Supply Guidelines for machine configuration 180 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Notes ● SINAMICS components have a reverse polarity protection on the 24 VDC infeed side. ● Line, Motor, Braking, Capacitor and Control Supply...

  • Page 181

    Connection of the Components 5.9 Control Supply Module (CSM) Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 181 5.8.8 Power Supply Connection Example Figure 5-39 Power Supply Connection Example 5.9 Control Supply Module (CSM) The Control Supply Module (...

  • Page 182

    Connection of the Components 5.9 Control Supply Module (CSM) Guidelines for machine configuration 182 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 To achieve longer bridging times, additional Capacitor Modules can be used to increase the DC link capacity. The consequent increased storage c...

  • Page 183

    Connection of the Components 5.9 Control Supply Module (CSM) Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 183 5.9.1 Connection example Figure 5-40 Example connection of Control Supply Module

  • Page 184

    Connection of the Components 5.9 Control Supply Module (CSM) Guidelines for machine configuration 184 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 The Control Supply Module (CSM) is connected to the line supply (380 V 3 AC –10 % up to 480 V +10 %) via the appropriate screw terminals (0.2...

  • Page 185

    Connection of the Components 5.9 Control Supply Module (CSM) Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 185 5.9.2 Criteria for the protection, line formation and monitoring Devices and cables must be protected against overload and short-circuit in acc...

  • Page 186

    Connection of the Components 5.9 Control Supply Module (CSM) Guidelines for machine configuration 186 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.9.3 Interconnection of the voltage output for the CSM Interconnection of the 24 VDC voltage output for the Control Supply Module ● Exclusiv...

  • Page 187

    Connection of the Components 5.9 Control Supply Module (CSM) Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 187 Use of several Control Supply Modules, division of the consumer lines An additional CSM must be provided if the load caused by the supplied con...

  • Page 188

    Connection of the Components 5.9 Control Supply Module (CSM) Guidelines for machine configuration 188 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Example: Division of protection (e.g. automatic devices) for consumer lines ● NCU ● Supply of the Sensor Modules ● Consumers such as rel...

  • Page 189

    Connection of the Components 5.9 Control Supply Module (CSM) Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 189 5.9.4 Control Supply Module Power Supply - Connection Example Figure 5-42 CSM power supply connection example 1. Protection using the manufact...

  • Page 190

    Connection of the Components 5.10 Cable Lengths Guidelines for machine configuration 190 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 7. The 24 VDC terminal adapters are included with the supplied Line Module. If additional terminal adapters are required, they must be ordered separately (6...

  • Page 191

    Connection of the Components 5.10 Cable Lengths Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 191 Alternative measures (e.g. routing behind mounting plates, suitable clearances) can also be used provided they have similar results. This excludes measures ...

  • Page 192

    Connection of the Components 5.10 Cable Lengths Guidelines for machine configuration 192 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.10.3 Equipotential Bonding The SINAMICS S120 Booksize drive system is designed for use in control cabinets with protective conductor terminal. If the dri...

  • Page 193

    Connection of the Components 5.11 Motor Connection Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 193 5.11 Motor Connection 5.11.1 Motor connection plug 5.11.1.1 Installation of the motor connection plug with locking mechanism Motor connection plugs with ...

  • Page 194

    Connection of the Components 5.11 Motor Connection Guidelines for machine configuration 194 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 1. Screw the interlock bolt into the threaded socket provided in the enclosure. 2. Insert the plug, including the motor cable, and lock it in place by tu...

  • Page 195

    Connection of the Components 5.11 Motor Connection Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 195 Installation on Motor Modules with interlock bolt Figure 5-46 Installation of the motor connection plug with screwed joint 1. Use a TX20 screwdriver t...

  • Page 196

    Connection of the Components 5.11 Motor Connection Guidelines for machine configuration 196 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.11.1.3 Removal and coding Removing the motor connection plug The motor connection plug of a pre-assembled motor cable might have to be removed if the c...

  • Page 197

    Connection of the Components 5.11 Motor Connection Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 197 Figure 5-49 Removing the motor connection plug with screwed joint In the case of motor connection plugs with a locking mechanism, the clamp first needs ...

  • Page 198

    Connection of the Components 5.11 Motor Connection Guidelines for machine configuration 198 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Coding the motor connection plug The coding of a motor connection plug is illustrated below, using the example of a plug with screwed joint. Coding can b...

  • Page 199

    Connection of the Components 5.11 Motor Connection Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 199 5.11.2 Connection examples Figure 5-52 Connection example of Motor Modules 3 A to 30 A and Double Motor Modules 3 A to 18 A

  • Page 200

    Connection of the Components 5.11 Motor Connection Guidelines for machine configuration 200 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 5-53 Example connection of Single Motor Modules 45 A to 200 A 5.11.3 Motor/brake connection Table 5- 48 Terminal strip X1/X2 Motor Modules 3 A to...

  • Page 201

    Connection of the Components 5.11 Motor Connection Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 201 Table 5- 49 Terminal strip Single Motor Module 45 A to 200 A Terminals Technical specifications U2 V2 W2 45 A to 60 A: Threaded bolt M6/6 Nm 1) 85 A: T...

  • Page 202

    Connection of the Components 5.11 Motor Connection Guidelines for machine configuration 202 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.11.4 X21/X22 EP terminals / temperature sensor Motor Module Table 5- 50 Terminal strip X21/X22 Terminal Function Technical specifications 1 + Temp 2 -...

  • Page 203

    Connection of the Components 5.12 Sensor Systems Connection Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 203 5.12 Sensor Systems Connection 5.12.1 Introduction The encoder system should be connected to SINAMICS S120 via DRIVE-CLiQ. Motors with DRIVE-CLi...

  • Page 204

    Connection of the Components 5.12 Sensor Systems Connection Guidelines for machine configuration 204 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.12.2 Overview of Sensor Modules Sensor Modules Cabinet-Mounted (SMC) Sensor Modules Cabinet-Mounted can be ordered and configured separately. ...

  • Page 205

    Connection of the Components 5.12 Sensor Systems Connection Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 205 The Sensor Modules External have a higher degree of protection (IP67) and are therefore suitable for installation outside the cabinet. Figure 5...

  • Page 206

    Connection of the Components 5.12 Sensor Systems Connection Guidelines for machine configuration 206 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.12.3 X200-X203 DRIVE-CLiQ interface Table 5- 52 DRIVE-CLiQ interface X200-X202: Single Motor Module DRIVE-CLiQ interface X200-X203: Double Mot...

  • Page 207

    Connection of the Components 5.12 Sensor Systems Connection Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 207 Figure 5-57 Sensor connection via a motor with a DRIVE-CLiQ interface Figure 5-58 Sensor connection using Sensor Module External (SME)

  • Page 208

    Connection of the Components 5.13 Brake connection Guidelines for machine configuration 208 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 5.13 Brake connection 5.13.1 General Notes The motors are optionally available with integrated holding brake. The holding brake prevents the axes from ma...

  • Page 209

    Connection of the Components 5.13 Brake connection Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 209 Motor Module 3 A to 30 A; 2 x 3 A to 2 x 18 A Motor Module 45 A to 200 A The brake outlet is internally equipped with an overvoltage protection circui...

  • Page 210

    Connection of the Components 5.14 Brake Control Guidelines for machine configuration 210 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Brake current IBR > 2 A DC Figure 5-59 Brake current IBR > 2 A DC Protective circuit for the interface relay is not required because this function ex...

  • Page 211

    Connection of the Components 5.14 Brake Control Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 211 The control command to open or close the holding brake is transferred directly to the Motor Module over the DRIVE-CLiQ from the Control Unit that logically ...

  • Page 212

    Connection of the Components 5.14 Brake Control Guidelines for machine configuration 212 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Timing examples: In all cases listed below, the drive starts the motion with an ON command (BB/OFF1). For clarification, the closing and opening times are s...

  • Page 213

    Connection of the Components 5.14 Brake Control Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 213 Start with ON command; stop with OFF1 command; stop with OFF3; stop with OFF2 The switch-off behavior in a fault situation will be assigned to the asso...

  • Page 214

    Connection of the Components 5.14 Brake Control Guidelines for machine configuration 214 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 The dynamization is also performed: ● For each brake control with "open holding brake" and "close holding brake" ● For selection of ...

  • Page 215

    Connection of the Components 5.15 Voltage Protection Module (VPM), external Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 215 5.15 Voltage Protection Module (VPM), external General information The external Voltage Protection Module (VPM) is used for the ...

  • Page 216

    Connection of the Components 5.15 Voltage Protection Module (VPM), external Guidelines for machine configuration 216 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Operation with VPM is possible only in conjunction with SINAMICS, SIMODRIVE 611 digital, SIMODRIVE 611 universal HR/HRS, and 1FE...

  • Page 217

    Connection of the Components 5.15 Voltage Protection Module (VPM), external Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 217 Connection example for VPM 120 Figure 5-63 Connection of Voltage Protection Module VPM 120 Signaling contact X3 The X3 signalin...

  • Page 218

    Connection of the Components 5.15 Voltage Protection Module (VPM), external Guidelines for machine configuration 218 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 WARNING Measures must be adopted to prevent the drive from starting automatically. If the external VPM is being used, the fol...

  • Page 219

    Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 219 Signal Interconnection 6 Introduction The drive wizard assigns functions to NCU and NX terminals (see 69,Section NCU 7x0 69, and 69,NX1x Terminal Assig 69,nment (Page 69,69)). This section discusses the...

  • Page 220

    Signal Interconnection 6.1 Application 1 Guidelines for machine configuration 220 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 6.1 Application 1 Figure 6-1 Infeed with DRIVE-CLiQ (SLM/ALM 16 kW to 120 kW)

  • Page 221

    Signal Interconnection 6.1 Application 1 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 221 Interconnection of the PLC input signals ● "Infeed ready" (NCU terminal X132.8) The infeed is ready for 1 signal. Interconnection of the PLC output sig...

  • Page 222

    Signal Interconnection 6.2 Application 2 Guidelines for machine configuration 222 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 6.2 Application 2 Figure 6-2 Infeed with DRIVE-CLiQ (SLM/ALM 16 kW to 120 kW) and line contactor without safe control Interconnection of the PLC input signals ●...

  • Page 223

    Signal Interconnection 6.2 Application 2 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 223 Interconnection of the PLC output signals ● "ON/OFF1" of the infeed (NCU terminal X122.1) The 0/1 edge activates the infeed. Interlocking with "in...

  • Page 224

    Signal Interconnection 6.3 Application 3 Guidelines for machine configuration 224 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 6.3 Application 3 Figure 6-3 Infeed without DRIVE-CLiQ (SLM 5/10 kW); line contactor without safe control

  • Page 225

    Signal Interconnection 6.3 Application 3 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 225 Interconnection of the PLC input signals ● "Infeed Ready" (SLM terminal X21.1) The infeed is operating for 1 signal. Interconnection of the PLC output ...

  • Page 226

    Signal Interconnection 6.3 Application 3 Guidelines for machine configuration 226 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 PLC output signal ● "Line contactor control" Control the line contactor taking into consideration the activation/deactivation condition CAUTION If t...

  • Page 227

    Signal Interconnection 6.4 Application 4 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 227 6.4 Application 4 Figure 6-4 Infeed with DRIVE-CLiQ (SLM/ALM 16 kW to 120 kW), use of a drive-integrated SH/SBC safety function by SINAMICS and line contactor wit...

  • Page 228

    Signal Interconnection 6.4 Application 4 Guidelines for machine configuration 228 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Interconnection of the PLC input signals ● "Infeed ready" (NCU terminal X132.8) The infeed is ready for 1 signal. Interconnection of the PLC output sig...

  • Page 229

    Signal Interconnection 6.4 Application 4 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 229 Interconnection between NCU and NX components ● After activating the infeed, given correct operation, the "Infeed operation" state will be attained and...

  • Page 230

    Signal Interconnection 6.5 Application 5 Guidelines for machine configuration 230 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 6.5 Application 5 Figure 6-5 Infeed without DRIVE-CLiQ (SLM 5 kW to 10 kW), use of a drive-integrated SH/SBC safety function by SINAMICS and line contactor with sa...

  • Page 231

    Signal Interconnection 6.5 Application 5 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 231 Interconnection of the PLC input signals ● "Infeed Ready" (SLM terminal X21.1) The infeed is operating for 1 signal. Interconnection of the PLC output ...

  • Page 232

    Signal Interconnection 6.5 Application 5 Guidelines for machine configuration 232 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Interconnection of the NCU 7x0 component ● "Infeed Ready" (connection between SLM terminal X21.1 and NCU terminal X122.1) After activating the infeed, ...

  • Page 233

    Signal Interconnection 6.5 Application 5 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 233 PLC output signal ● "Line contactor control" Control the line contactor taking into consideration the activation/deactivation condition CAUTION If t...

  • Page 234

    Signal Interconnection 6.6 Application 6 Guidelines for machine configuration 234 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 6.6 Application 6 Figure 6-6 Infeed with DRIVE-CLiQ (SLM/ALM 16 kW to 120 kW); use of the SINUMERIK system/drive-integrated safety function

  • Page 235

    Signal Interconnection 6.6 Application 6 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 235 Interconnection to the NCU component ● "Infeed ready" (NCU terminal X132.8) The infeed is ready for 1 signal. ● "ON/OFF1 Line Module" (NCU ...

  • Page 236

    Signal Interconnection 6.7 Application 7 Guidelines for machine configuration 236 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 6.7 Application 7 Figure 6-7 Infeed without DRIVE-CLiQ (SLM 5/10 kW); use of the SINUMERIK system/drive-integrated safety function

  • Page 237

    Signal Interconnection 6.7 Application 7 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 237 Interconnection of the NCU 7x0 component ● "Infeed Ready" (connection between SLM terminal X21.1 and NCU terminal X122.1) After activating the infeed, ...

  • Page 238

    Signal Interconnection 6.7 Application 7 Guidelines for machine configuration 238 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1

  • Page 239

    Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 239 Typical circuit diagrams 77.1 Connection Notes, Technical Data, Device Selection The associated connection notes and technical data from the current operating and configuring guides, and catalogs and appli...

  • Page 240

    Typical circuit diagrams 7.2 Functional description of the typical circuit diagrams Guidelines for machine configuration 240 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 ● EMC regulations (89/336 EEC) and low-voltage regulations (73/23/EEC) ● The associated environmental requirements (...

  • Page 241

    Typical circuit diagrams 7.2 Functional description of the typical circuit diagrams Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 241 The following section does not further discuss the setpoint and actual value interface and the user's machine control. T...

  • Page 242

    Typical circuit diagrams 7.3 Circuit Manual Group =1 Guidelines for machine configuration 242 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 7.3 Circuit Manual Group =1 Line infeed and creation of the 24 VDC power supply ● Line infeed including the main power switch ● Power outlets inclu...

  • Page 243

    Typical circuit diagrams 7.3 Circuit Manual Group =1 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 243 =1.-T31 =1.-T33 =1.-T36 SITOP power 24 VDC power supply for SINAMICS components Separate power supply (24 VDC, 20 A) for the power supply busbar of the...

  • Page 244

    Typical circuit diagrams 7.3 Circuit Manual Group =1 Guidelines for machine configuration 244 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Circuit manual group examples = 1 Figure 7-1 Circuit Manual Group =1, Page 1

  • Page 245

    Typical circuit diagrams 7.3 Circuit Manual Group =1 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 245 Figure 7-2 Circuit Manual Group =1, Page 2

  • Page 246

    Typical circuit diagrams 7.3 Circuit Manual Group =1 Guidelines for machine configuration 246 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 7-3 Circuit Manual Group =1, Page 3

  • Page 247

    Typical circuit diagrams 7.3 Circuit Manual Group =1 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 247 Figure 7-4 Circuit Manual Group =1, Page 4

  • Page 248

    Typical circuit diagrams 7.3 Circuit Manual Group =1 Guidelines for machine configuration 248 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 7-5 Circuit Manual Group =1, Page 5

  • Page 249

    Typical circuit diagrams 7.3 Circuit Manual Group =1 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 249 Figure 7-6 Circuit Manual Group =1, Page 6

  • Page 250

    Typical circuit diagrams 7.4 Circuit Manual Group =2 Guidelines for machine configuration 250 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 7.4 Circuit Manual Group =2 Drive group without safety, with line contactor ● Power supply of the NCU 710 (=2.-K11) ● Control signals to the NCU 71...

  • Page 251

    Typical circuit diagrams 7.4 Circuit Manual Group =2 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 251 ● Enabling signal from the Active Line Module: The protective circuit of the Enable Pulses digital input (-X21: 3/ 4) is essential for the Active Lin...

  • Page 252

    Typical circuit diagrams 7.4 Circuit Manual Group =2 Guidelines for machine configuration 252 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Circuit manual group examples = 2 Figure 7-7 Circuit Manual Group =2, Page 1

  • Page 253

    Typical circuit diagrams 7.4 Circuit Manual Group =2 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 253 Figure 7-8 Circuit Manual Group =2, Page 2

  • Page 254

    Typical circuit diagrams 7.4 Circuit Manual Group =2 Guidelines for machine configuration 254 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 7-9 Circuit Manual Group =2, Page 3

  • Page 255

    Typical circuit diagrams 7.4 Circuit Manual Group =2 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 255 Figure 7-10 Circuit Manual Group =2, Page 4

  • Page 256

    Typical circuit diagrams 7.4 Circuit Manual Group =2 Guidelines for machine configuration 256 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 7-11 Circuit Manual Group =2, Page 5

  • Page 257

    Typical circuit diagrams 7.4 Circuit Manual Group =2 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 257 Figure 7-12 Circuit Manual Group =2, Page 6

  • Page 258

    Typical circuit diagrams 7.4 Circuit Manual Group =2 Guidelines for machine configuration 258 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 7-13 Circuit Manual Group =2, Page 7

  • Page 259

    Typical circuit diagrams 7.5 Circuit Manual Group =3 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 259 7.5 Circuit Manual Group =3 Drive group with line contactor, Smart Line Module without DRIVE-CLiQ connection, without safety functions, motor protectio...

  • Page 260

    Typical circuit diagrams 7.5 Circuit Manual Group =3 Guidelines for machine configuration 260 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 ● Line contactor control The PLC is used to control the line contactor, because the Line Module 5/10 kW (without DRIVE-CLiQ) does not have any intern...

  • Page 261

    Typical circuit diagrams 7.5 Circuit Manual Group =3 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 261 Circuit manual group examples = 3 Figure 7-14 Circuit Manual Group =3, Page 1

  • Page 262

    Typical circuit diagrams 7.5 Circuit Manual Group =3 Guidelines for machine configuration 262 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 7-15 Circuit Manual Group =3, Page 2

  • Page 263

    Typical circuit diagrams 7.5 Circuit Manual Group =3 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 263 Figure 7-16 Circuit Manual Group =3, Page 3

  • Page 264

    Typical circuit diagrams 7.5 Circuit Manual Group =3 Guidelines for machine configuration 264 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 7-17 Circuit Manual Group =3, Page 4

  • Page 265

    Typical circuit diagrams 7.5 Circuit Manual Group =3 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 265 Figure 7-18 Circuit Manual Group =3, Page 5

  • Page 266

    Typical circuit diagrams 7.5 Circuit Manual Group =3 Guidelines for machine configuration 266 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 7-19 Circuit Manual Group =3, Page 6

  • Page 267

    Typical circuit diagrams 7.5 Circuit Manual Group =3 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 267 Figure 7-20 Circuit Manual Group =3, Page 7

  • Page 268

    Typical circuit diagrams 7.6 Circuit Manual Group =4 Guidelines for machine configuration 268 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 7.6 Circuit Manual Group =4 Drive group without line contactor, however, with safety functions using a safety relay (3TK28..). Disconnection of all dri...

  • Page 269

    Typical circuit diagrams 7.6 Circuit Manual Group =4 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 269 ● The feedback loop for the safety switching device (=4.-K71) is closed. The "Safe Standstill" feedback of the individual drive axes on the...

  • Page 270

    Typical circuit diagrams 7.6 Circuit Manual Group =4 Guidelines for machine configuration 270 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Circuit manual group examples = 4 Figure 7-21 Circuit Manual Group =4, Page 1

  • Page 271

    Typical circuit diagrams 7.6 Circuit Manual Group =4 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 271 Figure 7-22 Circuit Manual Group =4, Page 2

  • Page 272

    Typical circuit diagrams 7.6 Circuit Manual Group =4 Guidelines for machine configuration 272 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 7-23 Circuit Manual Group =4, Page 3

  • Page 273

    Typical circuit diagrams 7.6 Circuit Manual Group =4 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 273 Figure 7-24 Circuit Manual Group =4, Page 4

  • Page 274

    Typical circuit diagrams 7.6 Circuit Manual Group =4 Guidelines for machine configuration 274 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 7-25 Circuit Manual Group =4, Page 5

  • Page 275

    Typical circuit diagrams 7.6 Circuit Manual Group =4 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 275 Figure 7-26 Circuit Manual Group =4, Page 6

  • Page 276

    Typical circuit diagrams 7.6 Circuit Manual Group =4 Guidelines for machine configuration 276 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 7-27 Circuit Manual Group =4, Page 7

  • Page 277

    Typical circuit diagrams 7.7 Circuit Manual Group =5 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 277 7.7 Circuit Manual Group =5 Axis-specific drive with safety functions; shutdown with emergency stop (circuit manual group =4) or with the separate Axis...

  • Page 278

    Typical circuit diagrams 7.7 Circuit Manual Group =5 Guidelines for machine configuration 278 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 "Safe Standstill" function feedback The "Safe Standstill" function is monitored in the Control Unit and in the Motor Module. A corr...

  • Page 279

    Typical circuit diagrams 7.7 Circuit Manual Group =5 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 279 Circuit manual group examples = 5 Figure 7-28 Circuit Manual Group =5, Page 1

  • Page 280

    Typical circuit diagrams 7.7 Circuit Manual Group =5 Guidelines for machine configuration 280 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 7-29 Circuit Manual Group =5, Page 2

  • Page 281

    Typical circuit diagrams 7.8 Circuit Manual Group =6 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 281 7.8 Circuit Manual Group =6 A drive group without main contactor, however, with the system/drive-integrated safety function of the SINUMERIK 840D sl; c...

  • Page 282

    Typical circuit diagrams 7.8 Circuit Manual Group =6 Guidelines for machine configuration 282 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Circuit manual group examples = 6 Figure 7-30 Circuit manual group =, page 1

  • Page 283

    Typical circuit diagrams 7.8 Circuit Manual Group =6 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 283 Figure 7-31 Circuit Manual Group =6, Page 2

  • Page 284

    Typical circuit diagrams 7.8 Circuit Manual Group =6 Guidelines for machine configuration 284 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 7-32 Circuit Manual Group =6, Page 3

  • Page 285

    Typical circuit diagrams 7.8 Circuit Manual Group =6 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 285 Figure 7-33 Circuit Manual Group =6, Page 4

  • Page 286

    Typical circuit diagrams 7.8 Circuit Manual Group =6 Guidelines for machine configuration 286 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 7-34 Circuit Manual Group =6, Page 5

  • Page 287

    Typical circuit diagrams 7.8 Circuit Manual Group =6 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 287 Figure 7-35 Circuit Manual Group =6, Page 6

  • Page 288

    Typical circuit diagrams 7.8 Circuit Manual Group =6 Guidelines for machine configuration 288 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 7-36 Circuit Manual Group =6, Page 7

  • Page 289

    Typical circuit diagrams 7.8 Circuit Manual Group =6 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 289 snemeiSS002 TE-K82-A83Power module-K83.1-K84-K84.1-K84.2-K85Power module-K85.1-K86Power module-Q86.187654321FEDCBAFEDCBA87654321mutaD.braeB.rpeGmutaDgn...

  • Page 290

    Typical circuit diagrams 7.8 Circuit Manual Group =6 Guidelines for machine configuration 290 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure 7-38 Circuit Manual Group =6, Page 9

  • Page 291

    Typical circuit diagrams 7.8 Circuit Manual Group =6 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 291 Figure 7-39 Circuit Manual Group =6, Page 10

  • Page 292

    Typical circuit diagrams 7.8 Circuit Manual Group =6 Guidelines for machine configuration 292 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 87654321FEDCBAFEDCBA87654321mutaD.braeB.rpeGmutaDgnurednÄdnatsuZettohcSlliW-rebrepS60.60.31mroNemaN1H+316=11ttalB.lBCopyright (C) SIEMENS AG 2003 Al...

  • Page 293

    Typical circuit diagrams 7.8 Circuit Manual Group =6 Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 293 87654321FEDCBAFEDCBA87654321mutaD.braeB.rpeGmutaDgnurednÄdnatsuZettohcSlliW-rebrepS60.60.31mroNemaN1H+316=21ttalB.lBCopyright (C) SIEMENS AG 2003 Al...

  • Page 294

    Typical circuit diagrams 7.8 Circuit Manual Group =6 Guidelines for machine configuration 294 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 87654321FEDCBAFEDCBA87654321mutaD.braeB.rpeGmutaDgnurednÄdnatsuZettohcSlliW-rebrepS60.60.31mroNemaN1H+316=31ttalB.lBCopyright (C) SIEMENS AG 2003 Al...

  • Page 295

    Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 295 Additional Information 88.1 Distributed configuration For the distributed installation, an external busbar is used for the DC link connection. From there, the cables are led to the power units. DC link rec...

  • Page 296

    Additional Information 8.2 Cooling Systems Guidelines for machine configuration 296 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Additional references For details of DC link rectifier adapters in booksize format and information on cable installation, please refer to /GH2/ SINAMICS S120/B...

  • Page 297

    Additional Information 8.2 Cooling Systems Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 297 8.2.3 External Air Cooling The external air cooling is a cooling system for SINAMICS booksize power units. The through-hole technology is used for this construc...

  • Page 298

    Additional Information 8.2 Cooling Systems Guidelines for machine configuration 298 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 8.2.4 Cold Plate Cold plate cooling is a cooling system for SINAMICS S120 booksize power units. The flat aluminum cooling plate located at the rear side of the d...

  • Page 299

    Additional Information 8.2 Cooling Systems Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 299 Figure 8-3 Cooling systems for cold plate Note The associated notes contained in the manuals must be observed for the configuring and the layout of the corres...

  • Page 300

    Additional Information 8.2 Cooling Systems Guidelines for machine configuration 300 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1

  • Page 301

    Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 301 Activate/Deactivate Drive System 99.1 Overview of the Status Signals Figure 9-1 Overview of the Status Signals

  • Page 302

    Activate/Deactivate Drive System 9.2 Drive Group with Several Axes Guidelines for machine configuration 302 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 9.2 Drive Group with Several Axes The Motor Module is controlled via the -X21, -X22 terminal block and DRIVE-CLiQ at the -X200/201/202/20...

  • Page 303

    Activate/Deactivate Drive System 9.2 Drive Group with Several Axes Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 303 Activating the infeed -8932 -Function diagram87654321fp_8932_55_eng.vsdDO: A_INFSINAMICS S120/S15015.04.08V02.06.01Active Infeed -Sequenc...

  • Page 304

    Activate/Deactivate Drive System 9.2 Drive Group with Several Axes Guidelines for machine configuration 304 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Activating the drive S4: Operation ZSWA.00/01/02 = 1 ZSWA.11 = 1 ZSWA.06 = 0 Pulses enabled Controller enabled No jog operation: Setpoi...

  • Page 305

    Activate/Deactivate Drive System 9.2 Drive Group with Several Axes Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 305 Note Applies to CU320; with integrated drive solutions (e.g. NCU, NX, etc.), some signals are already processed by means of internal co...

  • Page 306

    Activate/Deactivate Drive System 9.2 Drive Group with Several Axes Guidelines for machine configuration 306 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Control and status signals Table 9- 1 Switching on/switching off the control system Signal name Internal control word Binector input PROF...

  • Page 307

    Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 307 Appendix A CAUTION Electrostatic sensitive devices (ESD) are single components, integrated circuits or devices that can be damaged by electrostatic fields or electrostatic discharges. Regulations for the...

  • Page 308

    Appendix A.1 Abbreviations Guidelines for machine configuration 308 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Abbreviation German meaning English meaning DO Antriebsobjekt Drive Object DP Dezentrale Peripherie Decentralized Peripherals DRIVE-CLiQ Drive Component Link with IQ Drive Compo...

  • Page 309

    Appendix A.2 Description of drive wizard (up to SINUMERIK V2.5) Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 309 A.2 Description of drive wizard (up to SINUMERIK V2.5) A.2.1 Commissioning Macros Overview Introduction For the sake of simplifying drive co...

  • Page 310

    Appendix A.2 Description of drive wizard (up to SINUMERIK V2.5) Guidelines for machine configuration 310 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 ● Macros 100116 for preassigning the data sets and message-frame types ● Update macro 150399 This macro executes an update of all drive ...

  • Page 311

    Appendix A.2 Description of drive wizard (up to SINUMERIK V2.5) Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 311 A.2.4 Procedure for calling ACX macros Introduction WARNING Prior to starting the macro for the drive configuration, all drive releases (O...

  • Page 312

    Appendix A.2 Description of drive wizard (up to SINUMERIK V2.5) Guidelines for machine configuration 312 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 Figure A-1 Process macro call for update (left) and for configuration (right)

  • Page 313

    Appendix A.2 Description of drive wizard (up to SINUMERIK V2.5) Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 313 Occurring operator errors Operator errors that frequently occur when starting macros include: ● Incorrect status of p0009 ● Active enabl...

  • Page 314

    Appendix A.2 Description of drive wizard (up to SINUMERIK V2.5) Guidelines for machine configuration 314 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1

  • Page 315

    Guidelines for machine configuration System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 315 Index 3 3TK28... safety relay, 84 A Active Interface Module, 103 Active Line Module, 158 Autotransformer, 75 Axes, 13 C Cable Installation, 190 Cable Shields, 191 Center infeed, 32 Components Active Interf...

  • Page 316

    Index Guidelines for machine configuration 316 System Manual, (MA1), 10/2009, 6FC5397-6CP10-0BA1 With DRIVE-CLiQ interface, 158 O Overcurrent, 178 P Power failure, 182 Power loss, 52 Power loss calculation, 62 PROFINET, 13 PROFIsafe, 90 R Rating plate, electronic, 15, 150 RCD Residual-current ...

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