Siemens SINUMERIK 828D Turning Installation guide

Sinumerik 828D
This document was produced for training purposes.
Siemens assumes no responsibility for its contents.
SINUMERIK 828D
Machine Commissioning
Training Manual
Edition 2009.8

SINUMERIK 828D
Commissioning Manual
Turning and Milling
Valid for
Controller:- Software:-
Sinumerik 828D 2.06.28

Contents
B060 System overview.
B021 Protection levels.
B002 Toolbox Installation.
B025 Time and Date Settings
B010 PPU Connections and Diagnostics.
B044 Licence and Option Commissioning.
B017 System Restore.
B008 Machine Control Panel .
B026 Creating a PLC Program.
B019 S7-200 PLC Instructions.
B034 PLC Interface.
B031 PLC Alarm and Message Structure.
B032 Remote Diagnosis .
B033 PI Services & PLC Functions.
B058 PLC On board Diagnostic.
B041 Machine and Setting Data.
B068 Commissioning Sequence.
B053 Axis and Drive Diagnostics.
B084 Referencing of Encoders.
B020 Maintenance Planner.
B009 Easy Extend .
B018 Easy Messenger.
B007 Electronic Logbook.
B067 Preparation of series machines.
B100 Servo Optimisation.
B051 Line and Motor Modules .
B006 Electrical Cabinet Design.
B099 Tips & Tricks

1 Brief description
Sinumerik 828D
This document was produced for training purposes.
Siemens assumes no responsibility for its contents.
SINUMERIK 828D Page 1 B060 B060
System Overview
B060
Module Objective:-
Upon completion of this module you will know the Sinumerik 828D system and the components which
make up the system.
Module Description:-
The Sinumerik 828D system is made up of a variety of hardware components. This module gives a
graphical overview of those components and shows where each component is connected.
A brief description of the hardware components is also given.

B060
B060 Page 2 SINUMERIK 828D
System Overview Section 2
Page 3
Machine Control
Panels
Drive Components Section 5
Page 10
828D/PPU Section 3
Page 4
Section 4
Page 6
NX10 Module Section 6
Page 14
Sensor Modules Section 7
Page 15
PLC Periphery
PP72/48
Section 8
Page 18
Hand-held Units Section 9
Page 20
B011
Contents:-

SINUMERIK 828D Page 3B060
Notes
}
Section 2
X122
X100 X101 X102
X140
X132
X142
X143
X130
PN1 PN2
X125
X1
X127
X135
Sinumerik 828D
& PPU2xx.1
USB
X127 Service
Ethernet
PN1 & PN2
Profinet
interfaces.
X100, X101 & X103
DriveCliq interfaces.
PP72/48PN PLC I/O
X140
RS232
interface
GSM/GPRS
modem
Digital I/O
X122, X132 & X142
Hand-wheels
Sinamics S120
Booksize drive
Modules.
MCP310PN
X145
Compact
Flash
X130-Facxtory Ethernet
Filter
Reactor
MCP483PN
SMC20/30 SMC20/30
DMC20
DriveCliq
hub
NX10
USB
Mini
HHU
System Overview

B060 Page 4 SINUMERIK 828D
Notes
Section 3 Hardware information
PPU2xx.1 with integrated 828D controller
General information.
The controller is available in vertical or horizontal formats. The functionality of the two
variants is identical.
The PPU includes “Qwerty” and numerical keyboard inputs and shortcut keys to spe-
cific machine areas.
The 828D encompasses the HMI, NC, PLC and CU logical components.
PPU interfaces:-
X125 USB interface.
X127 Ethernet service port.
X145 Compact Flash (CF) interface.
RDY Green ready LED
NC Red fault LED
CF Amber CF card activity LED
828D interfaces:-
X1-24V DC supply.
X100 to X103 –Drive Cliq interface.
X130-Ethernet factory network.
X135-USB interface.
X140-RS232 interface
X122 & X132-Digital I/O for Sinamics
X142-Digital I/O for NCK
X143-Hand-wheels x 2
LED Indicators:-
FAULT-Red-fault present, contact Siemens.
SYNCH-Green-synchronisation OK
Rx/Tx-Yellow network activity LED (1 each for PN1, PN2 & X130 interfaces)
Link-Green network connection indicator (1 each for PN1, PN2 & X130 interfaces)
Horizontal variant
PPU2x1.1
Vertical variant:
PPU2x0.1
A choice of horizontal or vertical mounting is available:-

SINUMERIK 828D Page 5B060
Notes
Section 3
PPU2xx.1 with integrated 828D controller
Part numbers
General Information.
The PPU type can be identified by the PPU number:-
PPU2xx.1
0 - Vertical
1 - Horizontal
6 - Standard
8 - Performance
PPU Horizontal layout:-
Standard version
6FC5370-5AA00-0AA0 PPU261.1 without system software.
Performance version
6FC5370-7AA00-0AA0 PPU281.1 without system software.
PPU Vertical layout:-
Standard version
6FC5370-6AA00-0AA0 PPU260.1 without system software.
Performance version
6FC5370-8AA00-0AA0 PPU280.1 without system software.
Software (Current system software delivered on CF card):-
Milling (Max 6 axes)
6FC5831-2GY00-0YA0 Standard for PPU260/PPU261
6FC5830-2GY00-0YA0 Performance for PPU280/PPU281
Turning
6FC5831-1GY00-0YA0 Standard for PPU260/PPU261
6FC5830-1GY00-0YA0 Performance for PPU280/PPU281 (Max 8 axes with NX10)
Specifications
Input voltage- 24V DC +20% /-15%
Power Consumption 60W
Protection –Front operator panel IP65
Rear of PPU IP20
Operational temperature 0-45 °C
Operational Relative humidity 5 to 90 % @ 25°C (No condensation)
Horizontal model Vertical model
Width 310mm(12.2 in) 483mm (19 in)
Height 380mm(15in) 220mm (8.66 in)
Depth 105mm(4.13 in) 105mm( 4.13 in)
Hardware information

B060 Page 6 SINUMERIK 828D
Notes
Section 4 Hardware information
Machine Control Panels (MCP’s)- Type MCP310C PN
The MCP310 is recommended for use with the vertical style PPU
MCP 310C PN(12.2”)
Part Number:-
6FC5303-0AF23-0AA1
Features:-
 49 mechanical keys with LED
Indicators (16 user assignable)
 Feed override control(16 positions)
 Key switch
 Emergency stop/Spindle override
optional
 6 x Pre-drilled holes for hard wired
user buttons
 Connections for 9 user Inputs & 6
outputs.
 Connection via Profinet.
H1 LED POWER OK
H2 LED BUSSYNC
H3 LED BUSFAULT
S2 IP address selection switch.
Consumable items:-
6FC5247-0AF13-1AA0-Feed
override rotary switch incl. cap, button,
pointer & dials.
6FC5247-0AF12-1AA0-Spindle
override rotary switch incl. cap, button,
pointer & dials.
Interfaces:-
X10 24V DC supply
X20 Ethernet port 1
X21 Ethernet port 1
X30 Feed override switch input
X31 Spindle override switch input
X51 User input connections.
X52 User input connections.
X55 User input connections.
X53 User output connections.
X54 User output connections.

SINUMERIK 828D Page 7B060
Notes
Section 4 Hardware information
Machine Control Panels (MCP’s)- Type MCP310 PN
The MCP310 is recommended for use with the vertical style PPU
MCP 310 PN(12.2”)
Part Number:-
6FC5303-0AF23-1AA1
Features:-
 49 membrane keys with LED
Indicators (16 user assignable)
 Feed override control(16 positions)
 Key switch
 Emergency stop/Spindle override
optional
 6 x Pre-drilled holes for hard wired
user buttons
 Connections for 9 user Inputs & 6
outputs.
 Connection via Profinet.
H1 LED POWER OK
H2 LED BUSSYNC
H3 LED BUSFAULT
S2 IP address selection switch.
Consumable items:-
6FC5247-0AF13-1AA0-Feed
override rotary switch incl. cap, button,
pointer & dials.
6FC5247-0AF12-1AA0-Spindle
override rotary switch incl. cap, button,
pointer & dials.
Interfaces:-
X10 24V DC supply
X20 Ethernet port 1
X21 Ethernet port 1
X30 Feed override switch input
X31 Spindle override switch input
X51 User input connections.
X52 User input connections.
X55 User input connections.
X53 User output connections.
X54 User output connections.

B060 Page 8 SINUMERIK 828D
Notes
Section 4
Hardware information
Machine Control Panels (MCP’s)- Type MCP483C PN.
The MCP483 is recommended for use with the horizontal style PPU.
Consumable items:-
6FC5247-0AF13-1AA0-Feed override
rotary switch incl. cap, button, pointer & di-
als.
6FC5247-0AF12-1AA0-Spindle override ro-
tary switch incl. cap, button, pointer & dials.
Hardware information
MCP 483C PN (19”)
Part Number:-
6FC5303-0AF22-0AA1
Features:-
 50 mechanical keys with LED
indicators (17 user assign-
able)
 Spindle & feed override con-
trol.
 Key switch
 Emergency stop button
 2 x Pre-drilled holes for hard
wired user buttons
 Connection via Ethernet
 2 x Hand-wheel connections
 Connections for 9 user
Inputs & 6 outputs.
 Connection via Profinet
Interfaces:-
X10 24V DC supply
X20 Ethernet port 1
X21 Ethernet port 2
X30 Feed override switch input
X31 Spindle override switch input
X51 User input connections.
X52 User input connections.
X55 User input connections.
X53 User output connections.
X54 User output connections.
LED Indicators:-
H1 LED POWER OK LED
H2 LED BUSSYNC (Bus ok & synchronised)
H3 LED BUSFAULT (Bus fault)
S1 Hand-wheel type selection switch
S2 IP address selection switch

SINUMERIK 828D Page 9B060
Notes
Section 4
Machine Control Panels (MCP’s)- Type MCP483 PN.
The MCP483 is recommended for use with the horizontal style PPU.
Consumable items:-
6FC5247-0AF13-1AA0-Feed override
rotary switch incl. cap, button, pointer & di-
als.
6FC5247-0AF12-1AA0-Spindle override ro-
tary switch incl. cap, button, pointer & dials.
Hardware information
MCP 483C PN (19”)
Part Number:-
6FC5303-0AF22-1AA1
Features:-
 50 membrane keys with LED
indicators (17 user assign-
able)
 Spindle & feed override con-
trol.
 Key switch
 Emergency stop button
 2 x Pre-drilled holes for hard
wired user buttons
 Connection via Ethernet
 2 x Hand-wheel connections
 Connections for 9 user
Inputs & 6 outputs.
 Connection via Profinet
Interfaces:-
X10 24V DC supply
X20 Ethernet port 1
X21 Ethernet port 2
X30 Feed override switch input
X31 Spindle override switch input
X51 User input connections.
X52 User input connections.
X55 User input connections.
X53 User output connections.
X54 User output connections.
LED Indicators:-
H1 LED POWER OK LED
H2 LED BUSSYNC (Bus ok & synchronised)
H3 LED BUSFAULT (Bus fault)
S1 Hand-wheel type selection switch
S2 IP address selection switch
Hardware information

B060 Page 10 SINUMERIK 828D
Notes
Section 5 Hardware information
Line Modules.
General.
Line modules are responsible for generating the DC link supply for the drive system.
They require 3-phase AC for the DC link and +24V DC for the electronic supply.
The DC link and 24V DC voltages are distributed to other drive modules in the
system via a bus bar system.
The modules are available in several variants of size and functionality.
Smart Line Modules (SLM)
These modules are capable of mains regeneration but the DC link is not
stabilised.
SLM modules of 5 & 10 Kw do not connect to the DriveCliq network.
Modules of 16 Kw and above do connect to the DriveCliq.
Active Line Modules (ALM)
These modules are capable of mains regeneration and the DC link is stabilised.
All ALM modules are connected to the DriveCliq network.
Active Line ModuleSmart Line Module
Interfaces:-
SLM (5 & 10Kw variant)
X21-Enable, ready and fault signals
X22-Regeneration inhibit and fault reset signals.
X24-24V DC electronics supply.
U1, V1, W1-3-Phase supply.
X200, X201, X202-DriveCliq connections.
SLM (16Kw and above) & ALM (All variants)
X21-Enable & temperature sensor input.
X24-24V DC electronics supply.
U1, V1, W1-3-Phase supply.
X200, X201, X202-DriveCliq connections

SINUMERIK 828D Page 11 B060
Notes
Section 5
Part Numbers-SLM
6SL3130-6AE15-0AB0 5Kw Internal cooling.
6SL3130-6AE21-0AB0 10Kw “ “
6SL3130-6TE21-6AA3 16Kw “ “
6SL3130-6TE23-6AA3 36Kw “ “
6SL3131-6AE15-0AA0 5Kw External cooling
6SL3131-6AE21-0AA0 10Kw ““
Part Numbers-ALM
6SL3130-7TE21-6AA3 16Kw Internal cooling.
6SL3130-7TE23-6AA3 36Kw “ “
6SL3130-7TE25-5AA3 55Kw “ “
6SL3130-7TE28-0AA3 80Kw “ “
6SL3130-7TE31-2AA3 120Kw “ “
6SL3131-7TE21-6AA3 16Kw External cooling
6SL3131-7TE23-6AA3 36Kw “ “
6SL3131-7TE25-5AA3 55Kw “ “
6SL3131-7TE28-0AA3 80Kw “ “
6SL3131-7TE31-2AA3 120Kw “ “
Line Modules-continued
Motor Modules (MM)
The motor modules convert the DC link
voltage into a variable AC voltage which
is then output to the servo
Motors.
They are also supplied with 24V DC via
the ALM/SLM
All motor modules are connected to the
DriveCliq network.
They are available in one or two axis
variants and can be internally or
externally cooled.
Single MM Double MM
Interfaces:-
MM –Single
X1-Output to Motor.
X21-Enable & temperature sensor input
X200, X201, X202-DriveCliq
connections.
MM –Double
X1 & X2-Output to Motors.
X21-Enable & temperature sensor input
(Motor 1)
X22-Enable & temperature sensor
input (Motor 2)
X200, X201, X202, X203-DriveCliq
connections.
Hardware information

B060 Page 12 SINUMERIK 828D
Notes
Section 5
If the regenerative capability of the line
module is inadequate it can be
supplemented by the inclusion of a braking
module.
These modules fit neatly into the drive
system.
Further braking capacity can be added in
the form of braking resistors which connect
to the braking module. Braking resistors
require good ventilation and ideally need to
be mounted externally.
Braking modules and resistors can also
facilitate the controlled shut down of the
drives in the event of a power failure.
Another feature is the fast discharge of the
DC link. This feature is used to quickly
discharge the capacitors so that
maintenance tasks can be carried without
having to await natural discharge times.
Fast discharging should only be carried out
1 to 2 times per week to avoid damaging
the capacitors.
The braking module is connected to the DC
link and 24V DC bus systems.
Connector X21 on the braking module is
used for enable/fault/ready signals.
Connector X1 is for connecting the
external resistor.
Motor Modules (MM)-continued
Part Numbers-single modules
6SL3120-1TE13-0AA3 1.6Kw Internal cooling.
6SL3120-1TE15-0AA3 2.7Kw “ “
6SL3120-1TE21-0AA3 4.8Kw “ “
6SL3120-1TE21-8AA3 9.7Kw “ “
6SL3120-1TE23-0AA3 16Kw “ “
6SL3120-1TE24-5AA3 24Kw ““
6SL3120-1TE26-0AA3 32Kw “ “
6SL3120-1TE28-5AA3 46Kw “ “
6SL3120-1TE31-3AA3 71Kw “ “
6SL3120-1TE32-0AA3 107Kw “ “
6SL3121-1TE13-0AA3 1.6Kw External cooling.
6SL3121-1TE15-0AA3 2.7Kw “ “
6SL3121-1TE21-0AA3 4.8Kw “ “
6SL3121-1TE21-8AA3 9.7Kw “ “
6SL3121-1TE23-0AA3 16Kw “ “
6SL3121-1TE24-5AA3 24Kw ““
6SL3121-1TE26-0AA3 32Kw “ “
6SL3121-1TE28-5AA3 46Kw “ “
6SL3121-1TE31-3AA3 71Kw “ “
6SL3121-1TE32-0AA3 107Kw “ “
Part Numbers-double modules
6SL3120-2TE13-0AA3 2 x 1.6Kw Internal cooling.
6SL3120-2TE15-0AA3 2 x 2.7Kw “ “
6SL3120-2TE21-0AA3 2 x 4.8Kw “ “
6SL3120-2TE21-8AA3 2 x 9.7Kw “ “
6SL3121-2TE13-0AA3 2 x 1.6Kw External cooling.
6SL3121-2TE15-0AA3 2 x 2.7Kw “ “
6SL3121-2TE21-0AA3 2 x 4.8Kw “ “
6SL3121-2TE21-8AA3 2 x 9.7Kw “ “
Braking Modules & Resistors.
Braking resistor
Braking Module
Hardware information

SINUMERIK 828D Page 13 B060
Notes
Section 5
Part Numbers-
6SL3100-1AE31-0AB0 Braking Module 1.5Kw rated power
6SN1113-1AA00-0DA0 Braking Resistor 0.3Kw rated power
6SL3100-1BE31-0AA0 Braking Resistor 1.5Kw rated power
Control Supply Modules.
Braking Modules & Resistors-continued
The Control Supply Module is a 24V/20A DC
Power Supply Unit.
It is used to maintain the 24V DC in the event of a
power failure.
The initial power to the module is taken from the
line supply, when a power failure occurs power is
taken from the residual voltage of the DC link.
Part number:-6SL3100-1DE22-0AA0
Control Supply
Module
Hardware information

B060 Page 14 SINUMERIK 828D
Notes
Section 6 Hardware information
General.
Since the integrated control unit (CU) can control
only 6 axes, an NX10 module is required to
achieve the maximum number of 8 axes allowed
by the system.
The modules are of the same design as the
Sinamics S120 drives and fit neatly into the drive
rack.
All modules have to be connected to the
DriveCliq network.
Digital input & output functionality is available.
Drive enable signals OFF1 and OFF3 are
required to be connected here.
The functionality of the inputs and outputs can be
assigned by the user.
To maintain consitency with the CU the
recommended drive enable connections are:-
X122.1 = OFF1
X122.2 = OFF3
A separate 24V DC supply is required in order for
the inputs and putputs to function.
Part Number:-
6SL3040-0NC00-0AA0
NX10 Module (Numerical Control Extension) Only for the T version
NX10