840D - OPs and PCUs Hardware Installation

Manual 11/2002 Edition
Operator Components
SINUMERIK 840D/840Di/810D
OP 030 1
OP 032S 2
OP 010 3
OP 010S 4
OP 010C 5
SINUMERIK 840D/840Di/810D OP 012 6
Touch Panel TP 012 7

Operator Components OP 015 8
OP 015A 9
Manual
15 TFT 10
Component PCU 20 11
Component PCU 50 12
Component PCU 70 13
Distributed Installation 14
Operator Component
PP 012 15
PP 031 MC 16
QWERTY Keyboard 17
Valid for PCI Adapter 18
Control Software version Floppy Disk Drive 19

SINUMERIK 840D 6
SINUMERIK 840DE (export variant) 6 Machine Control Panel 20
SINUMERIK 840D powerline 6
SINUMERIK 840DE powerline 6 Handheld Unit 21
SINUMERIK 840Di 2
SINUMERIK 840DiE (export variant) 2 Mini Handheld Unit 22
SINUMERIK 810D 3
SINUMERIK 810DE (export variant) 3
Handheld Terminal HT 6 23
SINUMERIK 810D powerline 6
SINUMERIK 810DE powerline 6
Heat Dissipation 24
Connection Conditions 25
11.2002 Edition Appendix A

SINUMERIK Documentation
3ls
Printing history
Brief details of this edition and previous editions are listed below.
The status of each edition is shown by the code in the Remarks column.
Status code in the Remarks column:
A . . . . . New documentation.
B . . . . . Unrevised reprint with new order no.
C . . . . . Revised edition with new status.
If factual changes have been made on the page in relation to the same software
version, this is indicated by a new edition coding in the header on that page.
Edition Order No. Remarks

06.94 6FC5 2970AA50-0BP0 A
02.95 6FC5 297-2AA50-0BP0 C
04.95 6FC5 297-2AA50-0BP1 C
09.95 6FC5 297-3AA01-0BP0 Description of differences
03.96 6FC5 297-3AA50-0BP0 C
08.97 6FC5 297-4AA50-0BP0 C
12.97 6FC5 297-4AA50-0BP1 C
12.98 6FC5 297-5AA50-0BP0 C
08.99 6FC5 297-5AA50-0BP1 C
04.00 6FC5 297-5AA50-0BP2 C
10.00 6FC5 297-6AA50-0BP0 C
09.01 6FC5 297-6AA50-0BP1 C
11.02 6FC5 297-6AA50-0BP2 C
This book is part of the documentation on CD-ROM (DOCONCD)

Edition Order No. Remarks
11.02 6FC5 298-6CA00-0BG3 C
Trademarks
SIMATICr, SIMATIC HMIr, SIMATIC NETr, SIROTECr, SINUMERIKr and SIMODRIVEr are trademarks of
Siemens. Other product names used in this documentation may be trademarks which, if used by third par-
ties, could infringe the rights of their owners.
Other functions not described in this documentation might be

executable in the control. However, no claim can be made regarding
Further information is available on the Internet under: the availability of these functions when the equipment is first supplied
http://www.ad.siemens.de/sinumerik or for service cases.
This publication was produced with Interleaf V7. We have checked that the contents of this document correspond to
the hardware and software described. Nonetheless, differences might
The reproduction, transmission or use of this document or its exist and therefore we cannot guarantee that they are completely
contents is not permitted without express written authority. Offenders identical. The information contained in this document is, however,
will be liable for damages. All rights, including those created by patent reviewed regularly and any necessary changes will be included in the
grant or registration of a utility model or design, are reserved. next edition. We welcome suggestions for improvement.
Siemens AG, 19942002. All rights reserved Subject to changes without prior notice
Order No. 6FC5 297-6AA50-0BP2 Siemens Aktiengesellschaft

Printed in Germany
Preface
Notes for the The SINUMERIK documentation is organized on three levels:

Reader
S General documentation
S User documentation
S Manufacturer/service documentation.
For more detailed information on SINUMERIK 840D/810D/FM-NC publications
and other publications covering all SINUMERIK controls, please contact your
local Siemens office.
Hotline If you have queries regarding the control system, please contact the following
hotline:
A&D Technical Support Phone: ++49-(0)180-5050-222

Fax: ++49-(0)180-5050-223
Email: adsupport@siemens.com
If you have queries regarding documentation (suggestions, corrections), please

send a fax to the following fax address:
Fax: ++49-(0)9131-98-2176
Email: motioncontrol.docu@erlf.siemens.de
Fax form: See the feedback page at the end of the document
Internet address http://www.ad.siemens.de/sinumerik

for SINUMERIK
SINUMERIK 840D Improved-performance variants

powerline
S SINUMERIK 840D powerline and
S SINUMERIK 840DE powerline
will be available from 09.2001 onwards. For a list of available powerline
modules, please refer to Section 1.1 of the Hardware Description /PHD/.
SINUMERIK 810D Improved-performance variants

powerline
S SINUMERIK 810D powerline and
S SINUMERIK 810DE powerline
will be available from 12.2001 onwards. For a list of available powerline
modules, please refer to Section 1.1 of the Hardware Description /PHC/.
Specified The SW versions specified in the documentation refer to the SINUMERIK 840D
SW version and SINUMERIK 810D control systems. The software versions are related to
each other, see Table 1.1.
Siemens AG, 2002. All rights reserved

SINUMERIK 840D/840Di/810D Operator Components Manual (BH) 11.02 Edition v
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Table 1-1 Corresponding SW version
SINUMERIK 840D SINUMERIK 810D SINUMERIK 810D SINUMERIK 840Di

powerline
6.3 (09.01) corresponds to 6.1 (12.01) 2.1 (07.01)
5.3 (04.00) corresponds to 3.3 (04.00) 1.1 (07.00)
3.7 (03.97) corresponds to 1.7 (03.97)
Target readership? S Configuring engineers

S Electricians and fitters
S Servicing and operating personnel
Content of this The information contained in this manual explains how to install the operator
manual components for the 840D numerical controls and describes how to maintain and
service them.
Safety and The following safety and warning information is used in this document. The
warning concept symbols used and their meaning are explained below.
Danger
! Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury or in substantial property damage.
Warning
! Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury or in substantial property damage.
Caution
! Used with the safety alert symbol indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate injury or in property da-
mage.
Caution
Used without safety alert symbol indicates a potentially hazardous situation
which, if not avoided, may result in property damage.

vi SINUMERIK 840D/840Di/810D Operator Components Manual (BH) 11.02 Edition
10.00
11.02
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Notice
Used without the safety alert symbol indicates a potential situation which, if not
avoided, may result in an undesirable result or state.
Other information The symbols used for other information are explained below.
!
Important
Important indicates an important or especially relevant item of information.
Note
Note refers to an important item of information about the product, handling of
the product or part of the documentation which is particularly relevant in the
current context.
Machine Manufacturer
This symbol appears in this documentation whenever the machine manufac-
turer can influence or modify the described functional behavior. Please observe
the information provided by the machine manufacturer.
Warnings and To safeguard your own personal safety as well as protect the product described
safety information and all connected equipment and machines against damage, please read and
observe the following warnings and safety information.
Warning
! Operational electrical equipment has parts and components which are at
hazardous voltage levels.
Allowing unqualified persons access to the equipment/system or failure to

heed the safety information could result in serious physical injury or substantial
property damage. Only properly qualified personnel who have been trained to
erect, install, start up or operate the product should be allowed to work on the
equipment/system.
Should it be necessary to test or take measurements on live equipment, then

the specifications and procedures defined in Accident Prevention Regulation
VBG 4.0 must be adhered to, in particular 8 Permissible deviations when
working on live components. Suitable electric tools must be used.

SINUMERIK 840D/840Di/810D Operator Components Manual (BH) 11.02 Edition vii
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Warning
! S Repairs to equipment supplied by Siemens must always be carried out by
SIEMENS after-sales service personnel or by repair centers authorized
by SIEMENS. Parts or components must always be replaced by parts or
components specified in the spare parts list.
S Always disconnect the power supply before you open the unit.
S EMERGENCY STOP devices in compliance with EN 60204 IEC 204 (VDE
0113) must remain operative in all operating modes of the automation de-
vice. Resetting the EMERGENCY STOP device must not result in any un-
controlled or undefined system restart.
S Wherever faults in the automation device have the potential to cause sub-
stantial material damage or even human injury, i.e. they can present a dan-
ger, additional external precautions must be taken or devices provided
which will guarantee or enforce a safe operating state in the event of a fault
(e.g. through independent limit value switches, mech. interlocks, etc.).
Caution
! S Connecting and signal leads must be installed such that inductive and ca-
pacitive interference cannot impair automation functions.

viii SINUMERIK 840D/840Di/810D Operator Components Manual (BH) 11.02 Edition
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ESDS instructions Components which can be destroyed by ElectroStatic Discharge
!
Important
Handling ESDS boards:
S When handling components which can be destroyed by electrostatic di-

scharge, it must be ensured that personnel, the workstation and packaging
are well grounded.
S As a general rule, electronic boards should only be touched when absolu-

tely necessary. Never hold PCBs in such a way that you touch the module
pins or printed conductors.
S You may only touch ESDS components if

you are continuously grounded via an ESDS bracelet,
you are wearing ESDS shoes or ESDS shoe grounding strips in con-
junction with an ESDS floor surface.
S Boards may only be placed on conductive surfaces (desk with ESDS sur-
face, conductive ESDS foam rubber, ESDS packing bag, ESDS transport
containers).
S Boards may not be brought close to data terminals, monitors or television

sets (a minimum of 10 cm should be kept between the board and the
screen).
S Boards may not be brought into contact with materials which can be char-
ged and are highly insulating, e.g. plastic foils, insulating desktops, articles
of clothing manufactured from man-made fibers.
S Measurements may be taken on the boards only if

the measuring equipment is grounded (e.g. via the protective conductor)
or
in the case of floating measuring instruments, the probe is briefly dis-
charged before a measurement is taken (e.g. through contact with bare
control housing).
Proper use The unit may be used only for the applications described in the catalog, and
only in combination with the equipment and components recommended and
approved by SIEMENS (e.g. SINUMERIK 840D/FM-NC).
J

SINUMERIK 840D/840Di/810D Operator Components Manual (BH) 11.02 Edition ix
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Notes

x SINUMERIK 840D/840Di/810D Operator Components Manual (BH) 11.02 Edition
Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
1 Operator Panel Front OP 030 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.1 Function blocks of operator panel front . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.2 Control elements and interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1.3 Dimension drawings and mounting instructions . . . . . . . . . . . . . . . . . . 1-26
1.4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
2 Flat Slimline Operator Panel Front OP 032S . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
2.1 Overview of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
2.1.1 US layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
2.2 Flat operator panel front OP 032S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
2.2.1 Function blocks of operator panel front . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
2.2.2 Control elements and interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
2.2.3 Mounting instructions, dimension drawing and panel cutout . . . . . . . . 2-39
2.2.4 Using an ISA/PCI adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
2.2.5 Technical data for flat operator panel front . . . . . . . . . . . . . . . . . . . . . . . 2-47
2.3 CNC keyboard OP 032S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
2.3.1 Function blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
2.3.2 Connection of CNC keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
2.3.3 Mounting instructions, dimension drawing and panel cutout . . . . . . . . 2-49
2.3.4 Technical data for CNC keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
2.4 Machine control panel OP 032S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
2.4.1 Function blocks of machine control panel . . . . . . . . . . . . . . . . . . . . . . . 2-52
2.4.2 Control elements and interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
2.4.3 Dimension drawing and panel cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
2.4.4 Input and output signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
2.4.5 Technical data for machine control panel . . . . . . . . . . . . . . . . . . . . . . . . 2-64
3 Operator Panel Front OP 010 (Order No. 6FC5 203-0AF00-0AA0) . . . . . . . . 3-65
3.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
3.2 Description of keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
3.3 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
3.3.1 Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
3.3.2 Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
3.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
3.4.1 Assembling OP 010 and PCU 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
3.4.2 Mounting preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
3.4.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
3.5 Soft key designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
3.6 Spare parts/accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
3.6.1 Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
3.6.2 Spare part replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78

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3.7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80

4 Operator Panel Front OP 010S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
4.1 User interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
4.2 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
4.2.1 Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
4.2.2 Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
4.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84
4.3.1 Installing OP 010S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84
4.3.2 Mounting PCU 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85
4.4.1 Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87
4.5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90
5 Operator Panel Front OP 010C (Order No. 6FC5 203-0AF01-0AA0) . . . . . . . 5-91
5.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5.3 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
5.3.1 Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
5.3.2 Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96
5.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
5.4.1 Assembling OP 010C and PCU 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
5.4.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-98
5.5 Changing key covers of short-stroke keys . . . . . . . . . . . . . . . . . . . . . . . 5-100
5.7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101
6.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-104
6.3 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-107
6.3.1 Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-107
6.3.2 Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-108
6.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-109
6.4.2 Direct control key submodule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-110
6.4.3 Installation preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-113
6.4.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-113
6.6.1 Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-116
6.7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119

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7 Touch Panel TP 012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-121

7.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-122
7.2 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-123
7.2.1 Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-123
7.2.2 Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-124
7.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-125
7.3.1 Assembling TP 012 and PCU 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-125
7.3.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-126
7.4.1 Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-128
7.5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-131
8.1 User interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-134
8.2 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-135
8.2.1 Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-135
8.2.2 Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-135
8.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-136
8.3.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-137
8.4.1 Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-139
8.5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-142
9 Operator Panel Front OP 015A (Order No. 6FC5 203-0AF05-0AA0) . . . . . . . 9-143
9.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-144
9.3 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-145
9.3.1 Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-145
9.3.2 Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-146
9.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-147
9.4.1 Assembling OP 015A and PCU 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-147
9.4.2 Direct control key submodule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-148
9.4.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-150
9.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-152
9.6.1 Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-152
9.7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-154

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10 SINUMERIK Operator Panel Front 15 TFT, Width 416mm . . . . . . . . . . . . . . . 10-155

10.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-155
10.2 System features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-156
10.3 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-158
10.3.1 Overview of function blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-158
10.3.2 Operator panel front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-159
10.3.3 Machine control panel for turning and milling . . . . . . . . . . . . . . . . . . . . 10-159
10.3.4 Videolink transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160
10.3.5 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161
10.4 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
10.4.1 Hardware interfaces overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
10.4.2 Interface assignment for operator panel front . . . . . . . . . . . . . . . . . . . . 10-163
10.4.3 Interface assignment for QWERTY keyboard . . . . . . . . . . . . . . . . . . . . 10-165
10.4.4 Interface assignment for MCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-167
10.4.5 Interface pin assignment for videolink transmitter . . . . . . . . . . . . . . . . . 10-169
10.4.6 Internal status displays (LEDs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-173
10.4.7 Software interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-174
10.5 Mechanical design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-176
10.5.2 MCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-177
10.6 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-182
10.6.2 Machine control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-184
10.7 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-188
10.8 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-192
10.9 Heat dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-193
11 Component PCU 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-195
11.1 Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-196
11.2 Interfaces and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-197
11.2.1 Interfaces on right side of casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-197
11.2.2 Interfaces on left side of casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-198
11.2.3 Mounting rail on underside of casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-199
11.2.4 Pin assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-200
11.3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-203
11.3.1 Mounting and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-203
11.3.2 Preparing for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-204
11.3.3 System boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-204
11.4 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-204
11.5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-205
12 Component PCU 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-207
12.1 Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-209

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12.2.3 Ports on bottom side of casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-211
12.2.4 Casing rear side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-211
12.2.5 Pin assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-212
12.3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-218
12.3.1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-218
12.3.2 Notes on installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-218
12.3.4 System boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-220
12.3.5 Working with PC cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-220
12.4 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-222
12.4.1 Changing hard disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-222
12.4.2 Changing power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-224
12.4.3 Changing device fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-225
12.4.4 Changing battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-226
12.5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-228
12.5.1 External floppy disk drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-228
12.5.2 Memory expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-229
12.5.3 Expansion boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-230
12.5.4 Mounting brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-233
12.6 System information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-234
12.6.1 Boot manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-234
12.6.2 BIOS default settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-234
12.6.3 Changing BIOS settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-237
12.7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-238
13 Component PCU 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-241
13.1 Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-242
13.2.3 Ports on bottom side of casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-244
13.2.4 Casing rear side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-245
13.2.5 Pin assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-245
13.3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-246
13.3.1 Mounting and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-246
13.3.2 Notes on installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-246
13.3.4 System boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-247
13.3.5 Working with PC cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-247
13.4 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-248
13.5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-248
13.5.1 External floppy disk drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-248
13.5.2 Memory extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-249
13.5.3 Expansion boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-249
13.6 System information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-249
13.7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-250

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14 Distributed Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-251

14.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-253
14.1.1 Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-253
14.1.2 View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-255
14.2 Description of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-257
14.2.2 Videolink receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-258
14.2.3 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-258
14.3 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-260
14.3.1 Hardware interfaces Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-260
14.3.2 Interface pin assignment for videolink transmitter . . . . . . . . . . . . . . . . . 14-260
14.3.3 Interface pin assignment for videolink receiver . . . . . . . . . . . . . . . . . . . 14-261
14.4 Operating and monitoring devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-263
14.4.2 Videolink receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-264
14.5 Mounting CPU (with videolink transmitter) . . . . . . . . . . . . . . . . . . . . . . . 14-265
14.5.1 Flat mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-265
14.5.2 Upright mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-269
14.5.3 Central mounting on operator panel front . . . . . . . . . . . . . . . . . . . . . . 14-271
14.6 Mounting videolink receiver (with operator panel front) . . . . . . . . . . . . 14-272
14.7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-274
15 Operator Component PP 012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-275
15.1 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-275
15.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-275
15.1.2 Interfaces and monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-276
15.1.3 Operator panel front interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-277
15.2 Function blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-278
15.3 Block diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-279
15.4 Control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-281
15.5 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-283
15.5.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-283
15.5.2 PP 012 individual wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-285
15.5.3 Individual wiring PCB input/output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-292
15.6 Handheld unit connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-296
15.6.1 Functional reliability of EMERGENCY STOP and enabling circuits . . 15-296
15.6.2 Two-channel enabling function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-297
15.8 Installation and mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-301
15.9 Labeling control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-302
15.10 PP 012 extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-304
15.11 Functions of PCB expansion card 12E/12A . . . . . . . . . . . . . . . . . . . . . . 15-306
15.11.1 Inputs/outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-306
15.11.2 Key assignment within matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-307

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15.12 Circuits and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-309

15.13 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-314
15.13.1 PP 012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-314
15.13.2 Input/output interface of individual wiring . . . . . . . . . . . . . . . . . . . . . . . . 15-314
15.14 PLC interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-318
15.15 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-320
15.16 Sample parameterization for communication between SIMATIC S7
and PP 012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-324
15.17 Service information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-326
15.18 Configuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-328
15.18.1 Delivery variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-328
15.18.2 Project-specific components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-330
15.18.3 Rating plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-331
16 Operator Component PP 031 MC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-333
16.1 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-333
16.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-333
16.1.2 Interfaces and monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-334
16.1.3 Operator panel front interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-335
16.2 Function blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-336
16.3 Block diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-337
16.4 Control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-339
16.5 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-341
16.5.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-341
16.5.2 PP 031 MC individual wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-343
16.5.3 Individual wiring PCB input/output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-350
16.6 Handheld unit connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-354
16.6.1 Functional reliability of EMERGENCY STOP and enabling circuits . . 16-354
16.6.2 Single-channel enabling function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-355
16.6.3 Two-channel enabling function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-357
16.8 Installation and mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-361
16.9 Labeling control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-362
16.10 Customer control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-364
16.11 Functions of PCB I/O PP 031 MC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-365
16.11.1 Inputs/outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-365
16.11.2 Key assignment within matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-366
16.12 Circuits and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-368
16.13 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-373
16.13.1 PP 031 MC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-373
16.13.2 I/O interface individual wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-373
16.14 PLC interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-377
16.15 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-379

SINUMERIK 840D/840Di/810D Operator Components Manual (BH) 11.02 Edition xvii
11.02
10.00
16.16 Sample parameterization for communication between SIMATIC S7

and PP 031 MC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-383
16.17 Service information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-385
16.18 Configuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-387
16.18.1 Delivery variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-387
16.18.2 Project-specific components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-389
16.18.3 Rating plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-390
17 QWERTY Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-391
17.1 Function blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-391
17.2 Control elements and interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-392
17.4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-396
18 PCI Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-397
19 3.5 Floppy Disk Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-409
20 Machine Control Panel, MPI Interface for Customer Operator Panel . . . . . 20-415
20.1 Function blocks of machine control panel . . . . . . . . . . . . . . . . . . . . . . . 20-415
20.2 Block diagram of machine control panel . . . . . . . . . . . . . . . . . . . . . . . . . 20-416
20.3 Control elements and interfaces of machine control panel . . . . . . . . . 20-417
20.3.1 Control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-417
20.3.2 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-419
20.4 Mounting, connecting and setting machine control panel . . . . . . . . . . 20-421
20.4.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-422
20.4.2 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-423
20.4.3 Machine control panel settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-424
20.5 Technical data for machine control panel . . . . . . . . . . . . . . . . . . . . . . . . 20-426
20.6 Spare parts for machine control panel . . . . . . . . . . . . . . . . . . . . . . . . . . 20-427
20.6.1 Key caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-427
20.6.2 Slide-in label film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-428
20.7 MPI interface for customer operator panel . . . . . . . . . . . . . . . . . . . . . . . 20-429
20.7.1 MPI interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-429
20.7.2 MPI interface settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-434
20.7.3 Technical data for MPI interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-435
20.8 Configuring machine control panel, setting interface parameters . . . . 20-436
21 Handheld Unit and Distributor Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-437
21.1 Handheld unit B-MPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-437
21.2 Block diagram of HHU and distributor box . . . . . . . . . . . . . . . . . . . . . . . 21-439
21.3 Plugging and unplugging HHU during operation . . . . . . . . . . . . . . . . . . 21-440
21.4 Operating several HHUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-443
21.5 HHU control elements and interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-444
21.6 Technical data for HHU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-446

xviii SINUMERIK 840D/840Di/810D Operator Components Manual (BH) 11.02 Edition
11.02
10.00
21.7 Settings in HHU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-447

21.8 Configuring HHU, setting interface parameters . . . . . . . . . . . . . . . . . . . 21-449
21.8.1 Interface signals for handheld unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-450
21.8.2 Example signal chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-454
21.9 Distributor box for handheld unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-457
21.10 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-461
22 Mini Handheld Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-463
22.1 Dimensions and control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-463
22.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-464
22.1.2 Description of control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-464
22.2 Circuit diagram and sample connection . . . . . . . . . . . . . . . . . . . . . . . . . 22-465
22.3 Coding of axis selection switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-466
22.4 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-466
22.5 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-467
22.6 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-468
22.7 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-469
23 Handheld Terminal HT 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-471
23.1 Overview and function blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-471
23.2 User interface and interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-473
23.2.1 User interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-473
23.2.2 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-475
23.3 Distributor box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-479
23.3.1 Distributor box for 3-core enabling cable (Order No. 6FX2006-1BC01) 23-479
23.3.2 Distributor box for 4-core enabling cable (Order No. 6FX2006-1BH01) 23-482
23.4 Connecting and disconnecting HT 6 during operation . . . . . . . . . . . . . 23-486
23.5 Configuring the HT 6, setting interface parameters . . . . . . . . . . . . . . . 23-490
23.5.1 Interface signals of HT 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-490
23.5.2 Standard configuration of the HT 6 (without MCP) . . . . . . . . . . . . . . . . 23-492
23.6 Key labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-493
23.6.1 Changing the slide-in labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-493
23.6.2 Labeling the slide-in labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-494
23.7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-495
24 Heat Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-497
25 Connection Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-501
25.1 Electrical boundary conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-501
25.1.1 Electromagnetic compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-502
25.1.2 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-503
25.1.3 Protective separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-504
25.1.4 Grounding concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-506
25.1.5 Interference suppression measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-507
25.2 Climatic and mechanical environmental conditions . . . . . . . . . . . . . . . 25-509
25.2.1 Transport and storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-509

SINUMERIK 840D/840Di/810D Operator Components Manual (BH) 11.02 Edition xix
11.02
10.00
25.2.2 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-510

25.3 MPI/OPI network rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-512
A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-515
B References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-519
C Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-531

xx SINUMERIK 840D/840Di/810D Operator Components Manual (BH) 11.02 Edition
Operator Panel Front OP 030 1
1.1 Function blocks of operator panel front
S Aluminum front panel with membrane keyboard

S Monochrome LCD module 240x128 pixels capable of text and graphics dis-
play with integrated controller and CCFL backlight
S Five horizontal soft keys

S Cursor key group
S Numerical key group with override and input key
Power supply 24VDC input

SINUMERIK 840D/840Di/810D Operator Components Manual (BH) 11.02 Edition 1-21
1 Operator Panel Front OP 030 10.00
1.2 Control elements and interfaces
Position of control
elements SIEMENS SINUMERIK
7 8 9 -
4 5 6 +
1 2 3
0 .
Numerical key
group with
override and
input key
Cursor key
group
Soft keys (horizontal)
Fig. 1-1 Front view of operator panel front
X101
X201
SIEMENS
1
2
3
X301
Fig. 1-2 Rear view
Overview of S X101: Serial RS-232-C

interfaces
S X201: OPI (operator panel front interface)
S X301: 24V power supply

1-22 SINUMERIK 840D/840Di/810D Operator Components Manual (BH) 11.02 Edition
10.00 1 Operator Panel Front OP 030
Serial RS-232-C Connector designation: X101

Connector type: Sub-D, 9-pin, straight
Max. cable length: 30m
Table 1-2 X101 pin assignments for serial RS-232-C
X303
Pin Name Type
1 DCD O
2 RxD I
3 TxD O
4 DTR I
5 M VO
6 DSR O
7 RTS I
8 CTS O
9 RI I
Jumpers closed
Pins 1 4 6
Pins 7 8
Signal names
TxD Transmit Data RS232C
RxD Receive Data RS232C
CTS Clear To Send
RTS Request To Send
DTR Data Terminal Ready
DSR Data Send Ready
RI Ring Indicator
DCD Data Carrier Detect
M Ground
Signal type
I Input
O Output
VO Voltage Output

OPI Connector designation: X201

(operator panel Connector type: Sub D-female, 9-pin, straight
front interface) Max. cable length: 200m
Table 1-3 X201 pin assignments for OPI

(operator panel front interface)
X201
Pin Name Type
1
2
3 RS_OPI B
4 ORTSAS_OPI O
5 MEXT VO
6 P5EXT VO
7
8 XRS_OPI B
9 IRTSPG_OPI I
Signal names
RS_OPI Operator panel interface cable A
XRS_OPI Operator panel interface cable B
IRTSPG_OPI Input Request To Send, programming
device
ORTSAS_OPI Output Request To Send, interface module
MEXT External ground
P5EXT 5V external, isolated
Signal type
I Input
O Output
B Bidirectional
VO Voltage Output

24V power supply Connector designation: X301

Connector type: Phoenix terminal block, 3-pin, right-angle
Table 1-4 X301 pin assignments for the 24V power

supply
X301
Pin Name Type
1 P24 VI
2 M24 VI
3 Shield
Signal names
P24 +24VDC supply voltage
M24 Ground
Shield Earth potential
Signal type
VI Voltage Input

1.3 Dimension drawings and mounting instructions
Dimension 280
drawings
SIEMENS SINUMERIK
7 8 9
4 5 6 +
1 2 3
0 . 182
Fig. 1-3 Front view
262.40.1 8.8
164.40.1
SIEMENS
1
2 82.20.1
3
8.8
131.20.1
Fig. 1-4 Rear view

60 4
Required clearance
40
203
Fig. 1-5 Side view (left)
Installing operator
Required clearance
panel front
280
22
234
47
Fig. 1-6 Plan view of housing
Mounting position max. 60

off vertical permissible
Front
Fig. 1-7 Mounting position

Panel cutout
0 80.5 131.20.1 254.40.5

262.4 0.1
164.40.1
156.40.5
82.20.1
1.5
80.5 1.0/100
0
5+0.5
Fig. 1-8 Cutout for operator panel front (front view)
Heat dissipation See Chapter Heat Dissipation

1.4 Technical data
1.4 Technical data
Table 1-5 Technical data for operator panel front
Electrical data (operation with open interfaces)

Total current +24V
Typical 200mA
Maximum 260mA
Mechanical data
Dimensions Width Height Depth
280mm 182mm 47mm
Basic color of casing Anthracite, acc. to SN 47030, Part 2, Color code:
614
Environmental conditions
Temperature ranges Installed/in operation Storage/transport
Limit values 0...40C 20 ... 60C
Service life 10,000h at 25C

1.4 Technical data
Notes

Flat Slimline Operator Panel Front
OP 032S 2
2.1 Overview of components
Note
The slimline operator panel front OP 032S (OP 032 Small) and its components
can be used in conjunction with the following control systems:
SINUMERIK 840D
SINUMERIK 810D.
Operator The operator panel front OP 032S consists of the following components:
components S Slimline operator panel front OP 032S
S CNC keyboard (QWERTY) OP 032S
S Machine control panel (MCP) OP 032S.
310 801) 24
Power
supply
Slimline operator
panel front
330
OP 032S
MMC-CPU
3)
CNC keyboard
680 (QWERTY) ISA/PCI
175 OP 032S adapter
4)
Machine con-
175 trol panel 2)
(MCP)
OP 032S
1) A clearance (approx. 30mm) should be provided.

2) The rear side is determined by the optional control elements.
3) Is required for operating the slimline operator panel front.
4) Can be installed as an option
Fig. 2-1 Overview of operator components

2 Flat Slimline Operator Panel Front OP 032S 10.00
Overview of
connections
24 V
Power
supply 0V
PE
MMC
NCU/CCU
CPU
X10/MF2
X4/MPI
OPI (1.5 Mbaud)/

MPI cable MPI (187.5 kbaud)
24 V X20
0 V X10
PE
Fig. 2-2 Overview of connections
For further on configuring, please refer to:

information
References: /PHD/ SINUMERIK 840D,
NCU 571573 Manual
References: /PHG/ SINUMERIK 810D,
Configuring Manual
Heat dissipation See Chapter Heat Dissipation.

10.00 2 Flat Slimline Operator Panel Front OP 032S
2.1.1 US layout
>
>
MACHINE MENU
SELECT
Fig. 2-3 Operator panel front with US layout

? & (
Q W E R T Y U I O P / 7 8 9
$ %
A S D F G H J K L , 4 5 6
*
! @ #
Z X C V B N M = [ ] 1 2 3

| < : ) >
TAB Ctrl Alt \ . ; + +/ 0

ALARM
RESET
HELP Alarm GROUP
CHANNEL
NEXT
WINDOW
PAGE
UP SELECT DEL

TOOL PAGE BACK
SHIFT PROGRAM End Insert Input
OFFSET DOWN SPACE
Fig. 2-4 CNC keyboard with US layout
Note
The five additional keys (Help, Alarm, Program, Tool Offset, Space key) are not
supported by the standard block DB 19 of the PLC basic program. The user
program must be adapted accordingly for this purpose.

JOG REPOS
REF
POINT
SPINDLE 100% SPINDLE
[VAR] DEC. INC.
MDI TEACH SPINDLE

RIGHT
SPINDLE
STOP
SPINDLE
LEFT
IN 1
AUTO
X
Y Z
10
SINGLE RESET
4 5 6
BLOCK 100
WCS FEED FEED

+
STOP START
1000 MCS STOP START RAPID
Fig. 2-5 MCP with US layout

2.2 Flat operator panel front OP 032S
2.2.1 Function blocks of operator panel front
S Soft keys (eight vertical, eight horizontal)

S Screen control keys (four pcs.)
S Screen
Display design:
TFT flat color screen, 10.4 inch, resolution 640x480
S 24V power supply

24VDC input
Power supply interface for MMC unit and display
S Mounting
W x H x D: 310x330x68mm
Add-on
components
S MMC CPUs (MMC 100, 100.2, 102, 103)
Note
For MMC 100 and 102, the following ribbon cable is required for connection
between MMC and power supply:
Ribbon cable for power supply

for MMC 100 / MMC 102 Order No. 6FC5 247-0AB28-0AA0

2.2.2 Control elements and interfaces
Position of control
elements
Soft key bar

(vertical)
Display
Soft key bar

(horizontal)
Screen
control keys
Fig. 2-6 Front view of flat operator panel front
PE
Power supply 0V
24V
Equipotential
bonding
X3 X4
X5
X6
Hard X10
MMC disk S1 X11
1 1
drive
S2
Fig. 2-7 Rear view of flat operator panel front

Installing MMC
module MMC 100, 1. Put the flat operator panel front on an appropriate surface as shown in
MMC 101/102 Fig. 2-7 (power supply module is on top).
2. Loosen the four Torx screws (M4) for attaching the MMC.
3. Suspend the MMC module from the four screws such that interfaces X4, X5
and X6 are facing to the right.
4. Push the complete module unit down until the bus connector snaps into
place.
5. Attach the MMC module by tightening the four Torx screws (max. tightening
torque 1.5Nm).
6. Connect the power supply to the MMC module using the ribbon cable.
Installing the MMC

module MMC 103 1. Put the slimline operator panel front on an appropriate surface as shown in
Fig. 2-7 (flat power supply module is on top).
2. Loosen the four Torx screws (M4) for the power supply module and push the
power supply module completely to the top.
3. Loosen the four Torx screws (M4) for attaching the MMC.
4. Suspend the MMC module from the 4 screws such that interfaces X4, X5
and X6 are facing to the right.
5. Push the complete module unit down until the bus connector snaps into
place.
6. Attach the MMC module by tightening the four Torx screws (max. tightening
torque 1.5Nm).
7. Push the power supply module down until the power supply connector
snaps into place.
8. Fix the MMC module by tightening the four Torx screws (max. tightening
torque 1.5Nm).
Power supply Connector designation: X1

interface (X1) Connector type: MSTB 2.5/3G5.08; 3-pin
Table 2-1 X1 pin assignments
Pin Signal, name Signal type

1 P24, 24V potential V, supply voltage
2 M24, 24V ground V, supply voltage
3 SHIELD, shield connection V, supply voltage

2.2.3 Mounting instructions, dimension drawing and panel cutout
4)
30
3)
2)
30
1)
1) 30 5)
2)
30
30 30
1) Necessary clearance
2) Measured from the upper edge of the MMC used
3) Permitted mounting position max. 60 degrees to the perpendicular
4) Recommended screw M4 with washer DIN 125
5) M5 grounding connector
Fig. 2-8 Mounting instructions for flat operator panel front

5.5 309.4 79.1

0 13.8 154.7 295.6 53.1 24
330
321 5 24
302.5
1)
73
2)
55
27.5
9 15
0
19.7 19.7
1) Minimum mounting depth for

MMC 103
2) Minimum mounting depth for

MMC 100.2
Fig. 2-9 Dimension drawing for flat operator panel front

4.4 0 136.5 273 277.4
307
302
280 7+ 0.5
2) 2) 2)
(4 times) 2)
0.5
Front panel cutout for flat
operator panel front 3)
2)
2) 2) 2)
22
0
5 15.8 0.5 1)
Front panel cutout
for CNC keyboard 3)
1) Necessary mounting clearance for using an ISA or ISA/PCI adapter

2) Rivet-down, insert nut M4 or extruded hole M4
3) Front panel cutouts for installation from the rear:
Operator panel front: W x H = 301.4x278mm
Keyboard: W x H = 301.4x153mm
Fig. 2-10 Panel cutout for flat operator panel front (rear view)

2.2.4 Using an ISA/PCI adapter
Arrangements for If an ISA/PCI adapter is used, the following arrangements are possible:
use of an ISA/PCI
S Vertical, flat arrangement
adapter
S Desk-type arrangement.
Vertical, Desk-type arrangement

flat arrangement

Power

supply Flat
operator
panel
front
Flat
operator
MMC panel
CPU front
Auxiliary

mounting plate
Same mount- (thickness =

ing surface 2mm)
ISA/PCI
adapter
CNC
CNC
keyboard
keyboard

Note: Note:
The ISA/PCI adapter is mounted on The ISA/PCI adapter is mounted
the rear panel of the CNC keyboard. on an auxiliary mounting plate.
Fig. 2-11 Arrangement when using an ISA/PCI adapter

Rear view when

using an
ISA/PCI adapter
Power
supply
Slimline
MMC operator
CPU panel front
ISA/PCI CNC
adapter keyboard
4050mm clearance for

connector of ISA/PCI plug-in cards
Fig. 2-12 Rear view when using an ISA/PCI adapter

Mounting the Mounting the adapter on the rear panel of the CNC keyboard is only possible for
ISA/PCI adapter on a vertical, flat arrangement.
the rear panel of Sequence for mounting:
the CNC keyboard
1. Fasten the two brackets on the adapter (1) as shown in Fig. 2-13.
2. Loosen both screws (2) on the rear of the keyboard.
3. Position the adapter on the rear panel of the CNC keyboard.
4. Push the adapter in the direction of the slimline operator panel front until the
interface snaps into place on the top right-hand side.
5. Tighten the screws on the bottom of the adapter (2).
2
2
Fig. 2-13 Mounting ISA/PCI adapter on rear panel of CNC keyboard

Mounting the When mounting the adapter on the desk-type arrangement, an auxiliary mount-
ISA/PCI adapter on ing plate is needed.
the auxiliary The mounting procedure is the same as on the rear panel of the CNC keyboard.
mounting plate
with precut
elongated holes Outline of flat operator panel front
Front panel cutout

for flat operator panel front
(display module)
0
Plate thickness = 2 mm
42.8
1) 1)
113.8
1) 1)
141
2) 2)
Outline
(175 x 299.4, as
CNC keyboard)
111.9 101.4 0 103.1 113.6
1) Cutout for support 4 + 0.2
(see detail Y)
Detail Y
2) M4 for mounting the supports
(rivet-down nut)
1.3 x 45 27.3
Tolerance for dimensions: 0.5
12
Note: The fastening holes for the auxiliary mounting
plate are not shown in this drawing. 6.5
Fig. 2-14 Hole pattern and dimensions for the auxiliary mounting plate (rear view)
Sequence for mounting:

1. Make the cutouts and holes for fastening the adapter (see Fig. 2-14).
2. Fasten the two brackets to the adapter using the provided screws (flange
inside).
3. Position the adapter on the auxiliary mounting plate.
interface snaps into place.
5. Tighten the screws on the bottom of the adapter.

Mounting the When mounting the adapter on the desk-type arrangement, an auxiliary mount-
ISA/PCI adapter on ing plate is needed.
the auxiliary
mounting plate
with precut Outline of flat operator panel front
elongated holes
Front panel cutout
for flat operator panel front
(display module)
0
1) 1)
33.6
35.6
75.6
1)
Mounting brackets
1)
107.1 required
(not supplied by
Plate thickness = 2mm Siemens)
Outline
(175x299.4, as
CNC keyboard)
127 0 125.5
1) M4 for mounting the supports
(rivet-down nut) Note: The fastening holes for the aux-
iliary mounting plate are not shown in
Tolerance for dimensions: 0.5 this drawing.
Mounting bracket
Not to dimension) 20
Plate thickness = 1mm 11
Rivet nut M4 15
7
40
50 Hole 4.5
Fig. 2-15 Hole pattern and dimensions for the auxiliary mounting plate (rear view)
Sequence for mounting:

1. Make the cutouts and holes for fastening the adapter and the mounting
bracket (see Fig. 2-15).
2. Fasten the two brackets on the right to the adapter using the provided
screws (flange outside).
3. Position the adapter on the auxiliary mounting plate.
interface snaps into place.
5. Tighten the screws on the right and left-hand sides of the adapter.

2.2.5 Technical data for flat operator panel front
Table 2-2 Technical data for flat operator panel front
Electrical data (data with open interfaces)

Total current +24V
Typical (without MMC) 0.3A
Max. 7.5A (for full expansion)
Power loss max. 180W
Mechanical data
309.4mm 330mm 26mm
Ground Approx. 3.88kg
Basic color of casing Anthracite, acc. to SN 47030, Part 2, Color code: 614
Temperature ranges Limit values for use/operation:
Rear 0 ... 55C
Front 0 ... 45C
Limit values for storage: 20 ... 60C
Temperature variation within 1 minute max. 0.2K
Service life Color display (without backlight) min. 20,000h
Permissible change in relative humidity EN 60721-3-3, Class 3K5
within 1 minute max. 0.1%
Intake air without aggressive gases
Degree of protection to DIN Front IP 54, rear IP 20
40050
Note
The backlights should be switched off with a screen saver, when the lamp re-
mains off for more than 1 hour on an average.
The component with the smallest temperature range in the whole configuration
determines the temperature range of the whole system.
For the technical data of the MMC component used, please refer to the relevant
section Technical data of MMCxxx.

2.3 CNC keyboard OP 032S
2.3.1 Function blocks
S 74 keys
S Layout similar to standard MFII keyboard
S Layout variants QWERTY and DIN available.
Fig. 2-16 Front view of CNC keyboard OP 032S
2.3.2 Connection of CNC keyboard
Keyboard interface Connector designation: X111

to MMC Connector type: Mini DIN connector, 6-pin, straight
(X111) Cable length to MMC-CPU: max. 0.5m
CNC keyboard
MMC-CPU
MFII interface
X10
X111
Fig. 2-17 Connection of CNC keyboard

2.3.3 Mounting instructions, dimension drawing and panel cutout
With ISA/PCI adapter

2)
30
5)1.8Nm
1)
60 4)
1)
30
3)
30 50 6) 30 30
1)
2)
30
2) Measured from the upper edge of the ISA/PCI adapter
4) Permitted mounting position max. 60 to the
perpendicular
5) Recommended screw M4 with washer DIN 125
Torque 1.8 Nm.
6) Required clearance for connector on ISA/PCI card
(depending on the connectors used)
Fig. 2-18 Mounting instructions for CNC keyboard

13.8 1) 309.4
0 154.7 295.6 103
1)
175
169
162.5
144.4
53.4
12.5
6
0
24.8 19.6 77 24
1)
1) Dimensions of the
ISA/PCI adapter
Fig. 2-19 Dimension drawing of CNC keyboard
M4 (6 times) 1)
158
153 7 (4 times)
145.5
0.5
7.5
0
5
1) Rivet-down, insert nut M4

.6.7 0 136.5 273 279.7 or
4.4 277.4 extruded hole M4
Front panel cutout for installation from the rear: WxH = 301.4x153mm
Fig. 2-20 Panel cutout for CNC keyboard (rear view)

2.3.4 Technical data for CNC keyboard
Table 2-3 Technical data for CNC keyboard OP 032S
Electrical data
Voltage max. 5.25V
Current, typical 18mA
Power loss max. 0.1W
Mechanical data
309.4mm 175mm 26mm
Ground Approx. 1.35 kg
Rear 0 ... 55C
Front 0 ... 45C
Temperature variation within 1 minute max. 0.2K
40050

2.4 Machine control panel OP 032S
2.4.1 Function blocks of machine control panel
S Key caps (49 pcs., 48 with LED, can all be assembled variably)
S Feedrate override switch
S Possibility of installing optional customer-specific keys,
EMERGENCY STOP or second override switch
S Ten free inputs 24V

six free 24V/250 mA outputs.
2.4.2 Control elements and interfaces
Key 1 Key 10 Recess for

LED 1 LED 10 dial (EMER-
GENCY
STOP, over-
ride switch)
Key 11
LED 11
Supple-
mentary
control ele-
ments
(EMER-
GENCY
STOP or
Key 41 override
LED 41 switch)
Feedrate
override
switch
Key 50
Supplementary control elements LED 50
(6 keys, 1 keyswitch)
Fig. 2-21 Front view of machine control panel, overview and location of control elements
Control elements When supplied, the following control elements are provided on the machine
when supplied control panel:
S Key caps (49 pcs., 48 with LED, can all be assembled variably)
S Feed override switch.

Making the The openings for the supplementary control elements are embossed on the rear
openings with a side of the machine control panel.
drilling tool The diameter for the horizontal cutouts is 16.2 to 16.4mm.
The diameter for the EMERGENCY STOP button is 22.2 to 22.4mm.
Recommended: Drill the openings from the rear as follows:
S Clamp the machine control panel for machining on the rear (use suitable
drilling support).
S Switch the chip extractor on or cover the electrical parts to prevent chips
from falling on them.
Note
Before drilling the opening, metal chips must be removed from the drills.
S Use the appropriate drill to drill the desired openings (openings are cen-
tered).
Making the cutouts The cutouts should be knocked out only if the control elements used cover the
by knocking out broken edges on the front panel (no sharp broken edges).
Supplementary The following control elements can be added:

control elements
S EMERGENCY STOP
Operator control element: SIEMENS 3SB3000-1HA20
Switching element 3SB3400-0A (1 NO contact + 1 NC contact)
S Additional override switch

Override switch with wing cap, spacer, cover, 2 dials.
CBS 1/1x1GG (16/15) switch
Spindle override 50120% dial
Rapid traverse override 0100% dial.
The second override switch must be connected via X31X32.
Order No. 6FC5 247-0AA34-0AA1.

Table 2-4 Example showing connection of additional override switch
Pin Meaning: Switch wiring

X31 pin 4 Ground = C
C
NC
N.C.
X32 pin 2 Significance 22 =4 4
N.C.
X32 pin 1 Significance 24 = 16 16

N.C.
8
X31 pin 3 Significance 23 = 8 N.C.
2
N.C.
X31 pin 2 Significance 21 = 2 1
X31 pin 1 Significance 20 = 1 Base of

override switch
S Cable set for additional command devices for interfaces X31X36

A maximum of six cables are required for each MCP.
60 cables x 500 mm
Order No. 6FC5 247-0AA35-0AA0
S Six keys with lamps + one keyswitch

The keys and the keyswitch are connected to X31X34 (input signals).
The lamps are connected to X35 and X36 (output signals).
Recommended type for keys and keyswitch:
Rafix 16, Lumotast 25, Schlegel QUARTRON
Source:
Schlegel (http://schlegel-ekontakt.de),
RAFI (http://www.rafi.de)

1) 22.4
X20
130.7
125.6 DIP switch
8 1

Plug connector
1 2 3 4
3) 1x6 pin 3)
4)
56.5
57 X10 2 9
24/0V
40 9
34.5
10.4
16.3
2
0 0
2)
259.98 228.92 177.8 147.45 117.1 86.75 56.4 26.05 0
233 208.15
1) Location intended for EMERGENCY STOP or second override switch (22mm)

Prepared for 22mm emergency stop mounting geometry
Recommended design:
Recommended design: SIEMENS 3SB3000-1HA20 Module variants:
Contact 3SB3400-0A 1S + 1O 3) 571241.9001.00
4) 571241.9001.01
2) Location for 7 control devices (16mm)
Fig. 2-22 Rear view of the machine control panel, dimensions of the machine control panel
X20 Operator panel front

interface (MPI)
Outputs DIP switch

8 1
O S3
N
LED: 1 2 3 4 Plug connector
1x6 pin DIP switch (8-fold),
assignments
X10
Pin 4 1 4 1 Pin 4 1 4 1
Inputs
Displays: LED 1, 2: Unassigned

Power supply LED 3: POWER (24V supply)
interface Protective earth LED 4: SEND, status change when sending protocol
For module variants see Fig. 2-22
Fig. 2-23 Rear view of the machine control panel, overview and location of interfaces


interface Connector type: 3-pin Phoenix terminal block, straight
(X10) Recommended type: Phoenix CombiCon
Order No.: MVSTBR 2.5/3-ST-5.08

1 P24, 24V potential V, supply voltage
2 M24, 24V ground V, supply voltage
3 SHIELD, shield connection V, supply voltage
Note
The power supply interface should be wired in accordance with the labeling on
the module.
OPI interface Connector designation: X20

(X20) Connector type: 9-pin Sub-D socket connector, straight
Maximum cable length: 200m
Special features: 1.5 Mbaud/187.5 kbaud data rate

1 Unassigned
2 Unassigned
3 RS_OPI, RS-485 data I/O, bidirectional
4 ORTSAS_OPI, Out Request To Send AS O, output
5 M5EXT, 5V ground, external V, supply voltage
6 P5EXT, 5V potential, external V, supply voltage
7 Unassigned
8 XRS_OPI, RS485 data I/O, bidirectional
9 IRTSPG_OPI, In Request To Send PG I/O, bidirectional
Note
The inputs/outputs implemented via X31 to X36 can be used as desired. The
function of the inputs/outputs is defined in the PLC user program.
The following inputs/outputs via X31 to X36 and their use are examples.

Assignments The following settings are possible with this DIP switch (8-fold):
Table 2-7 Assignments with switch S3
1 2 3 4 5 6 7 8 Meaning:
ON Baud rate: 1.5 Mbaud
OFF Baud rate: 187.5 kbaud
ON OFF 200 msecs transmission cycle time/2400msecs receipt
OFF ON monitoring
OFF OFF 100 msecs transmission cycle time/1200msecs receipt
monitoring
50 msecs transmission cycle time/600msecs receipt monitoring
ON ON ON ON Bus address: 15
ON ON ON OFF Bus address: 14
ON ON OFF ON Bus address: 13
ON ON OFF OFF Bus address: 12
ON OFF ON ON Bus address: 11
ON OFF ON OFF Bus address: 10
ON OFF OFF ON Bus address: 9
ON OFF OFF OFF Bus address: 8
OFF ON ON ON Bus address: 7
OFF ON ON OFF Bus address: 6
OFF ON OFF ON Bus address: 5
OFF ON OFF OFF Bus address: 4
OFF OFF ON ON Bus address: 3
OFF OFF ON OFF Bus address: 2
OFF OFF OFF ON Bus address: 1
OFF OFF OFF OFF Bus address: 0
ON MPI interface, customer operator panel front
OFF Serial hardware
Settings for the The PLC expects a message frame from the MCP at least every 500 msecs.
transmission The machine control panel sends a message frame to the PLC at cyclic inter-
cycle time vals when no key is pressed. This cycle time is set with S3 DIP switches 2 and
3. This enables the load on the PLC resulting from the machine control panel to
be adjusted.
Settings for The MCP receives message frames from the PLC at cyclic intervals and re-
receipt cycle time sponds to them at cyclic intervals. The receipt monitoring time is linked to the
transmission cycle time of the machine control panel and is set with S3 DIP
switches 2 and 3.
Bus address The bus address must be set to the value 6. Any other setting will be ignored by
the software.
Default setting The following default settings are suggested:
Table 2-8 Default setting for S3
1 2 3 4 5 6 7 8 Meaning:
ON OFF ON OFF ON ON OFF OFF Baud rate: 1.5 Mbaud
Transmission cycle time:
100 msecs
Bus address: 6

Displays These LEDs display the following:

(LEDs 1 ... 4)
LED 1, LED 2: Unassigned
LED 3: POWER (24V supply)
LED 4: SEND, status change when sending protocol
Interfaces for Connector designation: X31, X32

optional user keys Connector type: 4-pin plug connector
(X31, X32, inputs) Connector: Berg type Dubox
Table 2-9 X31 and X32 assignments

X31 X32
1 KT-IN 0, user key 1 KT-IN 3, user key 4 I, inputs
4 M5, ground M5, ground I, inputs
Note:
The inputs switch against ground (active low).
User key 1 (X31), 4 (X32)
rd1) User key 3 (X31), 6 (X32)
Ground
User key 2 (X31), 5 (X32)

View of pinside of
Dubox connector to be plugged (socket connector)
1) Color of line, red pin 1 in cable set
X31 X32
Pin 1 2 3 4 1 2 3 4
Plug connector
Machine control panel OP 032S (rear panel)


optional keyswitch Connector type: 4-pin plug connector
(X33, X34, inputs) Connector: Berg type Dubox

X33 X34
1 SS 0, SS 2, I, inputs
keyswitch input 0 keyswitch input 2
2 SS 1, SS 3, I, inputs
keyswitch input 1 keyswitch input 3
Note:
The inputs switch against ground (active low).
Other control elements can also be connected to these inputs.
X33 Position 1 Position 4 X34

Pin 1 Pin 1
Keyswitch
Ground

optional customer Connector type: 4-pin plug connector
lamps Connector: Berg type Dubox
(X35, X36, inputs)

X35 X36
1 KT-OUT 0, customer lamp 1 KT-OUT 3, customer lamp 4 O, outputs
4 M24, 24V ground M24, 24 V ground O, outputs
Note:
The outputs are designed for 24 V/250 mA.
Customer lamp 1 (X35), 4 (X36)

Pin 1 24V ground

2.4.3 Dimension drawing and panel cutout
5
175 169
162.5
125.6
48.9
49.4
19.5
12.5
6
0
2 24
0 13.8 154.7 260 309.4
295.6 42.4
1) 30.5
11.5
1) Protective-conductor terminal M5, min. 6 mm2
Fig. 2-24 Dimension drawing of machine control panel

M4
158
153 7
145.5
1)
0.5
38
0
5
6.7 0 136.5 273 279.7

10 4.4 277.4
1) DIN ISO 1101 Permissible mounting position of the operator panel plane max. 60
to the perpendicular
Front panel cutouts for installation from the rear: W x H = 301.4x153mm
Installation from the rear is necessary, for example, when user keys are incorporated.
Fig. 2-25 Panel cutout of machine control panel

2.4.4 Input and output signals
Input signals The control elements on the machine control panel are shown as input signals.
The start address n is set in the PLC user program by parameterization.
Input signals (MCP > PLC)

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
n Key 41 *) Key 8 Key 9 Key 10 Key 31 Key 1 Key 11 Key 21
n+1 Key 43 Key 18 Key 19*) Key 20 X34 pin 2 Key 3 Key 2 Key 12
n+2 Key 47 Key 46 *) Key 4 X33 pin 1 Key 44 Key 34 Key 24 Key 14
Feed override
n+3 Key 32 X34 pin 1 X33 pin 2
E D C B A
n+4 Key 50 Key 48 Key 49 X32 pin 2 X32 pin 1 X31 pin 3 X31 pin 2 X31 pin 1
n+5 Key 33 X32 pin 3 Key 40 Key 39 Key 38 Key 30 Key 29 Key 28
n+6 Key 27 Key 35 Key 36 Key 37 Key 45 Key 13 Key 22 Key 23
n+7 Key 5 Key 6 Key 7 Key 15 Key 16 Key 17 Key 25 Key 26
Note
The following general Key operated > input is high
rule applies: Key not operated > input is low
Exception: The keys marked with *) respond in the opposite way.
Output signals The LEDs and lamps on the machine control unit are actuated by means of the
following outputs.
The initial address m is set in the PLC user program by parameterization.
Output signals (PLC > MCP)

n LED 41 LED 8 LED 9 LED 10 LED 31 LED 1 LED 11 LED 21
m+1 LED 43 LED 18 LED 19 LED 20 Reserved LED 3 LED 2 LED 12
m+2 LED 47 LED 46 LED 4 Reserved LED 44 LED 34 LED 24 LED 14
m+3 Reserved
m+4 LED 50 LED 48 LED 49 X36 pin 2 X36 pin 1 X35 pin 3 X35 pin 2 X35 pin 1
m+5 LED 33 X36 pin 3 LED 40 LED 39 LED 38 LED 30 LED 29 LED 28
m+6 LED 27 LED 35 LED 36 LED 37 LED 45 LED 13 LED 22 LED 23
m+7 LED 5 LED 6 LED 7 LED 15 LED 16 LED 17 LED 25 LED 26

Programming For programming of individual keys and LEDs, we recommend the following
overview:
I n.2 n+1.1 n+1.2 n+2.5 n+7.7 n+7.6 n+7.5 n.6 n.5 n.4
O m.2 m+1.1 m+1.2 m+2.5 m+7.7 m+7.6 m+7.5 m.6 m.5 m.4
I n+0.1 n+1.0 n+6.2 n+2.0 n+7.4 n+7.3 n+7.2 n+1.6 n+1.5 n+1.4
O m+0.1 m+1.0 m+6.2 m+2.0 m+7.4 m+7.3 m+7.2 m+1.6 m+1.5 m+1.4
I n.0 n+6.1 n+6.0 n+2.1 n+7.1 n+7.0 n+6.7 n+5.0 n+5.1 n+5.2
O m.0 m+6.1 m+6.0 m+2.1 m+7.1 m+7.0 m+6.7 m+5.0 m+5.1 m+5.2
I n.3 n+3.7 n+5.7 n+2.2 n+6.6 n+6.5 n+6.4 n+5.3 n+5.4 n+5.5
O m.3 m+5.7 m+2.2 m+6.6 m+6.5 m+6.4 m+5.3 m+5.4 m+5.5
I n.7 n+1.7 n+2.3 n+6.3 n+2.6 n+2.7 n+4.6 n+4.5 n+4.7

O m.7 m+1.7 m+2.3 m+6.3 m+2.6 m+2.7 m+4.6 m+4.5 m+4.7
Example: n+1.7 The key is represented via the input n+1.7.

m+1.7 The LED is triggered via the output m+1.7.
n, m: The initial address for the inputs and outputs is defined via
the parameters in the PLC user program.
Fig. 2-26 Overview for programming of keys and LEDs (part of front view)
The labeled keys are shown in the following figure.
Fig. 2-27 Labeled and blank keys

Function block for Function block FC 24 controls the input/output signals of the OP 032S machine
MCP control panel.
The following applies to the block:
S The block is included in the program package

(applicable to SINUMERIK 840D SW 3.7 or SW 4.2 and higher)
S The block is available from the AUT 2 mailbox

S For a description of the block, please refer to the following manual:
References: /FB/, P3, Basic PLC Program (as of 08/97 Edition)
2.4.5 Technical data for machine control panel
Table 2-12 Technical data for machine control panel OP 032S
Electrical data
Total current 24V
Current typ. 150mA
Max. power loss 3.6W
Mechanical data
309.4mm 175mm 41mm (behind
support plate)
24mm (in front of
support plate)
Ground Approx. 1.22kg
Rear 0 ... 55C
Front 0 ... 45C
Temperature variation within 1 minute max. 0.2 K
Intake air No aggressive gases
40050

Operator Panel Front OP 010
(Order No. 6FC5 203-0AF00-0AA0) 3
Brief description The operator panel front OP 010 (successor to OP 031) described in the follow-
ing is characterized by:
S 19 subrack mounting, 7 HU (height units)

S Panel cutout (W x H): 450x290 mm
S Mounting depth (measured from the upper rear edge of the assembly panel)
in conjunction with PCU 50: 100mm + 10mm clearance
S 10.4 STN flat screen (color) with resolution of 640x480 pixels (VGA resolu-
tion)
S Membrane keyboard with alpha, numeric, cursor, control and hotkey key-
groups
S Soft keys:
1x eight horizontal and vertical rows of keys with soft key functions
S Shift key for switching to the second key level

(not used for case switching as only upper case letters are used)
S Status LEDs for power supply and overtemperature

S Front-mounted USB interface
S Degree of protection IP65
S Attachment: clamps at rear
S Can be combined with the component PCU 50
S External floppy disk drive can be connected.

10.00
3.1 Front view
3.1 Front view
Status LEDs: POWER TEMP *) Alpha key group Numerical key group
Softkeys Control
key group
Softkeys
Hotkey
group
Cursor
key group
USB
front
interface
Recall Machine area ETC key Area switchover
*) When the TEMP LED responds, increased wear should be taken into account
Fig. 3-1 Front view of operator panel front OP 010
Fig. 3-1 shows the front view of the OP 010 operator panel front.
The individual operator keygroups are described in Section 3.2.

10.00
3.2 Description of keyboard

Fig. 3-1 illustrates the distribution of the operator panel front over several key
groups:
S The Alpha key group contains the letters A, ..., Z on two levels arranged in
accordance with programming requirements.
S The numerical key group contains the digits 0 ... 9, the , /,=, + characters
and the decimal point.
S The cursor key group serves to navigate on the screen.

S The control key group provides special functions.
S The hotkey block is used for the direct selection of operating areas.
The key functions are contained in the list below:
Key Function corresponds to Key Function corresponds to

PC key function: PC key function:
Esc End
F11 Backspace
F12 Tab

Space (only intended for internal
keyboard switchover)
Home Ctrl key
Page up Alt key
Page down Delete
Cursor up Insert
Cursor to the left Enter
Cursor to the right F9
Cursor down F10
5 (in numerical key group) A, ..., Z <Shift> A, ..., Z

10.00

<Shift> F9 <Shift> F10

10.00
3.3 Interfaces
3.3 Interfaces
3.3.1 Arrangement
The OP 010 operator panel front provides the following interfaces:
Front USB front interface (see Fig. 3-1) for connection of external keyboard or mouse
on the front.
Note
Please note that, in respect of their EMC compatibility, many of the I/O devices
available from retail outlets are designed for office applications only.
For industrial use, components with a higher degree of certificate are recom-
mended.
Rear On the rear (see Fig.3-2):
S two cables for connecting the PCU are to be found:

I/O USB cable K1:(ribbon cable)
All signals that in addition to the display interface are used for con-
necting operator panel fronts.
Display cable K2:(ribbon cable as of 09.2001)
IO USB PCU 50
cable K1 main board
OP 010
Display cable K2 (ribbon cable as of 09.2001)
Fig. 3-2 OP 010 connections on the casing rear: PCU 50 connections

10.00
3.3 Interfaces
3.3.2 Assignment
USB front interface

Table 3-1 Assignment of the USB front interface (low current USB: 100mA)
Pin Name Type Remarks

1 USB_P5V_fused V +5V (fused) for ext. USB interface
2 USB_D0M B Data, USB channel 0
3 USB_D0P B Data+, USB channel 0
4 USB_GND V Ground for external USB interface
Signal type
B: Bidirectional V: Voltage

10.00
3.4 Installation
3.4 Installation
When combining OP 010 and PCU 50, it is recommended to attach them prior
to installation.
3.4.1 Assembling OP 010 and PCU 50
1. Put the PCU 50 with the front on a horizontal, smooth surface.

2. Lock the shipping brace of the hard disk by turning the handle to the non
operating position (see Fig. 3-3).
Shipping
brace
Fastening
screws Fastening
screws
Fig. 3-3 Shipping brace locked: Non-operating position
3. Release the four fastening screws of the hard disk drive brace
(see Fig. 3-3).
4. Put the OP 010 with the front on a horizontal, smooth surface.

10.00
3.4 Installation
Top Width = 483

Slot for soft key labels
Display
support plate 1)
3) 3) 3) 3)
Display
cable K2 2)
Cover plate for con-
nections 3) 3)
Height = 310
Keyboard controller
3) 3)
I/O USB 1) 3) 3)
cable K1 2) 3) 3)
1) Mounting slots for PCU straps

2) Cable shown folded together; ribbon cable as of 09.2001 Slots for soft key labels
3) Casing screws
Fig. 3-4 Operator panel rear with position of the interfaces,

the mounting slots and
the slots for the soft key slide-in labels
5. Insert the PCU 50 horizontally with the straps of the already preassembled
mounting rails into the appropriate mounting slots (Fig. 3-4) of the OP 010.
6. Tilt off the PCU 50 to the left whereby the two straps act as hinges, prevent-
ing accidental loosening of the connection.
7. Swing open the hard disk drive braces.
8. Insert the cable connectors K1 and K2 of OP 010 through the opening in the
PCU 50 casing (see Fig. 3-2) and plug them into the corresponding mating
pieces (Fig. 3-5). The connector of the I/O USB cable K1 has locks which
can be felt to engage when the connector is inserted correctly.
9. Secure the connector of the display cable K2 (ribbon cable as of 09.2001)
using the clamp to prevent it from loosening (see Fig. 3-5).
10. Secure the display cable K2 to the board using a cable tie (see Fig. 3-5).

10.00
3.4 Installation
Hard disk fixing plate swung upwards
PCU 50 Display cable K2

main board placed on OP 010 (ribbon cable as of 09.2001)
Fig. 3-5 PCU 50 Connection under the hard disk: connections to OP 010
11. Swing the hard disk fixing plate downwards and screw the 4 fixing screws in
place (0.8Nm).
12. Swing the PCU 50 to the limit position and fix it using the knurled screws
(torque 1.8Nm).
13. Unlock the shipping brace for the hard disk, otherwise the system will not
boot.
Note
If you want to insert or replace the soft key slide-in labels (are already installed
on delivery), you must do it before assembling OP 010 and PCU (see Fig. 3-4).
For instructions on how to label the replacement strips, see Section 3.5.
3.4.2 Mounting preparation
Table 3-2 Dimensions of the mounting hole (see Fig. 3-6)
PCU type Width (mm) Height (mm) Depth + clearance

used (mm)
PCU 50 450 290 100 + 10
Thanks to the tension jacks fastening the OP 010, holes or screw holes are not
needed.
In addition, this type of fastening provides degree of protection IP 65 (however,
only in conjunction with a circulating seal and with the protecting cap of the USB
interface fitted).

10.00
3.4 Installation
Tension jacks
**)
112.5* 77.75* 77.75* 112.5* **)
450 +1
290 +1
112.5*
235 +0.2
0.2
Setscrews
56.25*
5
**)
**)
465 +0.2
0.2
*) dimensions for pressure points of the 1.5min to 6 max
tension jacks
**) holes for screw fastening Assembly panel Sealing area
Fig. 3-6 Dimension sheet for installing the OP 010 operator panel front

10.00
3.4 Installation
3.4.3 Installation
1. Insert the assembled components OP 010 and PCU from the front into the
panel cutout.
2. Fix the operator panel front in the panel cutout from the rear using the six
tension jacks (see Fig. 3-6) by tightening the setscrews (torque 0.40.5Nm).
Note
Alternatively, you can also fasten the operator panel front using screws:
To do so, break through the edge of the OP 010 at the four intended positions
(see Fig. 3-1 and 3-6).
In this case, however, you should note that the operator panel front will no lon-
ger comply with degree of protection IP65, but with IP54.
Clearance The clearance at the PCU rear side must be at least 10 mm to make sure that
sufficient ventilation is provided (see Fig. 3-7).
For more detailed information, please refer to Chapter Component PCU 50
and Chapter Heat Dissipation.
17.3
38.7
Clips
PCU rotated through 90 degrees
Required clearance
Mounting rail
for ventilation 333
297
10
PCU in end position

35.8
100+3
20
Mounting rail
46.3
10
100.1 313.4 69.1
OP 010
Fig. 3-7 Attaching the PCU to the OP 010 operator panel front
Mounting position The permissible mounting positions depend on the conditions of the attached
PCU (see Chapter Component PCU50).

10.00
3.5 Soft key designation

The vertical and horizontal soft key bars can be assigned user-specific func-
tions. You can use printed labels to identify the soft keys.
Blank labels are already installed on delivery (see Subsection 3.4.1).
Making the labels To make the labels, DIN-A4 filmis available (Order No., see Section 3.6).
Procedure:
1. Letter the dull side of the film using a laser printer.
2. Cut the printed labels along the preprinted lines.
3. Loosen the four fastening screws of the PCU and tilt the PCU off the opera-
tor panel front.
4. Slide the labels from the rear of the operator panel front into the intended
slots (see Fig. 3-4).
5. Swing the PCU back towards the operator panel front and fix it in place by
tightening the screws.
If the PCU and operator panel front are already dismantled, omit steps 3. and 5.

10.00
3.6 Spare parts/accessories
3.6.1 Spare parts list
Spare parts for the OP 010 are (see Fig. 3-8):
S Front panel Order No. 6FC5 248-0AF00-0AA0

(without LCD unit, without keyboard controller)
S Cap seals Order No. 6FC5 248-0AF05-0AA0

for USB connection (10 pcs.)
S DIN A4 film for slide-in user labels Order No. 6FC5 248-0AF07-0AA0
Soft key slide-in labels
S Tension jacksset (6 pcs.) Order No. 6FC5 248-0AF06-0AA0
Backlight with
backlight
inverter
LCD unit
Display holder
Sealing cap for the Keyboard controller

Front plate USB connection
Fig. 3-8 Spare parts for the OP 010 operator panel front

10.00
3.6.2 Spare part replacement
Caution
! Spare parts may only be replaced by trained personnel (sensitive components
may be damaged due to static electricity)!
The replacement of USB sealing cap and tension jacks will not be described in
the following, since it is simple and self-explanatory.
Operator panel When changing the front plate, the existing LCD unit and keyboard controller
front can be reused and are therefore removed and installed again after the front
panel has been changed.
Note
It is recommended to continue to use the keyboard controller, to make sure that
the programmed control parameters are not lost.
Procedure:
1. Put the OP 010 with the front side on a horizontal, soft surface and loosen
the 12 casing screws (see Fig. 3-4).
2. Remove the soft key slide-in labels and the cover plate (see Fig.3-4).
3. Remove the following connectors from the keyboard controller (see
Fig. 3-9): Backlight (base X14) and IO USB cable K1.
4. Lift off the display holder with the display.
In addition to the keyboard controller, the rear sides of mouse and USB in-
terface become visible.
USB interface
Connection X1
for IO USB cable K1
Membrane connec-
Connection X11 tor for connecting
the keyboard of the
operator panel front
Connection X4
for mouse
Connection X14 for

backlight
Connection X12
(reserved) Keyboard controller
Fig. 3-9 Changing the operator panel front

10.00
5. After bending back the two clamping hooks, unplug the USB interface.
6. Loosen the three membrane connectors of the operator panel front key-
board from the sockets X7, X8 and X10 as follows:
Loosen the dark clamping frame of the socket by pressing it upward until
it locks in its upper, unlocked position (Fig. 3-10).
Carefully pull off the membrane connector upward.
Clamping frame
of socket
Fig. 3-10 Changing the operator panel front: Loosening a membrane connector
7. Loosen the fastening screws from the keyboard controller.

8. Lift USB interface and keyboard controller off the front plate. The intercon-
nections may remain plugged.
9. Install these components in the new operator panel front in reverse order.
Note
When reattaching the membrane connectors of the USB and keyboard in-
terfaces, observe the following order: With the clamping frame lifted, care-
fully insert the connector into the socket; then press the clamping frame
down to lock it in place (see Fig. 3-11).
When tightening the screws, observe the relevant torques (see Section
Technical data).
Fig. 3-11 Changing the front plate: Attaching a membrane connector
Film labels The procedure for replacement is described in Section 3.5.

10.00
3.7 Technical data
3.7 Technical data

Table 3-3 Technical data
Safety
Class of protection in conformity with VDE 0106 T1: 1982 (IEC 536)
Degree of protection Front IP 65/IP54 1) Rear IP 00
Safety regulations IEC in conformity with DIN VDE 0805/11.93
Approvals CE; FCC (Class 1 Div. II)
Electrical data (without PCU 50)
Power supply (via I/O Display Backlight in- Logic/USB
USB cable and display cable) verter
Voltage 5V +/ 5% 12V +/10% 5.2V +/ 2%
Current (typ./max. mA; 280/380 750/1000 350 2)/1000 3)
approx.)
Power consumption approx. 13W typical approx. 22W maximum
Mechanical data
Dimensions without PCU 50 Width 483mm Height 310mm Depth 110mm
Dimensions with PCU 50 in- Width 483mm Height 310mm Depth 120mm
cluding clearance for ventila-
tion(overall outer dimensions)
Weight approx. 5kg
Tension jack M3 screws: M4 screws:
Max. tightening torques
screws: 0.5Nm 0.8Nm 1.8Nm
Mechanical environmental Operation Transport
conditions (in packaging)
Vibration (whole system OP 1058Hz: 0.075mm 59Hz: 3.5mm
010 + PCU 50, tested to DIN 58200Hz: 9.8 m/secs2 9200Hz: 9.8m/secs2
IEC 6826)
Shock resistance (whole sys- 50 m/secs2, 30 msecs, 300 m/secs2, 6 msecs,
tem OP 010 + PCU 50, tested 18 shocks 18 shocks
to DIN IEC 68-2-29)
Climatic environmental conditions
Heat dissipation 4) by natural convection
Operation Storage/transport
0 ... 40C (front) 20 ... 60C
Temperature limit values
0 ... 55C (rear)
Tested to DIN EN 60068-2-2: 1994, DIN IEC 68-2-1,
DIN IEC 68-2-14
Limits for rel. humidity 5 ... 80% at 25C 5 ... 95% at 25C
Tested to DIN IEC 68-2-3, DIN IEC 68-2-30, DIN IEC 68-2-56
Temperature change max. 10K/h
Condensation not permissible
Intake air No aggressive gases
Service life Backlight 50,000h
1) IP54 when fastened with screws.

2) Typ. value without load on USB front connector.
3) Max. value incl. load on USB front connector.
4) See also Chapter 24 Heat Dissipation.
J

Operator Panel Front OP 010S
(Order No. 6FC5203-0AF04-0AA0)
4
Brief description The operator panel front OP 010S (successor to OP 032S) described in the
following is characterized by:
S Mounting format 310x330mm

S Panel cutout (W x H): 285x304mm
S Mounting depth (measured from the upper edge of the assembly panel) in
conjunction with PCU 50: 120mm + 10mm clearance
S 10.4 TFT flat screen (color) with a resolution of 640x480 pixels

(VGA resolution)
S Mechanical keys:
Eight horizontal soft keys
Eight vertical soft keys
Four control keys

S Degree of protection: IP54
S External floppy disk drive can be connected via PCU.

4 Operator Panel Front OP 010S 10.00
4.1 User interface
4.1 User interface
Status LEDs: POWER TEMP *)
Softkeys
Recall ETC key
Area switchover
Machine area
USB
front
interface Soft keys
Fig. 4-1 Front view of operator panel front OP 010S
Fig. 4-1 shows the user interface of the OP 010S:
S the 10.4 display

S the USB front interface
S eight vertical and horizontal soft keys
S four control keys with the following functions:
<Shift> F10 F9
<Shift> F9 F10

10.00 4 Operator Panel Front OP 010S
4.2 Interfaces
4.2 Interfaces
4.2.1 Arrangement
The OP 010S operator panel front provides the following interfaces:
on the front.
Note
mended.
Rear Two ribbon cables (Fig. 4-2) for connection of PCU on the rear:
S I/O USB cable K1: All signals that, in addition to the display interface are
used to connect operator panels.
S Display cable K2.
PCU 50
main board
PCU 50
IO USB
cable K1
Display OP 010S
cable K2
Fig. 4-2 OP 010S connections on the casing rear: PCU 50 connections
4.2.2 Assignment
USB front interface


Signal type B: Bidirectional V: Voltage

4.3 Installation
4.3 Installation
When you are using a combination of OP 010S and PCU 50, it is advisable to
install the OP 010S in the assembly panel first and then mount the PCU 50 on
the OP 010S.
4.3.1 Installing OP 010S

PCU type used Width (mm) Height (mm) Depth + clearance
(mm)
PCU 50 285 304 120 + 10
Thanks to the tension jacks fastening the OP 010S, holes or screw holes are
not needed.
In addition, this type of fastening affords degree of protection IP 54 (but only in
conjunction with a circular seal and plugged protective cap on the USB inter-
face).
Proceed as follows:
1. Insert the OP 010S in the panel cutout from the front.
2. Fix it in the panel cutout from the rear using the six tension jacks (see
Fig.4-3) by tightening the setscrews (torque 0.40.5Nm).
In the sealing area: Rz120
1.5 min to 6 max

Tension jack with setscrews
Sealing area 13 1
13 1
112 0.5
112 0.5
56 1 Pressure points
for tension jacks
235 0.2
15 1
304 +1
285 +1
Elongated hole
292 0.2 7 for screw
fastening
Fig. 4-3 Dimension sheet for installing the OP 010S operator panel front

4.3 Installation
4.3.2 Mounting PCU 50
310
Top
Casing 2) 1) 1) 1) 1) 2)
cover plate
Cover plate for

connections 1)
Keyboard controller 1)
IO USB
330
cable K1
Display
cable K2
1) 1)
1) 1)
2) 1) 1) 2)
1) Casing screws M3
2) Casing screws M4 for PCU mounting (on the side)
Fig. 4-4 Rear side of operator panel front with allocation of interfaces and mounting slots
1. Remove any mounting rails from the PCU 50 (see Chapter Component
PCU 50 Fig. 12-1 and Fig. 12-5).
2. Position the PCU 50 at approximate right angles to the OP 010S (see Fig.
4-2).
3. Insert the cable connectors K1 and K2 of the OP 010S into the correspond-
ing mating pieces behind the opening in the PCU 50 casing (see Fig. 4-2).
Make sure that the connectors lock in and the locks are closed.
4. Swing the PCU 50 onto the OP 010S.
5. Fix the PCU 50 to the OP 010S by means of the four M4 screws on the side
(torque 1.8Nm).
Clearance A clearance of at least 10 mm should be provided on the PCU rear to guarantee

sufficient ventilation (see Fig. 4-5).

4.3 Installation

100

OP010S
0.5
PCU
0.3

297
330

100

Clearance for cables and ventilation
160

22 1
0.5
267
10

350.5
PCU
+3

120
Additional clearance for

connection cable (for 840Di)
OP 010S
100.5
0.3
310
Fig. 4-5 Attaching the PCU to the OP 010S operator panel front with clearances
PCU (see Chapter Component PCU 50).

Spare parts for the OP 010S are (see Fig. 4-6):
S Front plate Order No. 6FC5 248-0AF04-0AA0

(without LCD unit, without USB interface, without keyboard controller)

Front plate Backlight with

backlight
inverter
LCD unit
Display holder with

keyboard controller
(rear)
Sealing cap for the
USB connection
Fig. 4-6 Spare parts for the OP 010S operator panel front
Caution

Front plate When changing the front plate, the existing USB interface and the display
holder (with display, backlight inverter and keyboard controller) can be reused.
Procedure:
1. Put the OP 010S like the replacement front plate with the front on a horizon-
tal, soft surface.
2. Loosen the casing screws (see Fig. 4-4) and remove the casing cover plate.
The display holder with the keyboard controller (Fig. 4-7) will be visible un-
derneath and, in a cutout of the mounting plate, the rear side of the USB
interface (Fig. 4-9).
Membrane lines Membrane lines from the op-

from the operator erator panel front keyboard
Connection X14
panel front keyboard Connection X12 for display and
Connections for (reserved) back-lighting
operator panel
front keyboard Connection
X7 X4 (reserved)
X10
X8
Display cable K2
Connection X11
IO USB cable K1 (reserved)
USB membrane line
Fig. 4-7 Keyboard controller
3. Loosen the membrane connectors of the operator panel front keyboard from
the sockets X7, X8 and X10 as follows:
Carefully pull out the membrane end upwards.
Clamping frame
of socket
Fig. 4-8 Changing the operator panel front: Disconnecting a membrane connection
4. Loosen the membrane connection of the USB connection cable (Fig. 4-9) as
described under Point 3.

Display holder
USB membrane line

(see Fig. 4-7)
USB interface
Fig. 4-9 USB interface viewed from the operator panel rear side
5. Loosen the screws of the display holder and lift it off.

6. Pull the USB interface off its seat and insert it into the replacement front
plate.
7. Place the display holder on the replacement front plate.
8. Assemble the operator panel front in reverse order.
Note
When reattaching the membrane connections of the USB and keyboard
interfaces, observe the following order: With the clamping frame lifted, carefully
insert the end of the membrane into the socket; then press the clamping frame
Technical data).
Fig. 4-10 Changing the front plate: Connecting a membrane connection

4.5 Technical data
4.5 Technical data

Safety
Degree of protection Front IP 54 Rear IP 00
Voltage 5V +/ 5% 12V +/10% 5.2V +/ 2%
Current 420/600 900/1050 350 1)/1000 2)
(typ./max. mA; approx.)
Mechanical data
Dimensions without PCU 50 Width 310mm Height 330mm Depth 45mm
Dimensions with PCU 50 and Width 310mm Height 330mm Depth 140mm
ventilation clearance(overall
outer dimensions)
Weight approx. 4kg
Mechanical Operation Transport
environmental conditions (in packaging)
010S + PCU 50, tested to DIN 58200Hz: 9.8m/secs2 9200Hz: 9.8m/secs2
IEC 6826)
tem OP 010S + PCU 50, 18 shocks 18 shocks
tested to DIN IEC 68-2-29)
0 ... 40C (front) 20 ... 60C
0 ... 55C (rear)
DIN IEC 68-2-14
1) Typ. value with 100mA load (low power device) on the USB front connector.
2) Max. value with 500mA load (high power dev.) on the USB front connector.
3) See also Chapter Heat Dissipation.
J

Operator Panel Front OP 010C
(Order No. 6FC5 203-0AF01-0AA0) 5
Brief description The OP 010C operator panel front described in the following is characterized
by:
S 19 subrack mounting, seven HU (height units)

conjunction with PCU 50: 100mm + 10mm free space

S Mechanical short-stroke keys with alpha, numeric, cursor, control and
hotkey key groups
S Soft keys:
1x eight horizontal row of keys with soft key functions
1x eight vertical row of keys with soft key functions


S Degree of protection IP 54

5 Operator Panel Front OP 010C 10.00
5.1 Front view
5.1 Front view
Status LEDs: POWER TEMP *) Screw hole

for fastening
screws (avail-
able soon)
Alpha key
group
Softkeys
Numerical
key group
Cursor
key group
Control
key group
USB
front
Soft keys interface
Recall Machine area ETC key Area switchover Hotkeys
Fig. 5-1 Front view of operator panel front OP 010C
Fig. 5-1 shows the front view of the OP 010C operator panel front.

10.00 5 Operator Panel Front OP 010C

groups:
S The Alpha key group contains the letters A, ..., Z and the blank.
S The numerical key group contains the digits 0 ... 9, the character and the
decimal point.

S The hotkey block is used for the direct selection of operating areas.

Esc End
F11 Backspace
F12 Tab

Home Ctrl key
Page up Alt key
Page down Delete
Cursor up Insert
Cursor down F10


OFFSET
Alarm
Reserved Reserved
PROGRAM
Reserved Program
MANAGER Reserved
Tool
CUSTOMER
Reserved Offset Reserved

5.3 Interfaces
5.3 Interfaces
5.3.1 Arrangement
The OP 010C operator panel front provides the following interfaces:
Front The USB front interface (see Fig.5-1) for connecting an external keyboard or
mouse is to be found on the front.
Note
mended.
S Two ribbon cables for connecting the PCU are to be found:

I/O USB cable K1:
necting operator panels.
Display cable K2
S Interface X11, reserved.
PCU 50
main board
PCU 50
IO USB
cable K1
Display OP 010C
cable K2
Fig. 5-2 OP 010C connections on the casing rear: PCU 50 connections

5.3 Interfaces
Keyboard
controller
Interface
X11
(reserved)
Interface
X12
(reserved)
Connection X1 for IO USB cable K1 Connection of backlighting
Fig. 5-3 OP 010C connections on the casing rear: Customer interface
5.3.2 Assignment
USB front interface


Signal type

5.4 Installation
5.4 Installation
When combining OP 010C and PCU 50, it is recommended to install them in an
assembly panel prior to installation.
5.4.1 Assembling OP 010C and PCU 50
Width = 483
Top
1) 1)
Display
support plate
Height = 310
Cover plate for
connections
Keyboard control-
ler
Display
cable K2 2)
I/O USB 1)
1)
cable K1 2)

2) Cables shown folded Casing screws
Fig. 5-4 Operator panel rear with position of the interfaces,

the mounting slots
1. Put the OP 010C with the front on a horizontal, soft surface.

mounting rails into the appropriate mounting slots (Fig. 4-4) of the OP 010C.
4. Insert the cable connectors K1 and K2 of the OP 010C into the correspond-
Make sure that the connectors lock in audibly and the locks are closed.
(torque 1.8Nm).

5.4 Installation
Table 5-2 Dimensions of the mounting hole (see Fig.5-5)

used (mm)
PCU 50 450 290 100 + 10
Thanks to the tension jacks fastening the OP 010C, holes or screw holes are
not needed.
Tension jacks
**)
112.5* 77.75* 77.75* 112.5* **)
450 +1
290 +1
112.5*
235 +0.2
0.2
Setscrews
56.25*
5
**)
Front
**)
465 +0.2
0.2
1.5 min to 6 max
*) dimensions for pressure points
of the tension jacks
**) holes for screw fastening Assembly panel Sealing area (front)
Fig. 5-5 Dimension sheet for installing the OP 010C operator panel front
5.4.3 Installation
1. Insert the assembled components OP 010C and PCU from the front into the
panel cutout.
2. Locate the operator panel front in the panel cutout from the rear using the
six tension jacks (see Fig.5-5) by tightening the setscrews (torque 0.4 ...
0.5Nm).

5.4 Installation
Note
To do so, break through the edge of the OP 010C at the four intended positions
(see Fig. 5-1 and 5-5).
Clearance The clearance on the PCU rear should amount to a minimum of 10mm to make
sure that sufficient ventilation is provided (see Fig.5-6).
17.3
38.7
Clips

Required clearance
Mounting rail
for ventilation
333
297
10
PCU in end position
35.8
100+3
20
Mounting rail
46.3
10
100.1 313.4 69.1
OP 010C
Fig. 5-6 Attaching the PCU to the OP 010C operator panel front (viewed from above)

5.5 Changing key covers of short-stroke keys

The key covers for the vertical soft keys (short-stroke keys) can be replaced for
the product SINUMERIK 840D/810D ManualTurn.
They are included in the scope of supply.
Procedure:
1. Lever off the key cover of the short-stroke key.
2. Press new key cover onto the frame of the short-stroke key.

Spare parts for the OP 010C are (see Fig. 5-7):

Sealing cap for the

USB connection
Fig. 5-7 Spare parts for the OP 010C operator panel front

5.7 Technical data
5.7 Technical data

Safety
Voltage 5V +/ 5% 12V +/10% 5.2V +/ 2%
Current 280/380 750/1000 350 1)/1000 2)/
(typ. /max. mA; approx.) 1200 3)
Power consumption approx. 13Wtypical approx. 22Wmaximum
Mechanical data
Dimensions Width 483mm Height 310mm Depth 110mm
(overall dimensions)
Weight approx. 5kg
Max. tightening torques screws: 0.8Nm 1.8Nm
0.5Nm
010C + PCU 50, tested to DIN 58200Hz: 9.8 m/secs2 9200Hz: 9.8 m/secs2
IEC 6826)
tem OP 010C + PCU 50, 18 shocks 18 shocks
0 ... 40C (front) 20 ... 60C
0 ... 55C (rear)
DIN IEC 68-2-14

J

5.7 Technical data
Notes

(Order No. 6FC5 203-0AF02-0AA0) 6
Brief description The OP 012 operator panel front described in the following is characterized by:


S Membrane keyboard with alpha, numeric, cursor and control keygroups
S Soft keys/direct control keys:
2x eight horizontal rows of keys with soft key functions
2x eight vertical rows of keys with soft key and direct control key func-
tions
Direct control keys via direct control key submodule (optional), PP031
MC or directly connectable to the I/Os

S Integrated mouse

6.1 Front view
6.1 Front view
Status LEDs: POWER TEMP *) Screw hole

for fastening
screws (avail-
able soon)
Softkeys and direct control keys

Alpha key
group
Numerical
key group
Cursor
key group
Control
key group
USB
front
Soft keys interface
Recall Machine area ETC key Area switchover Mouse
Fig. 6-1 shows the front view of the OP 012 operator panel front.


groups:
S The ALPHA key group contains the letters A, ..., Z and the blank.
decimal point.

S The mouse consists of the actuation field (corresponds to the function of a
track ball) and two mouse buttons.

Esc End
F11 Backspace
F12 Tab

Home Ctrl key
Page up Alt key
Page down Delete
Cursor up Insert
Cursor down F10



6.3 Interfaces
6.3 Interfaces
6.3.1 Arrangement
on the front.
Note
mended.

I/O USB cable K1:
Display cable K2
S Interface X11, normally hidden under the cover plate (Fig. 6-4):
Signals from the 16 direct control keys vertical soft keys.
PCU 50
PCU 50 main board
Cable clamp
for connection
of direct control
key submodule
Keyboard
controller
IO USB
cable K1
Direct control
key interface
X11
Interface
X12 (reserved)
OP 012
Display cable K2 Connection X1 for IO USB cable K1 Connection of backlighting

6.3 Interfaces
6.3.2 Assignment
USB front interface


Signal type
X11: 2x8 vertical The control states of the vertical direct control keys can be picked up here with-
direct control keys out firmware. These signals can be evaluated in the direct control key submo-
dule and in pushbutton operator panel fronts (e.g. PP031MC) with opto-iso-
lated inputs.
Connector to DIN 41651 plug connector, cable length max. 0.5m.
Table 6-2 Assignment of interface X11: 2 x 8 vertical direct control keys

1, ..., 16 DT 1, ..., 16 O Data output of direct control keys #1, ...,
16
17 P5V_D_fused V +5V (fused)
19 GND V Ground
20 GND V Ground
DT1 DT9
DT2 DT10
DT3 DT11
DT4 DT12
DT5 DT13
DT6 DT14
DT7 DT15
DT8 DT16
Fig. 6-3 Assignment of direct control keys

6.4 Installation
6.4 Installation
When using OP 012 and PCU 50 and also possibly a direct control key submo-
dule in combination (see Subsection 6.4.2), it is recommended to install them in
an assembly panel before final installation.
Width = 483
Top
Display 3) 3) 3) 1) 3)
1) 4) 4)
support plate
Cover plate for

connections 3) 3)
Keyboard controller
Height = 310
Cable
clamp 3) 3)
Display 4)
cable K2 2)
1)
3) 1) 4)
3) 3) 3)
I/O USB
cable K1 2)
1) Mounting slots for PCU straps 2) Cables shown folded 3) Casing screws
4) Slots for soft key labeling strips
Fig. 6-4 OP 012 reverse side
1. Put the OP 012 with the front on a horizontal, soft surface.

To install the direct control key connection see Subsection 6.4.2.
To install or replace the soft key labeling strips, see Section 6.5.
mounting rails into the mounting slots (Fig. 6-4) of the OP 012.
4. Insert the cable connectors K1 and K2 of the OP 012 into the corresponding
mating pieces behind the opening in the PCU 50 casing (see Fig. 6-2).
(torque 1.8Nm).

6.4 Installation
6.4.2 Direct control key submodule
Brief description The task of the direct control key submodule is to directly transfer the operating
signals for the two rows of keys on the side of the OP 012 (see Fig. 6-3) to SI-
MATIC without diversion through intermediate firmware.
The OP 012 outputs the signals from the two rows of keys on the side on its X11
terminal (see Fig. 6-2).
The direct control key submodule converts the key signals to PROFIBUS DP
protocol by means of the ASIC LSPM2 (PROFIBUS DIN 19245 Part 1, 12
Mbaud).
Power is supplied from the OP 012 PROFIBUS is completely isolated from the
direct control key submodule/OP 012 by means of an opto-coupler and DC/DC
converter.
The direct control key submodule operates as a slave on PROFIBUS. The ad-
dress can be set between 1 and 99 using a rotary switch. Two bytes of data are
transferred.
In SIMATIC, the keys are handled as if they were 16 ordinary digital inputs.
Assembly The direct control key submodule is installed to one side of the PCU50 on the
OP 012 and connected to the keyboard controller via a short ribbon cable.
1. Deinstall the PCU (if it is already installed) by removing the knurled-head
screws at the four corners and lifting off the PCU.
2. Remove the ribbon cable clamp alongside the keyboard controller cover
(see Fig. 6-4), by inserting a pointed tool in each of the two slits and loosen-
ing the fixing cams by levering in the direction shown (see Fig. 6-5).
OP 012
Tilting motion of
tool
Previous cover plate
Rubber rim
Cable
clamp
Fig. 6-5 Removing the cable clamp from the OP 012
3. Unscrew the keyboard controller cover plate.

The cover plate is no longer required because it will be replaced by a new
cover supplied with the direct control key submodule that is complete with
fixing nipples (see Step 6.).

6.4 Installation
4. Remove the rubber rim from the edge of the housing cutout (for fixing a
pushbutton panel ribbon cable) (see Fig. 6-5).
5. Insert the end of the ribbon cable supplied with the direct control key submo-
dule that is not rubber coated through the slit of the supplied cover into the
X11 socket of the keyboard controller (see Figures 6-2 and 6-6).
New cover plate
Fixing nipple for

direct control key
submodule
OP 012
Cable to the direct

control key sub-
module
Fig. 6-6 Installation of the direct control key submodule on the OP 012
6. Screw down the new cover tightly using the supplied screws.
7. Install the PCU as described in Subsection 6.4.1, Step 2. onwards.
8. Set the PROFIBUS address 01 to 99 on the coding switches of the direct
control key submodule (see Fig. 6-7; upper/lower coding switch:
Single/Block of ten).
Direct control key submodule
Coding switch
LEDs
Connection for
cable from OP 012
(not visible)
Fig. 6-7 Direct control key submodule complete with coding switches and LEDs

6.4 Installation
PCU 50
Direct control key

submodule
Cable from OP 012

to direct control
key submodule
OP 012
Cover plate
Fastening
screws
Fixing nipple for di-

rect control key sub-
module
Fig. 6-8 Installation of the direct control key submodule on the OP 012
9. Connect the ribbon cable to the direct control key submodule (in Fig. 6-8 out
of view on the rear).
10. Screw the direct control key submodule firmly to the cover using the knurled
screws on the side (see Fig. 6-8).
Figure 6-9 shows the completely assembled unit comprising OP 012, PCU 50
and direct control key submodule:
PCU 50
Direct control key

submodule
PROFIBUS
connection
OP 012
Fig. 6-9 Installed direct control key submodule
11. Insert the PROFIBUS plug (with straight outgoing cable) into the socket of
the direct control key submodule (see Fig. 6-9).
When the direct control key submodule is disconnected from PROFIBUS (or in
the event of other faults), the bus error LED is lit (see Fig. 6-7).
The direct control key submodule must be removed first on deinstallation of the
PCU.

6.4 Installation
6.4.3 Installation preparation
Table 6-3 Dimensions of the mounting opening (see Fig. 6-10)

used (mm)
PCU 50 450 290 100 + 10
needed.
only in conjunction with a circulating seal and with the sealing cap of the USB
interface fitted).
Tension jacks
**)
112.5* 77.75* 77.75* 112.5* **)
450 +1
290 +1
112.5*
235 +0.2
0.2
Setscrews
56.25*
5
**)
**)
465 +0.2
0.2
*) dimensions for pressure points 1.5 min to 6 max
of the tension jacks
**) holes for screw fastening Assembly panel Sealing area
6.4.4 Installation
1. Insert the preassembled OP 012 components (complete with any direct con-
trol key submodule; see Subsection 6.4.2) and the PCU into the panel cut-
out from the front.
2. Fix the operator panel front in the panel cutout from the rear using the six
tension jacks (see Fig. 6-10) by tightening the setscrews (torque
0.40.5Nm).

6.4 Installation
Note
To do so, break through the edge of the OP 012 at the four intended positions
(see Fig. 6-1 and 6-10).
In this case, however, you should note that the operator panel front will no lon-
ger comply with degree of protection IP65, but with IP54.

17.3
38.7
Clips

Required clearance
Mounting rail
for ventilation
333
297
10
PCU in end position

35.8
100+3
20
Mounting rail
46.3
10
100.1 313.4 69.1
OP 012
Fig. 6-11 Attaching the PCU to the OP 012 operator panel front (viewed from above)


The two vertical and two horizontal soft key bars can be assigned user-specific
functions. You can use printed labels to identify the soft keys.
Making the labels To make the labels, DIN-A4 filmis available (Order No., see Section 6.6).
Procedure:
1. Letter the dull side of the film using a laser printer.
2. Cut the printed labels along the preprinted lines.
tor panel.
4. Slide the labels from the rear of the operator panel into the intended slots
(see Fig. 6-4).


(without LCD unit, without mouse, without keyboard controller, without direct
control key submodule)
S USB mouse Order No. 6FC5 247-0AF01-0AA0
S Direct control key submodule Order No. 6FC5 247-0AF11-0AA0

S DIN A4 film for slide-in user labels Order No. 6FC5 248-0AF08-0AA0
Soft key slide-in labels
Backlight with
backlight
inverter
Direct control key

submodule
LCD unit
Display holder
Keyboard controller
Front plate Mouse Sealing cap for the

USB connection

Caution
Operator panel When changing the front plate, the existing mouse, LCD unit and keyboard con-
front/mouse troller can be reused and are therefore removed and installed again after the
front panel has been changed. The following description therefore applies both
to the operator panel front and for the mouse.
Note
Procedure:
1. Put the OP 012 with the front side on a horizontal, soft surface and loosen
2. Remove the soft key slide-in labels and the cover plate (see Fig. 6-4).
3. Remove the following connectors from the keyboard controller (see
Fig. 6-13): Backlight (base X14) and IO USB cable K1.
In addition to the keyboard controller, the rear sides of mouse and USB in-
terface become visible.
USB interface
Connection X1 Keyboard controller
Mouse for IO USB cable K1
Connection X11
Membrane connector
for connecting the key-
Connection X4 board of the
for mouse operator panel front
Connection X14 for

backlight
Connection X12
(reserved)

6. Loosen the three membrane connectors of the operator panel front key-
board from the sockets X7, X8 and X10 as follows:
Carefully pull off the membrane connector upward.
Clamping frame
of socket
Fig. 6-14 Changing the operator panel front: Loosening a membrane connector
7. Loosen the fastening screws from mouse and keyboard controller.

8. Lift USB interface, mouse and keyboard controller off the front plate. The
interconnections may remain plugged.
9. Install these components in the new operator panel front in reverse order.
Note
When reattaching the membrane connectors of the USB and keyboard in-
terfaces, observe the following order: With the clamping frame lifted, care-
fully insert the connector into the socket; then press the clamping frame
Technical data).
Fig. 6-15 Changing the front plate: Attaching a membrane connector
Film labels The procedure for replacement is described in Section 6.5.

6.7 Technical data
6.7 Technical data

Safety
Degree of protection Front IP 65/IP54 1) Rear IP 00
Voltage 5V +/ 5% 12V +/10% 5.2V +/ 2%
Current 280/380 750/1000 350 2)/1000 3)/
(typ. /max. mA; approx.) 1200 4)
Mechanical data
Weight approx. 4.8kg
Tension jack M3 screws: M4 screws: 1.8Nm
Max. tightening torques screws: 0.8Nm
0.5Nm
012 + PCU 50, tested to DIN 58200Hz: 9.8 9200Hz: 9.8 m/secs2
IEC 68-2-6) m/secs2
to DIN IEC 68-2-29)
0 ... 40C (front) 20 ... 60C
0 ... 55C (rear)
DIN IEC 68-2-14
1) IP54 when fastened with screws.

4) Max. value incl. load on USB front connector and 16-bit direct control keys.
J

6.7 Technical data
Notes

Touch Panel TP 012 7
Brief description The TP 012 operator panel front described in the following is characterized by:
S Subrack mounting 400x310mm, seven HU (height units)

S Color display (touchscreen) incl. backlight in

12.1 TFT technology with resolution of 800x600 pixels

S Front USB interface (Version 1.2)
S Can be combined with the component PCU 50:
centralized configuration (described in this chapter)
distributed configuration (see Chapter Distributed Installation).
Operation The panel is operated by touching the applicationspecific functions shown on

the touchsensitive display, e.g. by touching a displayed button.
Note
The touch panel TP 012 can be used in conjunction with customerspecific
HMI software.

7 Touch Panel TP 012 11.02
10.00
7.1 Front view
7.1 Front view
Status LEDs: POWER TEMP (If lit, panel is subject to greater wear)
Front USB interface for connecting

an external keyboard or mouse
Fig. 7-1 Front view of touch panel TP 012

11.02
10.00 7 Touch Panel TP 012
7.2 Interfaces
7.2 Interfaces
7.2.1 Arrangement
Front USB interface (Version 1.2) (see Fig. 7-1) allowing the following devices to be
connected on the front:
Table 7-1 Possible connections for the USB interface
Operating system Possible connections

Windows NT 4.0 Mouse, keyboard, USB floppy disk drive
Windows 98/2000/XP All devices supported by USB 1.2
Note
mended.
I/O USB cable K1:

Display cable K2.
PCU 50
IO USB
cable K1
Display cable K2
TP 012
Fig. 7-2 TP 012 connections on the casing rear: PCU 50 connections

10.00
7.2 Interfaces
7.2.2 Assignment
USB front interface


Signal type

11.02
7.3 Installation
7.3 Installation
With centralized installation, the operator unit (TP 012) and the processing unit
(PCU 50) are connected to each other using the piggyback method. It is advis-
able to connect the units prior to installation in an assembly panel.
7.3.1 Assembling TP 012 and PCU 50
Width = 400
Top
2)
1) 1)
1) Mounting slots for Test label
PCU straps 2)
2) Casing screws
2) Display
Height = 310
cable K2
Nameplate
1)
2)
IO USB
cable K1 1)
Fig. 7-3 TP 012 reverse side
1. Put the TP 012 with the front on a horizontal, soft surface.

mounting bracket into the mounting slots (Fig. 7-3) of the TP 012.
4. Insert the cable connectors K1 and K2 of the TP 012 into the corresponding
(torque 1.8Nm).

10.00
7.3 Installation

used (mm)
PCU 50 368 290 125 + 10
Thanks to the tension jacks fastening the TP 012, holes or screw holes are not
needed.
interface fitted).
1.5mm to 6mm
Sealing area A11
A2 1
112 0.5 S1 1 S2 1 112 0.5

Pressure points
for tension jacks
112 0.5
L2 +1
56 1
Rz 120
L1 +1
S1 1 S1 1
in the sealing area

L1 L2 S1 S2 A1 A2
368 290 35 19 16 10 Dimensions in mm
Fig. 7-4 Dimension sheet for installing the TP 012 operator unit
7.3.3 Installation
1. Insert the assembled components TP 012 and PCU 50 from the front into
the panel cutout.
2. Locate the touch panel in the panel cutout from the rear using the six ten-
sion jacks (see Fig. 7-4) by tightening the setscrews (torque 0.4 ... 0.5Nm).

11.02
7.3 Installation
Clearance The clearance at the PCU rear side must be at least 10mm to make sure that
sufficient ventilation is provided (see Fig. 7-5).
17.4
50.1

Required clearance
for ventilation
Mounting bracket
353
297
10
PCU in end position

125+3
Mounting bracket
55.9
36
28.6 33
10
313.6 57.8
TP 012
Fig. 7-5 Attaching the PCU to the TP 012 touch panel (viewed from above)

10.00
Spare parts for the TP 012 are (see Fig. 7-6):
S SINUMERIK operator panel front without LCD unit for SINUMERIK TP 012
(front panel + touchscreen) Order No. 6FC5 248-0AF16-0AA0
S Sealing caps Order No. 6FC5 248-0AF05-0AA0

Note
A sealing cap for the USB connection is factory-fitted on all initial orders.
Housing
Display
Touchscreen *)
Keyboard controller
Backlight inverter
for backlight
Display holder
Sealing cap for USB

connection *)
Front panel *) *) Spare parts
Fig. 7-6 Components of TP 012 touch panel

11.02
Caution
Front panel If the front panel only is to be replaced, the display, touch controller, USB mod-
ule and keyboard controller can be reused. These components are therefore
detached and then reattached following replacement of the front panel.
Note
Procedure:
1. Put the TP 012 with the front side on a horizontal, soft surface and loosen
2. Unplug the following connectors (see Fig. 7-7):
from keyboard controller:
Backlight (base X14), IO USB cable K1, membrane connector and con-
nection to USB module
Connection from touch controller to touchscreen
3. Remove the screws from the display holder.
6. Install these components in the new front panel in reverse order.
Note
When reattaching the membrane connector of the USB interface, observe
the following order: With the clamping frame lifted, carefully insert the con-
nector into the socket; then press the clamping frame down to lock it in
place (see Spare part replacement for OP 012).
Technical data).

10.00
Display holder
IO USB cable K1
Base X14
Backlight
Membrane connector
Touch controller
USB module
Keyboard controller

11.02
7.5 Technical data
7.5 Technical data

Safety
Power supply (via I/O Touchscreen Backlight in- Logic/USB
Voltage 5V +/ 5% 12V +/10% 5.2V +/ 2%
Current (typ./max. in mA) 280/380 750/1000 350 1)/1000 2)
Mechanical data
0.5Nm
Vibration (whole system 1058Hz: 0.075mm 59Hz: 3.5mm
TP 012 + PCU 50, tested to 58200Hz: 9.8 m/secs2 9200Hz: 9.8 m/secs2
DIN IEC 68-2-6)
tem TP 012 + PCU 50, tested 18 shocks 18 shocks
to DIN IEC 68-2-29)
Temperature limit values 5 ... 45C 20 ... 60C
DIN IEC 68-2-14

J

10.00
7.5 Technical data
Notes

(Order No. 6FC5 203-0AF03-0AA0) 8
Brief description The OP 015 operator panel front described in the following is characterized by:

S 15 TFT flat screen (color) with a resolution of 1024 x 768 pixels

S Membrane keyboard:
Eight horizontal soft keys
Eight vertical soft keys

S Degree of protection: IP65
S External floppy disk drive can be connected via PCU.

8.1 User interface
8.1 User interface
Soft keys
USB
front
interface
Soft keys
Machine area Recall ETC key Area
switchover
Fig. 8-1 shows the user interface of the OP 015:
S the 15 display
S the USB front interface
S eight vertical and horizontal soft keys
S four control keys with the following functions:
<Shift> F10 F9
<Shift> F9 F10

8.2 Interfaces
8.2 Interfaces
8.2.1 Arrangement
on the front.
Note
mended.
S I/O USB cable K1: All signals that in addition to the display interface are
used for connecting operator panels.
S Display cable K2.
PCU 50
main board
PCU 50
Cover plate for keyboard

IO USB
controller
cable K1
(see Fig. 8-7)
OP 015
Display
cable K2
8.2.2 Assignment
USB front interface


1 USB_P5V_fused V +5V (fused) for ext. USB interf.
Signal type B: Bidirectional V: Voltage

8.3 Installation
8.3 Installation
When combining OP 015 and PCU 50, it is recommended to install them in an
assembly panel prior to installation.
483
Top 2) 2) 2) 1)
1)
Casing
cover plate
3) 3)
Cover plate for
connections
310
Keyboard con-
troller
3) 3)
Display
cable K2
1)
IO USB 2) 2) 2) 1)
cable K1

2) Casing screws M3
3) Casing screws M4
Fig. 8-3 Rear side of operator panel front with allocation of interfaces and mounting slots
1. Put the OP 015 with the front on a horizontal, soft surface.

mounting rails into the appropriate mounting slots (Fig. 8-3) of the OP 015.
4. Insert the cable connectors K1 and K2 of the OP 015 into the corresponding
(torque 1.8Nm).

8.3 Installation

used (mm)
PCU 50 450 290 130 + 10
needed.
interface fitted).
1.5 min 6max
Sealing area A11
A2 1
112 0.5 L3 1 L3 1 112 0.5

Pressure points
for tension jacks
112 0.5
L2 +1
56 1
Rz 120
L1 +1
in the sealing area

L1 L2 L3 A1 A2
450 290 81 16 10
8.3.3 Installation
1. Insert the assembled components OP 015 and PCU from the front into the
panel cutout.
six tension jacks (see Fig. 8-4) by tightening the setscrews (torque 0.4 ...
0.5Nm).


8.3 Installation
B 1
267 0.5
H 0.5
Clearance for cables and ventilation
PCU 90o tilted off

Additional clearance for connection cables
(for 840Di only)
K
10
T +3
PCU in end position
297 0.5 A2
T2 0.5
U
10 0.5
L 0.3
Operator panel front

L H T T2 A B U K
483 310 130 42 87 23 22 220
All dimensions without the screws protruding
Fig. 8-5 Attaching the PCU to the OP 015 operator panel front


(without LCD unit, without USB interface, without keyboard controller)

Front plate
Backlight with
backlight
inverter
LCD unit
Display holder with

keyboard controller
Sealing cap for the (rear)
USB connection
Caution
the following, since it is easy and self-explaining.

Front plate When changing the front plate, the existing USB interface and the display
holder (with display, backlight inverter and keyboard controller) can be reused.
Procedure:
1. Put the OP 015 like the replacement front plate with the front on a horizontal,
soft surface.
2. Loosen the casing screws (see Fig. 8-3) and remove the casing cover plate.
The display holder with the keyboard controller (Fig. 8-7) will be visible un-
derneath and, in a cutout of the mounting plate, the rear side of the USB
interface (Fig. 8-9).
Membrane lines
Connection X11 from the operator
(reserved) panel front keyboard
IO USB cable K1
Connection X4
(reserved)
Connection X14
for display and
back-lighting
USB membrane line
Connection X12
(reserved)
X10 X8 X7
Connections for opera-
Display cable K2 tor panel front keyboard
Fig. 8-7 Keyboard controller
3. Loosen the membrane connectors of the operator panel front keyboard from
the sockets X7, X8 and X10 as follows:
Carefully pull out the membrane end upwards.
Clamping frame
of socket
Fig. 8-8 Changing the operator panel front: Disconnecting a membrane connection

4. Loosen the membrane connection of the USB connection cable (Fig. 8-9) as
described under Point 3.
Display holder
Fastening screw M4 USB membrane line

(see Fig. 8-7)
USB interface
Fig. 8-9 USB interface viewed from the operator panel rear side
5. Loosen the screws of the display holder and lift it off.

6. Pull the USB interface off its seat and insert it into the replacement front
plate.
7. Place the display holder on the replacement front plate.
8. Assemble the operator panel front in reverse order.
Note
When reattaching the membrane connections of the USB and keyboard
interfaces, observe the following order: With the clamping frame lifted, carefully
insert the end of the membrane into the socket; then press the clamping frame
Technical data).
Fig. 8-10 Changing the front plate: Connecting a membrane connection

8.5 Technical data
8.5 Technical data

Safety
Voltage 5V +/ 5% 12V +/10% 5.2V +/ 2%
Current (typ. /max. mA; 420/600 900/1050 350 1)/1000 2)
approx.)
Mechanical data
015 + PCU 50, tested to DIN 58200Hz: 9.8 m/secs2 9200Hz: 9.8m/secs2
IEC 68-2-6)
to DIN IEC 68-2-29)
0 ... 40C (front) 20 ... 60C
0 ... 55C (rear)
DIN IEC 68-2-14
1) Typ. value with 100mA load (low power device) on the USB front connector.
2) Max. value with 500mA load (high power device) on the USB front connector.
J

Operator Panel Front OP 015A
(Order No. 6FC5 203-0AF05-0AA0) 9
Brief description The OP 015A operator panel front described in the following is characterized
by:
S 19 subrack mounting, eight HU (height units)

S Panel cutout (WxH): 450x321mm
conjunction with PCU 50: 130mm ( + 10mm clearance for ventilation)
S 15 TFT flat screen (color) with a resolution of 1024x768 pixels

S Membrane keyboard with alpha, numeric, cursor and control keygroups
S Soft keys/direct control keys:
2x eight horizontal rows of keys with soft key functions
2x eight vertical rows of keys with soft key and direct control key
functions
Direct control keys via direct control key submodule (optional), PP031
MC or directly connectable to the I/Os

S Integrated mouse
S Can be combined with the component PCU 50.

9 Operator Panel Front OP 015A 10.00
9.1 Front view

Alpha key
group
Numerical
key group
Cursor
Soft keys key group
Control
key group
USB
front
interface
Recall Machine area Area switchover ETC key Mouse
Fig. 9-1 Front view of the OP 015A operator panel front

groups:
S The ALPHA key group contains the letters A, ..., Z and the blank.
decimal point.

S The mouse consists of the actuation field (corresponds to the function of a
track ball) and two mouse buttons.
The functions of the keys are described in detail in Section Description of key-
board of Chapter Operator Panel Front OP 012.

10.00 9 Operator Panel Front OP 015A
9.3 Interfaces
9.3 Interfaces
9.3.1 Arrangement
The OP 015A operator panel front provides the following interfaces:
on the front.
Note
mended.
Rear On the rear (see Fig. 9-2):

I/O USB cable K1:
Display cable K2
S Interface X11, normally hidden under the cover plate (Fig. 9-4):
Signals from the 16 direct control keys vertical soft keys.
PCU 50
PCU 50 main board
Cable clamp
for connection
of direct control
key submodule
IO USB
cable K1 Keyboard
controller
Direct control
key interface
X11
Interface
OP 015A X12 (reserved)
Display cable K2 Connection X1 for IO USB cable K1 Connection of backlighting
Fig. 9-2 OP 015A connections on the casing rear: PCU 50 connections

9.3 Interfaces
9.3.2 Assignment
USB front interface


2 USB_D0M Data, USB channel 0
B
3 USB_D0P Data+, USB channel 0
Signal type
X11: 2x8 vertical The control states of the vertical direct control keys can be picked up here with-
direct control keys out firmware. These signals can be evaluated in the direct control key submo-
dule and in pushbutton panels (e.g. PP031MC) with opto-isolated inputs.
Connector to DIN 41651 plug connector, cable length max. 0.5m.
Table 9-2 Assignment of interface X11: 2 x 8 vertical direct control keys

1, ..., 16 DT 1, ..., 16 O Data output of direct control keys #1, ..., 16
19 GND V Ground
20 GND V Ground
DT1 DT9
DT2 DT10
DT3 DT11
DT4 DT12
DT5 DT13
DT6 DT14
DT7 DT15
DT8 DT16
Fig. 9-3 Assignment of direct control keys

9.4 Installation
9.4 Installation
When using OP 015A and PCU 50 and also possibly a direct control key sub-
module in combination (see Subsection 9.4.2), it is recommended to install them
in an assembly panel before final installation.
9.4.1 Assembling OP 015A and PCU 50
Width = 483
Top
3) 3) 4) 3) 3) 3) 4)
Display sup- 1) 1) 3)
port plate
3)
3)
Cover plate for
connections
Height = 355
Keyboard controller
Cable
clamp
3)
3) 4)
Display 1)
cable K2 2)
1)
3) 3) 3)
3)
I/O USB
cable K1 2)
1) Mounting slots for PCU straps 2) Cables shown folded 3) Casing screws
4) Slots for soft key labeling strips
Fig. 9-4 OP 015A reverse side
1. Put the OP 015A with the front on a horizontal, soft surface.

To install the direct control key connection see Subsection 9.4.2.
To install or replace the soft key labeling strips, see Section 9.5.
mounting rails into the mounting slots (Fig. 9-4) of the OP 015A.
4. Insert the cable connectors K1 and K2 of the OP 015A into the correspond-
(torque 1.8Nm).

9.4 Installation
9.4.2 Direct control key submodule
Brief description The task of the direct control key submodule is to directly transfer the operating
signals for the two rows of keys on the side of the OP 015A (see Fig. 9-3) to
SIMATIC without diversion through intermediate firmware.
The OP 015A outputs the signals from the two rows of keys on the side on its
X11 terminal (see Fig. 9-2).
The direct control key submodule converts the key signals to PROFIBUS DP
protocol by means of the ASIC LSPM2 (PROFIBUS DIN 19245 Part 1, 12
Mbaud).
Power is supplied from the OP 015A PROFIBUS is completely isolated from the
direct control key submodule/OP 015A by means of an opto-coupler and
DC/DC converter.
The direct control key submodule operates as a slave on PROFIBUS. The ad-
dress can be set between 1 and 99 using a rotary switch. Two bytes of data are
transferred.
In SIMATIC, the keys are handled as if they were 16 ordinary digital inputs.
Assembly Assembly is described in Chapter Operator Panel Front OP 012 in Section

Direct control key submodule.

9.4 Installation
Table 9-3 Dimensions of the mounting hole (see Fig.9-5)

used (mm)
PCU 50 450 321 130 + 10
Thanks to the tension jacks, holes or screw holes are not needed.
interface fitted).
1.5 min 6 max

S5 0.5
0.5
S4
S6 0.5
A1 1
S3 0.5 S3 0.5
1
Sealing
A2
1 area
112 0.5 L3 1 L3 112 0.5

Pressure points
for tension jacks
L2 +1
L5 0.2
112 0.5
56 1

Hole for
Rz 120
screw fastening
M6/ 7
L1+1 in the sealing area

0.2
L4
Sizes L1 L2 L3 L4 L5 A1 A2 S3 S4 S5 S6 Assembly panel

in mm 450 321 51 465 279 16 17 24 186 135 5
Fig. 9-5 Dimension sheet for installing the OP 015A operator panel front

9.4 Installation
9.4.4 Installation
1. Insert the preassembled OP 015A components (complete with any direct

control key submodule; see Subsection 9.4.2) and the PCU into the panel
cutout from the front.
six tension jacks (see Fig.9-5) by tightening the setscrews (torque 0.4 ... 0.5
Nm).
Clearance The clearance on the PCU rear should amount to a minimum of 10 mm to make
sure that sufficient ventilation is provided (see Fig.9-6).
17.4
PCU 50 swung round 90
Required clearance
Clips
for ventilation
Mounting rail
358.7
297
10
PCU 50 in end position

127
Mounting rail
61.5
42
10
57.5 27.5
88.8 313.6 80.3
OP 015A
Fig. 9-6 Attaching the PCU 50 to the OP 015A operator panel front (viewed from above)


The two vertical and two horizontal soft key bars can be assigned user-specific
functions. You can use printed labels to identify the soft keys.
Making the labels If required, you can have new labels prepared and printed by Rafi or a screen-
printing shop. See Fig. 9-7 for dimensions.
391.65
353.50
279.00
16.00
Dimensions in mm
Fig. 9-7 Set of slide-in labels
Inserting the labels Procedure:
tor panel front.
2. Slide the labels from the rear of the operator panel front into the intended
slots (see Fig. 9-4).

9.6 Spare parts
9.6 Spare parts
Spare parts for the OP 015A are (see Fig. 9-8):
Designation Order number Note

without LCD unit, without mouse,
without keyboard controller,
Front plate 6FC5 248-0AF15-0AA0
without direct control key submo-
dule
USB mouse 6FC5 247-0AF01-0AA0
Direct control
key submo- 6FC5 247-0AF11-0AA0
dule
Sealing caps 6FC5 248-0AF05-0AA0 for USB connection (10 pcs.)
Tension jack
6FC5 248-0AF06-0AA0 6 pcs.
set
for PCU or videolink
Mounting
6FC5 248-0AF20-2AA0 receiver behind operator panel
bracket
front (2 pcs.)
for PCU and videolink transmitter
Mounting
6FC5 248-0AF20-3AA0 behind operator panel front (2
bracket
pcs.)
Front plate Backlight with

backlight
inverter
Direct control key

submodule
LCD unit
Display holder
Sealing cap for the
USB connection Mouse Keyboard controller
Fig. 9-8 Spare parts for the OP 015A operator panel front

9.6 Spare parts
Caution
The replacement of USB sealing cap and tension jacks is self-explanatory and
is therefore not described.
The replacement of the front panel and the mouse is described in Chapter Op-
erator Panel Front OP 012 in Section Spare part replacement.

9.7 Technical data
9.7 Technical data

Safety
Power supply (via I/O Display Backlight Logic/USB
USB cable and display cable) inverter
Voltage 5V +/ 5% 12V +/10% 5.2V +/ 2%
Current (typ. /max. mA; 280/380 750/1000 350 1)/1000
approx.) 2)/1200 3)

Mechanical data
Weight approx. 9kg
0.5Nm
Vibration (whole system 1058Hz: 0.075mm 59Hz: 3.5mm
OP 015A + PCU 50, tested to 58200Hz: 9.8 m/secs2 9200Hz: 9.8 m/secs2
DIN IEC 68-2-6)
tem OP 015A + PCU 50, 18 shocks 18 shocks
0 ... 40C (front) 20 ... 60C
0 ... 55C (rear)
DIN IEC 68-2-14

3) Max. value incl. load on USB front connector and 16-bit direct control keys.
J

SINUMERIK Operator Panel Front 15 TFT,
Width 416mm 10
10.1 Overview
The SINUMERIK operator panel front 15 TFT (width 416mm) consists of
S an operator panel front,

S a machine control panel (MCP) with CNC keyboard (QWERTY) with integrated
mouse.
The PCU belonging to the overall system (see Fig. 10-1) is installed separated from the
operator panel front (distributed installation).
Caution
The PCU should not be mounted with the air stream at the bottom (i.e. the interfaces at
the top) to prevent heat accumulation.
Information is transferred between the NC controller and PCU, operator panel front and
MCP using MPI, USB and videolink transmission technology (see Fig. 10-1).
Note
Where the Windows NT operating system is used, the USB interface only supports key-
boards and mouse units.
If other USB devices are used, the noise immunity of the entire system may be reduced.
The end user takes responsibility for the use of such devices.
The operator panel front consists of a 15 display with horizontal and vertical soft keys in
the form of short-stroke keys.
In the case of turning and milling technologies, the MCP keys are labeled differently, the
displays on the operator panel front are different and a handwheel instead of the second
override switch is provided for the turning variant.

10 SINUMERIK Operator Panel Front 15 TFT, Width 416mm 09.02
10.00
10.2 System features
Operator The operator panel front (see Fig. 10-1) consists of

panel front
S an operator panel front with integrated operator control functions in the form of vertical
and horizontal soft keys and
S a machine control panel with integrated CNC keyboard.
Communi- Since the PCU is installed physically separated from the operator panel front (distributed
cation installation), a data transmission line was created:
S The operator panel front (operator panel front + MCP) communicates with the PCU by
means of a cable and a videolink transmitter. The PCU transmits the image data us-
ing videolink technology and the keyboard data using USB technology.
As a result, the PCU and operator panel front can be installed up to 15m apart (XGA
resolution).
S NC and MCP functions on the operator panel front communicate by means of MPI.
S NC and PCU also communicate by means of MPI.
EMERGENCY There is an EMERGENCY STOP button on the operator panel front. This also has to be
STOP wired up (see Fig. 10-8).
Power The operator panel front and PCU must be supplied with 24V.
supply
Note
To prevent error messages when the PCU is booted, the operator panel front should be
switched on at the same time as the PCU using the 24V supply.
Order The order numbers of the individual components are listed below:
numbers
6FC5 203-0AF50-0AA0 SINUMERIK operator panel front 15 TFT, width 416mm,
with mech. buttons for integrated installation
with mech. buttons for distributed installation up to 10m
with mech. buttons for distributed installation up to 15m
6FC5 203-0AF50-3AA0 SINUMERIK 810D/840D machine control panel
width 416mm, milling version, mech. buttons, rapid traverse
and feedrate override, mouse, standard / US layout
6FC5 203-0AF50-4AA0 SINUMERIK 810D/840D machine control panel
width 416mm, turning version, mech. buttons, handwheel
and feedrate override, mouse, standard / US layout

09.02
10.00 10 SINUMERIK Operator Panel Front 15 TFT, Width 416mm
6FC5 247-0AF20-0AA0 SINUMERIK operator panel front, videolink transmitter

for distributed installation 110m
6FC5 247-0AF21-0AA0 SINUMERIK operator panel front, videolink transmitter
for distributed installation 120m
6FC5 248-0AF20-0AA0 SINUMERIK 810D/840D mounting bracket for flat
mounting of PCU 50 and videolink transmitter (distributed
installation)
6FC5 248-0AF20-1AA0 SINUMERIK 810D/840D mounting bracket for upright
mounting of PCU 50 and videolink transmitter (distributed
installation)
6FC5 248-0AF20-2AA0 SINUMERIK 810D/840D mounting bracket for mounting
of PCU 50 behind operator panel front
6FX2 002-1VL00-1BA01) Videolink cable, display unit <=> videolink transmitter
10m, with detachable connector jacket
6FX2 002-1VL00-1BF01) Videolink cable, display unit <=> videolink transmitter
6FX2 002-1VL00-1CA01) Videolink cable, display unit <=> videolink transmitter
1) ...-1XX0: XX is the length code: A = 0, B = 1, etc.

10.00
10.3 Functional description
10.3.1 Overview of function blocks
The entire system is shown in the schematic diagram in Fig. 10-1.

1. Operator panel front with videolink receiver (behind the operator panel front, not vis-
ible in the diagram)
2. MCP with QWERTY keyboard and machine control panel (MCP)
3. Videolink transmitter
4. PCU
5. NC unit
The subject of this hardware description are the function blocks 1., 2. and 3.

Videolink 1.
3. Videolink with USB
transmitter X101 X201
X102 (USB-A) X202

X103 X104
15 TFT
X203/
(2x USB-A)
4. 204
(24 V) X206
PCU
X205
USB
Machine control panel

MPI
X301 EMERGENCY 2.
STOP
X302
QWERTY
5.
(USB-B)
X303/304
(2 x USB-A)
MCP
NC X401
MPI
Override
X404
(24 V) Override/handwheel
1. + 2. = Operator panel front
Fig. 10-1 Function blocks of SINUMERIK operator panel front 15 TFT (width 416mm)

09.02
10.3.2 Operator panel front
S Resolution: XGA (1024x768 pixels), 15 TFT
S Control elements: Horizontal and vertical soft keys
S Interfaces: Inputs:
1x videolink MDR 36
1x USB-B
1x 24V power supply, terminal (3-pin)
Outputs:
1x plug connector (2x5-pin) with lock
2x USB-A
S Dimensions: WxHxD: 416 x 382 x 65
S Bearing edge: Top/bottom: 18mm

Right/left: 16mm
S Fastening: Four welded-on threaded bolts M5
S Seal: To be provided by customer
S Degree of protection: Max. IP54 at front / IP00 at rear.
10.3.3 Machine control panel for turning and milling
1. QWERTY keyboard
The QWERTY keyboard features:
S MF2 keyboard (without function keys)
S Operating area keys: MACHINE, PROGRAM, OFFSET, PROGRAM MANAGER,
ALARM and CUSTOM
S Other keys: ALARM CANCEL, HELP, GROUP CHANNEL, INSERT, SELECT and
NEXT WINDOW
S Integrated mouse.
2. MCP
The MCP features:
S 54 keys (technology-specific and manufacturer-specific)

S Turning: 1x feedrate override (0120%, 23 detent positions)
1x handwheel (100 impulses / revolution),
approx. 60mm wheel diameter
S Milling: 1x feedrate override (0120 %, 23 detent positions)

1x rapid traverse override (0100%, 23 detent positions).
3. Other operator panel front components
S 1x EMERGENCY STOP button, 2-channel (small)

S 1x illuminated key, machine ON (22mm system).

10.00
4. Interfaces
S Inputs: 1x plug connector (2x5-pin) with lock

1x USB-B 2
1x MPI interface, D-Sub (9-pin)
1x 24V power supply: terminal (3-pin)
S Outputs: 2x USB-A
2x 4-pin (reserved for optional interfaces,
not fitted in series)
5. Dimensions
WxHxD (mm): 416x370x107 (turning) / 84 (milling)
6. Fastening: Four welded-on threaded bolts M5
7. Seal: To be provided by customer
8. Degree of protection: Max. IP54 at front, IP00 at rear.
10.3.4 Videolink transmitter
1. Videolink transmitter 1 ... 10m
S Function: Transmitter module for video transmission

S Interfaces:
Inputs:
1x plug connector (20-pin) with lock
1x plug connector (26-pin) with lock
Outputs:
1x videolink MDR 36 for 1, ..., 10m (max. of 20m) (video data plus USB
signals)
1x USB-A
2. Videolink transmitter 1 ... 20m
S Function: As above, plus ExtremeUSB for 20m and branch for second operator
panel front with videolink output for 1 ... 20m
S Interfaces: Outputs
2x videolink MDR 36 for 1, ..., 15m (max. of 20m)
2x USB-A

09.02
10.3.5 Cables
1. Videolink cable
S 10m: Order No. 6FX2 002-1VL00-1BA0

S 15m: Order No. 6FX2 002-1VL00-1BF0
S 20m: Order No. 6FX2 002-1VL00-1CA0
Fig. 10-2 Videolink cable
2. MPI cable MPI/PROFIBUS cable (cut-to-length) and connector from Siemens
3. USB connection cable between X205 (operator panel front) and X301 (MCP):
10-pin ribbon cable with fitted socket connectors (supplied with display unit)

10.00
10.4 Interfaces
10.4 Interfaces
10.4.1 Hardware interfaces overview

Table 10-1 Overview of hardware interfaces
Interface
Type Function Designation Type
Videolink interface X201 MDR 36
(incl. USB)
USB input (reserved) X202 USB-B
Operator USB output X203 USB-A
panel front USB output X204 USB-A
USB output X205 Plug connector (2 x 5-pin)
with lock
24V power supply X206 Terminal (3-pin)
USB input X301 Plug connector (2 x 5-pin)
with lock
MCP
USB in
input
ut X302 USB
USB-B B
(QWERTY
(reserved opt. to X301)
keyboard)
y )
USB output X303 USB-A
USB output X304 USB-A
MPI interface X401 SUB-D (9-pin)
Optional interface X402 Plug connector (1 x 4-pin)
4 pin)
(in ut, reserved)
(input,
MCP
Optional interface X403 Plug connector (1 x 4-pin)
(input reserved)
(input,
24V power supply X404 Terminal (3-pin)
Videolink (incl. USB) X101 MDR 36
USB interface X102 USB-A
LVDS input X103 Plug connector (2 x 10-pin)
Videolink I/O interface for operator X104 Plug connector (2 x 13-pin)
transmitter panels from PC
1 ... 10 m LVDS output X107 Plug connector (2 x 10-pin)
I/O interface for operator X108 Plug connector (2 x 13-pin)
panels to local operator panel
front
Same as videolink transmitter 1
Videolink
... 10 m; plus:
transmitter
second videolink (incl. USB) X105 MDR 36
1 ... 15 m
USB interface X106 USB-A
Videolink transmitter <=> Videolink 10 m: Order No.
display unit 6FX2002-1VL00-1BA0
15 m: Order No.
6FX2002-1VL00-1BF0
Cable Videolink transmitter <=> PCU LVDS Ribbon cable (20-pin)
Videolink transmitter <=> PCU I/O Ribbon cable (26-pin)
Display unit <=> operator panel USB Ribbon cable (10-pin)
front MPI Standard PROFIBUS
NC <=> operator panel front
Signal types The abbreviations in the Signal type column in the tables below have the fol-
lowing meanings:
I Input
O Output
B Bidirectional
V Voltage
OC Open Collector

09.02
10.4 Interfaces
10.4.2 Interface assignment for operator panel front
X201 (Videolink Connector designation: X201; Mini D Ribbon (MDR), multiple contact strip
incl. USB) (36-pin)
Pin Signal name Signal type Meaning

1 A0M I
2 A0P I
3 A1M I
Data OPENLDI
4 A1P I
5 A2M I
6 A2P I
7 CLK1M I
I Clock OPENLDI
8 CLK1P
Enabling of LCD power supply
9 ENVCC_12V
I (12V level)
VI Reference ground
10 M_12V
for signals with 12V level
Shield for twisted pair
11 Shield
cables; connected to ground
12, ..., 21 Reserved
22 M Reserved (ground)
23 Reserved
24 M Reserved (ground)
25 M V Ground
Shield
26 Shield
for twisted pair cables
Received data A
27 RX_A / USB_M
I/B (Extreme USB) / USB data
I/B Received data B
28 RX_B / USB_P
(Extreme USB) / USB data+
Transmitted data A (Extreme
29 TX_A
O USB)
O Transmitted data B (Extreme
30 TX_B
USB)
31 BL_ON_12V Backlight On (12V signal)
I
32 M_12V VI Ground
RESET to hub
33 XRESET_HUB I (low active, 12V signal)
34 M_12V Ground
35 XPAN-PRES Operator panel front is present
O
I Ground from videolink transmit-
36 XPAN-PRES
ter, transmitted to Pin 35
} Twisted pair (shielded)

10.00
10.4 Interfaces
X202 (USB interface Connector designation: X202; USB socket connector (4-pin), type B
input)

Reserved
1
(capacitive connection to ground)
2 USB_DM Data; USB channel 0
B
3 USB_DP Data+; USB channel 0
Ground for external USB interface
4 USB_GND V
X203 / 204 (USB Connector designation: X203 / 204; USB socket connector (2x 4-pin),
interface output) type A
Table 10-4 X203 / 204 pin assignments

+ 5V (fused)
A1 P5V_3_fused VO
for external USB interface
A2 USB_D3M Data; USB channel 3
B
A3 USB_D3P Data+; USB channel 3
Ground
A4 USB_GND V
+ 5V (fused)
B1 VO
B2 USB_D4M Data; USB channel 4
B
B3 USB_D4P Data+; USB channel 4
Ground
B4 USB_GND V
X205 Connector designation: X205; plug connector (2x 5-pin), grid 2.54mm
(QWERTY Interface is configured as high current USB
interface) (500mA).

+ 5V (fused)
1 P5V_fused VO
2 USB_DM Data; USB channel 0
B
3 USB_DP Data+; USB channel 0
4/5 M V Ground
6, ..., 10 NC not connected

09.02
10.4 Interfaces
X206 (24 V power Connector designation: X206; terminal block (3-pin)

supply)

1 P24 24V potential
2 M24 V 24V ground
3 Shield Shield connection
Coding switch S1 Accessible internally only
S with Extreme USB: both switches set to 1 (factory setting)

S without Extreme USB: both switches set to 2.
10.4.3 Interface assignment for QWERTY keyboard
The QWERTY keyboard has a total of five USB interfaces, four of which can be
used by the user (see Fig. 10-1). The integrated mouse is connected to the fifth
USB interface (X305).
S Interface X301 connects the keyboard to the videolink receiver. The maxi-
mum cable length is 10m.
S The keyboard can be connected to the PCU using interface X302 and a
cable of max. 10m in length.
S The two interfaces X303 and X304 are accessible by means of a two-tier
USB-A connector.
X301 / X302 The two interfaces X301 and X302 (see Fig. 10-1) are connected in parallel and
configured as high powered interfaces with max. 500mA, 5V.
S X301 is used to form the connection to the videolink receiver; max. permissi-
ble ribbon cable length: 1 m.
S X302 supports a standard USB cable with length of max. 5m. This cable can
be used to form a direct connection to, for example, the PCU (e.g. for load-
ing customer-specific keyboard tables).
Caution
! The two interfaces X301 and X302 should not be used simultaneously be-
cause they are connected in parallel.
Connector designation: X301; plug connector (2x 5-pin) with lock

10.00
10.4 Interfaces

1 P5 V Power supply 5V
2 USB_P Data +
B
3 USB_M Data
4/5 M V Ground
6/7/8 NC Unassigned
9 SDA B Serial data for EEPROM
10 SCL I Clock for EEPROM
Connector designation: X302; USB-B connector (4-pin)

1 P5 V Power supply +5V
2 USB_DM0 Data; channel 0
B
3 USB_DP0 Data+; channel 0
4 M V Ground
X303 / X304 X303 / 304 is a double standard USB-A connector (see Fig. 10-1). X303 and
X304 are configured as low powered interfaces with max. of 100mA, 5V.
Connector designation: X303; USB-A connector (4-pin)

Power supply +5V
A1 1P5 V
for external USB device
A2 USB_DM2 Data; channel 2
B
A3 USB_DP2 Data+; channel 2
A4 M V Ground
Connector designation: X304; USB-A connector (4-pin)

Power supply +5V
B1 2P5 V
for external USB device
B2 USB_DM3 Data; channel 0
B
B3 USB_DP3 Data+; channel 0
B4 M V Ground

09.02
10.4 Interfaces
10.4.4 Interface assignment for MCP
X401 (MPI) The MCP is connected to the MPI of the NC by means of interface X401.
Connector designation: X401; 9-pin Sub-D socket

1/2 NC Unassigned
3 RS_OPI B RS-485 data
4 ORTSAS_OPI Output Request to Send, user in-
O
terface
5 M5EXT 5V external ground
V
6 P5EXT 5V external potential
7 NC Unassigned
8 XRS_OPI B RS-485 data
9 IRTSPG_OPI I In Request to Send PG
Baud rate (max. of 1.5 Mbaud) and station address of the MCP at the MPI bus
are set at DIP switch S3 of the keyboard controller.
X402 / 403 Not available
X404 (power See X206 (Subsection 10.4.2)

supply)
X11 / 12 (axis Depending on the panel variant, the operator panel front has one or two axis
override interface) override switches. These switches are connected to the MCP by means of rib-
bon cables.
Connector X11 is used to connect the rotary selector switch for feedrate over-
ride (32 graduations), irrespective of its installation position.
S With the milling version, the rotary selector switch for rapid traverse (32
graduations) is connected to X12.
S With the turning version, a handwheel is fitted in place of the rotary selector
switch. The handwheel is directly connected to the NC controller.

10.00
10.4 Interfaces
Connector designation: X11; plug connector (2x 5-pin) with lock

1/2 NC Unassigned
3/4 M V Ground
5 NC Unassigned
Setting of override rotary selector
switch
6 IN3_4 Significance 16
8 IN3_2 I Significance 4
Connector designation: X12; (optional interface for milling variant)

plug connector (2x 5-pin) with lock

1/2 NC Unassigned
3/4 M V Ground
5 NC Unassigned
Setting of override rotary selector
switch
8 IN7_2 I Significance 4

09.02
10.4 Interfaces
10.4.5 Interface pin assignment for videolink transmitter
X101 / X105 Connector designation: X101/105; Mini D Ribbon (MDR), multiple contact
(Videolink incl. strip, (36-pin)
USB)
Table 10-14 X101/105 pin assignments

1 A0M O
2 A0P O
3 A1M O
Data OPENLDI
4 A1P O
5 A2M O
6 A2P O
7 CLK1M O
O Clock OPENLDI
8 CLK1P
Enabling of LCD power supply
9 ENVCC_X
(12V level)
10 M Ground
Shield for twisted pair cables;
11 Shield
connected to ground
12, ..., 22
23 Reserved
24
25 M V Ground
26 Shield Shield for twisted pair cables
Transmitted data A (Extreme
27 TX_A / USB_M
O/B USB) / USB data
O/B Transmitted data B (Extreme
28 TX_B / USB_P
USB) / USB data+
29 RX_A I Received data A (Extreme USB)
30 RX_B I Received data B (Extreme USB)
31 BL_ON_x Backlight On (12V signal)
O
32 M O Ground
RESET to downstream hub (low
33 XRESET_HUB O active, 12V signal)
34 M Ground
35 XPAN-PRES_x Operator panel front is present
36 M V Ground
} Twisted pair (shielded)

10.00
10.4 Interfaces
X102 / X106 (USB Interface is configured as high-current USB (500mA)

downstream)
Connector designation: X102 / X106; USB socket connector (4-pin),
type A
Table 10-15 X102 / X106 pin assignments

+ 5V (fused) for external USB in-
1 USB_P5V_fused VO
terface
2 USB_D0M Data, USB channel 0
O
3 USB_D0P Data+, USB channel 0
Note
X106 is not available at present.
X103 (LVDS Connector designation: X103; plug connector (2x 10-pin), grid 2.54mm
input of PCU)

1/2 P5V VI +5V
3 RXIN0 LVDS input signal Bit 0 ()
I
4 RXIN0+ LVDS input signal Bit 0 (+)
5/6 P3V3 VI + 3.3V
I
9/10 GND V Ground
I
13/14 GND V Ground
15 RXCLKIN LVDS clock signal ()
I
16 RXCLKIN+ LVDS clock signal (+)
17/18 GND V Ground
19/20 Reserved

09.02
10.4 Interfaces
X104 (IO interface Connector designation: X104; plug connector (2-row), grid 2.54mm
for operator panels
from PC) Table 10-17 X104 pin assignments

1 GND V Ground
Power supply for inverter (max.
2 P12V VI
1.1A)
3 BL_ON I Backlight On (5V ... 12V = ON)
4 P5V_fused VI + 5V VCC (fused)
5 GND V Ground
6 P3V3_fused VI + 3.3V VCC (fused)
7, ..., 10 Reserved
12 USB_D1M USB data Channel 1
B
13 USB_D1P USB data+ Channel 1
14 GND V Ground
15 LCDSEL0 Display Type Select Signal 0
O
Reset signal (low active, with
19 RESET_N
pull-up resistor set to high)
(Connection for system loud-
20
speaker)
21 (HD LED) *)
22 (MPI/DP LED) *)
23 (Ethernet LED) *)
24 TEMP_ERR O (Temperature error LED) *)
25 (Watchdog error LED) *)
26 (Watchdog OK LED) *)
*) Anode with 1k in series on mother board

10.00
10.4 Interfaces
X107 (LVDS Connector designation: X107; plug connector (2x 10-pin), grid 2.54mm
output to operator
panel front) Table 10-18 X107 pin assignments

1/2 P5V VO +5V
3 TXOUT0 LVDS output signal Bit 0 ()
O
4 TXOUT0+ LVDS output signal Bit 0 (+)
5/6 P3V3 VO + 3.3V
O
9/10 GND V Ground
O
13/14 GND V Ground
15 TXCLKOUT LVDS clock signal ()
O
16 TXCLKOUT+ LVDS clock signal (+)
17/18 GND V Ground
19/20 Reserved
X108 (IO interface Connector designation: X108; plug connector (2x 13-pin), grid 2.54mm
for operator panels
to local operator Table 10-19 X108 pin assignments
panel front) Pin Signal name Signal type Meaning
1 GND V Ground
Power supply for inverter (max.
2 P12V VI
1.1A)
3 BL_ON I Backlight On (5V ... 12V = ON)
5 GND V Ground
6 P3V3_fused VI + 3.3V VCC (fused)
12 USB_D1M USB data Channel 1
B
13 USB_D1P USB data+ Channel 1
14 GND V Ground
(Temperature error LED; anode
24 TEMP_ERR O with 1k in series on mother
board)
25/26 NC not connected

09.02
10.4 Interfaces
Rotary selector Factory setting for selection of display type:

switch S1 Setting 9 corresponds to 15 TFT display.
Note
All the displays used in a system must be of the same type (15 TFT).
If the setting is incorrect, the display may be irreparably damaged in a short
time.
DIP switch S2
S 10m transmitter variant (1x Videolink): 1 and 3 = any or S2 not
fitted
2, 48 = OFF
S 20m transmitter variant (2x Videolink): 1 and 3 = ON

2, 48 = OFF
10.4.6 Internal status displays (LEDs)
Transmitter The following LEDs indicate the operating status of the transmitter:
Table 10-20 Operating status indicators on the transmitter
Designation Color Source Meaning

+3V3 red On ExtremeUSB module at + 3.3V supply OK
+5 V red X21/22/23 + 5V supply OK
H1 green ExtremeUSB module at Host OK
H2 green X21/22/23 Link OK
+3V3 red On ExtremeUSB module at + 3.3V supply OK
+5 V red X11/12/13 + 5V supply OK
H3 green ExtremeUSB module at Host OK
H4 green X11/12/13 Link OK
When the ExtremeUSB line is operating properly, both green LEDs of the transmitter
module (LEX) and both green LEDs of the receiver module (REX) light up on the video-
link transmitter.

10.00
10.4 Interfaces
Receiver The following LEDs indicate the operating status of the receiver:
Table 10-21 Operating status indicators on the receiver
Designation Color Source Meaning

+3V3 red + 3.3V supply OK
On the ExtremeUSB module
+5 V red + 5V supply OK
H1 green USB port OK
ExtremeUSB module
H2 green Link OK
H3 green OpenLDI receiver Video interface (OpenLDI) active
H4 green +12V, +3.3V, +5V of power Power OK
section
When the ExtremeUSB line is operating properly, both green LEDs of the transmitter
module (LEX) and both green LEDs of the receiver module (REX) light up on the video-
link receiver.
10.4.7 Software interfaces
Key layout
on MCP Table 10-22 Layout of the machine control keys (applies to turning and milling)
*)
00 01 02 03 04 05 06 07 08 09
10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28 29
30 31 32 33 34 35 36 37 38 39
*)
*) 43 44 45 46 47 48 49
40 42
50 51 52 53 54
*) Low-active keys

09.02
10.4 Interfaces
Input image
of MCP Table 10-23 Assignment of input words/bytes to the machine control keys
(the numbers Key 00, ..., 54 correspond to the key numbers from Table 10-22)
Input Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

(MSB) (LSB)
Word 0 Key 40
Key 36 Key 35 Key 34 Key 30 Key 00 Key 10 Key 20
Low *)
Word 0 Key 08
High *)
Word 1 Key 45
Low *)
Word 1 Over- Over- Over- Over- Over-
Key 31 Key 06 Key 14
High ride1 E ride1 D ride1 C ride1 B ride1 A
Word 2
Key 49 Key 47 Key 28 Key 15 Key 16 Key 17 Key 19 Key 21
Low
Word 2
High
Word 3
Low
Word 3 Over- Over- Over- Over- Over-
Key 52 Key 53 Key 54
High ride2 E ride2 D ride2 C ride2 B ride2 A
*) Low-active keys
Notes:
S The Override2 function only exists in the milling version. This function does not
exist in the turning version; the bits concerned are each set to 1.
S Significance with override: A = 1, B = 2, C = 4, D = 8, E = 16.

10.00
10.5 Mechanical design
.
.
. .
Videolink receiver
Dimensions in mm
Fig. 10-3 Front, side and rear view of operator panel front

09.02
Videolink Keyboard interface

receiver
Power supply
Supporting plate
Operator panel
front
Connection for
2x USB-A videolink cable
Fig. 10-4 Rear perspective of the operator panel front with mounted videolink receiver
10.5.2 MCP
Milling MCP Fig. 10-5 shows the front and side view of the milling MCP. Fig. 10-7 shows the rear
view with the connections, programming switch S3 and the status LEDs.
Threaded bolt M5
Dimensions in mm Exchangeable key caps (see detailed drawing in Fig. 10-6)
Fig. 10-5 Milling MCP

10.00
Threaded Welded threaded bolts (see Fig. 10-6) instead of drilled holes with press-in sleeves are
bolts used to secure the operator panel front and the MCP.

Threaded bolt M5 Spacer ring

M5
10

5

23
Front plate
Fig. 10-6 Bolt for securing operator panel front and MCP (detail drawing from Fig. 10-5)
X302
X301 X303/4
X401
X404
S3 87654321
X402 X403
Ground terminal
H4 H3 H2 H1 M5 thread
Fig. 10-7 Rear view of MCP (milling and turning) showing position of the connections,
programming switch S3 and the status LEDs H1, ..., H4
Table 10-24 Assignment of DIP Fix switch S3
No. Meaning Default

Setting Value
1 Baud rate ON
2 OFF
Cycle
3 ON
4 OFF
5 ON
Bus address
6 ON
7 OFF
8 HW platform OFF

09.02
Table 10-25 Meaning of status LEDs
No. Color Meaning

H1 red Hardware fault
H2 red Temperature error
H3 green Power OK
H4 yellow Operator panel front interface active
EMERGENCY Fig. 10-8 shows the wiring of the emergency stop button.
STOP
1 2 1 2
Fig. 10-8 Block diagram of emergency stop button
Turning All of the information given above for the milling MCP also applies to the turning MCP.
MCP
Exceptions (see Fig. 10-9):
A handwheel is integrated in place of the second override switch.
The keys are different.

10.00
Exchangeable keys
Threaded bolt M5
Dimensions in mm Exchangeable key caps (see detailed drawing in Fig. 10-6)
Fig. 10-9 Turning MCP

09.02
PCU Fig. 10-10 shows the PCU with the mounted videolink transmitter
(see Subsection 10.6.3 for information on mounting).
Mounting bracket
114
PCU 50
for videolink transmitter
PCU 50
Fastening screws
Videolink
transmitter
PCU 50
Dimensions in mm
Fig. 10-10 PCU 50 with videolink transmitter

10.00
10.6 Mounting
10.6 Mounting
Individual
components S Operator panel front
S Machine control panel with QWERTY keyboard and MCP
S Videolink transmitter.
The panel cutout for the operator panel front is shown in Fig. 10-11.

4.5

329+1

341

386+1

6.5

395
Dimensions in mm
Fig. 10-11 Panel cutout for operator panel front

09.02
10.6 Mounting
Cable The operator panel front is connected to the other components by means of cables
connections (see Fig. 10-1)
S Machine control panel (MCP):

For noise immunity reasons, the USB ribbon cable connection from the operator
panel front (interface X205) to the MCP (interface X301) must always be installed
and secured close to the top side of the metal plate.
No other cables which could cause noise interference should be installed in the
immediate vicinity.
S Videolink receiver:
The videolink cable connects interface X201 of the videolink receiver (mounted on
the rear of the operator panel front) to interface X101 of the videolink transmitter
(mounted on the rear of the PCU).
The cable is secured at the U-shaped panel cutouts on the rear of the operator
panel front using cable ties (see Fig. 10-12).
Securing in this way also relieves the strain on connectors which do not have
strong connector catches (e.g. USB).
Videolink receiver

(rear)
Videolink cable Cable tie Panel cutouts for cable attachment
Fig. 10-12 Cable attachment on rear of operator panel front
Note
S In cases where a high degree of noise interference is likely or the distance

between the operator panel front and the MCP is relatively large, it is advis-
able to purchase USB cables with shielding. Interface X203 behind the front
and interface X302 behind the machine control panel are then connected to
each other. The ribbon cable does not need to be fitted in this case.
S Connector X302 on the machine control panel (QWERTY keyboard) can also
be connected directly to the PCU or a PC using a standard USB cable.

10.00
10.6 Mounting
10.6.2 Machine control panel
The panel cutout for the machine control panel is shown in Fig. 10-13.

5.5

7.5
334 +1

349

384 +1

6.5
395 Dimensions in mm
Fig. 10-13 Panel cutout for machine control panel
Proceed as follows:
1. Position the operator panel front so that its four threaded bolts (Fig. 10-9) are in-
serted in the mounting holes of the prepared panel cutout (Fig. 10-13).
The spacer rings (Fig. 10-9) ensure that the rubber seal is not squashed when
installed.
2. Secure the operator panel front from the rear side using the M5 nuts and suitable
circlips.
3. Attach the ground connection (see Fig. 10-7).
4. Connect the interfaces, except X404 (see Fig. 10-7).
5. Connect X404 to the 24V power supply (see Fig. 10-7).

09.02
10.6 Mounting

The videolink transmitter is fitted between the mounting brackets under the PCU
(see Fig. 10-10).
1. Plug the supplied cables into the connectors of the videolink transmitter, as
shown in the photo below.
Hinge
bolts
Threaded holes
for fastening
screws
Fig. 10-14 Videolink transmitter with connecting cables
Caution
To prevent damage, plug the cable connectors only into the sockets shown in
the photo.
2. Mount the first mounting bracket on the PCU (see Fig. 10-15).
Mounting bracket
Fig. 10-15 PCU 50 with mounting brackets
3. Hook the videolink transmitter into this mounting bracket (see Fig. 10-17).

10.00
10.6 Mounting
4. Fit the second mounting bracket after having attached it to the opposite
hinge bolt (see Fig. 10-14) of the videolink transmitter.
5. Plug the connecting cable into the connectors on the PCU (Fig. 10-16).
Videolink
transmitter
PCU 50
Fig. 10-16 Videolink transmitter hooked into place with the hinge bolts
6. Swivel the videolink transmitter into place on the PCU (see Fig. 10-17).
Hinge
bolts
PCU 50 PCU 50
Fig. 10-17 Hinge of the videolink transmitter before being locked in position
7. Push the videolink transmitter forwards in the locking mechanism (to the left
in Fig. 10-17, see arrow) until it locks down into place (see Fig. 10-18).

09.02
10.6 Mounting
Videolink
transmitter
Hinge
bolts
Mounting
screw
PCU 50
PCU 50
Fig. 10-18 Videolink transmitter, locked in position and screwed tight
8. Secure the videolink transmitter to the mounting brackets with the screws
supplied (see Fig. 10-18).
The videolink transmitter is now fastened to the PCU mounting rails
(see Fig. 10-19) and can be installed together with the PCU for its intended use.
Videolink
transmitter
PCU 50
Fig. 10-19 Videolink transmitter fully mounted to the PCU 50
Caution
If it is necessary to dismantle the videolink transmitter, please release the fas-
tening screws and slide the video transmitter horizontally before swiveling it
away from the PCU, in accordance with step 7. and Fig. 10-17.
Otherwise, damage is likely.

10.00
10.7 Spare parts
10.7 Spare parts

The following spare part kits are available for the operator panel front 15 TFT
(width 416mm):
Table 10-26 Spare part kits for operator panel front 15 TFT
Name Description Order number (MLFB)

Handwheel for machine control panel,
Handwheel 6FC5247-0AF50-0AA0
width 416mm, T-version
Rotary selector switch for feedrate /
Rotary selec-
rapid traverse override, 1x23G, 6FC5247-0AF50-1AA0
tor switch
grad=32, knob and cover
Mouse USB mouse for front 6FC5247-0AF01-0AA0
Mushroom-head 3SB2000-1AC01
EMERGENCY
Holder 3SB2908-0AA
STOP 1)
Switching element 3SB2404-0C
Complete 3SB3001-0AA71
Ill i t d key
Illuminated k
1) Switching element 3SB3400-0A
Switching element with lamp 3SB3400-1D
1) Submit orders to SIEMENS Amberg
Replacement of Remove the handwheel in the following way (see Fig. 10-20):
handwheel 1. Slacken the two hexagon-socket screws in the rotary knob and pull the
rotary knob off the spindle.
2. Undo the three M3 fastening screws using a T10 Torx screwdriver.
3. Pull the handwheel backwards out of the front panel and disconnect the
wiring.
Rotary knob (detached) Connecting terminals Handwheel
Grub screw
(hexagon-socket)
O-ring
Handwheel spindle Fastening screws M3
Fig. 10-20 Removal of handwheel
Installation is performed in the reverse order (installation kit is shown on the

right-hand side of Fig. 10-20).
Make sure that the O ring is fitted correctly.

09.02
10.7 Spare parts
Replacement of Remove a rotary selector switch in the following way (see Fig. 10-21):
rotary selector 1. Prise the cap (cover) off the rotary knob (snap-on fitting!).
switch
2. Loosen the nut of the collet using a wrench (width 10).
3. Pull the complete rotary knob off the shaft of the rotary selector switch.
4. Remove the nut on the shaft of the rotary selector switch from the front side
using a wrench (width 14).
5. Unplug the connector at the end of the rotary selector switch cable from the
receptacle.
6. Remove the rotary selector switch.
Collet nut Rotary knob Rotary selector switch spindle
Dial
Cap Fastening nut
Fig. 10-21 Removal of rotary selector switch
Install the rotary selector switch in the following way:

The installation kit for a rotary selector switch is shown on the left-hand side of
Fig. 10-22.
Fastening nut Rotary knob Connecting cable
Cap
Arrow ring
O-ring Terminal board
Fig. 10-22 Installation of rotary selector switch
1. Push the O-ring onto the shaft of the new rotary selector switch (for sealing
purposes).
2. Insert the rotary selector switch into the front cutout so that pressure is ap-
plied to the O-ring.
3. Fasten the nut on the shaft of the rotary selector switch from the front side
using a wrench (width 14).

10.00
10.7 Spare parts
4. Attach the arrow ring to the rotary knob.

5. Attach the complete rotary knob to the shaft.
6. Tighten the collet nut of the rotary knob using a wrench (width 10). When
doing so, make sure that the arrow point is aligned with 0.
7. Place the cap (cover) on the rotary knob and snap on.
8. Connect the cable in the way shown on the right-hand side of Fig. 10-22.
Observe the recommended cable folds.
The second rotary selector switch is installed in the same way, except that the
recommended cable folds shown in Fig. 10-23 should be used.
Fig. 10-23 Both rotary selector switches installed (top switch [right] not yet connected)
Replacement of Fig. 10-24 shows the mouse prior to removal.

mouse
Connecting cable Mouse board Cable connectors
Clamping frame Fastening screw
Fig. 10-24 Mouse prior to removal

09.02
10.7 Spare parts
Remove in the following way:

1. Unplug the cable connectors from the mouse board.
2. Undo the four M3x6 fastening screws using a T10 Torx screwdriver.
3. Release the clamp frame.
Fig. 10-25 shows how the unit should then look.
Fig. 10-25 Mouse fastening released
4. Lever the mouse out of the front panel.

Fig. 10-26 shows the removed mouse.
Fig. 10-26 Removed mouse
Installation is performed in the reverse order.

Make sure that the mouse symbol is the correct way up.

10.00
10.8 Technical data
10.8 Technical data

Table 10-27 Technical data for operator panel front
Dimensions (WxHxD) approx. 416x382x65mm

Display 15 TFT with brightness of 200 cd/m2
Keys Vertical and horizontal soft keys (short-stroke keys)
Power supply Rated voltage 24V, voltage range 1931V
Power consumption approx. 19W
Interfaces Videolink, USB, 24V terminal connection
Degree of protection Front: IP54; rear: IP00
Ambient temperature External: 0C to 45C Internal: 0C to 55C
during operation (at display)
Ventilation Free convection, without fan
Housing Front panel: Stainless steel, brushed diagonally (grain 240)
Rear panel: Galvanized steel plate
Machine control panel

Table 10-28 Technical data for MCP
Dimensions (WxHxD) Turning: approx. 416x370x107mm Milling: approx. 416x370x84mm

Mounting depth max. 65mm
Keys Mechanical short-stroke keys
Power supply Rated voltage 24V, voltage range 1931 V
Interfaces USB, MPI, 24V terminal connection
Degree of protection Front: IP54; rear: IP00
Ambient temperature External Internal
during operation
0C to 45C (due to display) 0C to 55C
Housing As for operator panel front
Videolink transmitter
Table 10-29 Technical data for videolink transmitter
Dimensions (WxHxD) approx 265x277x35mm

approx.
Weight approx. 2.2kg with two brackets, without PCU
Power supply Videolink transmitter is supplied with power from the PCU
Interfaces Videolink, USB, LVDS, keyboard and special interface
Degree of protection IP00 / mounted on PCU: IP20
Ambient temperature 0C to 55C during operation
Housing Galvanized steel plate

09.02
10.9 Heat dissipation

The following correlations apply for heat dissipation at the operator panel front
(the surfaces of the front and bottom side are not considered when calculating
the convection surface):
The heat produced by the operator panel front is generated almost exclusively
by the display unit (approx. 19W). It is therefore sufficient to apply 20W as the
basis for calculation.
The necessary free convection surface area of the space to be enclosed (steel or
aluminum sheet, 1.5mm thick) is calculated, referred to a temperature difference
T2 T1 = DT 10K, approximately from:

Pvtotal [W]
T2 T1 A [m2] =
5 DT [K]
Example: T1 = 45C, T2 = 55C

MCP Pvtotal = 20W
!A = 0.4m2
Fig. 10-27 Heat dissipation by natural convection

10.00
Notes

Component PCU 20 11
The PCU 20 component can be used in combination with the operator panel
fronts OP 010, OP 010C, OP 010S, OP 012, OP 015, OP 015A, TP 012 and
Trumpf operator panel. It is available in the following variants:
Processor User memory Onboard FLASH Order No.

clock speed (RAM) memory 6FC5210-0DF00 ...
166MHz 16 MByte 8 MByte ...-0AA0
Features S Rugged design (continuous operation, high noise immunity)

S Space-saving design thanks to compact dimensions (WxHxD):
297x267x56mm
S Easy installation with four screws at the rear side of the operator panel front
S Wide variety of mounting locations and positions
S All-around fire protection (to EN60950)
S Single-chip PC processor with embedded operating system
S Flash card 100/200 type I/II, max. 64MB (68-pin) or memory card/ATA flash
card interface (68-pin PC card connector)
S Screen resolution: 640x480 (VGA), up to 1024x768 (XGA)
S Power supply 24VDC
S Interfaces:
COM1 serial RS-232 interface (25-pin Sub-D socket connector)
COM2 serial RS-232 interface (9-pin Sub-D socket connector)
PS/2 keyboard (6-pin mini-DIN)
USB interface (4-pin USB socket connector)
MPI/DP interface RS-485 (9-pin female Sub-D), max. 1.5 Mbaud
Ethernet port 10/100 Mbaud (8-pin RJ45 socket)
Memory card/ATA flash card interface (68-pin PC card connector) or
flash card 100/200 type I/II, max. 64MB (68-pin)
Floppy disk drive interface (34-pin ribbon cable plug socket)
Interfaces to operator panel front:
LVDS interface for TFT operator panel front (20-pin plug, 2.54mm),
CMOS interface for STN operator panel front (34-pin plug, 2.54mm),
operator panel front I/O interface for USB data signal/display selection/
LEDs/power supply (26-pin plug, 2.54mm),
USB interface for operator panel front (internal)

11 Component PCU 20 10.00
11.1 Views
11.1 Views
The Figures 11-1 to 11-5 show different views of the PCU 20.
Left *) Top *)
Right *)
*) Orientation relative to operation with the
19 operator panel fronts
Fig. 11-1 PCU 20: viewed in perspective
Width = 297
Ext. floppy disk drive (optional)
Power supply interface
Fastening screws
Height = 267
Fastening screws
Fixing lugs
Interfaces
Fixing lugs
Nameplate
Depth: 53mm (without screws protruding)
Fig. 11-2 Top view PCU 20

10.00 11 Component PCU 20
11.2 Interfaces and connections
Note
The orientation drawings top, right, left etc. refer to the mounting position
when operated with OP 012 (see Fig. 11-1 and 11-7) viewed at the rear of the
PCU 20/OP 012 combination.
11.2.1 Interfaces on right side of casing
Depth = 56
53
PS/2 mouse COM1/RS-232-C COM2/RS-232-C USB Ethernet MPI/L2-DP Flash card/memory card
Fig. 11-3 Side view of PCU 20 from right with interfaces
Table 11-1 Interfaces on the right side of the casing
Port Function
COM1/RS-232-C Serial interface 1 (RS-232-C), 25-pin Sub-D socket connector
PS/2 mouse/keyboard PS/2 mouse plug/keyboard connection
USB External connection for Universal Serial Bus
MPI/DP (RS-485) Multi-Point-Interface/PROFIBUS DP connection
Connecting an S7 programmable controller, 9-pin Sub-D socket
connector
Ethernet Connection for local area network (LAN), SW option
Memory card Slot for ATA flash card/memory card or
flash card 100/200 type I/II

11.2.2 Interfaces on left side of casing
The following interfaces are located on the left-hand casing panel:
Interfaces for the

operator panel front:
CMOS for STN display

(OP 010)
I/O interface
LVDS for TFT display
Data interface for ex-

ternal floppy disk drive
Reset
24V supply connection
Fig. 11-4 Interfaces on left side of casing
Fastening screw for cover plate of ex-

ternal floppy disk drive port
Interfaces for the
operator panel front:
Shield connection
I/O for USB data
Ground terminal LVDS for TFT display
Fig. 11-5 Rear of PCU 20 housing complete with interfaces

The interfaces for the operator panel front to be installed:

Front interface for connecting the IO USB cable
LVDS interface for connecting a TFT display
CMOS interface for connecting an STN display (X420)
Procedure for mounting the operator panel front: see Subsection 11.3.1.
Table 11-2 Interfaces on the left side of the casing
Port Function
LVDS LVDS interface for TFT operator panel front
I/O for USB I/O interface for USB data
CMOS CMOS interface for STN operator panel front (X420)
24V 24V supply connection
Floppy Data interface (34-pin ribbon cable plug socket) for external
floppy disk unit
Note
Pressing the Reset button will cause a hardware reset. The PCU reboots.
11.2.3 Mounting rail on underside of casing
Mounting rail for screwing to the operator

panel front
Fig. 11-6 View of PCU 20 from below

11.2.4 Pin assignments
X9: Cable length: max. of 30m

Serial interface Table 11-3 Assignment for the serial interface COM1 (PLC/RS-232-C/modem)
COM1
Pin Name Type Meaning
1 Shield
2 TxD (D1) O Serial transmitted data
3 RxD (D2) I Serial received data
4 RTS (S2) O Request To Send
5 CTS (M2) I Clear To Send
6 DSR (M1) I Data Set Ready
7 GND (E2) V System ground (reference potential)
8 DCD (M5) I Receive signal level (carrier)
919 Unassigned
20 DTR (S1) O Data Terminal Ready
21 O Unassigned
22 RI (M3) I Incoming call
2325 Unassigned
X11:
Serial interface Table 11-4 Assignment for the serial interface COM2 (RS-232-C)
COM2
1 DCD I Receive signal level (carrier)
2 RxD I Serial received data
3 TxD O Serial transmitted data
4 DTR O Data Terminal Ready
5 GND V System ground (reference potential)
7 RTS O Request To Send
8 CTS I Clear To Send
9 RI I Incoming call
X6:
PS/2 keyboard/ Table 11-5 Assignment for the PS/2 keyboard/mouse interface
mouse interface
1 Keyboard_data I Mouse data line
2 Mouse_data I Unassigned
3 GND V System ground (reference potential)
4 P5 V +5V supply voltage
(current limited)
5 Keyboard_CLK I/O Mouse clock signal
6 Mouse_CLK I/O Unassigned

X40 Cable length: max. of 5m

USB interface Table 11-6 Assignment for the USB interface (high current 500mA)

1 USB_P5_fused V +5 V supply voltage
2 USB_D0M I/O USB data
3 USB_D0P I/O USB data +
4 USB_GND V System ground (reference potential)
X800: Cable length: max. of 200m at 1.5 Mbaud

MPI/DP interface Table 11-7 Assignment for the MPI/DP interface

1, 2 Unassigned
3 MPSS_A I/O KBus Line A
4 IN_RTS_AS I Control signal for receive data stream.
Signal active 1 when the directly con-
nected AS sends.
5 2M V Return conductor (GND) for the 5V sup-
ply. Current load from a load of 90mA
max. connected between P5EXT and
M5EXT.
6 2P5 V Unassigned
7 Unassigned
8 XMPSS_B I/O KBus Line B
9 RTS_PG I RTS signal of the MPI module
Shield On plug casing
X805:
Ethernet RJ45 Table 11-8 Assignment for the Ethernet RJ45 interface
interface
1 TxD+ O Transmitted data +
2 RxD+ I Received data +
3 TXD O Transmitted data
4 RxD I Received data
5 to 8 Unassigned
Yellow Link O Yellow LED signal: Connected
LED
Green Activity O Green LED signal: Active
LED
Signal type
I: Input Input or receive (receive)
O: Output Output or transmit (transmit)
I/O: input/output Bidirectional (bidirectional)
V: Voltage Power supply (supply)
: shield/na Shield or not assigned (not available)

X400: Cable length: max. of 0.5m

Display interface Table 11-9 Assignment for the display interface (LVDS)
(LVDS) for TFT
operator panel
front 1, 2 P5V_D_fused V + 5V display supply voltage (fused)
3 TXOUT0 I LVDS input signal Bit 0 ()
4 TXOUT0+ I LVDS input signal Bit 0 (+)
5, 6 P3V3 V + 3.3V display voltage (fused)
9, 10 GND V System ground (reference potential)
15 TXCLKOUT I LVDS clock signal ()
16 TXCLKOUT+ I LVDS clock signal (+)
19, 20 Unassigned
X401: Cable length: max. of 0.5m

Front interface for
IO USB interface

11.3 Start-up
11.3 Start-up
11.3.1 Mounting and installation
The PCU 20 meets the relevant demands placed on a fire protection casing to
EN60950. It can therefore be integrated without an additional fire protection sur-
round.
Combination with When used in combination with the operator panel front (e.g. OP 012), the PCU
operator panel front 20 is first screwed to the operator panel front and this is then secured to the
assembly panel using tension jacks.
The procedure is described in this manual in the chapter about the operator
panel front concerned.
Please note the following during installation:
S As far as possible, extreme environmental conditions should be avoided.

Protect the PCU from dust, humidity and heat.
S Do not expose the PCU to direct sun radiation.
S Install the device such that no danger (e.g. by falling down) may result.
S The clearance at the PCU rear side must be at least 10mm to make sure
that sufficient ventilation is provided (see Fig. 11-7). Clearances on the
sides, see Chapter Heat Dissipation.
S Do not cover the vent slots.
Permissible mounting positions:
*) Clearance for ventilation: 10mm

Interfaces
*)
Interfaces
*)
Interfaces
Interfaces
Interfaces
Interfaces
Preferred mounting position To be avoided Preferred mounting position

when operating with OP 010S when operating with the 19
operator panel fronts
Fig. 11-7 Permissible mounting positions of PCU 20 with the 19 operator panel fronts
An inclined position of 5_ is permitted. Vertical mounting is recommended.

11.4 Accessories
11.3.2 Preparing for operation
Connecting I/O Before you connect the PCU to a power supply, you must connect an operator
devices panel front.
1. Insert the interconnecting cables for the operator panel front into the ap-
propriate sockets on the interface side of the PCU 20 (see Fig. 11-4 and
11-5).
2. After the operator panel front has been connected, the device is ready.
Information on how to adapt and set the interface and which connection cable
is required, is to be found in the manual of your I/O device.
Note
When connecting I/O devices, please make sure that the components are de-
signed for use in industry.
Caution
When plugging/unplugging I/O connections (keyboard, mouse, printer, etc.),
make sure that the I/O devices and the PCU are disconnected from the power
supply. Otherwise damage may result.
This does not apply to USB connections.
Connecting the The PCU 20 is supplied with 24VDC (see Fig. 11-3).
power supply
Turning on and A mains switch is not provided so that the power supply is turned on/turned off
turning off by plugging/unplugging the power supply plug (see above).
11.3.3 System boot
After connecting the power supply, the preinstalled system boots automatically
and finally shows the start screen.
11.4 Accessories
Floppy disk drive The external floppy disk drive can be connected to the PCU 20.
The port for the external floppy disk drive is located on the left side panel of the
casing (see Fig. 114).
For further information on the floppy disk drive, see Chapter 3.5 Floppy Disk
Drive in this manual.

11.5 Technical data
11.5 Technical data

Safety
Degree of protection IP20
Protection class Protection Class I in conformity with VDE 0106 T1: 1982
(IEC 536)
Safety regulations IEC 950/09.91 in conformity with DIN VDE 0805/11.93
Approval CE; FCC (Class 1 Div. II)
Power supply 3) 24V/typ. 12W, max. of 16W
Mechanical data
Dimensions (mm) Width 297 Height 267 Depth 56
Weight approx. 4kg
012 + PCU 20, tested to DIN 58200Hz: 9.8 m/secs2 9200Hz: 9.8 m/secs2
IEC 68-2-6)
to DIN IEC 68-2-29)
Heat dissipation 1) Open-circuit ventilation
Power Temp. Temperature range
range
Temperature limits 12W 0 ... 55C 20 ... 60C
DIN IEC 68-2-14
Temp. change; dewing max. of 10K/h; not permissible
Quality assurance to ISO 9001
Motherboard
Order No. 6FC5210-0DF00
...0AA0 ...0AA1 ...1AA1
...
Processor: Single-chip PC
166MHz 166MHz 233MHz
processor 2)
User memory (SDRAM) 16 MByte 32 MByte 32 MByte
Onboard FLASH memory 8 MByte 16 MByte 16 MByte
Operating system HMI embedded
Free expansion slots PCMCIA memory card
2) See ordering documents
3) For details, see Chapter Connection Conditions.
J

11.5 Technical data
Notes

Component PCU 50 12
Introduction The SINUMERIK PCU 50 components described in this section can be used to
assemble innovative operator panels. The PCU 50 units can be mounted on the
rear of the SINUMERIK operator panel fronts or, with distributed installation, can
be installed separately in a control cabinet.
The description applies to the following devices:
Operating sys- Order No.

Processor Other features
tem 6FC5 2...
...10-0DF01-0AA0
Pentium II, 333MHz NT 4.0 incl. HMI Advanced ...10-0DF02-0AA0
incl. MCI board ...20-0AA00-1AA0
...10-0DF05-0AA0
Pentium III,
III 500MHz NT 4
4.0
0
incl. MCI board ...20-0AA01-1AA0
...10-0DF20-0AA0
NT 4
4.0
0
Celeron, 566MHz incl. MCI board ...20-0AA20-0AA0
XP *) ...10-0DF21-2AA0
...10-0DF22-0AA0
NT 4
4.0
0
Celeron, 1.2GHz incl. MCI board ...20-0AA22-0AA0
XP *) ...10-0DF22-2AA0
*) Cannot be used for operation with touch panel.
Features S Rugged design (continuous operation, high noise immunity)

S Space-saving design thanks to compact dimensions (WxHxD):
297x267x80 mm
S Service-friendly design
S Easy installation with four screws at the rear side of the operator panel front
S Wide variety of mounting locations and positions
S Processor: see table above
S User memory (RAM), max. 512MB
S Hard disk 10.4GB
S Operating system Windows NT or Windows XP
S Interfaces:
Parallel interface (LPT1)

10.00
Serial interfaces: 1xRS-232-C (25-pin), 1x RS-232-C (9-pin)

PS/2 keyboard interface
PS/2 mouse interface
MPI/DP (max. 12 Mbaud)
VGA interface for external monitor
Ethernet connection 10/100 Mbaud
2 slots: 1x PCI and 1x shared PCI/ISA
PC card slot
USB interface (for Windows NT: for standard PC keyboard and mouse)
Interfaces to operator panel front:
LVDS interface,
CMOS interface,
IO interface.

11.02
12.1 Views
12.1 Views
Figures 12-1 and 12-2 show different views of the PCU 50:
Top *)
Right *)
*) Orientation with reference
to operation with OP 012
Fig. 12-1 PCU 50 v 500MHz: Perspective view with the hard disk drive installed
Width = 297
Casing cover screws

Interface for external floppy disk drive
Screws for power supply cover Height = 267

Interfaces
Handle of Hard disk drive

shipping brace Rating plate
Power supply
Depth: 80mm (without screws protruding)
Fig. 12-2 Top view of PCU 50

10.00
24V power supply Cover plate for connecting a Cover plate for PCI/ISA
PCI slot PCI slot slot connection
Slot 1
Depth = 80
Slot 2
PS/2 mouse LPT1 COM1 COM2 MPI/DP Cover plate for PC card slot
(serial
PS/2 keyboard VGA mouse) USB *) Ethernet
*) top USB interface only for PCU 50 > 500MHz
Fig. 12-3 Side view of PCU 50 from right with interfaces
Port Function
LPT1/printer Parallel interface (e.g. printer), 25-pin Sub-D socket connector
COM2 Serial interface 2 (RS-232-C), 9-pin Sub-D connector
Keyboard PS/2 keyboard connection
Mouse PS/2mouse plug
PCU 50 v 500MHz One external USB connection Windows NT: one can be used
USB
PCU 50 > 500MHz Two external USB connections for standard PC or mouse
Multi-Point-Interface/PROFIBUS DP connection
MPI/DP (RS -485)
Connecting an S7 programmable controller, 9-pin Sub-D socket connector
VGA VGA interface for external monitor, 15-pin Sub-D socket connector
Ethernet Connection for local area network (LAN)
PC card slot Slot for ATA flash card/memory card or flash card 100/200 type I/II
PCI slot Slot for expansion boards 1)
PCI/ISA slot Slot for expansion boards 1)
Power supply 24VDC
1)If expansion boards are installed, the cover plates in Fig. 12-3 are replaced by the front plates of the ap-
propriate module.
Please refer to the board description for further details.

11.02
Device fan Reset button Connection for external floppy disk drive (34-pin plug connector)
Fig. 12-4 Side view of PCU 50 from left with the port for an external floppy disk drive
The connection shown in Fig. 12-4 can be used to connect an external floppy
disk drive (see Section 12.5 and Fig. 12-16).
Note
Pressing the Reset button will cause a hardware reset. The PCU reboots.
12.2.3 Ports on bottom side of casing
There is a ground connection on the bottom side of the casing (see Fig. 12-5).
Ground connection
Fig. 12-5 Bottom side of the PCU 50
12.2.4 Casing rear side
The two interfaces for the operator panel front to be mounted are located behind
a rectangular cutout in the rear side of the casing:
the IO interface for connecting the IO USB cable and
the LVDS interface for connecting a TFT display.
Procedure for mounting the operator panel front: see Subsection 12.3.1.

10.00
Parallel interface
LPT1 Table 12-2 Assignment for the parallel interface LPT1

1 Strobe (CLK) Open Collector
O
29 Data bits 0, ..., 7 TTL level
10 ACK (ACKNOWLEDGE)
11 BUSY
I 4 7k Pull Up
4.7k
12 PE (PAPER END)
13 SELECT
14 AUTO FEED O Open Collector
15 ERROR I 4.7k Pull Up
16 INIT
O Open Collector
17 SELECT IN
1825 GND System ground (reference potential)
Signal type
I: Input O: Output I/O: Input / output
: shield/na: Shield or not assigned (not available)
Serial interface
COM1 Table 12-3 Assignment for the serial interface COM1 (PLC/RS-232-C/modem)

1 Shield
2 TxD (D1) O Serial transmitted data
3 RxD (D2) I Serial received data
5 CTS (M2) Clear To Send
I
6 DSR (M1) Data Set Ready
7 GND (E2) System ground (reference potential)
8 DCD (M5) I Receive signal level (carrier)
918 NC Unassigned
19 + 20 mA Floating current source
20 DTR (S1) O Data Terminal Ready
21 NC Unassigned
22 RI (M3) I Incoming call
2325 NC Unassigned

11.02
Serial interface
COM2 Table 12-4 Assignment for the serial interface COM2 (RS-232-C/mouse)

1 DCD (M5) Receive signal level (carrier)
I
2 RxD (D2) Serial received data
3 TxD (D1) Serial transmitted data
O
4 DTR (S1) Data Terminal Ready
5 GND (E2) System ground (reference potential)
8 CTS (M2) Clear To Send
I
9 RI (M3) Incoming call
PS/2 keyboard
interface Table 12-5 Assignment for the PS/2 keyboard interface

1 DAT I/O Keyboard data line
2 NC Unassigned

4 P5VFK O +5V (fused)
5 CLK I/O Clock line
6 NC Unassigned
PS/2 mouse
interface Table 12-6 Assignment for the PS/2 mouse interface

1 DAT I/O Data line
2 NC Unassigned

4 P5VFK O +5V (fused)
5 CLK I/O Clock line
6 NC Unassigned
USB interface
Table 12-7 Assignment for the USB interface (high current 500mA)

1 VCC O +5V (fused)
2 Data
I/O Data line
3 + Data

10.00
MPI/DP interface
Table 12-8 Assignment for the MPI/DP interface

1, 2 NC Unassigned
3 LTG_B I/O Signal line B of the MPI module
Control signal for received data stream.
4 RTS_AS I Signal active 1 when the directly con-
nected AS sends.
Return conductor (GND) for the 5V sup-
ply. Current load from a load of 90mA
5 M5EXT
O max. connected between P5EXT and
M5EXT.
6 P5EXT 5V supply (current load see M5EXT)
7 NC Unassigned
8 LTG_A I/O Signal line A of the MPI module
RTS signal from MPI module;
9 RTS_PG O
signal is 1 if PG is transmitting
Shield On plug casing
VGA interface
Table 12-9 Assignment for the VGA interface

1 R Red
2 G O Green
3 B Blue
4 NC Unassigned

9 5V O +5V (fused)

11 NC Unassigned
12 DDC_DAT I/O DDC data line
13 EXT_H Horizontal synchronization
O
14 EXT_V Vertical synchronization
15 DDC_CLK I/O DDC clock line

11.02
Ethernet RJ45
interface Table 12-10 Assignment for the Ethernet RJ45 interface

1 TD+
O Transmitted data
2 TD
3 RD+ I Received data
4,5 * SYMR
6 RD I Received data
7,8 * SYMT
S Shield
Yellow
Link Yellow LED signal (connection)
LED
Green
Activity Green LED signal (activity)
LED
* Terminated internally with 75; not required for data transmission
Display interface TFT displays with LVDS interface can be connected to this interface. It is pos-
(LVDS) sible to connect 18-bit displays with a resolution of up to 1024x768 pixels.
Max. cable length: 50cm.
Table 12-11 Assignment for the display interface (LVDS)

1, 2 P5V_D_fused + 5V display supply voltage (fused)
3 RXIN0 LVDS output signal Bit 0 ()
4 RXIN0+ LVDS output signal Bit 0 (+)
O
5, 6 P3V3_D_fused + 3.3V display voltage (fused)
8 RXIN1 LVDS output signal Bit 1 (+)
9, 10 GND System ground (reference potential)
O
12 RXIN2+ LVDS output signal Bit 2 (+)
15 RXCLKIN LVDS clock signal ()
O
16 RXCLKIN+ LVDS clock signal (+)

19, 20 NC Unassigned

10.00
Display interface D-STN and TFT displays with 5V CMOS interface and VGA resolution (640x480
(CMOS) pixels) can be connected to this interface.
Max. cable length: 50cm.
Table 12-12 Assignment for the display interface (CMOS)
Pin Name Meaning (DSTN) Name (TFT) Meaning (TFT)

(DSTN)
P5V_D_ + 5V (fused) Display + 5V (fused) Display
1, 2 P5V_D_fused
fused VCC VCC
3 GND GND
4 CLK Shift clock CLK Shift clock
5 GND GND
6 LP Horiz. sync HSYNC Horiz. sync
7 FP Vert. sync VSYNC Vert. sync
8 R0 Signal red bit 0 (LSB)
9 R1 Signal red bit 1
10 UD6 Upper data bit 6 R2 Signal red bit 2
11 GND GND
14 UD3 Upper data bit 3 R5 Signal red bit 5 (MSB)
15 GND GND
16 UD1 Upper data bit 1 G0 Signal green bit 0 (LSB)
17 UD0 Upper data bit 0 G1 Signal green bit 1
18 LD3 Lower data bit 3 G2 Signal green bit 2
19 GND GND
22 LD0 Lower data bit 0 G5 Signal green bit 5 (MSB)
23 GND GND
24 UD5 Upper data bit 5 B0 Signal blue bit 0 (LSB)
25 UD4 Upper data bit 4 B1 Signal blue bit 1
26 LD7 Lower data bit 7 B2 Signal blue bit 2
27 GND GND
30 LD4 Lower data bit 4 B5 Signal blue bit 5 (MSB)
31 VCON Contrast voltage
32 M Data enable ENAB Data enable
33 DispOn Display ON DispOn Display ON
34 Res. Reserved Res. Reserved

11.02
Front interface for Cable length: max. of 0.5m

IO USB interface
Power supply
interface Table 12-13 Assignment for the power supply interface
1 SHIELD Shield potential
2 M24 24V ground

V
3 P24 24VDC potential

10.00
12.3 Start-up
12.3 Start-up
12.3.1 Mounting
There are four mounting options for the PCU 50:
1. Standard mounting for assembly of PCU + operator panel front

2. Flat mounting for distributed installation of PCU + videolink transmitter
3. Upright mounting for distributed installation of PCU + videolink transmitter
4. Central mounting for distributed installation of PCU + videolink transmitter
A special set of mounting brackets is available for each of these mounting op-
tions.
The description for 1. can be found under Mounting in Chapter OP 012; the
description for 2., 3. and 4. can be found under Mounting PCU with videolink
transmitter in Chapter Distributed Installation.
S Point 1.
for the TFT displays, see Mounting in Chapter OP 012
for the STN displays, see Mounting in Chapter OP 010
S Points 2., 3. and 4., see Mounting PCU with videolink transmitter in Chap-
ter Distributed Installation.
Notice
When attaching the mounting brackets, make sure that they are positioned
correctly (the brackets are not symmetrical).
12.3.2 Notes on installation

Protect the PCU from severe vibrations / jolts, dust, humidity and heat.
S An external fire protection casing is required.
S Ventilation clearance:
On fan side: 100mm
On rear side: 10mm (see Fig. 12-6)

11.02
12.3 Start-up
Installation The permitted installation positions are shown in Fig. 12-6:

position
*) Device fan Interfaces

Hard disk
Interfaces
Hard disk
Interfaces Hard disk Device fan *)
Device fan
Interfaces
Device fan
Hard disk
Device fan
Device fan
Interfaces
Hard disk
Hard disk
Interfaces
Mounting position when the

Impermissible mounting position device is operated with OP 012
*) 10 mm clearance for ventilation
Fig. 12-6 Permitted installation positions of the PCU 50

Inclined position: Deviations of 5_ relative to the installation positions shown in the illustration are per-
mitted.
Connecting I/O Before you connect the PCU to a power supply, you must unlock the hard disk
devices and connect up the I/O devices (operator panel front, keyboard, mouse, ...).
1. Insert the interconnecting cables of the I/O devices into the appropriate
socket connectors on the interface side of the PCU 50 (see Fig. 12-3 and
Table 12-1.)
2. After the I/O devices have been connected, the device is ready.
is required, is to be found in the Users Manual of your I/O device.
Note
Caution

10.00
12.3 Start-up
Connecting the The PCU 50 is supplied with 24VDC (see Fig. 12-3 and Subsection 12.4.2).
power supply
Caution
! The device should only be connected to a 24VDC power supply which satisfies
the requirements of safe extra low voltage (SELV).
The cable cross-section must be large enough to ensure that no damage can
be caused by the cables if there is a short-circuit at the PCU.
Switching on and A mains switch is not provided which means that the device must be switched
off on and off at the external power supply.
12.3.4 System boot
When the power supply is switched on, the preinstalled system boots automati-
cally and finally shows the start screen (see IM4: Start-up Guide, Section Boot-
ing the system).
12.3.5 Working with PC cards
The PCU 50 is equipped with a PC card interfce. This can be used to operate
cardbus cards (32 bit) and PCMCIA cards (16 bit). Communication boards for
MODEM, FAX MODEM, ISDN, Token Ring, ETHERNET, memory extensions
and SCSI interfaces can be inserted in checkcard format.
Before using these cards:
Software The software Cardware is required for Windows NT.

See catalog for information on ordering.
BIOS settings Depending on the PCU configuration, it may be that there is no interrupt free to
operate a PC card.
If this is the case, reserve an interrupt in the BIOS setup by, in the PCI/PNP ISA
IRQ Resource Exclusion submenu, setting the interrupt the PC card needs to
reserved (default: available).
To operate the PC card, Cardbus/PCMCIA Slot in the BIOS SETUP, Hardware
Options menu, must be set to Enabled (default setting).

11.02
12.3 Start-up
Caution
Before you insert the PC card, the ejector for cardbus/PC cards must be
fully depressed. Otherwise, if you are inserting slim PC cards (e.g. Flash
Memory Cards), the card may get stuck in the slot.
The PC card then cannot be inserted properly.
Before you insert or withdraw cardbus/PC cards, you must discharge your
bodys static loading by briefly touching a grounded object.
Otherwise faults can occur.
When you plug it in, the PC card nameplate must point towards the back of
the PCU.
Otherwise the PC card and/or the PCU could be damaged.
Only take out the card when data is no longer being transferred (risk of loss
of data and system crash).
Handling When inserting the card, proceed as follows (see Fig. 12-7):
1. Open the interface cover by loosening the plastic rivets with a flat-bladed
screwdriver (there are two parts).
2. Remove the cover plate from the guide.
3. Insert the required PCMCIA card or cardbus card.
Cover plate fastening rivets
Cover plate for

PC card slot
PC card eject button

Fig. 12-7 PC card interface

10.00
12.4 Spare parts
12.4 Spare parts

The following spare parts are available for the PCU 50:
Spare part PCU variant Order number
Hard disk with mounting

g PCU 50 v 500MHz 6FC5 247-0AF08-0AA0
plate and damper PCU 50 > 500MHz 6FC5 247-0AF08-0AA1 *)
Device fan A5E00019079
Backup battery 3.6V W79084-E1003-B1
PCU 50 v 500MHz A5E00166828

Power supply 24VDC
PCU 50 > 500MHz A5E00100846
*) Can also be installed in PCU 50 v 500MHz
12.4.1 Changing hard disk
Hard disk holder
Ribbon cable for

connecting the hard disk
Plug connector for connection

of an external floppy disk drive
Fig. 12-8 PCU 50 500MHz: Perspective view with the hard disk drive swung out

11.02
12.4 Spare parts
The installed hard disk drive is connected to the socket of the PCU mother
board via a ribbon cable (see Fig. 12-8).
Procedure:
1. Lock the shipping brace of the hard disk by turning the handle to the non
operating position (see Fig. 12-9).
2. Loosen the four fastening screws of the drive holder.
3. Swing the drive holder open (see Fig. 12-8).
4. Remove the ribbon cable from the socket. To this aim, press the two locking
noses of the connector rearwards.
5. Repeat the above steps in reverse order to install the new drive. The new
drive must be of the same type as the removed one.
6. Unlock the shipping brace; otherwise, the system will not boot (see
Fig. 12-10).
Fig. 12-9 Shipping brace locked: Non-operating position
Fig. 12-10 Shipping brace not locked: Operating position

10.00
12.4 Spare parts
12.4.2 Changing power supply
1. Lock the shipping brace of the hard disk.

2. Loosen the fastening screws of the hard disk. The hard disk cables, how-
ever, may remain connected.
3. Open the casing by loosening the casing cover screws (see Fig. 12-2).
4. Remove the screws securing the power supply cover to the casing and lift
off the cover (see Fig. 12-11).
5. Only for power supply No. A5E00100846: Unplug the connecting cable con-
nector from the main board (see Fig. 12-12).
6. Release the two fastening screws on the casing.
7. Pull the power supply up and out of the casing.
8. Repeat the above steps in reverse order to install the new power supply.
Device fan Power supply cover

*) *) *)
Split rivets for

device fan *)
Fastening screws
*) Fastening screws of power supply cover Power supply
of power supply
Fig. 12-11 Removal/installation of the power supply (Art. No. A5E00166828)

11.02
12.4 Spare parts
Power supply
cover
Fastening
screws Fastening
screws
Power supply
Connector for power

supply
Fig. 12-12 Removal/installation of the power supply, Art. No. A5E00100846
12.4.3 Changing device fan
To change the device fan, proceed as follows:

1. Open the casing by undoing the casing cover screws (see Fig. 12-2).
2. Pull the top, long card (if inserted) out of the PCI slot (see Fig. 12-23).
3. Remove the card guide rail by taking out the split rivets (Fig. 12-13).
4. Disconnect the device fan cable from the socket (see Fig. 12-14 and
Fig. 12-15).
5. Pull out the two split rivets, then the hollow rivets (see Figs. 12-13, 12-15
and 12-22).
6. Change the device fan.
7. Installation is in reverse order.
Note
When installing the device fan, note the direction of flow from the device fan
(blower outward; note the arrow on the device fan casing).

10.00
12.4 Spare parts
Split rivets for at- *) Split rivets for at-

taching card guide taching device fan
rail (see also (see also Fig. 12-22)
Fig. 12-23)
Device
fan
*) Direction of air flow
Fig. 12-13 Device fan replacement for PCU 50 v 500MHz
12.4.4 Changing battery
Battery supply for A backup battery (3.6V lithium battery) supplies the hardware clock with power
clock and even when the device has been switched off. In addition to the time, the BIOS
configuration settings of the device are also stored. If the backup battery fails to operate or if it
is separated from the plug contact, these data are lost.
Thanks to the low power consumption of the clock and the high capacity of the
lithium battery, the battery can back up the clock for at least 8.5 years. For this
reason, changing the battery is hardly ever necessary.
Battery voltage too If the battery voltage is too low, the current time will be lost and a correct device
low configuration can no longer be guaranteed.
Changing the In this case, the backup battery must be replaced with a new one. The battery is
battery located on the main board (see Figs. 12-14 and 12-15).
Warning
! Risk of injury and damage, risk of pollutant discharge.
A lithium battery can explode if handled incorrectly. Pollutants can be dis-
charged if old batteries are not disposed of correctly.
Do not throw new or discharged lithium batteries into a fire. Do not solder the
cell body. Do not recharge lithium batteries. Do not force open lithium batteries.
Lithium batteries should only be ordered from Siemens (Order No.:
W79084-E1003-B1).
Wherever possible, old lithium batteries should be returned to the battery
manufacturer/recycler and disposed of as special waste.

11.02
12.4 Spare parts
Proceed as follows (PCU 50 v 500MHz, see Fig. 12-14; PCU 50 > 500MHz,
see Fig. 12-15):
1. Turn off the device, remove the mains cable and release all interconnecting
cables.
3. Remove the battery plug (see also Fig. 12-23) from the socket on the mother
board and release the battery clip.
4. Install the new battery and secure it.
5. Plug the battery plug on the mother board.
6. Close the device.
RAM bank 0 Base for

RAM bank 1
(not assigned)
Backup battery
Fixing hole for
board retainer
Battery
connection Connector for device fan
plug
Fig. 12-14 Main board PCU 50 v 500MHz (cutout) with location of RAMs and backup battery
RAM bank 1
RAM bank 0
Connector for proces-

sor fan
Backup battery Connector for device fan
Fig. 12-15 Main board PCU 50 > 500MHz (cutout) with location of RAMs and backup battery

10.00
12.5 Accessories
12.5 Accessories
Accessories for PCU 50 are:
Component Order numbers

External floppy disk
6FC5 235-0AA05-0AA1
drive
PCU 50 v 500MHz PCU 50 > 500MHz

Memory expansion 128MB 6ES7791-0KS00-0XA0 6ES7648-2AC10-0CA0
PC 100) 4)
(SDRAM PC-100) 256MB 6ES7791
6ES7791-0KT00-0XA0
0KT00 0XA0 6ES7648
6ES7648-2AC20-0CA0
2AC20 0CA0
Expansion board (according to AT/PCI specification)
standard 1) 6FC5 248-0AF20-2AA0
flat 2) 6FC5 248-0AF20-0AA0
Mounting bracket
upright 2) 6FC5 248-0AF20-1AA0
central 3) 6FC5 248-0AF20-3AA0
____________________________________________
1) For assembly of PCU + operator panel front
2) For distributed installation of PCU + videolink transmitter
3) For distributed installation of PCU + videolink transmitter + operator panel
front
4) See Fig. 12-14 and 12-15.
12.5.1 External floppy disk drive
Fig. 12-16 shows the external floppy disk drive that can be connected to the
drive connection on the left side of the casing (see Fig. 12-4).
For further information, see Chapter 3.5 Floppy Disk Drive in this manual.
Fig. 12-16 External floppy disk drive

11.02
12.5 Accessories
12.5.2 Memory expansion
Two slots are provided on the mother board (Banks, see Fig. 12-14 and
12-15) for 144-pin SO DIMM memory modules. Use these modules to extend
the user memory of the PCU to 512MB.
Standard memory The basic configuration is a 128/256MB SDRAM module.
Memory (MByte) 64MB submo- 128MB submo- 256MB submo-

dule dule dule
128 2
128 1
192 1 1
256 2
256 1
320 1 1
384 1 1
512 2
Installation Procedure:
2. Insert the module(s) into the base (Fig. 12-14). When doing so, pay attention
to the recess (anti-rotation element) on the plug side of the SO-DIMM mod-
ule.
3. Press the module downwards, applying slight pressure until the locking
snaps into place.
Caution
Risk of damage! The submodules must be seated firmly in the receptacle,
otherwise they may fall out and be damaged.
System boot The memory configuration is detected automatically when the system is booting
(see IAM: Start-up Guide, Section Booting the system).
Memory After expanding the memory, it is advisable to then optimize the use of the com-
optimization puter resources.
(Windows NT *) To do this, in the Windows interface Control Panel, increase the size of virtual
memory (also called the SWAP file) to correspond to the memory extension.
Proceed as follows:
1. When booting, use the Service menu to start the SINUMERIK Desktop, as de-
scribed in the HMI Advanced installation and startup (IM4) document in Sub-
section 3.4.5.
2. Activate the Control Panel by means of Start / Settings / Control Panel.

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12.5 Accessories
3. In the Control Panel, choose System / Performance / Virtual Memory /

Change. This will display a window corresponding to Fig. 12-17.
4. Modify the values Initial Size and Maximum Size. These should be the same
size and exceed the installed RAM by at least 12 MByte.
*) For Windows XP: see IM4 (Start-up Guide for HMI Advanced).
Typical recommended values:
Memory capacity (MByte) Initial Size Maximum Size

512 550 550
5. Activate the Set menu button and exit the menu by pressing OK.
Fig. 12-17 Adjusting virtual memory
Note
In the event of a repair and return of equipment, the memory extension is taken
into account.
In the event of a spare parts and return goods service, the memory extension is
not taken into account.
12.5.3 Expansion boards
The PCU 50 is designed for use of modules according to the AT/PCI specifica-
tion (see Fig. 12-22).

11.02
12.5 Accessories
Note
You must sign an OEM agreement before you can use PCI/ISA modules.
It is not recommended to use ISA modules, since with future PCUs, this inter-
face is not installed.
The dimensions of the boards must not exceed the specified dimensions.
Otherwise, contact problems, malfunctions and installation difficulty cannot be
ruled out. The diagrams show cards of the full AT/PCI overall length. Depending
on the slot, restrictions may apply with respect to the overall length.
17mm
6.89
106.7mm
4.201
A31 A1
Fig. 12-18 XT module
17mm
6.89 121.92mm
4.8
C18 C1 A31 A1
Fig. 12-19 AT module
174.6mm
6.875
106.66mm
8.19mm
4.2
0.322
Fig. 12-20 Short PCI module (5V)

10.00
12.5 Accessories
26mm
10.48
106.68mm
4.2
8.19mm
0.322
Fig. 12-21 2/3-length PCI module (5V)
Note
To allow longer PCI modules to be guided along the guide rails of ISA modules,
they must be provided with a so-called extender. This should be included in the
scope of supply of the longer PCI module.
For expansion boards
PCI slot Shared ISA/PCI slot Bus board Device fan

Cover plates
Split rivets
for device
fan
(see also
Fig. 12-13)
Fastening
screws for
cover plates
or external mod-
ule connections Board Fastening screw for
retainer board retainer
Fig. 12-22 Slots for expansion boards

11.02
12.5 Accessories
Fastening
Device screw for
fan board
retainer
Board
retainer
Battery
connector
Guide rail for
expansion
board
Plastic
support
Fig. 12-23 Mounting of an expansion board
Installation Proceed as follows:
2. Release the fastening screw to remove the board retainer and remove
the plastic holder (if fitted) from its slot by pushing it through to the inside
(see Figs. 12-22 and 12-23).
3. Release the fastening screws to be able to remove the corresponding cover
plate (see also Fig. 12-3).
4. Carefully insert the module into the desired slot; firm seat should be en-
sured.
5. Screw the connecting plate of the module tight.
6. Install the board retainer.
7. Locate the module by inserting a new plastic holder (enclosed) into the ap-
propriate slot of the board retainer until it locates the edge of the module with
its groove. Use a diagonal cutter to cut off the protruding part of the plastic
holder.
12.5.4 Mounting brackets
The four mounting options for the PCU 50 have already been described in Sub-
section 12.3.1.
A special set of mounting brackets is available for each of these mounting op-
tions (see catalog).

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12.6 System information

When the system boots, the system parameters stored in the BIOS (Basic Input
Output System, see Subsection 12.6.2) become operative.
For more detailed information, refer to the Manual IAM (Start-up Guide), Sec-
tion Booting the system.
12.6.1 Boot manager
If you let the system boot automatically, a query will appear on the screen
whether you will branch
1. to the User main menu or
2. to the Service menu.
As a user, you will usually choose no. 1. Use the Input key (see Fig. 12-24) to
confirm your selection and let the system boot to the chosen menu.
12.6.2 BIOS default settings
The following table contains all adjustable BIOS parameters together with their
default values:
Table 12-14 Adjustable standard BIOS parameters of the PCU 50
Designation Default setting

Menu / Parameter PCU 50 v 500MHz PCU 50 > 500MHz
and PCU 70
Main
1.44MB, 3 1/2 (connected externally
Disk A:
=> in addition, disable floppy disk check)
Primary Master C: 20496MB
Primary Slave None
Secondary Master None
Secondary Slave None
Memory Cache Write back
Boot Options
Quick Boot Mode Enabled
SETUP prompt Enabled
POST Errors Enabled Disabled
Floppy check Disabled
Summary screen Enabled Disabled
Keyboard Features
Num Lock Off
Key Click Disabled
Keyboard auto-repeat rate 30/secs
Keyboard auto-repeat delay 1/2secs

11.02

and PCU 70
Hardware Options
PCI MPI/DP Enabled
On-board Ethernet Enabled
LAN Remote Boot Enabled
Cardbus/PCMCIA slot Enabled
Fan control Enabled
SafeCard Functions Enabled
Legacy USB support Enabled
CRT/LCD selection Simultan
LCD screensize Expand
DSTN contrast 154
PS2 Mouse AUTO
Advanced
COM/LPT Configuration
Internal COM1 Enabled
Base I/O address 3F8
Interrupt IRQ4
Internal COM2 Enabled
Base I/O address 2F8
Interrupt IRQ3
Internal LPT1 Enabled
Mode EPP
Base I/O address
Interrupt IRQ7
DMA channel
PCI Configuration: PCI Device Slot 1 / 2
Option ROM scan Enabled
Enable master Enabled
Latency timer 0040 h
PCI Device Slot 3 / 4 *)
Option ROM scan Enabled
Enable master Enabled
Latency timer 0040 h
PCI/PnP ISA IRQ Exclusion
IRQ3 Available
IRQ4 Available
IRQ5 Available
IRQ7 Available
IRQ9 Available

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and PCU 70
IRQ10 Available
IRQ11 Reserved
PCI IRQ line 1 5
PCI IRQ line 2 Auto-select
PCI IRQ Line 3 / 4 *) Auto-select
Installed O/S Other
Reset configuration data No
Floppy disk controller Enabled
Primary
Local bus IDE adapter Both
& secondary
Large disk access mode DOS
Hard disk pre-delay Disabled
Memory gap at 15MB Disabled
Video Adapter Settings
Frame Buffer Size 8MB
AGP Rate 2x
Default Primary Video Adaptor AGP
Security
Supervisor password is Disabled
User password is Disabled
Set supervisor password [Enter]
Set user password [Enter]
Password on boot Disabled
Fixed disk boot sector Normal
Diskette access Supervisor
Power
APM Enabled
Power savings Disabled
Standby timeout off
Hard disk timeout Disabled
Boot Sequence
Hard drive
Removable devices
CD-ROM Drive
IBA 4.0 (Intel Boot Agent) 22 Slot 0048
*) BIOS lines PCI Device Slot 3 / Slot 4 and PCI IRQ Line 3 / Line 4:
only available for PCU 70 and PCU 50 v 500MHz;
only relevant for PCU 70

11.02
12.6.3 Changing BIOS settings
After installing or mounting additional components (e.g. ext. floppy disk drive),
these must be registered with the system in the BIOS setup.
You can activate this via the operator panel front (Fig. 12-24) as described be-
low.
1. Boot the device.
2. After you are prompted to activate BIOS Setup, press key <F2>. The BIOS
Setup menu will appear.
3. In the menu, use the cursor keys for navigating to the desired selection field,
e.g. Disk A:
4. Change the setting using the + key (simultaneously press <SHIFT> and
<X>) or the <> key (in the numerical key group).
5. If required, you can use the right/left cursor keys to go to other Setup
menus.
6. Use <Escape> (<Alarm Cancel> key) to access the Exit menu (can also be
accessed by continuously pressing the cursor right key).
7. Press the <Input> key to quit the setup menu.
8. Press the <Input> key to confirm your decision to exit BIOS Setup with
Yes.
The system will then boot as described in Subsection 12.6.1.
Shift key
SHIFT
ALARM
Escape key
CANCEL
Input key
INPUT
Press <F2> to enter BIOS setup
F2 key
Fig. 12-24 PCU 50: Using the BIOS Setup via an operator panel front
Note
Any changes to BIOS settings, with the exception of the Boot sequence and
the LPT mode (EPP, EPC), require you to sign an OEM agreement.

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12.7 Technical data
12.7 Technical data

Safety
Protection class Protection Class I in conformity with VDE 0106 T1: 1982
(IEC 536)
Approval CE
Power supply 1) 24V/typ. 40 W/max. 130W
Mechanical data
Weight approx. 6kg
Noise < 55dB(A) to DIN 45635
Vibration (whole system
1058Hz: 0.075mm 59Hz: 7.5mm
OP 012 + PCU 50, tested to
58200Hz: 1g 9200Hz: 2g
DIN IEC 68-2-6) 2)
Shock resistance (whole sys-
tem OP 012 + PCU 50, tested 50 m/secs2, 30 msecs 300 m/secs2, 6 msecs
to DIN IEC 68-2-29)
Heat dissipation (see Chapter
Open-circuit ventilation
Heat Dissipation)
Max. output for Temp.
Temperature range
extensions 3) range
Temperature limit values 15W 5 ... 55C
(whole system 20W 5 ... 50C 20 ... 60C
OP 012 + PCU 50) 30W 5 ... 45C
Limits for rel. humidity 10 ... 80% 5 ... 95%
Tested to DIN IEC 68-2-30
Temp. change; dewing max. 10K/h; not permissible
Motherboard
PCU 50 Intel Pentium II/333 or P. III/500
v 500MHz with Windows NT
Processor / operating system
PCU 50 Intel Celeron 566 or 1.2GHz
> 500MHz with Windows NT or XP 4)
User memory 128 MB SDRAM, max. 512 MByte 4)
1 PCI (max. 265mm long)
Unused expansion slots
1 shared ISA/PCI (max. 175mm long)
Max. power consumption PCI slot ISA slot Combined
5V 2A 2A 3A
12V 0.3A 0.3A 0.6A
12V 0.1A 0.1V 0.15A
Hard disk drive 2.5, EIDE, UDMA33; for capacity, see 4)

11.02
12.7 Technical data
1) For further information, see Chapter Connection Conditions

2) The additional ruggedness ensures continuous reliable operation when the
device is subjected to more severe vibration even when the limit values are
exceeded temporarily.
3) PCI/ISA slots, PC card and USB interface count as expansions.
4) See ordering documents
J

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12.7 Technical data
Notes

Component PCU 70 13
Note
The PCU 70 component is based on the PCU 50 component. We will therefore
frequently refer to the PCU 50 during the technical description. The main differ-
ence is the increased number of PCI slots and the resulting increase in the
overall depth of the device.
Introduction The SINUMERIK PCU 70 component is installed in a distributed configuration in

a control cabinet (see Chapter Distributed Installation).
Features The PCU 70 serves as the basic component for distributed PC-based machine
control panels (e.g. OP 012 or OP 015):
S Rugged design (continuous operation, high noise immunity)
S Dimensions (WxHxD): 297x267x122mm
S Service-friendly design
S Processor, min. Pentium III, 500MHz
S User memory (RAM), max. 512MB
S Hard disk, min. 10.4GB (interchangeable)
S Operating system, Windows NT 4.0
S Interfaces:
Parallel interface (LPT1)
Serial interfaces, 2x RS-232-C
PS/2 mouse interface
MPI/DP (max. 12 Mbaud)
VGA interface for additional monitor
Ethernet connection 10/100 Mbaud
4 slots: 3x PCI and 1x shared PCI/ISA
PC card slot
USB interface
Interfaces to operator panel front (via videolink transmitter):
LVDS interface
CMOS interface
IO interface
Order numbers PCU 70: 500MHz, 128MB, Win NT4.0 6FC5 210-0DF04-0AA0
Flat mounting bracket (must also be ordered): 6FC5 248-0AF20-0AA0

10.00
13.1 Views
13.1 Views
Left
Top
Right
Fig. 13-1 Perspective view of PCU 70
Width = 297
Interface for ext. floppy disk drive
Casing cover screws
Screws for power supply cover

Height = 267
Interfaces
Screws securing
hard disk module
Handle of
shipping brace Hard disk module Depth = 122mm (without screws protruding)
Fig. 13-2 Top view PCU 70

11.02

24 V power supply Power supply shield Cover plates for PCI slot connections
Slot 3 (Slave)
Slot 4 (Slave)
Depth = 122
Slot 1 (Master/Slave)
Slot 2 (Master/Slave)
PS/2 mouse LPT1 COM1 MPI/DP Cover plate for PCI/ISA

COM2
(serial slot connection
PS/2 keyboard VGA mouse) USB Ethernet Cover plate for PC card slot
Fig. 13-3 Side view of PCU 70 from right (see Fig. 13-1) with interfaces
Port Function
LPT1/printer Parallel interface (e.g. printer), 25-pin Sub-D socket connector
COM2 Serial interface 2 (RS-232-C), 9-pin Sub-D connector
Keyboard PS/2 trackball keyboard connection
Mouse PS/2mouse plug
USB External connection for Universal Serial Bus
MPI/DP (RS-485) Multi-Point-Interface / PROFIBUS DP connection; Connecting an S7 program-
mable controller, 9-pin Sub-D socket connector
VGA VGA interface for external monitor, 15-pin Sub-D socket connector
Ethernet Connection for local area network (LAN)
PC card slot Slot for ATA flash card/memory card or flash card 100/200 type I/II
PCI slot Three slots for expansion boards 1)
PCI/ISA slot Slot for expansion board 1)
Power supply 24VDC
1) If expansion boards are installed, the cover plates in Fig. 13-3 must be replaced by the front plates of the appropriate
module. See the description for the respective module.
Caution
The MCI board of the SINUMERIK 840Di should be fitted in Slot 1 only.

10.00
Connection for external

floppy disk drive
(34-pin plug connector)
Device fan Reset button
Fig. 13-4 Side view of PCU 70 from left (see Fig. 13-1) with the port for an external floppy disk drive
The connection shown in Fig. 13-4 can be used to connect an external floppy
disk drive (see Section 13.5 and Fig. 13-7).
Note
Pressing the Reset button will cause a hardware reset. The PC reboots.
13.2.3 Ports on bottom side of casing
There is a ground connection on the bottom side of the casing (see Fig. 13-5).
Ground connection
Fig. 13-5 Bottom side of PCU 70 with ground connection

11.02
13.2.4 Casing rear side
The two interfaces for connecting an operator panel front (via the videolink
transmitter; see Chapter Distributed Installation) are behind a rectangular cut-
out in the rear side of the casing:
the IO interface for connecting the IO cable and
the LVDS interface for connecting a TFT display.
Procedure for mounting the videolink transmitter: see Subsection 13.3.1 and
Chapter Distributed Installation.
See Pin assignments in Chapter Component PCU 50.

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13.3 Start-up
13.3 Start-up
13.3.1 Mounting and installation
The PCU 70 is intended for flat mounting in a distributed installation comprising

PCU + videolink transmitter (see Chapter Distributed Installation.
A special set of mounting brackets are available for this purpose (see Sec-
tion 13.4).
The mounting description can be found under Mounting CPU with videolink
transmitter in Chapter Distributed Installation.
Notice
When attaching the mounting brackets, make sure that they are positioned
correctly (the brackets are not symmetrical).
13.3.2 Notes on installation

Protect the PCU from severe vibrations / jolts, dust, humidity and heat.
S An external fire protection casing is required.
S Ventilation clearance:
On fan side: 100mm
On rear side: 10mm (see Fig. 13-6)
Installation The permitted installation positions are shown in Fig. 13-6:

position
Interfaces
Device fan
Hard disk
Device fan
Device fan
Interfaces
Hard disk
Hard disk
Interfaces
Impermissible mounting
position
Fig. 13-6 Permitted installation positions of the PCU 50

Inclined position: Deviations of 5_ relative to the installation positions shown in the illustration are per-
mitted.

11.02
13.3 Start-up
Connecting I/O Before you connect the PCU to a power supply, you must unlock the hard disk
devices and connect up the I/O devices (operator panel front, keyboard, mouse, ...).
1. Insert the interconnecting cables of the I/O devices into the appropriate
socket connectors on the interface side of the PCU 70 (see Fig. 13-3 and
Table 13-1.)
2. After the I/O devices have been connected, the device is ready.
is required, is to be found in the Users Manual of your I/O device.
Note
Caution
Connecting the The PCU 70 is supplied with 24VDC (see Fig. 13-3).
power supply
Caution
! The device should only be connected to a 24VDC power supply which satisfies
the requirements of safe extra low voltage (SELV).
The cable cross-section must be large enough to ensure that no damage can
be caused by the cables if there is a short-circuit at the PCU.
Switching on and A mains switch is not provided which means that the device must be switched
off on and off at the external power supply.
13.3.4 System boot
See System boot in Chapter Component PCU 50.
13.3.5 Working with PC cards
See Working with PC cards in Chapter Component PCU 50.

10.00
13.5 Accessories
13.4 Spare parts

Spare parts for the PCU 70 are:
Spare part Order number

Hard disk with mounting plate and damper 6FC5 247-0AF08-0AA1
Device fan A5E00019079
Backup battery 3.6V W79084-E1003-B1
Power supply 24VDC A5E00117073
Spare part Information on spare part replacement is given under Spare parts in Chapter
replacement Component PCU 50.
It is important to note that the power supply cover of the PCU 70 has one screw
more than the PCU 50 (see Fig. 13-2)
13.5 Accessories
Accessories Order number

Mounting bracket (flat) 6FC5 248-0AF20-0AA0
External floppy disk drive 6FC5 235-0AA05-0AA1
Memory expansion
128MB SO-DIMM PC-133 6ES7 791-0KS00-0XA0
256MB SO-DIMM PC-133 6ES7 791-0KT00-0XA0
Expansion boards
13.5.1 External floppy disk drive

Fig. 13-7 shows the external floppy disk drive that can be connected to the drive
connection on the left side of the casing (see Fig. 13-4).
For further information, see Chapter 3.5 Floppy Disk Drive in this manual.
Fig. 13-7 External floppy disk drive

11.02
13.5.2 Memory extension
Two slots are provided on the mother board (Banks, see Changing battery in
Chapter Component PCU 50) for 144-pin SO DIMM memory modules. Use
these modules to extend the user memory of the PCU to 512MB.
Standard memory The basic configuration is a 128MB SDRAM module.
Memory (MByte) 128MB submodule 256MB submodule

128 1
256 2
256 1
384 1 1
512 2
Mounting, system See Memory expansion in Chapter Component PCU 50.

boot
13.5.3 Expansion boards

See Expansion boards in Chapter Component PCU 50.

Information on the boot manager and reading out/changing BIOS settings can
be found under System information in Chapter Component PCU 50.

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13.7 Technical data
13.7 Technical data

Safety
Protection class Protection Class I in conformity with VDE 0106 T1: 1982 (IEC 536)
Approval CE (if PCU 70 is installed in fully-enclosed control cabinet)
Power supply 1) 24V/typ. 40W/max. 145W
Mechanical data
Noise < 55 dB(A) to DIN 45635
Mechanical environmental conditions Operation Transport
(in packaging)
1058Hz: 0.075mm 59Hz: 7.5 mm
Vibration (tested to DIN IEC 68-2-6) 2)
58200Hz: 1g 9200Hz: 2g
Shock resistance (tested to DIN IEC 68-2-27,
50 m/secs2, 30 msecs 300 m/secs2, 6 msecs
Ea)
Heat dissipation (see Chapter Heat Dissipa- Open-circuit ventilation
tion)
max. output for ex- Temp. Temperature range
tensions 3) range
10W 5 ... 50C
20 ... 60C
40W 5 ... 45C
Limits for rel. humidity 10 ... 80% 5 ... 95%
Tested to DIN IEC 68-2-30
Temp. change; dewing max. of 10K/h; not permissible
Motherboard
Processor Intel Pentium III/500 with Windows NT
User memory 128MB SDRAM, max. 512MB 4)
3xPCI (max. 265mm long),
Unused expansion slots
1x shared ISA/PCI (max. 175mm long)
5V 12V 12V
Max. power consumption,
Max consumption dependent on fitted
expansion boards 1 PCI or ISA slot 2A 0.3A 0.1A
total 6A 0.6A 0.1A
2.5 , EIDE, UDMA33, min. 10 Gbyte (interchangeable),
Hard disk drive
1GB of which is used for user data 4)
1) For further information, see Chapter Connection Conditions.
2) The additional ruggedness ensures continuous reliable operation when the device is subjected to more
severe vibration, even when the limit values are exceeded temporarily.
3) PCI/ISA slots, PC card and USB interface count as expansions.
4) See ordering documents.
J

Distributed Installation 14
Use With SINUMERIK distributed installation it is possible to connect up to three
physically remote operator panel fronts of the same kind to a PCU.
This spatial flexibility allows you to install the PCU at less hazardous locations
of the system (e.g. control cabinet).
Table 14-1 Max. permitted number of operator panel fronts which can be combined with a PCU in a distributed instal-
lation
Operator Number Number Number Number Number Number Number Number

panel of of of of of of of of
PCU ... OP 010 OP 010S OP 010C OP 012 TP 012 OP 015 OP 015A BT 15
416mm
PCU 50 2 3 3 3 3 3 2
PCU 70 2 2 2 2 2 2 2
Features S Used for

slimline operator consoles with any orientation
closed fan-free operator consoles
S Robust due to separate installation of the PCU in protected areas (e.g. con-
trol cabinet)
S Simple implementation of a second/third operator panel front with digital
screen quality
S Additional USB ports for service and I/O devices (keyboard, mouse, etc.)
S Extensive use of software-neutral technology for all operating systems
Components SINUMERIK distributed installation comprises a selection of components
based on the building block principle suitable for a wide variety of operator
panel fronts:
S Videolink transmitter for mounting on a PCU 50/70

1:1 (with one output) or
1:2 (with two outputs)
S Videolink receiver for mounting on a TFT operator panel front (OP 010 S/C,
OP 012, OP 015, OP 015 A, TP 012)
Note
OP 010 is not supported (owing to STN color display).
S Videolink cable in standard lengths 10m, 15m and 20m

14 Distributed Installation 11.02
10.00
S Application-specific fixing sets such as

flat mounting bracket for PCU with videolink transmitter in control cabi-
net
upright mounting bracket for PCU with videolink transmitter in control
cabinet
central mounting bracket for PCU with videolink transmitter behind op-
erator panel front (not with OP 010S)
standard mounting bracket for mounting the receiver on the operator
panel front (not required for OP 010S).
Note
The various transmitter and receiver types cannot be freely combined with
each other.
Table 14-2 shows which combinations are possible.
Table 14-2 Possible combinations of the various transmitter and receiver types
The order numbers are 6FC5247-...
Transmit- ...0AF20-0AA0 ...0AF21-0AA0 ...0AF22-1AA0 ...0AF22-2AA0

ter
Receiver
...0AF20-1AA0 + +
...0AF21-1AA0 + +
...0AF22-0AA0 + +

11.02
10.00 14 Distributed Installation
14.1 Overview
14.1 Overview
The maximum cable length for the videolinks is 20m.
Caution
All of the displays used in a system must have the same resolution since they
can be damaged within a few seconds if they are incorrectly set.
It is therefore essential to observe the Caution note in Subsection 14.4.1!
14.1.1 Configurations
Fig. 14-1 and 14-2 show the possible configurations for the distributed installa-
tion:
Videolink 6FX20021VL001xx0
Videolink
Transmitter Videolink receiver
Videolinkreceiver
Transmitter1:1
1:1
PCU
PCU Operator panel frontfront
Operator panel
2xUSB
USB
USB USB
Mounting bracket
6FC5 2480AF000AA0 or
6FC5 2480AF201AA0 required
Videolink 6FX20021VL001xx0
Videolink Videolink receiver
Videolinkreceiver
Transmitter
Transmitter1:2
1:2
PCU
PCU Operator panel
Operator frontfront
panel
2xUSB
USB
Videolink receiver
Videolinkreceiver
USB USB 6FX20021VL001xx0
Mounting bracket Operator panel
Operator frontfront
panel
6FC5 2480AF000AA0 or
2xUSB
PCU
transmitter
USB
Videolink
Mounting bracket
6FC5 248-0AF20-2AA0
PCU
required
Mounting bracket Mounting bracket

flat upright
6FC5 2480AF200AA0 6FC5 2480AF201AA0
Fig. 14-1 Distributed installation configuration with up to two operator panel fronts

11.02
10.00
14.1 Overview
Configuration with In Fig. 14-1 (left top and center), the PCU and videolink transmitter components
up to two operator are combined to form a unit. They can be mounted physically separated from
panel fronts the operator panel front, i.e. in a distributed installation (e.g. in a control cabi-
net).
The two installation options shown bottom left can be used: flat mounting and
upright mounting.
A third installation option (not shown here), central mounting, is identical to flat
mounting, except an additional operator panel front is directly mounted behind
the videolink transmitter (see Fig. 14-2).
The mounting kits (see Subsection 10.5.3) must be ordered separately (see
below).
The associated operator panel front and videolink receiver components which
are combined to form a unit are shown on the right. They can be mounted in an
operator console.
Configuration with Fig. 14-2 shows another application option for distributed configuration:
up to 3 operator The PCU with the videolink transmitter is mounted behind an additional (central)
panel fronts operator panel front (not intended for OP 010S). This allows up to three operator
panel fronts to be operated at a PCU at the same time.
PCU
PCU USB
Videolink
Videolink transmitter 1:1 Videolink receiver
VideolinkReceiver
6FX20021VL001xx0
Operator panel front Operator panel front
2xUSB
USB
USB USB
Mounting bracket
Receiver
PCU
PCU USB
Videolink
Videolink transmitter 1:2 Videolink receiver
VideolinkReceiver
6FX20021VL001xx0
Operator panel front Operator panel front
2 xUSB
USB
USB USB
Mounting bracket Videolink receiver

VideolinkReceiver
6FX20021VL001xx0
2xUSB
USB
Mounting bracket
Fig. 14-2 Configuration with up to three operator panel fronts on one PCU

11.02
11.02
14.1 Overview
Notice
If a central operator panel front is used, it is important to ensure that DIP switch
S2 of the videolink transmitter is set to the correct position (see Section 14.4).
Order numbers 6FC5 247-0AF22-1AA0 Videolink transmitter 1 : 1 (see Fig. 14.4)

6FC5 247-0AF22-2AA0 Videolink transmitter 1 : 2
6FC5 248-0AF20-0AA0 Flat mounting bracket for PCU 50/70
6FC5 248-0AF20-1AA0 Upright mounting bracket for PCU 50
6FC5 248-0AF20-3AA0 Central mounting bracket for PCU 50
6FX2002-1VL00-1BA0 Videolink cable 10m
6FX2002-1VL00-1BF0 Videolink cable 15m
6FX2002-1VL00-1CA0 Videolink cable 20m
6FC5 247-0AF22-0AA0 Videolink receiver
6FC5 248-0AF20-2AA0 Mounting bracket for videolink receiver behind
operator panel front (identical to that for PCU)
14.1.2 View
Videolink
transmitter 1:2
PCU 50
Videolink
cable ( 20m)
*) see note below
Fig. 14-3 View of distributed installation: Example with two OP 012 operator panel fronts

11.02
10.00
14.1 Overview
Fig. 14-3 shows the components for distributed installation:

The PCU communicates with two operator panel fronts (here OP 012) by
means of
videolink transmitters 1:2 mounted on the PCU
two videolink cables and
two videolink receivers (not visible in the illustration since they are mounted
behind the operator panel fronts; see Fig. 14-5 and 14-19).
Power supply Operator panel fronts, PCU and videolink receivers should be supplied with
24VDC (the videolink transmitter is supplied with power from the PCU).
Note
To prevent error messages when the PCU is booted, the operator panel front
should be switched on at the same time as the PCU via the 24VDC supply.

11.02
11.02
14.2 Description of components
Configuration Fig. 14-4 shows a videolink transmitter (mounted on the PCU with the aid of the
flat mounting bracket, see Subsection 14.5.1).
*) Always observe Subsection 14.4.1! Cover plate
for covering the opening used
to connect a central operator
Flat mounting panel front
bracket
Videolink
transmitter
Display coding
switch S1 *)
USB-A
PCU 50
Connections for
videolink cable USB-A
Fig. 14-4 PCU with videolink transmitter (1:2 variant) and flat mounting bracket
Description The videolink transmitter is mounted on the underneath of the PCU between the
mounting brackets. It does not require a separate power supply because it is
supplied via the interfaces to the PCU.
The videolink transmitter is available in two versions:

1. Videolink transmitter 1:1
S Inputs (not visible in Fig. 14-4):

1x LVDS interface
1x IO/USB interface
S Outputs:
1x videolink for 1, ..., 20m (video data plus USB signals)
1x USB-A
1x LVDS interface (for connecting a centr. operator panel front)
1x IO/USB interface ( )
2. Videolink transmitter 1:2
S Inputs: same as 1.
S Outputs:
2x USB-A
1x LVDS interface (for connecting a centr. operator panel front)

11.02
10.00
14.2.2 Videolink receiver
2x USB-A Videolink receiver
Videolink cable
Cable tie
(see Section 14.6)
Keyboard interface
Power supply
Supporting plate
Standard mounting bracket

(not required for OP 010S)
Fig. 14-5 Videolink receiver for mounting to OP 010C, OP 012, OP 015, OP 015A or TP012
Fig. 14-5 shows the position of the receiver interfaces:
S Inputs:
1x 24VDC power supply
S Outputs:
2x USB-A
1x keyboard interface (for USB keyboard)
1x LVDS interface (not visible in Fig. 14-5)
14.2.3 Cables
The videolink cable is available in three standard lengths:
S 10m: Order No. 6FX2002-1VL00-1BA0

S 15m: Order No. 6FX2002-1VL00-1BF0
S 20m: Order No. 6FX2002-1VL00-1CA0
Other lengths require special preparation and have longer delivery times.

11.02
11.02
Fig. 14-6 Videolink cable
The housing can be removed on angular connectors. This reduces the outer
dimensions and allows the connector to be introduced into conduits with 35mm
diameter or greater. The minimum diameter for permanently mounted connec-
tors is 42mm.
Note
These high-quality cables should not be shortened or lengthened.
For technical reasons, the length is limited to max. of 20m.

11.02
10.00
14.3 Interfaces
14.3 Interfaces
14.3.1 Hardware interfaces Overview

Table 14-3 Overview of hardware interfaces
Interface
Type Function Designa- I/O Type
tion
Videolink (incl. USB) X101 O Multiple contact strip,
36-pin
USB interface X102 O USB-A
LVDS interface X103 I Plug connector, 2 x
Videolink
10-pin
transmit-
I/O interface for operator X104 I/O Plug connector, 2 x
ter
panel of PC 13-pin
1:1
LVDS interface X107 O Plug connector, 2 x
to central operator panel front 10-pin
I/O interface to central X108 I/O Plug connector, 2 x
operator panel front 13-pin
same as videolink transmitter
Videolink
1:1; in addition:
transmit-
second videolink (incl. USB) X105 O Multiple contact strip,
ter
36-pin
1:2
USB interface X106 O USB-A
Videolink (incl. USB) X201 I Multiple contact strip,
36-pin
USB interface X203/204 O 2x USB-A
Keyboard interface X205 O Plug connector, 2 x
Videolink 5-pin
receiver Power supply X206 I Terminal block, 3-pin
I/O interface to operator X207 I/O Plug connector, 2 x
panel 13-pin
LVDS interface X208 O Plug connector, 2 x
10-pin
10m
Vid
Videolink
li k ttransmitter
itt <=>Video-
Vid 15m
Videolink I/O
link receiver
Cable 20m
LVDS Flat ribbon, 20-pin
Videolink transmitter <=> PCU I/O
I/O Flat ribbon, 26-pin
14.3.2 Interface pin assignment for videolink transmitter
Signal types The abbreviations in the Signal type column in the tables below have the fol-
lowing meanings:
I Input
O Output
B Bidirectional
V Voltage
OC Open Collector

11.02
11.02
14.3 Interfaces
X102/X1061) (USB) Interface is configured as high-current USB (500mA)

Connector designation: X102 / X106; USB socket connector (4-pin), type A
Max. line length: 5m
Max. number of hubs 3
Table 14-4 Pin assignment of connector X102 and X106 (USB)
Signal
Pin Signal name Meaning
type
1 USB_P5V_fused VO + 5V (fused) for external USB interface
2 USB_D0M Data
O USB channel 0
3 USB_D0P Data +
_________________________________________________________
1) X106 is switched off via switch S2 with transmitter 1 : 2 only (see Section 14.4).
Note
It is advisable to use only self-powered hubs (i.e. hubs with their own power
supply).
14.3.3 Interface pin assignment for videolink receiver
X203 / X204 (USB) Both interfaces are designed as high-current USB (500 mA)
Connector designation: X203 / X204; USB socket connector,
2 x 4-pin, type A
Max. line length: Mouse, printer, keyboard: 5m
If hub used: 3.5m 2)
Table 14-5 Pin assignment of connector X203 / 204 (USB)

A1 P5V_3_fused VO
terface
A2 USB_DM USB data (A)
B
A3 USB_DP USB data + (A)
A4 GND V Ground
B1 P5V_4_fused VO
terface
B2 USB_DM USB data (B)
B
B3 USB_DP USB data + (B)
B4 GND V Ground
_________________________________________________________
2)Length incl. supply lead to hub and connected terminal; max. of one hub is permitted. It is
important to note that some keyboards already have a hub.

11.02
10.00
14.3 Interfaces
X205 (USB Interface designed as high-current USB (500mA)

keyboard
Connector designation: X205; plug connector, 2x 5-pin
interface)
Max. line length: 0.5m
Table 14-6 Pin assignment of connector X205 (USB keyboard interface)

1 P5V_fused VO
terface
2 USB_DM USB data
B
3 USB_DP USB data +
4.5 GND V Ground
6, ..., 10 NC Unassigned
X206 (power Connector designation: X206; terminal block, 3-pin

supply)
Table 14-7 Pin assignment of connector X206 (videolink receiver)

1 24VDC VI 24VDC
2 GND V Ground for 24VDC
3 PE Protective earth

11.02
11.02
14.4 Operating and monitoring devices
Rotary selector For selecting the display type.

switch S1 S Setting 0 Display switched off (factory setting)
S Setting 8 12 TFT SVGA 800x600 pixels
S Setting 9 15 TFT XGA 1024x768 pixels
S Setting B 10 TFT VGA 640x480 pixels
Videolink USB
transmitter interface
Illustration not to
scale !
Fig. 14-7 Rotary selector switch S1 for setting the display type, here shown with factory
setting (switch setting 0)
For space reasons, the values 1, 3, ..., F are replaced by lines in the illustra-
tion.
Note
When supplied, S1 is set to 0.
Before operation, S1 must be set to the used display type according to the
list above.
The selected switch setting only becomes effective when the PCU is
(re)started.
All displays used in a system must have the same resolution.
Caution
If the setting is incorrect, the displays could be damaged within a few seconds.

11.02
10.00
DIP switch S2 With the 1:2 configuration, the USB signal must be switched to the selected
interfaces (X106 or X108) using S2. The default setting is activation of the inter-
nal interface X108. Interface X106 can only be used for flat and upright
mounting.
Table 14-8 Function of selector S2
Function Switch position

USB signal X 106
1/1
(X 108 not functional, 2nd USB interface active)
USB signal X 108
2/2 (default)
(X 106 not functional, central operator panel front active)
X 106
2
X 108
1
2
Fig. 14-8 DIP switch S2 for controlling the USB signal
The recommended default setting for S2 is 2/2 (central operator panel front).
Notice
If a central operator panel front (see Subsection 14.1.1) is connected to
X107/108, the DIP switch S2 must be set to X108 (2/2), otherwise the key-
board, mouse and USB connector on the operator panel front will not function.
The second USB interface X106 cannot then be used.
14.4.2 Videolink receiver
Temperature A temperature monitor is integrated in the receiver module. When the threshold
monitor 75 5C is exceeded, the TEMP LED on the operator panel front lights up.
The LED goes out again when the temperature falls below the threshold
69 5C.

11.02
11.02
14.5 Mounting CPU (with videolink transmitter)
Note
S The tightening torque for all screws is: M3: 0.8Nm / M4: 1.8Nm
S To ensure optimum heat dissipation, we recommend the mounting
positions:
Device fan upwards
Device fan to left (not possible with upright mounting; Subsection
14.5.2)
14.5.1 Flat mounting
PCU + videolink Assemble the PCU and videolink transmitter in the following way:
transmitter
1. Check switch S2 (if fitted). With flat mounting, it must be set to 1/1 (X 106)
(see Subsection 14.4.1).
2. Set S1 according to the used display type.
Caution
To prevent damage, it is essential to observe Subsection 14.4.1 when set-
ting S1.
Ribbon cable PCU
Hinge
bolts
USB inter-
face X 102
USB interface
X 106 Threaded holes
for fastening
DIP switch S2 Rotary selector switch S1 screws
Fig. 14-9 Videolink transmitter 1:2 with connecting cables

11.02
10.00
Connection for central

operator panel front
PCU 50
Flat mounting bracket
Fig. 14-10 PCU with flat mounting brackets
3. Mount one mounting bracket on the PCU first (see Fig. 14-10).
4. Hook the videolink transmitter into this mounting bracket (see Fig. 14-12).
5. Mount the second mounting bracket after having attached it to the opposite
hinge bolt (see Fig. 14-9) of the videolink transmitter.
6. Plug the connecting cable into the socket on the PCU (Fig. 14-11).
Videolink
transmitter
PCU 50
Fig. 14-11 Videolink transmitter hooked into place with the hinge bolts
7. Swivel the videolink transmitter into place on the PCU (see Fig. 14-12).

11.02
11.02
Videolink
transmitter
Hinge
bearing
Hinge
bolts
Flat mount-
ing bracket
PCU 50
Fig. 14-12 Hinge of the videolink transmitter prior to alignment on the PCU
8. Slide the videolink transmitter along the angular hinge bearing (to left in Fig.
14-12, see arrow) and push it into the position shown in Fig. 14-13.
Videolink
transmitter
Hinge
Mounting bolts
screw
PCU 50
Fig. 14-13 Videolink transmitter, aligned and screwed tight
9. Secure the videolink transmitter to the mounting brackets with the screws
supplied (see Fig. 14-13).
The videolink transmitter is now fastened to the PCU mounting brackets
(see Fig. 14-14 and 14-15) and can be installed together with the PCU for its
intended use.
Caution
If it is necessary to dismantle the videolink transmitter, please release the fas-
tening screws and slide the video transmitter horizontally before swiveling it
away from the PCU, in accordance with step 8. and Fig. 14-12.
Otherwise, damage is likely.

11.02
10.00
Cover plate
over connec-
tion for cen-
tral operator
panel front
PCU 50
Fig. 14-14 PCU/transmitter unit assembled for flat mounting
290 Flat mounting 114

bracket
for videolink transmitter

PCU 50
Fastening screws
232
337
PCU 50
Mounting slots
for M4 screws
Videolink
transmitter PCU 50
Device fan
309 Dimensions in mm
Fig. 14-15 Joining of PCU 50 and videolink transmitter using the flat mounting brackets
Installation of With flat mounting, the assembly unit comprising the PCU and videolink trans-
PCU/transmitter mitter is mounted flat against the control cabinet wall panel (see Fig. 14-1).
unit Features:
S Easily accessible hard disk
S Relatively large amount of space required in control cabinet.

11.02
11.02
14.5.2 Upright mounting
PCU + videolink Assemble the PCU and videolink transmitter in the following way:
transmitter
1. Set the switch S2 (if fitted) to 1/1 (X106; see Subsection 14.4.1).
2. Disconnect the two cables from the transmitter.
3. Insert the free ends of the ribbon cables in the sockets of the PCU first (see
Fig. 14-11).
4. Reconnect the two cable ends to the transmitter.
5. Screw the PCU and videolink transmitter together using the upright mount-
ing bracket (see Fig. 14-16).
6. Set the display switch S1 to the used display type.
Caution
To prevent damage, it is essential to observe Subsection 14.4.1 when set-
ting S1.
280
Upright mounting bracket for joining the PCU and videolink transmitter
7.3
Upright mounting bracket for joining the PCU and videolink transmitter
PCU 50
Upright mounting brackets
PCU 50
375.6
360
together and for mounting to the assembly panel

17.5
together
Mounting
50 slots for
PCU 50 85 M4/M5
113 screws
Device fan Dimensions in mm
Fig. 14-16 Joining of PCU 50 and videolink transmitter using the upright mounting
brackets

11.02
10.00
Installation of With upright mounting, the rear plate of the PCU/videolink transmitter unit is
PCU/transmitter mounted at an angle of 90 to the rear panel (see Fig. 14-1).
unit Features:
S Only one mounting position possible: fan at top
S Space required with PCU 50 less than that required for flat mounting
S Keep a clearance for hard disk operation (approx. 10cm).

11.02
11.02
14.5.3 Central mounting on operator panel front
PCU + videolink The components are joined together in the same way as for upright mounting,
transmitter with the following exceptions:
S Switch S2 (see Subsection 14.4.1) (if fitted) must be set to 2/2 (X108).
S The cover plate on the transmitter (see Fig. 14-14) must be removed prior to
mounting.
S The central mounting brackets are used (see Fig. 14-17).
S The assembled PCU/videolink transmitter unit is connected to an operator
panel front and secured using the knurled screws of the mounting brackets
in the way described under Installation in Chapter Operator Panel Front
OP 012.
289 117.8
24.8
PCU 50
PCU 50
338.4
Mounting bracket (central)
124
PCU 50
Device fan
Dimensions in mm
Fig. 14-17 Joining of PCU 50 and videolink transmitter using the central mounting brack-
ets to be attached to the operator panel front
Installation of With central mounting, the PCU/videolink transmitter unit is mounted in the
PCU/transmitter usual way directly behind an operator panel front.
unit Features:
S Mounting depth of the operator panel front increased by approx. 30mm
S Not possible with OP 010S, not possible with PCU 70 (too heavy).

11.02
10.00
14.6 Mounting videolink receiver (with operator panel front)
OP 010S The operator panel front OP 010S and the receiver are screwed together with-
out additional mounting brackets.
86.8
36
Fastening screws
4xM3 for
fastening receiver
OP 010S supporting plate
to operator panel
front (1 of 4)
265
Videolink
13.4
receiver
260
Supporting plate
USB cable Videolink cable Dimensions in mm
Fig. 14-18 Front, side and rear view of operator panel front OP 010S with screwed-on videolink receiver

11.02
11.02
OP 010C, OP 012, To allow the receiver to be mounted to the operator panel fronts OP 010C, OP
OP 015, OP 015A, 012, OP 015, OP 015A and TP 012 (see Fig. 14-5), two mounting brackets
TP 012 must be screwed on, which in turn (like a PCU) must be fitted and screwed to
the operator panel front.
OP 012
OP 012
42
Knurled screw for attaching the supporting plate to
the operator panel front (1 of 4) Supporting plate
Videolink
receiver
OP 012
269
Videolink cable
USB cable
260
338.4
Dimensions in mm
Fig. 14-19 Front, side and rear view of operator panel front (example: OP 012 with screwed-on videolink receiver;
order No. 6FC5 247-0AF22-0AA0)
Cable connections Fig. 14-5 shows the outward-bound connections:

S Dual USB interface
S Videolink interface (cable inserted)
S Keyboard interface
S Power supply connection.
Since some of the connections do not have a cable strain relief, it is recom-
mended to fix the cables to the U-shaped lugs on the supporting plate using
cable ties (see Fig. 14-5).

11.02
10.00
14.7 Technical data
14.7 Technical data
Operator panel For the technical data of the operator panel fronts, please refer to the corre-
front sponding chapters: OP 010S, OP 010C, OP 012, OP 015, OP 015A and
TP 012.
PCU 50 / 70 For the technical data of the PCUs, please refer to the corresponding chapters:
PCU 50 and PCU 70.
Table 14-9 Technical data for videolink transmitter
Dimensions (WxHxD) approx 265x277x35mm

approx.
Videolink Mounting Upright mounting Mounting bracket
Weights (a
(approx.
rox. kg) transmitter bracket (flat) bracket (central)
1, 2 0.6 1.0 0.6
Power supply Videolink transmitter is supplied with power from the PCU
Interfaces Videolink, USB, LVDS and I/O
Degree of protection IP00 / mounted on PCU: IP20
Vibration and
See technical data for PCU
shock resistance
Ambient temperature See technical data for PCU
Heat dissipation Free convection, without fan (see Chapter Heat Dissipation)
Oriented to DIN EN 60721-3-3: Cl. 3K5
Humidity rating
Condensation and icing excluded. Low air temperature 0C
Videolink receiver
Table 14-10 Technical data for videolink receiver
a rox. 260x265x37mm (including cover plate

approx. late and su
supporting
orting plate;
late
Dimensions (WxHxD)
excluding operator panel front and fastening bracket)
Weight approx 1
approx. 1.8kg
8kg
Internal consumption of videolink receiver typ. 1.5W
Power consumption with operator panel front OP 015 typ. 20W
with
ith 24 V DC with operator panel front OP 015 + USB inter-
typ. 28W
face (loaded with 500mA)
Interfaces Videolink, USB, LVDS, I/O, keyboard and power supply
Vibration and
See technical data for operator panel front
shock resistance
Ambient temperature See technical data for operator panel front
Heat dissipation Free convection, without fan (see Chapter Heat Dissipation)

Operator Component PP 012 15
15.1 System description
15.1.1 Introduction
Operator panel Control systems 810D,

840D, S7-AS300 or MCU
Key- NC-CPU
board
con-
troller
COM PLC
COM MPI
OPI/MPI
PCB distributor PCB in- PCB Di- Connection Connection for

put/output rect Keys for 840D CPU 3XY or MCU
Pushbutton PCB-PP 031R basic module
panel
PP 012/H
Individual wiring
interface
HT6
HPU
HHU
Programming device (PG)
PP 012 extension
Fig. 15-1 Pushbutton panel PP 012 in example configuration
Application Machine control panel for machine tools in conjunction with the control systems
810D, 840D, S7-300 and FM NC.

15 Operator Component PP 012 11.02
10.00
Structure The PP 012 consists of
S the basic module

S the distributor
S the direct keys
S the frontplate.
The basic module can be equipped with a handheld unit connection and/or
additional inputs/outputs as options.
Communication The p.c. board is connected to the control system via the MPI interface.
Flexibility S 10 control devices can be installed, depending on the current requirements.

S 4-stage mode selector switch
S A programming device can be connected to the front panel, COM connec-
tion
S Selector switch for speed/rapid traverse and feedrate override
S Handheld unit connection with jumpering pushbutton
S 16 inputs for direct keys
S PCB_IO as an option, scanning up to 14 individual keys or 120 keys in a
matrix, control of a maximum of 16 lamps
15.1.2 Interfaces and monitoring
MPI/OPI The PP 012 is connected to the appropriate control system via the MPI/OPI
interface interface. DIP switches allow you to select a parameter set from three possible
variants (see Tables 15-48 to 15-50).
PG interface Data and control signals correspond to the OPI. Handheld programming de-
vices require an external 24V power supply for operation.
The interface is not supplied with an external 5V potential (P5.EXT).
COM interface Carries the signals from the COM interface of the operator panel to the PP 012.
Inputs/outputs in 60 inputs and 26 outputs are assigned functions by the PP 012. The transmis-
control system sion is word by word.
Power supply 24V input voltage

11.02
10.00 15 Operator Component PP 012
Monitoring PP 012 has monitoring LEDs for service and start-up:

S Voltage monitoring (POWER ON > 4.7V)
S Temperature monitoring (enabled > 60C; disabled < 55 3C)
S OPI LED flashes during data transfer
S Bus request Repeater Segment 1
S Bus request Repeater Segment 2.
15.1.3 Operator panel front interface
Inputs for The printed circuit board distributor has three isolated inputs.
custom-made
wiring
EMERGENCY When actuated, the EMERGENCY STOP chain will ensure your own personal
STOP chain safety, as well as to protect the product in case of danger. The EMERGENCY
STOP chain is also active when the handheld units are removed. The Emer-
gency Stop button can be jumpered on the handheld unit by pressing S11 when
the handheld unit is plugged/removed.
This is necessary to prevent the EMERGENCY STOP chain from being inter-
rupted.
Note
To effectively deal with any malfunction by the jumpering key S11 (e.g. jam-
ming), the user PLC program must generate EMERGENCY STOP when a
monitoring time (approximately 5min.) expires (see Figs. 15-7 and 15-17).
Actuating The actuating elements S1 to S4, S7 to S10, S14 and S15 are connected to the
elements control system via the MPI/OPI. In addition, they have isolated contacts (com-
mon root) for custom-made wiring.
Lamps The lamps HS1 to HS4, HS7 to HS10, HS14 and HS15 are connected to the
control system via MPI/OPI. Alternatively, they can also be controlled from ex-
ternal non-isolated contacts.
EMERGENCY are also connected to the control system via MPI/OPI and have isolated con-
STOP and tacts for custom-made wiring.
mode selector
switches

10.00
15.2 Function blocks
Function blocks
PP 012 S Interface/CPU/monitoring
S Distributor with repeater
S Handheld unit connection XS12
S I/O connection X20, X21
S Direct control key connection X19
S Interconnecting cable COM X26
S 4-stage mode selector switch WS1
S Feed override WS2
S Speed/rapid traverse override WS3
S Max. 12 control devices, one of them an Emergency Stop button S13 and a
jumper button S11
S Max. 10 pilot lamps that can be controlled either from PLC or externally
S Inputs for configuring global data (GD) (DIP switches)
S Isolated operator panel front interface X15 with additional programming de-
vice interface X16
S DIP switches for generating S16, S17, S18 (baud rate, node address)
S Power supply.
Function blocks
PCB input/output S 16 isolated outputs for controlling lamps, four of them optional (key matrix
option)
S 14 isolated inputs for scanning individual keys/switches
S Key matrix option up to 120 keys can be scanned
S Short-circuit-proof 24V output for external keys
S Matrix keys momentary-contact.
Function blocks
PCB direct keys S 16 isolated inputs for scanning the direct keys from the operator panel

SINUMERIK 840D/840Di/810D Operator Components Manual (BH) 11.02 Edition
Fig. 15-2
15.3
11.02
I/O (option) Direct keys COM
10.00
1
F1 Authorization Conn-
X21 X20 X19 X27 WS4
3 1P24 key-operated X26 ection
switch to OP
2 Filter 1M24 16 VCC GND GND 16 GND
D0 ... D15 GND SB VCC GND
2P24 60
Block diagram of PP 012
X8
Block diagrams
X18.1
Operating modes 1 2 3 4 7 8 9 10 5 6 GND
X12 power MPI 10 Speed C
51
9 WS1 5 GND 4
Block S1/HS1
ON MPI /
6 52
13 Test Rapid 16
10 7 50
Blocks S2/HS2
Blocks S3/HS3
Blocks S4/HS4
Blocks S7/HS7
Blocks S8/HS8
Blocks S9/HS9
Blocks S10/HS10
Blocks S14/HS14
Blocks S15/HS15
15 8 X13 X14 traverse 8
Conn.
11 Override 2
GND 1) X18.2
WS3
30 49
1 2 3 1
PG
50
EMERGENCY STOP 52
GND X25 HS1
S13
interf.
PG
2P24
GND
X16
M24
1M24
GND
VCC
GND
X13 C
4 59
OPI
X11 4 4 Feed
Filter X15 16 61
78 12 11 10 9 1 2 X2 3 4 X1 X6 override 8 60
WS2 2 58
1) 57
3M24
3P24
Repeater 4 18 3221 17 Switch 1
GD project S18.2
S18.3
X17
S16.1
S18.4
13 =1
2
Emergency Stop circuit1
Emergency Stop circuit2
PCB distributor 3P24 4 GND

X22 3 GND
3M24
Handwheel
1 8 9 10 11 12 26 27 28 29 14 16
2 15
3 7
4 16 17
II only
With distrib.
Jumper S1 S2
Block S14
16
Block S7
Block S8
Block S9
Block S10
Block S4
Block S3
Block S15
X23 S11 X23 11
15 Operator Component PP 012

Block S2
Block S1
P24 7 32 31 8
5 44 43 6 10 ()
6
GND
GND
4 21 22 3 (+)
1 14 13 2 1 GND
14
12
HPU/OPI
15.3 Block diagrams

9
2P24
5 X1
2 4 X10 3 1 3 21
M24 X5
2P24
X24 X4
4 3 2 1
8 9 6
7 11 1 2 12 3 4 5 10 XS12 5 1 6 7 11 12 X6
X11 6 5 4 2 3 1 10 9 2 X3 3 8 4 3 21
15-279
Br1
Custom-made PCB HPU
wiring
10.00
11.02
4
X40
3
GND
2
M24 (even)
1
PB
VCC
Key Matrix
4
W12
M Ext.
Option
X43
X19
3
W11
19 20
2
W10
1
W9
16
Block F16
7 8
HS31 F16
X42
15
Block (HS28...HS31) HS30 Block F15
6
4
W7 HS29 F15
14
5
HS28 Block F14
3
W6 F14
X42
13
(PB) Block F13
2
W5 F13
7 8
Block E19 E19 HS27
12
Block F12
X41
1
W3 Block (HS24...HS27) HS26 F12
11
Lock by HS25 Block F11 F11
5
manually latched switching HS24
10
Block F10
4
W8 Block E55 device for authorization F10

E55 X20
Block diagram of PCB expansion card 12E/12A

3
9
Block E54 Block F9
X41
8
W4 E54 HS23 F9
X47
7
2
W2 Block E53 Block (HS20...HS23) HS22
Block diagram of PCB direct keys PP 012

E53 Block F8 F8
6
1
W1 Block E52 OUT_EN HS21

E52
7
GND HS20 Block F7 F7
4
Block E23
R10 E23
Block F6
6
X47
VCC
3
Block E22 Block (HS16...HS18) F6

R9 E22
5
2
Block E21
15 Operator Component PP 012
R8 E21 Block F5 5F
Output power switch

1
X21
Block E14
4
R7 E14 Block F4
24 V / 0.5A
Block E63 D(15:0) 4F
4
6 7 8
E63 HS19
3
R6
X46
Block F3
X46
Block E62 3F
3
E62 HS18
Memory
R5
2
Block E61 GND HS17 Block F2
2
2F
15.3 Block diagrams
R4 E61
X30
HS16
1
Block E30 E30 Block F1

R3
Block E24
4
1
R2 E24
X45
Block E12
2
F1
17 18
M24 WDR1
3
R1
10A
E12
1
1
F1
X44
M24
2
10A
M24
15-280
Fig. 15-4
Fig. 15-3
2F
I<0.7A
3
P24_5 P24
11.02
15.4 Control elements
Position of
control elements LOGO S1
HS1
S2
HS2
S3
HS3
S4
HS4
S14
HS14 70
80 90
100
110
power 60
0 120
XS12 S7 S8 S9 S10 S15 40 6070

S11 20 80
HS7 HS8 HS9 HS10 HS15 10 90
6 100
1 2 110
2
0 120
0 3
A B C D E K F G H I
Fig. 15-5 Position of control elements
Overview of A: S13 EMERGENCY STOP button

control elements B: WS1 Selector switch
C: S11 Jumper button
D: XS12 Connection for handheld units
E: X16 Programming device connection
F: X26 COM connection
G: Control devices for variable fitting
H: WS2 Feed override
I: WS3 Speed/rapid traverse override
K: Mechanically latched switching device for authorization (on request)
EMERGENCY Operate the red EMERGENCY STOP button in emergency situations:

STOP button
1. When there is a risk to human life,
2. when there is the danger of machine or workpiece being damaged.
Turn the EMERGENCY STOP button counterclockwise to unlatch it.
Applies to drives:
As a rule, when operating the EMERGENCY STOP button, all drives are
brought to a standstill with max. braking torque.
For further or different reactions to the EMERGENCY STOP:
See machine tool manufacturers instructions!
Power S Display of power supply, lights green when controller operating voltage
> 4.7V

11.02
10.00
Selector switch S 2-way, 4 stages, 60 switching angles

S Centrally mounted with front ring
S Design as a keyswitch CG4-1A251-600 * FS1 V750D/2J
Can be modified to knob-operated switch FS1 by the customer
S Key can be removed in all positions
Notice
When used as a mode selector switch, the keyswitch should be used accord-
ing to Guideline 89/392/EWG.
Variably fitted S In slots S1 to S4, S7 to S10, S14 and S15, control devices can be installed
actuating elements as per Table 15-54.
S For function and contacts, see Block Diagram, Fig. 15-2.

S Pushbutton S11 (designed as a jumper button) is provided with a sealing
cap. This prevents the pushbutton from being locked easily.
S To effectively deal with any malfunction by the jumpering key S11 (e.g. jam-
monitoring time (approximately 5min.) expires (see Figs. 15-7 and 15-17).

10.00
11.02
15.5 Interfaces
15.5 Interfaces
15.5.1 Overview
The letters refer to Fig. 15-6.

A: S13: EMERGENCY STOP
B: WS1: Selector switch
C: X1 to X4, X6, X10, X11, X22 and X24:
I/O interface individual wiring
D: X8: 24V power supply
E: LED basic modules H 1...4:
H 1: Not used
H 2: Overtemperature
H 3: Power ON
H 4: SEND: status change on protocol transmission
F: X15: Operator panel front interface
Socket: 9-pin Sub-D socket connector, straight
G: X30: Direct control key connection
H: S16; S17; S18: For DIP switches see Table 15-44
K: Connection for equipotential bonding connector via screw connection M5
L: LED distributor:
H1: Bus segment 1
H2: Bus segment 2
M: X40 ... X43: Connection PCB_IO keyboard matrix/lamps
N: X44: 24V power supply;
X45 ... X47: Connection PCB_IO single contacts/lamps
Notice
Inputs X47:1 to 4 are assigned when the manually latched switching device for
authorization is in use.
It cannot be used in this case to scan keys on the extension panel at X47.

10.00
15.5 Interfaces
Position of
interfaces
E H3 S13
WS1
B S11
F X15 X4
C
X12 X23
X24
X13
L X5 X22
XS12 K
X16
Basic module
X26
X44
X40
X10
X2
X45
X41
PCB_IO
M
X46
C N
X42
X11
X3
X47
X43
X1
Direct keys
X30
X6
G
D
X8
H1
H
H2
E H4
X18.1 X18.2 X17

S18 S16 S17
Fig. 15-6 Device rear side

10.00
11.02
15.5 Interfaces
Signal type O Outputs

I Inputs
I/O Bi-directional signals
V Supply voltage
Emergency button Button designation: S13

S13
Button type: Mushroom turn-to-set button 3SB3000-1HA20 with holder
3SB3000-1HA20 and 1x NO contact 3SB3400-0B (inter-
nal use) max. 4x NC contacts
Table 15-1 Switching element: NC contact 3SB3400-0E

Pin Signal Type Signal name Function

1 OE_S13.x I/O NC contact S13.x
EMERGENCY STOP

2

OE_S13.x I/O Reference potential S13.x
Selector switch Switch designation: WS1

interface WS1
Switch type: CG41 A251600 FS1 V750 D/2J (keyswitch)
Table 15-2 Selector switch interface
Pin Signal Type Signal name Switch Function

position

11 IR I/O Mode 4

15 ES I/O Mode 3

10 BZ_WS I/O Reference signal

13 IB I/O Mode 2
9 VK I/O Mode 1
15.5.2 PP 012 individual wiring
Notice
When PLC signals are linked with signals of the individual wiring, note that the
signal change of the individual contacts may take place at different moments.
Simultaneously opening and closing the contacts of a key within the actuating
travel is not possible.

10.00
15.5 Interfaces
Connector X1 Connector X1: direction ; pilot lamp HS14

Connector type: 4-pin Mini-Combicon MC 1.5/4-G-5.08
Table 15-3 Connector X1


1 BZ_S14 I/O Reference potential NO contact
S14

2

S_S14.1
I/O NO contact S14.1 direction

3

S_S14.2

4

HS 14
I Pilot lamp HS14
Connector X2 Connector X2: Pilot lamps HS7 to HS10


Pin

Signal
Type Signal name Function

1

HS 7
I Pilot lamp HS7 All inputs

2

HS 8
I Pilot lamp HS8 High active

3

HS 9
I Pilot lamp HS9

4

HS10
I Pilot lamp HS10
Connector X3 Connector X3: Contacts S7 to S10



1 OE_S7 I/O NC contact S7

3

OE_S9
I/O NC contact S9

4

OE_S10

I/O NC contact S10

10 BZOE_S7-10 I/O Reference potential NC contacts
S7-10

5

S_S7
I/O NO contact S7

6

S_S8
I/O NO contact S8

7

S_S9
I/O NO contact S9

8

S_S10
I/O NO contact S10
9

BZS_S7-10 I/O Reference potential NO contact

S7-10

11
2P24 V +24V potential

12

11.02
15.5 Interfaces
Connector X4 Connector X4: Euchner connection


Pin Signal Type Signal name Connection Function
XS12 pin

1 KEY 0
I Input 1
2
KEY 1

I Input 2

3 KEY 2 I Input 3 11

Reference potential
4 BZ_KEY I

KEY0...2

5 1M24 V Ground 24V
EMER- S11

2.2

GENCY_STOP

I/O
EMERGENCY
STOP circuit 2
12

EMERGENCY
7 I/O 1
STOP circuit 2.1

8

AUFR_RICHT I/O Direction call
S11
1P24

6 S11
9 ZUST_TA I/O X24:2
(via S11)

10

ZS1/ZS1.1 *) I/O 5

Enabling button
11 ZS2/ZS2.1 *) I/O 14

ZSCommon/

12 I/O 6
ZS2.2 *)
*) two-channel
Connector X6 Connector X6: + direction; pilot lamp HS15


Pin

Signal

1

BZ_S15
I/O Reference potential NO contact

S15

2 S_S15.1 I/O NO contact S15.1 + direction


4 HS 15 I Pilot lamp HS15

10.00
15.5 Interfaces
Connector X10/X11 Connector X10 / X11: Contacts S1 to S6; pilot lamps HS1 to HS6
Connector type X10: 4-pin Mini-Combicon MC 1.5/4-G-5.08
Table 15-8 Connectors X10/X11

Conn. Pin Signal Type Signal name Function

X10 1 OE_S2 I/O NC contact S2



X10 3 BZOE_S1-4 I/O Reference potential NC con-

4
BZS_S1-S6 I/O
tacts S1 ... S4
Reference potential NO con-

tacts S1... S6

X11 3 S_S4 I/O NO contact S4

4 S_S3 I/O NO contact S3


6 S_S1.1 I/O NO contact S1.1

7 BZS_S1.2 I/O Reference potential NO con-
tact S1.2

8
S_S1.2 I/O NO contact S1.2

9
HS 4 I Pilot lamp HS4

10 HS 3 I Pilot lamp HS3 All inputs

High
11 HS 2 I Pilot lamp HS2 active

Connector X22 Connector X22: Handwheel


Pin

Signal Type Signal name

1

HR_A O Handwheel track A

2

XHR_A O Handwheel track A negated

3

HR_B O Handwheel track B

4

XHR_B O Handwheel track B negated

11.02
15.5 Interfaces
Connector X24 Connector X24: EMERGENCY STOP circuit 1


Pin

Signal Type Signal name Function

1

2
2P24

OE_S11/ZS2.2
V +24V
NC contact S11
S11

*) X4:9

EMERGENCY_ S11
3
STOP 1.1

EMERGENCY STOP
circuit
i it 1

EMERGENCY_
4
STOP 1.2
*) two-channel
Power Connector X8: Power supply

supply
Connector type: 3-pin print terminal block MSTBA 2.5/3-G-5.08
interface X8
Table 15-11 Power supply interface X8

Pin


1

Shield Shield potential

2

M24 V 24V ground

3

P24 V 24V potential
Operator panel Connector X15: Operator panel front interface (MPI)

front interface
Connector type: 9-pin Sub-D socket connector, screw locking UNC4/40
(MPI) X15
Notice
Use MPI bus connector 6FX2003-0AA02!
Table 15-12 Operator panel front interface (MPI) X15

Pin Signal Type Signal name

1 NC not connected

2 NC not connected

3 rs I/O RS-485 data

4 ORTSAS O Output Request to Send, user interface

5 GND_EXT V 5V external ground

6 VCC_EXT V 5V external potential

7 NC not connected

8 XRS I/O RS-485 data
9 IRTSPG I/O In Request to Send PG

10.00
15.5 Interfaces
Programming Connector X16: Programming device (PG) interface

device interface
(PG) X16


1 NC not connected

2 3M24 V Reference potential 24V

4

ORTSAS O Output Request to Send, user interface

5

GND_EXT V 5V external ground

7

NC not connected

8

9
XRS

IRTSPG
I/O
I/O
RS-485 data
In Request to Send PG
The power supply potential P24 is not provided by PP 012. An external 24V
power voltage supply enables handheld programming devices 702 and 705 to
be connected. External terminals with a separate 5V power supply cannot be
operated (fiber-optic technology).
Serial interface Connector X26: Serial interface RS-232-C (COM)

RS-232-C (COM) Connector type: 9-pin Sub-D, pin, straight, screw locking UNC4/40
X26
Max. line length 25m
Table 15-14 Serial interface RS-232 (COM)

Pin

1

Signal

DCD
Type
O
Signal name
Data Carrier Detect

2

RxD I Receive Data RS-232-C

3

TxD O Transmit Data RS-232-C

4 DTR I Data Terminal Ready
5 M V Supply voltage
6 DSR O Data Send Ready
7 RTS I Request To Send
8 CTS O Clear To Send
9 RI I Ring Indicator

11.02
15.5 Interfaces
Handheld unit Connector: Handheld unit interface XS12

interface XS12
Connector type: Euchner flange connector RC17S1NM2H3PW
Code Y (315)
Table 15-15 Handheld unit interface XS12

Pin Signal
g Type
yp Signal
g name Function
enabling function

EMERGENCY_STOP Emergency Stop NC

1 EMERGENCY STOP
2.1 contact 2.1

2 MPI_A I/O RS-485 data MPI

3 3M24 V 24V ground Su ly
Supply

4 3P24 V +24V voltage

5 ZS1.1 Enabling button
Enabling function

6 ZS2.2 Call enable key

7 HR_B Handwheel B
Handwheel

8 HR_A Handwheel A

EMERGENCY_STOP EMERGENCY STOP
9
1.2 NC contact 1.2

EMERGENCY STOP
10

1.1 NC contact 1.1

Jumper short-circuit
11 KEY2 I Key scanning No.3
connector


12 EMERGENCY STOP
2.2 NC contact 2.2
13 MPI_B I/O RS-485 data MPI
14 ZS2.1 Enabling button Enabling function
15 HR_XA Handwheel A negated Handwheel
Not assigned/enab-
16 ZS1.2 N.C./enable key
ling function
17 HR_XB Handwheel B negated Handwheel

10.00
15.5 Interfaces
Printed circuit Connector X30: Printed circuit board Direct keys

board direct Connector type: Ribbon cable plug connector with protective collar
keys X30 20-pin 2-row with lock
Table 15-16 Printed circuit board Direct keys

Pin


1

F1 I Direct key 1

2

F2 I Direct key 2
3

3F I Direct key 3

4
5
6

4F
5F
F6
I
I
I
Direct key 4
Direct key 5
Direct key 6
7 F7 I Direct key 7
8 F8 I Direct key 8
9 F9 I Direct key 9
10 F10 I Direct key 10
17
P5 TAC
P5_TAC V 5V keyboard controller
18
19
M TAC
M_TAC V Ground of keyboard controller
20
The direct key module serves to connect the 16 direct keys of the operator
panel.
15.5.3 Individual wiring PCB input/output
Connector X40 Connector type: 4-pin, Combicon base casing MC 1.5/4-G-3.81
Table 15-17 Printed circuit board input/output X40

Pin

1

Signal

P24_5
Type
V
Signal name
24V potential

2 M24 V 24V ground

3 E55/W8 I Input key 55/matrix row 8

11.02
15.5 Interfaces

1
Pin

Signal

E52/W1
Type
I
Signal name
Input key 52/matrix row 1



5 HS24 O Connection of lamp HS24


1 W3 I Matrix row 3

2 W5 I Matrix row 5

3 W6 I Matrix row 6
4 W7 I Matrix row 7

Pin


1

W9 I Matrix row 9

2

W10 I Matrix row 10

3
4

W11

W12
I
I
Matrix row 11
Matrix row 12
Connector X44 Connector type: 3-pin print terminal block MSTBA 2.5/3-G-5.08


1 Shield I Ground

2 M24 V 24V ground
3 P24 V 24V potential

10.00
15.5 Interfaces

Pin

1

Signal

P24_5
Type
V
Signal name
24V potential

2 M24 V 24V ground

3 E12/R1 I Input key 12 / matrix line 1


Pin


1

E30/R3 I Input key 30/matrix line 3

2


3

4
E62/R5

E63/R6
I
I
Input key 62/matrix line 5

Pin

1

Signal

E14/R7
Type
I
Signal name

2


3


4
5
E23/R10
HS20 O
I Input key 23/matrix line 10
Connection of lamp HS20

11.02
15.5 Interfaces
Connector parts
for I/O module Table 15-25 Connector parts for I/O module
Connec- Signal Port Phoenix

tor MINI-COMBICON connector part, Article

PCB-IO matrix 3.81 No.
MC 1
1.5/4-ST-3.81
5/4 ST 3 81 Screw 1.5
15 1803594
FRONT-MC 1.5/4-ST-3.81 Screw 1.5 1850686
X40
X40,
FK MCP 1.5/4-ST-3.81
FK-MCP 1 5/4 ST 3 81 Spring
S ring force 1.5
15 1851067

X43
X43,
X45 Housing MCC 1/4-STZ-3,81 Crimp 1852192
Socket connector MCC-MT 0

0.2...0.35
2 0 35 Crimp 0.2
0 2 to 0.35
0 35 1859988

contact MCC
MCC-MT
MT 0
0.5...1.0
5 10 Crimp 0
0.5
5 to 1
1.0
0 1859991
MC 1.5/8-ST-3.81 Screw 1.5 1803633
FRONT-MC 1.5/8-ST-3.81 Screw 1.5 1850725
X41,
X42, FK-MCP 1.5/8-ST-3.81 Spring force 1.5 1851106
X46
X46, Housing MCC 1/8-STZ-3,81
1/8 STZ 3 81 Crimp
Crim 1852231
X47
Socket connector MCC-MT 0.2...0.35 Crimp 0.2 to 0.35 1859988
contact MCC-MT 0.5...1.0 Crimp 0.5 to 1.0 1859991
Connec- COMBICON connector part, Port Phoenix

tor matrix 5.08 Article
PCB-IO No.

X44 MSTBA 2.5/3-G-5.08 Screw 2.5

1779990

10.00
15.6 Handheld unit connection
Terminator Whether a terminator or a handheld unit is connected can be determined by

querying word 0 bit 2, KEY 2. Terminator connected corresponds to High on
input KEY2.
Properties of
jumper S Interlocking of axis motion via the PLC
button S11
S Interlocking of the enable key
S Jumpering of EMERGENCY STOP contacts on the handheld unit
S Manipulation-proof: Sealing cap prevents accidental actuation of key
S Jumper button, non-latching
S Initiation of a monitoring time for checking the operability of the EMER-
GENCY STOP jumpering function
S Interruption in power supply for handheld unit connection, two-channel vari-

ant, when S11 is actuated.
Warning
! It is the users responsibility to ensure that the enable key is designed to DIN
EN 6020411, Subsection 9.2.5.8, and, when released or pushed down, stops
dangerous movements reliably.
When S11 is utilized for the EMERGENCY STOP jumpering function, an inter-
lock of hazardous motions must be implemented via the PLC with S11 and a
time monitor activated simultaneously, in addition to Fig. 15-7. If the signaling
contact on S11:31/32 is not properly closed again on expiry of the monitoring
time (approximately 5 minutes), then EMERGENCY STOP must be generated
by the PLC.
15.6.1 Functional reliability of EMERGENCY STOP and enabling circuits
See Fig. 15-7
EMERGENCY STOP The EMERGENCY STOP circuit is a two-channel configuration with the follow-
circuits ing layout:
S For circuit 1:
NC contact S13X4:6X5:12XS12:12EMERGENCY STOP handheld
unitXS12:1X5:1X4:7
S For circuit 2:
unitXS12:10X5:10X24:3.

11.02
To avoid interruption of the EMERGENCY STOP circuits on changeover be-

tween the handheld unit and the terminator at XS12, the EMERGENCY STOP
contacts of the handheld unit can be jumpered via S11.
Contact S11:13/14 jumpers via X23:1/2 the EMERGENCY STOP contact
XS12:1/12 of the handheld unit in circuit 1,
The time monitoring function in the PLC serves to detect malfunctions in push-
button S11:
If contact S11:31/32 does not close properly within the specified time frame, the
PLC must interrupt the EMERGENCY STOP circuit. The contact status is
scanned via circuit X23:8X4:8X4:1optocoupler KEY0Word 0, bit 0 of
PLC input image (see Section 15.14).
Enable circuit The two-channel variant of the enable function is used for PP 012:
S The enable key is called via

X4:12X5:17XS12:16 and
X24:2X5:6 XS12:6.
S Scanning is performed via

XS12:5X5:5X4:10 and
XS12:14X5:14X4:11.
S In addition, the power supply for the handheld units connected at XS12:4 is
interrupted via contact S11:31/32X23:8 and X5:4 when S11 is actuated.
S The interlock between S11 and the enable key must be implemented in the
PLC.
Note
Only 2-channel handheld units can be connected.
15.6.2 Two-channel enabling function
The circuit is illustrated in Fig. 15-7 and the terminal assignments in Table 15-26
(see below).
Applicability The two-channel enabling function applies to order numbers

6FC5 203-0AF25-1AA0 and
6FC5 203-0AF27-1AA0-Z.

10.00
PP 012H X25
EMERGENCY STOP
interf.
2P24
M24
X16
PG
M
M P5
S13
OPI
Filter X15
X13
Repeater
3M24
3P24
13 13
PCB dis 2 2
tributor II 4 4
X22
1 1 3M24 3 3
2 2 1 8 8
3 3 2 15 15
4 4 3 7 7
4 16 17
Jumper 17 16
S11 X23
X23 11 11
2P24 7 32 31 8
5 44 43 6 10 10
4 21 22 3 6 6
1 14 13 2 1 1
14 14
12 12
9 9
5 5
M24 X5
HPU/OPI
/ OP7HH
2P24
X24 X4
EMERGENCY STOP 4 3 2 1 9 6 8 7 1 11 2 12 3 4 5 10
circuit 2
Br5 *)
EMERGENCY STOP circuit 1 Br1
6 14 16 5
Enabling button
Custom-made wiring
1 12 9 10 6 5 14 16 7 15 8 17 11 4 3 2 13
XS12
Handheld unit HHU

Type (B-MPI) MPI
6FX20071AE13
Power
EMERGENCY STOP Enabling button Handwheel supply
1 12 9 10 6 5 14 16 4 3 2 13
HT6
Handheld terminal
HT6 MPI
6FC5 403-0AA10-0AA0
EMERGENCY STOP Power
supply
Enabling button 11 4
1 12 9 10
Terminator
Terminator
(component PP 012H) 3P24
*) Signal to PLC: Triggers a monitoring timer.

If the signal level is still low or open when the monitoring time has expired (approxi-
mately 5min.), the PLC must initiate an EMERGENCY STOP (see also Fig. 15-17).
Fig. 15-7 Connection for handheld unit ZS (two-channel)

11.02
Table 15-26 Terminal assignments XS12 handheld unit (two-channel)
PIN PP 012H HHU(MPI) HT6 Termi-

nator

1

EMERGENCY_
STOP 2.1
EMERGENCY STOP
button 2.1
EMERGENCY STOP
button 2.1

Br1

2
3

MPI_A
3M24
MPI_A
M
MPI_A
M

4 3P24 P24 P24 BR3
5 ZS1.1 ZS1.1 ZS1.1
6 ZS2.2 ZS2.2 ZS2.2
7 HR_B HRB
8 HR_A HRA
9 EMERGENCY_ EMERGENCY STOP EMERGENCY STOP Br2
STOP 1.2 button 1.2 button 1.2
11 KEY2 KEY2 KEY2 BR3
13 MPI_B MPI_B MPI_B
14 ZS2.1 ZS2.1 ZS2.1
15 HR_XA HR_XA
16 ZS1.2 ZS1.2 ZS1.2
17 HR_XB HR_XB

10.00
Dimension
drawing
482.6
155

444
105

50
70
Identification of anode connection:

Insert the light emitting diode with the + polarity on the
marked end into the button.
Fig. 15-8 Dimension drawing of PP 012
Panel cutout The required panel cutout is 451.0x137.6mm.

Mounting background Operator panel front Tension jacks A-A
1.5 to 6 thick 1.5 to 6
132,5 132,5
451+1
B B
137.6+1
155
Cutout symmetrical with operator panel front
34.2 123.5 155.8 103.3 34.2
482.6
35
B-B Max. torque

0.5Nm
Fig. 15-9 Panel cutout for PP 012

11.02
15.8 Installation and mounting
Mounting The PP012 (dimensions, see Fig. 15-9) is fastened by means of tension jacks
preparations (included in the scope of supply) at the rear side of the operator panel. Due to
the surrounding seal located on the rear side, the frame profile complies with
degree of protection IP65 when all 9 tension jacks are fastened.
Only IP54 can be achieved for the complete pushbutton panel, however, due to
the installation of a keyswitch.
If necessary, the tension jacks (9 items) can be supplied as a spare part (Order
No. 6FC5 248-0AF13-0AA0).
Connecting The 24V power supply is connected via a 3-way terminal block (see Fig. 15-6)
24V power supply to connector X8 on the rear side of the machine control panel. The equipotential
bonding conductor is fastened using an M5 screw and must be linked with the
central ground standard part.
Danger
! The 24VDC power supply must always be grounded and be designed as
Protective Extra Low Voltage (PELV) protection by function low volt-
age with safe isolation!
Connecting The PP 012 is connected to the 840D or S7-300 control by means of an MPI
MPI connection bus line. The MPI connector is plugged into X15 on the rear of the PP 012 and
fixed with a screw.
Connecting Emergency stop, selector switch and single contacts are connected according
individual wiring to the required custom-made links.
(For function see Figs. 15-17 to 15-21)
Supply voltages for inputs and outputs must always be grounded!
Note
To use the actuating element WS1 as a mode selector switch a keyswitch
CG4-1A251-600 *FS1 V750D/2J must be installed in accordance with EU
Directive 89/392/EEC.

10.00
15.9 Labeling control elements
Device front
80 90
70 100
110
power 60 WS3
0 120
WS1 PG interface
COM
40 6070
20 80
10 90
6 100
WS2 110
2
0 120
Free layout of labeling areas thanks to the use of slide-in user labels
Fig. 15-10 Control panel (example)
Dimensions for The following drawing is intended purely as an example; multiple slide-in labels
labeling the can also be arranged.
slide-in labels
Window area bordering
Cutting edge bordering
Corners rounded R1.5
or chamfered 1.5x45
5 5
must not be printed
must be printed
110
Dimensions for labeling the slide-in user labels

degrees
85.5
76.5
1
10 64.5
180 55.5
(Designation field, WS1)
7 7
146
(variable switching elements S1 to S4; S7 to S10; S14; S15)
21.5
38
113 0
16
1
80 19
0
slide-in labels (S11, XS12)
14.4
Dimensions for labeling
47
16
56.4
23.8
14
0 85
1
19
Fig. 15-11 Dimensions for texts on the slide-in labels

11.02
Labeling
on the rear side of
the device
S11
2P24
*HR-B
HR-B
*HR-A
HR-A
HS7
2 1
HS8
S1
X43
S2 HS9
X44 3
HS10
1
HS1
1
8
HS2 S7
X45
HS3 S8
X41
HS4 S9
WS1 S11
4
S10
1
8 1
S1 S7
S1 S8
X46
S2 S9
X42
S3 S10
8
S4
S3
1
4 1
Board INPUT/OUTPUT
S4 2P24
S1 S7
X47
HS1 HS7
X43
8
1
S2 S8
Option
Option
HS2 HS8
S3 S9
HS3 HS9
HS14
S14 S15
S14 S15
S4 S10
HS4 HS10 HS15
S14 S15
HS14 HS15
1.6AT
X30
WS3 WS2
HW FAULT S7-300(2)
>
S7-300
BUS
Request 840 D
4321 ON
4321 4 3 21
OFF
S18 S16 S17
Fig. 15-12 Labeling on rear of device

10.00
15.10 PP 012 extension
Front view with

section
95
64 33
482.6
A-A
Center
70
Operator control element
26.6
25.5
38
10
21
42.2
Fig. 15-13 PP 012 extension
S Order code 6FC5 247-0AA43-1AA0

S Can be equipped with max. 12 control devices, diameter 22mm, grid 33mm
S Labeling with exchangeable text labels.

11.02
Panel cutout
Mounting background Operator panel front Tension jacks A-A

1.5 to 6 thick 1.5 to 6
B B
132,5 132,5
77.6+1
95
34.2 123,5 155.8 103.3 34.2
451+1
35
482.6
Max. torque
B-B 0.5Nm
Fig. 15-14 Panel cutout for PP 012 extension
Dimensions for The following drawing is intended purely as an example; multiple slide-in labels
labeling the can also be arranged.
slide-in labels
1 Corners rounded R1.5

or chamfered 1.5x45 degrees
(variable switching elements S7 to S12)
1
23.8
must be printed
16.1
20

must not be printed
13
112
145
178
0
46
79
208
Slide-in direction

(variable switching elements S1 to S6)
23.8 1
16.1
20
112
13
178
145
235
0
79
46
Slide-in direction
Fig. 15-15 Dimensions for texts on the slide-in labels (PP 012 extension)

10.00
15.11 Functions of PCB expansion card 12E/12A
15.11.1 Inputs/outputs
Inputs
Table 15-27 Inputs (possible combinations)
Without authorization key-operated With authorization key-operated switch

switch
Design Key matrix Switch/ Design Key matrix Switch/
(option) independent (option) independent
single con- single con-

tacts tacts

1 without 14 contacts 14 without 10 contacts
2 7 keys 11 contacts 15 7 keys 7 contacts
8 60 keys 5 contacts 21 60 keys 1 contact
10 84 keys 3 contacts
Functions of keys in the matrix:
+ Non-latching key
12 108 keys 1 contact + Single-key actuation
+ No switch function
Outputs 16 outputs for driving lamps, four of which are optional.
Key matrix Eight inputs W3, W5, W6, W7, W9, W10, W11, W12 for matrix.
option Four outputs A28 to A31 for driving lamps.

11.02
15.11.2 Key assignment within matrix
Table 15-28 Key assignment within the matrix
Key value Wn Matrix row Rn

Wn W8/ W4/ W2/ W1/ E19/ Rn E12 E24 E30 E61 E62 E63 E14 E21 E22 E23
E55 E54 E53 E52 PB
1 0 0 0 1 0 1 0 1 1 1 1 1 1 1 1 1
2 0 0 1 0 0 2 1 0 1 1 1 1 1 1 1 1
3 0 0 1 1 1 3 1 1 0 1 1 1 1 1 1 1
4 0 1 0 0 0 4 1 1 1 0 1 1 1 1 1 1
5 0 1 0 1 1 5 1 1 1 1 0 1 1 1 1 1
6 0 1 1 0 1 6 1 1 1 1 1 0 1 1 1 1
7 0 1 1 1 0 7 1 1 1 1 1 1 0 1 1 1
8 1 0 0 0 0 8 1 1 1 1 1 1 1 0 1 1
9 1 0 0 1 1 9 1 1 1 1 1 1 1 1 0 1
10 1 0 1 0 1 10 1 1 1 1 1 1 1 1 1 0
11 1 0 1 1 0
12 1 1 0 0 1

10.00
Matrix keyboard
scan
Scan input R1 ... Rn

n 10 *)
Number No
of active blocks
= 1?
Yes
Save the active
block Rn
Scan inputs
W1, W2, W4, W8
Save the active

block Wn
Scan parity bit E19
Parity No
OK?
Yes
Save RnWn
Bounce suppression
function
Output of key RnWn
*) n = number of matrix blocks
Fig. 15-16 Matrix scan sequence

11.02
15.12 Circuits and wiring
Custom-made There are various possible applications for connecting the key inputs KEY0 to
wiring KEY2:
1. Enable key connection according to Fig. 15-7
2. Use as isolated inputs with reference potential at X4/5
3. Use of button S11 with PLC function without jumpering.
For the required jumper assignment and their meaning, please refer to the
Tables below.
Table 15-29 Custom-made wiring

Br1 Br5

Use of the connections X4:1;2;3 as isolated inputs. The refer-

ence potential is at X4:4 here.

X X PLC function
Use of
connections Table 15-30 Use of the connections

Potential Port Use
X3/11,12 Control of inputs HS1 to HS4, HS7 to HS10, HS14 and HS15

2P24
X24/1 Controlling the inputs KEY 0 to KEY 2

KEY0...2

X4/1 ... 3

Inputs KEY0 to KEY2
Reference potential of inputs KEY 0 to KEY 2;

M24 X4/5
no external use.
Button S11 with

PLC function
S11
2P24 X5
2P24
2P24 M24
X24 1) X4
4321 9 6 5 10 7 4 12 11 8 1 2 3 X3
11 12
Br1 Br52)
External contacts
1) S11 connection with single-channel variant only
2) Signal to PLC: Triggers a monitoring timer.
If the signal level is still low or open when the monitoring time has expired (approximately
5min.), the PLC must initiate an EMERGENCY STOP (see also Fig. 15-7).
Fig. 15-17 Button S11 with PLC function

10.00
Ext. control of
pilot lamps
HS1 ... HS10
Block Sn
HSn 2P24
1M24
X1; X2; X6; X11 X3

11 12
External contact
Fig. 15-18 External control of signaling lamps in keys HSn
Circuit for
EMERGENCY
STOP button
1 1 1 1 3
EMER- to PLC
GENCY
STOP button 2 2 2 2 4
optional
EMERGENCY STOP machine control
Fig. 15-19 Suggested circuit for EMERGENCY STOP circuit

11.02
Connection of
spindle speed
override WS3 X18.1 WS3 6FC5 247-0AA34-0AA1
rd
C
16
rd
8
X18.2
Fig. 15-20 Connection WS3 spindle speed override spindle speed/rapid traverse
Direct control key

connection
X30
20
19
18
17
16 F16
15 F15
14 F14
13 F13
12 F12
PCB direct keys
PP 012 11 F11
10 F10
9 F9 +
8 F8
5V +
10 %
7 F7
6 F6
5 5F
4 4F
3 3F
2 2F
1 F1
Fig. 15-21 Direct control key connection

10.00
Extension panel
Single contacts
connection W8
Lamps
SE11 SE12 SE13 SE14
W4 HS27
W1; W2; W4; W8
only as an alternative HS26
to the key matrix, W2
HS25
X42, X43
Unassigned W1 HS24
R10*) HS23
SE7 SE8 SE9 SE10

R9*) HS22
*) assigned when the
authorization key- R8*) HS21
operated switch is R7*) HS20
used
X43
R6 HS19
X47
SE3 SE4 SE5 SE6

R5 HS18
R4
PCB expansion
HS17
X42
R3
card 12E/12A
X46
HS16
X41
P24_5
M24
X45 R2
SE1 SE2
R1
X40
M24
X44
P24
Key matrix (option)

Rows n=3 to 10
P24_5
Row n=1
Row n=2
Group
Group
Group
M24
SMn
SM2
SM1
W12
SMn.7 SMn.8 SMn.9 SMn.10 SMn.11 SMn.12

SM1.9 SM1.10 SM1.11 SM1.12
SM2.9 SM2.10 SM2.11 SM2.12
W11
W10
W9
Lamps
W8 corresponding individual contacts are not needed

SM2.7 SM2.8
SM1.7 SM1.8
HS31
W7
HS30
HS29 W6
HS28
SMn.6
SM2.6
SM1.4 SM1.5 SM1.6
W5
When these are connected, the
SMn.3 SMn.4 SMn.5
SM2.4 SM2.5
W4
W3
Inputs R1 to R10
SM1.1 SM1.2 SM1.3
SM2.3
W2
SMn.1 SMn.2
SM2.1 SM2.2
W1
Fig. 15-22 Connecting the extension panel to PCB expansion card 12E/12A

11.02
Wiring
example P24_5 * switch
Not usable
is used
Individual M24 Authorization
X45
keys switch is used
SE7* SE8* SE9* SE10*

R10 *
E23*
R9 *
E22*
X47
R8 *
E21*
R7 *
E14*
SE3 SE4 SE5 SE6

R6
E63
R5
E62
X46
R4
E61
R3
E30
SE2
R2
E24
X45
SE1
R1
E12
SM1.7 SM1.6 SM1.5 SM1.4 SM1.3 SM1.2 SM1.1
(W1)
E52
(W2)
E53
(W3)
(W4)
E54
(W5)
(W6)
Inputs PLC
(W7)
Group
X41, X42
SM1
SEW8
(W8)
E55
(W9)
nc
nc = not connected
(W10)
nc nc
(W11)
X43
(W12)
nc
(W8)
P24_5 PB
E19
M24 (even)
X40
X44 1 3 2
from central
power M24
supply P24
PP 012 extension PCB expansion card 12E/12A
Fig. 15-23 Wiring example eleven single keys and seven matrix keys

10.00
15.13 Technical data
15.13.1 PP 012
Table 15-31 Technical data for PP 012
Electrical data
Total current Rated volts. Voltage up- Voltage Fuse
per limit lower limit
max. 1A 24VDC 30.2VDC 18.5VDC 1.6AT
Mechanical data
Dimensions Height Width Mounting Depth to the
depth front
155mm 483mm 105mm 70mm
Installed/in operation Storage/transport
Front Rear side
Temperature ranges 0 ... 45C 0 ... 55C 40 ... 70C
Degree of protection IP 54 IP 10A
Degree of protection I to IEC 204 I
15.13.2 Input/output interface of individual wiring
Key contact maker Contacts with floating outputs S1 to S4; S7 to S10; S11; S14; S15 (NC contact
or NO contact)
Table 15-32 NO contacts S1 to S4; S7 to S10; S14; S15

AC DC

Nominal insulation voltage Ue 50V 50V

Nominal operating current Ie 2A

Rated operating current at 24V Ie 2A

Min. rated operating current at 5V Imin 10mA

Volume resistance < 20m

Switching capacity 10Ie 1.1le
Max. operating current for reference po- 8A 8A

tential


11.02
Selector switch Contacts with floating outputs WS1/911; 13; 15;
Table 15-33 Selector switch

Nominal operating voltage
Load

Ue
AC
300V
DC
300V

resistive 10A
Switching capacity

inductive > 2A

resistive 10A
Switching capacity at 24V

inductive 6A

Nominal values for arc-
0.3A 0.22A
free switching at 24V
EMERGENCY Contacts with floating outputs S13

STOP button
Table 15-34 EMERGENCY STOP button
Utilization category AC DC

(EN 60947-5-1)

Rated operating voltage Ue 24V 24V
AC-12 le 10A
AC-15 le 6A
Switching capacity
DC-12 le 10A
DC-13 le 3A
Min. rated operating current at lmin 1mA
5V
For further parameters, see pushbutton and indicator light SIGNUM 3SB3
Inputs X4: KEY 0 to KEY 2
Table 15-35 Inputs X4: KEY 0 to KEY 2:

Status Voltage Current switched

switched

Nominal value 24V
H signal

Min. 4mA (at 15V)
Signal level +15V to +30V
Max. 9.5mA (at 30V)

L signal

Nominal value
Signal level
0V or open
3V to +5V

In a group of 3

Max. 50m
Cable length
AWG 2016

10.00
X1, X2, X6, X11
Table 15-36 Inputs HS1 to HS4; HS7 to HS10; HS14; HS15

Status

Nominal value
Voltage switched
24V
Current switched
50mA

Pilot lamp ON (making current
Signal level +18V to +30V max. 600mA)

Pilot lamp OFF
Nominal value open

Cable length
Max. 10 m AWG 2016
X30
Table 15-37 Input X30 direct keys, F1 to F16

Status

Voltage switched Current switched

Nominal value 5V

H signal
Signal level +5V or open

Nominal value
L signal

Signal level 3V to +1V < 11mA

In a group of 16

Cable length Max 0.6m AWG 28
Printed circuit X44

board Input/output
(option)
Table 15-38 Inputs X44
Power supply

Total current Rated voltage Voltage up- Voltage Fuse


Max. = 5A, depend-
24VDC 30.2VDC 18.5VDC 2x10A
ing on the lamp load
Inputs X41, X42, X43, X45, X46, X47: E12, E14, E21 to E24, E30, E52 to E55, E61 to
E63, W1 to W12
Table 15-39 Inputs

Status Voltage switched Current switched

Nominal value +24V

H signal Min. 3.6mA (at 15V)
Max. 8mA (at 30V)

Nominal value 0V or open

L signal
Signal level 3V to +5V

In a group of
Cable length common root
Max. 50m, AWG 16

11.02
Lamp outputs X41, X42, X43, X46, X47: HS16 to HS31
Table 15-40 Lamp outputs

Status

Nominal value
Voltage switched
+24V
Current switched

H signal
Signal level +20V to +30V Max. 0.5A/output

Nominal value
L signal

Signal level open < 25A

In a group of 16
Cable length Max. 50m, AWG 16
Output
Max. of 5A
total current
Outputs P24_5 X40:1, X45:1
Table 15-41 Outputs P24_5

Status


Output total current
Nominal value +24V
Max. of 700mA

10.00
15.14 PLC interface
15.14 PLC interface
Table 15-42 Input signals
Inputs Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

Word 0 Mode GD project Isolated inputs
Low
WS1/4 WS1/3 WS1/2 WS1/1 *) DIP X4/3 X4/2 X4/1
ER ES IB VK S16/1 KEY2 KEY1 KEY0

Word 0 + direction I/O direction Variable keys

High
S15 E14/R7 S14 E12/R1 S4 S3 S2 S1

Key
switch 0
Word 1 I/O GD project Version activation GD project
Low
E23/R10 E22/R9 E21/R8 DIP E19/PB High *) DIP DIP
key Key Key S18/3 (parity) (reserve) S16/1 S18/4
switch 3 switch S2 switch 1
Word 1 GD project I/O EMER- Variable keys
High GENCY

STOP

*) DIP E30/R3 S13 S10 S9 S8 S7 E24/R2
S16/1
Word 2 Direct keys
Low
F8 F7 F6 5F 4F 3F F2 F1
Word 2 Direct keys
High
GD project
F16 F15 F14 F13 F12 F11 F10 F9
Word 3 I/O Spindle speed/rapid traverse
Low
E55/W8 E54/W4 E53/W2 E52/W1 D C B A
Word 3 I/O Feed override
High
E63/R6 E62/R5 E61/R4 E D C B A
*) All bits identified with DIP-S16/1 are simultaneously switched when S16/1 is actuated.

Legend:

High active signals S1 ... S4; High active/Low active settable via S18.2
S7... S10; S18.2 closed = Low active

S14;
S15
S18.2 open = High active
Low active signals Ex/HSx I/O high active via a plug-on card supplied as
an option

10.00
11.02
15.14 PLC interface
Table 15-43 Output signals (see Table 15-42 for legend)
Outputs Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

Word 0 Pilot lamps
Lo
Low
HS8 HS7 HS15 HS14 HS4 HS3 HS2 HS1
Word 0 Unassigned Pilot lamps
High
HS10 HS9
Word 1 I/O
Lo
Low
Word 1 Option Key matrix on I/O I/O
High
Word 2 Unassigned
Lo
Low
Word 2 Unassigned
High
Word 3 Unassigned
Lo
Low
Word 3 Unassigned
High
Notice
When the mode is switched over, Low can be output briefly for all signals on
selector switch SW1!
I.e., all safety-relevant signals are linked such that they are only possible if
switch WS1 has a defined position.

10.00
15.15 Initialization
Assignments The following settings are possible with the switches DIP S16, S17, S18:
Table 15-44 Assignments of S16, S17, S18 on PP 012
S17 S16 S18 Meaning

4 3 2 1 4 3 2 1 4 3 2 1
on Baud rate: 1.5 Mbaud OPI
off Baud rate: 187.5 kbaud MPI
on on not applicable
on off 200 msecs transmission cycle
time
off on 100 msecs transmission cycle
time
off off 50 msecs transmission cycle
time
on on on on Bus address: 15
on on on off Bus address: 14
on on off on Bus address: 13
on on off off Bus address: 12
on off on on Bus address: 11
on off on off Bus address: 10
on off off on Bus address: 9
on off off off Bus address: 8
off on on on Bus address: 7
off on on off Bus address: 6
off on off on Bus address: 5
off on off off Bus address: 4
off off on on Bus address: 3
off off on off Bus address: 2
off off off on Bus address: 1
off off off off Bus address: 0
off off Set of parameters 1
on off Set of parameters 2
on on Set of parameters 3
on Hardware reset ON
off Hardware reset OFF
on Pushbutton panel factory set-
ting: NC contact
off Pushbutton panel
Make function
X Reserve GD project

11.02
DIP switch
settings Table 15-45 Default setting for 840D
Application:
Connecting the PP 012 to an 840D
S17 S16 S18
Meaning
4 3 2 1 4 3 2 1 4 3 2 1
X off on off on on off off off off X off 187.5 kbaud/1.5 Mbaud
Transmission cycle time
100 msecs, bus address 6
Set of parameters 1
Prerequisite:
none, can be directly connected to the MPI/OPI of the 840D
Table 15-46 Default setting for S7-300
Application:
Connecting the PP 012 to an S7300
S17 S16 S18
Meaning
4 3 2 1 4 3 2 1 4 3 2 1
off off on off on on off on off off X off 187.5 kbaud
100 msecs bus address 6
Set of parameters 2
Prerequisite:
A global data table created using HISTEP
Table 15-47 Setting for S7-300 with two machine control panels
Application:
Connecting two PP 012s to an S7300
S17 S16 S18
Meaning
4 3 2 1 4 3 2 1 4 3 2 1
off off on off on on off on off on X off 187.5 kbaud
Set of parameters 3
Prerequisite:
Settings of The load on the PLC by the PP 012 can thus be adapted.
transmission
cycle time The PLC expects a message frame from the PP 012 at least every 500 msecs.
The PP 012 sends a message frame to the PLC at cyclic intervals when no key
is pressed. This cycle time is set on S17 DIP switches 2 and 3.

10.00
Communication The switchover of the sets of parameters (GD identifications) for communication
parameters between control system and PP 012 is carried out using the DIP switches S16/1
or S18/3.
The switchover will only come into effect after power ON on PP 012.
The following applies: Transmitted Data = PP 012 Control

Received data = Control PP 012
Table 15-48 Set of parameters
Index Designation Set of Set of Set of

parame- parame- parame-

ters 1 ters 2 ters 3

1

Receive GD circuit no. 1 2

2 Receive GBZ no. 1 1

3 Object no. for receive GBZ Internal 1 1
Assign-

4 Send GD circuit no. ment 1 2

5 Send GBZ no. 2 2

6 Object no. for send GBZ 1 1
Global data table When the PP 012 is operated in conjunction with an S7-300 CPU, set of param-
eters 2 is selected and a global data table is created using HISTEP.
In this case, communication with the PP 012 must be configured as follows:
Table 15-49 Global data for set of parameters 2

GD identification ebf/s7-300:: ebf/PP 012::

GD 1.1.1 >>ab60:8 eb0:8

GD 1.2.1 eb60:8 >>ab0:8
The specifications ab60 and eb60 for S7 are only examples; the signals can
also be transferred to other locations.
The GD identification is generated by the compiler.
GD 1.1.1 PP 012 is receiver
GD 1.2.1 PP 012 is transmitter
This assignment corresponds to set of parameters 2 as per Table 15-48.
Note
Make sure that a data width of eight bytes is always assigned for the input and
output image!
If two PP 012s are to be connected to an S7-300 CPU, set of parameters 3

must be set, and the following global data table must be created using HISTEP.

11.02

GD 1.1.1

GD identification ebf/s7-300::
>>ab60:8
ebf/PP 012::
eb0:8
ebf/PP 012_2::

GD 1.2.1

GD 2.1.1

eb60:8
>>ab120:8
>>ab0:8
eb0:8

GD 2.2.1
eb118:8 >>ab0:8
Further GD communications can be configured in the following lines.
Danger
! The transmission path (MPI/OPI) from PP 012 to the central controller must be
monitored by the user.

10.00
15.16 Sample parameterization for communication between SIMATIC S7 and PP 012
15.16 Sample parameterization for communication between

SIMATIC S7 and PP 012
Your program can read the information of the GD package status from the oper-
ands you assign the corresponding GDS identification in the global data table in
the STEP 7 tool Communication Configuration.
If a communication error occurs, the operating system writes error information to
these operands (described in the Table below). You can then use this informa-
tion to create conditional program branches as a response to the communica-
tion errors.
For the status information of the communication, a double word (32 bit) is pro-
vided.
For the contents of the double word, see the Table below:
Table 15-51 State information
Bit Status: Description of error From From

Send CPU Receive
CPU
0 Area length error in sender + +
1 Block cannot be found in sender + +
2 I/O access error in sender + +
3 GD package lost + +
in sender
in connection
in receiver
4 Syntax error in GD package + +
5 GD object missing in GD package +
6 Wrong assignment of GD object length in +
sender and receiver
7 Address range length error in sender +
8 GD package cannot be found in receiver +
9 I/O access error in receiver +
10 Timeout in receiver +
11 Restart of receiver +
1230 Reserved +
31 Receive new data +
References: / / SIMATIC S 7, User Manual
Note
Monitoring of the MPI link between SIMATIC S7 and PP 012 can be imple-
mented with the global data bit, bit 31. The user can reset bit 31 and provide it
with a watchdog. If this bit is not set again within the predefined time interval, a
fault in the line is the cause.

11.02
15.16 Sample parameterization for communication between SIMATIC S7 and PP 012
Table 15-52 Example
GD identification as314//cpu1:: pp012_1//cpu1::

GST md120
GDS 1.1 md130
SR 1.1 4 1
GD 1.1.1 >>ab120:8 ab0:8
GDS 1.2 md140
SR1.2 4 4
GD 1.2.1 eb118:8 >>eb0:8

11.02
10.00
15.17 Service information
Lamp replacement 1. Prize off the button cap towards the front with a screwdriver.
for illuminated
2. Lever out the button holder using lamp remover LZ5.
keys, illuminated
switches 3. Change the lamp using service tool LZ5 or a suitable insulating tube.
4. Refit the button holder and cap in reverse order.
Note
Lamp remover LZ5 is not a SIEMENS product. It can be obtained from the
Schlegel company.
Changing the 1. Prize off the cap and the label holder towards the front with a screwdriver.
lamps on pilot 2. Use the lamp remover of service tool LZ5 or a suitable insulating tube to
lamps change the lamp.
3. Refit the cap and the label holder.
Notice
When using LEDs, make sure that they are connected with the correct polarity
(see Fig. 15-8: dimension drawing of PP 012) !
Mounting 1. Screw off the dummy plug.

additional 2. Press the contact maker onto the base and install the lamp if necessary.
control elements
3. Insert the pushbutton through the front plate and screw on the cap nut with
several turns.
4. Screw the cap nut tight. Please note the position of the anti-rotation element.
5. Screw the cap nut tight (max. torque 0.8Nm).
Insert slide-in
labels 1. Create the slide-in labels (see Fig. 15-10).
2. Remove the protective film from the label slot.
3. Slide in the labels (with print facing the operator side).
4. Align the texts in the window.
Note
Slide in the labels when the PP 012 operator panel front is not yet installed.

11.02
Changing a 1. Loosen the cap nut on the pushbutton until the contact maker has almost
contact maker been reached.
2. Pull the pushbutton and the contact maker approximately 3mm out of the
fixture (the locating pin of the pushbutton must be freed).
3. Turn the pushbutton approx. 20 to the right or left, remove it from the con-
tact maker and remove the cap nut.
4. Change the contact element, remove the defective contact maker from the
fixture and press the new contact maker down into the fixture.
5. Insert the pushbutton into the opening and screw on the cap nut partially.
6. Press the pushbutton down until it rests on the contact maker. When doing
so, observe the position of the locking lose.

10.00
15.18 Configuring
15.18 Configuring
15.18.1 Delivery variants
Note
When replacing the existing PP 031 devices with variants of the PP 012, down-
wards compatibility cannot always be guaranteed!
Table 15-53 Delivery variants
Pushbutton panel PP 012 6 F C 5 2 0 3 0 A F 2 X X A A 0

PP 012 basic unit 6 F C 5 2 0 3 0 A F 2 4 0 A A 0
EMERGENCY STOP with 2 NC contacts + 1
NO contact, keyswitch, 8 illuminated keys with
incandescent lamps, button caps 2*GR, 2*RT,
2*GB, 2*Kl, 2* dummy plugs BVR22, program-
ming device and RS232C interfaces, feedrate
override, cover plate for 2nd override, with
blank special film for slide-in labels with dimen-
sion drawing for
PCB Direct keys with ribbon cable 1)
PP 012H 6 F C 5 2 0 3 0 A F 2 5 1 A A 0
as the base unit, in addition, with 17-pin hand-
held
unit socket connector and jumper button with
repeater function and distributor,
two-channel enabling function
PP 012/S 6 F C 5 2 0 3 0 A F 2 6 0 A A 0
Special version based on PP 012; Z
the assembly is identified clearly by a
Z option specification
PP 012H/S 6 F C 5 2 0 3 0 A F 2 7 1 A A 0
Special version based on PP 012H; Z
the assembly is identified clearly by a
Z option specification,
1) When assigning the colors for keys and pilot lamps to the corresponding functionality,
observe the standard EN 60204 Part1 or VDE 0113 Part1, Section Pushbuttons/Colors.

11.02
15.18 Configuring
Extensions to the PP 012 (can be ordered and installed by the customer separately)
Override switch, 16-level speed 6 F C 5 2 4 7 0 A A 3 4
0 A A 1
+/ keys raised 6 F C 5 2 4 7 0 A A 4 1
0 A A 0
PCB expansion card 12E/12A 6 F C 5 2 4 7 0 A A 4 2
0 A A 0
Extension panel with 12 slots 6 F C 5 2 4 7 0 A A 4 3
1 A A 0
2xNC contacts for Emergency Stop buttons 3 S B 3 4 0 0 0 E
Spare parts kit PP 031MC 6 F C 5 2 4 7 0 A A 2 7
5 covers, 5 films, 2 sealing caps, set of button 0 A A 0
caps, 5 incandescent lamps with base,
1 dummy plug, 1 illuminated key contact
maker,
1 printed drawing A5E00122711A-A1
Extensions for project-specific variants

Slide-in labels as per customer layout
Set of light emitting diodes (ultra-bright)
Knob FS1 for WS1
Actuator and contact maker 1) according to Tabelle 15-54
Authorization key-operated switch at customer request

PCB_input/output with key matrix at customer request

10.00
15.18 Configuring
15.18.2 Project-specific components

Table 15-54 Control elements that can be retrofitted by the user
Function Upper part Holder Mount- Use

Actuator/accessories Switching element/ ing
Pilot lamp location

Pilot lamp

Lamp nipple

28mm
RXJN-GB (yellow)
Lamp socket AL5 with
incandescent lamp
T5.5K/30
S1 ... S4
S7 ...
S10
Lamp

RXJN-GN (green) or spot LED L5.5K28UG S14,

RXJN-RT (red) (green) L5.5K28UR S15
RXJN-BL (blue) (red) L5.5K28UW

RXJN-KL (transp. (white) L5.5K28UY (am-
ber)

glass)
RXJN-WS (white) L5.5K28UB (blue)

Buttons

Pushbutton 28mm Button contact maker S11

RXJT-GB (yellow) AT2 1 NC contact (internal), 2 NO
RXJT-GN (green) contact + 1 NC contact (ext.)

RXJT-RT (red) For S1 1 NC contact (inter-

RXJT-BL (blue) nal), 2 NO contact + 1 NC
RXJT-KL (transparent contact (external)

glass) For S2...S4, S7...S10 1 NC
RXJT-GSW (black) contact (int.), 1 NO contact +

1 NC contact (external)

For S14, S15 1 NC contact
int., 2 NO contacts ext.

Illuminated keys

Pushbutton 28mm Illuminated key contact For S1 1 NC contact (inter-

with fixture for T5.5K RXJT-GB (yellow) maker ATL2 with incan- nal), 2 NO contact + 1 NC
RXJT-GN (green) descent lamp T5.5K/30 contact (external)

RXJT-RT (red) or spot LED For S...S4, S7...S10 1 NC

RXJT-BL (blue) L5,5K28UG (green) contact (internal), 1 NO con-
RXJT-KL (transparent L5.5K28UR (red) tact + 1 NC contact (ext.)

glass) L5.5K28UW (white) For S14, S15 1 NC contact

L5.5K28UY (yellow) (internal), 2 NO contacts (ext.)
L5.5K28UB (blue) Lamp externally controllable

Keyswitch

Safety lock cylinder Button contact maker For S1 1 NC contact (int.), 2

Switching angle 900 28mm AT2 NO cont. + 1 NC cont. (ext.)
2 position keys, re- RXJSSA 15 E For S1...S4, S7...S10

movable in both posi- 1 NC contact (internal), 1 NO

tions contact + 1 NC contact (exter-
nal) S14, S15 1 NC contact

(internal), 2 NO contacts (ext.)

Raised keys 6FC5 2 RTAO pushbuttons 2 AT2
247-0AA41-0AA0 with plunger elong. Special design
Designation field

Replaceable text insert
strips

Dummy plug BVR22 S14 and S15 with base unit
Selector switch Knob FS1 WS1 Re-equipping to knob-oper-
ated switch
Speed/rapid 6FC5 247-0AA34-0AA1 WS3 Connection to PCB PP 031R
traverse override
EMERGENCY Switching
g element: 2 3SB3400-0E Expans. NC contact EMER-
NC contacts
t t S13 GENCY STOP
STOP
Note
When assigning the colors for keys and pilot lamps to the corresponding func-
tionality, observe the standard EN 60204 Part1 or VDE 0113 Part1, Section
Pushbuttons/Colors.

11.02
15.18 Configuring
15.18.3 Rating plates
One of the following rating plates is attached to the components and modules:
Components Example:
F2 L3
A5E00112382 A/B
6FC5 2030AF0AA0
PP012
Explanation: F2 Place of manufacture

L3 Date of manufacture
A5E00112382 ID number
A/B/C/D Product version
6FC5 203-0AF24-0AA0 Order No.
PP 012 Component name
Printed circuit Example:

boards
A5E00017606 A1 L2 F2
Explanation: A5E00017606 ID number

A1 Product version
F2 Place of manufacture
In case of technical queries or service, please quote all data on the rating plate
to the local SIEMENS office responsible for your equipment.
J

10.00
15.18 Configuring
Notes

Operator Component PP 031 MC 16
16.1.1 Introduction
A&D PC Control systems 810D,

840D, S7-AS300 or MCU
Key- NC-CPU
board
con-
troller
COM PLC
COM MPI
OPI/MPI
PCB in- PCB Di- Connection Connection for

PCB distributor
put/output rect Keys for 840D CPU 3XY or MCU
Pushbutton PCB-PP 031R basic module

panel
PP 031-
MC/HR
Individual wiring
interface
HT6
HPU
HHU
Programming device (PG)
Customer control panel
Fig. 16-1 Pushbutton panel PP 031 MC in example configuration
Application Machine control panel for machine tools in conjunction with the control systems
810D, 840D, STEP7 300 and FM NC.

16 Operator Component PP 031 MC 10.00
Structure The PP 031 MC consists of
S the basic module

S the distributor
S the direct keys
S the frontplate.
The basic module can be equipped with a handheld unit connection and/or
additional inputs/outputs as options.
Communication The p.c. board is connected to the control system via the MPI interface.
Flexibility S 10 control devices can be installed, depending on the current requirements.

S 4-stage mode selector switch
S A programming device can be connected to the front panel, COM connec-
tion
S Selector switch for speed/rapid traverse and feedrate override
S Handheld unit connection with jumpering pushbutton
S 16 inputs for direct keys
S PCB_IO as an option, scanning up to 14 individual keys or 120 keys in a
matrix, control of a maximum of 16 lamps.
16.1.2 Interfaces and monitoring
MPI/OPI The PP 031 MC is connected to the appropriate control system via the MPI/OPI
interface interface. DIP switches allow you to select a parameter set from three possible
variants (see Tables 16-49 to 16-51).
PG interface Data and control signals correspond to the OPI. Handheld programming de-
vices require an external 24V power supply for operation.
The interface is not supplied with an external 5V potential (P5.EXT).
COM interface Carries the signals from the COM interface of the A&D-PC to the PP 031 MC.
Inputs/outputs in 60 inputs and 26 outputs are assigned functions by the PP 031 MC. The trans-
control system mission is word by word.
Power 24V input voltage

supply

10.00 16 Operator Component PP 031 MC
Monitoring PP 031 MC has monitoring LEDs for service and start-up:
S Voltage monitoring (POWER ON > 4.7V)

S Temperature monitoring (enabled > 60C; disabled < 55 3C)
S OPI LED flashes during data transfer
S Bus request Repeater Segment 1
S Bus request Repeater Segment 2.
16.1.3 Operator panel front interface
Inputs for The printed circuit board has three isolated inputs.
custom-made
wiring
EMERGENCY When actuated, the EMERGENCY STOP chain will ensure your own personal
STOP chain safety, as well as to protect the product in case of danger. The EMERGENCY
STOP chain is also active when the handheld units are removed. The Emer-
gency Stop button can be jumpered on the handheld unit by pressing S11 when
the handheld unit is plugged/removed.
This is necessary to prevent the EMERGENCY STOP chain from being inter-
rupted.
Note
To effectively deal with any malfunction by the jumpering key S11 (e.g. jam-
monitoring time (approximately 5 min.) expires (see Figs. 16-7 and 16-17).
Actuating The actuating elements S1 to S4, S7 to S10, S14 and S15 are connected to the
elements control system via the MPI/OPI. In addition, they have isolated contacts (com-
mon root) for custom-made wiring.
Lamps The lamps HS1 to HS4, HS7 to HS10, HS14 and HS15 are connected to the
control system via MPI/OPI. Alternatively, they can also be controlled from ex-
ternal non-isolated contacts.
EMERGENCY are also connected to the control system via MPI/OPI and have isolated con-
STOP and tacts for custom-made wiring.
mode selector
switches

Function blocks
PP 031 MC S Interface/CPU/monitoring
S Distributor with repeater
S Handheld unit connection XS12
S I/O connection X20, X21
S Direct control key connection X19
S Interconnecting cable COM X26
S 4-stage mode selector switch WS1
S Feed override WS2
S Speed/rapid traverse override WS3
S Max. 12 control devices, one of them an Emergency Stop button S13 and a
jumper button S11
S Max. 10 pilot lamps that can be controlled either from PLC or externally
S Inputs for configuring global data (GD) (DIP switches)
S Isolated operator panel front interface X15 with additional programming de-
vice interface X16
S DIP switches for generating S16, S17, S18 (baud rate, node address)
S Power supply.
Function blocks
PCB input/output S 16 isolated outputs for controlling lamps, four of them optional (key matrix
option)
S 14 isolated inputs for scanning individual keys/switches
S Key matrix option up to 120 keys can be scanned
S Short-circuit-proof 24V output for external keys
S Matrix keys momentary-contact.
Function blocks
PCB direct keys S 16 isolated inputs for scanning the direct keys from the A&D control panel.

Fig. 16-2
16.3
I/O (option) Direct keys COM
10.00
1 Conn-
F1 Authorization ection
X21 X20 X19 X27 WS4
3 1P24 key-operated X26 to
Filter 1M24 A&D PC
2 D0 ... D15 16 VCC GND GND 16 GND switch
GND SB VCC GND
2P24 60
Block diagram of PP 031 MC; /HR; -S
X8
Block diagrams
X18.1
Operating modes 1 2 3 4 7 8 9 10 5 6 GND
X12 power MPI 10 Speed C
51
9 WS1 5 GND 4
Block S1/HS1
ON MPI /
6 52
13 Test Rapid 16
10 7 50
Blocks S2/HS2
Blocks S3/HS3
Blocks S4/HS4
Blocks S7/HS7
Blocks S8/HS8
Blocks S9/HS9
Blocks S10/HS10
Blocks S14/HS14
Blocks S15/HS15
15 8 X13 X14 traverse 8
Conn.
11 Override
2
GND 1) X18.2
WS3
30 49
1 2 3 1
PG
50
EMERGENCY STOP 52
GND X25 HS1
S13
PG
interf.
2P24
GND
X16
M24
1M24
GND
VCC
GND
X13 C
4 59
OPI
X11 4 4 Feed
Filter X15 16 61
78 12 11 10 9 1 2 X2 3 4 X1 X6 override 8 60
WS2 2 58
1) 57
3M24
3P24
Repeater 4 18 3221 17 Switch 1
GD project S18.2
S18.3
X17
S16.1
S18.4
13 =1
2
EMERGENCY STOP circuit1
EMERGENCY STOP circuit2
PCB distributor 3P24 4 GND

X22 3 GND
3M24
Handwheel
1 8 9 10 11 12 26 27 28 29 14 16
2 15
3 7
4 16 17
16 Operator Component PP 031 MC

butor II only
With distri-
Jumper S1 S2
Block S14
16
Block S7
Block S8
Block S9
Block S10
Block S4
Block S3
Block S15
X23 S11 X23 11
Block S2
Block S1
P24 7 32 31 8
5 44 43 6 10 ()
6
GND
GND
4 21 22 3 (+)
1 14 13 2 1 GND
14
12
HPU/OPI
16.3 Block diagrams

9
2P24
5 X1
2 4 X10 3 1 3 21
M24 X5
2P24
X24 X4
4 3 2 1
8 9 6
7 11 1 2 12 3 4 5 10 XS12 5 1 6 7 11 12 X6
X11 6 5 4 2 3 1 10 9 2 X3 3 8 4 3 21
16-337
Br1
Custom-made PCB HPU
wiring
10.00
4
X40
3
GND
2
M24 (even)
1
PB
VCC
key matrix
4
W12
M Ext.
Option
X43
X19
3
W11
19 20
2
W10
1
W9
16
Block F16
7 8
HS31 F16
X42
15
Block (HS28...HS31) HS30 Block F15
6
4
W7 HS29 F15
14
5
HS28 Block F14
3
W6 F14
X42
13
(PB) Block F13
2
W5 F13
7 8
Block E19 E19 HS27
12
Block F12
X41
1
W3 Block (HS24...HS27) HS26 F12
11
Lock by HS25 Block F11 F11
5
manually latched switching device for authorization HS24
10
Block F10
4
W8 Block E55 F10

E55 X20
Block diagram of PCB input/output PP 031 MC

3
Block diagram of PCB direct keys PP 031 MC

9
Block E54 Block F9
X41
8
W4 E54 HS23 F9
X47
7
2
W2 Block E53 Block (HS20...HS23) HS22
8
E53 Block F8 F8
6
1
W1 Block E52 OUT_EN HS21

E52
7
GND HS20 Block F7 F7
4
Block E23
16 Operator Component PP 031 MC
R10 E23
Block F6
6
X47
VCC
3
Block E22 Block (HS16...HS18) F6

R9 E22
5
2
Block E21 Block F5
Output Power Switch

R8 E21 5F
1
X21
Block E14
4
R7 E14 Block F4
D(15:0) 4F
24 V/0.5A
Block E63
4
6 7 8
E63 HS19
3
R6
X46
Block F3
X46
Block E62 3F
3
E62 HS18
Memory
R5
2
Block E61 GND HS17 Block F2
2
2F
16.3 Block diagrams
R4 E61
X30
HS16
1
Block E30 E30 Block F1

R3
Block E24
4
1
R2 E24
X45
Block E12
2
F1
17 18
M24 WDR1
3
R1
10A
E12
1
1
F1
X44
M24
2
10A
M24
16-338
Fig. 16-4
Fig. 16-3
2F
I<0.7A
3
P24_5 P24
Position of control
elements LOGO S1
HS1
S2
HS2
S3
HS3
S4
HS4
S14
HS14 70
80 90
100
110
power 60
0 120
XS12 S7 S8 S9 S10 S15 40 6070

S11 20 80
HS7 HS8 HS9 HS10 HS15 10 90
6 100
1 2 110
2
0 120
0 3
L A B C D E K F G H IL
Fig. 16-5 Position of control elements
Overview of A: S13 EMERGENCY STOP button

control elements B: WS1 Selector switch
C: S11 Jumper button
D: XS12 Connection for handheld units
E: X16 Programming device connection
F: X26 COM connection
G: Control devices for variable fitting
H: WS2 Feed override
I: WS3 Speed/rapid traverse override
K: Mechanically latched switching device for authorization (on request)
L: Flange bolts for keyboard support.
EMERGENCY Operate the red EMERGENCY STOP button in emergency situations:

STOP button
Applies to drives:

10.00
Power S Display of power supply, lights green when controller operating voltage >
4.7V
Selector switch S 2-way, 4 stages, 60 switching angles

S Centrally mounted with front ring
S Design as a keyswitch CG4-1A251-600 * FS1 V750D/2J
Can be modified to knob-operated switch FS1 by the customer
S Key can be removed in all positions.
Notice
When used as a mode selector switch, the keyswitch should be used accord-
ing to Guideline 89/392/EWG.
Variably fitted S In the slots S1 to S4, S7 to S10, S14 and S15, control devices can be
actuating elements installed as per Table 16-55.
S For function and contacts, see Block Diagram, Fig. 16-2.

S Pushbutton S11 (designed as a jumper button) is provided with a sealing
cap. This prevents the pushbutton from being locked easily.
S To effectively deal with any malfunction by the jumpering key S11 (e.g. jam-
monitoring time (approximately 5 min.) expires (see Figs. 16-7 and 16-17).

10.00
16.5 Interfaces
16.5 Interfaces
16.5.1 Overview
The letters refer to Fig. 16-6.

A: S13: EMERGENCY STOP
B: WS1: Selector switch
C: X1 to X4, X6, X10, X11, X22 and X24:
I/O interface individual wiring
D: X8: 24V power supply
E: LED basic modules H 1...4:
H 1: Not used
H 2: Overtemperature
H 3: Power On
H 4: SEND: status change on protocol transmission
F: X15: Operator panel front interface
Socket: 9-pin Sub-D socket connector, straight
G: X30: Direct control key connection
H: S16; S17; S18: For DIP switches see Table 16-45
K: Connection for equipotential bonding connector via screw connection M5
L: LED distributor:
H1: Bus segment 1
H2: Bus segment 2
M: X40 ... X43: Connection PCB_IO keyboard matrix/lamps
N: X44: 24V power supply;
X45 ... X47: Connection PCB_IO single contacts/lamps
Notice
Inputs X47:1 to 4 are assigned when the manually latched switching device for
authorization is in use.
It cannot be used in this case to scan keys on the customer control panel at
X47.

16.5 Interfaces
Position of
interfaces
E H3 S13
WS1
B S11
F X15 X4
C
X12 X23
X24
X13
L X5 X22
XS12 K
X16
Basic module
X26
X44
X40
X10
X2
X45
X41
PCB_IO
M
X46
C N
X42
X11
X3
X47
X43
X1
Direct keys
X30
X6
G
D
X8
H1
H
H2
E H4
X18.1 X18.2 X17

S18 S16 S17
Fig. 16-6 Device rear side

10.00
16.5 Interfaces
Signal type O Outputs

I Inputs
I/O Bi-directional signals
V Supply voltage
Emergency button Button designation: S13

S13
Button type: Mushroom turn-to-set button 3SB3000-1HA20 with holder
3SB3000-1HA20 and 1x NO contact 3SB3400-0B (inter-
nal use) max. 4x NC contacts
Table 16-1 Switching element: NC contact 3SB3400-0E


1 OE_S13.x I/O NC contact S13.x
EMERGENCY STOP

2

OE_S13.x I/O Reference potential S13.x
Selector switch Switch designation: WS1

interface WS1
Switch type: CG41 A251600 FS1 V750 D/2J (keyswitch)
Table 16-2 Selector switch interface
Pin Signal Type Signal name Switch Function

position

11 IR I/O Mode 4

15 ES I/O Mode 3

10 BZ_WS I/O Reference signal

13 IB I/O Mode 2
9 VK I/O Mode 1
16.5.2 PP 031 MC individual wiring
Notice
When PLC signals are linked with signals of the individual wiring, note that the
signal change of the individual contacts may take place at different moments.
Simultaneously opening and closing the contacts of a key within the actuating
travel is not possible.

16.5 Interfaces
Connector X1 Connector X1: direction ; pilot lamp HS14



1 BZ_S14 I/O Reference potential NO contact
S14

2

S_S14.1

3

S_S14.2

4

HS 14
I Pilot lamp HS14
Connector X2 Connector X2: Pilot lamps HS7 to HS10


Pin

Signal

1

HS 7
I Pilot lamp HS7 All inputs

2

HS 8
I Pilot lamp HS8 High active

3

HS 9
I Pilot lamp HS9

4

HS10
I Pilot lamp HS10
Connector X3 Connector X3: Contacts S7 to S10




3

OE_S9
I/O NC contact S9

4

OE_S10

I/O NC contact S10

10 BZOE_S7-10 I/O Reference potential NC contacts
S7-10

5

S_S7
I/O NO contact S7

6

S_S8
I/O NO contact S8

7

S_S9
I/O NO contact S9

8

S_S10
I/O NO contact S10
9

BZS_S7-10 I/O Reference potential NO contact

S7-10

11
2P24 V +24V potential

12

16.5 Interfaces
Connector X4 Connector X4: Euchner connection


Pin Signal Type Signal name Connection Function
XS12 pin

1 KEY 0
I Input 1
2
KEY 1

I Input 2

3 KEY 2 I Input 3 11

Reference potential
4 BZ_KEY I

KEY0...2

5 1M24 V Ground 24V
EMER- S11

2.2

GENCY_STOP

I/O
EMERGENCY
STOP circuit 2
12

EMERGENCY
7 I/O 1
STOP circuit 2.1

8

AUFR_RICHT I/O Direction call
S11
1P24

6 S11
9 ZUST_TA I/O X24:2
(via S11)

10

ZS1/ZS1.1 *) I/O 5

Enabling button
11 ZS2/ZS2.1 *) I/O 14

ZSCommon/

12 I/O 6
ZS2.2 *)
*) two-channel
Connector X6 Connector X6: + direction; pilot lamp HS15


Pin

Signal

1

BZ_S15
I/O Reference potential NO contact

S15




16.5 Interfaces
Connector X10/X11 Connector X10 / X11: Contacts S1 to S6; pilot lamps HS1 to HS6
Table 16-8 Connectors X10/X11

Conn. Pin Signal Type Signal name Function



3 BZOE_S1-4 I/O Reference potential NC con-
tacts S1 ... S4

4

BZS_S1-S6 I/O Reference potential NO con-

tacts S1... S6






6 S_S1.1 I/O NO contact S1.1

7 BZS_S1.2 I/O Reference potential NO con-
tact S1.2

8

S_S1.2 I/O NO contact S1.2

9

HS 4 I Pilot lamp HS4

10 HS 3 I Pilot lamp HS3 All inputs

High
11 HS 2 I Pilot lamp HS2 active

Connector X22 Connector X22: Handwheel


Pin


1

HR_A O Handwheel track A

2

XHR_A O Handwheel track A negated

3

HR_B O Handwheel track B

4

XHR_B O Handwheel track B negated

16.5 Interfaces
Connector X24 Connector X24: EMERGENCY STOP circuit 1


Pin

Signal Type Signal name Function

1

2P24

OE_S11/ZS2.2
V +24V
S11

2 NC contact S11 X4:9
*)

EMER- S11
3 GENCY_

STOP 1.1

EMERGENCY STOP circuit 1
EMER-

4 GENCY_
STOP 1.2
*) two-channel
Power Connector X8: Power supply

supply
Connector type: 3-pin print terminal block MSTBA 2.5/3-G-5.08
interface X8
Table 16-11 Power supply interface X8

Pin


1

Shield Shield potential

2 M24 V 24V ground

3 P24 V 24V potential
Operator panel Connector X15: Operator panel front interface (MPI)

front interface
(MPI) X15
Notice
Use MPI bus connector 6FX2003-0A-0AA02!
Table 16-12 Operator panel front interface (MPI) X15

Pin


NC

2 NC
not connected
not connected


4 ORTSAS O Output Request to Send, user interface

5 GND_EXT V 5V external ground

6 VCC_EXT V 5V external potential

7 NC not connected

8 XRS I/O RS-485 data

9 IRTSPG I/O In Request to Send PG

16.5 Interfaces
Programming Connector X16: Programming device (PG) interface

device interface
(PG) X16


1 NC not connected

2 3M24 V Reference potential 24V

4

ORTSAS O Output Request to Send, user interface

5

GND_EXT V 5V external ground

7

NC not connected

8

9
XRS

IRTSPG
I/O
I/O
RS-485 data
In Request to Send PG
The power supply potential P24 is not provided by PP 031 MC. An external 24V
power voltage supply enables handheld programming devices 702 and 705 to
be connected. External terminals with a separate 5V power supply cannot be
operated (fiber-optic technology).
Serial interface Connector X26: Serial interface RS-232-C (COM)

RS-232-C (COM) Connector type: 9-pin Sub-D, pin, straight, screw locking UNC4/40
X26
Max. line length 25m
Table 16-14 Serial interface RS232 (COM)

Pin

1

Signal

DCD
Type
O
Signal name
Data Carrier Detect

2

RxD I Receive Data RS-232-C

3

TxD O Transmit Data RS-232-C

4 DTR I Data Terminal Ready
5 M V Supply voltage
6 DSR O Data Send Ready
7 RTS I Request To Send
8 CTS O Clear To Send
9 RI I Ring Indicator

16.5 Interfaces
Handheld unit Connector: Handheld unit interface XS12

interface XS12
Connector type: Euchner flange connector RC-17S1NM2H3PW
Table 16-15 Handheld unit interface XS12

enabling function

single-chan- two-
nel channel

1

EMERGENCY_STOP

2.1
EMERGENCY STOP
NC contact 2.1
EMERGENCY STOP

2 MPI_A I/O RS-485 data MPI

3 3M24 V 24V ground Su ly
Supply

4 3P24 V +24V voltage

5 ZS1 ZS1.1 Enabling button
Enabling function

6 ZSCommon ZS2.2 Call enable key
7 HR_B Handwheel B

Handwheel
8 HR_A Handwheel A


9
1.2 NC contact 1.2
EMERGENCY STOP

10

1.1 NC contact 1.1
Jumper short-circuit

11 KEY2 I Key scanning No.3
connector

12

13

EMERGENCY_STOP

2.2
MPI_B I/O
EMERGENCY STOP
NC contact 2.2
RS-485 data
EMERGENCY STOP
MPI
14 ZS2 ZS2.1 Enabling button Enabling function
15 HR_XA Handwheel A negated Handwheel
Not assigned/enab-
16 N.C. ZS1.2 N.C./enable key
ling function
17 HR_XB Handwheel B negated Handwheel

16.5 Interfaces
Printed circuit Connector X30: Printed circuit board Direct keys

board direct Connector type: Ribbon cable plug connector with protective collar
keys X30 20-pin 2-row with lock
Table 16-16 Printed circuit board Direct keys

Pin


1

F1 I Direct key 1

2

F2 I Direct key 2
3

3F I Direct key 3

4
5
6

4F
5F
F6
I
I
I
Direct key 4
Direct key 5
Direct key 6
7 F7 I Direct key 7
8 F8 I Direct key 8
9 F9 I Direct key 9
17
P5 TAC
P5_TAC V 5V keyboard controller
18
19
M TAC
M_TAC V Ground of keyboard controller
20
The direct key module serves to connect the 16 direct keys of the A&D operator
panel front.
16.5.3 Individual wiring PCB input/output

Pin

1

Signal

P24_5
Type
V
Signal name
24V potential

2 M24 V 24V ground


16.5 Interfaces

1
Pin

Signal

E52/W1
Type
I
Signal name
Input key 52/matrix row 1





1 W3 I Matrix row 3

2 W5 I Matrix row 5

3 W6 I Matrix row 6
4 W7 I Matrix row 7

Pin


1

W9 I Matrix row 9

2

W10 I Matrix row 10

3
4

W11

W12
I
I
Matrix row 11
Matrix row 12
Connector X44 Connector type: 3-pin print terminal block MSTBA 2.5/3-G-5.08


1 Shield I Ground

2 M24 V 24V potential
3 P24 V 24V ground

16.5 Interfaces

Pin

1

Signal

P24_5
Type
V
Signal name
24V potential

2 M24 V 24V ground



Pin


1


2


3

4
E62/R5

E63/R6
I
I

Pin

1

Signal

E14/R7
Type
I
Signal name

2


3


4
5
E23/R10
HS20 O
I Input key 23/matrix line 10
Connection of lamp HS20

16.5 Interfaces
Connector parts
for I/O module Table 16-25 Connector parts for I/O module
Connector MINI-COMBICON connector part, Phoenix Article


MC 1.5/4-ST-3.81 1803591

FRONT-MC 1.5/4-ST-3.81 1850686
X40 X43
X40, X43, X45

FK-MCP 1.5/4-ST-3.81 1851067

MCC 1/4-STZ-3,81 1852192
MC 1.5/8-ST-3.81 1803633
X41, X42, X46, FRONT-MC 1.5/8-ST-3.81 1850725

X47 FK-MCP 1.5/8-ST-3.81 1851106
MCC 1/8-STZ-3,81 1852231
Connector COMBICON connector part, Phoenix Article


X44 MSTBA 2.5/3-G-5.08 1779990

Terminator Whether a terminator or a handheld unit is connected can be determined by

querying word 0 bit 2, KEY 2. Terminator connected corresponds to High on
input KEY2.
Properties of
jumper S Interlocking of axis motion via the PLC
button S11
S Interlocking of the enable key
S Jumpering of EMERGENCY STOP contacts on the handheld unit
S Manipulation-proof: Sealing cap prevents accidental actuation of key
S Jumper button, non-latching
S Initiation of a monitoring time for checking the operability of the EMER-
GENCY STOP jumpering function
S Interruption in power supply for handheld unit connection, two-channel vari-

ant, when S11 is actuated
Warning
! It is the users responsibility to ensure that the enable key is designed to DIN
EN 6020411, Subsection 9.2.5.8, and, when released or pushed down, stops
dangerous movements reliably.
When S11 is utilized for the EMERGENCY STOP jumpering function, an inter-
lock of hazardous motions must be implemented via the PLC with S11 and a
time monitor activated simultaneously, in addition to Fig. 16-7 and Fig. 16-8. If
the signaling contact on S11:31/32 is not properly closed again on expiry of the
monitoring time (approximately 5 minutes), then EMERGENCY STOP must
be generated by the PLC.
16.6.1 Functional reliability of EMERGENCY STOP and enabling circuits
See Fig. 16-7 or 16-8
EMERGENCY STOP The EMERGENCY STOP circuit is a two-channel configuration with the follow-
circuits ing layout:
S For circuit 1:
unitXS12:1X5:1X4:7
S For circuit 2:
unitXS12:10X5:10X24:3.

To avoid interruption of the EMERGENCY STOP circuits on changeover be-

tween the handheld unit and the terminator at XS12, the EMERGENCY STOP
contacts of the handheld unit can be jumpered via S11.
The time monitoring function in the PLC serves to detect malfunctions in push-
button S11:
If contact S11:31/32 does not close properly within the specified time frame, the
PLC must interrupt the EMERGENCY STOP circuit. The contact status is
scanned via circuit X23:8X4:8X4:1optocoupler KEY0Word 0, bit 0 of
PLC input image (see Section 16.14).
Enable circuits There are two variants of enable circuit, i.e. single-channel and two-channel
(see below).
S Single-channel enable device:

The enable key is called via
X4:9X23:4S11:21/22X23:3X5:6XS12:6 and scanned via
XS12:5X5:5X4:10 and XS12:14X5:14X4:11.
The call is gated via NC contact S11:21/22, thus preventing enabling while
S11 is actuated.
S Two-channel enable device:

As compared to the single-channel variant, this has two call paths, i.e.
X4:12X5:17XS12:16
X24:2X5:6 XS12:6.
In addition, the power supply for the handheld units connected at XS12:4 is
interrupted via contact S11:31/32X23:8 and X5:4 when S11 is actuated.
This variant has no interlock between S11 and the enable key. This must be
implemented in the PLC.
16.6.2 Single-channel enabling function
(see below).
Applicability The single-channel enabling function applies to order numbers

6FC5 203-0AD25-0AA0 and
6FC5 203-0AD27-0AA0.

PP031-MC X25
EMERGENCY STOP
interf.
X16
2P24
M24
PG
M
M P5
S13
OPI
Filter X15
X13
Repeater
3M24
3P24
13 13
PCB dis 2 2
tributor II 4 4
X22
1 1 3M24 3 3
2 2 1 8 8
3 3 2 15 15
4 4 3 7 7
4 16 17
Jumper 17 16
S11 X23
X23 11 11
2P24 7 32 31 8
5 44 43 6 10 10
4 21 22 3 6 6
1 14 13 2 1 1
14 14
12 12
9 9
5 5
M24 X5
HPU/OPI
/ OP7HH
2P24
X24 X4
EMERGENCY STOP 4 3 2 1 9 6 8 7 1 11 2 12 3 4 5 10
circuit 2
Br5 *)
6 14 16 5
Enabling button
Custom-made wiring
1 12 9 10 6 5 14 7 15 8 17 11 4 3 2 13
XS12
Handheld unit HHU

Type (B-MPI) MPI
6FX20071AC13
Power
1 12 9 10 6 5 14 4 3 2 13
HPU
Handheld
programming unit HPU MPI
Type MPI
EMERGENCY STOP Enabling button Power
6FC5403-0AA00-0AA1 supply
1 12 9 10 11 4
Terminator
Terminator
(component PP031-MC) 3P24

mately 5 min.), the PLC must initiate an EMERGENCY STOP (see also Fig. 16-17).
Fig. 16-7 Connection for handheld unit ZS (single-channel)

Table 16-26 Terminal assignments XS12 handheld unit (single-channel)
PIN PP 031 MC/HR HHU HPU Termina-

tor

1 EMER- EMERGENCY STOP EMERGENCY STOP Br1
GENCY_ button 2.1 button 2.1

2
3

STOP 2.1

MPI_A
3M24
XRS_KP
0V
SD0
0V

4 3P24 24V 24V BR3
5 ZS1 Enabling button Enabling button
6 ZSCommon Enabling button
7 HR_B Handwheel pulses,
track B
8 HR_A Handwheel pulses,
track A
STOP 1.2
STOP 1.1
11 KEY2 BR3
STOP 2.2
13 MPI_B RS_KP NSD0
14 ZS2 Enabling button Enabling button
15 HR_XA Handwheel pulses,
track XA
16
17 HR_XB Handwheel pulses,
track XB
16.6.3 Two-channel enabling function
(see below).
Applicability The two-channel enabling function applies to order numbers

6FC5 203-0AD25-1AA0 and
6FC5 203-0AD27-1AA0.

PP031-MC X25
EMERGENCY STOP
2P24
M24
X16
interf.
PG
M
M P5
S13
OPI
Filter X15
X13
Repeater
3M24
3P24
13 13
PCB dis 2 2
tributor II 4 4
X22
1 1 3M24 3 3
2 2 1 8 8
3 3 2 15 15
4 4 3 7 7
4 16 17
Jumper 17 16
S11 X23
X23 11 11
2P24 7 32 31 8
5 44 43 6 10 10
4 21 22 3 6 6
1 14 13 2 1 1
14 14
12 12
9 9
5 5
M24 X5
HPU/OPI
/ OP7HH
2P24
X24 X4
EMERGENCY STOP 4 3 2 1 9 6 8 7 1 11 2 12 3 4 5 10
circuit 2
Br5 *)
6 14 16 5
Enabling button
Custom-made wiring
1 12 9 10 6 5 14 16 7 15 8 17 11 4 3 2 13
XS12
Handheld unit HHU

Type (B-MPI) MPI
6FX20071AE13
Power
1 12 9 10 6 5 14 16 4 3 2 13
HT6
Handheld terminal
HT6 MPI
6FC5 403-0AA10-0AA0
EMERGENCY STOP Power
supply
Enabling button 11 4
1 12 9 10
Terminator
Terminator
(component PP031 MC) 3P24

mately 5min.), the PLC must initiate an EMERGENCY STOP (see also Fig. 16-17).
Fig. 16-8 Connection for handheld unit ZS (two-channel)

Table 16-27 Terminal assignments XS12 handheld unit (two-channel)
PIN PP 031 MC/HR HHU(MPI) HT6 Termina-

tor

1

EMERGENCY_
STOP 2.1
EMERGENCY STOP
button 2.1
EMERGENCY STOP
button 2.1

Br1

2
3

MPI_A
3M24
MPI_A
M
MPI_A
M

4 3P24 P24 P24 BR3
5 ZS1.1 ZS1.1 ZS1.1
6 ZS2.2 ZS2.2 ZS2.2
7 HR_B HRB
8 HR_A HRA
11 KEY2 KEY2 KEY2 BR3
13 MPI_B MPI_B MPI_B
14 ZS2.1 ZS2.1 ZS2.1
15 HR_XA HR_XA
16 ZS1.2 ZS1.2 ZS1.2
17 HR_XB HR_XB

Dimension
drawing
482.6
Power
155

444
105

50
70
Identification of anode connection:

Insert the light emitting diode with the + polarity on the
marked end into the button.
Fig. 16-9 Dimension drawing of PP 031 MC
Panel cutout
1)
+0.2
137.4 0.2
+0.5
131.4 452.8$ 1
1
Panel cutout for PP 031 MC

125.4
4.8 or M4
6 0.5
0
0
0.5
0.2
0.2
0.2
116.2+0.2
0.2
464.8 +0.2
232.4 +0.2
348.6 +0.2
458.8 +0.5
6
1) Distance to the next PP 031 MC > 18

All dimensions in mm
Fig. 16-10 Panel cutout for PP 031 MC

Mounting For fastening the PP 031 MC (dimensions, see Fig. 16-10) it is recommended to
preparations use 10 screws M4x10 with washers and sealing strips on the rear side of the
operator panel. The washers are essential to avoid damage to the surface.
Normally, degree of protection IP65 is achieved through the sealing strips in the
shipped state provided the mounting surface is even. In case of uneven mount-
ing surfaces, it is possible that only IP54 can be achieved.
Recommended material: e.g. foam scotch tape Y-9533,
9x0.8mm
from 3M
Connecting 24V The 24V power supply is connected via a 3-way terminal block (see Fig. 16-6)
power supply to connector X8 on the rear side of the machine control panel. The equipotential
bonding conductor is fastened using an M5 screw and must be linked with the
central ground standard part.
Danger
! The 24VDC power supply must always be grounded and be designed as
Protective Extra Low Voltage (PELV) protection by function low volt-
age with safe isolation!
Connecting MPI The PP 031 MC is connected to the 840D or S7-300 control by means of an
connection MPI bus line. The MPI connector is plugged into X15 on the rear of the PP 031
MC and fixed with a screw.
Connecting Emergency stop, selector switch and single contacts are connected according
individual wiring to the required custom-made links.
(for function see Figs. 16-17 to 16-21)
Supply voltages for inputs and outputs must always be grounded!
Note
To use the actuating element WS1 as a mode selector switch a keyswitch
CG4-1A251-600 *FS1 V750D/2J must be installed in accordance with EU
Directive 89/392/EEC.

Device front
80 90
70 100
60 110
power
0 120
40 6070
20 80
10 90
6 100
2 110
0 120
Free layout of labeling areas thanks to the use of slide-in user labels
Fig. 16-11 Control panel (example)
Dimensions for
labeling the
slide-in labels
must not be printed
0
must be printed
8.5
19.9
Dimensions for labeling the slide-in labels (designation field; WS1)
34.1
13
(variable switching elements S1 to S4; S7 to S10; S14; S15)
45.5
7 7
180
Slide-in direction
43.8
82
146
16.1
Dimensions for labeling the slide-in labels (S11; XS12)

113 124

20 10 0
80
83
or chamfered 1.5 x45 degrees

69
47

Slide-in direction
Slide-in direction
16.1 26.5
23.8
14
0 0
10
20
Fig. 16-12 Dimensions for texts on the slide-in labels
Labeling
on the rear side of
the device
S11
2P24
*HR-B
HR-B
*HR-A
HR-A
HS7
2 1
HS8
S1
X43
S2 HS9
X44 3
HS10
1
HS1
1
8
HS2 S7
X45
HS3 S8
X41
HS4 S9
WS1 S11
4
S10
1
8 1
S1 S7
S1 S8
X46
S2 S9
X42
S3 S10
8
S4
S3
1
4 1
Board INPUT/OUTPUT
S4 2P24
S1 S7
X47
HS1 HS7
X43
8
1
S2 S8
Option
Option
HS2 HS8
S3 S9
HS3 HS9
HS14
S14 S15
S14 S15
S4 S10
HS4 HS10 HS15
S14 S15
HS14 HS15
1.6AT
X30
WS3 WS2
HW FAULT S7-300(2)
>
S7-300
BUS
Request 840 D
4321 ON
4321 4 3 21
OFF
S18 S16 S17
Fig. 16-13 Labeling on rear of device

16.10 Customer control panel
16.10 Customer control panel
PP 031 MC
Expansion
customer control
panel CCP
95
8.8
125.05
482.6 8.8
Fig. 16-14 Customer control panel
S Order code A5E00032795

S Can be equipped with max. 12 control devices, diameter 22mm, grid 36mm
S Labeling with exchangeable text labels.
Panel cutout
1)
+0.2
77.4 0.2
+0.5
71.4 452.8$ 1
1
Panel cutout for PP 031 MC extension

65.4
4.8 or M4
6 0.5
0
0
0.5
0.2
116.2 +0.2
0.2
0.2
0.2
464.8 +0.2
232.4 +0.2
348.6 +0.2
458.8 +0.5
6
1) Distance to the next PP 031 MC > 18

All dimensions in mm
Fig. 16-15 Panel cutout for PP 031 MC extension

16.11 Functions of PCB I/O PP 031 MC
16.11.1 Inputs/outputs
Inputs
Table 16-28 Inputs (possible combinations)
Without authorization key-operated With authorization key-operated switch

switch
Design Key matrix Switch/ Design Key matrix Switch/
(option) independent (option) independent
single con- single con-

tacts tacts

1 without 14 contacts 14 without 10 contacts
8 60 keys 5 contacts 21 60 keys 1 contact
Functions of keys in the matrix:
+ Non-latching key
12 108 keys 1 contact + Single-key actuation
+ No switch function
Outputs 16 outputs for driving lamps, four of which are optional
Key matrix Eight inputs W3, W5, W6, W7, W9, W10, W11, W12 for matrix.
option Four outputs A28 to A31 for driving lamps.

16.11.2 Key assignment within matrix
Table 16-29 Key assignment within the matrix
Key value Wn Matrix row Rn

Wn W8/ W4/ W2/ W1/ E19/ Rn E12 E24 E30 E61 E62 E63 E14 E21 E22 E23
E55 E54 E53 E52 PB
1 0 0 0 1 0 1 0 1 1 1 1 1 1 1 1 1
2 0 0 1 0 0 2 1 0 1 1 1 1 1 1 1 1
3 0 0 1 1 1 3 1 1 0 1 1 1 1 1 1 1
4 0 1 0 0 0 4 1 1 1 0 1 1 1 1 1 1
5 0 1 0 1 1 5 1 1 1 1 0 1 1 1 1 1
6 0 1 1 0 1 6 1 1 1 1 1 0 1 1 1 1
7 0 1 1 1 0 7 1 1 1 1 1 1 0 1 1 1
8 1 0 0 0 0 8 1 1 1 1 1 1 1 0 1 1
9 1 0 0 1 1 9 1 1 1 1 1 1 1 1 0 1
10 1 0 1 0 1 10 1 1 1 1 1 1 1 1 1 0
11 1 0 1 1 0
12 1 1 0 0 1

Matrix keyboard
scan
Scan input R1 ... Rn

n v 10 *)
Number No
of active blocks
= 1?
Yes
Save the active
block Rn
Scan inputs
W1, W2, W4, W8
Save the active

block Wn
Scan parity bit E19
Parity No
OK?
Yes
Save RnWn
Bounce suppression
function
Output of key RnWn
*) n = number of matrix blocks
Fig. 16-16 Matrix scan sequence

Custom-made There are various possible applications for connecting the key inputs KEY0 to
wiring KEY2:
1. Enabling key connection according to Fig. 16-7 and 16-8.
2. Use as isolated inputs with reference potential at X4/5
3. Use of button S11 with PLC function without jumpering.
For the required jumper assignment and their meaning, please refer to the
Tables below.
Table 16-30 Custom-made wiring

Br1 Br5

Use of the connections X4:1;2;3 as isolated inputs. The refer-

ence potential is at X4:4 here.

X X PLC function
Use of the
connections Table 16-31 Use of the connections

Potential Port Use
X3/11,12 Control of inputs HS1 to HS4, HS7 to HS10, HS14 and HS15

2P24
X24/1 Controlling the inputs KEY 0 to KEY 2

KEY0...2

X4/1 ... 3

Inputs KEY0 to KEY2
Reference potential of inputs KEY 0 to KEY 2;

M24 X4/5
no external use.
Button S11 with

PLC function
S11
2P24 X5
2P24
2P24 M24
X24 1) X4
4321 9 6 5 10 7 4 12 11 8 1 2 3 X3
11 12
Br1 Br52)
External contacts
1) S11 connection with single-channel variant only
2) Signal to PLC: Triggers a monitoring timer.
If the signal level is still low or open on timeout (approx. 5min),
the PLC must initiate an EMERGENCY STOP (see also Fig. 137).
Fig. 16-17 Button S11 with PLC function

Ext. control of
pilot lamps
HS1 ... HS10
Block Sn
HSn 2P24
1M24
X1; X2; X6; X11 X3

11 12
External contact
Fig. 16-18 External control of signaling lamps in keys HSn
Circuit for
EMERGENCY
STOP button
1 1 1 1 3
EMER- to PLC
GENCY
STOP button 2 2 2 2 4
optional
EMERGENCY STOP machine control

Connection of
spindle speed
override WS3 X18.1 WS3 6FC5 247-0AA34-0AA0
rd
C
16
rd
8
X18.2
Fig. 16-20 Connection WS3 spindle speed override spindle speed/rapid traverse
Direct control key

connection
X30
20
19
18
17
16 F16
15 F15
14 F14
13 F13
12 F12
PCB direct keys
PP031 MC 11 F11
10 F10
9 F9 +
8 F8
5 V +10%
7 F7
6 F6
5 5F
4 4F
3 3F
2 2F
1 F1
Fig. 16-21 Direct control key connection

Connection of
Single contacts
customer control W8
Lamps
SE11 SE12 SE13 SE14
panel W4 HS27
W1; W2; W4; W8
only as an alternative HS26
to the key matrix, W2
HS25
X42, X43
Unassigned W1 HS24
R10*) HS23
SE7 SE8 SE9 SE10

R9*) HS22
*) assigned when the
authorization key- R8*) HS21
operated switch is R7*) HS20
used
X43
R6 HS19
X47
SE3 SE4 SE5 SE6

R5 HS18
PCB I/O PP031 MC

R4 HS17
X42
R3
X46
HS16
X41
P24_5
M24
X45 R2
SE1 SE2
R1
X40
M24
X44
P24
Key matrix (option)

Rows n=3 to 10
P24_5
Row n=1
Row n=2
Group
Group
Group
M24
SMn
SM2
SM1
W12
SMn.7 SMn.8 SMn.9 SMn.10 SMn.11 SMn.12

SM1.9 SM1.10 SM1.11 SM1.12
SM2.9 SM2.10 SM2.11 SM2.12
W11
W10
W9
Lamps
W8 corresponding individual contacts are not needed

SM2.7 SM2.8
SM1.7 SM1.8
HS31
W7
HS30
HS29 W6
HS28
SMn.6
SM2.6
SM1.4 SM1.5 SM1.6
W5
When these are connected, the
SMn.3 SMn.4 SMn.5
SM2.4 SM2.5
W4
W3
Inputs R1 to R10
SM1.1 SM1.2 SM1.3
SM2.3
W2
SMn.1 SMn.2
SM2.1 SM2.2
W1
Fig. 16-22 Connecting the customer control panel to the I/O PCB

Wiring
example P24_5 * switch
Not usable
is used
Individual M24 Authorization
X45
keys switch is used
SE7* SE8* SE9* SE10*

R10 *
E23*
R9 *
E22*
X47
R8 *
E21*
R7 *
E14*
SE3 SE4 SE5 SE6

R6
E63
R5
E62
X46
R4
E61
R3
E30
SE2
R2
E24
X45
SE1
R1
E12
SM1.7 SM1.6 SM1.5 SM1.4 SM1.3 SM1.2 SM1.1
(W1)
E52
(W2)
E53
(W3)
(W4)
E54
(W5)
(W6)
Inputs PLC
(W7)
Group
X41, X42
SM1
SEW8
(W8)
E55
(W9)
nc
nc = not connected
(W10)
nc nc
(W11)
X43
(W12)
nc
(W8)
P24_5 PB
E19
M24 (even)
X40
X44 1 3 2
from central
power M24
supply P24
Customer control panel PCB I/O PP031 MC
Fig. 16-23 Wiring example eleven single keys and seven matrix keys

16.13.1 PP 031 MC
Table 16-32 Technical data for PP 031 MC
Electrical data
Total current Rated volts. Voltage up- Voltage Fuse
max. 1A 24VDC 30.2VDC 18.5VDC 1.6AT
Mechanical data
Dimensions Height Width Mounting Depth to the
depth front
155mm 483mm 105mm 70mm
Installed/in operation Storage/transport
Front Rear side
Temperature ranges 0 ... 45C 0 ... 55C 40 ... 70C
Degree of protection IP 54 IP 10A
Degree of protection I to IEC 204 I
16.13.2 I/O interface individual wiring
Key contact maker Contacts with floating outputs S1 to S4; S7 to S10; S11; S14; S15 (NC contact
or NO contact)
Table 16-33 NO contacts S1 to S4; S7 to S10; S14; S15

AC DC

Nominal insulation voltage Ue 50V 50V

Nominal operating current Ie 2A

Rated operating current at 24V Ie 2A

Min. rated operating current at 5V Imin 1mA

Volume resistance < 20m

Switching capacity 10Ie 1.1le
Max. operating current for reference po- 8A 8A

tential


Selector switch Contacts with floating outputs WS1/911; 13; 15;
Table 16-34 Selector switch

Nominal operating voltage
Load

Ue
AC
300V
DC
300V

resistive 10A
Switching capacity

inductive > 2A

resistive 10A
Switching capacity at 24V

inductive 6A

Nominal values for arc-
0.3A 0.22A
free switching at 24V
EMERGENCY Contacts with floating outputs S13

STOP button
Table 16-35 EMERGENCY STOP button
Utilization category AC DC

(EN 60947-5-1)

Rated operating voltage Ue 24V 24V
AC-12 le 10A
AC-15 le 6A
Switching capacity
DC-12 le 10A
DC-13 le 3A
Min. rated operating current at lmin 1mA
5V
For further parameters, see pushbutton and indicator light SIGNUM 3SB3
Inputs X4: KEY 0 to KEY 2
Table 16-36 Inputs X4: KEY 0 to KEY 2:

Status Voltage Current switched

switched

Nominal value 24V
H signal

Min. 4mA (at 15V)
Max. 9.5mA (at 30V)

L signal

Nominal value
Signal level
0V or open
3V to +5V

In a group of 3

Max. 50m
Cable length
AWG 2016

X1, X2, X6, X11
Table 16-37 Inputs HS1 to HS4; HS7 to HS10; HS14; HS15

Status

Nominal value
Voltage switched
24V
Current switched
50mA

Pilot lamp ON (making current
Signal level +18V to +30V max. 600mA)

Pilot lamp OFF Nominal value open

Cable length
Max. 10m AWG 2016
X30
Table 16-38 Input X30 direct keys, F1 to F16

Status


Nominal value 5V

H signal
Signal level +5V or open

Nominal value
L signal

Signal level 3V to +1V < 11mA

In a group of 16

Cable length Max 0.6m AWG 28
Printed circuit X44

board Input/output
(option)
Table 16-39 Inputs X44
Power supply

Total current Rated voltage Voltage up- Voltage Fuse


Max. = 5A, depend-
24VDC 30.2VDC 18.5VDC 2x10A
ing on the lamp load
Inputs X41, X42, X43, X45, X46, X47: E12, E14, E21 to E24, E30, E52 to E55, E61 to
E63, W1 to W12
Table 16-40 Inputs

Status Voltage switched Current switched

Nominal value +24V

H signal Min. 3.6mA (at 15V)
Max. 8mA (at 30V)

Nominal value 0V or open

L signal
Signal level 3V to +5V

In a group of
Cable length
Common root
Max. 50m, AWG 16

Lamp outputs X41, X42, X43, X46, X47: HS16 to HS31
Table 16-41 Lamp outputs

Status

Nominal value
Voltage switched
+24V
Current switched

H signal
Signal level +20V to +30V Max. 0.5A/output

Nominal value
L signal

Signal level open < 25A

In a group of 16
Cable length Max. 50m, AWG 16
Output
Max. 5A
total current
Outputs P24_5 X40:1, X45:1
Table 16-42 Outputs P24_5

Status


Output total current
Nominal value +24V
Max. 700mA

16.14 PLC interface
16.14 PLC interface
Table 16-43 Input signals
Inputs Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

Word 0 Mode GD project Isolated inputs
Low
WS1/4 WS1/3 WS1/2 WS1/1 *) DIP X4/3 X4/2 X4/1
ER ES IB VK S16/1 KEY2 KEY1 KEY0

Word 0 + direction I/O direction Variable keys
High

S15 E14/R7 S14 E12/R1 S4 S3 S2 S1
Key
Word 1
Low

switch 0
I/O GD project Version activation GD project
E23/R10 E22/R9 E21/R8 DIP E19/PB High *) DIP DIP

key Key Key S18/3 (parity) (reserve) S16/1 S18/4
switch 3 switch S2 switch 1
Word 1 GD project I/O EMER- Variable keys
High GENCY

STOP

*) DIP E30/R3 S13 S10 S9 S8 S7 E24/R2
S16/1
Word 2 Direct keys
Low
F8 F7 F6 5F 4F 3F F2 F1
Word 2 Direct keys
High
GD project
F16 F15 F14 F13 F12 F11 F10 F9
Word 3 I/O Spindle speed/rapid traverse
Low
E55/W8 E54/W4 E53/W2 E52/W1 D C B A
Word 3 I/O Feed override
High
E63/R6 E62/R5 E61/R4 E D C B A
*) All bits identified with DIP-S16/1 are simultaneously switched when S16/1 is actuated.

Legend:

High active signals S1 ... S4; High active/Low active settable via S18.2
S7... S10; S18.2 closed = Low active

S14;
S15
S18.2 open = High active
Low active signals Ex/HSx I/O high active via a plug-on card supplied as
an option

10.00
16.14 PLC interface
Table 16-44 Output signals (see Table 16-43 for legend)
Outputs Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

Word 0 Pilot lamps
Lo
Low
Word 0 Unassigned Pilot lamps
High
HS10 HS9
Word 1 I/O
Lo
Low
Word 1 Option Key matrix on I/O I/O
High
Word 2 Unassigned
Lo
Low
Word 2 Unassigned
High
Word 3 Unassigned
Lo
Low
Word 3 Unassigned
High
Notice
When the mode is switched over, Low can be output briefly for all signals on
selector switch SW1!
I.e., all safety-relevant signals are linked such that they are only possible if
switch WS1 has a defined position.

Assignments The following settings are possible with the switches DIP S16, S17, S18:
Table 16-45 Assignments of S16, S17, S18 on PP 031 MC
S17 S16 S18 Meaning

4 3 2 1 4 3 2 1 4 3 2 1
on Baud rate: 1.5 Mbaud OPI
off Baud rate: 187.5 kbaud MPI
on on not applicable
on off 200 msecs transmission cycle
time
off on 100 mseccs transmission cycle
time
off off 50 msecs transmission cycle
time
on on on on Bus address: 15
on on on off Bus address: 14
on on off on Bus address: 13
on on off off Bus address: 12
on off on on Bus address: 11
on off on off Bus address: 10
on off off on Bus address: 9
on off off off Bus address: 8
off on on on Bus address: 7
off on on off Bus address: 6
off on off on Bus address: 5
off on off off Bus address: 4
off off on on Bus address: 3
off off on off Bus address: 2
off off off on Bus address: 1
off off off off Bus address: 0
off off Set of parameters 1
on off Set of parameters 2
on on Set of parameters 3
on Hardware reset ON
off Hardware reset OFF
on Pushbutton panel
Break function *)
off Pushbutton panel
Make function
X Reserve GD project
*) Function is identical to PP 031 (previous version).

DIP switch
settings Table 16-46 Default setting for 840D
Application:
Connecting the PP 031 MC to an 840D
S17 S16 S18
Meaning
4 3 2 1 4 3 2 1 4 3 2 1
X off on off on on off off off off X off 187.5 kbaud/1.5 Mbaud
Set of parameters 1
Prerequisite:
none, can be directly connected to the MPI/OPI of the 840D
Table 16-47 Default setting for S7-300
Application:
Connecting the PP 031 MC to an S7-300
S17 S16 S18
Meaning
4 3 2 1 4 3 2 1 4 3 2 1
off off on off on on off on off off X off 187.5 kbaud
Set of parameters 2
Prerequisite:
Table 16-48 Setting for S7-300 with two machine control panels
Application:
Connecting two PP 031 MCs to an S7-300
S17 S16 S18
Meaning
4 3 2 1 4 3 2 1 4 3 2 1
off off on off on on off on off on X off 187.5 kbaud
Set of parameters 3
Prerequisite:
Settings of The load on the PLC by the PP 031 MC can thus be adapted.
transmission
cycle time The PLC expects a message frame from the PP 031 MC at least every
500 msecs.
The PP 031 MC sends a message frame to the PLC at cyclic intervals when no
key is pressed. This cycle time is set on S17 DIP switches 2 and 3.

Communication The switchover of the sets of parameters (GD identifications) for communication
parameters between control system and PP 031 MC is carried out using the DIP switches
S16/1 or S18/3.
The switchover will only come into effect after power ON on PP 031 MC.
The following applies: Transmitted Data = PP 031 MC Control

Received data = Control PP 031 MC
Table 16-49 Set of parameters
Index Designation Set of Set of Set of

parame- parame- parame-

ters 1 ters 2 ters 3

1

Receive GD circuit no. 1 2

2 Receive GBZ no. Internal 1 1

3 Object no. for receive GBZ Assign- 1 1

ment

4 Send GD circuit no. 1 2
5 Send GBZ no. 2 2

6

Object no. for send GBZ 1 1
Global data table When the PP 031 MC is operated in conjunction with an S7-300 CPU, set of
parameters 2 is selected and a global data table is created using HISTEP.
In this case, communication with the PP 031 MC must be configured as follows:

GD identification ebf/s7-300:: ebf/PP 031 MC::

GD 1.1.1 >>ab60:8 eb0:8
GD 1.2.1 eb60:8 >>ab0:8
The specifications ab60 and eb60 for S7 are only examples; the signals can
also be transferred to other locations.
The GD identification is generated by the compiler.
GD 1.1.1 PP 031 MC is receiver
GD 1.2.1 PP 031 MC is transmitter
This assignment corresponds to set of parameters 2 as per Table 16-49.
Note
Make sure that a data width of eight bytes is always assigned for the input and
output image!
If two PP 031 MCs are to be connected to an S7-300 CPU, set of parameters 3

must be set, and the following global data table must be created using HISTEP.


GD 1.1.1

GD identification ebf/s7-300::
>>ab60:8
ebf/PP 031 MC::
eb0:8
ebf/PP 031 MC_2::

GD 1.2.1

GD 2.1.1

eb60:8
>>ab120:8
>>ab0:8
eb0:8

GD 2.2.1

eb118:8 >>ab0:8
Further GD communications can be configured in the following lines.
Danger
! The transmission path (MPI/OPI) from PP 031 MC to the central controller must
be monitored by the user.

16.16 Sample parameterization for communication between SIMATIC S7 and PP 031 MC
16.16 Sample parameterization for communication between

SIMATIC S7 and PP 031 MC
Your program can read the information of the GD package status from the oper-
ands you assign the corresponding GDS identification in the global data table in
the STEP7 tool Communication Configuration.
If a communication error occurs, the operating system writes error information to
these operands (described in the Table below). You can then use this informa-
tion to create conditional program branches as a response to the communica-
tion errors.
For the status information of the communication, a double word (32 bit) is pro-
vided.
For the contents of the double word, see the Table below:
Table 16-52 State information
Bit Status: Description of error From Send From Re-

CPU ceive CPU
0 Area length error in sender + +
1 Block cannot be found in sender + +
2 I/O access error in sender + +
3 GD package lost + +
in sender
in connection
in receiver
4 Syntax error in GD package + +
5 GD object missing in GD package +
6 Wrong assignment of GD object length in +
sender and receiver
7 Address range length error in sender +
8 GD package cannot be found in receiver +
9 I/O access error in receiver +
10 Timeout in receiver +
11 Restart of receiver +
1230 Reserved +
31 Receive new data +
References: / / SIMATIC S 7, User Manual
Note
Monitoring of the MPI link between SIMATIC S7 and PP 031 can be imple-
mented with the global data bit, bit 31. The user can reset bit 31 and provide it
with a watchdog. If this bit is not set again within the predefined time interval, a
fault in the line is the cause.

16.16 Sample parameterization for communication between SIMATIC S7 and PP 031 MC
Table 16-53 Example
GD identification as314//cpu1:: PP 031_1//cpu1::

GST md120
GDS 1.1 md130
SR 1.1 4 1
GD 1.1.1 >>ab120:8 ab0:8
GDS 1.2 md140
SR1.2 4 4
GD 1.2.1 eb118:8 >>eb0:8

10.00
Lamp replacement 1. Prize off the button cap towards the front with a screwdriver.
for illuminated
2. Lever out the button holder using lamp remover LZ5.
keys, illuminated
switches 3. Change the lamp using service tool LZ5 or a suitable insulating tube.
4. Refit the button holder and cap in reverse order.
Note
Lamp remover LZ5 is not a SIEMENS product. It can be obtained from the
Schlegel company.
Changing the 1. Prize off the cap and the label holder towards the front with a screwdriver.
lamps on pilot 2. Use the lamp remover of service tool LZ5 or a suitable insulating tube to
lamps change the lamp.
3. Refit the cap and the label holder.
Notice
When using LEDs, make sure that they are connected with the correct polarity
(see Fig. 16-9: dimension drawing of PP 031 MC) !
Mounting 1. Screw off the dummy plug.

additional 2. Press the contact maker onto the base and install the lamp if necessary.
control elements
3. Insert the pushbutton through the front plate and screw on the cap nut with
several turns.
4. Screw the cap nut tight. Please note the position of the anti-rotation element.
Insert slide-in
labels 1. Create the slide-in labels (see Fig. 16-11).
2. Remove the protective film from the label slot.
3. Slide in the labels (with print facing the operator side).
4. Align the texts in the window.
Note
Slide in the labels when the PP 031 MC operator panel front is not yet installed.

Changing a 1. Loosen the cap nut on the pushbutton until the contact maker has almost
contact maker been reached.
2. Pull the pushbutton and the contact maker approximately 3mm out of the
fixture (the locating pin of the pushbutton must be freed).
3. Turn the pushbutton approx. 20 to the right or left, remove it from the con-
tact maker and remove the cap nut.
4. Change the contact element, remove the defective contact maker from the
fixture and press the new contact maker down into the fixture.
5. Insert the pushbutton into the opening and screw on the cap nut partially.
6. Press the pushbutton down until it rests on the contact maker. When doing
so, observe the position of the locking lose.

16.18 Configuring
16.18 Configuring
16.18.1 Delivery variants
Note
When replacing the existing PP 031 devices with variants of the PP 031 MC,
downwards compatibility cannot always be guaranteed!
Table 16-54 Delivery variants
Pushbutton panel PP 031 MC 6 F C 5 2 0 3 0 A D 2 X

0 A A 0
PP 031 MC basic unit 6 F C 5 2 0 3 0 A D 2 4
EMERGENCY STOP with 2 NC contacts + 1 0 A A 0
NO contact, keyswitch, 8 illuminated keys with
incandescent lamps, button caps 2*GR, 2*RT,
2*GB, 2*Kl, 2* dummy plugs BVR22, program-
ming device and RS-232-C interfaces, fee-
drate override, cover plate for 2nd override,
with blank special film for slide-in labels with
dimensional drawing for PCB Direct keys
with ribbon cable1)
PP 031 MC/HR 6 F C 5 2 0 3 0 A D 2 5
as the base unit, in addition, 0 A A 0
with 17-pin handheld unit socket connector
and jumper button with repeater function and
distributor
single-channel enabling function
PP 031 MC/HR II 6 F C 5 2 0 3 0 A D 2 5
as the base unit, in addition, 1 A A 0
with 17-pin handheld unit socket connector
and jumper button with repeater function and
distributor
PP 031 MC-S 6 F C 5 2 0 3 0 A D 2 6
Special variant based on PP 031 MC; 0 A A 0
the appropriate fitting is uniquely defined by an
additional ID No.
(see Subsection 16.18.3)
PP 031 MC/HR-S 6 F C 5 2 0 3 0 A D 2 7
Special variant based on PP 031 MC; 0 A A 0
the appropriate fitting is uniquely defined by an
additional ID No. (see Subsection 16.18.3),
single-channel enabling function
PP 031 MC/HR-S II 6 F C 5 2 0 3 0 A D 2 7
Special variant based on PP 031 MC; the ap- 1 A A 0
propriate fitting is uniquely defined by an addi-
tional ID No. (see Subsection 16.18.3),

16.18 Configuring
Extensions to the PP 031 (can be ordered and installed by the customer separately)
Override switch, 16-level speed 6 F C 5 2 4 7 0 A A 3 4
0 A A 1
Suspension device for keyboard and mouse 6 F C 5 2 4 7 0 A A 4 0
0 A A 0
+/ keys raised 6 F C 5 2 4 7 0 A A 4 1
0 A A 0
PCB_input/output without option 6 F C 5 2 4 7 0 A A 4 2
0 A A 0
Set of M4x12 flange bolts (30) 6 F C 5 2 4 7 0 A A 4 4
0 A A 0
2x NC contacts for Emergency Stop buttons 3 S B 3 4 0 0 0 E
EMERGENCY STOP protective shroud 3 S B 3 9 2 1 0 A K
Spare parts kit PP 031 MC 6 F C 5 2 4 7 0 A A 2 7
5 covers, 5 films, 2 sealing caps, set of button 0 A A 0
caps, 5 incandescent lamps with base,
1 dummy plug, 1 illuminated key contact
maker
Extensions for project-specific variants

Slide-in labels as per customer layout
Set of light emitting diodes (ultra-bright)
Knob FS1 for WS1
Actuator and contact maker according to Tabelle 16-55
Authorization key-operated switch at customer request
PCB_input/output with key matrix 1) at customer request
PP 031 MC extension See Fig. 16-1 Custom-made control elements
1) See also PP 031 MC application PCB I/O; drawing no. J32010-A0001-U003-A1-0018.

16.18 Configuring
16.18.2 Project-specific components
Table 16-55 Control elements that can be retrofitted by the user

Function Upper part Holder Mount- Use

Actuator/accessories Switching element/ ing
Pilot lamp location

Pilot lamp

Lamp nipple

28mm
RXJN-GB (yellow)
Lamp socket AL5 with
incandescent lamp
T5.5K/30
S1 ... S4
S7 ...
S10
Lamp

RXJN-GN (green) or spot LED L5.5K28UG S14,

RXJN-RT (red) (green) L5.5K28UR S15
RXJN-BL (blue) (red) L5.5K28UW

RXJN-KL (transp. (white) L5.5K28UY (am-

glass) ber)
RXJN-WS (white) L5.5K28UB (blue)

Buttons

Pushbutton 28mm Button contact maker S11

RXJT-GB (yellow) AT2 1 NC contact (internal), 2 NO
RXJT-GN (green) contact + 1 NC contact (ext.)

RXJT-RT (red) For S1 1 NC contact (int.), 2

RXJT-BL (blue) NO cont. + 1 NC cont. (ext.)
RXJT-KL (transparent For S2...S4, S7...S10 1 NC

glass) contact (internal), 1 NO con-
RXJT-GSW (black) tact + 1 NC contact (external)

For S14, S15 1 NC contact

int., 2 NO contacts ext.
Illuminated keys Pushbutton 28mm Illuminated key contact For S1 1 NC contact (inter.), 2

with fixture for T5.5K RXJT-GB (yellow) maker ATL2 with incan- NO cont. + 1 NC cont. (ext.)

RXJT-GN (green) descent lamp T5.5K/30 For S...S4, S7...S10 1 NC
RXJT-RT (red) or spot LED contact (internal), 1 NO con-

RXJT-BL (blue) L5,5K28UG (green) tact + 1 NC contact (external)

RXJT-KL (transparent L5.5K28UR (red) For S14, S15 1 NC contact
glass) L5.5K28UW (white) (internal), 2 NO contacts (ext.)

L5.5K28UY (yellow) Lamp externally controllable
L5.5K28UB (blue)

Keyswitch

Switching angle 900

Safety lock cylinder

28mm
Button contact maker
AT2
For S1 1 NC contact (int.), 2
NO cont. + 1 NC cont. (ext.)

2 position keys, RXJSSA 15 E For S1...S4, S7...S10
removable in both 1 NC contact (internal), 1 NO

positions contact + 1 NC contact (ext.)
S14, S15 1 NC contact (int.),

2 NO contacts (ext.)

Raised keys 6FC5 2 RTAO pushbuttons 2 AT2
247-0AA41-0AA0 with plunger elong. Special design
Designation field
Replaceable text insert

strips

Dummy plug BVR22 S14 and S15 with base unit
Selector switch Knob FS1 WS1 Re-equipping to knob-oper-
ated switch
Speed/rapid 6FC5 247-0AA34-0AA1 WS3 Connection to PCB PP 031R
traverse override
Switching element: 2 3SB3400-0E Expans. NC contact EMER-
EMERGENCY NC contacts GENCY STOP
S13
STOP Protective collar for 3SB3921-0AK Protection against accidental
frontplate fixing release
Note
When assigning the colors for keys and pilot lamps to the corresponding func-
tionality, observe the standard EN 60204 Part1 or VDE 0113 Part1, Section
Pushbuttons/Colors.

16.18 Configuring
16.18.3 Rating plates
One of the following rating plates is attached to the components and modules:
Components Example:
F2 L3
A5E00022993 A/B
6FC5 2030A220AA0
PP031 MC
Explanation: F2 Place of manufacture

A500022993 ID number
A/B/C/D Product version
6FC5 203-0AD24-0AA0 Order No.
PP 031 MC Component name
Printed circuit Example:

boards
A5E00017606 A1 L2 F2
Explanation: A5E00017606 ID number

A1 Product version
F2 Place of manufacture
In case of technical queries or service, please quote all data on the rating plate
to the local SIEMENS office responsible for your equipment.
J

QWERTY Keyboard 17
S 77 keys, arranged similarly to a standard MFII keyboard.

S Arranged in three keygroups.
Alphanumeric keygroup
with special characters.
NC function/cursor
keygroup with special characters.
Numerical keygroup
with special characters.
S The key information is transmitted to the MMC via a mini DIN (PS/2) inter-
face.
Connecting cable between keyboard and MMC.
S Switch S78 (as of 12.98)

You can use switch S78 to switch over from AT mode (delivery status) to XT
mode. Switch S78 is located at the rear of the keyboard (CNC keyboard
XT/AT).
Note Either a QWERTY keyboard or a standard full keyboard can be connected to

the MFII interface of the MMC CPU.
Purpose The QWERTY keyboard can be used as a full keyboard and as an NC key-
board.

17 QWERTY Keyboard 10.00
Key assignments
Alphanumeric keygroup NC function/cursor Numerical key-
with special characters keygroup with spe- group with spe-
cial characters cial characters
1...n & * (
Q W E R T Y U I O P 7 8 9 /?
A S D F G H J K L Del ~ 4$ 5% 6 ^ * Del

: | _
Z X C V B N M ; \ 1! 2@ 3 #
Ctrl [ { ]} ,< Alt End =

+ 0 ) .> +
NC-specific Selection key

Info key
keys
1...n Channel switchover key Edit key
Window switchover key Key for alarm acknowledgment
Keyboard interface
to MMC
MMC CPU
MFII
interface X10
X111 QWERTY keyboard
Connector designation: X111

Connector type: 6-way mini DIN connector, straight

10.00 17 QWERTY Keyboard
PIN Signal Type

1 KBDATA B
2 Unassigned
3 M V
4 P5 V
5 KBCLK O
6 Unassigned
Signal names:
KBCLK Keyboard Clock
KBDATA Keyboard Data
P5 +5V
M Ground
Signal type:
O Output
B Bidirectional
V Voltage Input
Electric/ Required voltages: +5V

mechanical brief Required power: 25mA
data
Switch S78
AT XT
(as of 12.98)
Rear side of keyboard S78
You can use switch S78 to toggle between AT mode (delivery status) and XT
mode and vice versa.
Note
When you change the mode, you must reboot the control/PC so that the new
switch settings are recognized.
The QWERTY keyboard with S78 switch can be ordered under Order No.:
6FC5 203-0AC00-0AA2.

Dimension
drawings 132.5
123.7
8.8
0
0 8.8 125 241.2 357.4 473.8 482.6
Fig. 17-1 Plan view of QWERTY keyboard
Installation of
QWERTY keyboard

Required clearance
500

18 M5 grounding connector Z

12.5
Recommended bolt M4
with washer DIN 125,
enclosed as loose part
(for front mounting)

M4 welding stud
without flange

for rear
mounting
Detail Z
Fig. 17-2 QWERTY keyboard top view
Permitted mounting
position max. 60
to the perpendicular
Front
Fig. 17-3 Mounting position

10.00 17 QWERTY Keyboard
Panel cutout
Distance when mounting the QWERTY keyboard
and the operator panel >18
4.3 or M4
114.90.2
107.20.5
Panel cutout
7.70.5 R1.5 recommended for rear mounting only

0
7.70.5 116.20.2 232.40.2 348.60.2
457.1 0.5
0 464.80.2
Fig. 17-4 Panel cutout (front view)

17.4 Technical data
17.4 Technical data
Table 17-2 Technical data for QWERTY keyboard
Electrical data
Max. voltage 5.25V
Typical 18mA
Max. power loss 131.25mVA
Mechanical data
482.6mm 132mm 15mm
Ground 1500g
Basic color of casing Anthracite, acc. to SN 47030, Part 2, Color code:
614
Mean time between failures 1507.33 fit (875.7 years)
Temperature ranges Rear 0 ... 55C
Front 0 ... 45C
Temperature changes within 1 minute max. 0.2K
Storage 20C to 60C
Degree of protection to DIN 40050 Front IP 54, rear IP 00

PCI Adapter 18
Function The PCI adapter is an option for the MMC 103.
The PCI adapter is an expansion for the MMC-CPU, MMC 103. A maximum of
two standard cards (2/3 length) can be inserted.
The bus connectors are part of the adapter.
Shared Slots allow the following combinations:
Slot 1 Slot 2
ISA/card ISA/card
PCI ISA/card
ISA/card PCI
PCI PCI
Note
The ISA card will no longer be supported in the medium term. Please use only
PCI cards for new installations.
Function block Bus terminal
Bus terminal
X221
Slot 1 X4
X220
X3
Slot 2
Card bus PCI bus

Card slots
120 4 72
X151...X153 X1 X121...X123
Cards option Fan (not equipped)
Fig. 18-1 PCI adapter block diagram

18 PCI Adapter 10.00
Warning
! The PCI adapter cannot be used on the MMC 101/102.
Position of
interfaces
Card interface
X153
8/16-bit card
interface
X151
X221
X220
X3
X4
X122
X123
X121
PCI
interface PCI slot interface
Fig. 18-2 PCI adapter interface location
Interface overview
S X3, X4: PCI slot interface
S X220, X221: 8/16-bit card interface
S X121...X123: PCI option interface

10.00 18 PCI Adapter
PCI slot
interface
Table 18-1 Pin assignments for PCI adapter connectors X3, X4

X3, X4
Pin A

Designation Signal type Pin B Designation Signal type

1 XTRST in (pull down) 1 N12 power

2 P12 power 2 TCK in (pull down)
3 TMS in (pull up) 3 M power

4 TDI in (pull up) 4 TDO (open)

5 P5 power 5 P5 power
6 XINTA o/d 6 P5 power

(X4: XINTB)

7 XINTC o/d 7 XINTB o/d
(X4: XINTD) (X4: XINTC)

8 P5 power 8 XINTD o/d

(X4: XINTA)
9 Reserved 9 XPRSNT1 in (via 10nF on M)

10 P5 power 10 Reserved

11 Reserved 11 XPRSNT2 in (via 10nF on M)
12 M power 12 M power

13 M power 13 M power

14 Reserved 14 Reserved
15 XRST in 15 M power
16

P5

power 16 CLK0 in

(X4: CLK1)
17 XGNT0 t/s 17 M power

(X4: XGNT1)

18 M power 18 XREQ0 t/s
(X4: XREQ1)

19 Reserved 19 P5 power

20 AD30 t/s 20 AD31 t/s
21 P3V3 power 21 AD29 t/s
22

AD28

t/s 22 M power

23 AD26 t/s 23 AD27 t/s
24 M power 24 AD25 t/s
25
26

AD24

IDSEL

t/s
t/s (X3: AD28, X4: AD29)
25
26
P3V3
XCBE3
power
t/s

28 AD22 t/s 28 M power

29 AD20 t/s 29 AD21 t/s

31 AD18 t/s 31 P3V3 power

32 AD16 t/s 32 AD17 t/s
33 P3V3 power 33 XCBE2 t/s

X3, X4
Pin A

Designation Signal type Pin B Designation Signal type

34 XFRAME s/t/s 34 M power
35 M power 35 XIRDY s/t/s
36

XTRDY

s/t/s 36 P3V3 power

37 M power 37 XDEVSEL s/t/s

38 XSTOP s/t/s 38 M power
39 P3V3 power 39 XLOCK s/t/s

40 SDONE in/out (pull up) 40 XPERR s/t/s

41 XSBO in/out (pull up) 41 P3V3 power
42 M power 42 XSERR o/d

43 PAR t/s 43 P3V3 power

44 AD15 t/s 44 XCBE1 t/s


47

AD11

t/s 47 AD12 t/s


50 mechanical coding 50 mechanical coding
51
52
53

XCBE0
P3V3

mechanical

t/s
power
coding 51
52
53
AD8
AD7
mechanical
t/s
t/s
coding
54

AD6

t/s 54 P3V3 power

55 AD4 t/s 55 AD5 t/s


58 AD0 t/s 58 AD1 t/s

60 XREQ64 s/t/s (pull up) 60 XACK64 s/t/s (pull up)

in = input, out = output, t/s = tri state and bidirectional, s/t/s = sustained tri state
and bidirectional, o/d = open drain
Signal names: XTRST Test reset
TMS Test mode select
TDI Test data input
XINTA Interrupt A
XINTC Interrupt B
XRST Reset
XGNT Grant
AD(0..32) System address bus/system data bus
XFRAME Cycle frame
XTRDY Target ready (=selected device ready)
XSTOP Stops the current transaction
SDONE Snoop done
XSBO Snoop backoff
PAR Parity
XCBE0 Bus command(0) and byte enable(0)
multiplexed on the same PCI pin
XREQ Request

8/16-bit card Electrically compatible with PC I/O channel

interface
Connector designation: X220, X221
Connector type: 98-pin card slot
Table 18-2 Pin assignments for connectors X220, X221
X220, X221
Pin Pin Pin Pin
Name Type Name Type Name Type Name Type
B A D C
1 1M VO 1 XIOCHCK I 1 XMEMCS16 I 1 XSBHE O
2 RSTDRV O 2 SD7 B 2 XIOCS16 I 2 LA23 O
3 1P5 VO 3 SD6 B 3 IRQ10 I 3 LA22 O
4 IRQ9 I 4 SD5 B 4 IRQ11 I 4 LA21 O
5 1N5 5 SD4 B 5 IRQ12 I 5 LA20 O
6 DRQ2 O 6 SD3 B 6 IRQ15 I 6 LA19 O
7 1N12 VO 7 SD2 B 7 IRQ14 I 7 LA18 O
8 XZEROWS I 8 SD1 B 8 XDACK0 I 8 LA17 O
9 1P12 VO 9 SD0 B 9 DRQ0 O 9 XMEMR O
10 1M VO 10 IOCHRDY I 10 XDACK5 I 10 XMEMW O
11 XSMEMW O 11 AEN O 11 DRQ5 O 11 SD8 B
12 XSMEMR O 12 SA19 O 12 XDACK6 I 12 SD9 B
13 XIOW O 13 SA18 O 13 DRQ6 O 13 SD10 B
14 XIOR O 14 SA17 O 14 XDACK7 I 14 SD11 B
15 XDACK3 I 15 SA16 O 15 DRQ7 O 15 SD12 B
16 DRQ3 O 16 SA15 O 16 1P5 VO 16 SD13 B
17 XDACK1 I 17 SA14 O 17 XMASTER I 17 SD14 B
18 DRQ1 O 18 SA13 O 18 1M VO 18 SD15 B
19 XREFRESH O 19 SA12 O
20 SYSCLK O 20 SA11 O
21 IRQ7 I 21 SA10 O
22 IRQ6 I 22 SA9 O
23 IRQ5 I 23 SA8 O
24 IRQ4 I 24 SA7 O
25 IRQ3 I 25 SA6 O
26 XDACK2 I 26 SA5 O
27 TC O 27 SA4 O
28 BALE O 28 SA3 O
29 1P5 VO 29 SA2 O
30 OSC14 O 30 SA1 O
31 1M VO 31 SA0 O

Signal names
RSTDRV Reset Drive
IRQ[3...7], [9...12, 14.15] Interrupt Requests
DRQ[0...3], [5...7] DMA Requests
XDACK[0...3], [5...7] DMA Acknowledge
XZEROWS 0 Wait State
XSMEMR Memory Read to 1MB
XSMEMW Memory Write to 1MB
XMEMR Memory Read
XMEMW Memory Write
XIOR IO Read
XIOW IO Write
AEN Address Enable
XIOCHECK IO Channel Check
IOCHRDY IO Channel Ready
XMASTER Master
XIOCS16 IO Chip Select 16
XMEMCS16 Memory Chip Select 16
XSBHE Byte High Enable
BALE Bus Address Latch
XREFRESH Memory Refresh
TC Terminal Count
SYSCLK Bus Clock 8.33MHz
OSC14 14.31818MHz
SD[0...15] System Data Bus
SA[0...19] System Address Bus
LA[17...23] System Address Bus
(not stored)
1P5 +5V
1P12 +12V
1N12 12V
1M Signal Ground
1N5 5V
Signal type
B Bidirectional
O Output
VO Voltage Output
I Input
Table 18-3 Technical data for PCI adapter
Electrical data (operation with open interfaces)

Required voltages + 3.3V; " 5V; "12V
Max. current load + 3.3V 2A
+ 5V 3A
5V 0.15A
+12V 0.25A
12V 0.25A
Mechanical data
Dimensions Height Width Depth
265mm 157.5mm 77mm
Temperature change within 1 minute max. 0.2K
Limit values 0 ... 55C 20 ... 60C

Memory
address ranges
Table 18-4 Memory address ranges in the MMC
Designation Designation Area (hex)

Boot vector FFFF000:FFF0
BIOS system (after reset)
FFFF000:0000
Reserved
200000:0000
DRAM
40000:0000
DRAM
10000:0000
Boot vector F000:FFF0
BIOS system
F000:0000
PCMCIA window area/EMS
E000:0000
ROM option (PCMCIA/LAN/SCSI)
D000:0000
CC00:0800
MPI/AMPlus L-area
CC00:0000
MMC 101/102 MMC 103
C800:0000
VGA BIOS
VGA BIOS
C000:0000
VGA DRAM
A000:0000
DRAM
0050:0000
BIOS variables
0040:0000
Vector table
0000:0000

Interrupt The table below shows the interrupt requests (IRQs) and the possible assign-
assignment MMC ment for a PCI adapter or a PC card adapter. In this case, Prio 0 stands for the
highest priority.
Table 18-5 Interrupt assignment
Prio Interrupt controller 1 IRQ Card PC card

adapter adapter
(option)
0 Timer 0 No No
1 Keyboard controller 1 Yes No
Interrupt controller 2 2
2 Real time clock 8 No No
3 Unassigned (graphics) 9 Yes Yes
4 MPI (OPI) 10 Yes Yes
5 Unassigned 11*) Yes Yes
6 Unassigned (COM3/4) 12 Yes Yes
7 Math. coprocessor 13 No No
8 Hard disk drive 14 Yes Yes
9 Unassigned 15*) Yes Yes
10 Serial interface 2: COM 2 3 Yes Yes
11 Serial interface 1: COM 1 4 Yes Yes
12 Unassigned (par. interface 2: LPT2, LAN) 5 Yes Yes
13 Floppy drive 6 Yes No
14 Parallel interface 1: LPT1 7 Yes Yes
Note
For the MMC 103, IRQ11 and 15 are reserved in the BIOS setup for external
cards.
I/O address ranges The external card I/O address ranges are as follows
for the MMC
(PC/AT)
Table 18-6 I/O address ranges in the PCI adapter
Description Address (hex)

DMA controller 1, 8237A-5 000-01F
Interrupt controller, 8259A 020-03F
Timer 8254.2 040-05F
Keyboard controller 8042, 81C51SL, Port B 060-06F
Real time clock, CMOS memory 070-07F
Manufacturers diagnostic checkpoint 80
DMA page register 74LS612 080-09F
Interrupt controller 2, 8259A 0A0-0BF
DMA controller 2, 8237A-5 0C0-0DF

Table 18-6 I/O address ranges in the PCI adapter
Description Address (hex)

Math. coprocessor 0F0-0FF
Hard disk (secondary) *) 170-177
Hard disk 1F0-1F7
Game I/O (joystick A/D port) *) 200-207
Sound card / computer link module DF15 (COM4) *) 220-257 / 238-23F
MMC NMI nControlregister 264-267
Parallel printer 2 (3 with MDA) *) 278-27F
EGA 2 2C0-2DF
Asynchronous adapter port 2 2F8-2FF
Prototype card *) 300-31F
Computer link module DF15 (COM3) *) 338-33F
LAN card *) 360-36F
Diskette controller (secondary) 370-377
Parallel printer 1 (2 with MDA) 378-37F
Synchronous Data Link Control (SDLC) *) 380-38F
Bisynchronous port 1 *) 3A0-3AF
Video Graphics Array (VGA) 3B0-3DF
Monochrome display adapter/printer 1 3B0-3BF
Enhanced Graphics Adapter (EGA) 1 3C0-3CF
Color/Graphics Adapter (CGA) and (EGA) 3D0-3DF
PCMCIA controller 3E0-3E1
Diskette controller 3F0-3F7
Asynchronous adapter port 1 3F8-3FF
*) Option, not integrated on the MMC.

Dimension
drawing
157.2
Fixing screw (M4x10, 3x)3)
Card holder bottom3)
Clamping screw3)
Clamping piece (2x)3) (Ejot PT, K30-10, 2x)

X153

X151

SIN 840D operator panel
X221
X220

Card holder top 3)

253.5
X3

X4

2291)

6)

136 2)
4)

X122
X123

X121
Card fastening (M3x8 screw, 2x)3)
1) Maximum card length

2) Minimum card length
3) Enclosed as loose part
4) Shorter card is plugged into upper slot (X221) when
different card lengths are used
5) Maximum overall height, or pin protrusion, respectively
6) Maximum card width 120mm
Fig. 18-3 Dimension drawing of PCI adapter

Installing a
PCI card
Warning
! S PCI cards must be installed by properly qualified personnel only. Regula-
tions for handling electrostatically sensitive devices (ESD) must be obser-
ved.
S Shut off the complete system. Check for zero potential and secure against
unauthorized energizing.
Danger
! The operator panel front must be switched off when installing PCI cards.
1. Switch off equipment

2. Insert card
With 2 cards insert the shorter card in slot 1
3. Attach the mounting blocks for fixing the card to the busbars.
J

Notes

3.5 Floppy Disk Drive 19
Function The AT-compatible floppy disk drive with lockable front door is used to read and
write data from/to 3.5 disks. It can be installed in a customer operator panel
front.
Function block 3.5 floppy disk drive including connecting cables for connection to the MMC
101/102/103 (length: max. of 0.5m).
Dimension
drawings 145
50
Fig. 19-1 Front view
Ribbon cable socket connector
48.6 185
Fig. 19-2 Side view (right)

19 3.5 Floppy Disk Drive 10.00
1 2 3
185
17
Fig. 19-3 Plan view
M3 fixing screw
max. screw-in depth: 4mm Ribbon cable socket connector (34-pin)
M4 shield
Ground connection
connector
X111 X121
(unassigned) (power supply interface)
Fig. 19-4 Rear view
Power supply X121: 3-pin terminal block

interface
Table 19-1 Pin assignments for power supply
X1
Pin Name Type
1 P24 V VI
2 M VI
3 PE VI

10.00 19 3.5 Floppy Disk Drive
Signal names
P24 external +24VDC
M external Ground
PE Protective conductor
Signal type
VI Voltage Input
Installation
M3 fixing screw
instructions max. screw-in depth: 4mm
133.8
6
3.6 R3
42 25 32 38.7
112
118
130
Fig. 19-5 Panel cutout
!
Important
The floppy disk drive can be installed in any position except upside down:
Fig. 19-6 Non-permissible installation position

Connecting floppy The floppy disk drive must be connected to the X9 interface of the
disk drive MMC 101/102.
D12 X8 SIEMENS
S1 X3
X121X122
S2
X7 X6 X5 X4
X11
X9
Floppy disk drive interface
Fig. 19-7 MMC cutout with X9 interface
Technical data
Table 19-2 Technical data for floppy disk drive
Electrical data
Input voltage 24VDC
Power consumption max. 5W
Mechanical data
50mm 145mm 185mm
Limit values 5...55C 20 ... 60C
Temperature changes within 1 minute max. 0.2K
Type 3.5
Capacity 1.44MB
Weight Approx. 0.8kg
Vibratory load 1.5G 10 to 100Hz
capacity 1.0G 100 to 200Hz
0.5G 200 to 600Hz

10.00 19 3.5 Floppy Disk Drive
Dimension A
drawing of
blanking plate 138.50.1
49.90.2
44.2
SIEMENS
11)
5.5
3
0
0 R1.5
3 B 144.80.2
5.5 139.1
Section A B
7
10 degrees

_______
1) all around
2.4+0.1

2.5
5

8.50.1 0
5.5
3.5
Fig. 19-8 Dimension drawing of blanking plate

J

Notes

Machine Control Panel, MPI Interface for
Customer Operator Panel 20
20.1 Function blocks of machine control panel
S Microcontroller
S Program memory
S Data memory
S 64 inputs/48 outputs (5V, no electrical isolation)
S Voltage monitor
S Temperature monitor
S Watch dog timer
S Isolated operator panel front interface (MPI)
Baud rate SINUMERIK 840D/810D: 1.5 Mbaud
Baud rate SINUMERIK FM-NC: 187.5 kbaud.
Order numbers 6FC5 203-0AD10-0AA0 (key version, screw attachment)

6FC5 203-0AD12-0AA0 (membrane version, screw attachment)
6FC5 203-0AF22-1AA0 (membrane version, tension jack attachment)
Fig. 20-1 View (example: machine control panel 6FC5 203-0AF22-1AA0; milling version)

20 Machine Control Panel, MPI Interface for Customer Operator Panel 09.02
10.00
20.2 Block diagram of machine control panel
20.2 Block diagram of machine control panel
LEDs Keyboard
48 outputs 64 inputs
Isolated MPI
X20
Serial I/O 9 5
Controller controller
6 1
9-pin
Sub-D
2P5 socket
X10
Monitoring:
voltage, tempera- Program memory Data memory 5V
ture, watchdog
24V P24
5V
1P5
DC/DC converter Terminal block
Fig. 20-2 Block diagram of machine control panel

09.02
10.0 20 Machine Control Panel, MPI Interface for Customer Operator Panel
20.3 Control elements and interfaces of machine control panel
20.3 Control elements and interfaces of machine control

panel
20.3.1 Control elements
Position of Front view

control elements
T1 T2 T3 R1 R2 R3
X Y Z
T4 T5 T6 R4 R5 R6
[.] 1 4 5 6
T7 T8 T9 R7 R8 R9
10 100 7 8 9 % %
T10 T11 T12 R10 R11 R12
WCS
1000 10000 MCS
T13 T14 T15 R13 R14 R15
+
A B C D E F G H I
Fig. 20-3 Machine control panel for milling machine (M-version)
T1 T2 T3 R1 R2 R3
+Y +X +C
T4 T5 T6 R4 R5 R6
[.] 1 Z +Z
T7 T8 T9 R7 R8 R9
10 100 C X Y % %
T10 T11 T12 R10 R11 R12
WCS
1000 10000 MCS
T13 T14 T15 R13 R14 R15
Fig. 20-4 Machine control panel for turning machine (T-version)
Designation of A: Emergency stop button

control elements B: Reset button
C: Program control
D: Operating modes, machine functions
E: User keys (T1 to T15)
F: Direction keys with rapid traverse override (R1 to R15)
G: Spindle control
H: Feedrate control
I: Keyswitch (four positions)
The machine control panel operates on 5VDC.

10.00
Overview of
control elements S 64 inputs (30 keys, two rotary selector switches, keyswitch with four posi-
tions)
S 48 outputs (LEDs, assigned to the keys).

All keys are scanned individually, i.e. all keys can be pressed simultaneously.
Description of
control elements
EMERGENCY STOP button (A)

Press the red button in emergency situations:
As a rule, EMERGENCY STOP causes all drives to be brought to a standstill
with the maximum possible braking torque.
Circuit for
EMERGENCY
STOP button
2 4
EMERGENCY
STOP button
1 3
Connect cable to
1 3 4 2 button
Terminal
EMERGENCY STOP
machine control

09.02
20.3.2 Interfaces
Position of Rear view of machine control panel

interfaces
Connection for equipotential bonding conductor LEDs 1...4
1 2 3 4
X20 ON
3 1
S3
4 2
X10
Power supply
interface X10
Operator panel front S3 switch EMERGENCY
interface (MPI) X20 STOP button
1 2 3
SHIELD M24 P24
Fig. 20-6 Position of interfaces on rear side of machine control panel
Interface overview
S X20: Operator panel front interface (MPI)
Socket: 9-pin female Sub-D connector strip, straight
S X10: Power supply interface

Phoenix terminal block: 3-pin, straight
S S3: DIP switch (8-way)

For setting of baud rate see: Section 20.4 Assignments
References: /PHF/, NCU 570 Manual
/PHD/, NCU 571-573 Manual
S LEDs 1...4:
LED1: Not used
LED2: Not used
LED3: POWER: 24V supply
LED4: SEND: status change on protocol transmission.

10.00
Operator panel Connector designation: X20

front interface Connector type: 9-pin Sub-D socket connector, straight
(MPI) Maximum cable length: 200m
Table 20-1 X20 pin assignments for machine control panel
X20
Pin Name Type Pin Name Type
1/2 Unassigned 6 2P5 VO
3 RS_OPI B 7 Unassigned
4 RTSAS_OPI O 8 XRS_OPI B
5 2M VO 9 RTSPG_OPI I
Signal names
RS_OPI, XRS_OPI Differential RS485 data OPI
RTSPG_OPI Request to Send PG OPI
RTSAS_OPI Request to Send PLC OPI
2M Signal Ground, isolated
2P5 +5V, isolated
Signal type
B Bidirectional
O Output
VO Voltage Output
I Input
Power Connector designation: X10

supply Connector type: 3-pin Phoenix terminal block, straight
interface
Table 20-2 X10 pin assignments for machine control panel
X10
Pin Name Type
1 SHIELD
2 M24 VI
3 P24
Signal names
SHIELD Shield terminal
P24 24V potential
M24 24V ground
Signal type
VI Voltage Input

09.02
20.4 Mounting, connecting and setting machine control panel

Dimension drawing
4.8 +0,1
155
146.2
4)
8.8
0
241.2
482.6
473.6
357.4
125
8.8
0
500
1)
4)
> 60
46.3
Front
mounting
Mounting
42
plane
Rear
mounting

3)
Detail
2)
Front
M4 welding stud

without flange

2) M4 fixing bolt with DIN 125 washer, enclosed as loose part
3) Permitted mounting position max. 75C to the perpendicular (see note)
Fig. 20-7 Dimension drawing of machine control panel (version 6FC5 203-0AD10-0AA0 / 6FC5 203-0AD12-0AA0)
Note
For mounting positions greater than 60C a fan must additionally be installed to
keep the environmental conditions of the machine control panel constantly be-
low 55C.

10.00
20.4.1 Installation
Screw The machine control panels 6FC5 203-0AD10-0AA0 and 6FC5

attachment 203-0AD12-0AA0 are attached using ten screws (M4x10). Locking elements
are recommended in order to avoid damage to the surface.
Panel cutout for operator panel front
3)
137.4"0.2
129.7+0.5
4.3 or M4
R1.51) Machine control panel mounting cutout
7.70.5
0
+0.5
7.7 0.5
464.8 0.2
116.2 0.2
232.4 0.2
348.6 0.2
0
1.5
457.1
1.0/100 2)
1) Recommended for rear mounting only

2) DIN ISO 1101
3) Spacing when machine control panel and operator panel are mounted one below the other w18
Fig. 20-8 Panel cutout for machine control panels 6FC5 203-0AD10-0AA0 and 6FC5 203-0AD12-0AA0

09.02
Tension jack The machine control panel 6FC5203-0AF22-1AA0 is attached using tension
attachment jacks (see Fig. 20-9).
Control
Mounting base
panel Tension 1.5 to 6
1.56 thick
jacks
132.5 132.5
Cutout symmetrical to control panel .
34.2 123.5 155.8 103.3 34.2
482.6
Max.
torque
0.5Nm
Fig. 20-9 Panel cutout for machine control panel 6FC5 203-0AF22-1AA0
20.4.2 Connection
Connecting the The 24V supply is connected to the X10 connector at the rear of the machine
24V supply control panel via a 3-pin terminal block (see Fig. 20-6). The equipotential bond-
ing conductor is fixed by means of an M5 screw.
MPI connection The machine control panel is connected to the OPI on the NCU (X101) using an
(X20) MPI bus cable via the MMC interface (X4) or the PCU interface (MPI/DP). The
MPI connector is plugged into X20 on the rear of the machine control panel (see
Fig. 20-6) and fixed with a screw.

10.00
20.4.3 Machine control panel settings
Assignments The following settings are possible with the S3 DIP switch (see Fig. 20-6):
Table 20-3 Assignments with S3 on machine control panel
1 2 3 4 5 6 7 8 Meaning

ON OFF 200 msecs transmission cycle time/2400 msecs
OFF ON receipt monitoring
OFF OFF 100 msecs transmission cycle time/1200 msecs
receipt monitoring
50 msecs transmission cycle time/600 msecs re-
ceipt monitoring
ON MPI interface, customer operator panel
OFF Serial hardware
The following default settings are suggested:
Table 20-4 Default settings S3
1 2 3 4 5 6 7 8 Meaning
Baud rate: 1.5 Mbaud / Transmission cycle time: 100 msecs
ON OFF ON OFF ON ON OFF OFF
Bus address: 6 / serial hardware
Setting the The PLC expects a message frame from the machine control panel at least ev-
transmission ery 500 msecs. The machine control panel sends a message frame to the PLC
cycle time at cyclic intervals when no key is pressed. This cycle time is set with S3 DIP
switches 2 and 3. This enables the load on the PLC resulting from the machine
control panel to be adjusted.
Setting the The machine control panel receives message frames at cycle intervals from the
receipt PLC and answers these at cycle intervals. The receipt monitoring time is linked
cycle time to the transmission cycle time of the machine control panel and is set with the
S3 DIP switch (2 and 3).

09.02
the software.

10.00
20.5 Technical data for machine control panel
20.5 Technical data for machine control panel
Table 20-5 Technical data for machine control panel
Electrical data
Input voltage 24VDC
Power consumption
5W
(max.)
Degree of protection to
DIN EN 60529 (IEC Front side: IP 54 Rear side: IP 00
60529)
Mechanical data
155mm 483mm 47mm
Basic color of casing Anthracite, acc. to SN 47030, Part 2, Color code: 614
Front side: 0, ..., 55C
Limit values 20 ..., 60C
20,
Rear side: 0, ..., 45C

09.02
20.6 Spare parts for machine control panel
20.6.1 Key caps
The following sets of key caps with blank labels are available for machine con-
trol panel No. 6FC5 203-0AD10-0AA0:
Table 20-6 Key caps for machine control panel 6FC5 203-0AD10-0AA0
Order number Quantity Description

6FC5 148-0AA14-0AA0 16 Transparent, with stickers
6FC5 148-0AA13-0AA0 90 ergo-gray
20 red
20 green
20 yellow
20 median gray

10.00
20.6.2 Slide-in label film
The slide-in label film shown in Fig. 20-10 can be ordered under the number
6FC5 248-0AF22-0AA0 and printed with user-specific labels.
Distance from
edge of film
32
2.32
5
4
15.05
14
4
15.05
1)
11
14
4
15.05
14
2)
115
4
15.05
4
46.8
15
4
15.05
4
15.05
4
15.05
4
15.05
4
35
190
1) Labeling area for 6FC5 203-0AD12-0AA0 2) Labeling area for 6FC5 203-0AF22-1AA0
Fig. 20-10 Slide-in label film for machine control panel 6FC5 203-0AD12-0AA0 and 6FC5 203-0AF22-1AA0,
A4 format for laser printers, with transparent windows for LEDs (without lines or text/numbers)

09.02
20.7 MPI interface for customer operator panel
20.7.1 MPI interfaces
MPI interface A customer operator panel can be connected via the MPI interface. For this pur-
pose, 64 digital inputs and 64 digital outputs with CMOS level (5V) are available
on the module.
Position of
interfaces
289.4
64.7
X20 X211 X221

X231
MPI connection
Equipotential bonding connection 92.7
H3
H1 3.5
X10 ON LEDs H4
Holes 3.6
S3 " H2
7.2
207.3
Fig. 20-11 Front view of MPI interface for customer operator panel

interface Connector type: 3-pin Phoenix terminal block, straight
X10
Pin Name Type
1 SHIELD
2 M24 VI
3 P24
Signal names
SHIELD Shield terminal
P24 24V potential
M24 24V ground
Signal type
VI Voltage Input

10.00
Note
The maximum length of the equipotential bonding cable (fine-core, 10 mm2) is
30cm.
MPI interface Connector designation: X20

Connector type: 9-pin Sub-D socket connector, straight
Table 20-8 X20 pin assignments for MPI
X20
1/2 Unassigned 6 2P5 VO
3 RS_OPI B 7 Unassigned
4 RTSAS_OPI O 8 XRS_OPI B
5 2M VO 9 RTSPG_OPI I
Signal names
RS_OPI, XRS_OPI Differential RS485 data OPI
RTSPG_OPI Request to Send PG OPI
RTSAS_OPI Request to Send PLC OPI
2M Signal Ground, isolated
2P5 +5V, isolated
Signal type
B Bidirectional
O Output
VO Voltage Output
I Input
Digital inputs/ Connector designation: X211, X221 (2x32-pin)

outputs with X231 (2x10-pin)
C-MOS level (5V) Connector type: Ribbon cable connector DIN 41651
Maximum cable length: 0.5m
Note
The inputs/outputs are assigned CMOS level (5V). The outputs are not short-
circuit-proof. Applying a higher voltage to the inputs will destroy them.

09.02
Potential pins:
The inputs/outputs (interfaces X211, X221, X231) can be loaded with a maxi-
mum current of 0.2A via the internal 5V power supply of the MPI interface mod-
ule. This value stands for the total of all currents flowing over these interfaces.
S 64 outputs may drive a maximum current of 200mA.

S The maximum current per output is limited to 5mA.
X221
1 OUT 0 33 IN 14 I
2 OUT 1 34 P5 V
3 OUT 2 35 IN 15
4 OUT 3 36 IN 16
5 OUT 4 37 IN 24
6 OUT 5 38 IN 17
7 OUT 6 39 IN 25
I
8 OUT 7 40 IN 18
O
9 OUT 8 41 IN 26
10 OUT 9 42 IN 19
11 OUT 10 43 IN 27
12 OUT 11 44 IN 20
13 OUT 12 45 M V
14 OUT 13 46 IN 21
15 OUT 14 47 IN 28
I
16 OUT 15 48 IN 22
17 M V 49 IN 29
18 IN 0 50 IN 23 V
19 IN 8 51 IN 30 I
20 IN 1 52 P5 V
21 IN 9 53 IN 31 I
22 IN 2 I 54 Unassigned
23 IN 10 55 M V
24 IN 3 56 OUT 16
25 IN 11 57 OUT 17
26 IN 4 58 OUT 18
27 M V 59 OUT 19
O
28 IN 5 60 OUT 20
29 IN 12 61 OUT 21
30 IN 6 I 62 OUT 22
31 IN 13 63 OUT 23
32 IN 7 64 Unassigned

10.00
X211
1 Unassigned 33 IN 39
2 OUT 47 34 IN 45
3 OUT 46 35 IN 38 I
4 OUT 45 36 IN 44
5 OUT 44 37 IN 37
O
6 OUT 43 38 M V
7 OUT 42 39 IN 36
8 OUT 41 40 IN 43
9 OUT 40 41 IN 35
10 M V 42 IN 42
11 Unassigned 43 IN 34 I
12 IN 63 I 44 IN 41
13 P5 V 45 IN 33
14 IN 62 46 IN 40
15 IN 55 47 IN 32
16 IN 61 48 M V
I
17 IN 54 49 OUT 39
18 IN 60 50 OUT 38
19 IN 53 51 OUT 37
20 M V 52 OUT 36
21 IN 52 53 OUT 35
22 IN 59 54 OUT 34
23 IN 51 55 OUT 33
24 IN 58 56 OUT 32
O
25 IN 50 57 OUT 31
I
26 IN 57 58 OUT 30
27 IN 49 59 OUT 29
28 IN 56 60 OUT 28
29 IN 48 61 OUT 27
30 IN 47 62 OUT 26
31 P5 V 63 OUT 25
32 IN 46 I 64 OUT 24

09.02
X231
1 OUT 48 11 OUT 56
2 OUT 49 12 OUT 57
3 OUT 50 13 OUT 58
4 OUT 51 14 OUT 59
O O
5 OUT 52 15 OUT 60
6 OUT 53 16 OUT 61
7 OUT 54 17 OUT 62
8 OUT 55 18 OUT 63
9/10 M V 19/20 P5 V
Signal names
OUT 0 ..63 Outputs
IN 0 .. 63 Inputs
P5 5V power supply
M 0V
Signal type
O Output
I Input
V Voltage
Signal description
OUT 0 OUT 63: Output signals with C-MOS level 5V max. 5mA.
IN 0 IN 63: CMOS inputs with 5V level
Note
OUT 0 to OUT 47:
are switched over at cyclic intervals between 5V and 0V level after POWER
ON. After booting of the control, these outputs can be triggered via the PLC.
OUT 48 to OUT 63:
are set to 5V level after POWER ON (connection and triggering of relay pos-
sible). After booting of the control, these outputs can be triggered via the PLC.
IN 0 to 63:
5V > FALSE status seen from the PLC
0V > TRUE status seen from the PLC
LEDs LED H1, ..., H4:

H3: POWER: 24V power supply
H1: Unassigned
H4: SEND: change of state on sending of protocol
H2: Not used

10.00
20.7.2 MPI interface settings
Assignments The following settings are possible with the S3 DIP switch (see Fig. 20-11):
Table 20-9 Assignments of S3 on MPI interface for customer operator panel
1 2 3 4 5 6 7 8 Meaning:

ON OFF 200 msecs transmission cycle time/2400 msecs receipt monitor-
OFF ON ing
OFF OFF 100 msecs transmission cycle time/1200 msecs receipt monitor-
ing
50 msecs transmission cycle time/600 msecs receipt monitoring
ON MPI interface, customer operator panel
OFF Serial hardware
The following default settings are suggested:
Table 20-10 MPI interface for customer operator panel, default settings of S3 for 840D
1 2 3 4 5 6 7 8 Meaning:
ON OFF ON OFF ON ON OFF ON Baud rate: 1.5 Mbaud
100 msecs
Bus address: 6
MPI interface for customer ope-
rator panel
Table 20-10 MPI interface for customer operator panel, default settings of S3 for
FM NC
1 2 3 4 5 6 7 8 Meaning:
OFF OFF ON OFF ON ON OFF ON Baud rate: 187.5 kbaud
100 msecs
Bus address: 6
MPI interface for customer op-
erator panel

09.02
Setting the The PLC expects a message frame from the interface module at least every
transmission 500 msecs. If no key is pressed, the interface module sends message frames to
cycle time the PLC at cyclic intervals. The S3 switches (2 and 3) are used to set this cycle
time. In this way, the load on the PLC caused by the interface module can be
adjusted.
Setting the The machine control panel receives message frames at cycle intervals from the
receipt PLC and answers these at cycle intervals. The receipt monitoring time is linked
cycle time to the transmission cycle time of the machine control panel and is set with the
S3 DIP switch (2 and 3).
the software.
20.7.3 Technical data for MPI interface
Table 20-11 Technical data of MPI interface for customer operator panel
Electrical data
Total current 24V
Typical 100mA
Mechanical data
92mm 293mm 15mm
Weight 0.5kg
Limit values 0, ..., 55C 40, ..., 70C
Degree of protection IP 00 to DIN 40 050
Humidity rating F Permissible humidity to DIN 40 040

10.00
20.8 Configuring machine control panel, setting interface parameters
20.8 Configuring machine control panel, setting interface

parameters
Before the machine control panel can exchange data with the PLC CPU via the
MPI interface, the appropriate interface parameters for the configuration must
be activated. They are activated by means of the MPI bus address settings us-
ing DIP switch S3 in accordance with the following table.
Table 20-12 Correlation between MPI bus address and GD parameters with machine
control panel
MPI ad- Sequence for configuring pur- Preset GD parameters Receive

dress poses Transmit
0, ..., 3 Reserved
4 5th machine control panel 5.1.1 5.2.1
6 Reserved
8 4th machine control panel 4.1:1 4.2.1
9 3rd machine control panel 3.1.1 3.2.1
10 3rd machine control panel 3.1.1 3.2.1
11 2nd machine control panel 2.1.1 2.2.1
12 2nd machine control panel 2.1.1 2.2.1
13 1st machine control panel 1.1.1 1.2.1
control panel
Transmitting
Machine
AS 314
(PLC)
Receiving
Fig. 20-12 Receiving and transmitting from view of machine control panel

Handheld Unit and Distributor Box 21
21.1 Handheld unit B-MPI
77
A A
SIEMENS
K
B
C J
D
%
405060
I
30 70
E 20 80
90
10
F 0 110100
252
114 110
Fig. 21-1 Handheld unit
Control and A EMERGENCY STOP button, two-channel

display elements B Two-line digital display with 2x 16 characters
C 20 user-assignable keys
D 16 LEDs freely selectable by user
E Keyswitch with ON/OFF position
F Override switch with 12 positions
G Electronic handwheel
H Connecting cable 10m long or coiled cable up to 3.5m long
I Two enabling buttons, designed as a 2-position switches; two channels
respectively
J Magnetic clamp
K Wall holder

21 Handheld Unit and Distributor Box 10.00
21.1 Handheld unit B-MPI
Key symbols The key symbols are on a slide-in label that can be changed as necessary.
The labeling strip is located between the PCB and the front of the housing and
can be accessed from the right.
Changing labeling To change the labeling strip, proceed as follows.

strip
S Remove the labeling strip carefully to approx. the half using flat pliers.
S Slide half of the new labeling strip under the old one.
S Remove the old labeling strip and slide the new one in to its final position.
Magnetic clamp The magnetic clamp is not intended for permanent fixing of the HHU to the per-
pendicular sheet metal parts.
Caution
! S The HHU cannot be connected using the MPI cable 6FX2002-4EA04-IAF0
(or other lengths), since the bus terminators are integral components of this
cable.
Please use the MPI cable specified in the catalog
References: /Z/ Catalog NCZ.
S If the connection between the HHU and the distributor box is interrupted
(HHU cable pulled out), an emergency stop is triggered. There is no auto-
matic EMERGENCY STOP overriding.
HHU variants The handheld unit and the distributor are offered in two wiring versions.
1. In the version with 2-channel enable keys and 3-core connection of these
keys.
2. In the version with 2-channel enable keys and 4-core connection of these
keys.
In this version, monitoring for cross short-circuit in the enable circuit is pos-
sible.
Due to modified connector design, these HHUs can only be operated on the
distributor designed for the corresponding mode. In the version with 4-core con-
nection of the enable keys, the connector insert of the connector is arranged
coded at an angle of 45_ to avoid destruction of the unit by accidental wrong
connection.

10.00 21 Handheld Unit and Distributor Box
21.2 Block diagram of HHU and distributor box
21.2 Block diagram of HHU and distributor box
HHU
MPI bus
LEDs Keys Digital
display
Conn.
MPI Distribu-
submodule tor box
DIP switches
S EMERGENCY
STOP
S Enabling button
EMER-
GENCY S Handwheel pulses
Rotary switch Keyswitch STOP Hand- Enabling
wheel buttons S 24VDC
Fig. 21-2 Block diagram of HHU and distributor box
Connecting to The HHU is connected to the distributor box, connector X4. The EMERGENCY
distributor box STOP button, enabling buttons and handwheel signals are not transmitted to
the PLC but decoupled in the distributor box terminal block X3. Power supply to
the HHU is via the distributor box. All other signals are transmitted to the PLC
via the MPI/OPI bus.
Note
S Bus terminating resistors are integral components of the HHU.

S A maximum of two handheld units may be connected per bus segment.
S Further HHUs may be connected using repeaters.

21.3 Plugging and unplugging HHU during operation
Purpose Trouble-free plugging and unplugging of the HHU during machine operation
requires:
S activation and deactivation of the power supply to the distributor box,

S release or override of the EMERGENCY STOP switch of the HHU,
S connection of the HHU to the OPI/MPI via PROFIBUS repeater.
NCU/ ON OFF OFF ON

CCU MPI/OPI
ON ON ON
Distributor box Distributor box
HHU
RS-485 repeater
OFF ON
Terminating resistor open
ON Terminating resistor closed
Fig. 21-3 Connecting the HHU via PROFIBUS repeater
A PROFIBUS repeater must be connected upstream of the HHU distributor box

for each branch. The individual bus segments (MPI/OPI line and/or the repeater
and HHU) must be terminated with terminating resistors at the ends of the bus.
Repeater RS-485 The repeater can be ordered under the number 6ES7 972-0AA00-0XA0.
For further information, please refer to the Catalog
/IK10/ Industrial Communication Networks SIMATIC-NET.
Note
S The HHU already has an installed bus terminating resistor.

S The cable length from the repeater to the distributor box must not exceed
2m.

A keyswitch with two positions and two contacts must be installed at each HHU
connection point.
EMERGENCY STOP circuit

Sample circuit
Keyswitch 1) with
positive-action contacts
24V
Keyswitch = ON
Signal to PLC
triggers a timer. If
the signal level is still
low after the moni-
toring period
(approx. 5min), the
M PLC must initiate an
1 11 12 2 9 10 EMERGENCY
X3
P (24V) M (0V) STOP
EMERGENCY Distributor box

STOP terminals for HHU
X4
HHU Circular connector for

connecting the HHU
EMERGENCY
STOP button
1) Keyswitch consisting of 2x 3SB1400-0A switching elements and

control element 3SB10 or 3SB16
(corresponding safety lock upon selection)
Catalog: Switching devices and systems (NSK) at A&D CD
Fig. 21-4 Sample circuit for emergency stop override (illustration shows keyswitch set to ON with HHU connected)
Note
Please note that the customer is responsible for implementing the sample cir-
cuits.

Procedure for Initial state

connecting HHU
S Keyswitch set to OFF, passive.
S EMERGENCY STOP terminals to the HHU are short-circuited.
S Signal HHU Stop = 1 (or HHU=0), end communication.
1. Connect and fasten the HHU connector.
The EMERGENCY STOP of the HHU must be unlocked.
2. Set keyswitch to ON, active.
HHU is activated.
3. Signal HHU Stop = 0, communication commences with the HHU.
Procedure for Initial state

disconnecting
Keyswitch set to ON, active.
HHU
HHU is active, including EMERGENCY STOP.
Set keyswitch to OFF, passive position.
Signal HHU Stop = 0 switchover to 1 (end communication).
S HHU has no voltage and goes into passive mode.

S EMERGENCY STOP of HHU is short-circuited.
1. Loosen the HHU connector and unplug it.
2. The keyswitch is required for reasons of security, to ensure that an EMER-
GENCY STOP is triggered if an attempt is made to activate the HHU while it
is not connected.
Danger
! EMERGENCY STOP switches that are inactive
S may not be recognizable as such

S may not be accessible.
This is to prevent the EMERGENCY STOP button (e.g. on the HHU) from being
used inadvertently.

21.4 Operating several HHUs
21.4 Operating several HHUs
Purpose If more than two HHUs are to be connected to a bus segment, or if the HHU
cannot be connected at the end of the bus, a PROFIBUS repeater is recom-
mended for the connection of the HHUs.
OFF OFF
NCU/ ON OFF
MPI/OPI
CCU
ON
OFF
MCP
Distributor
Distributor box box
HHU HHU
RS-485 repeater
OFF ON ON
Fig. 21-5 Connecting the HHU via repeater
Repeater RS 485 The repeater can be ordered under Order No. 6ES7972-0AA01-0XA0. For fur-
ther information, please refer to the Catalog
Note
S If HHUs are connected to the ends of the bus, the repeaters may be omitted
since the HHU already contains an installed bus terminating resistor.
2m.
S Cable lengths for MPI/OPI, see /IAD/ Start-Up Guide 840D or /IAC/ Start-Up
Guide 810D, Chapter 3.
For further information about simultaneous operation of several HHUs on one
NCU, please refer to the Description of Functions, Basic Machine, Part 1,
Chapter Basic PLC Program (P3), Section Configurability of machine control
panel, handheld unit, subheading Switchover of MPI, OPI address.

21.5 HHU control elements and interface
Description of EMERGENCY STOP button, NC contact, 24V/2A contact load

control elements
Operate the red button in emergency situations:

Internal circuit of EMERGENCY STOP button Handwheel Enabling button

HHU and
distributor box
with 3-core
connection of the HHU
enable keys
X4
11 12 1 2 3 4 5 6 7 8 9 10 13 X3
Distributor
box 2.1 2.2 1.1 1.2 A A B B ZS1 ZS2 24V 0V COM
EMERGENCY STOP
Fig. 21-6 Internal circuit of EMERGENCY STOP button, handwheel, enabling buttons
3-core

Internal circuit of
EMERGENCY STOP button Handwheel Enabling button
HHU and
distributor box
with 4-core
connection of the HHU
enable keys
X4
11 12 1 2 3 4 5 6 7 8 9 10 13 14 15 X3
Distributor
box 2.1 2.2 1.1 1.2 A A B B ZS ZS 24V 0V ZS ZS KEY2
1.1 2.1 2.2 1.2
EMERGENCY STOP
Fig. 21-7 Internal circuit of EMERGENCY STOP button, handwheel, enabling buttons
4-core
Enabling buttons The enabling buttons are designed as 2-position switches and are located at
the left and right of the handheld unit. The keys are NO contacts and connected
in parallel. They are two-channel keys. Connection 3- or 4-core, depending on
type. A 4-core connection allows cross short-circuit monitoring in the enable
circuit.
24V/2A contact load.
Handwheel The electronic handwheel supplies two tracks with rectangular signal. The sig-
nals can be tapped from the distributor box and taken to the NCU connector
X121 via the cable distributor.
Keyswitch Keyswitch with two positions is transmitted to the PLC.
Override switch Switch with 12 positions is transmitted to the PLC.
Keys 20 keys are transmitted to the PLC and are freely assignable by the user.
The labeling symbols can be changed (unscrew HHU).
LED 16 LEDs in the keys, freely controllable via the PLC.
Digital display 2-tier digital display, each with 16 characters controlled via the PLC.
Connecting cable The HHU is connected to the distributor box via the connecting cable (either a
coiled cable with max. length 3.5m or a 10m connecting cable).
Interface to The EMERGENCY STOP button and the enable keys, as well as handwheel
distributor box signals and power supply are connected to terminal block X3.

21.6 Technical data for HHU
21.6 Technical data for HHU
Table 21-1 Technical data for HHU
Electrical data
Power supply 24V
Power consumption approx. 250mA
EMERGENCY STOP button 24V 2A NC contact
Enabling buttons designed as 24V 2A 2 parallel NO
2-position switches contacts
Electrical handwheel 2 tracks 500mA TTL level
General data
Keyswitch 2 positions ON/OFF
Override switch 12 positions
Connecting cable 3.5m or 10m long
Mechanical data
252mm 114mm 110mm
Weight 1.2kg without connecting cable
Temperature ranges Installed/in op- Storage/trans-
eration port
0 ... 55C 20 ... 60C
Degree of protection IP 65

21.7 Settings in HHU
Displaying The software version of the HHU is displayed after booting as long as the HHU
software version is not communicating with the PLC.
of HHU
Example: Display of HHU
Waiting for PLC
V04.01.01 F / 1.5 M *)
SW version of the HHU is V04.01.01

Bus address of the HHU is Fhex (15dec) } *) Display changes
Baud rate of the HHU is 1.5 Mbaud } between F and 1.5 M
DIP switches To set the bus parameters and the IDLE time, two quadruple DIP switches are
provided on the basic module of the HHU.
The HHU must be opened for access to the DIP switches.
Note
Open the device only if the HHU connector has been previously
removed!
Switch settings
Setting the baud
ON OFF rate and bus address ON OFF
S1 via DIP via S1
4 switches display *) 4
3 1.5 Mbaud 3
Switch position
2 without function 2
ON OFF IDLE time
4 100 msecs
3 1 1
S1 2
1
4
S2 3
2 S2 S2
1 4 4
3 Bus 3
Switch position
address
without function
2 15 2
1 1
____________________________
*) SW 04.01.01 and higher
Fig. 21-8 DIP switches in the HHU

Meaning of DIP
switches
Table 21-2 S1 and S2 assignments in the HHU
Meaning S1 S1 S1 S1 S2 S2 S2 S2
1 2 3 4 1 2 3 4
via display
Setting the ON
(SW 4.1.1 only)
baud rate and
bus address via DIP switches (all
OFF
SW versions)
IDLE time *) 100msecs OFF ON
1.5 Mbaud ON
Baud rate *)
187.5 kbaud OFF
Bus address *) 15 ON ON ON ON
14 ON ON ON OFF
13 ON ON OFF ON
12 ON ON OFF OFF
11 ON OFF ON ON
10 ON OFF ON OFF
9 ON OFF OFF ON
8 ON OFF OFF OFF
7 OFF ON ON ON
6 OFF ON ON OFF
5 OFF ON OFF ON
4 OFF ON OFF OFF
3 OFF OFF ON ON
2 OFF OFF ON OFF
1 OFF OFF OFF ON
0 OFF OFF OFF OFF
Delivery state SW V01.01.02 OFF ON ON OFF ON ON ON ON

(default) SW V04.01.01 OFF ON ON ON ON ON ON ON
*) If S1.4 = on and SW version w V04.01.01: Switch inoperative
Note
S The maximum possible transmission rate for SINUMERIK 810D is 187.5

kbaud. For this reason, set switch S1.3 to off before you start up the sys-
tem.
S With switch position S1.4 = on and software version w V04.01.01, bus ad-
dresses from 0 to 31 can be set, i.e. up to 32 nodes can be supported on
the OPI/MPI.
S Bus addresses that are already assigned are preceded by an * symbol in

the display for easy identification.

21.8 Configuring HHU, setting interface parameters

The GD parameters must be set before the submodule can communicate via
the MPI interface. The setting can be activated in the ramp-up phase (while
waiting for the first GD message frame) from the PLC (Waiting for PLC status)
via the operator interface of the HHU using the key combination Jog (top
T2
left outside) and T2 (top right outside). You are then prompted via the
display of the HHU to enter the individual parameters via the HHU keyboard.
The default values can be modified within the permissible value ranges using
the + or keys.
Switching on to the next parameter is effected by operating the automatic key
. The parameters are stored in the flash EPROM by advancing after the
last parameter. Setting is therefore only required on startup and when changing
the interface. If interface parameter assignment is not activated after power On,
the stored values are accepted or the default values (see table) are loaded.
Transmitting
AS 315
HHU (PLC)
Receiving
Fig. 21-9 Receiving and transmitting as viewed from the HHU
Meaning of GD There are separate GD parameters for receipt and transmission.

parameters
GD 1.1.1
Object number
GBZ number (global identifier)
GD circuit number (global data no.)
Fig. 21-10 Meaning of GD parameters
Note
The GD parameters of the HHU and AS315 or PLC block FB1/0B100 must be
set identically.

Table 21-3 Value range for GD parameters of HHU
Designation Display Default Value

value range
Receive GD circuit no. Rec-GD-No: 2 116
Receive GBZ no. Rec-GBZ-No: 2 (fixed)
Object no. for receive Rec-Obj-No: 1 (fixed)

GBZ
Send GD circuit no. Send-GD-No: 2 (fixed)
Send GBZ no. Send-GBZ-No: 1 (fixed)
Object no. for send GBZ Send-Obj-No: 1 (fixed)
As from SW 4 Baud rate Baud rate: 1.5 M 187.5/

(baud) 1.5 M
Bus address Bus address: 15 031
21.8.1 Interface signals for handheld unit
PLC module The FC13 HHUDisp supports operation of the LCD display. For a detailed de-
scription, please refer to:
References: /FB/, P3, Basic PLC Program.
Note
The customer is responsible for programming the transfer of key signals to the
interface in a PLC user program.
User Layout of keys and LEDs

interface
T21 T11 T2 T1 T6 T21 T11 T2
T12 T7 T3 T8 T22 T12 T7
T13 T16 T4 T9 T23 T13 T16
T14 T5 T10 T24 T14 T15
a) Standard inscription b) Numbered keys
Fig. 21-11 HHU control keys

Input image of You can tap the signals for the keys, feedrate override switch, keyswitch and
handheld unit acknowledgment of the digital display at the input area. The address range is
set by parameter assignment with STEP7 tools.
Byte
Input signals to PLC
No.
IB Reserved Reserved
Reserved Reserved Reserved Reserved Reserved Reserved
m
IB Reserved Reserved
Reserved Reserved Reserved Reserved Reserved Reserved
m+1
Feed Key un- AUTO- Spindle Feed Key un-
IB NC stop JOG
start assigned MATIC stop stop assigned
m+2 T8 T7 T6 T5 T4 T3 T2 T1
Key un- Hand- Key un- Key un- Key un- Key un- Spindle
IB NC start
assigned wheel assigned assigned assigned assigned start
m+3 T16 T15 T14 T13 T12 T11 T10 T9
Direction Rapid tra- Direction Key un-

IB verse
key overlay key + assigned
m +4
T24 T23 T22 T21
Acknowl- Rapid traverse/feedrate override switch

IB edgment
g Key-
y
m +5 di it l
digital switch
display E D C B A
Tx = 1 Key pressed
HHU rotary Table 21-4

selector switch
Position % EDCBA
settings
1 0 00001
2 10 00100
3 20 01100
4 30 01101
5 40 01111
6 50 01110
7 60 01010
8 70 01011
9 80 01000
10 90 11001
11 100 11010
12 110 11111
HHU keyswitch 0 (horizontal position)

1 (vertical position)

Output image of The signals for controlling the LEDs, HHU mode, display signals and digital dis-
handheld unit play are present at the output area.
L1 L6 L11 L2
L3 L8 L12 L7
L4 L9 L13 L16
L5 L10 L14 L15
Fig. 21-12 Control keys with integrated LEDs in HHU
Byte
Output signals to HHU
No.
QB
1
m
New data
QB for se-
Selection
m+1 lected line line
QB
L8 L7 L6 L5 L4 L3 L2 L1
m+2
QB
L16 L15 L14 L13 L12 L11 L10 L9
m+3
Lx = 1 LED lights up

Output image of Control of the digital display in the HHU

digital display
Byte
Output signals to HHU
No.
QB Default setting of 1st character (right) of selected line

m+4
QB Default setting of 2nd character of selected line
m+5
QB Default setting of 3rd character of selected line
m+6
QB Default setting of 4th character of selected line
m+7
m+8
m+9
m + 10
m +11
m + 12
m + 13
m + 14
m + 15
m + 16
m +17
m + 18
QB Default setting of 16th character (left) of selected line
m + 19

Note
The value of the output byte QBm bit 7 must always be 1!
This sets the output mode of the display.
Display The digital display is used as a 2-line alphanumeric display with 16 digits per
line.
The display data are coded according to the character set given in the table
ASCII code of digital display via the QBm + 4...19 bytes. The decimal point re-
quires a digit of its own. The display always starts line by line right-justified with
the byte QBm + 4 and is built up towards the left up to QBm + 19.
Selecting the line QBm + 1, bit 0

This bit is used to select the line to be written.
Bit 0 = 0: The 1st line is selected.
Bit 0 = 1: The 2nd line is selected.
New data for QBm + 1, bit 7

selected line This bit is used to request writing in of new data into a line. The bit is set by the
user program and can be reset on detection of the acknowledgment bit IBm + 5,
bit 7.
Bit 7 = 0: Reset request
Bit 7 = 1: Set request
Acknowledging IBm + 5, bit 7

the digital display This bit is set by the system after the new data has been accepted.
Bit 7 = 0: No new data
Bit 7 = 1: New data has been accepted
21.8.2 Example signal chart
Example Example of a signal chart when writing data for two lines
signal chart
1. Selecting the line with QBm + 1, bit 0.
2. Writing new data with QBm + 4...19.
3. Set request: new data for selected line QBm + 1, bit 7.
4. Acknowledgment digital display IBm + 5, bit 7, via system.
5. Reset request.

Note
The request must be reset before a new line is written.
1 Lower line
1. Selecting the line
Upper line
0
1 Data for upper line Data for lower line

2. Writing new data
0
1
3. Request: New data b b
0
a a
c c
d d
1
4. Acknowledgement digital display
0
a: PLC user sets signal and waits for acknowledgment
b: System sets acknowledgment
c: User resets request
d: System resets acknowledgment
Fig. 21-13 Signal chart example for writing data into the HHU display
ASCII code of Representation of characters on specification of the corresponding bit pattern or

digital display hexadecimal format in the bytes QBm + 4...19. The characters from Hex 20 to
Hex 7F are default values.

Table 21-5 ASCII table for HHU display (to 7F only)
Charac- Hex Bit pattern Charac- Hex Bit pattern Charac- Hex Bit pattern
ter ter ter
SPACE 20 0010 0000 @ 40 0100 0000 60 0110 0000
! 21 0010 0001 A 41 0100 0001 a 61 0110 0001
22 0010 0010 B 42 0100 0010 b 62 0110 0010
# 23 0010 0011 C 43 0100 0011 c 63 0110 0011
$ 24 0010 0100 D 44 0100 0100 d 64 0110 0100
% 25 0010 0101 E 45 0100 0101 e 65 0110 0101
& 26 0010 0110 F 46 0100 0110 f 66 0110 0110
27 0010 0111 G 47 0100 0111 g 67 0110 0111
( 28 0010 1000 H 48 0100 1000 h 68 0110 1000
) 29 0010 1001 I 49 0100 1001 i 69 0110 1001
* 2A 0010 1010 J 4A 0100 1010 j 6A 0110 1010
+ 2B 0010 1011 K 4B 0100 1011 k 6B 0110 1011
, 2C 0010 1100 L 4C 0100 1100 l 6C 0110 1100
2D 0010 1101 M 4D 0100 1101 m 6D 0110 1101
. 2E 0010 1110 N 4E 0100 1110 n 6E 0110 1110
/ 2F 0010 1111 O 4F 0100 1111 o 6F 0110 1111
0 30 0011 0000 P 50 0101 0000 p 70 0111 0000
1 31 0011 0001 Q 51 0101 0001 q 71 0111 0001
2 32 0011 0010 R 52 0101 0010 r 72 0111 0010
3 33 0011 0011 S 53 0101 0011 s 73 0111 0011
4 34 0011 0100 T 54 0101 0100 t 74 0111 0100
5 35 0011 0101 U 55 0101 0101 u 75 0111 0101
6 36 0011 0110 V 56 0101 0110 v 76 0111 0110
7 37 0011 0111 W 57 0101 0111 w 77 0111 0111
8 38 0011 1000 X 58 0101 1000 x 78 0111 1000
9 39 0011 1001 Y 59 0101 1001 y 79 0111 1001
: 3A 0011 1010 Z 5A 0101 1010 z 7A 0111 1010
; 3B 0011 1011 [ 5B 0101 1011 { 7B 0111 1011
< 3C 0011 1100 \ 5C 0101 1100 | 7C 0111 1100
= 3D 0011 1101 ] 5D 0101 1101 } 7D 0111 1101
> 3E 0011 1110 ^ 5E 0101 1110 ~ 7E 0111 1110
? 3F 0011 1111 _ 5F 0101 1111 DEL 7F 0111 1111

21.9 Distributor box for handheld unit
Distributor box The handheld unit is connected to the distributor box.

and HHU The distributor box is designed for installation in the control cubicle or in a sepa-
rate housing.
The distributor box has an interface to the MPI bus and a terminal block for con-
necting the EMERGENCY STOP button, the enabling buttons, the handwheel
and the 24V power supply. The equipotential bonding connector is also ar-
ranged at the distributor box. Equipotential bonding has to be made using a
low-resistance connection between the distributor box and the earth potential.
The equipotential bonding conductor should be a stranded cable having a
cross-section of at least 10 mm2 and a length of less than 30cm, if possible.
References: /PHF/ Configuring Manual
/PHD/ Configuring Manual
Versions of the The distributor box is available both in standard version and in a UL-certified
distributor box version. In conjunction with the UL-certified distributor box, HHU and HPU are
UL-certified for USA and Canada. Both variants of the distributor box are me-
chanically installation-compatible and electrically connection-compatible.
The distributor must be designed for 3-core or 4-core connection of the enable
keys, depending on the HHU used.
Connecting the The 24VDC power supply is connected to terminal block X3, terminals 9 and 10.
24VDC power
supply
Installing the The HHU is connected to the X4 screw connection on the distributor box. When
distributor box drilling a hole (e.g. into a housing) for the X4 screw terminal, the requirements of
degree of protection IP54 must be complied with.
Connecting the The distributor box is connected to the relevant interface (e.g. to the MPI bus for
MPI bus or OPI FM-NC, 810D, 840D or to the OPI possible only for 840D) via the X5 MPI bus
connection.
Connecting the The first channel of the EMERGENCY STOP button is connected to the X3 ter-
EMERGENCY minal block, terminals 1 and 2.
STOP button The second channel of the EMERGENCY STOP button is connected to terminal
block X3, terminals 11 and 12.
Connecting the The electronic handwheel can be connected to terminal block X3, terminals 3 to
handwheel 6. If the handwheel is to be connected to the NCU, a connection must be made
to the cable distributor.
Enabling buttons The enabling buttons are connected to terminal block X3.
connection

Equipotential Equipotential bonding has to be made using a low-resistance connection be-

bonding tween the distributor box and the earth potential. The equipotential bonding con-
connection ductor should be a stranded cable having a cross-section of at least 10 mm2
and a length of less than 30cm, if possible.
Caution
! The 2nd channel of the EMERGENCY STOP circuit may be connected only if a
2-channel handheld unit is used.
Order No.: 6FX2007-1AC01 or 6FX2007-1AC11 and
6FX2007-1AC02 or 6FX2007-1AC12 and
6FX2007-1AC03 or 6FX2007-1AC13.
Position of
Front view Side view
interfaces and
100 36.5 34
terminals 90
X1
X5
X2
Equipotential 120 20
bonding X4 110
connection X3
1 2 3 4 5 6 7 8 9 10 1112 13 14 15 O26 hole

for M25
connector
10.5
Fig. 21-14 Distributor box for MPI and MPC bus
X1 and X2 exist only in the version 3-core connection of the enable buttons.
X3/terminals 14/15 exist only in the version 4-core connection of the enable
buttons.
X1, X2 For link to MPC bus.

The distributor box can be used for the MPI or the MPC bus.

X3 Terminal strip for the control elements of the HHU

Terminal block designation X3
Terminal block Terminals for 1.5 mm2
Table 21-6 Assignment of terminal block X3 with enable key, 3-core

1 EMERGENCY STOP button 1.1 (24V, 2A) I, input
2 EMERGENCY STOP button 1.2 (24V, 2A) O, output
3 Handwheel track A I/O, bidirectional
5 Handwheel track B I/O, bidirectional
7 Enabling button ZS1 (24V, 2A) O, output
8 Enabling button ZS1 (24V, 2A) O, output
9 24V (power supply for HHU) I, input
10 0V (Mext for HHU) I, input
13 Enabling button ZS1 (24V, 2A) I, input
Table 21-7 Assignment of terminal block X3 with enable key, 4-core

7 Enabling button ZS1.1 (24V, 2A) O, output
8 Enabling button ZS2.1 (24V, 2A) O, output
9 24V (power supply for HHU) I, input
10 0V (Mext for HHU) I, input
13 Enabling button ZS 2.2 I, input
14 Enabling button ZS 1.2 I, input
15 KEY 2 Unassigned
X4 HHU interface
Connector designation X4
Type of connector Circular screw-type connector
Special characteristics Interface according to IP54

Signal names
EMERGENCY STOP button
EMERGENCY STOP button
Protective conductor
Enabling button
Enabling button
+24V
0V
Handwheel track A
Handwheel track A
Handwheel track B
Handwheel track B
MPI bus lines
X5 MPI interface
Connector designation X5
Connector type 9-pin Sub-D socket connector
Max. cable length 200m
Special feature Electrical isolation
X5
1 Unassigned 6 P5 VO
2 Unassigned 7 Unassigned
3 RS_KP B 8 XRS_KP B
4 RTSAS_KP O 9 RTSPG_KP I
5 M VO
Signal names
RS_KP, XRS_KP Differential RS485 data C bus from PLC
RTSAS_KP AS Request to Send communication bus
from PLC
RTSPG_KP PG Request to Send communication bus
from PLC
M Ground
P5 5V
Signal type
B Bidirectional
O Output
VO Voltage Output
I Input
EMC measures The interference currents are earthed via the shield plates. To prevent these
discharged currents from becoming a source of interference themselves, make
sure that the path of the interference currents to earth is of low-resistance.
S Securely tighten all fixing screws of cable connectors, modules and cables
referred to a potential.
S Make sure that all contacting areas of cables referred to a potential are pro-
tected against corrosion.
S Cables referred to a potential should have a length of less than 30cm and a
cross-section of 10mm2.

21.10 Spare parts
21.10 Spare parts

The following spare parts are available:
Table 21-9 Spare parts HHU
Designation Length Con- Cod- Remarks Ident No.

nector ing (Order No.
Euchner, see
below)
for 6FX2007-1AB03
0_ 075384
Coiled cable 3.5m 17-pin
17 in ...-1AC03
45 _ for 6FX2007-1AE03 078999
for 6FX2007-1AB13
0_ 075385
Straight cable 10m 17-pin
17 in ...-1AC13
45 _ for 6FX2007-1AE13 079000
Terminator, for 6FX2006-1BC01
075910
for 3-core ZS circuits ...1BF00
Terminator, 17-pin 0_
for 6FX2006-1BC01
for 3-core ZS circuits, 072764
...1BF00
captive, with chain
Terminator, for 4-core ZS cir-
17-pin 45 _ for 6FX2006-1BH01 078952
cuits, captive, with chain
Keyswitch Complete 072604
Spare key for key-operated switch 075387
Replacement for old
EMERGENCY STOP switch, turn to reset,
HHUs 052958
with 1 NC contact
6FX2007-1Axx0
Replacement for new
EMERGENCY STOP switch, pull to reset, HHUs
073985
2-channel, tamper-proof 6FX2007-1Axx1 and
the following
with ribbon
Handwheel (encoder HKD100V100A05) 057036
connecting cable
Setting wheel C1702 (operating wheel) for handwheel 071380
Cover for keyboard 075772
Set, 1 x printed,
Slide-in plastic strips 075909
1 x unprinted
Override stepper switch, 12-way gray-coded 077097
Rotary button for override stepper switch with arrow dial 073973
For detailed description, see Prodis, article no. 490 700 4 dated 18.5.2000.
Order address
Euchner GmbH + Co
Vertrieb Technik
Kohlhammerstr. 16
D-70771 Leinfelden-Echterdingen
Germany
Phone: ++49-(0)711-7597-0
Fax: ++49-(0)711-7597-303
J

21.10 Spare parts
Notes

Mini Handheld Unit 22
22.1 Dimensions and control elements
20 60 108
F
E
216
H
D
B
I C
88 83.5
Fig. 22-1 Mini handheld unit
Control elements A EMERGENCY STOP button, two-channel

B Enabling button, 2-channel
C Selection switch for 5 axes and neutral position
D Function keys F1, F2, F3
E Traversing keys in +, directions
F Rapid traverse key for fast traversing with traversing keys or handwheel
G Handwheel
H Magnetic clamp for fastening to metal parts
I Connecting cable 1.5m...3.5m.

22 Mini Handheld Unit 10.00
22.1 Dimensions and control elements
22.1.1 General
The mini handheld unit (Mini HHU) is a small easy-to-handle unit for setting up
and operating simple machines in the JobShop area or similar applications.
Special attention has been paid to ergonomics and logical operating in the de-
sign of the housing and the arrangement of the control elements.
The Mini HHU is intended for connection to 810D and 840D controls. It can also
be used with the 840C and FM-NC.
22.1.2 Description of control elements
EMERGENCY The EMERGENCY STOP button must be operated in cases of emergency.

STOP button
1. When a person is at risk,
Enabling button The enabling button is designed as a 2-way switch. It must be pressed to initiate
traversing movements.
Axis selection The axis selection switch can be used to select up to five axes.
switch
Function keys The function keys can be used to trigger machine-specific functions.
Traversing keys The +, traversing keys can be used to trigger traversing movements at the
axis selected using the axis selection switch.
Handwheel The handwheel can be used to initiate movements at the axis selected using
the axis selection switch. The handwheel supplies two guide signals with
100 I/U.
Rapid traverse The rapid traverse button can be used to increase the traversing speed of the
button axis selected using the axis selection switch. The rapid traverse button is active
both for traversing commands issued via the +/ keys and for handwheel sig-
nals.

10.00 22 Mini Handheld Unit
22.2 Circuit diagram and sample connection
22.2 Circuit diagram and sample connection
X1
S1 12 22
wh 0.34 mm 2
EMERGENCY STOP
11
br 0.34 mm 2
EMERGENCY STOP/enable circuit
21
gn 0.34 mm 2
3
4 ye 0.34 mm 2
S2
gr 0.34 mm 2
Enabling button
14 24
5
13 23
rs 0.34 mm 2
6
bl 0.34 mm 2
7
S3
A2 1
A2
0ZXY45
C
rd 0.14 mm 2
Axis selection
2
bk 0.14 mm 2
9
4
5
vio 0.14 mm 2
10
8
16 C
4
bl
6
0.14 mm 2
A1 8
A1
+24 VDC +
to PLC
ye-br 0.14 mm 2
16
gr-rs 0.14 mm 2 S1
11
S2
rd-bl 0.14 mm 2

12
S3
wh-gn 0.14 mm 2
13
F1
S4
br-gn 0.14 mm 2
F1
14
2F
S5
wh-ye 0.14 mm 2
2F
15
3F
S6
wh-gr 0.14 mm 2
3F
17
6
B1
B1
Shield
SM
SM
24
gr-br 0.34 mm 2 0V
0V
18 19
0.34 mm 2
5 VDC
wh-rs +5 V
Handwheel
rs-br 0.14 mm 2 /B
/B
20 21 22 23
wh-bl 0.14 mm 2 B
B /A A
br-bl 0.14 mm 2 /A
3
wh-rd 0.14 mm 2 A
2
Fig. 22-2 Circuit diagram and sample connection

22.4 Configuration
The mini HHU is connected to the PLC or the connector for handwheels via a
flange socket. There is no need for an additional distributor. The signals are
sent to the NC in parallel without (MPI). The flange socket is contained in the
connection kit.
22.3 Coding of axis selection switch

The coding of the axis selection switch is carried out in Gray Code.
Table 22-1 Coding of the axis selection switch
Connector X1 Switch posi- Function

tion
Pin 8 Pin 9 Pin 10
0 0 0 Mini HHU not connected
1 1 0 0 No axis selected
0 1 0 Z Z axis selected
0 1 1 X X axis selected
1 1 1 Y Y axis selected
1 0 1 4 Axis 4 selected
0 0 1 5 Axis 5 selected
22.4 Configuration
The FC76 module supplied in the toolbox supports configuration of the mini
HHU. It is located in the toolbox in the BSP_PROG directory in the file
MINI_BHG.EXE. The file is a self-extracting file which also contains the docu-
mentation for the module.
The FC76 contains a standard program for the mini HHU and is valid for use
with SINUMERIK 840D/810D. The program is generally valid and therefore re-
quires several input and output signals when called.
To avoid collisions (caused by simultaneous access to one and the same sig-
nal), the FC2 (NCKPLC interface) that occurs in the basic program must be
processed before the FC76.

22.5 Connection
22.5 Connection
Connection kit A connection kit that must be ordered separately is required for connection of
the mini HHU. This connection kit contains a 24-way flange socket for installa-
tion at the machine and a dummy plug for overriding the EMERGENCY STOP
circuit when the HHU is not connected.
Connection of The 6FX2002-4AA21-1xx0 cable can be used to connect the handwheel sig-
handwheel signals nals to the NC.
The pin contacts on the cable must be replaced with the socket contacts con-
tained in the connection kit.
Connection in accordance with circuit diagram (see Fig. 22-2).
Sealing ring Casing wall

O 3.8mm
O 39mm
4 1
9 5
15 10
20 16
24 21
Seal 36.6mm
View of connection side
Fig. 22-3 Dimensions of the flange socket
Use the contacts supplied when connecting the cables.
S 20x AMP crimp socket contact

No. 163088-2 for AWG 24-20; 0.200.56 mm2
S 6x AMP crimp socket contact

No. 163092-2 for AWG 26-24; 0.120.25 mm2
Note
The crimping tool suggested should be used:
AMP crimping tool No. 169475-1 or 90277-1.

22.6 Technical data
22.6 Technical data
Table 22-2 Technical data for mini HHU
Control elements
Enabling button 1 button: two-channel NO contact
floating
EMERGENCY STOP button 1 button: two-channel NC contact,
floating turn-to-reset
Axis selection switch 5 axes: X, Y, Z, 4, 5 and neutral position
Jog key + Positive traverse direction
Jog key Negative traverse direction
Job key Rapid traverse for job keys and handwheel
Function keys 3 keys: F1, F2, F3
Handwheel 100 I/U
Electrical data
Operating voltage for switch- 24V
ing signals
Operating voltage for hand- 5V
wheel
Power consumption 5V Approx. 90mA
Handwheel signals RS-422
EMERGENCY STOP button 24V 2A NC contact
Enabling button 24V 2A NO contact
General data
Housing Optimum ergonomic casing made of polyamide 6,
intuitive arrangement of control elements
Fastening 2 magnetic clamps
Connecting cable Spiral cable 1.5m; expandable up to 3.5m;
Plug with pin contacts
CE conformity Yes
Mechanical data
Approx. 250mm 110mm 90mm
Weight Approx. 0.8 kg without connecting cable
Temperature ranges Installed/in op- Storage/transport
eration
0 ... 55C 20 ... 60C
Temperature change Within 1 minute max. 0.2K
Within 1 minute Max. 0.1%
Connection kit
Flange socket 24-pin with socket contacts and dummy plug
Dummy for overriding the EMERGENCY STOP circuit

22.7 Spare parts
22.7 Spare parts

The following spare parts are available:
Table 22-3 Spare parts for mini HHU
Designation Ident No.

Servo handwheel, 5VDC, A/B push-pull, without dial 1009 010
Rotary selector switch, 6 positions, without dial 1009 219
EMERGENCY STOP button, complete with keyset, label and switching 1009 221
element
Enable key, complete 1009 933
Set of control knobs, for servo handwheel, rotary selector switch and 1009 227
enable key
Connection cable, coiled, wired on connector, connection end preas- 1009 081
sembled
Flange-mounting socket-outlet, complete with seals and contacts 1009 084
Jumper connector, with jumpered EMERGENCY STOP contacts 1009 046
Crimp contacts
S Set of crimp contact sockets, 1009 222

consisting of 10 x 0.120.25 mm2, 30 x 0.200.56 mm2
1009 223
S Set of crimp contact pins,
consisting of 10 x 0.120.25 mm2, 30 x 0.200.56 mm2
Tool
S Ejector for crimp socket and pin contacts 0080811
S Mounting tools for EMERGENCY STOP button 1009 224
S Pressure-cap remover for enable key 1009 217
See PRODOK, document Current position measurement for detailed descrip-

tion.
Current No. 1999/019
Status: 13/12/1999
Order address
Fa. R&D Steuerungstechnik GmbH + Co KG
Abteilung Service
Hocksteiner Weg 8795
D-41189 Moenchengladbach
Germany
Phone: ++49-(0)2166-5506-34
Fax: ++49-(0)2166-5506-55
J

22.7 Spare parts
Notes

Handheld Terminal HT 6 23
23.1 Overview and function blocks
Overview of HT 6 The SINUMERIK HT 6 (Handheld Terminal with a 6 display diagonal) is an op-

eration and programming device and can be used in conjunction with the
SINUMERIK 810D, 840D, FM 357-2H and 840Di controllers.
The following components and cables are necessary for connection:
Computer unit Other

station nodes
OPI (1.5 Mbaud) for SINUMERIK 840D MPI cable

MPI (187.5 kbaud) for SINUMERIK 840D/810D
MPI (1.5 Mbaud) for SINUMERIK 840Di X5
X4
Handheld X3
Terminal (HT 6)
Distributor box, e.g.

6FX2006-1BH01
Terminal block
For power supply for the HT 6
Wiring for EMERGENCY STOP on HT 6
HT 6 cable Wiring for enabling key on HT 6
Fig. 23-1 Connection diagram for Handheld Terminal HT 6
Connections The Handheld Terminal must be connected to the MPI bus as the final node on
the MPI bus. The bus terminating resistors are integrated in the device. The
general rules apply for the MPI bus.
Note
The HT6 cannot be connected using the MPI cable 6FX2002-4EA04-IAF0 (or
other lengths), since the bus terminators are integral components of this cable.
Please use the MPI cable specified in the catalog
References: /Z/ Catalog NCZ.

23 Handheld Terminal HT 6 10.00
23.1 Overview and function blocks
HT 6 cable
Order No.: 6FX2002... Remarks Suitable distributor
...-1AA83-1jj0 3-core enable cable 6FX2006-1BC01
...-1AA23-1jj0 4-core enable cable 6FX2006-1BH01
Examples (order by the meter, max. 40 m):

...-1AA83-1BA0 10m ...-1AA23-1CA0 20m
Note
Distributor box 6FX2006-1BF00 cannot be used.
Caution
! An EMERGENCY STOP is triggered if the connection between the HT 6 and
the distributor box is interrupted (e.g. the HT 6 cable was unplugged). EMER-
GENCY STOP overriding does not take place automatically (see Section 23.4).
Function blocks of
HT 6 S 80486 DX4 microprocessor
S Memory:
SDRAM 16MB
FLASH 8MB
PC memory card: 8MB FLASH, plugged in externally
S LC display with
5.7 diagonal, monochrome (blue) STN, 320*240 pixels (1/4 VGA),
backlit, variable brightness and contrast
16, ..., 20 lines, 38, ..., 52 characters per line (as configured)
S Membrane keyboard with

Machine control key block: RESET, ALARM CANCEL, JOG, TEACH,
AUTO, CONTROL PANEL FUNCTION, STOP, START,
12 traversing keys (6 + and 6 for labeling with slide-in labels)
Horizontal soft key bar with eight keys
Number block (12 keys, shift key switches to alpha characters)
Cursor key block (nine keys)
Customer-configurable keys: S1, S2, U1, ..., U8 (with slide-in labels)
Function keys: Operating area (MENU SELECT), HELP, Recall (^)
S Override switch (19 positions with fixed stop)

S EMERGENCY STOP button
S At the rear:
Enabling buttons (two buttons with two channels each, with two positions
for Safety Category 3)
HT 6 cable connection
Serial RS-232-C interface

10.00 23 Handheld Terminal HT 6
23.2 User interface and interfaces
PC memory card interface

Reset button
Belt fastener
Two M5 threaded holes for customized bracket.
23.2.1 User interface
The user interface of the HT 6 visible from the front is shown in Fig. 23-2.
Rear side:
Two enabling Override switch
buttons (with fixed stop)
EMER-
GENCY
STOP
Display X
1
Y
2
Z
3 Traversing keys,
A for configuring and
4 labeling by the cus-
B tomer 1)
Soft keys 5
C
6
Special keys,
Function keys, customer-configur-
for configuring and able
labeling by the cus-
tomer 1)
Connecting cable
1) See Section 23.6
Fig. 23-2 User interface of HT 6

Number block The Shift key is used to switch the function of the number block keys between
text and numerical mode. Changeover only becomes effective when the Shift
key is released. In text mode, each key is assigned to several alpha characters.
The required character is selected with Shift + character key.
EMERGENCY EMERGENCY STOP button

STOP Operate the red EMERGENCY STOP button in emergency situations:
S When a person is at risk,
S when there is the danger of machine or workpiece being damaged.
For other reactions to the EMERGENCY STOP, please refer to the machine
tool manufacturers instructions!
The rear of the HT 6 complete with the enabling buttons and the interface cov-
ers is shown in Fig. 23-3.
RS-232 interface
(under the cover)
M5 threaded bushes
for fixing bracket
Interface cover:
PC MEMORY card Enabling button
interface
MF2 keyboard interface
RESET key Belt fastener
(under the cover)
Connecting cable
Fig. 23-3 Rear of the HT 6 with the interfaces
Enabling button The enabling button is designed as a 2-channel, 2-position switch (see Section
23.3).
In the case of operations that require enabling (e.g. manual traversing within a
danger zone), only one enabling button has to be operated.
Note
Press the enabling button firmly as far as the stop to ensure reliable action.

M5 threaded There are two M5 threaded bushes on the rear of the HT 6 for attaching to a
bushes for fixing fixing bracket supplied by the customer, see following Figure.
brackets For both threads, compliance with the maximum tightening torque of 1.8Nm is
essential to ensure that the bushes are not overloaded.
16
M5
117
Fig. 23-4 M5 threaded bushes for fixing bracket
23.2.2 Interfaces
HT 6 cable Connector designation: X101

interface (X101) Connector type: 15-pin high-density Sub-D male insert with
UNC 4 screw fitting
Pin Signal name Signal mode Signal

type
1 B RS-485 differential signal B
2 NC Not connected
3 ZS2.2 Enabling buttons, Contact 2
5 NA1.1 EMERGENCY STOP button, Contact 1
6 A RS-485 differential signal B
7 NC Not connected
11 GND M (Mext for HT 6) VI


type
12 Ub 24V (power supply for HT 6) VI
14 SHIELD Shield
Installation of connecting cable:
S Release the two M3 Torx screws of the connecting cable cover

S Remove cover
S Plug connecting cable into the socket and attach with the fixing screws
S Replace cover and tighten screws again.
RS232C interface Connector designation: X201

(X201) Connector type: 9-pin Sub-D
Max. cable length: 30m

type
1 DCD Data Carrier Detect O
2 RxD Receive Data I
3 TxD Transmit Data O
4 DTR Data Terminal Ready I
5 1M Ground VO
6 DSR Data Send Ready O
7 RTS Request To Send I
8 CTS Clear To Send O
9 RI Ring Indicator I
Signal type
B: Bidirectional I: Input O: Output
VI: Voltage Input VO: Voltage Output
Releasing the RS-232-C cover:
S Pull the lug on the cover upwards.

S Rotate the cover to the side; the RS-232 interface is accessible.
S To reassemble, place cover on the HT 6 and latch in place with gentle pres-
sure.

PC memory card Connector designation: X401

interface (X401) Connector type: 68-pin PC card adapter
Pin Signal name Signal type Pin Signal name Signal type
1 1M VO 35 1M VO
2 D3 B 36 XCARDDET O
3 D4 B 37 D11 B
4 D5 B 38 D12 B
5 D6 B 39 D13 B
6 D7 B 40 D14 B
7 XCSCARDF O 41 D15 B
8 A10 O 42 XCSCARDF O
9 XOEP O 43 NC
10 A11 O 44 NC
11 A9 O 45 NC
12 A8 O 46 A17 O
13 A13 O 47 A18 O
14 A14 O 48 A19 O
15 XWEP O 49 A20 O
16 NC 50 A21 O
17 1P5 VO 51 1P5 VO
18 VPP VO 52 VPP VO
19 A16 O 53 A22 O
20 A15 O 54 A23 O
21 A12 O 55 A24 O
22 A7 O 56 A25 O
23 A6 O 57 NC
24 A5 O 58 RESET O
25 A4 O 59 NC
26 A3 O 60 NC
27 A2 O 61 XREG O
28 A1 O 62 NC
29 1M VO 63 NC
30 D0 B 64 D8 B
31 D1 B 65 D9 B
32 D2 B 66 D10 B
33 NC 67 NC
34 1M VO 68 1M VO
Explanation
A0, ..., A25: Address 0, ..., 25 B: Bidirectional
D0, ..., 15: Data 0, ..., 15 O: Output VO: Voltage Output

Release interface cover:
S Unlatch cover by depressing the lug

S Hold the cover at the two recesses and pull off
sure.
PS/2 keyboard Connector designation: X301

interface (X301) for Connector type: 6-pin Mini-DIN socket connector
MF2 keyboard

type
1 KDATA Keyboard Data I
2 NC Not connected
3 1M Ground VO
4 1P5 +5V (power supply) VO
5 KCLK Keyboard Clock O
6 NC Not connected
Signal type
I: Input O: Output VO: Voltage Output

sure.
RESET button The HT 6 can be booted up again using the RESET button.
The RESET button can be accessed under the interface cover by inserting a
screwdriver into a hole.

sure.
References for The following manuals are available for the handheld terminal (HT 6):
further reading
References: /BAH/ Operators Guide HT 6
/FBPH/ Function description HT 6
Configuration of the HT 6 user interface
/IAM BE1/ User interface extension

23.3 Distributor box
Note
The IP 54 degree of protection is only guaranteed when the interface covers
and the RS-232-C covers are closed.
Distributor box The handheld terminal is connected to a distributor box. The distributor box has
and HT 6 an interface to the MPI bus and a terminal block for connecting the EMER-
GENCY STOP circuit, enabling button circuit, 24V power supply and an equipo-
tential bonding connection.
The following are suggested for the connections
Distribution box (Order No. 6FX2006-1BC01) for 3-core enabling cable
(Order No. 6FX2002-1AA83, see Subsection 23.3.1)
Distribution box (Order No. 6FX2006-1BH01) for 4-core enabling cable
(Order No. 6FX2002-1AA23, see Subsection 23.3.2)
23.3.1 Distributor box for 3-core enabling cable

(Order No. 6FX2006-1BC01)
Location of
interfaces and
100 36.5 34
terminal blocks 90
Nameplate
X5 X5
Equipotential
bonding X4
connector 120
X4 110
X3
O26 hole X3
1 2 3 4 5 6 7 8 9 10 11 12 13 for M25
connector
10.5
Fig. 23-5 Distributor box 6FX2006-1BC01: Location of interfaces and terminal blocks

24V supply for the The 24V supply is connected to terminal block X3 (see Fig. 23-6):
HT 6
Terminal 9 Ub
Terminal 10 GND
Connecting the The HT 6 is connected to the X4 screw connection on the distributor box by
HT 6 means of the HT 6 cable.
Note
When drilling a hole (e.g. into a housing) for the X4 screw terminal, the require-
ments of degree of protection IP 54 must be complied with.
MPI bus The distributor box is connected to the appropriate interface via MPI bus termi-
connection nal X5, e.g. on the MPI bus.
Connecting the The EMERGENCY STOP button is connected to terminal block X3 (see
EMERGENCY Fig. 23-6).
STOP button
Terminal Assignment
1 Input
EMERGENCY STOP contact 1
2 Output
11 Input
12 Output
Connection for the

enabling button EMERGENCY STOP button Enabling button
(three-core)
1 2
HT 6
5 10 15 9 8 13 3 4 X101
Cable plugs
HT 6 cable
6FX2002-1AA83
X4
Distributor box
6FX2006-1BC01
1 11 12 2 3 4 5 6 7 8 9 10 13 X3
1.1 2.1 2.2 1.2 1.1 2.1 Ub GND 1.2/2.2
Fig. 23-6 Distributor box 6FX2006-1BC01: Connection to the HT 6

Terminal block Connector designation: X3

(X3) Connector type: Terminal block for 1.5 mm2
Table 23-5 Distributor box 6FX2006-1BC01: X 3 pin assignments for terminal block

type
1 NA1.1 EMERGENCY STOP button 1.1 (24V, 1A) I
2 NA1.2 EMERGENCY STOP button 1.2 (24V, 1A) O
3, ..., 6 NC Not connected
7 ZS1.1 Enabling button (24V, 1A) O
9 Ub 24V (power supply for HT 6) I
10 GND M (Mext for HT 6) I
11 NA2.1 EMERGENCY STOP button 2.1 (24V, 1A) I
12 NA2.2 EMERGENCY STOP button 2.2 (24V, 1A) O
13 ZS1.2/ZS2.2 Enabling button (24V, 1A) I
HT 6 interface (X4) Connector designation: X4

Connector type: Circular screw-type connector
Table 23-6 Distributor box 6FX2006-1BC01: X4 pin assignments

type
1 NA2.1 EMERGENCY STOP button (24V, 1A) I
2 MPI_A
6 ZS1.2/ZS2.2 Enabling button (24V, 1A) I
7, 8 NC Not connected
9 NA1.2 EMERGENCY STOP button (24V, 1A) O
11 NC Not connected
13 MPI_B
15, ... 17 NC Not connected


(X5) Connector type: 9-pin Sub-D socket connector
Table 23-7 Distributor box 6FX2006-1BC01: X5 pin assignments

type
3 MPI_B B
8 MPI_A B
Connection for Equipotential bonding has to be made using a low-resistance connection be-
equipotential tween the distributor box and the earth potential.
bonding
EMC measures To ensure that the drained currents do not become a source of interference in
their own right, compliance with the following points is essential:
S Use a stranded reference potential conductor (of up to 30cm in length and at

least 10 mm2 cross-section).
23.3.2 Distributor box for 4-core enabling cable

(Order No. 6FX2006-1BH01)
Location of
interfaces and
terminal blocks
100 36.5 34
90
Nameplate
X5 X5
Equipotential
bonding X4
connector 120
X4 110
X3
O26 hole X3
1 2 3 4 5 6 7 8 9 10 11 12 13 1415 for M25
connector
10.5
Fig. 23-7 Distributor box 6FX2006-1BH01: Location of interfaces and terminal blocks

24V power supply The 24V power supply is connected to terminal block X3.
for the HT 6
Terminal 9 Ub
Terminal 10 GND
Connecting the The HT 6 is connected to the X4 screw connection on the distributor box by
HT 6 means of the HT 6 cable.
Note
When drilling a hole (e.g. into a housing) for the X4 screw terminal, the require-
ments of degree of protection IP 54 must be complied with.
MPI bus The distributor box is connected to the appropriate interface via MPI bus termi-
connection nal X5, e.g. on the MPI bus.
Connecting the The EMERGENCY STOP button is connected to terminal block X3 (see
EMERGENCY Fig. 23-8).
STOP button
Terminal Assignment
1 Input
2 Output
11 Input
12 Output
Connection for the

enabling button EMERGENCY STOP button Enabling button
(four-core)
1 2
HT 6
5 10 15 9 8 13 3 4 X101
Cable plugs
HT 6 cable
6FX2002-1AA23
X4
Distributor box
6FX2006-1BH01
1 11 12 2 3 4 5 6 7 8 9 10 13 14 X3
1.1 2.1 2.2 1.2 1.1 2.1 Ub GND 2.2 1.2
Fig. 23-8 Distributor box 6FX2006-1BH01: Connection to the HT 6

Terminal block Connector designation: X3

(X3) Connector type: Terminal block for 1.5 mm2
Table 23-8 Distributor box 6FX2006-1BH01: X 3 pin assignments for terminal block
Termi- Signal name Signal mode Signal

nal type
3, ..., 6 NC Not connected
13 ZS2.2 Enabling button (24V, 1A) I
15 KEY2 Indicator for plugged in short-circuit plug. If so O
> 24V
HT 6 interface (X4) Connector designation: X4

Connector type: Circular screw-type connector
Table 23-9 Distributor box 6FX2006-1BH01: X4 pin assignments

type
2 MPI_A B
7, 8 NC Not connected
11 KEY2 Indicator for plugged in short-circuit plug. If so O
> 24V
13 MPI_B B
15 NC Not connected
17 HR_B Not connected


(X5) Connector type: 9-pin Sub-D socket connector
Table 23-10 Distributor box 6FX2006-1BH01: X5 pin assignments

type
3 MPI_B B
8 MPI_A B
Connection for Equipotential bonding has to be made using a low-resistance connection be-
equipotential tween the distributor box and the earth potential.
bonding
EMC measures To ensure that the drained currents do not become a source of interference in
their own right, compliance with the following points is essential:
S Use a stranded reference potential conductor (of up to 30cm in length and at

least 10 mm2 cross-section).

23.4 Connecting and disconnecting HT 6 during operation
Purpose Trouble-free disconnection and connection of the HT 6 during machine opera-

tion requires the following:
S Release or override of the HT 6 EMERGENCY STOP

S Connection of the HT 6 to the OPI/MPI via a PROFIBUS repeater.
NCU/ ON OFF OFF ON

CCU MPI/OPI
ON ON ON
Distributor box
Distributor box
HT 6
RS-485 repeater
OFF ON
Fig. 23-9 Connecting the HT 6 using a PROFIBUS repeater
A PROFIBUS repeater must be connected upstream of the HT 6 distributor box

for each branch. The individual bus segments (MPI/OPI cable and/or the local
segments between repeater and HT 6) must be terminated with connector resis-
tors at the ends of the bus.
Repeater RS-485 The repeater can be ordered under Order No. 6ES7972-0AA01-0XA0. For fur-
ther information, please refer to the Catalog
Note
S The HT 6 already has an installed bus terminating resistor.

2m.
S Cable lengths for MPI/OPI, see /IAD/ Start-Up Guide 840D or /IAC/ Start-Up
Guide 810D, Chapter 3.

EMERGENCY STOP circuit (system EMERGENCY STOP)
Keyswitch 1) with positive-action contacts
24V
Signal to PLC 2)
Keyswitch1)
1 11 12 2 9 10
X3
P (24V) M (0V)
Distributor box
6FX2006-1BC01
10 1 12 9
X4
HT 6
X4 (distributor): 10 1 12 9
EMERGENCY
STOP button
Short-circuit connector
1) Keyswitch consisting of 2) triggers a timer.

If the signal level is still low after the
S Two switching elements 3SB1400-0A and monitoring period (approx. 5 min), the PLC
must initiate an EMERGENCY STOP.
S Actuating element 3SB10 or 3SB16 To ensure a reliable HIGH/LOW signal transi-
tion, use a pull-down resistor if necessary.
(corresponding safety lock after selection)
Catalog: Switching devices and systems (NSK) at A&D CD
Fig. 23-10 Distributor box 6FX2006-1BC01: Sample circuit for EMERGENCY STOP override
Note
cuits.

EMERGENCY STOP circuit (system EMERGENCY STOP)
Keyswitch 1) with positive-action contacts
24V
Signal to PLC 2)
Keyswitch1)
Signal KEY2 to PLC 3)
1 11 12 2 9 15 10
X3
P (24V) M (0V)
Distributor
6FX2006-1BH01
10 1 12 9 4 11
X4
HT 6
X4 (distributor): 4 10 1 12 9 11
EMERGENCY
STOP button
Short-circuit connector
1) Keyswitch consisting of 2) triggers a timer.

If the signal level is still low after the
S Two switching elements 3SB1400-0A and monitoring period (approx. 5 min), the PLC must
initiate an EMERGENCY STOP.
S Actuating element 3SB10 or 3SB16 To ensure a reliable HIGH/LOW signal transi-
(corresponding safety lock after selection) tion, use a pull-down resistor if necessary.
Catalog: Switching devices and systems (NSK) at 3)At 24V, when short-circuit connector is
A&D CD plugged in. Can be routed to the PLC.
Fig. 23-11 Distributor box 6FX2006-1BH01: Sample circuit for EMERGENCY STOP override
Note
cuits.

Procedure for HT 6 is active including EMERGENCY STOP.

disconnecting 1. Override the EMERGENCY STOP circuit of the HT 6 using the keyswitch.
HT 6 2. This connects the HT 6 supply voltage and the signal to the PLC to the LOW
signal level (provide a pull-down resistor if necessary). This HIGH-LOW tran-
sition starts a timer in the PLC, which opens the EMERGENCY STOP circuit
via the relevant PLC outputs and series-connected relays after the change-
over period (approx. 5 min) if the keyswitch is not reset to its initial position
within this period.
3. The HT 6 must be removed within the changeover period and the EMER-
GENCY STOP circuit overridden using a short-circuit connector.
Procedure for Changeover from short-circuit connector to HT 6 connection is carried out in

connecting HT 6 reverse order.
Danger
! EMERGENCY STOP switches that are inactive
S may not be recognizable as such

S may not be accessible.
This is to prevent the EMERGENCY STOP switch from being used inad-
vertently.

23.5 Configuring the HT 6, setting interface parameters
Note
Interface parameters are configured using the IK Screen Kit.
References: /FBPH/, Configuring User Interface HT 6

IK, Screen Kit: Software update and configuration
23.5.1 Interface signals of HT 6
MCP simulation is available for the HT 6. MCP simulation of the HT 6 must be

parameterized with the function block FB1 as MCP, to enable the basic PLC
program to monitor the HT 6 for failure.
Input signals The start address n is set by the parameters in the PLC user program (FB1).
Table 23-11 HT 6 PLC interface

Function key block
IBn
WCS/MCS
(REF) TEACH AUTO (MDA) JOG ACK RESET
Function key block
IBn 1
IBn+1
Control
panel func- U4 U3 Reserved U2 U1 (INC) (REPOS)
tion
JOG keys positive direction
IBn+2 Reserved
(AXSEL1) AXSEL0 JOG6+ JOG5+ JOG4+ JOG3+ JOG2+ JOG1+
JOG keys negative direction
IBn+3 Reserved Reserved JOG6 JOG5 JOG4 JOG3 JOG2 JOG1
IBn+4 Reserved
IBn+5 Reserved U8 U7 U6 U5 Step Reserved Reserved
Start key block
IBn 6
IBn+6
Reserved Reserved Reserved
(HW1) * (HW0) * SF2 SF1 START STOP *
Feed override
IBn 7
IBn+7
E* D* C* B* A*
Notes:
Only the keys on light gray background are evaluated by the basic PLC program (FC26).
Only the keys on dark gray background are evaluated in FC26 from SW 6.1.
Signals shown in () brackets do not exist, but are emulated by the software (e.g. with a soft key).
Transfer of the signals to the PLC can be inhibited in the software, except for those marked with *.
Use of keys U1 to U8 and S1, S2 and their inputs can be customized by the PLC user.

Output signals The start address n is set by the parameters in the PLC user program (FB1).
Table 23-12 PLC > HT 6 interface

QBn WCS/MCS
QBn+1
Travel keys
Axis system
QBn+2 (reserved) AXSEL0
QBn+3
QBn+4
QBn+5
QBn+6
QBn+7
Notes:
Signals are evaluated by the HT 6 status display.
Signals on a gray background are supplied by the basic PLC program (FC26).
The other signals may need to be supplied by the user program.
In parallel to the PLC functions FC 19 and FC 25, there is FC 26. It is described

in
References: /FB/ P3, Basic PLC Program.
The machine data which specify the offset values have to be set as follows:
S MD 12000: OVR_AX_IS_GRAY_CODE = 1
S MD 12020: OVR_FEED_IS_GRAY_CODE = 1
S MD 12040: OVR_RAPID_IS_GRAY_CODE = 1
S MD 12060: OVR_SPIND_IS_GRAY_CODE = 1.
Non-supported As standard, the following signals cannot be influenced by means of MCP

signals emulation; they are initialized on control power-up:
S Keyswitch at position 0
S Spindle offset at 0
S Rapid traverse override at 0.
Only parameters BAGNo and ChanNo are provided for FC 26. That is why
the information that is normally transmitted to the caller via the parameters
FeedHold and SpindleHold has to be calculated by the user.

23.5.2 Standard configuration of the HT 6 (without MCP)
For the default setting of the HT 6, the FB1 call in DB100 available on the basic
program diskette (tool box) must be used.
This call is valid for the first MCP or the HT 6.
This setting corresponds to the hardware of the HT 6 when supplied.
The default setting is:
S MPI address: 14.
Parameterization
+ The parameter settings in FB1 for the handheld programming unit correspond to
of basic PLC those of the first MCP:
program (FB1) MCPNum:=1 // one HT 6
MCPIn:=P#E0.0 // HT 6 input signals
MCPOut:=P#Q0.0 // HT 6 output signals
MCPStatRec:=P#Q12.0 // status double word
MCPStatSend:=P#Q8.0 //
MCPMPI:=TRUE //
MCP1BusAdr:=14 //
PLC SW Please note the following when using SW 05.03.04 (for 840D) or SW 03.03.04
(for 810D):
The following must be set while OB 100 is booting:
DB8.DBB2=0 if the HT 6 is configured as the first MCP,
DB8.DBB64=0 if the HT 6 is configured as the second MCP.
This is not necessary with any of the higher SW versions.

23.6 Key labeling
23.6 Key labeling

In the case of the HT 6, the traverse and function keys U1, ..., U8 (see Fig.
23-2) can be labeled by the customer as required.
23.6.1 Changing the slide-in labels
The labeling strips can be changed following deinstallation of the HT 6 key-

board support (Fig. 23-12, right).
Note
The deinstalled keyboard support must be totally protected from soiling, other-
wise the readability of the display and key labels can be permanently affected.
If the inner face becomes dirty, any dirt must be carefully removed using an
Isopropanol cleansing agent or a cellulose cloth soaked in Isopropanol.
Film labels
Override button
Grooves for levering off

the keyboard support
Clamping lugs
(2 of 4)
Flat connector
Fig. 23-12 Changing the slide-in labels
Procedure
1. Deinstall override button in the zero position (Fig. 23-12, left):
Lever off the cover plate with a flat-ended tool (screwdriver),
release expansion screw with screwdriver,
pull knob off the spindle.
2. Depress the four clamping lugs and lever off the keyboard support by insert-
ing a screwdriver in the grooves in the handhold (Fig. 23-12, right).

23.6 Key labeling
3. Pull out flat connector carefully vertically.

4. Turn over keyboard support, slide out any labels and insert new ones.
5. On replacing the keyboard support, plug in the flat connector vertically tak-
ing care not to bend the protruding pins in the bottom part and latch the
cover in place applying gentle pressure.
6. Install the override button following the previous steps in reverse order:
Replace with pointer at zero.
Clamp with expanding screw.
Replace cover.
23.6.2 Labeling the slide-in labels
Slide-in labels can also be made from ordinary paper (80 g/m2).
The dimensions (in mm) can be obtained from Fig. 23-13. The crosses indicate
the center of the text or symbol.
Slide-in labels for Slide-in labels for

traversing keys function keys
14.7
Fig. 23-13 Dimensional drawing for labeling the slide-in labels

23.7 Technical data
23.7 Technical data
Table 23-13 Technical data for HT 6
Electrical data
Power supply 24V via HT 6 cable
Power consumption approx. 500mA
EMERGENCY STOP button 24V 1A 2 NC contacts
Enabling button 24V 1A 2 NO contacts
each
Power loss 12W
General data
Connecting cable Length max. 40m (order by the meter)
Mechanical data
Dimensions Diameter Depth
approx. 290mm approx. 53mm
Ground approx. 1500g
Temperature ranges Installed/in op- Storage/transport
eration
0 ... 45C 1) 20 ... +60C
Temperature change max. 0.2K per min.
Change in relative humidity max. 0.1% Class 3K5
per min. according to DIN EN 60721-3-3
Vibration and shock load Class 3M6 according to DIN EN 60721-3-3
________________________________________________________
1) At ambient temperatures > 40oC it is recommended that the screen saver is
activated during long periods of inactivity via the display machine data DIS-
PLAY_BLACK_TIME).
J

23.7 Technical data
Notes

Heat Dissipation 24
For the technical data of the control components (e.g. degree of protection,
power loss, etc.), please refer to Section Technical data ... for the individual
component.
!
Important
To calculate the heat dissipation, the total power loss PVtotal of all heat-generat-
ing components in a casing must be taken into account.
Total power loss PVtotal= Pv1 + Pv2 + Pv3 + ...[]
Convection surface A [m2]:
The surfaces of the front and bottom side are not taken into consideration when
calculating the convection surface.
Means of heat Heat dissipation can take place as follows:

dissipation
S Heat dissipation by natural convection
S Heat dissipation by natural convection and internal air turbulence
S Heat dissipation by open-circuit ventilation
S Heat dissipation by open-circuit ventilation.

24 Heat Dissipation 10.00
Heat dissipation by Heat dissipation by

natural convection natural convection and
internal air turbulence Recommended:
The fan must be mounted in such a
way to ensure optimum heat dis-
sipation.
In addition, ventilation clearance of
min. 100 mm must also provided in
front of the fan.
In the case of open-circuit cooling
Operator Operator or ventilation, the ventilation slots
panel front panel front
must remain free.
T1 T2 T1 T2
Notes:
The necessary free convection surface area A[m2] of the space to be Air filters must be provided to
enclosed (steel or aluminum sheet, 1.5 mm thick) is calculated, referred to maintain the permissible environ-
a temperature difference T2 T1 = T 10K, approximately from: mental conditions stated in Section
Technical data ....
PVtotal[W] PVtotal[W] Air flow through fan:
A [m2] = 100...165 m3/h
A [m2] = 10 * T [K]
5 T [K]
Heat removal by Heat dissipation

open-circuit ventilation by open-circuit ventilation
The approximate air flow neces-

sary for removing lost heat is cal-
culated from:
Operator Operator
panel front panel front
3.5 * PVtotal [W]
T1 T2 T1 T2 V [m3/h] =
T [K]
Fig. 24-1 Means of heat dissipation
Note
If the convection area A [m2] is not sufficient for heat dissipation by natural
convection, then heat dissipation by natural convection and internal air
turbulence or heat dissipation by open-circuit cooling or ventilation should be
used.
For hot spots and heat concentration in narrow casings, Heat dissipation by
natural convection and internal air turbulence is recommended.
For thermally critical applications, the total power loss PVtotal can also be deter-
mined as follows:
Current measurement at 24V power supply
Power loss with PVtotal [W] = U (24V) * I (measured in amps).

10.00 24 Heat Dissipation
Calculating power The power loss caused by the components in an operator unit is to be removed
loss PCU 50 by open-circuit ventilation.
The air flow V required for a temperature difference T2 T1 = T 10K must
be calculated.
Example for heat dissipation

with open-circuit ventilation:
PCU 50 with OP 012
Calculating the power loss

(including internal power supply):
OP 012 13W
PCU 50 40W

PVtotal = 53W
T1 T2
(max. 180W)
3.5 * PVtotal [W]

Operator
panel front
PCU V= = 18.6 [m3/h]
T [K]
External temperature = T1 = 45 degrees

Internal temperature = T2 = 55 degrees > T = 10K
Fig. 24-2 Calculating heat dissipation for PCU 50 with OP 012

24 Heat Dissipation 10.00
Notes

Connection Conditions 25
25.1 Electrical boundary conditions
Compliance with The control system is tested with regard to its compliance with the
connection environmental conditions specified below. Trouble-free operation can only be
conditions guaranteed if
S these environmental conditions are satisfied during operation and transport,

S genuine components and spare parts are used. It is particularly important to
ensure that the specified cables and connectors are used.
S the system components are mounted correctly.

The system must not be started up until it has been confirmed that the system
and its components comply with the specifications of the directive 98/37/EC.
Additional References: /EMC/, Description

information
Support and The connection conditions must be satisfied during assembly of the overall
advice system. Please contact your sales partner for support.
Note
Please refer to the documentation for the respective operator components for
information on deviations to the standard connection conditions.

25 Connection Conditions 11.02
10.00
25.1.1 Electromagnetic compatibility (EMC)
Radio interference Applicable standards: EN 50081-1 and -2, EN 55011, EN 55022, EN 61800-3
suppression
Table 25-1 Limit values for radio interference suppression
Limit value according to

Cable-born radio interference suppression Limit class A for use in industrial areas
Interference radiation Limit class A for use in industrial areas
Please contact your sales partner for information on compliance with limit class
B (residential areas).
Note
The system operator must consider the interference radiation with respect to
the system as a whole. It is especially important to consider the cable and
wiring. Please contact your sales partner for support.
Noise immunity Applicable standards: EN 50178, EN 61000-3-2 and -3-3,

EN 61000-6-2, EN 61000-4-2, -3, -4, -5, -6, -8, and -11
EN 61800-3
Tested phenomena:
S static discharge
S radio-frequency radiation
S cable-born interference variables (burst)
S impulse voltages (surge)
S RF energization of cables
S magnetic fields with power frequencies
S voltage dips and interruptions
S voltage fluctuations and flicker
S harmonic currents.

11.02
10.00 25 Connection Conditions
25.1.2 Power supply
Requirements for The alternating current supply is only required for external devices and acces-
alternating current sories and is not part of the standard scope of delivery.
supply
Table 25-2 Requirements for alternating current supply
Rated voltage 230VAC

S Tolerance 20%, +10% (184V to 253V)
S Frequency 50/60Hz 10%

Any
S Ramp-up time at power on
Harmonic content According to EN 50178 10%
Voltage dips
S Voltage interruption at rated voltage and 3 msecs
current
S Recovery time 10 secs
S Events per hour 10
Requirements for
direct current
supplies
Warning
! S The direct current is always referred to ground and must not be generated
using an autotransformer.
S To ensure protective separation of the user interface, the direct current

supply must also have protective separation. See Subsection 25.1.3.
S With supply lines > 10m, protective elements must be provided at the
device input to protect the device against lightening strike (surge).
S For EMC and functional reasons, the direct current supply must be
connected to ground/shield of the NC. For EMC reasons, the connection
should only be made at one position. Usually this connection is already
provided as standard in the S7-300 I/O devices. If in exceptional cases this
is not the case, the ground connection should be made at the grounding rail
of the NC installation cabinet; see also /EMC/ SINUMERIK, SIROTEC,
SIMODRIVE, EMC installation guideline (06.99).

10.00
Table 25-3 Requirements for direct current supply
Rated voltage According to IEC 65A (Co) 22I 24VDC

S Voltage range (mean value) 20.4VDC to 28.8VDC
S Voltage ripple at rated voltage and 5% (unsmoothed 6-pulse rectification)

rated current (peak/peak)
S Ramp-up time at power on Any
Harmonic content According to EN 50178 10%
Non-periodic voltage surge 35V
S Duration of voltage surge 500 msecs
Voltage dips S Duration of voltage dips 5 msecs

25.1.3 Protective separation
The overall system comprises user interfaces (UI) and interfaces for service,
start-up and maintenance.
User interfaces UIs are all interfaces which are freely accessible to the machine operator, i.e. no
(UI) tools or other equipment are required. These user interfaces have protective
separation in accordance with EN 60204-1 and EN 50178.
Interfaces for
service/start-up
and maintenance
Warning
! The interfaces for service, start-up and maintenance purposes do not have
protective separation.
If necessary, these interfaces can be separated using an additional adapter

(insulation voltage 230VAC). These adapters are not part of the Siemens scope
of delivery, but are commercially available. Please contact your sales partner for
advice.

11.02
Warning
! Protective separation can only be guaranteed if the system configuration speci-
fied below is strictly observed. If additional components (e.g. S7-300 FM, IP)
with UIs are installed, it must be ensured that the UIs have at least basic insula-
tion for 230VAC.
3 AC 400V
Mp
Casing / shield 8
MCP MMC
1
4 11 24V M
4 4 11
2
3 HHU
Distributor box 4 6 7

5
840D / 611D Machine
9
10 S7-300 I/O device
10
M
11
5 Human operator Terminal
block
Basic insulation Protective separation
Fig. 25-1 Protective separation
Fig. 25-1 shows the total potential of the 840D/611D/S7-300 system. Legend:
1. Floating current supply of SIMODRIVE electronics with
basic insulation 230VAC
2. Floating transistor controls of AC rectifier jumper with basic insulation
230VAC
3. Floating transistor controls per axis of AC inverter jumpers with basic insula-
tion 230VAC
4. Floating signal connection from NC to MMC or HHU with basic insulation
230VAC
5. Non-floating signal connection between NC and I/I devices
6. Non-floating user interface with protective separation for 230VAC by means
of interfaces 1 to 4 and 7.
7. Separated 5VDC current supply fed from a 24VDC supply unit.

10.00
8. 24VDC current supply for external devices and for machine adaption control
configured according to standard as PELV (Protective Extra Low Voltage)
circuit with protective separation.
9. Floating interfaces to machine (not accessible to user)
10. Floating signal interfaces which are directly accessible to user (e.g.
RS-232-C etc.) With these interfaces, it must always be ensured that either
protective separation or two basic insulation elements (each configured for
230VAC) are provided for the supply voltage.
11. 5VDC current supply with basic insulation, fed from a 24VDC supply unit.
25.1.4 Grounding concept
The grounding concept is described below using a SINUMERIK 840D as an

example. The 840D system consists of several individual components, each of
which must satisfy the EMC requirements and safety standards. The individual
components are:
S NCU box/CCU box

S machine control panel (MCP)
S QWERTY keyboard
S operator panel front components (various monitors with different MMC-
CPUs)
S terminal block (NCU and L2-DP)

S distributor box and handheld unit.
The NCU box is a 50mm wide cassette which is integrated in the system com-
prising I/RF, FDD and MSD.
The individual modules are attached to a metallic cabinet panel using screws. It
is important to note that low-impedance contacting of the NCU box to the cabi-
net panel may occur at the screws. Insulating paints at the connection points
must be removed.
The electronics grounds of the modules are connected to each other via the
device and drive bus, and simultaneously routed to terminal X131 of the I/RF
module.

11.02

Control Power Distribu-

electronics electronics tor box
NCU
EB/PC
Operator panel Machine
MMC
front control panel
EB/PC PC in motor cable

EB/PC GR
Ground (frame)
GR
S
Terminal
S7-300 I/O device
block
M
EB/PC
EB/PC
EB EB
Machine base
Grounding rail GR: Shielded signal cable with ground reference

M: Motor
S: Sensor
Central ground connection EB: Equipotential bonding conductor Cross sections (mm2)
PC: Protective conductor w10
Mains connection S PC min.
S v 16 S
S v S v 35 16
S w 35 S/2
Fig. 25-2 Grounding concept
References: /EMC/ SINUMERIK, SIROTEC, SIMODRIVE

EMC installation guide
25.1.5 Interference suppression measures
Special measures to ensure reliable and trouble-free operation of the system

are required in addition to the measures for protective grounding of the system
components. These special measures include shielded signal cables, and
special equipotential bonding and grounding connections.
Shielded The cables specified in the individual plans must be used to ensure reliable and
signal lines trouble-free operation of the system.
With digital signal transmission, the shield must always be conductively
connected to the casings at both ends.
Exception:
S If external devices are connected (e.g. printers, programming devices),

standard shielded cables with single-ended grounding can also be used.
These devices should, however, not be connected to the control system
during normal operation. If operation is not possible without external
devices, the shields must be connected at both ends. In addition, these
devices must be connected to the control system by means of an
equipotential bonding conductor.

10.00
Line definitions Definition:
S Signal lines (e.g.)

Data lines (MPI, sensor lines, etc.)
Binary inputs and outputs
Emergency stop lines
S Load lines (e.g.)

Low-voltage supply lines (230VAC, +24VDC, etc.)
Feed lines of contactors (primary and secondary circuit)
EMC installation guide
Installation rules In order to achieve the highest possible noise immunity for the overall system
(control system, power module, machine), the following EMC measures must be
observed:
S The greatest possible clearance must be provided between signal and load
lines.
S If necessary, signal and load lines may cross (wherever possible at an angle
of 90), but they should never be installed closely to each other or run
parallel.
S Only use the cables available from the NC manufacturer as signal cables
from and to the NC and PLC.
S Signal lines should not be installed too closely to strong external magnetic
fields (e.g. motors and transformers).
S Pulse-loaded high-current/high-voltage lines must always be installed

completely separated from all other lines.
S If it is not possible to provide adequate clearance between the lines, signal

lines must be installed in shielded cable ducts (metal).
S The distance (interference injection area) between the following lines must
be as small as possible:
signal line and signal line
signal line and associated equipotential bonding conductor
equipotential bonding conductor and its protective conductor.
!
Important
For further information on interference suppression measures and the
connection of shielded cables, see
EMC Installation Guide

11.02
25.2 Climatic and mechanical environmental conditions
25.2.1 Transport and storage conditions
Applicable IEC 68-2-1, IEC 68-2-2, IEC 68-2-3

standards
Components in The following information applies to components in transport packing material:

original packing
material
Table 25-4 Climatic conditions
Temperature range See technical data for respective component

Relative humidity U Annual average U v 75%
Up to 30 days (24 hours) per U v 95%
year
Temperature change Within one hour < 10K
Atmospheric pressure The specified values 66 kPa to 108 kPa
correspond to a transport
altitude of up to 3265 m
above MSL
Table 25-5 Mechanical conditions for transport in original packing material
Vibration load (to IEC Frequency range Const. excursion

68-2-6) 59Hz 3.5mm
Ampl. of acceleration
Above 9200Hz 9.8m/s2
Transporting Backup batteries should only be transported in the original packing material. No
backup batteries special authorization is required for transporting the backup batteries. The
lithium content is approx. 300mg.
Note: According to air freight regulations, the backup battery has Hazardous
Goods Class 9.
Applicable standards: DIN EN 60086(-4)
Warning
! Improper handling of backup batteries can cause the batteries to ignite,
explode or burn.

10.00
Rules for handling The following instructions to DIN EN 60086(-4) must always be observed:
backup batteries
Backup batteries
S Do not charge batteries

S Do not heat or burn batteries
S Do not drill holes in or crush batteries
S Do not mechanically or electrically tamper with batteries in any other way!
Rules for handling The hard disk unit of the MMC unit is fitted with vibration absorbers.
MMC101/102 Nevertheless, it is essential to observe the following rules when handling the
unit:
!
Important
Hard disk unit
S Only transport in its original packing material.
S Do not throw it or subject it to other impacts.
S Do not remove it from the supplied mechanical assembly.
S Do not tamper with the springs used!
25.2.2 Operating conditions
Applicable IEC 60068-2-1, IEC 60068-2-2, IEC 60068-2-3, EN 60721

standards
Climatic If the specified values cannot be observed, a heat exchanger or an air

environmental conditioner must be provided.
conditions
Table 25-6 Climatic environmental conditions
Temperature range See technical data for respective component

Permissible change in within 1 minute max. 0.1%
relative humidity
EN 60721-3-3, Class 3K5
Atmospheric pressure Used at altitude of 1500m 86 kPa to 108 kPa
above MSL. At higher
altitude, upper temperature
limit must be reduced by
3.5C per 500m.

11.02
Table 25-7 Mechanical environmental conditions
Vibration load (to IEC Frequency range Const. excursion

68-2-6) 1058Hz 0.075mm
Ampl. of acceleration
Above 58200Hz 9.8 m/secs2
Shock load (Test Category Acceleration 15 m/secs2
E, Test Ea to IEC 68, Part
227)
Acceleration for screen 2 m/secs2
units
Duration of nominal shock 11 msecs / 30 msecs for
disk drives
Acceleration for disk drive 5 m/secs2
components
Function-
impairing gases Table 25-8 Function-impairing gases
Sulfur dioxide (SO2)

(to IEC 68-2-42) Concentration 10 cm3/m3
Temperature 25C "2C

Relative humidity 75% "5%
Test duration 10 days
Hydrogen sulfide (H2S)

Concentration 1 cm3/m3
(to IEC 68-2-43)
Temperature 25C "2C
Relative humidity 75% "5%
Test duration 10 days
Function-impairing If operated in rooms with function-impairing dust, the control system must be
dust operated in a cabinet with heat exchanger or in a cabinet with a suitable
fresh-air supply.
Maximum permitted dust content of air circulated inside cabinet:
Suspended matter 0.2 mg/m3
Deposit 1.5 mg/m2/h

10.00
25.3 MPI/OPI network rules
Use The MPI bus can be used to connect the following devices together:
S NCU/CCU
S HHU
S MCP
S HPU
S HT 6.
The MPI connecting cables are available in various lengths.
Network The following basic rules must be observed for network installations:
installations
1. The MPI connection can be continued from one node to the next by con-
necting the MPI connector of the outgoing cable to the MPI connector of the
incoming cable.
2. The bus line must be terminated at both ends. For this purpose, switch on
the terminating resistor in the MPI connector of the first and last node; switch
off the other terminating resistors (see Fig. 25-3).
Note
S Only two installed terminators are permitted.
S With HHU / HPU / HT 6, bus terminating resistors are permanently
installed in the device.
3. At least one terminator must be supplied with 5V voltage.

To allow this, the MPI connector with installed terminating resistor must be
connected to a switched-on device.
Note
The connection on the NC control is recommended for this purpose.
4. Spur lines (feed cable from the bus segment to the node) should be as short
as possible.
Note
Unused spur lines should be removed.
5. Each MPI node must be connected first and then activated.

When an MPI node is disconnected, the connection must be deactivated
first and then the connector must be unplugged.
6. A maximum of two of the three components HHU, HPU and HT 6 can be
connected per bus segment.

11.02
It is also possible to connect two components of the same type, provided

that they have different node addresses.
Setting the addresses (see also the chapter for the appropriate component):
HHU: using DIP switches or display (see Chapter Handheld Unit)
HPU and HT 6: by adapting the address prior to start-up (see Chapter
Handheld Programming Unit and Handheld Terminal HT 6).
No bus terminators should be installed at the distributor boxes of a HHU /
HPU or HT 6 (see Note under point 2.).
If necessary, more than one HHU/HPU can be connected to a bus segment
using an intermediate repeater.
7. The following cable lengths for MPI and OPI (standard configuration without
repeater) should not be exceeded:
MPI (187.5 kbaud): max. total cable length 1000m
OPI (1.5 Mbaud): max. total cable length 200m
46 46
O O
N N
55
OFF Terminating resistor ON
Fig. 25-3 MPI connector
References: /Z/, Accessories and Equipment for Special Machines

J

10.00
Notes

Abbreviations A
AS Automation System
AT Advanced Technology
BIOS Basic Input Output System
C bus Communication bus
CDROM Compact Disk Read Only Memory
COM Communications Module
CPU Central Processing Unit
CRT Cathode Ray Tube
CS Chip Select
DIP Dual In-line Package
DKM Direct Key Module
DRAM Dynamic Random Access Memory
EMC ElectroMagnetic Compatibility
GD Global Data
GND Ground
HHU HandHeld Unit
HID Human Interface Device
HMI Human Machine Interface
HU Height Units
IDE Integrated Drive Electronics
ISA Industry Standard Architecture (AT-Standard)

SINUMERIK 840D/840Di/810D Operator Components Manual (BH) 11.02 Edition A-515
A Abbreviations 09.01
10.00
I/O Input/Output
I/Os Peripherals
LCD Liquid Crystal Display
LED Ligth Emitting Diode
LPT Line Print Terminal
MCP Machine Control Panel
MCU Motion Control Unit, Digital Single-Axis/Positioning Control
MFII Multi-Function Keyboard II
MMC Man Machine Communication
MPI Multi Point Interface
NC Numeric Control
NCU Numeric Control Unit
NMI Non-Maskable Interrupt
OP Operator Panel
OPI Operator Panel Interface
P Bus I/O bus
PBP Push Button Panel
PCMCIA Personal Computer Memory Card International Association
PCU PC Unit
PC/XT Personal Computer Extended Technology
PELV Protective Extra Low Voltage
PG Programming Unit
PLC Programmable Logic Controller (component of NC control)
PP031 Pushbutton Panel 031
PS/2 Personal System/2
RS-232-C Interface Standard to CCITT (V.24)
SIM Single in-line Module
SPC Siemens PROFIBUS Controller

A-516 SINUMERIK 840D/840Di/810D Operator Components Manual (BH) 11.02 Edition
09.01
03.96
10.00 A Abbreviations
STN Super Twisted Nematic
TFT Thin Film Transistor
UOP Unit Operator Panel
USB Universal Serial Bus
VGA Video Graphics Adapter
WD Watchdog

SINUMERIK 840D/840Di/810D Operator Components Manual (BH) 11.02 Edition A-517
A Abbreviations 09.01
10.00
Notes

A-518 SINUMERIK 840D/840Di/810D Operator Components Manual (BH) 11.02 Edition
References B
General Documentation
/BU/ SINUMERIK 840D/840Di/810D/802S, C, D

Ordering Information
Catalog NC 60
Order No.: E86060-K4460-A101-A9-7600
/IKPI/ Catalog IK PI 2000

Industrial Communication and Field Devices
Order No. of bound edition: E86060-K6710-A101-A9-7600
Order No. of single-sheet edition: E86060-K6710-A100-A9-7600
/ST7/ SIMATIC
SIMATIC S7 Programmable Logic Controllers
Catalog ST 70
Order No.: E86 060-K4670-A111-A3-7600
/Z/ SINUMERIK, SIROTEC, SIMODRIVE

Accessories and Equipment for Special-Purpose Machines
Catalog NC Z
Order No.: E86060-K4490-A001-A8-7600
Electronic Documentation
/CD1/ The SINUMERIK System (11.02 Edition)

DOC ON CD
(includes all SINUMERIK 840D/840Di/810D/802 and SIMODRIVE publications)
Order No.: 6FC5 298-6CA00-0BG3

SINUMERIK 840D/840Di/810D Operator Components Manual (BH) 11.02 Edition B-519
B References 11.02
10.00
User Documentation
/AUK/ SINUMERIK 840D/810D

Short Guide AutoTurn Operation (09.99 Edition)
Order No.: 6FC5 298-4AA30-0BP2
/AUP/ SINUMERIK 840D/810D

AutoTurn Graphic Programming System (02.02 Edition)
Programming/Setup
/BA/ SINUMERIK 840D/810D

Operators Guide MMC (10.00 Edition)
/BAD/ SINUMERIK 840D/840Di/810D

Operators Guide HMI Advanced (11.02 Edition)
Order No.: 6FC5 298-6AF00-0BP2
/BEM/ SINUMERIK 840D/810D

Operators Guide HMI Embedded (11.02 Edition)
Order No.: 6FC5 298-6AC00-0BP2
/BAH/ SINUMERIK 840D/840Di/810D

Operators Guide HT 6 (06.02 Edition)
Order No.: 6FC5 298-0AD60-0BP2
/BAK/ SINUMERIK 840D/840Di/810D

Short Guide Operation (02.01 Edition)
/BAM/ SINUMERIK 840D/810D

Operation/Programming ManualTurn (08.02 Edition)
/BAS/ SINUMERIK 840D/810D

Operation/Programming ShopMill (11.02 Edition)
/BAT/ SINUMERIK 840D/810D

Operation/Programming ShopTurn (03.03 Edition)

B-520 SINUMERIK 840D/840Di/810D Operator Components Manual (BH) 11.02 Edition
11.02
10.00 B References
/BNM/ SINUMERIK 840D/840Di/810D

Users Guide Measuring Cycles (11.02 Edition)
/CAD/ SINUMERIK 840D/840Di/810D

Operators Guide CAD Reader (03.02 Edition)
Order No.: (included in online help)
/DA/ SINUMERIK 840D/840Di/810D

Diagnostics Guide (11.02 Edition)
/KAM/ SINUMERIK 840D/810D

Short Guide ManualTurn (04.01 Edition)
/KAS/ SINUMERIK 840D/810D

Short Guide ShopMill (04.01 Edition)
/KAT/ SINUMERIK 840D/810D

Short Guide ShopTurn (07.01 Edition)
/PG/ SINUMERIK 840D/840Di/810D

Programming Guide Fundamentals (11.02 Edition)
Order No.: 6FC5 298-6AB00-0BP2
/PGA/ SINUMERIK 840D/840Di/810D

Programming Guide Advanced (11.02 Edition)
/PGK/ SINUMERIK 840D/840Di/810D

Short Guide Programming (02.01 Edition)
/PGM/ SINUMERIK 840D/840Di/810D

Programming Guide ISO Milling (11.02 Edition)
/PGT/ SINUMERIK 840D/840Di/810D

Programming Guide ISO Turning (11.02 Edition)

B References 11.02
10.00
/PGZ/ SINUMERIK 840D/840Di/810D

Programming Guide Cycles (11.02 Edition)
/PI/ PCIN 4.4

Software for Data Transfer to/from MMC Module
Order No.: 6FX2 060 4AA00-4XB0 (English, French, German)
Order from: WK Frth
/SYI/ SINUMERIK 840Di

System Overview (02.01 Edition)
Order No.: 6FC5 298-6AE40-0BP0
Manufacturer/Service Documentation
a) Lists
/LIS/ SINUMERIK 840D/840Di/810D

SIMODRIVE 611D
Lists (11.02 Edition)
b) Hardware
/BH/ SINUMERIK 840D/840Di/810D

Operator Components Manual (HW) (11.02 Edition)
/BHA/ SIMODRIVE Sensor

Absolute Position Sensor with Profibus-DP
Users Guide (HW) (02.99 Edition)
Order No.: 6SN1197-0AB10-0YP1
/EMV/ SINUMERIK, SIROTEC, SIMODRIVE

EMC Installation Guide
Planning Guide (HW) (06.99 Edition)
/GHA/ ADI4 Analog Drive Interface for 4 Axes

Manual (09.02 Edition)
Order No.: 6FC5 297-0BA01-0BP0

11.02
10.00 B References
/PHC/ SINUMERIK 810D

Configuring Manual (HW) (03.02 Edition)
/PHD/ SINUMERIK 840D

Configuring Manual NCU 561.2-573.4 (HW) (10.02 Edition)
/PMH/ SIMODRIVE Sensor

Hollow-Shaft Measuring System SIMAG H
Configuring/Installation Guide (HW) (07.02 Edition)
Order No.: 6SN1197-0AB30-0BP1
c) Software
/FB1/ SINUMERIK 840D/840Di/810D

Description of Functions, Basic Machine (Part 1) (11.02 Edition)
(the various sections are listed below)
A2 Various Interface Signals
A3 Axis Monitoring, Protection Zones
B1 Continuous Path Mode, Exact Stop and Look Ahead
B2 Acceleration
D1 Diagnostic Tools
D2 Interactive Programming
F1 Travel to Fixed Stop
G2 Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control
H2 Output of Auxiliary Functions to PLC
K1 Mode Group, Channel, Program Operation Mode
K2 Axes, Coordinate Systems, Frames,
Actual-Value System for Workpiece, External Zero Offset
K4 Communication
N2 EMERGENCY STOP
P1 Transverse Axes
P3 Basic PLC Program
R1 Reference Point Approach
S1 Spindles
V1 Feeds
W1 Tool Offset
/FB2/ SINUMERIK 840D/840Di/810D(CCU2)

Description of Functions, Extended Functions (Part 2) (11.02 Edition)
including FM-NC: Turning, Stepper Motor
A4 Digital and Analog NCK I/Os
B3 Several Operator Panels and NCUs
B4 Operation via PG/PC
F3 Remote Diagnostics
H1 JOG with/without Handwheel
K3 Compensations

B References 11.02
10.00
K5 Mode Groups, Channels, Axis Replacement

L1 FM-NC Local Bus
M1 Kinematic Transformation
M5 Measurement
N3 Software Cams, Position Switching Signals
N4 Punching and Nibbling
P2 Positioning Axes
P5 Oscillation
R2 Rotary Axes
S3 Synchronous Spindles
S5 Synchronized Actions (up to and including SW 3)
S6 Stepper Motor Control
S7 Memory Configuration
T1 Indexing Axes
W3 Tool Change
W4 Grinding
/FB3/ SINUMERIK 840D/840Di/810D(CCU2)

Description of Functions, Special Functions (Part 3) (11.02 Edition)
F2 3-Axis to 5-Axis Transformation
G1 Gantry Axes
G3 Cycle Times
K6 Contour Tunnel Monitoring
M3 Coupled Motion and Leading Value Coupling
S8 Constant Workpiece Speed for Centerless Grinding
T3 Tangential Control
TE0 Installation and Activation of Compile Cycles
TE1 Clearance Control
TE2 Analog Axis
TE3 Master-Slave for Drives
TE4 Transformation Package Handling
TE5 Setpoint Exchange
TE6 MCS Coupling
TE7 Retrace Support
TE8 Path-Synchronous Switch Signal
V2 Preprocessing
W5 3D Tool Radius Compensation
/FBA/ SIMODRIVE 611D/SINUMERIK 840D/810D

Description of Functions Drive Functions (11.02 Edition)
Order No.: 6SN1 197-0AA80-0BP9
DB1 Operational Messages/Alarm Reactions
DD1 Diagnostic Functions
DD2 Speed Control Loop
DE1 Extended Drive Functions
DF1 Enable Commands
DG1 Encoder Parameterization
DL1 Linear Motor MD
DM1 Calculation of Motor/Power Section Parameters and
Controller Data
DS1 Current Control Loop
D1 Monitors/Limitations

11.02
10.00 B References
/FBAN/ SINUMERIK 840D/SIMODRIVE 611 digital

Description of Functions
ANA MODULE (02.00 Edition)
Order No.: 6SN1 197-0AB80-0BP0
/FBD/ SINUMERIK 840D

Description of Functions Digitizing (07.99 Edition)
DI1 Start-up
DI2 Scanning with Tactile Sensors (scancad scan)
DI3 Scanning with Lasers (scancad laser)
DI4 Milling Program Generation (scancad mill)
/FBDN/ IT Solutions
System for NC Data Management and Data
Distribution (DNC NT-2000) (01.02 Edition)
/FBDT/ SINUMERIK 840D/840Di/810D

IT Solutions
Sin DNC NC Data Transfer via Network (09.02 Edition)
/FBFA/ SINUMERIK 840D/840Di/810D

ISO Dialects for SINUMERIK (11.02 Edition)
/FBFE/ SINUMERIK 840D/840Di/810D

Description of Functions Remote Diagnosis (11.02 Edition)
/FBH/ SINUMERIK 840D/840Di/810D

HMI Configuring Package (11.02 Edition)
Order No.: (supplied with the software)
Part 1 Users Guide

Part 2 Description of Functions
/FBHLA/ SINUMERIK 840D/SIMODRIVE 611 digital

Description of Functions HLA Module (04.00 Edition)
/FBMA/ SINUMERIK 840D/810D

Description of Functions ManualTurn (08.02 Edition)

B References 11.02
10.00
/FBO/ SINUMERIK 840D/810D

Configuring OP 030 Operator Interface (09.01 Edition)
BA Operators Guide
EU Development Environment (Configuring Package)
PS Online only: Configuring Syntax (Configuring Package)
PSE Introduction to Configuring of Operator Interface
IK Screen Kit: Software Update and Configuration
/FBP/ SINUMERIK 840D

Description of Functions C-PLC Programming (03.96 Edition)
/FBR/ SINUMERIK 840D/810D

IT Solutions
Description of Functions Computer Link (SinCOM) (09.01 Edition)
NFL Host Computer Interface
NPL PLC/NCK Interface
/FBSI/ SINUMERIK 840D / SIMODRIVE 611 digital (09.02 Edition)

Description of Functions SINUMERIK Safety Integrated
/FBSP/ SINUMERIK 840D/810D

Description of Functions ShopMill (11.02 Edition)
/FBST/ SIMATIC (01.01 Edition)

Description of Functions FM STEPDRIVE/SIMOSTEP
Order No.: 6SN1 197-0AA70-0YP4
/FBSY/ SINUMERIK 840D/840Di/810D

Description of Functions Synchronized Actions (10.02 Edition)
/FBT/ SINUMERIK 840D/810D

Description of Functions ShopTurn (03.03 Edition)
/FBTC/ SINUMERIK 840D/810D

IT Solutions
SINUMERIK Tool Data Communication SinTDC (01.02 Edition)

11.02
10.00 B References
/FBTD/ SINUMERIK 840D/810D

IT Solutions
Tool Information System (SinTDI) with Online Help
Description of Functions (02.01 Edition)
/FBU/ SIMODRIVE 611 universal/universal E

Closed-Loop Control Component for Speed Control and Positioning
Description of Functions (02.02 Edition)
/FBW/ SINUMERIK 840D/840Di/810D

Description of Functions Tool Management (10.02 Edition)
/FBWI/ SINUMERIK 840D/840Di/810D

Description of Functions WinTPM (02.02 Edition)
Order No.: The document is an integral part of the software
/HBA/ SINUMERIK 840D/840Di/810D

Manual @Event (03.02 Edition)
Order No.: 6AU1900-0CL20-0BA0
/HBI/ SINUMERIK 840Di

Manual (09.02 Edition)
/INC/ SINUMERIK 840D/840Di/810D

Commissioning Tool SINUMERIK SinuCOM NC (02.02 Edition)
System Description
Order No.: (an integral part of the online help for the start-up tool)
/PAP/ SIMODRIVE Sensor

Absolute Encoder with Profibus-DP
Users Guide (02.99 Edition)
Order No.: 6SN1197-0AB10-0YP1
/PFK/ SIMODRIVE
Planning Guide 1FT5, 1FT6, 1FK6 Motors (12.01 Edition)
AC servo motors for feed and main spindle drives
Order No.: 6SN1 197-0AC20-0BP0

B References 11.02
10.00
/PJE/ SINUMERIK 840D/810D

Configuring Package HMI Embedded (08.01 Edition)
Description of Functions: Software Update, Configuration Installation
Order No.: 6FC5 297-6EA10-0BP0
(the document PS Configuring Syntax is supplied with the software
and available as a pdf file)
/PJFE/ SIMODRIVE
Planning Guide 1FE1 Built-In Synchronous Motors
Three-Phase AC Motors for Main Spindle Drives (09.01 Edition)
/PJLM/ SIMODRIVE
Planning Guide 1FN1, 1FN3 Linear Motors (11.01 Edition)
ALL General Information about Linear Motors
1FN1 1FN1 Three-Phase AC Linear Motor
1FN3 1FN3 Three-Phase AC Linear Motor
CON Connections
/PJM/ SIMODRIVE
Planning Guide Motors (11.00 Edition)
Three-Phase AC Motors for Feed and Main Spindle Drives
/PJTM/ SIMODRIVE
Planning Guide Integrated Torque Motors 1FW6 (08.02 Edition)
Order No.: 6SN1 197-0AD00-0BP0
/PJU/ SIMODRIVE 611

Planning Guide Inverters (05.01 Edition)
/PMS/ SIMODRIVE (04.02 Edition)

Planning Guide ECO Motor Spindle for Main Spindle Drives
/POS1/ SIMODRIVE POSMO A (08.02 Edition)

Distributed Positioning Motor on PROFIBUS DP, Users Guide
Order No.: 6SN2197-0AA00-0BP3
/POS2/ SIMODRIVE POSMO A

Installation Instructions (enclosed with POSMO A)
/POS3/ SIMODRIVE POSMO SI/CD/CA (08.02 Edition)

Distributed Servo Drive Systems, Users Guide
Order No.: 6SN2197-0AA20-0BP3

11.02
10.00 B References
/PPH/ SIMODRIVE
Planning Guide 1PH2, 1PH4, 1PH7 Motors (12.01 Edition)
AC Induction Motors for Main Spindle Drives
/PPM/ SIMODRIVE
Planning Guide Hollow-Shaft Motors (10.01 Edition)
for 1PM4 and 1PM6 Main Spindle Drives
/S7H/ SIMATIC S7300 (2002 Edition)

Manual: CPU Data (Hardware)
Reference Manual: Module Data
Manual: Technological Functions
Installation Manual
Order No.: 6ES7 398-8FA10-8BA0
/S7HT/ SIMATIC S7300 (03.97 Edition)

Manual STEP7, Fundamentals, V. 3.1
Order No.: 6ES7 810-4CA02-8BA0
/S7HR/ SIMATIC S7300 (03.97 Edition)

Manual STEP7, Reference Manuals, V. 3.1
Order No.: 6ES7 810-4CA02-8AR0
/S7S/ SIMATIC S7300 (04.97 Edition)

FM 353 Positioning Module for Stepper Drive
Order together with configuring package
/S7L/ SIMATIC S7300 (04.97 Edition)

FM 354 Positioning Module for Servo Drive
/S7M/ SIMATIC S7300 (01.01 Edition)

FM 357.2 Multimodule for Servo and Stepper Drives
/SP/ SIMODRIVE 611A/611D,

SimoPro 3.1
Program for Configuring Machine-Tool Drives
Order No.: 6SC6 111-6PC00-0BAj, Order from: WK Frth

B References 11.02
10.00
d) Installation and
Start-Up
/IAA/ SIMODRIVE 611A

Installation and Start-Up Guide (10.00 Edition)
Order No.: 6SN 1197-0AA60-0BP6
/IAC/ SINUMERIK 810D

(incl. description of SIMODRIVE 611D start-up software)
/IAD/ SINUMERIK 840D/SIMODRIVE 611D

(incl. description of SIMODRIVE 611D start-up software)
/IAM/ SINUMERIK 840D/840Di/810D

HMI/MMC Installation and Start-Up Guide (11.02 Edition)
AE1 Updates/Supplements
BE1 Expanding the Operator Interface
HE1 Online Help
IM2 Starting up HMI Embedded
IM4 Starting up HMI Advanced
TX1 Creating Foreign Language Texts

Index C
Numbers Auxiliary mounting plate, 2-45, 2-46
15 TFT
Communication, 10-156
Function blocks, 10-158 B
Functional description, 10-158 Backlight, 2-47, 3-77, 4-87, 6-116, 7-128, 8-139,
Heat dissipation, 10-193 9-152
Interface, 10-162 Backlight inverter, 3-77, 4-87, 6-116, 7-128,
Mechanical design, 10-176 8-139, 9-152
Mounting, 10-182 Backup battery, 12-222, 12-226, 12-227, 13-248
Operator panel front, 10-156, 10-159 Rules, 25-510
Overview, 10-155 Transporting, 25-509
Spare parts, 10-188 Battery
System features, 10-156 Changing, 12-226
Technical data, 10-192 Clip, 12-227
24V power supply, 12-210, 13-243, 14-256, Plug, 12-227
20-423 Voltage, 12-226
Battery connector, 12-233
Battery replacement, 12-226
A BIOS
Default settings, 12-234
Abbreviations, A-515 Parameters, 12-234
Actuation field, 6-105, 9-144 Settings, 12-226
Aggressive gases, 2-47, 2-51, 4-90, 7-131, 8-142, Settings, changing, 12-237
9-154 Setup, 12-237
Aggressive gases, 5-101, 6-119 BIOS, Setup, 12-237
Alarm, key, 2-34 Board retainer, 12-227, 12-233
Alpha key group, 3-66, 3-67, 5-92, 5-93, 6-104, Boot
6-105, 9-144 Manager, 12-234
Alternating current supply, 25-503 Sequence, 12-237
Aluminum front panel, 1-21 Booting the system, 12-229, 12-234
Anti-rotation element, 12-229 Boundary conditions, electrical, 25-501
Approval, 13-250
Approvals, 11-205, 12-238
Area switchover, 4-82, 5-92, 6-104, 8-134, 9-144
key, 3-66 C
Assembly, panel, 3-74, 5-98, 6-113, 11-203 Cable connector, 3-72
AT module, 12-231 Cable connectors, 4-85, 5-97, 6-109, 7-125,
AT/PCI specification, 12-230 8-136, 9-147
Atmospheric pressure, 25-510 Cable set, 2-54
Attachment, 3-65, 4-81, 5-91, 6-103, 7-121, Cardbus, 12-220
8-133, 9-143

SINUMERIK 840D/840Di/810D Operator Components Manual (BH) 11.02 Edition Index-531
11.02
10.00
Casing color, 1-29 D

Casing cover screws, 12-209, 12-225, 13-242
Central operator panel front, 14-266 Data Carrier Detect, 1-23
Chip extractor, 2-53 Data memory, 20-415
Clamps, 3-65, 4-81, 5-91, 6-103, 7-121, 8-133, Data Send Ready, 1-23
9-143 Data Terminal Ready, 1-23
Clear To Send, 1-23 DC/DC converter, 20-416
Clearance, 1-27, 2-31, 2-39, 2-49, 3-75, 5-99, Decimal point, 3-67, 5-93, 6-105, 9-144
6-114, 7-127, 9-150, 11-203, 12-218, 13-246 Degree of protection, 3-73, 3-80, 4-84, 4-90,
Climatic conditions, 3-80, 4-90, 5-101, 6-119, 5-101, 6-113, 6-119, 7-126, 7-131, 8-137,
7-131, 8-142, 9-154, 25-509 8-142, 9-149, 9-154, 11-205, 12-238, 13-250
Climatic environmental conditions, 25-509, Description of control elements
25-510 Axis selection switch, 22-464
CNC keyboard, 2-31, 2-42, 2-44, 2-45, 2-48 Function keys, 22-464
CNC keyboard XT/AT, 17-391 Handwheel, 22-464
COM1, 11-197, 12-210, 13-243 Rapid traverse button, 22-464
Interface, 11-200, 12-212 Traversing keys, 22-464
COM1/RS232C, 12-210, 13-243 Description of the control elements, enabling but-
COM2, 12-210, 13-243 ton, 22-464
Interface, 12-213 Desk-type arrangement, 2-45, 2-46
Components, 7-128 Device fan, 12-211, 12-224, 12-226, 14-265,
Condensation, 3-80, 4-90, 5-101, 6-119, 7-131, 14-269
8-142, 9-154 Cable, 12-225
Configuring machine control panel, 20-436 Changing, 12-225
Connecting plate, 12-233 Connection, 12-227
Connection, 20-423 Dial, 2-53
Connection cable, 11-204, 12-219, 13-247 Dimensions, 3-80, 4-90, 5-101, 6-119, 7-131,
Connection conditions, 25-501 8-142, 9-154, 11-205, 12-238, 13-250
Contact change, 15-327 DIMM, 12-229, 13-249
Contact problems, 12-231 DIN-A4 film, 3-76, 6-115
Control cabinet, 14-268 DIP switch S2, 14-264
Control elements, 15-302 Direct control key
Control key group, 3-66, 3-67, 5-92, 5-93, 6-104, Connection, 6-109, 9-147
6-105, 9-144 Submodule, 6-116
Control parameters, 3-78, 6-117, 7-129 Direct control key submodule, 6-110, 9-148,
Control states, 6-108, 9-146 9-152
Convection surface area, 10-193 Direct control keys, 6-103, 6-108, 9-143, 9-146
Cover plate, 3-72, 4-85, 5-97, 6-107, 6-109, vertical, 6-108, 9-146
8-136, 9-145, 9-147, 12-210, 13-243, 14-268 Direct current supplies, 25-503
Current Direction keys, 20-417
CNC keyboard, typical, 2-51 Disk A, 12-234
Total current, 1-29 Dismantling, 14-267
Cursor key group, 1-21, 1-22, 3-66, 3-67, 5-92, Display
5-93, 6-104, 6-105, 9-144 Cable K2, 3-69, 3-72, 3-73, 4-83, 4-85, 5-95,
Cursor keys, 12-237 5-97, 6-107, 6-109, 7-123, 7-125, 8-135,
Customer operator panel, 20-429 8-136, 9-145, 9-147
Assignments, 20-434 Holder, 3-77
Bus address, 20-435 Interface, 3-69, 4-83, 5-95, 6-107, 7-123,
Digital inputs/outputs, 20-430 8-135, 9-145
Interfaces, 20-429 Interface (LVDS), 11-202, 12-215, 12-216
LEDs, 20-433 Module, 2-45
MPI interface, 20-429, 20-430 Setting, 14-263
Power supply interface, 20-429 Display support plate, 6-109, 9-147
Receipt cycle time, 20-435 Display switch S1, 14-269
Transmission cycle time, 20-435 Display type, 14-263
Distributed installation, 14-256

Index-532 SINUMERIK 840D/840Di/810D Operator Components Manual (BH) 11.02 Edition
11.02
10.00
Distributor box, interface, 21-445 Dimension drawing, 19-409

Drive, connection, 12-228, 13-248 Dimension drawing, blanking plate, 19-413
Drive holder, 12-223 External, 13-248
Dust, 11-203, 12-218, 13-246 Front view, 19-409
Function-impairing, 25-511 Function, 19-409
Installation, 19-411
Panel cutout, 19-411
Plan view, 19-410
E Power supply interface, 19-410
EIDE, 12-238, 13-250 Rear view, 19-410
Electrical boundary conditions, 25-501 Side view, 19-409
Electrical isolation, 20-415 Technical data, 19-412
Electromagnetic compatibility, 25-502 Front, panel cutout, 2-41, 2-50
EMC, 25-502 Front panel, 7-128
EMC compatibility, 3-69, 4-83, 5-95, 6-107, 7-123, Front plate, 4-87, 6-116, 8-139, 9-152, 12-210,
8-135, 9-145 13-243
Emergency button S13, 16-343 Function-impairing dust, 25-511
EMERGENCY STOP, 2-52, 2-53, 2-55, 20-417, Function-impairing gases, 25-511
20-418
Emergency stop, 10-156, 15-281, 16-339, 22-464
Environmental conditions, 11-203, 12-218, 13-246
Equipotential bonding, 2-37
G
Escape key, 12-237 Gases, function-impairing, 25-511
ETC key, 3-66, 4-82, 5-92, 6-104, 8-134, 9-144 Ground connection, 12-211, 13-244
Ethernet, 11-195, 11-197, 12-208, 12-210, Grounding concept, 25-506
13-241, 13-243 Grounding connector, 2-49
Interface, 11-201, 12-215 Guide rail, 12-232, 12-233
Exit menu, 12-237
Expansion board, 12-210, 12-228, 12-230,
12-233, 13-243, 13-248
Expansion slots, 12-238, 13-250
H
Extender, 12-232 Handheld programming unit
External Cable interface, 23-475
Floppy disk drive, 12-211, 12-228, 13-244, Connecting, 23-489
13-248 Connecting and disconnecting during opera-
External keyboard, 3-69, 4-83, 5-95, 6-107, tion, 23-486
8-135, 9-145 Disconnecting, 23-489
External monitor, 12-210, 13-243 Distributor box, 23-479
Extruded hole, 2-50 Distributor box for 3-core enabling, 23-479
Distributor box for 4-core enabling, 23-482
Function blocks, 23-472
Input signals, 23-490
F Interface signals, 23-490
F2 key, 12-237 Output signals, 23-491
Fan, 12-233, 13-244 Parameterization of basic PLC program,
Connection, 12-227 23-492
Fastening hole, 2-45 RS-232 interface, 23-476
Fastening screws, 3-76, 6-115, 9-151 Technical data, 23-495
Feedrate control, 20-417 Handheld terminal, 23-471
Feedrate override switch, 2-52 Handheld unit, 21-437
Film, 6-115 ASCII code, 21-455
Film for soft key labels, 3-76 Block diagram, 21-439
Fire protection, 11-195, 11-203 Changing labeling strip, 21-438
Firmware, 6-108, 9-146 Connecting, 21-442
Flash card, 11-197 Control and display elements, 21-437
Flat mounting, 14-265, 14-268 Control elements, 21-444
Floppy check, 12-234 Digital display, 21-453
Floppy disk drive, 3-65, 4-81, 5-91, 6-103, 8-133, DIP switch, 21-448
12-211, 13-244, 19-409 Disconnecting, 21-442
Connection, 19-412 Distributor box, 21-457

11.02
10.00
Distributor box, connection, 21-439 Industrial use, designed for, 11-204, 12-219,
Enabling buttons, 21-445 13-247
GD parameters, 21-449 Initialization, 15-320
Handwheel, 21-445 Input key, 12-234, 12-237
Input image, 21-451 Insert nut, 2-41, 2-50
Interface signals, 21-450 Installation, 7-126, 8-137, 9-150, 12-207, 13-246
Keyswitch, 21-445, 21-451 Intake air, 2-51
LED, 21-445 Interconnecting cables, 12-219, 13-247
Magnetic clamp, 21-438 Interface, 10-160, 10-162, 15-314
Operating several, 21-443 Pin assignment, 14-261
Operation, 21-440 Interfaces, 4-83, 5-95, 6-107, 8-135, 9-145,
Output image, 21-452 12-207, 13-241, 14-260, 15-284
Override switch, 21-445 Interference suppression measures, 25-507
PLC module, 21-450 IO USB cable, 12-211, 13-245
Rotary selector settings, 21-451 IO/USB cable K1, 4-85, 7-125, 8-136
Signal chart, 21-454 ISA
Spare parts, 21-461 Module, 12-232
Spare parts, 22-469 Slot, 12-238, 13-250
Technical data, 21-446 ISA/PCI
User interface, 21-450 Adapter, 2-31, 2-41, 2-44, 2-49, 2-50
Handheld unit connection, 15-296 Card, 2-49
Hard disk, 12-219, 13-247, 14-268 ISA/PCI plug-in card, 2-43
Changing, 12-222
Hard disk connection, 12-222
Hard disk drive, 12-209, 12-222, 12-223, 12-238,
13-250
K
Hard disk holder, 12-222 K1, 4-83, 5-95, 6-107, 7-123, 8-135, 9-145
Hard disk module, 13-242 K2, 4-83, 5-95, 6-107, 7-123, 8-135, 9-145
Hardware clock, 12-226 Key cap, 2-52
Hardware reset, 11-199, 12-211, 13-244 Key symbols, 21-438
Heat, 11-203, 12-218, 13-246 Keyboard, 12-210, 12-219, 13-243, 13-247,
Heat dissipation, 1-28, 3-80, 4-90, 5-101, 6-119, 14-264, 20-416
7-131, 8-142, 9-154, 11-205, 12-238, 13-250, Keyboard, controller, 3-77
14-265, 24-497 Keyboard controller, 3-72, 3-77, 3-78, 4-87, 6-116,
Help, key, 2-34 6-117, 7-128, 7-129, 8-139, 9-152
Hinge bolt, 14-266 Keyswitch, 2-52, 2-54, 20-417, 20-418
Hollow rivet, 12-225 Knurled screws, 3-73, 5-97, 6-109, 7-125, 8-136,
Hotkey group, 3-66 9-147
Hotkeys, 5-92
HT 6
Connecting cable, 23-476
PC card interface, 23-477
L
PS/2 keyboard interface, 23-478 LAN, 11-197, 12-210, 13-243
Threaded bushes, 23-475 Laser printer, 3-76, 6-115
User interface, 23-473 LCD, unit, 9-152
Humidity, 11-203, 12-218, 13-246 LCD unit, 3-77, 4-87, 6-116, 8-139
LEDs, 10-173, 20-416, 20-418
Lithium battery, 12-226
Local area network, 11-197, 12-210, 13-243
I Locking, 12-229
I/O devices, 3-69, 4-83, 5-95, 6-107, 7-123, Low current USB, 3-70, 4-83, 5-96, 6-108, 7-124,
8-135, 9-145, 11-204, 12-219, 13-247 8-135, 9-146
I/O USB cable K1, 3-69, 3-72, 4-83, 5-95, 5-97, LPT1, 12-210, 13-243
6-107, 6-109, 7-123, 8-135, 9-145, 9-147 LPT mode, 12-237
IAM, 12-229, 12-234 Interface, 12-207, 12-212, 13-241
Inclined position, 11-203, 12-219, 13-246 Lumotast, 2-54
Individual wiring, 15-301 LVDS, 11-195, 13-241
Industrial, use, 3-69, 4-83, 5-95, 6-107, 7-123, LVDS interface, 12-211, 13-245
8-135, 9-145

11.02
10.00
M Minimum mounting depth, 2-40

MMC-CPU, 2-31, 2-48
M-version, 20-417 Monitor, 12-208, 13-241
Machine, area, 4-82, 5-92, 6-104, 8-134, 9-144 Mother board, 12-223, 12-227
Machine area, key, 3-66 Mounting, 11-199, 12-211, 13-245
Machine control panel, 2-31, 20-415 Depth, 3-65, 4-81, 5-91, 6-103, 7-121, 8-133,
24V supply, 20-423 9-143
Assignments, 20-424 Format, 4-81
Block diagram, 20-416 PCU, 14-265
Bus address, 20-425 Position, 2-39, 11-203
Control elements, 20-417, 20-418 Rail, 3-72, 3-75, 5-97, 5-99, 6-109, 6-114,
Dimension drawing, 20-421 8-136, 9-147, 9-150, 11-199
Function blocks, 20-415 Videolink receiver, 14-272
Interface parameters, 20-436 Mounting bracket, 7-125, 7-127, 9-152, 14-266
Interfaces, 20-419 Mounting position, 1-27, 14-265
Mounting, 20-421 Mounting screw, 14-267
MPI connection, 20-423 Mounting slot, 14-269
Operator panel interface, 20-420 Mouse, 6-104, 6-105, 6-116, 9-144, 9-152,
Power supply interface, 20-420 12-210, 12-219, 13-243, 13-247, 14-264
Receipt cycle time, 20-424 Mouse plug, 12-210, 13-243
Technical data, 20-426 MPI, 2-32
Transmission cycle time, 20-424 Cable, 2-32
Main board, 12-226 Connection, 15-301
Mains Module, 12-214
Cable, 12-227 MPI/DP, 12-210, 13-243
Switch, 11-204, 12-220, 13-247 Interface, 11-201, 12-208, 12-214, 13-241
Malfunction, 12-231 MPI/L2-DP, interface, 11-195
MCP, 10-177 MPI/L2-DP, 11-197
MCP OP 032S, function block, 2-64 MPI/OPI network rules, 25-512
Mechanical environmental conditions, 25-511
Membrane keyboard, 1-21, 3-65, 6-103, 8-133,
9-143
Memory Cache, 12-234 N
Memory capacity, 12-230 Natural convection, 3-80, 4-90, 5-101, 6-119,
Memory configuration, 12-229 7-131, 8-142, 9-154, 10-193
Memory expansion, 12-228, 12-229, 13-248, Noise, 12-238, 13-250
13-249 Noise immunity, 25-502
Memory extension, installation, 13-249 Noise immunity of overall system, 25-508
Memory modules, 12-229 Numerical key group, 1-21, 1-22, 3-66, 3-67,
Menu, 12-234 5-92, 5-93, 6-104, 6-105, 9-144
MFII interface, 2-48
MFII keyboard, 17-391
Microcontroller, 20-415
Milling machine, 20-417 O
Mini DIN connector, 2-48 OEM agreement, 12-231, 12-237
Mini handheld unit OP 010
Axis selection switch, 22-466 Brief description, 3-65
Circuit diagram, 22-465 Front panel, 3-77
Coding of axis selection switch, 22-466 Front view, 3-66
Configuration, 22-466 Installation, 3-71, 3-75
Connection, 22-467 Interface assignment, 3-70
Control elements, 22-463 Interfaces, 3-69
Description of control elements, 22-464 Keyboard, 3-67
Dimensions, 22-463 Mounting preparation, 3-73
Dimensions of flange socket, 22-467 Soft key designation, 3-76
Sample circuit, 22-465 Spare part replacement, 3-78
Technical data, 22-468 Spare parts, 3-77
Mini HHU connection Technical data, 3-80
Connection kit, 22-467 OP 010 S, 14-272
Handwheel signals, 22-467

11.02
10.00
OP 010C Front view, 1-26

Assignment, 5-96 Function blocks, 1-21
Brief description, 5-91 Installation, 1-27
Front view, 5-92 Interfaces, 1-22
Installation, 5-97, 5-98 Operator panel interface, 1-24
Interfaces, 5-95 Panel cutout, 1-28
Keyboard, 5-93 Power supply, 1-25
Mounting preparation, 5-98 Rear view, 1-26
Spare parts, 5-100 Serial RS232C interface, 1-23
Technical data, 5-101 Side view, 1-27
OP 010S Technical data, 1-29
Assignment, 4-83 OP 032S, 2-31
Brief description, 4-81 Casing color, 2-47
Installation, 4-84 CNC keyboard, 2-48
Interfaces, 4-83 CNC keyboard connection, 2-48
Spare part replacement, 4-87 CNC keyboard dimension drawing, 2-50
Spare parts, 4-87 CNC keyboard function blocks, 2-48
Spare parts list, 4-87 CNC keyboard mounting instructions, 2-49
Technical data, 4-90 CNC keyboard panel cutout, 2-50
User interface, 4-82 Control elements, 2-37, 2-52
OP 012, 11-203 Dimension drawing, 2-40
Assignment, 6-108 Dimension drawing of machine control panel,
Brief description, 6-103 2-60
Front view, 6-104 Dimensions, 2-47, 2-51
Installation, 6-109, 6-113 Function blocks, 2-36
Installation preparation, 6-113 Function blocks, machine control panel, 2-52
Interfaces, 6-107 Input signals of machine control panel, 2-62
Keyboard, 6-105 ISA/PCI adapter, 2-42
Soft key designation, 6-115 ISA/PCI adapter, mounting, 2-44
Spare part replacement, 6-117 Machine control panel, 2-52
Spare parts, 6-116 Machine control panel interfaces, 2-56
Spare parts list, 6-116 MMC installation, 2-38
Technical data, 6-119 Mounting instructions, 2-39
OP 015 Operator components, 2-31
Assembly, 8-136 Output signals of machine control panel, 2-62
Assignment, 8-135 Overview of connections, 2-32
Brief description, 8-133 Panel cutout, 2-41
Installation, 8-136 Panel cutout of machine control panel, 2-61
Interfaces, 8-135 Power loss, 2-47
Mounting preparation, 8-137 Power supply interface, 2-38
Spare part replacement, 8-139 Relative humidity, 2-47
Spare parts, 8-139 Service life, 2-47
Spare parts list, 8-139 Technical data, 2-47
Technical data, 8-142 Technical data for CNC keyboard, 2-51
OP 015A Technical data for machine control panel, 2-64
Assembly, 9-147 Temperature ranges, 2-47
Assignment, 9-146 Temperature variation, 2-47
Brief description, 9-143 Total current, 2-47
Front view, 9-144 OP015, user interface, 8-134
Installation, 9-147 Operating conditions, 25-510
Installation preparation, 9-149 Operating modes, 20-417
Interfaces, 9-145 Operating system, 11-205, 12-207, 13-241
Keyboard, 9-144 Operator panel, 14-256
Soft key designation, 9-151 Interface, 20-415
Spare parts, 9-152 Operator panel front, 9-152, 10-156, 11-203,
Spare parts list, 9-152 14-264
OP 015S, technical data, 9-154 OPI, 2-32
OP 030, 1-21 Optional customer-specific keys, 2-52
Control elements, 1-22 Opto-isolated inputs, 6-108, 9-146
Dimension drawing, 1-26 Order No., 3-77, 4-87, 6-116, 7-128, 8-139

11.02
10.00
Order number, 9-152, 10-156, 12-222, 13-248 PCU 70, 13-241

Overall length, 12-231 Accessories, 13-248
Override switch, 2-53, 2-54, 2-55 Connections, 13-243
Expansion boards, 13-249
Installation, 13-246
Interface, 13-243
P Mounting, 13-246
Panel, cutout, 1-28, 3-75, 4-84, 5-98, 6-113, Order numbers, 13-241
7-126, 8-137, 9-150 Start-up, 13-246
Panel cutout, 15-300 System information, 13-249
Parallel interface, 12-210, 13-243 Technical data, 13-250
PC card, 12-208, 12-210, 12-220, 13-241, Phoenix terminal block, 1-25
13-243, 13-247 Plastic holder, 12-233
PC keyboard, standard, 12-208 Plastic support, 12-233
PCI adapter, 18-397 Plate thickness, 2-46
Card slot interface, 18-401 PLC, basic program, 2-34
Dimension drawing, 18-406 PLC interface, 15-318
Function block, 18-397 Plug connector, 12-211, 13-244
I/O address ranges, 18-404 POST Errors, 12-234
Interface, 18-398 Power, supply, 2-31, 2-36, 2-37
Interrupt assignment, 18-404 Power consumption, 3-80, 4-90, 5-101, 6-119,
Memory address ranges, 18-403 7-131, 8-142, 9-154, 12-226, 12-238, 13-250
PCI card, installation, 18-407 POWER LED, 4-82, 5-92, 6-104, 7-122, 8-134,
Pin assignments, 18-401 9-144
SLOT interface, 18-399 Power loss, 24-499
Technical data, 18-402 CNC keyboard, 2-51
PCI module, 12-231, 12-232 Power supply, 1-21, 1-22, 10-156, 11-195,
PCI slot, 12-208, 12-210, 12-238, 13-241, 13-243, 11-204, 11-205, 12-207, 12-210, 12-219,
13-250 12-222, 12-224, 12-225, 12-238, 13-241,
PCI/ISA, 12-231 13-243, 13-247, 13-248, 13-250, 15-289,
PCI/ISA slot, 12-210, 13-243 25-503
PCU, 3-76, 6-115, 9-151, 10-158, 14-266 Changing, 12-224
Connection, 3-69, 4-83, 5-95, 6-107, 7-123, Power supply cover, 12-209, 13-242
8-135, 9-145 POWER-LED, 3-66
PCU 20 PP 012
Accessories, 11-204 Circuits, 15-309
Connections, 11-197 COM interface, 15-276
Installation, 11-203 Communication parameters, 15-322
Interfaces, 11-197 Configuring, 15-328
Mounting, 11-203 Connecting 24V power supply, 15-301
Start-up, 11-203 Connections, 15-309
Technical data, 11-205 Control elements, 15-281
Views, 11-196 Delivery variants, 15-328
PCU 50, 3-65, 4-81, 5-91, 6-103, 7-121, 8-133, Dimension drawing, 15-300
9-143, 12-209 Emergency button, 15-285
Assembly, 4-85 Euchner pin connector, 15-291
Accessories, 12-228 Extension, 15-304
Assembly, 3-71, 5-97, 6-109, 7-125, 8-136, Function blocks, 15-278
9-147 Global data table, 15-322
Connections, 12-210 Input signals, 15-318
Interfaces, 12-210 Inputs/outputs, 15-276
Mounting, 12-218 Installation, 15-301
Mounting bracket, 12-233 Interface, 15-276
Notes on installation, 12-218 Labeling, 15-302
Spare parts, 12-222 Monitoring, 15-277
Spare parts, 13-248 Mounting, 15-301
Start-up, 12-218 MPI/OPI interface, 15-276
System boot, 12-220 Operator panel, 15-277
Technical data, 12-238 Operator panel front interface, 15-289
Views, 12-209 Output signals, 15-319

11.02
10.00
Panel cutout, 15-305 Processor, 12-207, 12-238, 13-241, 13-250

PCB I/O, 15-306 PCU 20, 11-205
PG interface, 15-276 PROFIBUS, 11-197, 12-210, 13-243
Power, 15-281 Program, key, 2-34
Power supply, 15-276 Program memory, 20-415
Programming device interface, 15-290 Protecting, cap, 3-73
Project-specific components, 15-330 Protection
Rating plates, 15-331 Class, 3-80, 4-90, 5-101, 6-119, 7-131, 8-142,
Service information, 15-326 9-154
System description, 15-275 Degree, 4-81, 8-133
Technical data, 15-314 Degree of, 3-65, 5-91, 6-103, 7-121, 9-143
Wiring, 15-309 Degree of, CNC keyboard, 2-51
PP 031 MC Protection class, 11-205, 12-238, 13-250
Block diagrams, 16-337 Protective earth, 2-55
Changing contact maker, 16-386 Protective separation, 25-504
Circuits, 16-368 PS/2
COM interface, 16-334 Keyboard, 12-210, 13-243
Communication parameters, 16-381 Keyboard interface, 11-195, 11-200, 12-208,
Configuring, 16-387 12-213, 13-241
Connecting 24V power supply, 16-361 Mouse, 11-197, 12-210, 13-243
Connecting MPI connection, 16-361 Mouse interface, 12-208, 12-213, 13-241
Control elements, 16-339, 16-362 Pushbutton panel, 6-108, 9-146
Customer control panel, 16-364 Pushbutton panel PP 012, 15-275
Delivery variants, 16-387
Dimension drawing, 16-360
Direct keys, 16-350
Function blocks, 16-336
Q
Global data table, 16-381 Quick Boot Mode, 12-234
Handheld unit interface, 16-349 QWERTY, 2-48
Individual wiring, 16-343, 16-361 Control elements, 17-392
Initialization, 16-379 Dimension drawing, 17-394
Input signals, 16-377 Function blocks, 17-391
Inputs/outputs, 16-334 Installation, 17-394
Installation, 16-361 Interfaces, 17-392
Interfaces, 16-334, 16-341 Key assignments, 17-392
Labeling, 16-362 NC-specific keys, 17-392
Monitoring, 16-335 Panel cutout, 17-395
Mounting, 16-361 Technical data, 17-396
Operator panel front, 16-335 QWERTY keyboard, 17-391
OPI interface, 16-334
Output signals, 16-378
Panel cutout, 16-360, 16-364
PCB I/O, 16-365
R
PG interface, 16-334 Radio interference suppression, 25-502
PLC interface, 16-377 RAFI, 2-54
Power, 16-340 RAM, 12-207, 13-241
Power supply, 16-334 RAM bank, 12-227, 12-229, 13-249
Programming device interface, 16-348 Rating plate, 12-209
Project-specific components, 16-389 Readiness for operation, 11-204, 12-219, 13-247
Pushbutton panel, 16-333 Recall, 4-82, 5-92, 6-104, 8-134, 9-144
Rating plates, 16-390 key, 3-66
Service information, 16-385 Receipt time, cyclic, 2-57
System description, 16-333 Receive Data, 1-23
Technical data, 16-373 Relative humidity, 2-64, 3-80, 4-90, 5-101, 6-119,
Terminator, 16-354 7-131, 8-142, 9-154, 11-205, 12-238, 13-250,
PP031 MC (pushbutton panel), direct control key 17-396, 19-412, 20-426, 21-446, 23-495,
Connection, 6-108, 9-146 25-509, 25-510
Primary Master, 12-234 CNC keyboard, 2-51
Primary Slave, 12-234 Repeater, 21-443, 23-486
Printer, 12-210, 13-243 Request To Send, 1-23, 1-24

11.02
10.00
Reset, 11-199, 12-211, 13-244, 20-417 Labels, 3-72, 6-109, 9-147

RESET button, 23-478 Soft keys, 3-65, 5-91, 6-103, 9-143
Resolution, 4-81, 5-91, 6-103, 7-121, 8-133, Horizontal, 1-22, 2-37
9-143, 14-263 Vertical, 2-37, 6-107, 9-145
Ribbon cable, 3-69, 4-83, 5-95, 6-107, 7-123, Space key, 2-34
8-135, 9-145, 12-222, 12-223 Spare parts, 3-77, 4-87, 5-100, 6-116, 8-139,
Ring Indicator, 1-23 9-152
Rivet-down nut, 2-45, 2-46 Spindle control, 20-417
Rotary selector switch S1, 14-263, 14-265 Split rivet, 12-224, 12-225
Rotary selector switches, 20-418 Standard block DB 19, 2-34
RS-485, 12-210, 13-243 Standard MFII keyboard, 2-48
RS-232 interface, 1-22 Start-Up, Guide, 12-229, 12-234
RTS signal, 12-214 Static electricity, 3-78, 4-87, 6-117, 7-129, 8-139,
9-153
Status LED, 3-65, 3-66, 4-81, 4-82, 5-91, 5-92,
6-103, 6-104, 7-121, 7-122, 8-133, 8-134,
S 9-143, 9-144
S 78, 17-391 STN flat screen, 3-65
S7, 11-197, 12-210, 13-243 Storage conditions, 25-509
Safety, 3-80, 4-90, 5-101, 6-119, 7-131, 8-142, Sub-D
9-154, 11-205, 12-238, 13-250 Connector, 12-210, 13-243
Safety regulations, 3-80, 4-90, 5-101, 6-119, Socket connector, 12-210, 13-243
7-131, 8-142, 9-154, 11-205, 12-238, 13-250 Subrack, mounting, 3-65, 5-91, 6-103, 7-121,
Screen control key, 2-36 8-133, 9-143
Screen resolution, 11-195, 12-207, 13-241 Summary screen, 12-234
SDRAM, 12-228, 12-229, 12-238, 13-249, 13-250 Sun radiation, 11-203, 12-218, 13-246
module, 12-229, 13-249 Switch S2, 14-265, 14-269
Seal, 3-73, 4-84, 6-113, 7-126, 8-137, 9-149 Switch S78, 17-391
Sealing area, 3-74, 5-98, 6-113 System boot, 11-204, 12-229, 12-234, 13-247
Sealing cap, 9-152 System information, 12-234
Sealing cap for the USB connection, 3-77, 4-87, System parameters, 12-234
5-100, 6-116, 8-139, 9-152
Sealing cap for USB connection, 7-128
Secondary Master, 12-234
Secondary Slave, 12-234
T
Selector switch, 15-282, 16-340 T-version, 20-417
Serial interface, 11-197, 12-210, 13-243 Technical data, 14-274
Serial mouse, 12-210, 13-243 TEMP LED, 4-82, 5-92, 6-104, 7-122, 8-134,
Service life, 1-29, 3-80, 4-90, 5-101, 6-119, 7-131, 9-144
8-142, 9-154 TEMP-LED, 3-66
Service menu, 12-234 Temperature, 12-238, 13-250
Setscrews, 3-74, 3-75, 4-84, 5-98, 6-113, 7-126, Change, 3-80, 4-90, 5-101, 6-119, 7-131,
8-137, 9-150 8-142, 9-154, 25-509
Settings, machine control panel, 20-424 CNC keyboard, 2-51
Setup menu, 12-237 LED, 14-264
SETUP prompt, 12-234 Limit values, 3-80, 4-90, 5-101, 6-119, 7-131,
Shared PCI/ISA slot, 12-208, 13-241 8-142, 9-154, 12-238
Shielded signal lines, 25-507 Limit values for CNC keyboard, 2-51
Shift key, 3-65, 5-91, 6-103, 9-143, 12-237 Monitor, 14-264
Shipping brace, 3-71, 12-209, 12-223, 12-224 Threshold, 14-264
Shock load, 25-511 Temperature limit values, PCU 70, 13-250
Signal type, 4-83, 5-96, 6-108, 7-124, 8-135, Temperature monitor, 20-415
9-146, 11-201, 12-212, 15-285, 16-343, Tension jack, 3-77, 4-87, 5-100, 6-116, 7-128,
23-476, 23-478 8-139, 9-152, 11-203, 20-423
Slide-in label set, 9-151 Tension jacks, 3-74, 3-75, 4-84, 5-98, 6-113,
Slide-in user labels, 3-77, 6-116 7-126, 8-137, 9-149, 9-150
Slot, 12-231, 12-233 Fastening, 3-73
SO-DIMM module, 12-229 Terminal block, 20-416
Socket, 12-223 Terminator, 15-296
Soft key, 2-36 TFT, color flat screen, 2-36

11.02
10.00
TFT display, 12-211, 13-245 User keys, 20-417

TFT flat screen, 4-81, 5-91, 6-103, 8-133, 9-143 User main menu, 12-234
Threaded bolt, 10-178 User memory, 11-205, 12-229, 12-238, 13-249,
Tightening torque, 14-265 13-250
Tool Offset, key, 2-34 User-specific functions, 3-76, 6-115, 9-151
Torque, 2-49, 3-75, 4-84, 5-98, 6-113, 7-126,
8-137, 9-150
TP 012
Assembly, 7-125
V
Assignment, 7-124 Vent slots, 11-203, 12-218, 13-246
Brief description, 7-121 Ventilation, 11-203, 11-205, 12-238, 13-250
Front view, 7-122 VGA, 12-210, 13-243
Installation, 7-125 Interface, 12-208, 12-214, 13-241
Installation preparation, 7-126 Resolution, 3-65
Interfaces, 7-123 Vibration load, 25-511
Operation, 7-121 Vibration resistance, 13-250
Spare part replacement, 7-129 Videolink
Spare parts, 7-128 Cable, 14-251, 14-256
Spare parts list, 7-128 Receiver, 9-152, 14-251, 14-256
Track ball, 6-105, 9-144, 13-243 Transmitter, 9-152, 10-181, 10-185, 14-251,
Transmission time, cyclic, 2-57 14-256, 14-263, 14-268
Transmit Data, 1-23 Voltage, 2-51
Transport conditions, 25-509 Voltage monitor, 20-415
Turning machine, 20-417
W
U Watch dog, 20-415
Universal Serial Bus, 11-197, 13-243 Weight, 3-80, 4-90, 5-101, 6-119, 7-131, 8-142,
Upright mounting, 14-265, 14-269, 14-270 9-154, 11-205, 12-238, 13-250
US layout, 2-34, 2-35 Windows NT, 12-207, 13-241
USB, 11-197, 12-210, 13-243 Windows XP, 12-207
Connection, 3-77, 4-87, 5-100, 6-116, 7-128,
8-139, 9-152
Front interface, 3-66, 3-69, 3-70, 4-82, 4-83,
5-92, 5-95, 5-96, 6-104, 6-107, 6-108,
X
7-122, 7-124, 8-134, 8-135, 9-144, 9-145, X1, 15-286, 16-344
9-146 X10/X11, 15-288, 16-346
Interface, 11-201, 12-213 X11, 5-95, 6-107, 6-108, 9-145, 9-146
Mouse, 6-116, 9-152 X2, 15-286, 16-344
USB connector, 14-264 X3, 15-286, 16-344
USB interface, 4-87, 8-139, 11-195, 12-208, X4, 15-287, 16-345
13-241, 14-263, 14-264, 14-265 XGA, 11-195, 12-207, 13-241
USB signal, 14-264 XT module, 12-231

To Suggestions
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A&D MC BMS For Publication/Manual:
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SINUMERIK 840D/840Di/810D
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Fax: ++49-(0)9131-98-2176 [Documentation]
Email: motioncontrol.docu@erlf.siemens.de) Manufacturer Documentation
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Overview of SINUMERIK 840D/840Di/810D Documentation (11.2002)
General Documentation User Documentation
SINUMERIK
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840D/840Di/ 840D/810D 840Di 840D/840Di/ 840D/810D 840D/840Di/
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Program. Guide Operators Guide System Overview Configuring Operator Description of Description of
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611D 840D/840Di/ 840D/840Di/ 840D/810D 840D/810D 840D/810D
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Description of Description of Description of Configuring Kit Description of IT Solutions

Functions Functions Functions HMI Embedded Functions Computer Link
Drive Functions *) Basic Machine *) Tool Manage- Operator Interface Tool Data Information System
Extended Functions ment OP 030 NC Data Management
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Tool Data Communication
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*) These documents are a minimum requirement
Siemens AG
Automation & Drives
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P.O. Box 3180, D-91050 Erlangen Siemens AG, 2002
Subject to change without prior notice
Germany Order No: 6FC5 297-6AA50-0BP2
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Manual 11/2002 Edition

SINUMERIK 840D/840Di/810D OP 012 6

Touch Panel TP 012 7

Valid for PCI Adapter 18

Control Software version Floppy Disk Drive 19

11.2002 Edition Appendix A

Status code in the Remarks column:

Edition Order No. Remarks

This book is part of the documentation on CD-ROM (DOCONCD)

Other functions not described in this documentation might be

Order No. 6FC5 297-6AA50-0BP2 Siemens Aktiengesellschaft

Notes for the The SINUMERIK documentation is organized on three levels:

A&D Technical Support Phone: ++49-(0)180-5050-222

If you have queries regarding documentation (suggestions, corrections), please

Internet address http://www.ad.siemens.de/sinumerik

SINUMERIK 840D Improved-performance variants

SINUMERIK 810D Improved-performance variants

Siemens AG, 2002. All rights reserved

Table 1-1 Corresponding SW version

SINUMERIK 840D SINUMERIK 810D SINUMERIK 810D SINUMERIK 840Di

Target readership? S Configuring engineers

Siemens AG, 2002. All rights reserved

Allowing unqualified persons access to the equipment/system or failure to

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

Siemens AG, 2002. All rights reserved

Siemens AG, 2002. All rights reserved

ESDS instructions Components which can be destroyed by ElectroStatic Discharge

S When handling components which can be destroyed by electrostatic di-

S As a general rule, electronic boards should only be touched when absolu-

S You may only touch ESDS components if

S Boards may not be brought close to data terminals, monitors or television

S Measurements may be taken on the boards only if

Siemens AG, 2002. All rights reserved

Siemens AG, 2002. All rights reserved

Siemens AG, 2002. All rights reserved

3.7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80

Siemens AG, 2002. All rights reserved

7 Touch Panel TP 012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-121

Siemens AG, 2002. All rights reserved

10 SINUMERIK Operator Panel Front 15 TFT, Width 416mm . . . . . . . . . . . . . . . 10-155

Siemens AG, 2002. All rights reserved

12.2.1 Interfaces on right side of casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-210

Siemens AG, 2002. All rights reserved

14 Distributed Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-251

Siemens AG, 2002. All rights reserved

15.12 Circuits and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-309

Siemens AG, 2002. All rights reserved

16.16 Sample parameterization for communication between SIMATIC S7

Siemens AG, 2002. All rights reserved

21.7 Settings in HHU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-447

Siemens AG, 2002. All rights reserved

25.2.2 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-510

Siemens AG, 2002. All rights reserved

S Aluminum front panel with membrane keyboard

S Five horizontal soft keys

Power supply 24VDC input

Siemens AG, 2002. All rights reserved

1.2 Control elements and interfaces

Fig. 1-1 Front view of operator panel front

Fig. 1-2 Rear view

Overview of S X101: Serial RS-232-C

Siemens AG, 2002. All rights reserved

Serial RS-232-C Connector designation: X101