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

Networking

5.4 Service and diagnostics

Example:

[Station]

maxhostindex=2

/* Number of nodes that are defined under

[host_1] and [host_2].

mcpIndex=192

tcuIndex=1

eksIndex=0

[host_1]

Address=192.168.214.1

/* Address of the NCU to which the

connection is established during booting.

[host_2]

Address=157.163.230.202

/* Address of the PC

password=123456

/* Password of the VNC server on the PC

Switching over between the nodes

With the menu back key + MENU SELECT, the following actions are triggered:

● The TCU name is displayed in the header of the displayed window, e.g. TCU1.

● A selection list for connecting to the other nodes is displayed on the TCU.

5.4

Service and diagnostics

5.4.1

Using the TCU's main menu

"Main menu"

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

key:

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5.4 Service and diagnostics

① "Main menu" title followed by the TCU name in brackets

② Central area with the list of servers and two further permanent items, "Select service session"

and "Service this panel":

● "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.

● "Service this panel" opens the "Service menu for operator panel" submenu.

③ Eight vertical softkeys for use depending on the context

④ Four horizontal softkeys for navigating with the cursor

⑤ Message line whose content can be set via HWS commands from the servers

⑥ Error line in which error messages as well as transient status messages are output

Figure 5-2

TCU menu: Main menu

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5.4 Service and diagnostics

Figure 5-5

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 servers

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 server from the IP side

(if switched off, for example).

● "HMI running/ not running", if an HMI VNC server is accessible.

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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5.4 Service and diagnostics

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 backg16round. This may

mean that these specifications change spontaneously if a change is made on the relevant

server, e.g. it may be switched off, the HMI may become available, etc.

5.4.3

Operating the TCU menu "Service menu"

"Service menu for operator panel (TCU)" dialog

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

Figure 5-6

TCU menu: Service menu

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5.4 Service and diagnostics

The following menu items are available here:

● "Show status" shows status information, for example: Software version, hardware

information, TCU network data, and their configuration:

Figure 5-7

TCU menu: OP status

● "Show local logfile" shows a filtered version of the system log file in the /var/log/

messages directory, which contains only the messages of the local TCUs.

Syslog messages received via the network are not displayed.

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5.4 Service and diagnostics

Figure 5-8

TCU menu: Local log file

● "Show logfile of remote devices" shows the log file 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" opens another submenu, see next section.

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

an available touch screen.

● "Reboot" initiates a restart of the TCU.

Note

Long lines are broken and wrapped around.

Lines that are longer than the space available wrap round onto the next line so that you do not

have to scroll horizontally. When this occurs, the line has a right-facing arrow at its right edge.

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5.4 Service and diagnostics

5.4.4

Operating the TCU menu "Modify settings"

"Modify settings for operator panel (TCU)" dialog

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

Figure 5-9

TCU menu: Settings

The following TCU parameters are set here during the first commissioning:

● "HT 8 individual mode" (yes/no)

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

You do not have to make settings for an HT 8 in Auto Mode because the name is generated

automatically: ("DIP<n>") MCP address and TCU index are derived from the DIP setting

("DIP<n>").

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

Defines the TCU index; see column "TCU" on the user interface.

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

Specifies the address of the associated MCP; see column "MCP" on the user interface.

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

Specifies the index of the associated EKS; see column "EKS" on the user interface.

● "Enable direct keys" (yes/no)

Specifies whether direct keys are registered with the PLC (yes) or are treated as ordinary

keys (no); see column "DCK" on the user interface.

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5.4 Service and diagnostics

●

"Virtual Keyboard" (Auto/On/Off)

Specifies whether a virtual keyboard is shown on the screen for touch screens.

Depending on the panel features (Auto), the HMI decides whether a touch screen or

keyboard is available.

This parameter can also be set manually (On/Off).

●

"Software Caps-Lock" (Auto/On/Off)

The HMI can manage the Caps-Lock status of a keyboard in the software itself, when, for

example, the key is not available. This is normally (Auto) switched on via a display machine

data item. This machine data item can be overwritten individually for the TCU with the

setting (On/Off).

●

"Emulation Type" (TCU/TCU20.2/TCU30.3, only for modular TCU30.3)

Specifies which TCU type is to be emulated when the TCU30.3 is operated as replacement

device for an older TCU or as new device on a software version older than 4.7 SP2.

●

"Screen Rotation" (0°/90°/180°/-90°/Auto)

Specifies in which angle the screen is to be rotated in the software. This is useful when the

panel is to be rotated during installation.

For the "Auto" setting, the rotation of the display is taken from the panel.

●

"Old VNC Password"

If a password has already been set, it must be entered here so that it can be changed. If no

password has been set, this field is grayed-out. The existing password can also be deleted

if, after entering the old password, no new password is to be entered at "Set VNC Password"

and "Repeat Password".

●

"Set VNC Password"

Assign a password which is stored in the TCU and, if required, sent to the server when the

VNC connection is established.

●

"Repeat Password"

Repeat the password entered at "Set VNC Password".

●

"Enable touch capability" (yes/no)

Specifies whether the screen can be operated by touch. If you deactivate this option, you will

need a keyboard to reactivate it.

The values are applied and stored with "OK". You can also make any subsequent adaptations

or changes via the user interface in the "Setup" operating area > menu forward key > "OPs"

softkey.

5.4.5

Operating the menu for a new TCU or spare part TCU

Registering a new TCU

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 is displayed. The

accessibility of all the registered TCUs is tested in the backg16round.

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

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5.4 Service and diagnostics

Figure 5-11

TCU menu: Name of TCU

If a TCU30.3 is to be operated with a software version < 4.7 SP2, the TCU is operated in

compatibility mode. If required, you can view and change the emulation type in the settings.

Replacing a device

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

which are active in the network are grayed out. They are functioning and should not be replaced

by a spare part. The cursor automatically defaults to the first line for selection.

As the accessibility test is still running in the backg16round, the active status of the lines 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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5.4 Service and diagnostics

If a static.ini of the TCU to be replaced (as of SW4.5) is found on the server, then the type of the

old TCU is preselected based on the HW ID found there. If this is not the case, the TCU20.2 type

is selected.

The following TCU types can be emulated:

● TCU

● TCU 20.2

● TCU 30.2

Note that if an older TCU is to be replaced by a TCU30.3, some interfaces cannot be used when

the HMI version is older than V4.7. The following interfaces are affected:

TCU to be replaced

Interfaces that cannot be used

TCU

X212, X213 (because they do not exist in the TCU)

TCU 20.2

X212 (because it does not exist in the TCU 20.2)

TCU 30.2

X211 (because it does not exist in the TCU 30.3)

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5.4 Service and diagnostics

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.

Figure 5-13

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 appears 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.

5.4.6

How to register a TCU on the system network

Requirement

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

be switched on and available in the network.

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5.4 Service and diagnostics

Using the TCU

Procedure:

1. Connect the TCU.

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

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 preselected for the TCU:

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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5.4 Service and diagnostics

Procedure for the HT 8

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

Additional softkeys are available for convenient touch panel operation:

- "OK" has the same function 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

TCU index for the HT 8

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:

SINUMERIK Basic Functions Function Manual, Basic PLC Program (P3)

Definition: Operator panel

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

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

All TCUs, PCU 50s and IPCs can be used along with the OP/TP with "integrated TCU", e.g.

OP 08T, OP 015T, TP 015AT.

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5.4 Service and diagnostics

Specifying settings without machine control panel

If a PCU, IPC or TCU does not have a machine control panel (MCP), one of the two following

options must be set:

● 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, IPC or TCU, the previous machine control

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

5.4.7

This is how you register a spare part TCU

To connect the spare part TCU, proceed as follows:

1. Connect the new TCU.

The "New operator panel (TCU)" dialog opens.

This dialog lists the TCUs on the system network along with their "active" or "inactive" status:

2. Select the name previously assigned to the defective TCU. 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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5.4 Service and diagnostics

5.4.8

Booting of the TCU

5.4.8.1

Messages during booting

Messages when booting

While the TCU boots, a progress indicator is displayed with messages showing the current

status after the BIOS has been loaded and before the operating system is started. While the IP

address is being determined via DHCP and the TFTP is being downloaded (boot image), a

progress bar indicates that booting of the TCU is not yet complete, or that a fault has occurred.

The figure below shows the structure of these messages:

You can see the current boot phase below the progress bar. If a fault occurs, you can call further

information by touching the "F1" field.

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5.4 Service and diagnostics

5.4.8.2

Diagnostics options during booting

Diagnostics while booting supplementary conditions

In the following supplementary conditions, the diagnostics window is displayed and booting of

the TCU is interrupted:

● When the <1 / F1> function is selected during booting

● When a warning message is displayed

● When a fault occurs

You can select functions <1 / F1> to <8 / F8> mentioned below by tapping on the Panel.

Alternatively, you can do this via the corresponding function keys of a connected USB

keyboard.

Using the <1 / F1> function

7hin Client Bootloader

V05.00.45.00

Boot Progress

BIOS Version

V15.00.00.00

MAC Address

08:06:00:F1:F7:F8

Hardware-ID

7.9.2.0

Network link

1000MB, full duplex

Boot from USB

no device found

IP Address

192.168.214.14

Netmask

255.255.255.0

DHCP Server

192.168.214.1

Boot Server

192.168.214.1

Image Metadata

71 bytes

Image Version

V05.00.46.00

Linux Image (linux.bin)

3295436 bytes

Image Kind

from boot server

Booting

ready

<1/F1> protocol <2/F2> Readme_OSS

<7/F7> continue <8/F8> reboot

Key / text

Meaning

F1 protocol

Display detailed information

F2 Readme_OSS

Details of the Open Source licenses

F7 continue

Continue booting of the TCU

F8 reboot

Restart the TCU

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Service and maintenance

Cleaning the device

The TCU is designed for low-maintenance operation.

Preparation

Note

Clean the TCU only when it is switched off.

For cleaning, use a soft cloth moistened either with water or a mild cleaning agent. Use only

dish soap as cleaning agent.

Procedure

Do not spray the cleaning agent directly on the TCU, but rather on a cleaning cloth. Never use

caustic solvents or abrasive cleaners.

Note

Do not clean the TCU using compressed air or steam jets because they can damage it.

Checking the device

In order to prevent foreign bodies or liquids entering the TCU, regularly check the device:

● Ensure that all the housing screws are in place and tight

● For damage to the housing

● For damage to the cable cover or cable entry

Protect the device from environmental effects

Protect the TCU against:

● Direct sunshine and heat sources

● Mechanical vibration and shock

● Dust

● Humidity

● Strong magnetic fields

Suspected malfunction

If you suspect a malfunction due to unusual feedback messages, immediately isolate the

device from power and inform qualified personnel to check for proper functioning.

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Technical data

7.1

Technical data

Safety

Safety class

Degree of protection accord-

IP00 (open equipment) ²⁾

ing to EN 60529 ¹⁾

IP20 (mounted, end application minimum requirement)

Approvals

CE / cULus

Flame resistance

UL 94 V-1 ³⁾

Electrical data

Overvoltage category

Secondary circuit supplied from primary circuits up to Cat. II,

300 VAC ⁴⁾

Power supply ⁵⁾

24 VDC (20.4 V ... 28.8 V)

Current consumption

Typically approx. 0.2 A ⁶⁾

Maximum approx. 2.9 A

Power consumption, max.

10.5 W ⁷⁾ / 60 W ⁸⁾

Mechanical data (without packaging)

Dimensions

Width: 260 mm

Height: 265 mm

Depth: 34 mm

Weight

1.6 kg

Tightening torques, max.

M3:

0.8 Nm standard

M4:

1.7 Nm

M5:

3 Nm standard

Mechan. stability

According to UL 61010 ³⁾

1) The system installer ensures the system is sealed properly according to IP20, IP classification has not

been checked by UL, UL TYPE 1.

2) Open equipment according to UL 61010.

3) The customer must ensure that the product, with the rear cover to be attached by the customer, meets

the requirements for flame resistance of the material according to UL 94 V-1 and the mechan. stability /

fire protection requirements / touch protection according to UL 61010.

4) If power supply units with primary-side supplies up to 600 VAC (line-to-neutral voltage) have to be

deployed, the transient voltages on the primary side of the power supply unit must be limited to 4000 V.

5) Connect the device only to a 24 VDC power supply that is compliant with protective extra-low voltage

(PELV) requirements according to UL 61010.

6) Without connection of a panel.

7) Only TCU.

8) TCU with OP 019 and 2 x 0.5 A / 4 x 0.1 A on USB.

Note

The 24 VDC power source must be adapted to the input data of the device (see "Electrical

data").

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Technical data

7.2 Supplementary electrical conditions

7.2

Supplementary electrical conditions

7.2.1

Power supply

Requirements for DC power supplies

WARNING

Electric shock due to connection of an unsuitable power supply

When equipment is connected to an unsuitable power supply and/or insufficiently grounded

(Page 23), exposed components may carry a hazardous voltage that might result in serious

injury or death.

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

(Protective Extra Low Voltage) output voltages acc. to UL 61010 for all connections and

terminals of the electronics modules.

WARNING

Inadequately fused supply cables can be life-threatening

In the case of supply lines >30 m, protectors must be installed at the device input 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 7-1

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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Technical data

7.2 Supplementary electrical conditions

7.2.2

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.

Please note that interruption of the grounding during maintenance work is not permissible.

Additional references

EMC Design Guidelines

7.2.3

RI suppression measures

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

taken to ensure safe, fault-free operation of the system. These measures include shielded

signal lines, special equipotential bonding connections, and isolation and shielding measures.

Shielded signal cables

● Use the specified cables for safe and fault-free operation of the system.

● Connect the shield conductively at both ends to the housing for digital signal transmission.

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Technical data

7.2 Supplementary 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.

Further information on RFI suppression measures and the connection of shielded cables can

be found in the EMC Installation Guidelines.

7.2.4

SINUMERIK_SouthKorea_Note

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).

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Technical data

7.3 Climatic and mechanical environmental conditions

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

respectively in the Installation Guideline EMC.

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

label attached to the individual unit.

7.3

Climatic and mechanical environmental conditions

7.3.1

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 7-2

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

Mechanical environmental condi-

Class 2M3 according to EN

Class 1M2 according to EN

tions

60721-3-2, in transport pack-

60721-3-1, in product packag-

aging ⁴⁾

ing ⁵⁾

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 ⁶⁾

sible ⁷⁾

loading surfaces ⁶⁾

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Technical data

7.3 Climatic and mechanical environmental conditions

Type of condition

Permissible range/class

Height

Max. 4,000 m above sea level

Condensation, splash water,

Permissible

Not permis-

Permissible ⁶⁾

icing, salt spray

sible ⁷⁾

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).

Transport packaging is either packaging that is directly suitable for transport or secondary packaging,

which together with the product packaging, satisfies the requirements for transport.

Product packaging (storage packaging) is an individual packaging for storage and does not satisfy the

requirements for transport. As a consequence, product packaging is therefore not suitable for

shipping.

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.

7.3.2

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.

Ambient climatic conditions

Climate class according to EN

Better than class 3K3

60721-3-3

Temperature

0 ... 55° C (without derating)

Installation altitude

Up to 1000 m without derating

From 1000 m to 3000 m with linear ambient temperature de-

rating, -0.5 K per 100 m

TCU 30.3

Manual, 05/2019, A5E40874197B AB

Technical data

7.3 Climatic and mechanical environmental conditions

Ambient climatic conditions

Relative humidity

5 ... 95% (no condensation)

Oil mist, salt mist, ice formation, con-

Not permitted

densation, dripping water, spraying

water, splashing water and water jets

Biological, chemical, electrical and mechanical influences, pollutants

Biological environmental conditions

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

Mold, mold growth, slime, rodents, termites and other animal

vermin are not permissible.

Chemically active environmental con-

Class 3C1 according to EN 60721-3-3

ditions

Mechanically active environmental

Class 3M1 according to EN 60721-3-3:

conditions

Conductive dust not permissible.

Classification of the mechanical

3M3 for components on the machine

environment

3M1/3M2 for components in the control cabinet

Vibration test in operation

According to IEC 60068-2-6 test Fc (sinusoidal)

●

10…57 Hz: 0.075 mm deflection amplitude

●

57…150 Hz: 1 g acceleration amplitude

●

10 frequency cycles per axis

Shock test in operation

According to IEC 60068-2-27 test Ea (half-sine)

●

5 g peak acceleration

●

30 ms duration

●

3 shocks in all three axes in both directions

Degree of contamination

2 (only use indoors)

EMC conducted / radiation

Class C2 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.

Note

In a residential environment, this product can cause high-frequency interference, which may

make interference suppression measures necessary.

Have the installation and commissioning with appropriate radio interference suppression

measures performed by qualified personnel.

TCU 30.3

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Technical data

7.5 Recycling and disposal

7.4

Standards and approvals

Approvals

CE approval

Figure 7-1

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)

7.5

Recycling and disposal

For environmentally friendly recycling and disposal of your old device, please contact a

company certified for the disposal of electrical and electronic waste and dispose of the device

in accordance with the regulations in your country.

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Spare parts / accessories

8.1

Accessories

Table 8-1

Accessories for the TCU

Component

Description

Quantity

Article number

Mounting bracket

Mounting bracket for PCU, video link re-

1 set

6FC5248-0AF20-2AA0

ceiver or TCU behind operator panel front

(2 items)

Direct key cable

Ribbon cable for connection of the direct

6FC5347-0AF10-0AA0

key interfaces for OP and TCU.

Industrial

IE FC Standard Ca-

4-core, shielded TP installation cable for

6XV1840-2AH10

Ethernet ca-

ble GP 2 x 2 (Type A)

connection to IE FC Outlet RJ45/

ble

IE FC RJ45 Plug; PROFINET-compatible;

with UL approval;

sold by the meter (max. 1000 m; min. 20 m);

IE FC Trailing Cable

4-core, shielded TP installation cable for

6XV1840-3AH10

GP 2 x 2 (Type C)

connection to IE FC Outlet RJ45/

IE FC RJ45 Plug 180/90 for use in trailing

cables; PROFINET-compatible; without UL

approval;

sold by the meter (max. 1000 m; min. 20 m);

Plug con-

IE FC RJ45 Plug 180

RJ plug connector for Industrial Ethernet

6GK1901-1BB10-2AA0

nector

with robust metal housing and integrated

cutting/clamping contacts; with 180° outgo-

ing cable

Spare parts for the TCU

There are no parts of this device that can be replaced by the user.

8.2

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

TCU 30.3

Manual, 05/2019, A5E40874197B AB

Spare parts / accessories

8.2 Handling membrane connectors

Figure 8-1

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).

TCU 30.3

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e interface for

Preface_______________

4 axes

Safety information______

System overview_______

SINUMERIK

Description__________

SINUMERIK 840D sl / 840Di sl /

802D sl

Hardware___________

ADI4 - Analog drive interface for

4 axes

Parameter assignment ____

Manual

Further information______

Valid for

Control

SINUMERIK 840D sl/840DE sl

SINUMERIK 840Di pl/840DiE pl

SINUMERIK 840Di sl/840DiE sl

SINUMERIK 802D sl

Software Version

ADI4 system software 1.4.8

03/2010

6FC5297-0BA01-0BP5

Preface

Structure of the manual

SINUMERIK® Documentation

The SINUMERIK documentation is organized in 3 parts:

● General documentation

● User documentation

● Manufacturer/Service Documentation

Information on the following topics is available at

http://www.siemens.com/motioncontrol/docu:

● Ordering documentation

Here you can find an up-to-date overview of publications.

● Downloading documentation

Links to more information for downloading files from Service & Support.

● Researching documentation online

Information on DOConCD and direct access to the publications in DOConWEB.

● Compiling individual documentation on the basis of Siemens contents with the

My Documentation Manager (MDM), refer to http://www.siemens.com/mdm.

My Documentation Manager provides you with a range of features for generating your

own machine documentation

● Training and FAQs

Information on the range of training courses and FAQs (frequently asked questions) are

available via the page navigation

Target group

This documentation is intended for manufacturers of machine tools, particularly:

● Project engineers, electricians and installers

● Maintenance and service personnel

Benefits

The information in this manual facilitates installation and connection of the SINUMERIK

840D numerical control in the control cabinet.

ADI4 - Analog drive interface for 4 axes

Manual, 03/2010, 6FC5297-0BA01-0BP5

Preface

Standard scope

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

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

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

However, no claim can be made regarding the availability of these functions when the

equipment is first supplied or in the event of 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 case of installation, operation, or

maintenance.

Technical Support

If you have any technical questions, please contact our hotline:

Europe/Africa

Phone

+49 180 5050 222

Fax

+49 180 5050 223

0.14 €/min. from German landlines, max. 0.42 €/min for calls from a mobile phone

Internet

http://www.siemens.com/automation/support-request

America

Phone

+1 423 262 2522

Fax

+1 423 262 2200

E-mail

mailto:techsupport.sea@siemens.com

Asia/Pacific

Phone

+86 1064 757575

Fax

+86 1064 747474

E-mail

mailto:support.asia.automation@siemens.com

Note

For technical support telephone numbers for different countries, go to:

http://www.automation.siemens.com/partner

Questions about the documentation

If you have any questions (suggestions, corrections) regarding this documentation, please

fax or e-mail us at:

Fax:

+49 9131 98 2176

E-mail: mailto:docu.motioncontrol@siemens.com

A fax form is available in the appendix of this document.

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Preface

SINUMERIK Internet address

http://www.siemens.com/sinumerik

EC Declaration of Conformity

The EC Declaration of Conformity for the EMC Directive can be found/obtained:

● On the Internet: http://support.automation.siemens.com

under product/order number 15257461

● From the relevant regional office of the I DT MC division of Siemens AG

Convention

Throughout this document, the term "Control Unit" is also used for product designations

NCU 7x0, provided that the technical conditions described are applicable to all variants.

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Manual, 03/2010, 6FC5297-0BA01-0BP5

Table of contents

Preface

Safety information

1.1

Danger notices

1.2

ESD information

1.3

Safe isolation to EN 61800-5-1

1.4

RI suppression measures

System overview

Description

3.1

Properties

3.2

Essential features

3.3

Order number and firmware version

3.4

Boundary conditions

Hardware

4.1

Overview of connections

4.2

Interface description

4.2.1

Interface overview

4.2.2

Interface (X1): External power supply

4.2.3

Interface (X2): PROFIBUS DP

4.2.4

Interface (S2): PROFIBUS address

4.2.5

Interface (X3): Analog setpoint interface

4.2.6

Interfaces (X4-1/X4-2/X5-1/X5-2): Encoder interfaces

4.2.7

Interface (X6-1): Digital outputs

4.2.8

Interface (X6-2): Digital inputs

4.2.9

Interface (H1/H2): Module status

4.3

Control cabinet installation

4.4

Power supply

4.5

Grounding

4.6

Dimension drawing

4.7

Technical data

Parameter assignment

5.1

Boundary conditions of ADI4 DP slave

5.2

Preconditions, SINUMERIK 802D sl

5.3

Preconditions, SINUMERIK 840Di sl

5.4

Preconditions, SINUMERIK 840D sl

5.5

PROFIBUS DP parameter assignment

5.5.1

Parameter assignment sequence

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Table of contents

5.5.2

Inserting an ADI4 DP slave in the configuration

5.6

PROFIBUS parameters for SINUMERIK 802D sl

5.7

PROFIBUS parameters

5.7.1

Parameter components

5.7.2

PROFIBUS address

5.7.3

Message frame type

5.7.4

I/O addresses

5.7.5

Consistency

5.8

Function parameters for SINUMERIK 802D sl

5.9

Function parameters

5.9.1

Encoder type

5.9.2

Unipolar spindle or unipolar motor

5.9.3

Shutdown ramp

5.9.4

Shutdown delay

5.9.5

Tolerable sign-of-life failures

5.9.6

Reserved bits for fine resolution

5.9.7

611U conformant mode

5.9.8

Homing using encoder zero mark

5.9.9

Homing using external zero mark

5.9.10

Boundary conditions

5.10

Parameterization of the DP communication

5.10.1

Parameter assignment of the equidistant cyclic DP communication

5.10.2

Activation of the equidistant DP cycle

5.10.3

Equidistant master cyclic component TDX

5.10.4

Equidistant DP cycle TDP

5.10.5

DP cycle TDP

5.10.6

Master application cycle TMAPC

5.10.7

Actual value acquisition Ti

5.10.8

Setpoint acceptance To

5.10.9

Alignment

5.10.10

Boundary conditions

Further information

6.1

Wiring of drive ready signals

6.2

Supported SSI encoder formats

6.3

Linear encoder with distance-coded zero marks / reference marks

Index

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Safety information

1.1

Danger notices

The following notices are intended firstly for your personal safety and secondly to prevent

damage occurring to the product described or any connected devices and machines. Non-

observance of the warnings can result in severe personal injury or property damage.

DANGER

Only appropriately qualified personnel may commission/start-up SINUMERIK equipment.

The personnel must take into account the information provided in the technical customer

documentation for the product, and be familiar with and observe the specified danger and

warning notices.

When electrical equipment and motors are operated, the electrical circuits automatically

conduct a dangerous voltage.

When the system is operating, dangerous axis movements may occur throughout the entire

work area.

A potential fire hazard exists due to the energy being transferred in the equipment and the

work materials used.

All work on the electrical system must be performed after the system has been switched off

and disconnected from the power supply.

DANGER

Proper transportation, expert storage, installation and mounting, as well as careful

operation and maintenance are essential for this SINUMERIK device to operate correctly

and reliably.

The details in the catalogs and proposals also apply to the design of special equipment

versions.

In addition to the danger and warning information provided in the technical customer

documentation, the applicable national, local, and system-specific regulations and

requirements must be taken into account.

Only protective extra-low voltages (PELVs) that comply with EN 61800-5-1 can be

connected to all connections and terminals between 0 and 48 V.

Should it be necessary to test or take measurements on live equipment, then the

specifications and procedural instructions defined in Accident Prevention Regulation VBG

A2 must be adhered to, in particular § 8 "Permissible deviations when working on live

components". Suitable electric tools should be used.

ADI4 - Analog drive interface for 4 axes

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Safety information

1.2 ESD information

WARNING

Operating the equipment in the immediate vicinity (< 1.5 m) of mobile telephones with a

transmitting power of > 1 W may lead to incorrect functioning of the devices.

Connecting cables and signal lines should be installed so that inductive and capacitive

interference does not in any way impair the automation and safety functions.

DANGER

Repairs to devices that have been supplied by our company may only be carried out by

SIEMENS customer service or by repair centers authorized by SIEMENS.

When replacing parts or components, only use those parts that are included in the spare

parts list.

EMERGENCY STOP devices EN 60204-1 (VDE 0113 Part 1) must remain active in all

modes of the automation equipment. Resetting the EMERGENCY STOP device must not

cause an uncontrolled or undefined restart.

Anywhere in the automation equipment where faults might cause physical injury or major

material damage, in other words, where faults could be dangerous, additional external

precautions must be taken, or facilities must be provided, that guarantee or enforce a safe

operational state, even when there is a fault (e.g. using an independent limit value switch,

mechanical locking mechanisms, EMERGENCY STOP devices)

1.2

ESD information

CAUTION

The modules contain electrostatically sensitive devices. Discharge yourself of electrostatic

energy before touching the components. The easiest way to do this is to touch a

conductive, grounded object immediately beforehand (for example, bare metal parts of

control cabinet or the protective ground contact of a socket outlet).

ADI4 - Analog drive interface for 4 axes

Manual, 03/2010, 6FC5297-0BA01-0BP5

Safety information

1.3 Safe isolation to EN 61800-5-1

NOTICE

Handling ESD-modules:

• When handling electrostatically sensitive devices, make sure that operator, workplace

and packing material are properly grounded.

• Generally, electronic modules must not be touched unless work has to be carried out on

them. When handling PCBs make absolutely sure that you do not touch component pins

or printed conductors.

• Touch components only if:

- You are permanently grounded via an ESD armband

- You are wearing ESD shoes or ESD shoe-grounding-strips, if ESD flooring is

available

• Modules may only be placed on electrically conductive surfaces (table with ESD top,

conductive ESD foam plastic, ESD packaging bags, ESD transport containers).

• Keep modules away from visual display units, monitors or TV sets (minimum distance

from screen 10 cm).

• Do not bring ESD-sensitive modules into contact with chargeable and highly-insulating

materials, such as plastic, insulating table tops or clothing made of synthetic materials.

• Measurements on modules are allowed only if:

- The measuring instrument is properly earthed (e.g., protective conductor) or

- Before measuring with a floating measuring instrument, the probe is briefly

discharged (e.g., touch the bare metal parts of the control housing).

1.3

Safe isolation to EN 61800-5-1

Prerequisite

The complete system includes user interfaces (UIs) and interfaces for servicing, startup and

maintenance.

User interfaces (UIs)

UIs are all the interfaces that are freely accessible to the machine operator without the need

for tools or aids. These user interfaces provide safe isolation up to 230 V AC according to

EN 61800-5-1.

Interfaces for servicing, startup and maintenance

DANGER

The interfaces for servicing/installation and start-up/maintenance purposes are provided

without protective separation.

ADI4 - Analog drive interface for 4 axes

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Safety information

1.4 RI suppression measures

If necessary, these interfaces can be isolated safely using a supplementary adapter

(insulation voltage 230 V AC). Although these adapters are not included in the Siemens

scope of delivery, you can buy these parts from your local dealer, who will be happy to

advise you.

DANGER

Safe isolation can only be ensured if the system configuration specified below is strictly

adhered to. When installing additional components with EUIs, please make sure that the

EUIs have safe isolation for at least 230 V AC.

Note

The components of the drive control comply with EN 61800-5-1 and contain only circuits and

customer terminals with class DVC A voltages and safety isolation from circuits with

dangerous voltages (PELV circuits).

1.4

RI suppression measures

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

taken to ensure safe, fault-free operation of the system. These measures include shielded

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

measures.

Shielded signal lines

● For the safe and smooth operation of the system, the specified cables must be used.

Please refer to the chapter titled Connection.

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

sides of the housing.

Exception:

Standard shielded cables grounded on one side can be used for devices from other

manufacturers (printers, programming devices, etc.). However, these devices must not be

connected to the controller during normal operation. However, if the system cannot

operate without them, then the cable shields must be connected at both ends.

Furthermore, the non-Siemens device must be connected to the controller via an

equipotential bonding cable.

ADI4 - Analog drive interface for 4 axes

Manual, 03/2010, 6FC5297-0BA01-0BP5

Safety information

1.4 RI suppression measures

Cable definitions

● Signal cables (example)

- Data cables (Ethernet, PROFINET, DRIVE-CLiQ, sensor cables, etc.)

- Ribbon cables for digital inputs/outputs

- EMERGENCY OFF lines

● Power cables (example)

- Low-voltage supply cables (230 V AC, 24 V DC, etc.)

- Supply cables to contactors (primary and secondary circuit)

Rules for routing cables

In order to maximize noise immunity for the complete system (controller, power section,

machine) the following EMC measures must be observed:

● Signal cables and power cables must be routed at the greatest possible distance from

one another.

● 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.

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

and transformers).

● Pulse-loaded HC/HV lines must always be laid completely separately from all other lines.

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

installed in grounded cable ducts (metal).

● The clearance (interference injection area) between the following lines must be kept to a

minimum:

- Signal line and electrical circuit signal line (twisted)

- Signal line and associated equipotential bonding conductor

- Equipotential bonding conductor and protective conductor (routed together)

Note

For more information about interference suppression measures and connection of

shielded cables, see

References

/EMC/ EMC Installation Guide

ADI4 - Analog drive interface for 4 axes

Manual, 03/2010, 6FC5297-0BA01-0BP5

System overview

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

tasks within a single NCU (Numerical Control Unit).

Components

For operation, programming, and visualization purposes, the corresponding operating

software is already integrated into the CNC software for the NCU and therefore runs on the

high-performance NCU multi-processor module. For increased operating performance, the

SINUMERIK PCU 50.3 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.

6,180(5,.

6,180(5,. RSHUDWRU SDQHO IURQWV ZLWK 7&8

6,180(5,.

3&8

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6,180(5,.

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Figure 2-1

Typical topology of the SINUMERIK 840D sl complete system

The following components can be attached to the Control Unit:

● SINUMERIK operator panel front with TCU/PCU 50.3 and Machine Control

Panel/Machine Push Button Panel

● SIMATIC CE panel

● SINUMERIK handheld units

● Distributed PLC I/O via PROFIBUS DP or PROFINET I/O (only applies to NCU 720.2 PN

and NCU 730.2 PN)

ADI4 - Analog drive interface for 4 axes

Manual, 03/2010, 6FC5297-0BA01-0BP5

System overview

● SINUMERIK PP 72/48 peripheral module

● SINUMERIK ADI4 (Analog Drive Interface for 4 Axes)

● SINAMICS 120 drive system

● Feed and main spindle motors

- 1FT/1FK/1FN/1FW6/1FE1/2SP1 synchronous motors

- 1PH/1PM asynchronous motors

With the NCU 720.2 PN and NCU 730.2 PN, the SINUMERIK 840D sl is offering integrated

PROFINET functionality for the first time.

Supported:

● PROFINET CBA functionality

The CBA functionality integrated in the NCU allows users to modularize machinery and

systems: Rapid real-time communication (up to 10 ms) between the controllers means

that systems lend themselves better to standardization and can be reused or expanded

more easily. Response to customer demands is faster and more flexible and startup is

simplified and speeded up by pretesting at component level.

● PROFINET IO

As part of PROFINET, PROFINET IO is a communication concept that is used to

implement modular, distributed applications. PROFINET IO is based on Industrial

Ethernet and allows distributed field and I/O equipment to be connected to the central

processing unit.

256 PROFINET IO devices can be operated on the NCU as an IO controller.

ADI4 - Analog drive interface for 4 axes

Manual, 03/2010, 6FC5297-0BA01-0BP5

Description

3.1

Properties

Properties of ADI4 module

An ADI4 module (Analog Drive Interface for 4 axes) is an interface module suitable for

operating up to four drives with an analog setpoint interface and TTL/SSI encoders on an

equidistant PROFIBUS-DP.

Communication between the controller and the ADI4 is performed via an ADI4-specific

message frame type which, in addition to digital input/output data, also contains a message

frame type for each drive specified according to a PROFIDrive profile (standard message

frame 3, see Chapter "Message frame type (Page 46)"). As part of cyclic DP communication,

the actual drive values (encoder values) are transferred from the ADI4 module to the

controller via PROFIBUS DP, and the speed setpoints calculated by the controller are

transferred to the ADI4 module.

The transferred speed setpoints are then output from the ADI4 module to the drives as

analog values.

3.2

Essential features

Features of the ADI4 module

The module has the following essential features:

● PROFIBUS DP connection (maximum of 12 Mbits/s)

●

4 servo interfaces

- Inputs: TTL/SSI encoder for incremental and absolute measuring systems

- Bidirectional analog outputs: ±10 V

● General and drive-specific digital input/output signals

● On-board status display via four diagnostic LEDs

To supply the module and digital outputs with power, an external voltage source (+24 VDC)

is needed.

3.3

Order number and firmware version

Order number

Order no.: 6FC5211-0BA01-0AA4

ADI4 - Analog drive interface for 4 axes

Manual, 03/2010, 6FC5297-0BA01-0BP5

Description

3.4 Boundary conditions

Firmware version

Firmware version: 1.4.8

To display the firmware version of the module, see the note on PROFIBUS address 127 in

Chapter "PROFIBUS address (Page 45)".

3.4

Boundary conditions

The following supplementary conditions must be taken into account for the operation of an

ADI4 on the PROFIBUS DP:

● An ADI4 can only be operated on an equidistant PROFIBUS DP.

● An ADI4 is not a certified DP standard slave as defined by the PROFIDrive profile. For

example, an ADI4 does not permit acyclic communication.

SINUMERIK 840D sl Hardware. Manual (2011-2020) - page 20