Siemens SINUMERIK 828D Turning User manual

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PP 72/48D 2/2A PN I/O module
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SINUMERIK
SINUMERIK 828D
PP 72/48D 2/2A PN I/O module
Manual
Valid for SINUMERIK 828D control
03/2010
Safety notes 1
Description
2
Dimension drawings
3
Assembling
4
Connection
5
Assigning parameters
6
Error and system messages
7
Technical data
8
List of abbreviations
A

Legal information
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
Ⓟ 02/2010
Copyright © Siemens AG 2010.
Technical data subject to change

PP 72/48D 2/2A PN I/O module
Manual, 03/2010 3
Table of contents
1 Safety notes............................................................................................................................................... 5
1.1 Danger notices...............................................................................................................................5
1.2 ESD notices ...................................................................................................................................7
1.3 Protective Separation as per EN 61800-5-1 ..................................................................................8
1.4 RI suppression measures ..............................................................................................................9
2 Description............................................................................................................................................... 11
3 Dimension drawings ................................................................................................................................ 15
4 Assembling.............................................................................................................................................. 17
5 Connection .............................................................................................................................................. 19
5.1 Interface overview........................................................................................................................19
5.2 I/O module....................................................................................................................................20
5.3 X1 power supply ..........................................................................................................................21
5.3.1 Requirements for the power supply .............................................................................................21
5.3.2 Wiring the power supply...............................................................................................................22
5.4 X2 PROFINET..............................................................................................................................23
5.5 X111, X222 and X333 digital inputs/outputs................................................................................25
5.6 Analog X3 inputs/outputs .............................................................................................................31
6 Assigning parameters.............................................................................................................................. 37
6.1 Addressing the I/O modules.........................................................................................................37
6.2 Input / output images ...................................................................................................................38
6.3 Assigning parameters to the analog inputs / outputs...................................................................40
6.4 Analog value representation ........................................................................................................42
6.5 Examples .....................................................................................................................................45
7 Error and system messages .................................................................................................................... 47
7.1 LED displays ................................................................................................................................47
7.2 Diagnostics via input image .........................................................................................................48
8 Technical data ......................................................................................................................................... 51
A List of abbreviations................................................................................................................................. 53
Index........................................................................................................................................................ 55

Table of contents
PP 72/48D 2/2A PN I/O module
4 Manual, 03/2010

PP 72/48D 2/2A PN I/O module
Manual, 03/2010 5
Safety notes 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
operation and maintenance are essential for this SINUMERIK device to operate correctly
and reliably.
The details in the catalogs and proposals also apply to the design of special equipment
versions.
In addition to the danger and warning information provided in the technical customer
documentation, the applicable national, local, and system-specific regulations and
requirements must be taken into account.
Only class DVC A protective extra-low voltages (PELVs) may be connected to connections
and terminals up to 60 V DC in accordance with EN 61800-5-1.
Should it be necessary to test or take measurements on live equipment, then the
specifications and procedural instructions defined in Accident Prevention Regulation BGV
A2 must be adhered to, in particular § 8 "Permissible deviations when working on live
components". Suitable electric tools should be used.

Safety notes
1.1 Danger notices
PP 72/48D 2/2A PN I/O module
6 Manual, 03/2010
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 in such a way 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/EMERGENCY OFF devices according to EN 60204-1 (VDE 0113
Part 1) must remain active in all modes of the automation equipment. Resetting the
EMERGENCY STOP/EMERGENCY OFF 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/EMERGENCY OFF devices).
DANGER
External power supply units for supplying components of the drive control must have safety
isolation from circuits with dangerous voltages (DVC A according to EN 61800-5-1;
SELV/PELV). In addition only power units with control circuits that have safety isolation
from circuits with dangerous voltages may be connected.

Safety notes
1.2 ESD notices
PP 72/48D 2/2A PN I/O module
Manual, 03/2010 7
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
conductive, 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 PC boards make absolutely sure that you do not touch component
pins or printed conductors.
Touch components only if:
– you are constantly grounded via an ESD arm band,
– ESD shoes or ESD shoe grounding strips if there is an ESD floor.
Boards/modules must only be placed on conductive surfaces (table with ESD surface,
conductive ESD foam, ESD packaging, ESD transport container).
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 notes
1.3 Protective Separation as per EN 61800-5-1
PP 72/48D 2/2A PN I/O module
8 Manual, 03/2010
1.3 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 safe isolation up to 230 V AC according to
EN 61800-5-1.
Interfaces for servicing, startup and maintenance
DANGER
The interfaces for servicing/installation and start-up/maintenance purposes are provided
without protective separation.
If necessary, these interfaces can be isolated safely using a supplementary adapter
(insulation voltage 230 V AC). Although these adapters are not included in the Siemens
scope of delivery, you can buy these parts from your local dealer, who will be happy to
advise you.
DANGER
Safe isolation can only be ensured if the system configuration specified below is strictly
adhered to. When installing additional components with EUIs, please make sure that the
EUIs have safe isolation for at least 230 V AC.
Note
The components of the drive control comply with EN 61800-5-1 and contain only circuits and
customer terminals with class DVC A voltages and safety isolation from circuits with
dangerous voltages (PELV circuits).

Safety notes
1.4 RI suppression measures
PP 72/48D 2/2A PN I/O module
Manual, 03/2010 9
1.4 RI suppression measures
In addition to the protective grounding of system components, special precautions must be
taken to ensure safe, fault-free operation of the system. These measures include shielded
signal cables, special equipotential bonding, isolation, and shielding measures.
Shielded signal lines
● For the safe and smooth operation of the system, the specified cables must be used.
Please refer to the chapter titled Connection.
● For digital signal transmission, the shield must have a conductive connection at both
sides of the housing.
Exception:
Standard shielded cables grounded on one side can be used for devices from other
manufacturers (printers, programming devices, etc.). However, these devices must not be
connected to the controller during normal operation. However, if the system cannot
operate without them, then the cable shields must be connected at both ends.
Furthermore, the non-Siemens device must be connected to the controller via an
equipotential bonding cable.
Cable definitions
● Signal cables (example)
– Data cables (Ethernet, PROFINET, DRIVE-CLiQ, sensor cables, etc.)
– Ribbon cables for digital inputs/outputs
– EMERGENCY OFF lines
● Power cables (example)
– Low-voltage supply cables (230 V AC, 24 V DC, etc.)
– Supply cables to contactors (primary and secondary circuit)
Rules for routing cables
In order to maximize noise immunity for the complete system (controller, power section,
machine) the following EMC measures must be observed:
● Signal cables and power cables must be routed at the greatest possible distance from
one another.
● If necessary, signal and power cables may cross one another (if possible at an angle of
90°), but must never be laid close or parallel to one another.
● Signal cables may not be routed close to strong external magnetic fields (e.g., motors
and transformers).
● Pulse-loaded HC/HV lines must always be laid completely separately from all other lines.

Safety notes
1.4 RI suppression measures
PP 72/48D 2/2A PN I/O module
10 Manual, 03/2010
● If signal lines cannot be routed a sufficient distance away from other cables, they must be
installed in grounded cable ducts (metal).
● The clearance (interference injection area) between the following lines must be kept to a
minimum:
– Signal line and electrical circuit signal line (twisted)
– Signal line and associated equipotential bonding conductor
– Equipotential bonding conductor and protective conductor (routed together)
Note
For more information about interference suppression measures and connection of
shielded cables, see
References
/EMC/EMC Installation Guide

PP 72/48D 2/2A PN I/O module
Manual, 03/2010 11
Description 2
Features
The I/O module is a simple module (without a separate enclosure) for connecting digital and
analog input/outputs as part of an automation system based on PROFINET IO.
The module has the following important features:
● 72 digital inputs and 48 digital outputs
● 2 analog inputs and 2 analog outputs
Analog process signals such as for detecting temperatures or controlling hydraulic
workholders can be implemented via analog inputs/outputs.
● PROFINET IO connection (max. 100 MBaud)
● On-board status display via six LEDs
● The 3 plug-in connectors for the digital inputs and outputs are 50-pin terminal posts for
connecting ribbon cables.
● Terminal strip converters can be used, or the direct connection of distribution boards, for
example, is possible.
● Analog signal cables can be connected directly to terminal contacts on the module.
An external power supply unit (24 V DC) is required to supply the module and the digital
outputs.

Description
PP 72/48D 2/2A PN I/O module
12 Manual, 03/2010
Illustration
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Description
PP 72/48D 2/2A PN I/O module
Manual, 03/2010 13
Note
The type plate and the MAC address label are on the rear side of the mounting plate. It is
advisable to make a note of relevant data as it is no longer visible after installation.

Description
PP 72/48D 2/2A PN I/O module
14 Manual, 03/2010

PP 72/48D 2/2A PN I/O module
Manual, 03/2010 15
Dimension drawings 3
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Dimension drawings
PP 72/48D 2/2A PN I/O module
16 Manual, 03/2010

PP 72/48D 2/2A PN I/O module
Manual, 03/2010 17
Assembling 4
The I/O module can be fastened to the wall of the control cabinet using a mounting plate.
The module must be installed according to EN 60204.
Mounting versions:
● Portrait mounting at the lateral strap of the mounting plate (2x M5 or M6 screws).
● Flat mounting at the rear wall of the mounting plate (4x M5 or M6 screws).
WARNING
A protective conductor must be connected using the grounding screw.

Assembling
PP 72/48D 2/2A PN I/O module
18 Manual, 03/2010

PP 72/48D 2/2A PN I/O module
Manual, 03/2010 19
Connection 5
5.1 Interface overview
Interface overview
Table 5- 1 Interfaces of the PP 72/48D 2/2A PN I/O module
Interface Designation Type
Power supply connection X1 Screw-terminal block
PROFINET IO X2 (ports 1 and 2) Socket
Analog inputs/outputs X3 Terminal block
PROFINET address S1 DIP switch
Digital input/outputs 1 X111 Ribbon cable connector
Digital input/outputs 2 X222 Ribbon cable connector
Digital input/outputs 3 X333 Ribbon cable connector
The following abbreviations are used:
Signal type Meaning
I Input
O Output
B Bidirectional
V Supply voltage
GND Protective ground (reference potential)
NOTICE
Digital and analog signals must not be laid together within a cable.

Connection
5.2 I/O module
PP 72/48D 2/2A PN I/O module
20 Manual, 03/2010
5.2 I/O module
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NOTICE
With PPU 28x a maximum of five and with PPU 26x a maximum of four I/O modules can be
operated within a SINUMERIK 828D control.