Siemens SINUMERIK 840D sl User manual

SINUMERIK
SINUMERIK 840D sl
Operator panel front: OP 012
Manual
Valid for:
Control system
SINUMERIK 840D sl/840DE sl
05/2019
A5E36371591B AB
Fundamental safety
instructions 1
Description 2
Installation 3
Connecting 4
Networking 5
Service and maintenance 6
Technical specifications 7
Spare parts 8

Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be
used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property
damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified
personnel are those who, based on their training and experience, are capable of identifying risks and avoiding
potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended or
approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described.
Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this
publication is reviewed regularly and any necessary corrections are included in subsequent editions.
Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
Document order number: A5E36371591B AB
Ⓟ 06/2019 Subject to change
Copyright © Siemens AG 2007 - 2019.
All rights reserved

Table of contents
1 Fundamental safety instructions...................................................................................................................5
1.1 General safety instructions.......................................................................................................5
1.2 Equipment damage due to electric fields or electrostatic discharge ........................................8
1.3 Warranty and liability for application examples ........................................................................8
1.4 Industrial security .....................................................................................................................9
1.5 Residual risks of power drive systems ...................................................................................11
2 Description..................................................................................................................................................13
2.1 Overview ................................................................................................................................13
2.2 Operator control and display elements ..................................................................................14
2.2.1 View .......................................................................................................................................14
2.2.2 Keyboard................................................................................................................................15
2.2.3 Screen saver ..........................................................................................................................16
2.2.4 Touchpad mouse ...................................................................................................................17
2.3 Interfaces ...............................................................................................................................18
3 Installation ..................................................................................................................................................19
3.1 Preparation for mounting........................................................................................................19
3.2 Assembling an OP 012 and a PCU........................................................................................21
3.3 Mounting on the mounting wall ..............................................................................................24
3.4 Softkey labeling......................................................................................................................25
4 Connecting .................................................................................................................................................27
4.1 Pin assignment of the interfaces ............................................................................................27
4.2 Handling membrane connectors ............................................................................................33
5 Networking..................................................................................................................................................35
5.1 System settings......................................................................................................................35
5.1.1 Thin Client Unit (TCU)............................................................................................................35
5.1.2 Settings for SINUMERIK solution line ....................................................................................36
5.1.3 System boot with system network..........................................................................................38
5.1.4 Factory default settings ..........................................................................................................39
5.2 Commissioning TCU ..............................................................................................................41
5.2.1 Key assignment......................................................................................................................41
5.2.2 Settings in the "TCU.ini" file ...................................................................................................42
5.2.3 Displacement mechanism for TCUs.......................................................................................43
5.2.4 Disable switchover between TCU via PLC.............................................................................44
5.2.5 Example: How to select the behavior of the TCUs during boot up.........................................47
5.3 Network configuration ............................................................................................................48
5.3.1 Permissible network topologies..............................................................................................48
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5.3.2 Networks without connection to the company network ..........................................................49
5.3.2.1 Configuration 1: NCU and TCU..............................................................................................49
5.3.3 Networks with NCU connection to the company network ......................................................50
5.3.3.1 Configuration 2: NCU and TCU..............................................................................................50
5.3.3.2 Configuration 3: PCU/IPC with TCU on NCU.........................................................................51
5.3.3.3 Connecting the programming device (PG) to the NCU ..........................................................52
5.3.4 Example: Configuring a VNC connection to a PC..................................................................52
5.4 Service and diagnostics .........................................................................................................54
5.4.1 Using the TCU's main menu ..................................................................................................54
5.4.2 Operating the TCU menu "Service sessions" ........................................................................57
5.4.3 Operating the TCU menu "Service menu" .............................................................................59
5.4.4 Operating the TCU menu "Modify settings" ...........................................................................62
5.4.5 Operating the menu for a new TCU or spare part TCU .........................................................63
5.4.6 How to register a TCU on the system network.......................................................................68
5.4.7 This is how you register a spare part TCU.............................................................................71
5.4.8 Booting of the TCU ...............................................................................................................72
5.4.8.1 Messages during booting .......................................................................................................72
5.4.8.2 Diagnostics options during booting .......................................................................................73
6 Service and maintenance ...........................................................................................................................75
7 Technical specifications..............................................................................................................................77
7.1 Technical data........................................................................................................................77
7.2 Secondary electrical conditions..............................................................................................78
7.2.1 Power supply..........................................................................................................................78
7.2.2 Grounding concept.................................................................................................................79
7.2.3 EMC compatibility ..................................................................................................................79
7.2.4 EMC limit values in South Korea............................................................................................80
7.3 Ambient climatic and mechanical conditions..........................................................................81
7.3.1 Transport and storage conditions...........................................................................................81
7.3.2 Operating conditions ..............................................................................................................82
7.3.3 Cooling ...................................................................................................................................83
7.4 Standards and approvals .......................................................................................................86
7.5 Recycling and disposal ..........................................................................................................87
8 Spare parts .................................................................................................................................................89
8.1 Overview ................................................................................................................................89
8.2 Replacement ..........................................................................................................................90
Index...........................................................................................................................................................93
Table of contents
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Fundamental safety instructions 1
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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WARNING
Electric shock due to equipment damage
Improper handling may cause damage to equipment. For damaged devices, hazardous
voltages can be present at the enclosure or at exposed components; if touched, this can result
in death or severe injury.
● Ensure compliance with the limit values specified in the technical data during transport,
storage and operation.
● Do not use any damaged devices.
WARNING
Electric shock due to unconnected cable shields
Hazardous touch voltages can occur through capacitive cross-coupling due to unconnected
cable shields.
● As a minimum, connect cable shields and the cores of cables that are not used at one end
at the grounded housing potential.
WARNING
Electric shock if there is no ground connection
For missing or incorrectly implemented protective conductor connection for devices with
protection class I, high voltages can be present at open, exposed parts, which when touched,
can result in death or severe injury.
● Ground the device in compliance with the applicable regulations.
WARNING
Spread of fire from built-in devices
In the event of fire outbreak, the enclosures of built-in devices cannot prevent the escape of
fire and smoke. This can result in serious personal injury or property damage.
● Install built-in units in a suitable metal cabinet in such a way that personnel are protected
against fire and smoke, or take other appropriate measures to protect personnel.
● Ensure that smoke can only escape via controlled and monitored paths.
Fundamental safety instructions
1.1 General safety instructions
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WARNING
Unexpected movement of machines caused by radio devices or mobile phones
When radio devices or mobile phones with a transmission power > 1 W are used in the
immediate vicinity of components, they may cause the equipment to malfunction.
Malfunctions may impair the functional safety of machines and can therefore put people in
danger or lead to property damage.
● If you come closer than around 2 m to such components, switch off any radios or mobile
phones.
● Use the "SIEMENS Industry Online Support app" only on equipment that has already been
switched off.
WARNING
Fire due to inadequate ventilation clearances
Inadequate ventilation clearances can cause overheating of components with subsequent fire
and smoke. This can cause severe injury or even death. This can also result in increased
downtime and reduced service lives for devices/systems.
● Ensure compliance with the specified minimum clearance as ventilation clearance for the
respective component.
NOTICE
Overheating due to inadmissible mounting position
The device may overheat and therefore be damaged if mounted in an inadmissible position.
● Only operate the device in admissible mounting positions.
WARNING
Unexpected movement of machines caused by inactive safety functions
Inactive or non-adapted safety functions can trigger unexpected machine movements that
may result in serious injury or death.
● Observe the information in the appropriate product documentation before commissioning.
● Carry out a safety inspection for functions relevant to safety on the entire system, including
all safety-related components.
● Ensure that the safety functions used in your drives and automation tasks are adjusted and
activated through appropriate parameterizing.
● Perform a function test.
● Only put your plant into live operation once you have guaranteed that the functions relevant
to safety are running correctly.
Fundamental safety instructions
1.1 General safety instructions
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Note
Important safety notices for Safety Integrated functions
If you want to use Safety Integrated functions, you must observe the safety notices in the Safety
Integrated manuals.
1.2 Equipment damage due to electric fields or electrostatic discharge
Electrostatic sensitive devices (ESD) are individual components, integrated circuits, modules
or devices that may be damaged by either electric fields or electrostatic discharge.
NOTICE
Equipment damage due to electric fields or electrostatic discharge
Electric fields or electrostatic discharge can cause malfunctions through damaged individual
components, integrated circuits, modules or devices.
● Only pack, store, transport and send electronic components, modules or devices in their
original packaging or in other suitable materials, e.g conductive foam rubber of aluminum
foil.
● Only touch components, modules and devices when you are grounded by one of the
following methods:
– Wearing an ESD wrist strap
– Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring
● Only place electronic components, modules or devices on conductive surfaces (table with
ESD surface, conductive ESD foam, ESD packaging, ESD transport container).
1.3 Warranty and liability for application examples
Application examples are not binding and do not claim to be complete regarding configuration,
equipment or any eventuality which may arise. Application examples do not represent specific
customer solutions, but are only intended to provide support for typical tasks.
As the user you yourself are responsible for ensuring that the products described are operated
correctly. Application examples do not relieve you of your responsibility for safe handling when
using, installing, operating and maintaining the equipment.
Fundamental safety instructions
1.3 Warranty and liability for application examples
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1.4 Industrial security
Note
Industrial security
Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, systems, machines and networks.
In order to protect plants, systems, machines and networks against cyber threats, it is
necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial
security concept. Products and solutions from Siemens constitute one element of such a
concept.
Customers are responsible for preventing unauthorized access to their plants, systems,
machines and networks. Such systems, machines and components should only be connected
to an enterprise network or the Internet if and to the extent such a connection is necessary and
only when appropriate security measures (e.g. using firewalls and/or network segmentation)
are in place.
For additional information on industrial security measures that can be implemented, please
visit:
Industrial security (https://www.siemens.com/industrialsecurity)
Siemens’ products and solutions undergo continuous development to make them more secure.
Siemens strongly recommends that product updates are applied as soon as they become
available, and that only the latest product versions are used. Use of product versions that are
no longer supported, and failure to apply the latest updates may increase customer’s exposure
to cyber threats.
To stay informed about product updates, subscribe to the Siemens Industrial Security RSS
Feed at:
Industrial security (https://www.siemens.com/industrialsecurity)
Further information is provided on the Internet:
Industrial Security Configuration Manual (https://support.industry.siemens.com/cs/ww/en/
view/108862708)
Fundamental safety instructions
1.4 Industrial security
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WARNING
Unsafe operating states resulting from software manipulation
Software manipulations, e.g. viruses, Trojans, or worms, can cause unsafe operating states
in your system that may lead to death, serious injury, and property damage.
● Keep the software up to date.
● Incorporate the automation and drive components into a holistic, state-of-the-art industrial
security concept for the installation or machine.
● Make sure that you include all installed products into the holistic industrial security concept.
● Protect files stored on exchangeable storage media from malicious software by with
suitable protection measures, e.g. virus scanners.
● On completion of commissioning, check all security-related settings.
● Protect the drive against unauthorized changes by activating the "Know-how protection"
converter function.
Fundamental safety instructions
1.4 Industrial security
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1.5 Residual risks of power drive systems
When assessing the machine- or system-related risk in accordance with the respective local
regulations (e.g., EC Machinery Directive), the machine manufacturer or system installer must
take into account the following residual risks emanating from the control and drive components
of a drive system:
1. Unintentional movements of driven machine or system components during commissioning,
operation, maintenance, and repairs caused by, for example,
– Hardware and/or software errors in the sensors, control system, actuators, and cables
and connections
– Response times of the control system and of the drive
– Operation and/or environmental conditions outside the specification
– Condensation/conductive contamination
– Parameterization, programming, cabling, and installation errors
– Use of wireless devices/mobile phones in the immediate vicinity of electronic
components
– External influences/damage
– X-ray, ionizing radiation and cosmic radiation
2. Unusually high temperatures, including open flames, as well as emissions of light, noise,
particles, gases, etc., can occur inside and outside the components under fault conditions
caused by, for example:
– Component failure
– Software errors
– Operation and/or environmental conditions outside the specification
– External influences/damage
3. Hazardous shock voltages caused by, for example:
– Component failure
– Influence during electrostatic charging
– Induction of voltages in moving motors
– Operation and/or environmental conditions outside the specification
– Condensation/conductive contamination
– External influences/damage
4. Electrical, magnetic and electromagnetic fields generated in operation that can pose a risk
to people with a pacemaker, implants or metal replacement joints, etc., if they are too close
5. Release of environmental pollutants or emissions as a result of improper operation of the
system and/or failure to dispose of components safely and correctly
6. Influence of network-connected communication systems, e.g. ripple-control transmitters or
data communication via the network
For more information about the residual risks of the drive system components, see the relevant
sections in the technical user documentation.
Fundamental safety instructions
1.5 Residual risks of power drive systems
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Fundamental safety instructions
1.5 Residual risks of power drive systems
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Description 2
2.1 Overview
The SINUMERIK OP 012 operator panel front and 12.1" TFT color display with a resolution of
800 x 600 pixels (SVGA) features a 59-key membrane keyboard as well as 2 x (8 + 2) horizontal
and 2 x 8 vertical softkeys. The 2 x 8 vertical softkeys can be used as direct keys.
It is fixed from the rear using special clamps that are included in the delivery scope.
Validity
The description below applies to the OP 012 operator panel front.
Article number: 6FC5203-0AF02-0AA2
Features
● 19" mounting format, 7 HU (height units)
● Panel cutout (W x H): 450 x 290 mm
● Limited mounting depth
● 12.1" TFT flat screen (color) with SVGA resolution 800 x 600 pixels
● Membrane keyboard with alphabetic, numeric, cursor, and control keypad
● Softkeys / direct keys:
– 2 x 8 horizontal rows of keys with softkey function
– 2 x 8 vertical rows of keys with softkey and direct key functions
– Direct keys connectable via direct key / handwheel connection module or MCP interface
PN (optional), machine control panel, TCU or directly to the I/Os
● Shift key for switchover to the second key level (not for switching over the letters, since they
are uppercase only)
● Integrated touchpad mouse
● Front USB interface
● Degree of protection IP65
● Attachment: 12 tension jacks on the rear side
● Can be combined with PCU, TCU
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2.2 Operator control and display elements
2.2.1 View
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①Alphabetic key group
②Numeric key group
③Cursor key group
④Control key group
⑤Front USB interface
⑥Touchpad mouse
⑦Menu select key
⑧Menu forward key
⑨Horizontal softkeys
⑩Machine area button
⑪Menu back key
⑫Vertical softkeys (direct keys)
Figure 2-1 Front view of operator panel front OP 012
Description
2.2 Operator control and display elements
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2.2.2 Keyboard
Keyboard
Several keys and keypads are installed on the operator panel front:
● The alphabetic block contains the letters A - Z and the space character.
● The numeric block contains the digits 0 - 9, and the characters "-", "/", "=", "+" and ".".
● The cursor key group is used to navigate on the screen.
● The control key group includes special functions.
● The mouse comprises a touchpad, for finger operation, as well as for cursor navigation and
also for the left and right mouse buttons.
● The softkeys call up functions that are available on the screen via a menu bar.
● The "Menu back" key switches back to the higher-level horizontal menu.
● The "Menu forward" key advances in the extended horizontal softkey bar.
● The "Menu select" key calls the main menu to select the operating area.
● The "Machine area" key selects the "Machine" operating area.
Switching between upper and lower case
To toggle between upper and lower case letters, press the key combination Ctrl + Shift
Upper case is always activated as standard.
Overview of the key symbols
The key symbols used on the operator panel front are shown in the overview along with the
corresponding function keys on the PC keyboard.
Key Function corresponds to the
PC key function
Key Function corresponds to the
PC key function
Esc End
F11 Backspace
F12 Tab
Space (only intended for internal key‐
board changeover)
Home Ctrl key
Page up Alt key
Description
2.2 Operator control and display elements
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Key Function corresponds to the
PC key function
Key Function corresponds to the
PC key function
Page down Delete
Cursor up Insert
Cursor left Enter
Cursor right F9
Cursor down F10
5 (in numeric key group) A, ..., Z <Shift> A, ..., Z
<Shift> F9 <Shift> F10
Display
Note
Pixel error according to DIN EN ISO 9241-307, Error class II.
2.2.3 Screen saver
If an image with high contrast is displayed without change for longer than one hour, then the
screen dark switching must be activated for energy efficiency reasons.
The time can be adapted individually. Further information can be found at:
Commissioning of Basic Software and Operating Software, SINUMERIK Operate (IM9)
Description
2.2 Operator control and display elements
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2.2.4 Touchpad mouse
Operation
All of the mouse functions are based on 2-finger operation. The principle of operation of the OP
012 touchpad mouse is explained in the following table with reference to a classic 2-key mouse.
Action Touch event Corresponds to
Move the mouse pointer Place your finger on the touchpad, keep it in
position and then move it.
Move the mouse.
Select Touch the touchpad once with your finger. Click with the left mouse button
Execute Touch the touchpad twice with your finger. Double-click with left mouse button.
Drag, mark, move window Touch the touchpad twice in succession,
keep finger in position and then move.
Click with the left mouse button and drag the
mouse.
Open the context menu Touch the touchpad with two fingers, keep
briefly in place then lift one finger.
Click with the right mouse button.
Note
The touchpad cannot be used in environments with spray water or water jets. Operating the
touchpad in environments with dripping water is only possible with some restrictions.
Deactivate touchpad mouse
If necessary, you can disable the touchpad mouse. Depending on whether the OP012 is
connected to a TCU or a PCU, proceed as follows:
● TCU:
– Open the TCU menu "Modify Settings".
– Select the "No" option under the parameter "Enable touch capability".
Note
A keyboard or mouse connected via USB is required to reactivate this option.
Further information on this can be found in the Section "Diagnostics and Service" of the
"TCU 30.3" equipment manual.
● PCU: Disable the Windows control panel in the device manager.
Further information on this can be found in the Section "Activating/deactivating mice and
pointers" of the IHsl basic software and operating software (IM10) commissioning manual.
Description
2.2 Operator control and display elements
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2.3 Interfaces
Front
USB 1.1 Full Speed (12 Mbps), high power (500 mA), Type A connector for connecting an
external keyboard, mouse and USB flash drive (see View (Page 14)).
Note
Note that the electromagnetic compatibility of commercially available peripheral devices
operated via the USB interface is usually rated for office use only.
For industrial use, components with a higher degree of certification are recommended.
Rear
● Two flat ribbon cables for connecting the PCU:
– I/O USB cable K1 (ribbon cable): all signals that are used for the display interface and the
connection of operator panel fronts
(e.g. supply voltages).
– Display cable K2
● Direct key interface X11 (under the cover plate); signals from the 16 "vertical softkey" direct
keys
● Interface X12 - reserved (under the cover plate)
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①I/O USB cable K1
②Display cable K2
③Retainer for the connecting cable for the direct key module
④Direct key interface X11
⑤Interface X12 (reserved)
Figure 2-2 Connections on rear of housing: Connections to the PCU
Description
2.3 Interfaces
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Installation 3
3.1 Preparation for mounting
WARNING
Electric shock in the event of an individual error when grounding is insufficient
If the panel is installed with inadequate grounding in an environment with hazardous voltages,
this may cause an electric shock in the event of an individual error. This can result in death,
serious injury and material damage.
Adequately ground the conductive parts of the panel in accordance with the nationally
applicable regulations. When dimensioning the protective conductor connection, note the fuse
ratings of the electrical circuits with hazardous voltages, which would have an effect in
possible individual error scenarios.
WARNING
Parasitic voltage
If the device is installed with inadequate insulation in an environment with higher/more
hazardous voltages, parasitic voltages may occur. This can result in death, serious injury and
material damage.
Insulate the cables appropriately for the highest voltage coming into consideration.
The safety of a system with an integrated operator panel front is the responsibility of the system
installer.
The installation is performed in accordance with the installer's instructions.
Observe all the relevant information from this manual regarding installation.
Dimensions
Table 3-1 Dimensions of the mounting opening
Width (mm) Height (mm)
450 290
Thanks to the tension jacks on the OP 012, drill-holes or screw holes are not needed.
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This retaining method also enables the IP65 degree of protection (but only in conjunction with
a circumferential seal and when the protective USB cap is fitted).
Note
The OP 012 is supplied with 12 "small" tension jacks. If you have the "large" tension jacks
(6FC5248-0AF06-0AA0) in stock, then you can also use these.
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
Figure 3-1 Dimension sheet for installing the OP 012 operator panel front
Table 3-2 Dimensions to be observed when installing
Mounting depth T3 + clear‐
ance (mm)
Opening depth T5
(mm)
Protrusion P
(mm)
PCU 50.5 101 + 10 377 39
TCU 30.3 50 + 10 350 -12
Installation
3.1 Preparation for mounting
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