Siemens SINUMERIK 828D Turning User manual

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Hardware and Software
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SINUMERIK
SINUMERIK 828D
Hardware and Software
Service Manual
Valid for:
CNC software for SINUMERIK 828D V2.6
03/2010
6FC5397-5DP20-0BA0
Preface
Safety notes
1
System description
2
Service cases - software
3
Service cases - hardware
4
Spare parts and accessories
5
ESD guidelines
A
Appendix
B

Legal information
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation for the specific task, in particular its warning notices and
safety instructions. Qualified personnel are those who, based on their training and experience, are capable of
identifying risks and avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be adhered to. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
order number: 6FC5397-5DP20-0BA0
Ⓟ 04/2010
Copyright © Siemens AG 2010.
Technical data subject to change

Hardware and Software
Service Manual, 03/2010, 6FC5397-5DP20-0BA0 3
Preface
SINUMERIK documentation
The SINUMERIK documentation is organized in three parts:
● General documentation
● User documentation
● Manufacturer/service documentation
Information on the following topics is available under the link
(http://www.siemens.com/motioncontrol/docu):
● Ordering documentation
Here you can find an up-to-date overview of publications.
● Downloading documentation
Links to more information for downloading files from Service & Support.
● Researching documentation online
Information on DOConCD and direct access to the publications in DOConWEB.
● Customizing documentation based on Siemens content using
My Documentation Manager (MDM) (http://www.siemens.com/mdm).
● My Documentation Manager provides you with a range of features for generating your
own machine documentation.
● Training and FAQs
Information on our range of training courses and FAQs (frequently asked questions) is
available via the page navigation.
Target group
This document addresses maintenance and service personnel.
Benefits
Based on the Service Manual, the target group can correctly and safely perform service and
maintenance work.
Utilization phase: Maintenance and service phase
Standard version
This documentation only describes the functionality of the standard version. Extensions or
changes made by the machine manufacturer are documented by the machine manufacturer.
Other functions not described in this documentation might be executable in the control.
However, no claim can be made regarding the availability of these functions when the
equipment is first supplied or in the event of servicing.

Preface
Hardware and Software
4 Service Manual, 03/2010, 6FC5397-5DP20-0BA0
Further, for the sake of simplicity, this documentation does not contain all detailed
information about all types of the product and cannot cover every conceivable case of
installation, operation or maintenance.
Questions about this documentation
If you have any queries (suggestions, corrections) in relation to this documentation, please
send a fax or e-mail to the following address:
Fax: [phone]
A fax form is available at the end of this document.
E-mail (mailto:[e-mail])
SINUMERIK Internet address (http://www.siemens.com/sinumerik)
Service & Support
If you have any technical questions, please contact our hotline:
Europe / Africa
Phone [phone]
Fax [phone]
0.14 €/min from the German fixed-line network; cell phone charges may vary.
Internet (http://www.siemens.com/automation/support-request)
Americas
Phone [phone]
Fax [phone]
E-mail (mailto:[email protected])
Asia / Pacific
Phone [phone]
Fax [phone]
E-mail (mailto:[email protected]m)
Note
Country-specific telephone numbers for technical support are provided on the Internet
(http://www.siemens.com/automation/partner).

Preface
Hardware and Software
Service Manual, 03/2010, 6FC5397-5DP20-0BA0 5
EC Declaration of Conformity
The EC Declaration of Conformity for the EMC Directive can be found on the Internet
(http://support.automation.siemens.com) under the Product Order No. 15257461 or at the
relevant branch office of the I DT MC Division of Siemens AG.
CompactFlash cards for users:
● The SINUMERIK CNC supports the file systems FAT16 and FAT32 for
CompactFlash cards. You may need to format the memory card if you want to use a
memory card from another device or if you want to ensure the compatibility of the
memory card with the SINUMERIK. However, formatting the memory card will
permanently delete all data on it.
● Do not remove the memory card while it is being accessed. This can lead to damage of
the memory card and the SINUMERIK as well as the data on the memory card.
● If you cannot use a memory card with the SINUMERIK, it is probably because the
memory card is not formatted for the control system (e.g. Ext3 Linux file system), the
memory card file system is faulty or it is the wrong type of memory card.
● Insert the memory card carefully with the correct orientation into the memory card slot
(take note of arrows, etc.). This way you avoid mechanical damage to the memory card or
the device.
● Only use memory cards that have been approved by Siemens for use with SINUMERIK.
Even though the SINUMERIK keeps to the general industry standards for memory cards,
it is possible that memory cards from some manufacturers will not function perfectly in
this device or are not completely compatible with it (you can obtain information on
compatibility from the memory card manufacturer or supplier).
● The CompactFlash card from SanDisk "CompactFlash® 5000 Industrial Grade" has been
approved for SINUMERIK (Order Number 6FC5313-5AG00-0AA0).

Preface
Hardware and Software
6 Service Manual, 03/2010, 6FC5397-5DP20-0BA0

Hardware and Software
Service Manual, 03/2010, 6FC5397-5DP20-0BA0 7
Table of contents
Preface ...................................................................................................................................................... 3
1 Safety notes............................................................................................................................................. 11
2 System description .................................................................................................................................. 13
2.1 System overview..........................................................................................................................13
2.2 System versions...........................................................................................................................14
3 Service cases - software.......................................................................................................................... 17
3.1 Backing up user data ...................................................................................................................18
3.1.1 This is how you backup user data................................................................................................18
3.1.2 This is how you load the user data backup..................................................................................21
3.2 Series commissioning ..................................................................................................................23
3.2.1 This is how you generate a series commissioning archive on an external data carrier ..............23
3.2.2 This is how you import a series commissioning archive from an external data carrier ...............26
3.2.3 This is how you generate a series commissioning archive on the system CompactFlash
Card .............................................................................................................................................27
3.2.4 This is how you import a series commissioning archive from the system CompactFlash
Card .............................................................................................................................................29
3.3 Software backup ..........................................................................................................................32
3.3.1 This is how you generate a software backup...............................................................................32
3.3.2 This is how you install a software backup....................................................................................36
3.4 Software update...........................................................................................................................40
3.4.1 This is how you update the software ...........................................................................................40
3.5 Mini boot system on the CompactFlash Card..............................................................................44
3.5.1 This is how you generate a mini boot system..............................................................................44
3.5.2 This is how you install a software backup using the mini boot system........................................48
3.6 Licensing......................................................................................................................................51
3.6.1 Licensing after replacing the system CompactFlash Card ..........................................................51
3.6.2 This is how you license a CNC option .........................................................................................51
3.6.3 How to determine the license requirement ..................................................................................53
3.6.4 This is how you generated a new license key .............................................................................54
3.6.5 This is how you display the actual license key ............................................................................57
3.7 Enter the final end user data (EUNA) ..........................................................................................60
3.7.1 This is how you generate the machine logbook...........................................................................60
3.7.2 This is how you make a new entry in the logbook .......................................................................62
3.7.3 This is how you save the machine identity ..................................................................................64
3.7.4 This is how you send the end user final destination data............................................................66
4 Service cases - hardware ........................................................................................................................ 69
4.1 PPU26x/PPU28x..........................................................................................................................71
4.1.1 Status displays at the PPU ..........................................................................................................71
4.1.2 This is how you remove the PPU.................................................................................................73
4.1.3 This is how you install the PPU....................................................................................................74
4.2 Replacing the system CompactFlash Card .................................................................................76

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8 Service Manual, 03/2010, 6FC5397-5DP20-0BA0
4.2.1 This is how you remove the system CompactFlash Card........................................................... 76
4.2.2 This is how you insert the system CompactFlash Card.............................................................. 78
4.3 SINAUT modem .......................................................................................................................... 81
4.3.1 LED status displays..................................................................................................................... 81
4.3.2 This is how you insert the SIM card............................................................................................ 82
4.3.3 This is how you load the factory settings .................................................................................... 88
4.4 Machine control panels ............................................................................................................... 89
4.4.1 Status displays MCP 310C PN ................................................................................................... 89
4.4.2 This is how you remove the MCP 310C PN................................................................................ 90
4.4.3 This is how you install the MCP 310C PN ..................................................................................92
4.4.4 Status displays, MCP 483C PN .................................................................................................. 93
4.4.5 This is how you remove the MCP 483C PN................................................................................ 94
4.4.6 This is how you install the MCP 483C PN ..................................................................................96
4.5 I/O modules................................................................................................................................. 98
4.5.1 Status displays PP 72/48D PN ................................................................................................... 98
4.5.2 This is how you remove the PP 72/48D PN................................................................................ 99
4.5.3 This is how you install the PP 72/48D PN.................................................................................101
4.5.4 Status displays PP 72/48D 2/2A PN ......................................................................................... 102
4.5.5 This is how you remove the PP 72/48D 2/2A PN ..................................................................... 103
4.5.6 This is how you install the PP 72/48D 2/2A PN ........................................................................ 105
4.6 Expansion module NX10........................................................................................................... 106
4.6.1 Status displays on the NX10..................................................................................................... 106
4.6.2 This is how you remove the NX10 ............................................................................................ 106
4.6.3 This is how you install the NX10............................................................................................... 108
4.7 Single Motor Modules ............................................................................................................... 109
4.7.1 SMM status displays ................................................................................................................. 109
4.7.2 SMM connections...................................................................................................................... 110
4.7.3 This is how you remove a Motor Module .................................................................................. 111
4.7.4 This is how you install a Motor Module..................................................................................... 113
4.8 Double Motor Modules.............................................................................................................. 115
4.8.1 DMM status displays ................................................................................................................. 115
4.8.2 DMM connections ..................................................................................................................... 116
4.8.3 This is how you remove a Motor Module .................................................................................. 117
4.8.4 This is how you install a Motor Module..................................................................................... 119
4.9 Smart Line Modules .................................................................................................................. 121
4.9.1 SLM (< 16 kW) status displays ................................................................................................. 121
4.9.2 SLM (< 16 kW) connections...................................................................................................... 122
4.9.3 SLM (16 kW and higher) status displays .................................................................................. 123
4.9.4 SLM (16 kW and higher) connections.......................................................................................124
4.9.5 This is how you remove an SLM............................................................................................... 125
4.9.6 This is how you install an SLM.................................................................................................. 127
4.10 Active Line Modules.................................................................................................................. 129
4.10.1 ALM status displays .................................................................................................................. 129
4.10.2 ALM connections....................................................................................................................... 130
4.10.3 This is how you remove an ALM............................................................................................... 131
4.10.4 This is how you install an ALM.................................................................................................. 133
4.11 SMC20 / SMC30 ....................................................................................................................... 135
4.11.1 SMC20 status displays.............................................................................................................. 135
4.11.2 SMC20 connections .................................................................................................................. 136
4.11.3 This is how you remove an SMC20 .......................................................................................... 136
4.11.4 This is how you install an SMC20 ............................................................................................. 138

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Service Manual, 03/2010, 6FC5397-5DP20-0BA0 9
4.11.5 SMC30 status displays ..............................................................................................................139
4.11.6 SMC30 connections...................................................................................................................140
4.11.7 This is how you remove an SMC30 ...........................................................................................140
4.11.8 This is how you install an SMC30..............................................................................................142
4.12 SME20 / SME25 ........................................................................................................................144
4.12.1 SME20 connections ...................................................................................................................144
4.12.2 This is how you remove an SME20 and install it again .............................................................144
4.12.3 SME25 connections ...................................................................................................................145
4.12.4 This is how you remove an SME25 and install it again .............................................................146
4.13 DMC20.......................................................................................................................................147
4.13.1 DMC20 status displays ..............................................................................................................147
4.13.2 DMC20 connections...................................................................................................................148
4.13.3 This is how you remove a DMC20.............................................................................................148
4.13.4 This is how you install a DMC20................................................................................................150
5 Spare parts and accessories ................................................................................................................. 151
A ESD guidelines ...................................................................................................................................... 153
A.1 RI suppression measures ..........................................................................................................153
A.2 ESD measures...........................................................................................................................154
B Appendix................................................................................................................................................ 155
B.1 List of abbreviations ...................................................................................................................155
B.2 Feedback on the documentation................................................................................................159
B.3 Documentation overview............................................................................................................163
Index...................................................................................................................................................... 165

Table of contents
Hardware and Software
10 Service Manual, 03/2010, 6FC5397-5DP20-0BA0

Hardware and Software
Service Manual, 03/2010, 6FC5397-5DP20-0BA0 11
Safety notes 1
The following notices are intended firstly for your personal safety and secondly to prevent
damage occurring to the product described or any connected devices and machines. Non-
observance of the warnings can result in severe personal injury or property damage.
DANGER
Only appropriately qualified personnel may commission/start-up SINUMERIK equipment.
The personnel must take into account the information provided in the technical customer
documentation for the product, and be familiar with and observe the specified danger and
warning notices.
When electrical equipment and motors are operated, the electrical circuits automatically
conduct a dangerous voltage.
When the system is operating, dangerous axis movements may occur throughout the entire
work area.
A potential fire hazard exists due to the energy being transferred in the equipment and the
work materials used.
All work on the electrical system must be performed after the system has been switched off
and disconnected from the power supply.
DANGER
Proper transportation, expert storage, installation and mounting, as well as careful
operation and maintenance are essential for this SINUMERIK device to operate correctly
and reliably.
The details in the catalogs and proposals also apply to the design of special equipment
versions.
In addition to the danger and warning information provided in the technical customer
documentation, the applicable national, local, and system-specific regulations and
requirements must be taken into account.
Only class DVC A protective extra-low voltages (PELVs) may be connected to connections
and terminals up to 60 V DC in accordance with EN 61800-5-1.
Should it be necessary to test or take measurements on live equipment, then the
specifications and procedural instructions defined in Accident Prevention Regulation BGV
A2 must be adhered to, in particular § 8 "Permissible deviations when working on live
components". Suitable electric tools should be used.

Safety notes
Hardware and Software
12 Service Manual, 03/2010, 6FC5397-5DP20-0BA0
WARNING
Operating the equipment in the immediate vicinity (< 1.5 m) of mobile telephones with a
transmitting power of > 1 W may lead to incorrect functioning of the devices.
Connecting cables and signal lines should be installed in such a way that inductive and
capacitive interference does not in any way impair the automation and safety functions.
DANGER
Repairs to devices that have been supplied by our company may only be carried out by
SIEMENS customer service or by repair centers authorized by SIEMENS.
When replacing parts or components, only use those parts that are included in the spare
parts list.
EMERGENCY STOP/EMERGENCY OFF devices according to EN 60204-1 (VDE 0113
Part 1) must remain active in all modes of the automation equipment. Resetting the
EMERGENCY STOP/EMERGENCY OFF device must not cause an uncontrolled or
undefined restart.
Anywhere in the automation equipment where faults might cause physical injury or major
material damage, in other words, where faults could be dangerous, additional external
precautions must be taken, or facilities must be provided, that guarantee or enforce a safe
operational state, even when there is a fault (e.g. using an independent limit value switch,
mechanical locking mechanisms, EMERGENCY STOP/EMERGENCY OFF devices).
DANGER
External power supply units for supplying components of the drive control must have safety
isolation from circuits with dangerous voltages (DVC A according to EN 61800-5-1;
SELV/PELV). In addition only power units with control circuits that have safety isolation
from circuits with dangerous voltages may be connected.

Hardware and Software
Service Manual, 03/2010, 6FC5397-5DP20-0BA0 13
System description 2
2.1 System overview
System design
The following configuration shows a typical example:
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System description
2.2 System versions
Hardware and Software
14 Service Manual, 03/2010, 6FC5397-5DP20-0BA0
2.2 System versions
Front panel of the different versions with interfaces
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④ Control key group
⑤ Hotkey group
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System description
2.2 System versions
Hardware and Software
Service Manual, 03/2010, 6FC5397-5DP20-0BA0 15
⑦ Numerical block
⑧ Menu forward key
⑨ 3/8" threads for additional components
⑩ Protective cover for user interfaces
⑪ X127: Ethernet (service socket)
⑫ Status LEDs: RDY, NC, CF
⑬ X125: USB port
⑭ Slot for CompactFlash Card with user data
Figure 2-2 System versions
Rear of the PPU
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System description
2.2 System versions
Hardware and Software
16 Service Manual, 03/2010, 6FC5397-5DP20-0BA0

Hardware and Software
Service Manual, 03/2010, 6FC5397-5DP20-0BA0 17
Service cases - software 3
Overview
The following software tools should be used for the subsequently described service activities
and to backup system and user data:
● Toolbox CD V2.6 SINUMERIK 828D with the following contents:
– PLC Programming Tool for Integrated PLC
– Commissioning software for SINAMICS S120
– Recovery system
● RCS Commander V2.6 SP1
Backing up log files:
If system problems occur, then it is necessary to backup all of the existing log files in order to
provide these to the hotline for diagnostics. There is a special shortcut key for this function:
CTRL + ALT + D
This function generates a directory on the User CF card or on the front USB. If both are
available, then the directory is created in both storage media.
Example
The directory name has the following structure: LOG_Date_Time
LOG_091102_083615 stands for a directory generated on 02.11.2009 at 8:36:15.
This therefore ensures that a directory is not overwritten by pressing CTRL + ALT + D
several times. The directory contains all of the logbook and debug information available in
the system.

Service cases - software
3.1 Backing up user data
Hardware and Software
18 Service Manual, 03/2010, 6FC5397-5DP20-0BA0
3.1 Backing up user data
3.1.1 This is how you backup user data
Application
A backup of the data in the complete memory is generated with the "Save data" function.
This data backup must be performed for every control that has been commissioned in order
to be able to quickly restore the control system in the case of data loss. If the "Create
software backup" function is used, then it is essential to backup the memory data.
With the data backup, a copy of the limited buffered memory is stored in the permanent
memory. Backup of selected data (e.g. only machine data and no workpiece programs) is
not possible.
Data can be backed up without a password: i.e. always!
Note
Data backup
After making important changes to the data, immediately backup data, e.g. after the 1st
commissioning and the 2nd commissioning.
Backing up data
Preconditions:
● The control system has powered up.
● The power supply voltage is guaranteed during the data backup.
Proceed as follows to generate the internal data backup:
1. Press the <MENU SELECT> key.
2. Select the "Start-up" operating area.
3. Press the "Save data" softkey.

Service cases - software
3.1 Backing up user data
Hardware and Software
Service Manual, 03/2010, 6FC5397-5DP20-0BA0 19
4. This is followed by the "Query" to backup data:

Service cases - software
3.1 Backing up user data
Hardware and Software
20 Service Manual, 03/2010, 6FC5397-5DP20-0BA0
5. Press the "OK" softkey to backup the data.
– A progress indicator indicate the status of the data backup.
– After the data backup has been successfully completed, the following message is
output:
6. Confirm this message with "OK".
NOTICE
While the data is being backed up, the control system must neither be operated, nor turned
off.