SINUMERIK 840D sl Hardware. Manual (2011-2020)

Preface

SINUMERIK documentation

The SINUMERIK documentation is organized in the following categories:

● General documentation

● User documentation

● Manufacturer/service documentation

Additional information

You can find information on the following topics at http://www.siemens.com/motioncontrol/

docu:

● Ordering documentation / documentation overview

● Additional links to download documents

● Using documentation online (find and search in manuals/information)

For any questions about the technical documentation (e.g. suggestions for improvement,

corrections), please send an e-mail to the following address:

mailto:docu.motioncontrol@siemens.com

My Documentation Manager (MDM)

Under the following link you will find information on how to compile OEM-specific machine

documentation based on the Siemens content:

http://www.siemens.com/mdm

Training

Information about training courses can be found at:

● http://www.siemens.com/sitrain

SITRAIN - Siemens training for products, systems and solutions in automation technology

● http://www.siemens.com/sinutrain

SinuTrain - training software for SINUMERIK

FAQs

You can find Frequently Asked Questions in the Service&Support pages under Product

Support. http://support.automation.siemens.com

Operator Components and Networking

Manual, 03/2016, 6FC5397-1AP40-5BA3

Preface

SINUMERIK

You can find information about SINUMERIK at the following link:

http://www.siemens.com/sinumerik

Target group

This documentation is intended for:

● Project engineers, electricians and installers

● Maintenance and service personnel

Benefits

The manual provides information on the components and functions of devices so that the target

group is capable of installing, setting up, testing, operating, and troubleshooting the devices

correctly and in absolute safety.

Standard scope

This documentation only describes the functionality of the standard version. Additions or

revisions made by the machine manufacturer are documented by the machine manufacturer.

Other functions not described in this documentation might be executable in the controller. This

does not, however, represent an obligation to supply such functions with a new controller or

when servicing.

For the sake of simplicity, this documentation does not contain all detailed information about

all types of the product and cannot cover every conceivable installation, operation, or

maintenance situation.

Technical Support

You will find telephone numbers for other countries for technical support in the Internet under

http://www.siemens.com/automation/service&support

EC Declaration of Conformity

The EC Declaration of Conformity for the EMC Directive can be found on the Internet at:

http://support.automation.siemens.com/WW/view/de/10805517/134200

Operator Components and Networking

Manual, 03/2016, 6FC5397-1AP40-5BA3

Table of contents

Fundamental safety instructions

1.1

General safety instructions

1.2

Handling electrostatic sensitive devices (ESD)

1.3

Industrial security

1.4

Residual risks of power drive systems

System overview

2.1

Application

2.2

System configuration

2.3

Overview of operator components

Application planning

3.1

Secondary electrical conditions

3.1.1

Power supply

3.1.2

Grounding concept

3.1.3

EMC compatibility

3.2

Ambient climatic and mechanical conditions

3.2.1

Transport and storage conditions

3.2.2

Operating conditions

3.2.3

Cooling

3.3

Standards and approvals

3.4

Recycling and disposal

Connecting

4.1

Pin assignment of the interfaces

4.2

Handling membrane connectors

Networking

5.1

System settings

5.1.1

Settings for SINUMERIK solution line

5.1.2

System boot with system network

5.1.3

Thin Client Unit (TCU)

5.1.4

Factory default settings

5.2

Commissioning TCU

5.2.1

Using the TCU's main menu

5.2.2

Using additional TCU menus

5.2.3

How to register a TCU on the system network

5.2.4

How to calibrate a touch panel

5.2.5

Connecting-up the SIMATIC Thin Client Touch Panel

5.2.6

This is how you configure the SIMATIC Thin Client Touch Panel

5.2.7

Settings in the "config.ini" file

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Table of contents

5.2.8

Settings in the "TCU.ini" file

5.2.9

Displacement mechanism for TCUs

5.2.10

Disable switchover between TCU via PLC

5.2.11

Example: How to select the behavior of the TCUs during boot up

5.3

Network configuration

5.3.1

Permissible network topologies

5.3.2

Networks without connection to the company network

5.3.2.1

Configuration 1: NCU and TCU

5.3.2.2

Configuration 2: NCU and PCU with direct OP

5.3.3

Networks with NCU connection to the company network

5.3.3.1

Configuration 3: NCU and TCU

5.3.3.2

Configuration 4: NCU and PCU with direct OP

5.3.3.3

Configuration 5: PCU with TCU on NCU

5.3.3.4

Connecting the programming device (PG) to the NCU

5.3.4

Example: Configuring a VNC connection to a PC

5.3.5

Application example

5.4

Service and diagnostics

5.4.1

Booting of the TCU

Index

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Fundamental safety instructions

1.1

General safety instructions

DANGER

Danger to life due to live parts and other energy sources

Death or serious injury can result when live parts are touched.

● Only work on electrical devices when you are qualified for this job.

● Always observe the country-specific safety rules.

Generally, six steps apply when establishing safety:

1. Prepare for shutdown and notify all those who will be affected by the procedure.

2. Disconnect the machine from the supply.

- Switch off the machine.

- Wait until the discharge time specified on the warning labels has elapsed.

- Check that it really is in a no-voltage condition, from phase conductor to phase

conductor and phase conductor to protective conductor.

- Check whether the existing auxiliary supply circuits are de-energized.

- Ensure that the motors cannot move.

3. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or

water.

4. Isolate or neutralize all hazardous energy sources by closing switches, grounding or short-

circuiting or closing valves, for example.

5. Secure the energy sources against switching on again.

6. Ensure that the correct machine is completely interlocked.

After you have completed the work, restore the operational readiness in the inverse sequence.

WARNING

Danger to life through a hazardous voltage when connecting an unsuitable power supply

Touching live components can result in death or severe injury.

● Only use power supplies that provide SELV (Safety Extra Low Voltage) or PELV-

(Protective Extra Low Voltage) output voltages for all connections and terminals of the

electronics modules.

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Fundamental safety instructions

1.1 General safety instructions

WARNING

Danger to life when live parts are touched on damaged devices

Improper handling of devices can cause damage.

For damaged devices, hazardous voltages can be present at the enclosure or at exposed

components; if touched, this can result in death or severe injury.

● Ensure compliance with the limit values specified in the technical data during transport,

storage and operation.

● Do not use any damaged devices.

WARNING

Danger to life through electric shock due to unconnected cable shields

Hazardous touch voltages can occur through capacitive cross-coupling due to unconnected

cable shields.

● As a minimum, connect cable shields and the cores of cables that are not used at one end

at the grounded housing potential.

WARNING

Danger to life due to electric shock when not grounded

For missing or incorrectly implemented protective conductor connection for devices with

protection class I, high voltages can be present at open, exposed parts, which when touched,

can result in death or severe injury.

● Ground the device in compliance with the applicable regulations.

WARNING

Danger to life due to fire spreading if housing is inadequate

Fire and smoke development can cause severe personal injury or material damage.

● Install devices without a protective housing in a metal control cabinet (or protect the device

by another equivalent measure) in such a way that contact with fire is prevented.

● Ensure that smoke can only escape via controlled and monitored paths.

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Fundamental safety instructions

1.1 General safety instructions

WARNING

Danger to life through unexpected movement of machines when using mobile wireless

devices or mobile phones

Using mobile wireless devices or mobile phones with a transmit power > 1 W closer than

approx. 2 m to the components may cause the devices to malfunction, influence the functional

safety of machines therefore putting people at risk or causing material damage.

● Switch the wireless devices or mobile phones off in the immediate vicinity of the

components.

WARNING

Danger to life due to fire if overheating occurs because of insufficient ventilation clearances

Inadequate ventilation clearances can cause overheating of components with subsequent

fire and smoke. This can cause severe injury or even death. This can also result in increased

downtime and reduced service lives for devices/systems.

● Ensure compliance with the specified minimum clearance as ventilation clearance for the

respective component.

WARNING

Danger to life when safety functions are inactive

Safety functions that are inactive or that have not been adjusted accordingly can cause

operational faults on machines that could lead to serious injury or death.

● Observe the information in the appropriate product documentation before commissioning.

● Carry out a safety inspection for functions relevant to safety on the entire system, including

all safety-related components.

● Ensure that the safety functions used in your drives and automation tasks are adjusted

and activated through appropriate parameterizing.

● Perform a function test.

● Only put your plant into live operation once you have guaranteed that the functions relevant

to safety are running correctly.

Note

Important safety notices for Safety Integrated functions

If you want to use Safety Integrated functions, you must observe the safety notices in the Safety

Integrated manuals.

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Fundamental safety instructions

1.3 Industrial security

1.2

Handling electrostatic sensitive devices (ESD)

Electrostatic sensitive devices (ESD) are individual components, integrated circuits, modules

or devices that may be damaged by either electric fields or electrostatic discharge.

NOTICE

Damage through electric fields or electrostatic discharge

Electric fields or electrostatic discharge can cause malfunctions through damaged individual

components, integrated circuits, modules or devices.

● Only pack, store, transport and send electronic components, modules or devices in their

original packaging or in other suitable materials, e.g conductive foam rubber of aluminum

foil.

● Only touch components, modules and devices when you are grounded by one of the

following methods:

- Wearing an ESD wrist strap

- Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring

● Only place electronic components, modules or devices on conductive surfaces (table with

ESD surface, conductive ESD foam, ESD packaging, ESD transport container).

1.3

Industrial security

Note

Industrial security

Siemens provides products and solutions with industrial security functions that support the

secure operation of plants, solutions, machines, equipment and/or networks. They are

important components in a holistic industrial security concept. With this in mind, Siemens’

products and solutions undergo continuous development. Siemens recommends strongly that

you regularly check for product updates.

For the secure operation of Siemens products and solutions, it is necessary to take suitable

preventive action (e.g. cell protection concept) and integrate each component into a holistic,

state-of-the-art industrial security concept. Third-party products that may be in use should also

be considered. For more information about industrial security, visit this address (http://

www.siemens.com/industrialsecurity ).

To stay informed about product updates as they occur, sign up for a product-specific

newsletter. For more information, visit this address (http://support.automation.siemens.com ).

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Fundamental safety instructions

1.3 Industrial security

WARNING

Danger as a result of unsafe operating states resulting from software manipulation

Software manipulation (e.g. by viruses, Trojan horses, malware, worms) can cause unsafe

operating states to develop in your installation which can result in death, severe injuries and/

or material damage.

● Keep the software up to date.

You will find relevant information and newsletters at this address (http://

support.automation.siemens.com).

● Incorporate the automation and drive components into a holistic, state-of-the-art industrial

security concept for the installation or machine.

You will find further information at this address (http://www.siemens.com/

industrialsecurity).

● Make sure that you include all installed products into the holistic industrial security concept.

WARNING

Danger to life due to software manipulation when using exchangeable storage media

Storing files onto exchangeable storage media amounts to an increased risk of infection, e.g.

with viruses and malware. As a result of incorrect parameterization, machines can

malfunction, which in turn can lead to injuries or death.

● Protect files stored on exchangeable storage media from malicious software by taking

suitable protection measures, e.g. virus scanners.

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Fundamental safety instructions

1.4 Residual risks of power drive systems

1.4

Residual risks of power drive systems

When assessing the machine- or system-related risk in accordance with the respective local

regulations (e.g., EC Machinery Directive), the machine manufacturer or system installer must

take into account the following residual risks emanating from the control and drive components

of a drive system:

Unintentional movements of driven machine or system components during commissioning,

operation, maintenance, and repairs caused by, for example,

- Hardware and/or software errors in the sensors, control system, actuators, and cables

and connections

- Response times of the control system and of the drive

- Operation and/or environmental conditions outside the specification

- Condensation/conductive contamination

- Parameterization, programming, cabling, and installation errors

- Use of wireless devices/mobile phones in the immediate vicinity of electronic

components

- External influences/damage

- X-ray, ionizing radiation and cosmic radiation

Unusually high temperatures, including open flames, as well as emissions of light, noise,

particles, gases, etc., can occur inside and outside the components under fault conditions

caused by, for example:

- Component failure

- Software errors

- Operation and/or environmental conditions outside the specification

- External influences/damage

Hazardous shock voltages caused by, for example:

- Component failure

- Influence during electrostatic charging

- Induction of voltages in moving motors

- Operation and/or environmental conditions outside the specification

- Condensation/conductive contamination

- External influences/damage

Electrical, magnetic and electromagnetic fields generated in operation that can pose a risk

to people with a pacemaker, implants or metal replacement joints, etc., if they are too close

Release of environmental pollutants or emissions as a result of improper operation of the

system and/or failure to dispose of components safely and correctly

For more information about the residual risks of the drive system components, see the relevant

sections in the technical user documentation.

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System overview

2.1

Application

Overview

SINUMERIK 840D sl offers modularity, openness, flexibility and uniform structures for

operation, programming, and visualization. It provides a system platform with trend-setting

functions for almost all technologies.

Integrated into the SINAMICS S120 drive system and complemented by an automation

system, such as SIMATIC S7-300, the SINUMERIK 840D sl forms a complete digital system

that is ideally suited for the mid to upper performance range.

SINUMERIK 840D sl is characterized by:

● A high degree of flexibility

● Excellent dynamic response and precision

● Optimum integration into networks

Benefits

● Outstanding performance and flexibility for multi-axis systems of average to high complexity

thanks to scalable hardware and software.

● Universal openness of the user interface, the PLC and the NC kernel to allow integration

of your specialist know-how.

● Integrated safety functions for man and machine: SINUMERIK Safety Integrated

● Comprehensive range of products for integrating machine tools into communication,

engineering and production processes: SINUMERIK Integrate

Field of application

The SINUMERIK 840D sl can be used worldwide in tool and mold making, for high-speed

cutting applications, for wood and glass processing, for handling operations, in transfer lines

and rotary indexing machines, for mass production and JobShop production.

The SINUMERIK 840DE sl is available as an export version for use in countries where approval

is required.

2.2

System configuration

SINUMERIK 840D sl combines CNC, HMI, PLC, closed-loop control, and communication tasks

within a single NCU (Numerical Control Unit).

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System overview

2.2 System configuration

Components

For operating, programming and visualization, the corresponding operator software is already

integrated in the CNC software. For increased operating performance, the SINUMERIK PCU

50.5 industrial PC can be used.

Up to four distributed OPs can be operated on one NCU / PCU. The operator panel can be

installed as a Thin Client at a distance of up to 100 m.

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Image 2-1

Typical topology of the SINUMERIK 840D sl complete system

The following components can be connected to the SINUMERIK 840D sl:

● SINUMERIK operator panel front with PCU/TCU

● SINUMERIK machine control panel MCP/MPP

● SINUMERIK handheld units

● SIMATIC CE panel

● SIMATIC thin client (as of firmware V1.4)

● Distributed PLC I/O via PROFIBUS DP or PROFINET IO

● SINUMERIK PP 72/48 I/O module

● SINUMERIK ADI 4 analog drive interface for four axes

● SINAMICS S120 drive system

● Feed and main spindle motors

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Application planning

3.1

Secondary electrical conditions

3.1.1

Power supply

Requirements for DC power supplies

DANGER

Danger of death caused by unsafe power supply

The DC power supply must be implemented as a circuit of Category PELV/DVC A according

to EN 61800-5-1.

WARNING

Inadequately fused supply cables can be life-threatening

In the case of supply lines > 10 m, protectors must be installed at the device input in order to

protect against lightning (surge).

The DC power supply must be connected to the ground/shield of the NC for EMC and/or

functional reasons. For EMC reasons, this connection should only be made at one point. As

a rule, the connection is provided as standard in the S7-300 I/Os. In exceptional

circumstances when this is not the case, the ground connection should be made on the

grounding rail of the NC cabinet (also refer to /EMC/EMC Installation Guide.)

Table 3-1

Requirements of the DC power supply

Rated voltage

According to EN 61131-2

24 VDC

Voltage range (mean value)

20.4 VDC to 28.8 VDC

Voltage ripple, peak/peak

5% (unsmoothed 6-pulse recti-

Powering up time when switched

fication)

any

Non-periodic overvoltages

≤ 35 V

Period of overvoltage

≤ 500 ms

Recover time

≥ 50 s

Events per hour

≤ 10

Transient voltage interruptions

Downtime

≤ 3 ms

Recovery time

≥ 10 s

Events per hour

≤ 10

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Application planning

3.1 Secondary electrical conditions

3.1.2

Grounding concept

Components

The SINUMERIK 840D sl system consists of a number of individual components which have

been designed so that the system complies with the appropriate EMC and safety standards.

The individual system components are:

● Numerical Control Unit (NCU)

● Machine Control Panel (MCP), Machine Pushbutton Panel (MPP)

● Keyboard

● Operator panels (operator panel front + TCU/PCU)

● Distributor box and handheld unit

● S7-300 I/O with IM 153 interface module

Grounding measures

The individual modules are attached to a metal cabinet panel. Insulating paints on the mounting

points (e.g. tension jacks) must be removed.

It is permissible to cluster the operator control components regarding connection/potential

bonding.

Example: The control panel on the swivel arm.

It is sufficient in this instance to connect the ground connections of, for example, the PCU,

TCU, and operator panel front using a cable and to route a shared grounding conductor to the

central ground connection in the control cabinet.

Additional references

EMC Design Guidelines

3.1.3

EMC compatibility

In addition to the protective grounding of system components, special precautions must be

taken to guarantee safe, trouble-free operation of the system. These measures include

shielded signal lines, special equipotential bonding connections, and isolation and shielding

measures.

Shielded signal cables

● For safe and fault-free operation of the system, the specified cables must be used.

● For digital signal transmission, the shield must have a conductive connection at both sides

of the housing.

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Application planning

3.1 Secondary electrical conditions

Cable definition

Definition:

● Signal cables (example)

- Data cables (Ethernet, PROFIBUS, sensor cables, etc.)

- Digital I/Os

- Cables for safety functions (emergency stop, enabling)

● Power cables (example)

- Low-voltage supply lines (230 VAC, +24 VDC, etc.)

- Motor cables

Rules for routing cables

In order to achieve the greatest possible EMC compatibility for the complete system (control,

power unit, machine), the following EMC measures must be carefully observed:

● If necessary, signal and power cables may cross one another (if possible at an angle of

90°), but must never be laid close or parallel to one another.

● Only use cables approved by SIEMENS for the signal lines from and to the Control Unit.

● Signal cables must not be routed close to strong external magnetic fields (e.g. motors and

transformers).

● If signal lines cannot be routed a sufficient distance away from other cables, they must be

installed in grounded cable ducts (metal).

● The operator panel fronts, MCPs, MPPs, and full keyboards must be installed in metallically

enclosed EMC-compatible housings.

Note

For further information on interference suppression measures and the connection of

shielded cables, please refer to the EMC Installation Guide.

EMC limit values in South Korea

The EMC limit values to be complied with for South Korea correspond to the limit values of the

EMC product standard for variable-speed electric drives EN 61800-3, Category C2, or limit

value class A, Group 1 according to EN 55011. By applying suitable supplementary measures,

the limit values according to Category C2 or according to limit value class A, Group 1, are

maintained. Further, additional measures may be required, for instance, using an additional

radio interference suppression filter (EMC filter).

The measures for EMC-compliant design of the system are described in detail in this manual

respectively in the Installation Guideline EMC.

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Application planning

3.2 Ambient climatic and mechanical conditions

Please note that the final statement on compliance with the standard is given by the respective

label attached to the individual unit.

3.2

Ambient climatic and mechanical conditions

3.2.1

Transport and storage conditions

The components of the SINUMERIK 840D sl system exceed the requirements according to

EN 61800-2 with regard to shipping and storage conditions.

The following data applies under the following conditions:

● Long-term storage in the transport and product packaging:

At weather-protected locations that have continuous contact with outside air through

openings.

● Transport in the transport packaging:

- In unventilated containers under conditions not protected from weather effects.

- In the “cold" in accordance with outside air.

- Air transport in the air-conditioned cargo hold.

Table 3-2

Ambient conditions during storage and transport

Type of condition

Permissible range/class

Transport

Storage

Classification

EN 60721-3-2

EN 60721-3-1

Climate class

2K4

1K4

Ambient temperature ¹⁾

-40° C ... +70° C

-25° C ... +55° C

Biological environmental condi-

2B1 ²⁾

1B1 ²⁾

tions

Chemically active environmental

2C2 ³⁾

1C2 ³⁾

conditions

Maximum permissible tempera-

Direct interaction in air/air:

30 k/h

ture change

-40°/+30° C at 95% relative

humidity

Relative humidity (without conden-

5 to 95%

sation)

Precipitation, rain

6 mm/min ²⁾

Not permissible

Water other than rain

1 m/s and wet loading surfa-

Not permis-

1 m/s and wet

ces ⁴⁾

sible ⁵⁾

loading surfaces ⁴⁾

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Application planning

3.2 Ambient climatic and mechanical conditions

Type of condition

Permissible range/class

Height

Max. 4,000 m above sea level

Condensation, splash water,

Permissible

Not permis-

Permissible ⁴⁾

icing, salt spray

sible ⁵⁾

Transport and storage of operator panel fronts and diskette drives: -20° C to +55° C.

Mold growth, slime, rodents, termites and other animal vermin are not permissible.

In marine- and weather-resistant transport packaging (container).

For storage in the transport packaging.

For storage in the product packaging.

Note

Remove the transport protective foil and packaging material before installing the components.

Shipping backup batteries

Backup batteries must only be shipped in the original packaging. No special authorization is

required to ship backup batteries. The lithium content is approximately 300 mg.

Note

The backup battery is classified as a hazardous substance, Class 9 in accordance with the

relevant air-freight transportation regulations.

Storage of backup batteries

Always store backup batteries in a cool and dry place. The batteries have a maximum shelf

life of 10 years.

Rules for handling backup batteries

WARNING

Incorrect handling of backup batteries can lead to a risk of ignition, explosion and combustion

The stipulations of DIN EN 60086-4, in particular regarding avoidance of mechanical or

electrical tampering of any kind, must be complied with.

● Do not open a battery. Replace a faulty battery only with the same type.

● Obtain replacement batteries only from Siemens.

● Always try to return low batteries to the manufacturer or deliver these to a registered

recycling company.

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Application planning

3.2 Ambient climatic and mechanical conditions

3.2.2

Operating conditions

The components of the SINUMERIK 840D sl system are intended for a weatherproof, fixed

location. The documented

environmental conditions apply to the climate in the immediate vicinity of the units and to the

entry of the cooling air. They exceed the requirements according to EN 60204-1, EN 61800-2,

EN 61131-2 and IEC 62477-1.

NOTICE

Damage to components by coolants and lubricants

The SINUMERIK operator components have been designed for industrial use, particularly on

machine tools and production machines. This also takes into account the use of commercially

available coolants and lubricants. The use of aggressive compounds and additives can

damage components and result in their failure.

Contact between the operator components and coolants and lubricants should be avoided

as far as possible, as resistance to all coolants and lubricants cannot be guaranteed.

Table 3-3

Ambient conditions for operation

Environmental conditions

Application areas

Remarks

Climatic environmental conditions

Climate class

Better than class 3K3

According to EN 60721-3-3

Permissible ambient tempera-

0 ... 45 °C (32 ... 113

Except PCU50.5;

ture when installed vertically

°F), up to 2000 m

front-side for OP, MCP/MPP and CNC

(6562 ft) above sea

standard keyboards KB.

level

0 ... 55 °C (32 ... 131

All, rear-side for OP, MCP/MPP and CNC

°F), up to 2000 m

standard keyboards KB.

(6562 ft) above sea

level

5 ... 55 °C (41 ... 131

For PCU50.5

°F), up to 2000 m

(6562 ft) above sea

level

Above an altitude of 2000 m (6562 ft), the max. ambient temperature

decreases by 7 °C (44.6 °F) for every 1000 m (3281 ft) increase in

altitude

Relative humidity (without con-

5% to 95% (60% when corrosive gases and/or dusts are present)

densation)

Condensation, formation of ice

Not permissible

Dripping water, spray, splash

Not permissible

All components, except ...

water, jet-water according to de-

Permissible

For handheld units, front side of operator

gree of protection

and machine control panels (MCP and

MPP), front side of the keyboards KB 310

and KB 483C

Max. installation altitude

Up to 4000 m (13123 ft) above sea level

Air pressure

620 hPa ... 1060 hPa

According to altitude range 0 m to 4000 m

(0 ft to 13123 ft) above sea level

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Application planning

3.2 Ambient climatic and mechanical conditions

Environmental conditions

Application areas

Remarks

Biological, chemical and mechanical influences, pollutants

Biological environmental conditions

Class 3B1 according to EN 60 721-3-3:

Mold, mold growth, slime, rodents, termite

and other animal vermin are not permissible.

Chemically active environmental conditions

Class 3C1 according to EN 60721-3-3

Mechanically active environmental conditions

Class 3S1 according to EN 60721-3-3:

Conductive dust not permissible.

Classification of the mechanical

3M3 for components on the machine

environment

3M1/3M2 for components in the control cab-

inet

Degree of contamination

EMC conducted / radiation

Class C3 according to EN 61800-3

Note

The user must consider radio interference for the complete system. Particular attention should

be paid to cabling. Please contact your sales representative for assistance and support.

If compliance with limit value class C2 is required, please contact your local sales

representative.

3.2.3

Cooling

To calculate the heat dissipation, the total power loss P_Vtotal of all heat-generating components

in a housing must be taken into account.

Total power loss P_Vtotal = P_V1 + P_V2 + P_V3 +... [W]

Convection surface area A [m²]:

The surface areas of the front and bottom sides are not included in the convection surface

area calculation.

Note

A recommended value for the power loss of the operator control components is contained in

the "Technical data" section of the associated component (see "Power consumption").

Means of heat dissipation

Heat dissipation can take place as follows:

● Heat dissipation by natural convection

● Heat dissipation by natural convection and internal air turbulence

● Heat dissipation by open-circuit cooling

● Heat dissipation by open-circuit ventilation

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Manual, 03/2016, 6FC5397-1AP40-5BA3

Application planning

3.2 Ambient climatic and mechanical conditions

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Means of heat dissipation

Fan design

● The fan must be positioned to produce an optimum heat dissipation. A clearance of 10 mm

must be maintained in front of the fan.

● The inlet and outlet slots must remain free for the open-circuit ventilation.

● Air filters must be provided to maintain the permitted environmental conditions.

NOTICE

Damage to the operating components caused by temperatures that are too high or too low

Contaminated air filters impair the desired heat dissipation. For handling the air filters, pay

attention to:

● Proper handling

● Regular replacement

● Correct disposal

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Application planning

3.2 Ambient climatic and mechanical conditions

Guidelines

If the convection area A [m²] does not suffice for the "heat dissipation using natural convection",

then use:

● "Heat dissipation using natural convection and internal turbulence" for hot spots and heat

concentrations in housings subject to space constraints. The total power loss P_Ltot for

thermally critical applications can be determined as follows:

- Current measurement for a 24 V supply voltage

- Power loss P_Ltot [W] = U (24 V) * |measured value in ampères|

● Heat dissipation using open-circuit ventilation

Calculation of the volumetric flow

The power loss (thermal) dissipated by the components in an operator unit is to be dissipated

using open-circuit ventilation. The volumetric flow V required for this should be calculated at

a difference in temperature of T₂ - T₁ = ΔT ≥ 10K.

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Image 3-2

Calculating heat dissipation for PCU 50.5 with OP 019

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Application planning

3.3 Standards and approvals

3.3

Standards and approvals

Approvals

CE approval

Image 3-3

CE marking

The operator panels and the safety-relevant accessories satisfy the requirements and

protection objectives of the following EC directives. The operator panels and the safety-

relevant accessories comply with the harmonized European standards (EN), promulgated in

the Official Journals of the European Community:

●

2004/108/EC "Electromagnetic Compatibility" (EMC directive)

● Directive 2006/42/EC of the European Parliament and Council of May 17, 2006, on

machinery, and Directive 95/16/EC (amendment)

SIBE Switzerland Certification Service

For the HT 2 and HT 8 units.

Image 3-4

Symbol of the certifying body

HT 2

The HT 2 operator panel and the safety-relevant accessories (is identified in the "Accessories"

section for the respective devices) satisfy Category 3, PL d according to EN ISO 13849-1:2008.

The safety function Enabling device for special mode control and the emergency stop button

satisfy the following requirements:

● Category 3, PL d according to EN ISO 13849-1:2008

● Requirements of EN 60204-1:2006, when complying with the safety instructions in the

relevant chapters of this documentation

HT 8

The HT 8 operator panel and the safety-relevant accessories (is identified in the "Accessories"

section for the respective devices) satisfy Category 3, PL d according to EN ISO 13849-1:2008.

The emergency stop button meets the following requirements:

● Category 3, PL d according to EN ISO 13849-1:2008

● Requirements of EN 60204-1:2006, when complying with the safety instructions in the

relevant chapters of this documentation

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Application planning

3.4 Recycling and disposal

The safety function Enabling device for special mode control satisfies the following

requirements:

● Category 4, PL e according to EN ISO 13849-1:2008

● Requirements of EN 60204-1:2006, when complying with the safety instructions in the

relevant chapters of this documentation

Address:

NSBIV AG, SIBE Switzerland, Brünigstrasse 18, CH-6005 Lucerne

Accreditation SCESp 0046 / Notified Body 1247

Number of the prototype test certificate: No. 1416

Risk assessment

The following standards must be used to perform the risk assessment:

● EN ISO 12100-1:2003 and EN ISO 12100-2:2003, General Design Guidelines for Machines

● EN ISO 14121-1:2007, Risk Assessment for Machinery

● EN ISO 13849-1:2008, Safety-related Parts of Machines

These considerations result in a category (B, 1, 2, 3, 4) and a performance level (PL a to e) in

accordance with EN ISO 13849-1:2008 that ultimately dictate how the safety-related parts of

the system to be monitored must be constructed.

The connection examples with different monitoring units in "Handheld units", Section: "HT 2",

Section: "Connections" → "Connection examples for acknowledgment button and Emergency

Stop button" can also be used for other operator panels and demonstrate how Category 3, PL

d according to EN ISO 13849-1:2008 can be attained with the safety-related parts of the

operator panels. Note that the overall concept of the installation must be designed with this in

mind.

3.4

Recycling and disposal

Products should be disposed of corresponding to the relevant national regulations.

The products described in this manual can be mostly recycled due to the fact that they contain

very few damaging substances. To recycle and dispose of your old device in an

environmentally friendly way, please contact an appropriate disposal company.

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Connecting

4.1

Pin assignment of the interfaces

The pins of the component interfaces are assigned as specified in the tables below. Any

deviations are indicated at the relevant point.

Signal type:

Input

Output

Bidirectional (inputs/outputs)

Power supply

Ground (reference potential) or N.C. (not connected)

Power supply interface

Connector type:

Terminal block, 3-pin plug connector

Max. cable length:

10 m

Table 4-1

Assignment of the power supply interface

Name

Type

Meaning

P24 (+)

24 VDC potential (20.4 to 28.8 VDC)

M24 (-)

Ground 24 V

SHIELD (PE)

Shield potential

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Connecting

4.1 Pin assignment of the interfaces

Serial interface COM1

9-pin sub-D connector

Table 4-2

Assignment of the serial interface COM1 (V.24/RS232)

Connector

Name

Type

Remark

DCD (M5)

Receive signal level (carrier)

RxD (D2)

Serial receive data

TxD (D1)

Serial transmit data

DTR (S1)

Data terminal ready

GND (E2)

Ground (reference potential)

DSR (M1)

Data Set Ready

RTS (S2)

Request To Send

CTS (M2)

Clear To Send

RI (M3)

Incoming call

USB interfaces

The USB interfaces are implemented as sockets and comply with the generally valid standard.

The version information (1.1, 2.0 etc.), the maximum velocity (low speed, full speed, etc.) and

the socket type (A or B) are documented in the individual sections for the associated devices.

In principle, USB interfaces have the following characteristics:

● Integrated power supply up to 500 mA for each socket.

● Maximum cable length 3 m (Length including the supply cable to the hub and the connected

terminal device; only 1 hub at maximum is permitted. It should be noted that some

keyboards already have a hub.)

NOTICE

Cables that are too long can cause the screen to freeze

Observe the following restrictions for the USB front interface for connecting operator

panels to the keyboard, mouse or USB FlashDrive:

● Maximum cable length: 1.8 m

● Extension cables are not permissible

● Hot-plugging-capable devices are connected during operation and are identified

automatically.

Note

Correct identification is only guaranteed for USB I/Os that comply to 100% with the USB

specification.

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Connecting

4.1 Pin assignment of the interfaces

Table 4-3

Assignment of the USB interface

Type A socket

Type B socket

Name

Type

Remark

P5V_fused

+ 5 V (fused)

Data-

Data -

Data+

Data +

GND

Ground (reference potential)

USB sticks

If you want to connect a USB stick to the USB interface, preferably use the tested SIMATIC

USB stick 16 GB for this purpose (Article No.: 6ES7648-0DC60-0AA0). Alternatively, you can

use a USB stick with any memory size. It must, however, meet the following minimum

requirements:

● File system: FAT16 or FAT32

● Partitioning: only in PC partition format (MBR)

USB sticks that deviate from these requirements have not been tested can may not be

recognized by the NCU.

PROFIBUS DP / MPI interface

Connector type:

9-pin sub-D socket

Max. data transmission rate:

12 Mbit/s

Max. cable length:

100 m

Table 4-4

Assignment of the PROFIBUS DP / MPI interface

Connector

Name

Type

Remark

1,2

N.C.

Not connected

LTG_B

Signal line B of MPI module

RTS_AS

Control signal for receive data current. Signal 1

active if directly connected control is sending.

M5EXT

Return line (GND) of 5 V supply. Current load

from a load of 90 mA max. connected between

P5EXT and M5EXT.

P5EXT

5 V supply (current load see M5EXT)

N.C.

Not connected

LTG_A

Signal line A of MPI module

RTS_PG

RTS signal of MPI module; signal is "1", when

PG is sending

Shield

On connector housing

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4.1 Pin assignment of the interfaces

PROFIBUS DP interface

Connector type:

9-pin sub-D socket

Max. data transmission rate:

12 Mbit/s

Max. cable length:

100 m

Table 4-5

Assignment of the PROFIBUS DP interface

Connector

Name

Type

Remark

1,2

N.C.

Not connected

RS_DP

RS-485 differential signal

RTS_DP

Request To Send

M5EXT

5 V external ground

P5EXT

5 V external potential

N.C.

Not connected

XRS_DP

RS-485 differential signal

N.C.

Not connected

Ethernet RJ45 interface

Connector type:

Standard RJ45 socket

Max. data transmission rate:

10/100/1000 Mbit/s

Max. cable length:

100 m

Table 4-6

Assignment of the Ethernet RJ45 interface 10/100 Mbit/s

Connector

Name

Type

Remark

TxD+

Transmit data

TxD-

RxD+

Receive data

4/5

GND

(terminated internally with 75 Ω; not re-

quired for data transmission)

/('

RD-

Receive data

7/8

GND

(terminated internally with 75 Ω; not re-

quired for data transmission)

Shield

On connector housing

Green LED

Lights up: 10 or 100 Mbit/s

(right)

Off: No or faulty connection

Orange LED

Illuminated: Data exchange

(left)

Off: No data exchange

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4.1 Pin assignment of the interfaces

Table 4-7

Assignment of the Ethernet RJ45 interface 1000 Mbit/s

Connector

Name

Type

Remark

DA+

Bidirectional pair A+

DA-

Bidirectional pair A-

DB+

Bidirectional pair B+

DC+

Bidirectional pair C+

/('

DC-

Bidirectional pair C-

DB-

Bidirectional pair B-

DD+

Bidirectional pair D+

DD-

Bidirectional pair D-

Shield

On connector housing

Green LED

Illuminated orange: 1000 Mbit/s

(right)

Off: No or faulty connection

Orange LED

Illuminated: Data exchange

(left)

Off: No data exchange

Note

Connection only on LAN, not on telecommunication networks!

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4.1 Pin assignment of the interfaces

DVI-I interface

Table 4-8

Assignment of DVI-I interface

Connector

Name

Type

Remark

GND

Ground

GND

Ground

Red

Green

Blue

HSYNC

Horizontal synchronizing pulse

GND

Ground

CSA

GND

Ground

TX2N

TDMS data 2-

TX2P

TDMS data 2+

GND

Ground

N.C.

Not connected

N.C.

Not connected

DDC CLK

DDC clock

DDC CLK

DDC data

VSYNC

Vertical synchronizing pulse

TX1N

TDMS data 1-

TX1P

TDMS data 1+

GND

Ground

N.C.

Not connected

N.C.

Not connected

+ 5 V

GND

Ground

MONDET

Hot plug detect

TX0N

TDMS data 0-

TXoP

TDMS data 0+

GND

Ground

N.C.

Not connected

N.C.

Not connected

GND

Ground

TXCP

TDMS clock +

TXCN

TDMS clock -

I/O USB interface

All signals required for connecting operator panel fronts, with the exception of the display

interface, are assigned to this interface.

Associated interface cable:

Connector type:

2 x 13-pin socket connector

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Connecting

4.1 Pin assignment of the interfaces

Table 4-9

Allocation of the I/O USB interface

Connector

Name

Type

Meaning

GND

Ground

P12C

+power supply for backlight inverter

BL_ON

Backlight On

P5V_fused

+5 V VCC (fused in PCU/TCU)

GND

Ground

P3V3_fused

+3.3 V VCC (fused in PCU/TCU)

7 - 10

N.C.

Not connected

P5V_fused

+5 V VCC (fused in PCU/TCU)

USB_D1M

USB data- Channel 1

USB_D1P

USB data+ Channel 1

GND

Ground

LCD_SEL0

LCD_SEL1

Display type select signal

LCD_SEL2

LCD_SEL3

RESET_N

Reset signal (low active)

reserved

Reserved

HD_LED

HD LED, anode with 1 kΩ in series on the

motherboard

DP_LED

MPI/DP LED, anode with 1 KΩ in series

on the motherboard

Ethernet_LED

Ethernet LED, anode with 1 kΩ in series

on the motherboard

TEMP_ERR

LED temperature sensor; anode with 1

kΩ in series on the board

RUN_R *)

Watchdog error LED, anode with 1 kΩ in

series on the motherboard

RUN_G

Watchdog OK LED, anode with 1 kΩ in

series on the motherboard

LVDS display interface channel 1

Used to connect operator panel fronts with TFT displays with 640 x 480 pixels (VGA), 800 x

600 pixels (SVGA) or 1024 x 768 pixels (XGA).

Associated interface cable:

K2, max. length: 0.5 m

Connector type:

2 x 10-pin socket connector

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Connecting

4.1 Pin assignment of the interfaces

Table 4-10

Allocation of the LVDS display interface

Connector

Name

Type

Meaning

1/2

P5V_D_fused

+5 V display supply voltage (fused in PCU/

TCU)

RXIN0-

Bit 0 (-)

LVDS input signal

RXIN0+

Bit 0 (+)

5/6

P3V3_D_fused

+3.3 V display supply voltage (fused in PCU/

TCU)

RXIN1-

Bit 1 (-)

LVDS input signal

RXIN1+

Bit 1 (+)

9/10

GND

System ground (reference potential)

RXIN2-

Bit 2 (-)

LVDS input signal

RXIN2+

Bit 2 (+)

13/14

GND

System ground (reference potential)

RXCLKIN-

(-)

LVDS cycle clock signal

RXCLKIN+

(+)

17/18

GND

System ground (reference potential)

19/20

N.C.

Not connected

LVDS display interface channel 2

Used for expanding the LVDS display interface channel 1 to control TFT displays with 1280 x

1024 pixels (SXGA).

Associated interface cable:

Connector type:

2 x 10-pin socket connector

Table 4-11

Allocation of the LVDS display interface

Connector

Name

Type

Meaning

1/2

GND

System ground (reference potential)

RXIN10-

LVDS input signal

Bit 0 (-)

RXIN10+

Bit 0 (+)

5/6

GND

System ground (reference potential)

RXIN1-

LVDS input signal

Bit 1 (-)

RXIN1+

Bit 1 (+)

9/10

GND

System ground (reference potential)

RXIN2-

LVDS input signal

Bit 2 (-)

RXIN2+

Bit 2 (+)

13/14

GND

Ground

RXCLKIN-

LVDS cycle clock sig-

(-)

nal

RXCLKIN+

(+)

GND

Ground

18-20

P12VF

+12 V fused

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4.1 Pin assignment of the interfaces

Rotary switch: Feed override X30

Connector designation:

X30

Connector type:

2 x 5-pin plug connector, according to EN 60603-13 with coding

Max. cable length:

0.6 m

Table 4-12

Assignment of X30 connector (on delivery)

Name

Type

Meaning

N.C.

Not connected

N.C.

Not connected

Ground

N.C.

Not connected

5 V supply

OV_VS16

Override rotary switch value 16

OV_VS8

Override rotary switch value 8

OV_VS4

Override rotary switch value 4

OV_VS2

Override rotary switch value 2

OV_VS1

Override rotary switch value 1

Rotary switch: Spindle override X31

Connector designation:

X31

Connector type:

2 x 5-pin plug connector, according to EN 60603-13 with coding

Max. cable length:

0.6 m

Table 4-13

Assignment of X31 connector (on delivery)

Name

Type

Meaning

N.C.

Not connected

N.C.

Not connected

Ground

N.C.

Not connected

5 V supply

OV_SP16

Override rotary switch value 16

OV_SP8

Override rotary switch value 8

OV_SP4

Override rotary switch value 4

OV_SP2

Override rotary switch value 2

OV_SP1

Override rotary switch value 1

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Connecting

4.1 Pin assignment of the interfaces

Optional customer buttons IN (X51 / X52 / X55)

Only switches (passive inputs) may be connected via the X51, X52 and X55 connectors. X51

and X52 are typically used for connecting illuminated pushbuttons. The lamps in the buttons

are activated via X53 and X54. X55 has no corresponding outputs.

Note

Connection miniature handheld unit

Alternatively, at the inputs X51, X52 and X55, one miniature handheld unit may be operated.

For details, please refer to the corresponding section.

; L

.7M ,1

0 *1'

Image 4-1

Main circuit diagram of the input circuit for X51, X52 and X55

Connector designation:

X51 / X52 / X55

Connector type:

4-pin plug connector

Max. cable length:

0.6 m

Table 4-14

Assignment of connector X51

Name

Type

Meaning

KT-IN1

Customer key 1

KT-IN2

Customer key 2

KT-IN3

Customer key 3

Ground

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4.1 Pin assignment of the interfaces

Table 4-15

Assignment of connector X52

Name

Type

Meaning

KT-IN4

Customer key 4

KT-IN5

Customer key 5

KT-IN6

Customer key 6

Ground

Table 4-16

Assignment of connector X55

Name

Type

Meaning

KT-IN7

Customer key 7

KT-IN8

Customer key 8

KT-IN9

Customer key 9

Ground

Optional customer buttons OUT (X53 / X54)

The short-circuit-proof outputs X53/X54 are provided to control lamps in the keys.

Lamps with 24 V and 2.4 W per output are recommended.

;

.7 287

0 *1'

;

.7 287

0 *1'

Image 4-2

Main circuit diagram of the input circuit for X53 and X54

NOTICE

Damage to the electronics

Do not connect any relays, valves or other inductive loads.

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4.1 Pin assignment of the interfaces

Connector designation:

X53 / X54

Connector type:

4-pin plug connector

Max. cable length:

0.6 m

Table 4-17

Assignment of connector X53

Name

Type

Meaning

KT-OUT1

Output 1 lamp

KT-OUT2

Output 2 lamp

KT-OUT3

Output 3 lamp

Ground

Table 4-18

Assignment of connector X54

Name

Type

Meaning

KT-OUT4

Output 4 lamp

KT-OUT5

Output 5 lamp

KT-OUT6

Output 6 lamp

Ground

Interfaces for two handwheels X60 / X 61

Interface:

Handwheel 1

Handwheel 2

Connector designation:

X60

X61

Connector type:

15-pin Sub-D socket

Max. cable length:

25 m

Table 4-19

Assignment of connectors X60/X61

Name

Type

Meaning

P5HW

5 V power supply

Ground

HW1_A / HW2_A

Handwheel pulses track A

HW1_XA / HW2_XA

Handwheel pulses track A (negated)

N.C.

Not connected

HW1_B / HW2_B

Handwheel pulses track B

HW1_XB / HW2_XB

Handwheel pulses track B (negated)

N.C.

Not connected

P5HW

5 V power supply

N.C.

Not connected

Ground

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4.1 Pin assignment of the interfaces

Name

Type

Meaning

N.C.

Not connected

N.C.

Not connected

N.C.

Not connected

N.C.

Not connected

Note

The handwheels can either be operated with TTL or differential signals.

You set the signal type using S1 (wire bridge) on the COM board.

The handwheels are supplied with 5 V ± 5% and 100 mA via the interface.

Contour and velocity specification via handwheel are not supported.

Interfaces for direct keys

X11 on the operator panel (OP) fronts can be used to fetch the state of the direct keys. The

connection of a 20-pin ribbon cable allows the direct keys to evaluate the following components:

● Direct key module (DTM)

● X70 in the machine control panels (MCP, MPP) and the handwheel connection module

(HAM)

● X205 on the Thin Client Unit (TCU)

The signals are then forwarded to the control over the various communications networks. Note

that DTM and HAM can be operated only with PROFIBUS DP.

Image 4-3

Assignment of the direct keys to the vertical softkeys of an operator panel front

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Manual, 03/2016, 6FC5397-1AP40-5BA3

Connecting

4.1 Pin assignment of the interfaces

16 digital inputs (5 V) can be fetched via the X11 connector.

Connector designation:

X11

Connector type:

20-pin plug connector

Max. cable length:

0.85 m

Table 4-20

Assignment of connector X11

Name

Type

Meaning

DT1

Direct key 1

DT16

Direct key 16

P5V

+ 5 V (fused)

P5V

+ 5 V (fused)

GND

Ground

GND

Ground

16 digital inputs can be polled by the X70/X205/DTM connector.

Connector designation:

X70/X205/DTM

Connector type:

20-pin plug connector

Max. cable length:

0.85 m

Table 4-21

Assignment of connector X70 (MCP, MPP, HAM) / X205 (TCU) / DTM

Name

Type

Meaning

DT1

Direct key 1

I ¹⁾

DT16

Direct key 16

P5V / CON1 ²⁾

+ 5 V input voltage ³⁾

P5V / CON2 ²⁾

+ 5 V input voltage ³⁾

GND

Ground

GND

Ground

The inputs are electrically isolated for MCP / MPP / HAM and DTM.

For the TCU, it is evaluated whether the direct keys have been connected.

Power consumption: 100 mA for MCP / MPP / HAM; 500 mA for DTM

Table 4-22

Signal level

HIGH level:

5 V or open

Low level

<= 0.8 V

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4.2 Handling membrane connectors

4.2

Handling membrane connectors

When replacing parts it can sometimes be necessary to disconnect membrane connectors

from the boards and reconnect them again.

This should be done as follows:

(1)

Clamping frame of socket

Image 4-4

Removing (left) and attaching (right) a membrane connector

Unplugging the membrane connector

1. Loosen the dark clamping frame of the socket by pushing it up with your fingernails until it

engages in its upper, unlocked position (Fig. left).

2. Carefully pull off the membrane connector upward.

Plugging in the membrane connector

1. With the clamping frame in the upper position, carefully plug the membrane connector into

the socket.

2. Lock it in place by pushing down the clamping frame (Figure right).

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5.1

System settings

5.1.1

Settings for SINUMERIK solution line

Range of validity

This description is valid for:

● NCU 7x0.3 PN with NCU-Basesoftware (Linux-based)

● PCU 50.5 with PCU-Basesoftware (Windows XP, Windows 7)

Introduction

This manual describes the structure and commissioning of the system network with

SINUMERIK solution line control and operator components with Ethernet-based

communication. The fundamentals of the system network are described first, details and

special cases are described in subsequent chapters.

Fundamentals

The system network for SINUMERIK solution line is structured as a star topology with a central

Ethernet switch, to which all Ethernet-based components of the system are connected.

For an NCU the connection is executed via the X120 Ethernet socket, for PCU it is executed

via the "Ethernet 2" connection. There is no default for all other components with two Ethernet

connections. These components have an internal 2-port switch and may be used to connect

an additional operator component. Thus in this case there can be deviation from the strict star

topology.

System network

In the system network the IP address 192.168.214.xxx with subnet mask 255.255.255.0 is pre-

selected. Here there is precisely one DHCP server with DNS that can run on one NCU or one

PCU. The server ensures assignment of IP addresses to the Ethernet components in the

system network (DHCP clients) from a specified address band.

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5.1 System settings

The following rules apply for assignment of IP addresses in the system network:

● For all NCUs and PCUs the commissioning engineer assigns fixed IP addresses in the

associated address bands, as well as appropriate computer names (host names). All other

(operator) components are automatically assigned an IP address from the DHCP server.

Its name is generated automatically (for MCP, MPP, HT 8), or is entered at commissioning

(TCU).

● If there are multiple NCU and/or PCU in the system network the system automatically

(depending on the start-up sequence) specifies the DHCP server and automatically ensures

synchronization of all necessary data so that the next time the system boots any other NCU

or PCU could take on the role of DHCP server. However it is a good idea to specify a DHCP

master. This is an NCU or PCU in the system network that is available at each system boot

and which regularly takes over the task of the DHCP server and DNS server.

Synchronization of data takes place in any event so that any other NCU or PCU can take

over this task. All non-master NCU / PCU wait in the system boot an adjustable length of

time for availability of the master.

Note

In a system network, on a boot server respectively - i.e. the NCU or PCU which

accommodates the active DHCP server - a maximum of 30 operator stations may be

operated simultaneously with a TCU.

A maximum of 10 operator stations with a TCU may connect up simultaneously with the

same HMI application when powering up.

Connection to a company network

Each NCU can be connected via X130, and each PCU can be connected via "Ethernet 1" to

the company network. The company network is used to exchange operating software with

servers or to execute part-programs directly from servers in the company network. Company

network and system network should always be logically and also physically separated.

Service interface X127

The service interface X127 of the NCU is used for direct connection of a PG/PC for service

purposes. Here access with STEP 7 to the PLC, and with NCU 7x0.3 PN also to PROFINET

is possible.

With direct connection (peer-to-peer) of a PG/PC to X127 it is absolutely necessary that the

PG is operated as a DHCP client.

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5.1 System settings

5.1.2

System boot with system network

System behavior at boot

As of NCU system software V2.4 SP1 and PCU-Basesoftware V8.1, system boot behavior is

based on the following principle:

● For configuration of an NCU 7x0 with a PU 50, the default for a network configuration is as

follows: The NCU keeps the default IP address 192.168.214.1 on X120, the PCU 50 keeps

the default IP address 192.168.214.241 on Eth2.

● For a configuration of more than 1 NCU 7x0 without PCU, with one or several PCU 50, then

a differentiation must be made between two cases:

- At boot automatically all address conflicts and DHCP conflicts are resolved and the

system is ready for operation. In this configuration there is no guarantee that all NCUs

and PCUs will always receive the same IP address at each system boot.

- If in the user's view there is a requirement that all NCUs, and possibly also the PCUs,

get a defined constant IP address at each boot, for example because the IP address is

entered in the respective PLC program, then the user must configure a fixed IP address

for each NCU 7x0/PCU 50 in question, in the basesys.ini file.

● The user can specify a DHCP master in the basesys.ini file.

● Assigning names:

- The user should assign meaningful names for all NCUs in the basesys.ini file; if not the

names will be generated automatically.

- A PCU 50 always has a computer name that can be changed as needed.

● The IP addresses of TCUs and MCPs are freely assigned within the specified address band

at each boot. The MCPs are identified in the PLC via their DIP switch setting.

Using DNS name service

Availability of the DNS (Domain Name System) name service offers the following advantages

for system network administration:

● The name service enables easier configuration with names instead of IP addresses for

management of operating units: All components in the system network can be addressed

via a symbolic computer name. This name can to some extent be freely assigned, to some

extent it is derived automatically from a DIP switch setting (MCP, MPP, EKS, HT 8, HT 2).

● A computer node in the system network (NCU, PCU, TCU, MCP, HT 8, etc.) can be

addressed solely through assignment of the IP address, either via a freely selectable name

or via an internally generated name in the system network, and thus becomes independent

from its network address in the system network. Thus a change in the network address

does not necessarily necessitate a series of additional setting changes.

● In addition, the name service is used by the system for address resolution for MCP/MPP,

direct keys, and EKS when changing the user authorization.

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5.1 System settings

5.1.3

Thin Client Unit (TCU)

TCU overview

The Thin Client Unit (TCU) for the distributed configuration permits spatial separation of the

SINUMERIK operator panel front (OP/TP) and the SINUMERIK PCU or NCU. On the

SINUMERIK solution line, the TCU is used to display the user interface of the PCU 50 or the

NCU.

It is possible to connect one TCU to several PCUs/NCUs. All TCUs and PCUs/NCUs that are

connected to one another via a switch form the "system network". The user interface of a PCU/

NCU is copied to several OPs with one TCU each. In other words, all of the TCUs display the

same screen. Operator actions can only be performed on one TCU at a time. This TCU then

has user authorization. The PCU can also have its own OP connected directly to it.

The following diagram shows a configuration example for a distributed topology:

7&8

6,180(5,.

' VO

3&8

0&3

6ZLWFK

The mobile SINUMERIK HT 8 handheld terminal works on the thin client principle and

combines the functions of an operator panel with a machine control panel.

The configuration and cabling of the whole plant system based on a permissible configuration

is described in the chapter 'Network configurations".

Supplementary conditions

For operation of a TCU:

● In the system network, the number of active TCUs is limited:

- a maximum of 2 TCUs: NCU 710.3 PN

- a maximum of 4 TCUs: NCU 720.3 PN or NCU 730.3 PN

- a maximum of 4 TCUs: PCU

Any number of TCUs can be operated in the system network.

● CompactFlash Cards cannot be used on the TCU.

● A 16 bit or 32 bit depth of color setting may be selected.

● If a PC keyboard is connected to the TCU, it is not possible to ensure that all special keys,

e.g., multi-media keys, will be transferred to the software of the NCU / PCU.

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5.1 System settings

● Machine control panels connected via a PROFIBUS network are not supported for

switchover.

● Distributed memory media that are connected to the TCU via USB can be used.

5.1.4

Factory default settings

Meaning of the symbols:

○

Eth 1 as a DHCP client

●

Eth 2 as a DHCP server

■

Eth 2 with a fixed IP address

Preconfiguration of the TCU

The TCU is configured as a DHCP client and primarily accepts IP addresses from SINUMERIK

components, from the DHCP server of such components that are inherent to SINUMERIK, for

example, an NCU at X120 or a PCU on the system network or from a default DHCP server.

The behavior of the TCU cannot be modified here.

A TCU is a SINUMERIK DHCP client.

The TCU has a single Ethernet connection.

7&8

A TCU executes a boot via the network. The boot server is the computer node from which the

TCU also obtains its IP address.

Pre-configuration of the PCU

A PCU has two Ethernet interfaces with default settings suitable for use with SINUMERIK

solution line:

Eth 1 is pre-selected as a default DHCP client for connection to a

company network.

3&8

Eth 2 is pre-selected as a SINUMERIK DHCP server for connection

to a system network. On Eth 2 the fixed IP address

(WK

192.168.214.241 is pre-selected.

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5.1 System settings

Preconfiguration of the NCU

On the X120, the NCU is preconfigured for the SINUMERIK DHCP protocol. The NCU is pre-

selected here as a SINUMERIK DHCP server. On X120, the NCU occupies the fixed IP address

192.168.214.1 with the subnet mask 255.255.255.0 in its capacity as a DHCP server. The

DHCP server of the NCU assigns IP addresses from the range 192.168.214.10 -

192.168.214.239 to the DHCP clients. The behavior of the NCU on X120 cannot be

modified.

Restricting the available address band that is managed by the DHCP server of the NCU frees

up IP addresses 192.168.214.2 to 192.168.214.9 as well as addresses 192.168.214.241 to

192.168.214.254 for network nodes with fixed IP addresses.

The NCU has three Ethernet connections:

;

- X120 to connect to the system network with an active DHCP serv-

er (Eth 0)

1&8

- X130 to connect to the company network as a default DHCP client

;

(Eth 1)

- X127 as a service connection with an active DHCP server (Ibn 0)

On X130, the NCU is set as a default DHCP client for the address reference from a company

network. The IP address received here is specified by the DHCP server from the company

network.

On X127, an NCU is a standard DHCP server (in contrast to the SINUMERIK DHCP server).

On X127, the NCU has the fixed IP address 192.168.215.1 with the subnet mask

255.255.255.224). The IP addresses 192.168.215.2 - 192.168.215.23 are dynamically

assigned to the DHCP clients. The range 192.168.215.24 - 192.168.215.30 is reserved, and

can be used by stations on the network with a fixed IP address, e.g. by a modem.

Reserved IP addresses for NCU and PCU

The following defaults apply on delivery:

● Connection to the system network with subnet mask 255.255.255.0:

IP address

Network station

Remark

192.168.214.1

NCU on X120

Default

192.168.214.2 - 9

For additional NCUs with a fixed IP address on

Unassigned

the system network

192.168.214.10 - 239

For additional TCUs, subsequently for additional

DHCP clients

PCUs, NCUs, MCPs, MPPs

192.168.214.240

Reserved for EKS (Electronic Key System)

Default

192.168.214.241

Fixed IP address of the PCU on Eth 2

Default

192.168.214.242 - 249

For additional PCUs with a fixed IP address

Unassigned

192.168.214.250 - 254

For PGs with a fixed IP address (service con-

Unassigned

nection)

● Service connection with subnet mask 255.255.255.224:

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5.2 Commissioning TCU

IP address

Network station

Remark

192.168.215.1

NCU on X127

Default

192.168.215.2 - 23

for service purposes with PG, PC

DHCP clients

192.168.215.24 - 30

fixed IP address, for example for a modem

Unassigned

5.2

Commissioning TCU

5.2.1

Using the TCU's main menu

Key assignment

Functions of the keys and softkeys in the "Operator panel service system":

Softkey

Key on OP

External key-

Description

board

HSK1

<F1>

Moves the cursor down a row

HSK2

<F2>

Moves the cursor up a row

Page

HSK3

<F3>

Moves the cursor down a page

Page

HSK4

<F4>

Moves the cursor up a page

Char

HSK5

<F5>

Inserts text or digits

Char

HSK6

<F6>

Inserts text or digits

VSK7

←

Cancel / Return

Cancel

VSK8

→

OK / Confirm

---

Pos1

Moves the cursor to the top row

---

End

Moves the cursor to the bottom row

Exceptions to the above are mainly the result of input fields. Where these are present, the left/

right cursor keys move the input cursor rather than performing an OK/cancel function. The

Return key takes you to the next field (like the "down" key) rather than closing the entire dialog

with OK. There are also Backspace (deletes character to the left) and Delete (deletes character

to the right) keys for editing text and numbers. The F5, F6, Backspace, Delete, and Select

keys (between the cursor keys on the panel) can be used to switch between Yes/No fields.

Touch panels without any additional keys still have a special function which allows you to edit

letters and numbers with HSK5/HSK6 by moving characters forwards or backwards. With a

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5.2 Commissioning TCU

touch screen, you can activate all the softkeys and even select rows in a menu simply by

touching them.

See also: How to calibrate a touch panel (Page 65)

"Main menu"

The dialog "Main menu (TCU1)" is started with the menu back key and the key <MENU SE-

LECT>:

Image 5-1

TCU menu: Main menu

The main menu contains:

● A "Main menu" title followed by the TCU name in brackets

● A central area listing the servers from config.ini. This is followed by two more fixed items,

"Select service session" and "Service this panel".

- The penultimate menu item, "Select service session", triggers a server scan which

detects all the VNC servers in the local (system) network. These are then displayed in

a session menu which largely reflects the main menu.

- The last menu item on the main menu, "Service this panel", opens the "Service menu

for operator panel" submenu.

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5.2 Commissioning TCU

● The right-hand side of the menu has a column containing 8 softkeys for use on a context-

specific basis.

● The lower section of the menu has a row of 4 softkeys for navigating with the cursor.

● There is an error line for displaying error messages directly above the row of softkeys.

Transient status messages also occasionally appear in this line.

● There is a further message line above this error line. The contents of this line can be set

from the servers using HWS commands.

"Details" softkey

The following connection data for the selected device appears when the "Details" softkey is

pressed:

Image 5-2

TCU menu: Connection data

5.2.2

Using additional TCU menus

"Service sessions" dialog

When "Select service session" is selected from the main menu, the resulting process begins

by triggering a server scan:

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Image 5-4

TCU menu: Active sessions

Central area with the server list:

The individual server lines contain either "Show WHAT on NAME (IP)" or the IP address only

where the name is unknown.

Session number

VNC server

Session 0

HMI

Session 4

Command shell

Session 5

System logfile

Session 6

System Network Center (SNC)

Session <N>

other server

These details are followed by a status message regarding the accessibility of the VNC server.

"Connection not ok" appears if it is already impossible to access the VNC server from the IP

side (if switched off, for example). If it can be accessed, a message shows whether an HMI-

VNC server is also accessible ("HMI running/not running").

The VSK8, Return or right cursor keys can be used to launch a VNC viewer for the selected

server.

Connection status:

Further details on the connection status can be called with the "Details" softkey. In the next

dialog, "not ok" or "not running" are accompanied by an additional error message with more

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5.2 Commissioning TCU

precise details on the reason for the loss of function. With more favorable scenarios, the

session name for the VNC server will also be specified along with its resolution.

The connection and HMI status are monitored on a regular basis in the backg1round. This may

mean that these details change spontaneously if a change is made on the relevant server (for

example, it may be switched off, the HMI may become available, etc.).

"Service menu for operator panel (TCU)" dialog

The following dialog appears when "Service this panel" is selected from the main menu:

Image 5-5

TCU menu: Service menu

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Image 5-7

TCU menu: Local logfile

● "Show logfile of remote devices" displays the logfile of the other devices in the network:

The syslog messages of devices in the system network which send syslog messages by

broadcast, such as NCU 7x0, ...

● "Modify operator panel settings" calls a further submenu. Please refer to the next section.

● "Calibrate touch screen" is only active if there is a touch screen. This menu item recalibrates

the touch screen.

● "Reboot" restarts the TCU.

Note

Where the contents of a line exceed the space available, the remaining text runs onto the

next line so that you do not have to waste time scrolling across. When this occurs, the line

has a right-facing arrow at its right edge.

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"Modify settings for operator panel (TCU)" dialog

The following dialog appears when "Modify settings" is selected from the main menu:

Image 5-8

TCU menu: Settings

The central area is for setting the TCU parameters:

● "HT 8 individual mode" (yes/no)

This is only visible with HT 8, and is used to switch between Auto Mode and Individual

Mode.

There is no need to make any settings if an HT 8 is in Auto Mode, as the name is determined

automatically: ("DIP<n>") the MCP address and TCU index are determined by the DIP

setting ("DIP<n>").

It is possible, however, that another device is registered for the name selected. Such

situations may only prove to be temporary, as is the case when DIP settings or two HT 8

have been confused. For this reason, this status is not reported as an error immediately,

but identified as a possible problem instead ("potential name/DIP setting collision"). The

text will only read ("Name/DIP settings collision") if the situation remains unchanged after

some time has elapsed.

The process itself is unaffected, as the changes only relate to how the warning or error is

displayed. The explanatory text informs the user that they have probably assigned the same

DIP number twice and suggests they change one of them before rebooting the HT 8.

● "Operator panel index - TCU" (0-255)"

This specifies the TCU index. It matches the [Station] tcuIndex setting from the config.ini

file.

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● "Machine control panel address - MCP" (0-255)

This specifies the address of the associated MCP. It matches the [Station] mcpIndex setting

from config.ini.

● "Electronic key system index - EKS" (0-255)"

This specifies the index of the associated EKS. It matches the [Station] eksIndex setting

from config.ini.

● "Enable direct keys" (yes/no)

This specifies whether direct keys (if present) should communicate with the PLC (yes) or

be treated as ordinary keys (no).

"OK" saves any modified values to the config.ini file or to the Flashstore (HT 8 individual mode).

Parameters for the "config.ini" file

Two steps need to be performed:

1. Select "New" or "Replacement for existing panel".

2. Select what is to be replaced.

When an unknown TCU (i.e. not yet registered with the boot server) is started, a selection

menu containing both the "New" and "Replacement for existing panel" items will appear. The

accessibility of all the registered TCUs is tested in the backg1round.

The status of this test process appears in the message line: "(0/3 panels inactive)".

Image 5-9

TCU menu: New TCU

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If all the TCUs are active, the new one cannot be a replacement. The system will then

automatically switch to the name assignment phase after a set period of time has elapsed.

Image 5-10 TCU menu: Name of TCU

Replacing a device

If "Replacement" is selected, all the registered TCUs will appear in a selection menu. Those

which are active in the network will be grayed out. (As these are functioning, there should be

no question of replacing them.) The cursor automatically defaults to the first row for selection.

As the accessibility test is still running in the backg1round, the active status of the rows may

change if panels are switched on or off.

If a name is ultimately chosen, it will be applied to the new TCU along with the associated

saved settings.

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Assigning a name

If, as described above, the system automatically follows the "New" path, an additional message

will appear: "This operator panel (TCU) must be new, because there are no inactive panels."

This message will not appear if "New" is selected manually.

Image 5-12 TCU menu: Name of TCU

An available TCU name is suggested in the input field, although the user is able to change

this. The default name is "TCU<N>", where <N> is the lowest number yet to be used. If,

however, the name is already allocated after the OK softkey has been pressed (which may

happen if a number of TCUs log on at the same time) and the suggestion has not changed, a

new and unused name will be specified.

If the name selected was still available, this will now be allocated, and the TCU settings can

still be adapted if required. To enable any changes to be made, a new dialog will appear in

which all the parameters have been pre-assigned their default values. You can make any

changes you like or just select "OK" to accept the existing values.

5.2.3

How to register a TCU on the system network

Preconditions

The boot server (NCU or PCU 50) defined in the system network as a DHCP master, must be

switched on and be available in the network.

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Sequence for a TCU

Procedure:

1. Connect TCU.

This opens the dialog "New operator panel (TCU)".

2. Select "New" to connect a new TCU and "OK" to confirm.

3. In the next dialog, accept the name suggested by the system or enter a name and confirm

this with "OK".

The following parameters are pre-selected for the TCU:

Operator panel index - TCU [0-255]

Machine control panel address - MCP [0-255]

192

Electronic key system index - EKS [0-255]

Enable direct keys

4. Restart the TCU to apply the new settings.

5. If you want to change the parameters, select "Main menu" → "Service this panel" → "Modify

operator panel settings".

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Sequence for the HT 8

Procedure:

1. Connect HT 8 to a connection module and calibrate the touch screen.

Additional softkeys are available for convenient touch panel operation:

- "OK" has the same effect as the <INPUT> key

- Select "DEF" to save the "Default" settings.

- "Edit" has the same effect as the <F10> or <MENU SELECT> key.

2. Select HT 8 Individual Mode:

According to the default setting for an HT 8, "HT 8 Individual Mode" is deselected with "No".

This means "Auto" mode is activated for automatic detection in the system network. The

HT 8 is automatically detected based on its name "DIP_". If "HT 8 Individual Mode" is

activated with "Yes", the HT 8 is identified by its MAC address on the system network.

3. For an HT 8, confirm the "DIP..." name proposed by the system or adapt the name. You

can select any other characters.

Press the <INPUT> key to apply the following values as default settings for the HT 8:

HT8 Individual Mode

Operator panel index - TCU [0-255]

Machine control panel address - MCP [0-255]

Electronic key system index - EKS [0-255]

Enable direct keys

The following message will then appear: "New TCU 'DIP10' registered."

Note

The TCU index is used to evaluate the direct keys. Direct keys can only be activated by

appropriate devices. For an HT 8 the TCU index cannot be set, but is assigned by the

system.

Activate direct keys

The signals from pressing the direct keys are sent directly to the PLC. In the PLC, the keys

appear as 16 digital inputs.

Additional information on programming the PLC is provided in:

References: Function manual basic functions, basic PLC program (P3 sl)

Definition: Operator panel

The term operator panel designates a unit that consists of an OP/TP, a TCU or PCU and a

machine control panel (MCP), that are connected to each other via Ethernet.

All TCUs and PCU 50 can be used along with OP/TP with "integrated TCU", e.g.: OP 08T,

OP 015T, TP 015AT.

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Specifying settings without machine control panel

If a PCU or a TCU has no Machine Control Panel (MCP), you must set one of the two following

options:

● MCP address = 0 or no entry

After the change of user authorization, there is no switchover of the machine control panel;

the previously active MCP remains active.

● MCP address = 255

If the user authorization is transferred to this PCU or TCU, the previous machine control

panel is deactivated and there is no active machine control panel from this point on.

Connecting a replacement TCU

Procedure:

1. Connect the new TCU.

The following dialog lists the TCUs on the system network along with their "active" or

"inactive" status.

Image 5-13 TCU menu: New operator panel (TCU)

2. Select the name previously assigned to the faulty TCU from the "New operator panel (TCU)"

dialog. As a result, the new TCU is recognized on the network and acquires all of the

configuration settings from the TCU that has been replaced.

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SINUMERIK 840D sl Hardware. Manual (2011-2020) - page 1