Siemens SINUMERIK 840D sl User manual

SINUMERIK
SINUMERIK 840D sl
NCU
Manual
A
pplicable to controller
SINUMERIK 840D sl/840DE sl
03/2010
6FC5397-0AP10-3BA0
Preface
Safety Information
1
System overview
2
Application Planning
3
Description
4
Operating and display
elements
5
Interfaces
6
Dimension drawings
7
Mounting
8
Connecting
9
Technical Data
10
Spare Parts/Accessories
11
Appendix
A

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
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
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 for the specific task, 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 adhered to. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of the 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
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Ordernumber: 6FC5397-0AP10-3BA0
Ⓟ 03/2010
Copyright © Siemens AG 2010.
Technical data subject to change

NCU
Manual, 03/2010, 6FC5397-0AP10-3BA0 3
Preface
SINUMERIK® Documentation
The SINUMERIK documentation is organized in 3 parts:
● General documentation
● User documentation
● Manufacturer/Service Documentation
Information on the following topics is available at
http://www.siemens.com/motioncontrol/docu:
● Ordering documentation
Here you can find an up-to-date overview of publications.
● Downloading documentation
Links to more information for downloading files from Service & Support.
● Researching documentation online
Information on DOConCD and direct access to the publications in DOConWEB.
● Compiling individual documentation on the basis of Siemens contents with the
My Documentation Manager (MDM), refer to http://www.siemens.com/mdm.
My Documentation Manager provides you with a range of features for generating your
own machine documentation
● Training and FAQs
Information on the range of training courses and FAQs (frequently asked questions) are
available via the page navigation
Target group
This documentation is intended for manufacturers of machine tools, particularly:
● Project engineers, electricians and installers
● Maintenance and service personnel
Benefits
The information in this manual facilitates installation and connection of the SINUMERIK
840D numerical control in the control cabinet.
Standard scope
This documentation only describes the functionality of the standard version. Extensions or
changes made by the machine manufacturer are documented by the machine manufacturer.

Preface
NCU
4 Manual, 03/2010, 6FC5397-0AP10-3BA0
Other functions not described in this documentation might be executable in the control.
However, no claim can be made regarding the availability of these functions when the
equipment is first supplied or in the event of servicing.
For the sake of simplicity, this documentation does not contain all detailed information about
all types of the product and cannot cover every conceivable case of installation, operation, or
maintenance.
Technical Support
If you have any technical questions, please contact our hotline:
Europe/Africa
Phone [phone]
Fax [phone]
0.14 €/min. from German landlines, max. 0.42 €/min for calls from a mobile phone
Internet http://www.siemens.com/automation/support-request
America
Phone [phone]
Fax [phone]
E-mail [email protected]
Asia/Pacific
Phone [phone]
Fax [phone]
E-mail mailto:support.asia.automatio[email protected]
Note
For technical support telephone numbers for different countries, go to:
http://www.automation.siemens.com/partner
Questions about the documentation
If you have any questions (suggestions, corrections) regarding this documentation, please
fax or e-mail us at:
Fax: [phone]
E-mail: mailto:[email protected]m
A fax form is available in the appendix of this document.

Preface
NCU
Manual, 03/2010, 6FC5397-0AP10-3BA0 5
SINUMERIK Internet address
http://www.siemens.com/sinumerik
EC Declaration of Conformity
The EC Declaration of Conformity for the EMC Directive can be found/obtained:
● On the Internet: http://support.automation.siemens.com
under product/order number 15257461
● From the relevant regional office of the I DT MC division of Siemens AG
Convention
Throughout this document, the term "Control Unit" is also used for product designations
NCU 7x0, provided that the technical conditions described are applicable to all variants.

Preface
NCU
6 Manual, 03/2010, 6FC5397-0AP10-3BA0

NCU
Manual, 03/2010, 6FC5397-0AP10-3BA0 7
Table of contents
Preface ...................................................................................................................................................... 3
1 Safety Information.................................................................................................................................... 11
1.1 Danger notices.............................................................................................................................11
1.2 ESD notices .................................................................................................................................13
2 System overview...................................................................................................................................... 15
2.1 Application....................................................................................................................................15
2.2 System configuration ...................................................................................................................16
2.3 Variants........................................................................................................................................17
3 Application Planning ................................................................................................................................ 19
3.1 Secondary electrical conditions ...................................................................................................19
3.1.1 Protective Separation as per EN 61800-5-1 ................................................................................19
3.1.2 Grounding concept.......................................................................................................................20
3.1.3 RI suppression measures ............................................................................................................21
3.2 Ambient Climatic and Mechanical Conditions..............................................................................23
3.2.1 Ambient conditions.......................................................................................................................23
3.2.2 Transport and Storage Conditions...............................................................................................24
3.2.3 Operating Conditions ...................................................................................................................26
4 Description............................................................................................................................................... 29
4.1 Features.......................................................................................................................................29
4.2 Illustration.....................................................................................................................................29
4.3 Type plate ....................................................................................................................................32
5 Operating and display elements .............................................................................................................. 33
5.1 Overview of operating and display elements...............................................................................33
5.2 CompactFlash Card .....................................................................................................................34
5.2.1 Properties.....................................................................................................................................34
5.2.2 Inserting the CompactFlash card.................................................................................................35
5.3 LED displays ................................................................................................................................36
5.4 RESET button ..............................................................................................................................37
5.5 7-segment display........................................................................................................................37
5.6 Start-up and mode selector switch ..............................................................................................38
6 Interfaces................................................................................................................................................. 39
6.1 Interface overview........................................................................................................................39
6.2 Power supply X124 ......................................................................................................................40
6.3 DRIVE-CLiQ interfaces X100 - X105...........................................................................................41
6.4 Ethernet interfaces (X120, X130, X127) ......................................................................................42

Table of contents
NCU
8 Manual, 03/2010, 6FC5397-0AP10-3BA0
6.5 PROFINET interfaces, ports 1, 2 ................................................................................................45
6.6 PROFIBUS–DP/MPI interfaces X126, X136............................................................................... 47
6.7 Digital inputs/outputs X122 and X132......................................................................................... 48
6.7.1 Pin assignment............................................................................................................................ 48
6.7.2 Technical data............................................................................................................................. 50
7 Dimension drawings ................................................................................................................................ 51
7.1 Dimension drawing...................................................................................................................... 51
8 Mounting.................................................................................................................................................. 53
8.1 Safety information ....................................................................................................................... 53
8.2 Installation types ......................................................................................................................... 54
8.3 Mounting the control unit on the rear wall of the control cabinet ................................................ 56
8.3.1 Mounting control unit using spacers ........................................................................................... 56
8.3.2 Mounting the Control Unit without spacers ................................................................................. 56
8.3.3 Mounting the Control Unit for segregated heat removal............................................................. 58
8.4 Lateral mounting of Control Unit on the SINAMICS drive line-up............................................... 60
9 Connecting .............................................................................................................................................. 61
9.1 Overview ..................................................................................................................................... 61
9.2 Safety information for wiring........................................................................................................ 63
9.3 Opening the front cover............................................................................................................... 63
9.4 Power supply............................................................................................................................... 65
9.4.1 Requirements for the power supply ............................................................................................ 65
9.4.2 Connecting the power supply...................................................................................................... 66
9.5 DRIVE CLiQ components ........................................................................................................... 67
9.5.1 DRIVE-CLiQ wiring ..................................................................................................................... 67
9.5.2 Connectable DRIVE-CLiQ components...................................................................................... 68
9.6 Ethernet....................................................................................................................................... 69
9.7 PROFINET .................................................................................................................................. 69
9.7.1 Wiring PROFINET....................................................................................................................... 69
9.7.2 PROFINET cables....................................................................................................................... 70
9.7.3 Preparing the twisted pair cables................................................................................................ 71
9.7.4 Example PROFINET CBA configuration..................................................................................... 73
9.8 PROFIBUS / MPI ........................................................................................................................ 74
9.8.1 Application................................................................................................................................... 74
9.8.2 PROFIBUS cables and connectors............................................................................................. 74
9.8.3 Connection components in PROFIBUS...................................................................................... 76
9.8.4 Rules for the laying of PROFIBUS cables .................................................................................. 76
9.8.5 Connecting PROFIBUS DP.........................................................................................................77
9.8.6 Disconnecting stations from the PROFIBUS .............................................................................. 78
9.8.7 Operating the X136 interface as MPI.......................................................................................... 78
9.9 Digital inputs/outputs................................................................................................................... 80
9.9.1 Application................................................................................................................................... 80
9.9.2 Connecting digital inputs/outputs ................................................................................................ 82
9.10 USB ............................................................................................................................................. 83
9.11 Measuring sockets ...................................................................................................................... 84

Table of contents
NCU
Manual, 03/2010, 6FC5397-0AP10-3BA0 9
10 Technical Data......................................................................................................................................... 85
11 Spare Parts/Accessories ......................................................................................................................... 87
11.1 Dual fan/ battery module..............................................................................................................87
11.1.1 Application....................................................................................................................................87
11.1.2 Mounting ......................................................................................................................................88
11.2 NX10/15 .......................................................................................................................................90
11.2.1 Description ...................................................................................................................................90
11.2.2 Operating and display elements ..................................................................................................92
11.2.3 Interfaces .....................................................................................................................................93
11.2.4 Dimension drawing ......................................................................................................................97
11.2.5 Mounting ......................................................................................................................................98
11.2.6 Port.............................................................................................................................................100
11.2.7 Technical Data ...........................................................................................................................102
11.3 RS 232C (V.24) module COM01 ...............................................................................................102
11.3.1 Description .................................................................................................................................102
11.3.2 Operator controls and displays ..................................................................................................103
11.3.3 Interfaces ...................................................................................................................................104
11.3.4 Installation/Mounting ..................................................................................................................105
11.4 TM15 Terminal Module..............................................................................................................106
11.5 DRIVE-CLiQ Hub Module DMC20.............................................................................................106
11.6 DME20 DRIVE-CLiQ Hub Module.............................................................................................107
11.7 Ordering data .............................................................................................................................107
A Appendix................................................................................................................................................ 109
A.1 Abbreviations .............................................................................................................................109
A.2 Publication-specific information .................................................................................................110
A.2.1 Feedback on the documentation................................................................................................110
A.2.2 Overview ....................................................................................................................................112
Index...................................................................................................................................................... 113

Table of contents
NCU
10 Manual, 03/2010, 6FC5397-0AP10-3BA0

NCU
Manual, 03/2010, 6FC5397-0AP10-3BA0 11
Safety Information 1
1.1 Danger notices
The following notices are intended firstly for your personal safety and secondly to prevent
damage occurring to the product described or any connected devices and machines. Non-
observance of the warnings can result in severe personal injury or property damage.
DANGER
Only appropriately qualified personnel may commission/start-up SINUMERIK equipment.
The personnel must take into account the information provided in the technical customer
documentation for the product, and be familiar with and observe the specified danger and
warning notices.
When electrical equipment and motors are operated, the electrical circuits automatically
conduct a dangerous voltage.
When the system is operating, dangerous axis movements may occur throughout the entire
work area.
A potential fire hazard exists due to the energy being transferred in the equipment and the
work materials used.
All work on the electrical system must be performed after the system has been switched off
and disconnected from the power supply.
DANGER
Proper transportation, expert storage, installation and mounting, as well as careful opera-
tion and maintenance are essential for this SINUMERIK device to operate correctly and
reliably.
The details in the catalogs and proposals also apply to the design of special equipment
versions.
In addition to the danger and warning information provided in the technical customer docu-
mentation, the applicable national, local, and system-specific regulations and requirements
must be taken into account.
Only protective extra-low voltages (PELVs) that comply with EN 61800-5-1 can be connec-
ted to all connections and terminals between 0 and 48 V.
Should it be necessary to test or take measurements on live equipment, then the specifica-
tions and procedural instructions defined in Accident Prevention Regulation VBG A2 must
be adhered to, in particular § 8 "Permissible deviations when working on live components".
Suitable electric tools should be used.

Safety Information
1.1 Danger notices
NCU
12 Manual, 03/2010, 6FC5397-0AP10-3BA0
WARNING
Operating the equipment in the immediate vicinity (< 1.5 m) of mobile telephones with a
transmitting power of > 1 W may lead to incorrect functioning of the devices.
Connecting cables and signal lines should be installed so that inductive and capacitive
interference does not in any way impair the automation and safety functions.
DANGER
Repairs to devices that have been supplied by our company may only be carried out by
SIEMENS customer service or by repair centers authorized by SIEMENS.
When replacing parts or components, only use those parts that are included in the spare
parts list.
EMERGENCY STOP devices EN 60204-1 (VDE 0113 Part 1) must remain active in all
modes of the automation equipment. Resetting the EMERGENCY STOP device must not
cause an uncontrolled or undefined restart.
Anywhere in the automation equipment where faults might cause physical injury or major
material damage, in other words, where faults could be dangerous, additional external
precautions must be taken, or facilities must be provided, that guarantee or enforce a safe
operational state, even when there is a fault (e.g. using an independent limit value switch,
mechanical locking mechanisms, EMERGENCY STOP devices)

Safety Information
1.2 ESD notices
NCU
Manual, 03/2010, 6FC5397-0AP10-3BA0 13
1.2 ESD notices
CAUTION
The modules contain electrostatically sensitive devices. Discharge yourself of electrostatic
energy before touching the components. The easiest way to do this is to touch a conduc-
tive, grounded object immediately beforehand (for example, bare metal parts of control
cabinet or the protective ground contact of a socket outlet).
NOTICE
Handling ESD-modules:
•When handling electrostatically sensitive devices, make sure that operator, workplace
and packing material are properly grounded.
•Generally, electronic modules must not be touched unless work has to be carried out on
them. When handling PCBs make absolutely sure that you do not touch component pins
or printed conductors.
•Touch components only if:
– You are permanently grounded via an ESD armband
– You are wearing ESD shoes or ESD shoe-grounding-strips, if ESD flooring is
available
•Modules may only be placed on electrically conductive surfaces (table with ESD top,
conductive ESD foam plastic, ESD packaging bags, ESD transport containers).
•Keep modules away from visual display units, monitors or TV sets (minimum distance
from screen 10 cm).
•Do not bring ESD-sensitive modules into contact with chargeable and highly-insulating
materials, such as plastic, insulating table tops or clothing made of synthetic materials.
•Measurements on modules are allowed only if:
– The measuring instrument is properly earthed (e.g., protective conductor) or
– Before measuring with a floating measuring instrument, the probe is briefly
discharged (e.g., touch the bare metal parts of the control housing).

Safety Information
1.2 ESD notices
NCU
14 Manual, 03/2010, 6FC5397-0AP10-3BA0

NCU
Manual, 03/2010, 6FC5397-0AP10-3BA0 15
System overview 2
2.1 Application
Features
SINUMERIK 840D sl offers modularity, openness, flexibility, and uniform structures for
operation, programming, and visualization. It provides a system platform with trend-setting
functions for almost all technologies.
Integrated into the SINAMICS S120 drive system and complemented by the SIMATIC
S7-300 automation system, the SINUMERIK 840D sl forms a complete digital system that
is best suited for the mid to upper performance range.
The SINUMERIK 840D sl is characterized by:
● A high degree of flexibility
● Excellent dynamic response and precision
● Optimum integration into networks
Integrated and certified SINUMERIK Safety Integrated safety functions are available with
SINUMERIK 840D sl. Consequently, highly effective protection for personnel and machines
is achieved in a simple, economical, and practical manner.
Operating and programming software such as ShopMill or ShopTurn, as well as Motion
Control Information System Products (MCIS-Products) can be used for the production
sector.
Fields of application
The SINUMERIK 840D sl can be used worldwide for turning, drilling, milling, grinding, laser
machining, nibbling, punching, in tool and mold making, for high-speed cutting applications,
for wood and glass processing, for handling operations, in transfer lines and rotary indexing
machines, for mass production and JobShop production.
The SINUMERIK 840DE sl is available as an export version for use in countries requiring an
export authorization.

System overview
2.2 System configuration
NCU
16 Manual, 03/2010, 6FC5397-0AP10-3BA0
2.2 System configuration
SINUMERIK 840D sl combines CNC, HMI, PLC, closed-loop control, and communication
tasks within a single NCU (Numerical Control Unit).
Components
For operation, programming, and visualization purposes, the corresponding operating
software is already integrated into the CNC software for the NCU and therefore runs on the
high-performance NCU multi-processor module. For increased operating performance, the
SINUMERIK PCU 50.3 industrial PC can be used.
Up to four distributed OPs can be operated on one NCU/PCU. The operator panel can be
installed as a Thin Client at a distance of up to 100 m.
6,180(5,.RSHUDWRUSDQHOIURQWVZLWK7&8
6,180(5,.'VO
ZLWK
6,1$0,&66
6HUYRPRWRUV
0DLQVSLQGOHPRWRU
3RZHUVXSSO\
352),%86,2
6,1$0,&66
6,0$7,&
(7SUR
,QGXVWULDO(WKHUQHW
1;
1&8
ವವವ
ವವವ
'5,9(&/L4
6,180(5,.
+7
6,180(5,.
3&8
Figure 2-1 Typical topology of the SINUMERIK 840D sl complete system
The following components can be attached to the Control Unit:
● SINUMERIK operator panel front with TCU/PCU 50.3 and Machine Control
Panel/Machine Push Button Panel
● SIMATIC CE panel
● SINUMERIK handheld units
● Distributed PLC I/O via PROFIBUS DP or PROFINET I/O (only applies to NCU 720.2 PN
and NCU 730.2 PN)
● SINUMERIK PP 72/48 peripheral module
● SINUMERIK ADI 4 analog drive interface for four axes

System overview
2.3 Variants
NCU
Manual, 03/2010, 6FC5397-0AP10-3BA0 17
● SINAMICS 120 drive system
● Feed and main spindle motors
– 1FT/1FK/1FN/1FW6/1FE1/2SP1 synchronous motors
– 1PH/1PM asynchronous motors
With the NCU 720.2 PN and NCU 730.2 PN, the SINUMERIK 840D sl is offering integrated
PROFINET functionality for the first time.
Supported:
● PROFINET CBA functionality
The CBA functionality integrated in the NCU allows users to modularize machinery and
systems: Rapid real-time communication (up to 10 ms) between the controllers means
that systems lend themselves better to standardization and can be reused or expanded
more easily. Response to customer demands is faster and more flexible and startup is
simplified and speeded up by pretesting at component level.
● PROFINET IO
As part of PROFINET, PROFINET IO is a communication concept that is used to
implement modular, distributed applications. PROFINET IO is based on Industrial
Ethernet and allows distributed field and I/O equipment to be connected to the central
processing unit.
256 PROFINET IO devices can be operated on the NCU as an IO controller.
2.3 Variants
The scalability of the hardware and software – both from a CNC perspective and in terms of
operation – means the SINUMERIK 840D sl can be used in many sectors. The possibilities
range from simple positioning tasks up to complex multi-axis systems.
Application areas and performance
● As many as 6 axes can be implemented on an NCU 710. The NCU 710 can be expanded
by up to 2 NX modules. One possible benefit would be improved servo drive control
performance.
● On the NCU 720/730, the number of axes and/or the performance of the drive controller
can be increased to 31 axes. This is achieved by using the NX10/15 module. The NCU
720/730 can be expanded by up to 5 NX10/15 modules in terms of drive controller
performance and the number of axes.
● Use of an NCU 730 is recommended for maximum dynamics and accuracy in mold
making or in the high speed cutting sector.
● Since it has the highest PLC capacity, the NCU 730.2 PN represents the most advanced
configuration within the SINUMERIK 840D sl range.

System overview
2.3 Variants
NCU
18 Manual, 03/2010, 6FC5397-0AP10-3BA0
The following table shows the essential features of the various Control Units:
Table 2-1 Variants
Property NCU 710 .2 NCU 720.2/.2 PN NCU 730.2/.2 PN
DRIVE CLiQ ports 4 6 6
Axes Up to 6 Up to 31 Up to 31
NX10/15 Up to 2 Up to 3/Up to 5 Up to 3/Up to 5
TCU Up to 2 Up to 4 Up to 4

NCU
Manual, 03/2010, 6FC5397-0AP10-3BA0 19
Application Planning 3
3.1 Secondary electrical conditions
3.1.1 Protective Separation as per EN 61800-5-1
Prerequisite
The complete system includes user interfaces (UIs) and interfaces for servicing, startup and
maintenance.
User interfaces (UIs)
UIs are all the interfaces that are freely accessible to the machine operator without the need
for tools or aids. These user interfaces provide protective separation up to 230 VAC accord-
ing to EN 61800-5-1.
Interfaces for servicing, startup and maintenance
DANGER
The interfaces for servicing/installation and start-up/maintenance purposes are provided
without protective separation.
If necessary, these interfaces can be isolated safely using a supplementary adapter
(insulation voltage 230 V AC). Although these adapters are not included in the Siemens
scope of delivery, you can buy these parts from your local dealer, who will be happy to
advise you.
DANGER
Safe isolation can only be ensured if the system configuration specified below is strictly
adhered to. When installing additional components (e.g. S7-300 FM, IP) with an end user
interface, please make sure that the end user interface has protective separation for at
least 230 VAC.
Note
The components of the drive control comply with EN 61800-5-1 and contain only circuits and
customer terminals with class DVC A voltages and safety isolation from circuits with
dangerous voltages (PELV circuits).

Application Planning
3.1 Secondary electrical conditions
NCU
20 Manual, 03/2010, 6FC5397-0AP10-3BA0
3.1.2 Grounding concept
Components
The SINUMERIK 840D sl system consists of a number of individual components which have
been designed so that the system complies with the appropriate EMC and safety standards.
The individual system components are:
● Numerical Control Unit (NCU)
● Machine Control Panel MCP, Machine Push Button 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 by means of screws. Make
sure that near the screws a low-impedance contact of the Control Unit with the cabinet panel
can be made. Insulating paints at the contact point must be removed. The electronics unit
grounds of the modules are connected to each other via DRIVE-CLiQ.
It is permissible to have a cluster of operator components for ground connection/PA.
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.