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

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 X206

Connector designation:

X206

Connector type:

3-pin Combicon connector

Total cable length:

30 m

Name

Type

Meaning

P24 (+)

V/V/-

24 VDC potential (20.4 to 28.8 VDC)

M24 (-)

0 V

Functional earth

Connection for grounding the housing

X203, X204 and X213 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.

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Connecting

4.1 Pin assignment of the interfaces

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.

Table 4-1

Assignment of the USB interface

Type A 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 flash drive to the USB interface, you can use a USB flash drive

of 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 and may not be

recognized by the NCU.

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Connecting

4.1 Pin assignment of the interfaces

Ethernet RJ45 interface X202

Connector type:

Standard RJ45 socket

Max. data transmission rate:

10/100/1000 Mbit/s

Max. cable length:

100 m

Table 4-2

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 Mbps

(right)

Off: No or faulty connection

Orange LED

Illuminated: Data exchange

(left)

Off: No data exchange

Note

Connection is only possible on an LAN, not on telecommunication networks.

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 4-3

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 4-4

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

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.

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Connecting

4.1 Pin assignment of the interfaces

Figure 4-1

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

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 4-5

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 4-6

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

Name

Type

Meaning

DT1

Direct key 1

I ¹⁾

DT16

Direct key 16

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Connecting

4.2 Handling membrane connectors

Name

Type

Meaning

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 4-7

Signal level

HIGH level:

5 V or open

Low level

<= 0.8 V

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

Figure 4-2

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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Networking

5.1

System settings

5.1.1

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/SIMATIC IPC or NCU.

With SINUMERIK solution line, the TCU is used to visualize the user interface of the PCU 50,

SIMATIC IPC for SINUMERIK with PCU basic software or NCU.

One TCU can be connected to multiple PCUs/IPCs/NCUs. All TCUs and PCUs/IPCs/NCUs

that are connected to one other via a Gigabit switch form the "system network". The user

interface of a PCU/IPC/NCU is copied to several OPs each with one TCU. This means that all

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 classic operator panel fronts can be used with an IPC 427E if a TCU is available.

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

6,180(5,.

' VO

2SHUDWRU SDQHOV ZLWK 7&8V 0&3V DQG (0V

3&8

6,0$7,& ,3&

*LJDELW VZLWFK

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 system based on a permissible configuration is

described in Section "Network configurations (Page 48)".

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Networking

5.1 System settings

Supplementary conditions

The following supplementary conditions apply for the operation of a TCU:

● In the system network, the number of active thin clients 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/IPC

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/IPC.

● 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.

● The TOP Panels must be networked on the basis of the Gigabit standard, e.g. Gigabit switch

or Ethernet cable according to CAT 6 or higher.

5.1.2

Settings for SINUMERIK solution line

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 via the X120 Ethernet socket, for an IPC/PCU, it is via the

"Ethernet 2" or "X2" or "X2 P1" 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 deviations 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/IPC. 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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Networking

5.1 System settings

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

● For all NCUs and/or PCUs/IPCs, 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 by the DHCP server.

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

(TCU).

● If there are multiple NCUs, IPCs and/or PCUs in the system network, depending on the boot

sequence, the system automatically specifies the DHCP server and automatically ensures

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

IPC, or PCU could take on the role of DHCP server. However it is better to specify a DHCP

master. This is an NCU, IPC, or PCU in the system network that is available on 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, IPC, or PCU can

take over this task, unless you deactivate this option in the DHCP configuration. All non-

master NCUs/IPCs/PCUs wait while the system boots for a preset time for the master to

become available.

Note

In a system network or on a boot server, i.e. on the NCU, IPC, or PCU that accommodates

the active DHCP server, a maximum of 30 operator stations may be operated

simultaneously with the 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/IPC can be connected via "Ethernet 1"

to a 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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Networking

5.1 System settings

5.1.3

System boot with system network

System behavior at boot

The system boot behavior is based on the following principle:

● For the configuration of an NCU 7x0 with a PCU/IPC, the default for a network configuration

is as follows: The NCU keeps the default IP address 192.168.214.1 on X120, the PCU/IPC

keeps the default IP address 192.168.214.241 on Eth2.

● For a configuration of more than one NCU 7x0 without PCU/IPC, with one or morel PCUs/

IPCs, a distinction must be made between two cases:

- All address conflicts and DHCP conflicts are resolved automatically when booting and

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

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

- If the user requires all NCUs, and possibly also the PCU/IPC, to have a defined constant

IP address at each boot, for example, because the IP address is stated explicitly in the

PLC program, the user must configure a fixed IP address in the adapter settings in the

Windows Control Panel for each affected NCU 7x0/PCU/IPC.

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

● Assigning names:

- Assign meaningful names for all NCUs in the basesys.ini file otherwise the names will be

generated automatically.

- A PCU/IPC always has a computer name, which you can change if required.

● The IP addresses of the TCU, MCP/MPP, EKS, HT2, and HT8 are freely assigned within the

specified address range on each boot. MCP/MPP, HT2, and HT8 are identified in the PLC

via their DIP switch settings.

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/IPC, 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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Networking

5.1 System settings

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/IPC on the system network or from a standard DHCP

server. The behavior of the TCU cannot be changed 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 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 connec-

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

(WK

192.168.214.241 is pre-selected.

Preconfiguration of the IPC

An IPC has two Ethernet interfaces with default settings for use with SINUMERIK solution line:

X1 is preset as the standard DHCP client for connection to a com-

pany network.

,3&

X2 is preset as a SINUMERIK DHCP server for connection to a

system network. The fixed IP address 192.168.214.241 is preset

;

on X2.

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Networking

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.

It is also possible to make the NCU a DHCP client. The configured IP address in basesys.ini is

a "requested" IP address, which is rejected in the case of an address conflict and replaced by

a dynamic IP from the address range.

In large system networks, it makes sense to set an NCU/PCU/IPC as the DHCP master. If an

additional 2-3 hosts are used (NCU/PCU/IPC), the user sets the DHCP priority to "ON_HIGH".

For the other hosts, the user sets DHCP priority to "ON_CLIENT_SYNC" or

"ON_CLIENT_NO_SYNC".

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

server (Eth 0)

1&8

● X130 to connect to the company network as the standard

;

DHCP client (Eth 1)

● X127 as a service connection with an active DHCP server (Ibn

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

as Service input. 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.

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Networking

5.2 Commissioning TCU

IP address ranges reserved for NCU and PCU/IPC

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

Not assigned

the system network

192.168.214.10 - 239

For additional TCUs, later for additional PCUs,

DHCP clients

IPCs, NCUs, MCPs, MPPs

192.168.214.240

Reserved for EKS (Electronic Key System)

Default

192.168.214.241

Fixed IP address of PCU/IPC on Eth 2

Default

192.168.214.242 - 249

For additional PCUs/IPCs with a fixed IP ad-

Not assigned

dress

192.168.214.250 - 254

For PGs with a fixed IP address (Service con-

Not assigned

nection)

● Service connection with subnet mask 255.255.255.224:

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, e.g. for a modem

Not assigned

5.2

Commissioning TCU

5.2.1

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

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Networking

5.2 Commissioning TCU

Softkey

Key on OP

External key-

Description

board

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) can be used to switch between Yes/No fields.

Note

Special function for Touch Panels without additional keys

Letters and numbers in input fields can be edited with HSK5/HSK6, which switch one character

forward or backward. With a touch screen, you can activate all the softkeys and even select

rows in a menu simply by touching them.

For operator panel fronts without keys, a virtual keyboard automatically appears.

5.2.2

Settings in the "TCU.ini" file

Directories

The tcu.ini file is created in the following directories:

NCU:

../siemens/system/etc/tcu.ini

../user/system/etc/tcu.ini

../oem/system/etc/tcu.ini

PCU/IPC (Windows 7 and Windows 10):

C:\ProgramData\Siemens\MotionControl\siemens\System\etc\tcu.ini

C:\ProgramData\Siemens\MotionControl\user\System\etc\tcu.ini

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Networking

5.2 Commissioning TCU

C:\ProgramData\Siemens\MotionControl\oem\System\etc\tcu.ini

Note

The following entries are evaluated by SINUMERIK Operate:

● VNCServer/VetoMode

● VNCServer/AlarmBoxTimeOut

● VNCServer/FocusTimeout

● VNCServer/AdaptResolution

● VNCServer/MaxActiveTCUs

● VNCViewer/ExternalViewerSecurityPolicy

Restrictions

Restrictions for such external operator control units are:

● Neither MCP and direct keys nor an EKS system can be assigned. This also means that

these devices cannot be activated to be an operator control unit in the system.

● Direct keys cannot be triggered, i.e. the softkeys to the direct keys can be triggered in the

operating software. However, the keys do not appear in the direct key image to the PLC.

● There is no config.ini configuration file, as for a TCU, i.e. a configuration for a TCU is not

possible for such an operator control unit (power-up behavior, displacement, t:m:n);

however, the displacement mechanism on the external operator control units is effective.

● An external operator control unit is never signaled as active operator station in the PLC.

Configuring the external operator control units in the tcu.ini file in section:

[externalTcu]

# EXTERNAL TCU IP-ADDRESSES

# List of accepted TCUs in IP-V4-format (index 1 to maximal 16)

ExternalTcuIP_1=

You can also set the desired screen resolution in the tcu.ini file:

[VNCServer]

Resolution = ...

5.2.3

Displacement mechanism for TCUs

To operate a machine with more operating stations then the maximum number, the

displacement mechanism ensures that only the permitted number of TCUs are active in a

shadowing group. The remaining TCUs are switched to passive mode, which means they no

longer represent a load with regard to the resources. Thus the number of TCUs that can be

connected to one HMI application is practically no longer limited. The limitation is the number

of concurrently active TCUs.

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Networking

5.2 Commissioning TCU

Supplementary conditions

The following supplementary conditions apply when operating the TCU:

2 active TCU connected in parallel to NCU 710.3 PN

4 active TCU connected in parallel to NCU 720.3 PN, NCU 730.3 PN

4 active TCUs connected in parallel to PCU/IPC

Displacement rules

You configure the displacement mechanism in SINUMERIK Operate in the "Setup" operating

area > menu forward key > "OPs" softkey for the respective operator panel.

The TCU can assume the following states:

● The TCU is active and has user authorization: This can be identified as the TCU shows the

screen of the operating software and the screen is bright.

● The TCU is active, is in the monitoring mode and has no user authorization: This can be

identified as the TCU shows the screen of the operating software, however, it is darkened

in comparison to the TCU with user authorization.

● The TCU is passive: The TCU shows the selection menu of the possible connections

instead of a screen of the operating software, and the softkey for selection of the last active

connection of the TCU is shown in color.

When powering up, the TCU always always attempts to establish the first connection. The

TCUs from a shadowing group establish their specified connection one after the other as long

as the maximum number of permissible active operator units is not exceeded.

If a TCU encounters the situation that this number is already reached in its power up, then it

attempts to obtain a connection via the displacement mechanism. If it can displace a formerly

active operator unit then it takes on the active status itself, otherwise it transitions to passive

status immediately after booting.

5.2.4

Disable switchover between TCU via PLC

Overview

The TCU switchover disable offers the option of dynamically disabling switchover from one

TCU to the next when the system is running via the PLC. For the duration of the disable, a user

authorization request to change user authorizations between TCUs will be ignored by the

system and rejected.

The rejected user authorization request causes a message to be output in the dialog line of the

HMI, in the form of a feedback message for the requester. The message disappears after five

seconds.

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5.2 Commissioning TCU

HMI ↔ PLC data interface

The "switchover disable" function is always active and does not have to be switched on

explicitly. The function is controlled by a data bit in the PLC. The HMI transfers the active OP

to the PLC, thus forming the basis of the control function in the PLC.

The control bits and control information for this function are stored in the m:n data interface of

the PLC. In terms of m:n, this function can be operated separately for the currently overridden

HMIs in both m:n online interfaces (DB19.DBW120 ff for HMI1 and DB19.DBW130 ff for HMI2).

If a system is not running an m:n, only the first m:n online interface is used for this function.

Switchover disable is controlled by a TCU_SHIFT_LOCK bit, managed by the user, on each

HMI in the PLC. The bit address for the first HMI is DB19.DBB126.6 and DB19.DBB136.6 for

the second HMI.

The PLC m:n online interface is expanded so that byte DB19.DBB118 is also assigned to the

first interface and byte DB19.DBB119 to the second. These bytes acquire the index of the

active TCU/OP for the appropriate HMI. The byte is called TCU_INDEX. The appropriate HMI

uses the TCU index configured for the active TCU to describe the TCU_INDEX byte.

The TCU_SHIFT_LOCK bit is monitored by the appropriate HMI. A value = 1 triggers the

switchover disable. Switchover is enabled if the value returns to 0. The TCU_SHIFT_LOCK bit

can be set, for example, to the PLC by the user pressing a key or it can be managed by the PLC

user program according to its own logic. The TCU_SHIFT_LOCK bit is managed in the PLC

exclusively by the user; the HMI only accesses this bit in read-only mode.

The HMI assigns the TCU_INDEX field with the configured index to the TCU or PCU/IPC with

an OP that currently possesses user authorization in the shadow group. If no OP is active, a

value of 0 is entered in TCU_INDEX.

If no TCU index is configured for the active TCU/OP, the value 255 = undefined is transferred

as a TCU index. This means that the values 0 and 255 may not be configured as the TCU index.

Configuration

The TCU index is configured on the PCU/IPC in the same way as a machine control panel

address (MCP address). The TCU index is set in the "OP Properties" dialog of the "System

Network Center" program.

Operating principle

If the TCU_SHIFT_LOCK bit is set for switchover disable, a user authorization request is not

carried out independently of the mode set on the HMI for allocation of user authorizations (veto

mode), i.e. a change of user authorization is rejected.

This message appears on all OPs for approximately 5 seconds:

"No switchover: Switchover disable set in current PLC."

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5.2 Commissioning TCU

While this message is displayed, operations on the OP with the user authorization can still be

carried out unaffected.

Note

Active switching of an OP to another PCU/IPC is possible

The switchover disable only relates to changing the user authorization on the OPs in a

shadowing group on a PCU/IPC.

This means that active switching away from one OP to another PCU/IPC is not prevented.

Special features

The following special cases should be noted:

● Even if switchover disable is set, the TCU_INDEX field value may change in the PLC. This

is the case under the following circumstances:

- If the OP in possession of the user authorization is actively switched to another PCU/IPC.

Depending on whether another TCU takes over the user authorization or whether no

TCU is currently active, the index of the TCU or the PCU/IPC itself (if its directly

connected OP becomes active) is entered, in exactly the same way as when there is a

switchover of user authorization.

This can also be the value 255, if no TCU index is available for the OP. 0 is entered if an

OP is no longer available in the shadow group.

- If an m:n switchover is in progress. The HMI program of the incoming PCU/IPC

deactivates the HMI program which is active on it. Therefore, an OP from the shadow

group of the new (incoming) PCU/IPC must receive the user authorization. The TCU

index of this OP is entered in the TCU_INDEX field.

- If a PCU/IPC is disconnected from an NCK/PLC in the context of m:n. No HMI program

and, therefore, no OP with user authorization is then available on the exited NCK/PLC.

This is signaled independently of a switchover disable by entering the value 0 into the

TCU_INDEX field.

● If a TCU is actively switched over to another PCU/IPC, it can be deactivated there, i.e. it

does not receive user authorization if a switchover disable is set for the destination PCU/IPC.

● With an m:n PCU/IPC switchover - the PCU/IPC is switched to another NCK and, therefore,

to another PLC - the PCU/IPC accepts the switchover disable settings of that PLC.

● The m:n interlock options on the PLC side have priority over the TCU switchover disable, so

that a set TCU switchover disable cannot prevent an m:n switchover. If necessary, the m:n

interference options should be synchronized here with those for the TCU in the PLC. It may,

for example, be practical to set or remove the m:n displacement disable simultaneously with

the TCU switchover disable.

Obtaining user authorization

At a TCU, which has no user authorization, press any key. The operating software does not

evaluate this key; this only serves to request user authorization.

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5.2 Commissioning TCU

The settings for the right to veto are stored in file tcu.ini and are only effective if the operating

software is installed on the PCU/IPC. You can use the operating software on the OP or TCU in

the same way as on an OP connected directly to the PCU/IPC.

5.2.5

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

Example: Distributing boot support across two PCUs/IPCs

Make the following settings to distribute the boot support across two PCUs/IPCs:

● On PCU_1/IPC_1, select "Boot support runtime and configuration only (TFTP/FTP)"

● On PCU_2/IPC_2, select "Boot support IP address only (DHCP)"

● On PCU_3/IPC_3, select the configuration "No boot support"

TCU_1

TCU_2

TCU_3

TCU_4

192.168.214.10

192.168.214.11

192.168.214.12

192.168.214.13

VNC connections:

192.168.214.241

192.168.214.242

192.168.214.243

192.168.214.242

192.168.214.243

Switch to system network

PCU_1/IPC_1

PCU_2/IPC_2

PCU_3/IPC_3

192.168.214.241

192.168.214.242

192.168.214.243

Services:

X DHCP

✔ DHCP

X DHCP

✔ TFTP

X TFTP

✔ FTP

X FTP

✔ VNC

Company network

In this case, PCU_2/IPC_2 serves as the DHCP server which provides the IP addresses for the

connected TCUs. PCU_3/IPC_3 is not involved in booting the TCUs, it is however displayed by

the TCUs using VNC.

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5.3 Network configuration

5.3

Network configuration

5.3.1

Permissible network topologies

Ethernet connection

A SINUMERIK 840 D sl can only be operated as a network within which the individual

components communicate with one another via Ethernet connections. This network must be

set up.

The individual components are factory-set so that the most frequently occurring standard

configurations can be operated without changing the settings related to the network.

Division into system network and company network

On the SINUMERIK solution line, the components are generally split into a company network

on the one hand and a system network on the other.

The connection to the company network provides access to the network drives, for example.

On the system network, process data communication and image transmission runs from the

components with operator software to the display units of the respective TCU.

This separation is performed via the following specified use of the Ethernet interfaces on the

components:

● A TCU is connected exclusively to the system network.

● An NCU is always connected to the system network via X120.

● Ethernet interface Eth 2/X2 of the PCU/IPC is preconfigured for connection to the system

network; while Ethernet interface Eth 1/X1 is used for connection to the company network.

● An NCU is connected to the company network via X130.

Meaning of the connections:

○

Eth 1/X1 as DHCP client

●

Eth 2/X2 as DHCP server

■

Eth 2/X2 with fixed IP address

Green connection

Uncrossed Ethernet cable

Gray connection

Crossed Ethernet cable (crossover)

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5.3 Network configuration

5.3.2

Networks without connection to the company network

5.3.2.1

Configuration 1: NCU and TCU

6\VWHP QHWZRUN

7&8

;

1&8

&RPSDQ\ QHWZRUN

A direct Ethernet connection is used to connect a TCU to X120 of the NCU. NCU and TCU are

suitably preconfigured with IP addresses.

The IP addresses are not significant for further operation.

The TCU is connected to the NCU via a crossed Ethernet cable.

The direct connection of the NCU via X120 to the TCU automatically establishes a simple

system network consisting of two computer nodes.

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5.3 Network configuration

5.3.3

Networks with NCU connection to the company network

5.3.3.1

Configuration 2: NCU and TCU

6\VWHP QHWZRUN

7&8

;

1&8

;

6ZLWFK

&RPSDQ\ QHWZRUN

The TCU is directly connected to the NCU via a crossed Ethernet cable. On X130, the NCU is

connected to a switch to the company network with a straight cable.

As in configuration 1, there is a direct Ethernet connection between a TCU and X120 of the

NCU. NCU and TCU are suitably preconfigured with IP addresses. The IP addresses used here

are not significant for further operation.

IP configuration: DHCP server on the company network

On the X130, the NCU is set to the address reference via DHCP. If the company network has

a DHCP server that provides the NCU with an IP address/configuration, the NCU is integrated

in the company network.

Depending on the infrastructure available or the level of network administration of the company

network, the following network parameters must be set for the NCU on X130:

● Computer name on the company network

● The address of a DNS server

● The address of a gateway (default router)

The IP address of the NCU on this connection is also assigned via the network administration.

If the company network offers a low level of administration, in the worst case scenario the

network has only one DHCP server that assigns the addresses from a predefined address

range, the NCU receives an IP address that is initially unknown.

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5.3 Network configuration

5.3.3.2

Configuration 3: PCU/IPC with TCU on NCU

6\VWHP QHWZRUN

7&8

6ZLWFK

;

(WK

3&8

1&8

,3&

;

(WK

6ZLWFK

&RPSDQ\ QHWZRUN

In this configuration, a switch is also required for the system network. All components are

connected using straight Ethernet cables.

On X120, the NCU occupies the fixed IP address 192.168.214.1 in its capacity as a DHCP

server (not used in this configuration). For this configuration on Eth 2, the PCU/IPC is assigned

a static IP address in the range 192.168.214.241 - 192.168.214.249 with a subnet mask

255.255.255.0 . The DHCP server of the NCU supplies the TCU with an IP address and serves

as a boot server for the TCU.

The observations made for configuration 2 apply here with regard to the connection to the

company network. The connection to a switch on the company network is made via a patch

cable for Ethernet.

To connect one TCU to both HMI systems you must create an additional connection to the NCU

for the TCU.

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5.3 Network configuration

5.3.3.3

Connecting the programming device (PG) to the NCU

Description

6\VWHP QHWZRUN

7&8

6ZLWFK

(WK

;

3&8

1&8

;

,3&

(WK

3* 3&

;

6ZLWFK

&RPSDQ\ QHWZRUN

For service purposes a programming device is connected to the NCU at X127 as a standard

DHCP client (automatically obtain an IP address). An NCU is a standard DHCP server on X127.

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

255.255.255.224.

At X127, IP addresses from 192.168.215.2 onwards are assigned via DHCP; e.g. to connect a

programming device. This is the reason that a fixed IP address must not be set at the

programming device.

5.3.4

Example: Configuring a VNC connection to a PC

Requirements

In order to use a TCU to get visual access to a computer from a SINUMERIK system via VNC,

the following requirements apply:

● The VNC connections should be configured in the HMI.

● The boot server (active DHCP server) in the system network must be an NCU.

● This NCU must be integrated via X130 or X120, i.e. in the network that contains the

computer to be monitored.

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5.3 Network configuration

● The computer to be monitored must be configured in the config.ini configuration file of the

TCU according to the general configuration for a TCU in a separate host section as a

switchover target for this TCU.

Where necessary, a password has to be specified in the configuration, if the VNC server

requires one on the target system (see below).

● To ensure that the TCU recognizes the new switchover target, the TCU requires a restart

and reboot.

● The screen resolution of the observed computer must be adjusted to the characteristics of

the TCU. Otherwise the TCU scales the image it receives to match the display area

available to the TCU, which impairs the quality of the display on the TCU.

Configuration

6\VWHP QHWZRUN

7&8

;

1&8

;

3* 3&

1HWZRUN

Figure 5-1

Configuration example

Configuration

The config.ini file is located in the following directory:

NCU:

/user/common/tcu/<TCU name>/common/tcu

PCU/IPC (Windows 7 and Windows 10):

C:\ProgramData\Siemens\MotionControl\user\common\tcu\<TCU name>

\common\tcu

The config.ini file must be stored on the boot server (active DHCP).

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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 backg18round. 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 backg18round.

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 backg18round, 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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Networking

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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Networking

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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Networking

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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Networking

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 operator panel front is designed for low-maintenance operation. Nevertheless, you must

regularly clean the display.

Note

Switch the device off for cleaning

Clean the device only when it is switched off. This way, you ensure that you cannot

unintentionally trigger any functions by touching the touch-sensitive glass surface.

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

dish soap or foaming screen detergent as cleaning agents.

Procedure

Spray the cleaning agent on to a cleaning cloth. Never use caustic solvents or abrasive

cleaners.

Note

Avoid damage

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

Checking the device

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

the following:

● 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 device against the following environmental factors:

● Direct sunshine and heat sources

● Mechanical vibration and shock

● Dust

● Humidity

● Strong magnetic fields

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Service and maintenance

Spare parts

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

Suspected malfunction

If you suspect a malfunction due to unusual product reactions, isolate the device from power.

Immediately inform qualified personnel to check the function and ensure that the product

functions correctly.

The following signs can indicate a malfunction:

● Unusual or no functioning

● Unusual heat generation

● Smoke development

Repair

Send the device back to the manufacturer for repair. The device must only be repaired there.

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Technical data

Safety

Safety class

III; PELV according to EN 50178

Degree of protection accord-

Front: IP65 / IP66

ing to EN 60529

Rear: IPXXB

Approvals

CE / cULus

Electrical data

Power supply ¹⁾

24 VDC (20.4 V ... 28.8 V)

Current consumption

Typical, approx. 1.0 A

Maximum, approx. 2.0 A

Power consumption

Typical, approx. 24 W

Maximum, approx. 42 W

Mechanical data

Dimensions

Width: 483 mm

Height: 310 mm

Depth: 48 mm

Weight

Approx. 7 kg

Tightening torques, max.

Tension jack screws:

M3 screws:

M4 screws:

0.5 Nm

0.8 Nm

1.8 Nm

M5 grounding screw: 3 Nm

Permissible ambient temperatures

Operation

0 ... 45 °C (front)

0 ... 55 °C (rear)

Storage

-20 to 60° C

Mechanical environmental conditions

Classification of the mechani-

Class 3M1 in accordance with EN 60721-3-3

cal

environment

Vibrational load during opera-

Frequency range: 10 - 200 Hz

tion

Deflection at 10 - 58 Hz: 0.075 mm

Acceleration at 58 - 200 Hz: 1 g

Shock load during operation

Acceleration: 5 g

with shock-sensitive compo-

Shock duration: 30 ms

nents

Load: 3 x in each direction

Display

Size / resolution

15.6" / 1366 x 768 pixels

MTBF backlight

Typical 70 000 h at 25º C (dependent on the temperature)

The power supply must be provided as protective extra low-voltage with safe isolation (according to

EN 60204-1, PELV).

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Technical data

7.1 Secondary electrical conditions

Note

Information about the climatic and mechanical environmental conditions is contained in the

associated section under:

"General notes and interconnection" → "Operational planning".

7.1

Secondary electrical conditions

7.1.1

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 or

rear cover, 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.)

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Technical data

7.1 Secondary electrical conditions

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-

Ramp-up time when switched on

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

7.1.2

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.

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

Note

Proper grounding of the device and the machine corresponding to the EMC Design Guidelines

is absolutely necessary for the function of the touch screen.

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Technical data

7.1 Secondary electrical conditions

Additional references

EMC Design Guidelines

7.1.3

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.

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).

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Technical data

7.2 Ambient climatic and mechanical conditions

● 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.

7.1.4

EMC limit values in South Korea

The EMC limit values to be observed for Korea correspond to the limit values of the EMC

product standard for variable-speed electric drives EN 61800-3 of category C2 or the limit value

class A, Group 1 according to EN 55011. By implementing appropriate additional measures,

the limit values according to category C2 or limit value class A, Group 1, are observed. 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.

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

label attached to the individual unit.

7.2

Ambient climatic and mechanical conditions

7.2.1

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.

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Technical data

7.2 Ambient climatic and mechanical conditions

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⁾

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.

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Technical data

7.2 Ambient climatic and mechanical conditions

7.2.2

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.

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

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

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Technical data

7.2 Ambient climatic and mechanical conditions

Biological, chemical, electrical and mechanical influences, pollutants

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.

7.2.3

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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Technical data

7.2 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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Technical data

7.3 Standards and approvals

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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Figure 7-2

Calculating heat dissipation for PCU 50.5 with OP 019

7.3

Standards and approvals

Approvals

CE approval

Figure 7-3

CE marking

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Technical data

7.4 Recycling and disposal

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)

China RoHS

The products comply with the China RoHS directive Further information on this can be found

on the Internet at the following link: SIOS (https://support.industry.siemens.com/cs/document/

109738656/china-rohs-manufacturer?dti=0&lc=en-WW)

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.

7.4

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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Table of contents

Fundamental safety instructions

1.1

General safety instructions

1.2

Equipment damage due to electric fields or electrostatic discharge

1.3

Warranty and liability for application examples

1.4

Industrial security

1.5

Residual risks of power drive systems

Description

2.1

Overview

2.2

Operator control and display elements

2.2.1

View

2.2.2

Keyboard

2.2.3

Screen saver

2.2.4

Touchpad mouse

2.3

Interfaces

Installation

3.1

Preparation for mounting

3.2

Assembling an OP 012 and a PCU

3.3

Mounting on the mounting wall

3.4

Softkey labeling

Connecting

4.1

Pin assignment of the interfaces

4.2

Handling membrane connectors

Networking

5.1

System settings

5.1.1

Thin Client Unit (TCU)

5.1.2

Settings for SINUMERIK solution line

5.1.3

System boot with system network

5.1.4

Factory default settings

5.2

Commissioning TCU

5.2.1

Key assignment

5.2.2

Settings in the "TCU.ini" file

5.2.3

Displacement mechanism for TCUs

5.2.4

Disable switchover between TCU via PLC

5.2.5

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

5.3

Network configuration

5.3.1

Permissible network topologies

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Table of contents

5.3.2

Networks without connection to the company network

5.3.2.1

Configuration 1: NCU and TCU

5.3.3

Networks with NCU connection to the company network

5.3.3.1

Configuration 2: NCU and TCU

5.3.3.2

Configuration 3: PCU/IPC with TCU on NCU

5.3.3.3

Connecting the programming device (PG) to the NCU

5.3.4

Example: Configuring a VNC connection to a PC

5.4

Service and diagnostics

5.4.1

Using the TCU's main menu

5.4.2

Operating the TCU menu "Service sessions"

5.4.3

Operating the TCU menu "Service menu"

5.4.4

Operating the TCU menu "Modify settings"

5.4.5

Operating the menu for a new TCU or spare part TCU

5.4.6

How to register a TCU on the system network

5.4.7

This is how you register a spare part TCU

5.4.8

Booting of the TCU

5.4.8.1

Messages during booting

5.4.8.2

Diagnostics options during booting

Service and maintenance

Technical specifications

7.1

Technical data

7.2

Secondary electrical conditions

7.2.1

Power supply

7.2.2

Grounding concept

7.2.3

EMC compatibility

7.2.4

EMC limit values in South Korea

7.3

Ambient climatic and mechanical conditions

7.3.1

Transport and storage conditions

7.3.2

Operating conditions

7.3.3

Cooling

7.4

Standards and approvals

7.5

Recycling and disposal

Spare parts

8.1

Overview

8.2

Replacement

Index

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Fundamental safety instructions

1.1

General safety instructions

WARNING

Electric shock and danger to life due to other energy sources

Touching live components can result in death or severe injury.

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

● Always observe the country-specific safety rules.

Generally, the following six steps apply when establishing safety:

1. Prepare for disconnection. Notify all those who will be affected by the procedure.

2. Isolate the drive system from the power supply and take measures to prevent it being

switched back on again.

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

4. Check that there is no voltage between any of the power connections, and between any of

the power connections and the protective conductor connection.

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

6. Ensure that the motors cannot move.

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

water. Switch the energy sources to a safe state.

8. Check that the correct drive system is completely locked.

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

WARNING

Electric shock due to connection to an unsuitable power supply

When equipment is connected to an unsuitable power supply, exposed components may

carry a hazardous voltage. Contact with hazardous voltage can result in severe injury or death.

● 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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SINUMERIK 840D sl Hardware. Manual (2011-2020) - page 22