Siemens SINUMERIK 828D Turning User manual

Hardware and Software
_
_________________
_
_
_________________
_
_
_________________
_
_
_________________
_
_
_________________
_
_
_________________
_
_
_________________
_
_
_________________
_
SINUMERIK
SINUMERIK 828D
Hardware and Software
Service Manual
Valid for:
SINUMERIK 828D:
PPU 24x.2 BASIC T
PPU 24x.2 BASIC M
PPU 26x.2
PPU 28x.2
Software:
CNC software V4.3
03/2011
6FC5397-5DP40-0BA0
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: 6FC5397-5DP40-0BA0
Ⓟ 03/2011
Copyright © Siemens AG 2011.
Technical data subject to change

Hardware and Software
Service Manual, 03/2011, 6FC5397-5DP40-0BA0 3
Preface
SINUMERIK documentation
The SINUMERIK documentation is organized in the following categories:
● General documentation
● User documentation
● Manufacturer/service documentation
Additional information
You can find information on the following topics under the link
(http://www.siemens.com/motioncontrol/docu):
● Ordering documentation/overview of documentation
● Additional links to download documents
● Using documentation online (finding and searching in manuals/information)
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following address:
(mailto:[e-mail])
My Documentation Manager (MDM)
Under the following link you will find information to individually compile OEM-specific
machine documentation based on the Siemens content: MDM
(http://www.siemens.com/mdm)
Training
For information about the range of training courses, refer to:
● SITRAIN (www.siemens.com/sitrain) - training courses from Siemens for automation
products, systems and solutions
● SinuTrain (www.siemens.com/sinutrain) - training software for SINUMERIK
FAQs
You can find Frequently Asked Questions in the Service&Support pages under Product
Support (www.siemens.com/automation/service&support).
SINUMERIK
You can find information on SINUMERIK under the following link:
(http://www.siemens.com/sinumerik)

Preface
Hardware and Software
4 Service Manual, 03/2011, 6FC5397-5DP40-0BA0
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. This
does not, however, represent an obligation to supply such functions with a new control or
when servicing.
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.
Technical support
Country-specific telephone numbers for technical support are provided in the Internet under
"Contact" (www.siemens.com/automation/service&support).
EC Declaration of Conformity
The EC declaration of conformity for the EMC directive can be found in the Internet
(www.siemens.com/automation/service&support).
Here, enter the number 15257461 as the search term or contact your local Siemens office.
CompactFlash Cards
● 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.

Preface
Hardware and Software
Service Manual, 03/2011, 6FC5397-5DP40-0BA0 5
● 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).
● For SINUMERIK 828D, only the memory card (1 GB) with order number 6FC5313-
5AG00-0AA1 is permitted.

Preface
Hardware and Software
6 Service Manual, 03/2011, 6FC5397-5DP40-0BA0

Hardware and Software
Service Manual, 03/2011, 6FC5397-5DP40-0BA0 7
Table of contents
Preface ...................................................................................................................................................... 3
1 Safety notes............................................................................................................................................. 11
2 System description .................................................................................................................................. 13
2.1 System overview..........................................................................................................................13
2.2 System versions horizontal and vertical ......................................................................................15
2.3 System versions, BASIC T and BASIC M....................................................................................17
3 Service cases - software.......................................................................................................................... 21
3.1 Backing up user data ...................................................................................................................22
3.1.1 This is how you backup user data................................................................................................22
3.1.2 This is how you load the user data backup..................................................................................25
3.2 Generating a commissioning archive...........................................................................................27
3.2.1 This is how you generate a series commissioning archive on an external data carrier ..............27
3.2.2 This is how you import a series commissioning archive from an external data carrier ...............30
3.2.3 This is how you generate a series commissioning archive on the system CompactFlash
Card .............................................................................................................................................32
3.2.4 This is how you import a series commissioning archive from the system CompactFlash
Card .............................................................................................................................................34
3.3 Software backup ..........................................................................................................................36
3.3.1 This is how you generate a software backup...............................................................................36
3.3.2 This is how you install a software backup....................................................................................40
3.4 Software update...........................................................................................................................44
3.4.1 This is how you update the software ...........................................................................................44
3.5 Mini boot system on the CompactFlash Card..............................................................................48
3.5.1 This is how you generate a mini boot system..............................................................................48
3.5.2 This is how you install a software backup using the mini boot system........................................52
3.6 Licensing......................................................................................................................................55
3.6.1 Licensing after replacing the system CompactFlash Card ..........................................................55
3.6.2 This is how you license a CNC option .........................................................................................55
3.6.3 This is how you determine missing licenses/options ...................................................................57
3.6.4 This is how you generated a new license key .............................................................................58
3.6.5 This is how you display the actual license key ............................................................................61
3.7 Enter the final end user data (EUNA) ..........................................................................................64
3.7.1 This is how you generate the machine logbook...........................................................................64
3.7.2 This is how you make a new entry in the logbook .......................................................................66
3.7.3 This is how you save the machine identity ..................................................................................68
3.7.4 This is how you send the end user final destination data ............................................................69
4 Service cases - hardware ........................................................................................................................ 73
4.1 PPU 24x.2/26x.2/28x.2 ................................................................................................................74
4.1.1 PPU status displays .....................................................................................................................74

Table of contents
Hardware and Software
8 Service Manual, 03/2011, 6FC5397-5DP40-0BA0
4.1.2 This is how you remove the PPU................................................................................................ 77
4.1.3 This is how you install the PPU................................................................................................... 78
4.2 Replacing the system CompactFlash Card................................................................................. 79
4.2.1 This is how you remove the system CompactFlash Card........................................................... 79
4.2.2 This is how you insert the system CompactFlash Card.............................................................. 81
4.3 SINAUT modem .......................................................................................................................... 84
4.3.1 LED status displays..................................................................................................................... 84
4.3.2 This is how you insert the SIM card............................................................................................ 85
4.3.3 This is how you load the factory settings .................................................................................... 91
4.4 Machine control panels ............................................................................................................... 92
4.4.1 Status displays MCP 310C PN ................................................................................................... 92
4.4.2 This is how you remove the MCP 310C PN................................................................................ 93
4.4.3 This is how you install the MCP 310C PN ..................................................................................95
4.4.4 Status displays, MCP 483C PN .................................................................................................. 96
4.4.5 This is how you remove the MCP 483C PN................................................................................ 97
4.4.6 This is how you install the MCP 483C PN ..................................................................................99
4.5 I/O modules............................................................................................................................... 101
4.5.1 Status displays PP 72/48D PN ................................................................................................. 101
4.5.2 This is how you remove the PP 72/48D PN.............................................................................. 102
4.5.3 This is how you install the PP 72/48D PN.................................................................................104
4.5.4 Status displays PP 72/48D 2/2A PN ......................................................................................... 105
4.5.5 This is how you remove the PP 72/48D 2/2A PN ..................................................................... 107
4.5.6 This is how you install the PP 72/48D 2/2A PN ........................................................................ 109
4.6 Expansion module NX10.3........................................................................................................ 110
4.6.1 NX10.3 status displays.............................................................................................................. 110
4.6.2 NX10.3 connections.................................................................................................................. 111
4.6.3 This is how you remove the NX10.3 ......................................................................................... 112
4.6.4 This is how you install the NX10.3............................................................................................ 113
4.7 Installing SINAMICS components.............................................................................................115
4.7.1 Releasing with a screwdriver .................................................................................................... 115
4.7.2 Protective conductor connection and shield support ................................................................ 116
4.8 SINAMICS S120 Combi............................................................................................................ 117
4.8.1 S120 Combi status displays...................................................................................................... 117
4.8.2 Connections, 3-axis module...................................................................................................... 119
4.8.3 Connections, 4-axis module...................................................................................................... 121
4.8.4 How to mount an S120 Combi Power Module.......................................................................... 123
4.8.5 This is how you remove the front panel .................................................................................... 124
4.8.6 This is how you open the DC link cover.................................................................................... 126
4.8.7 This is how you connect the DC link busbars and 24 V busbars.............................................. 128
4.8.8 To connect the second component........................................................................................... 130
4.8.9 This is how you remove the internal fan ................................................................................... 133
4.8.10 This is how you install the internal fan ...................................................................................... 136
4.8.11 This is how you install the external fan ..................................................................................... 136
4.8.12 This is how you clean the heat sink of the S120 Combi ........................................................... 141
4.9 Motor Module Booksize Compact format.................................................................................. 144
4.9.1 Motor Module Booksize Compact status displays .................................................................... 144
4.9.2 Motor Module connections........................................................................................................ 145
4.9.3 This is how you mount a Motor Module Booksize Compact..................................................... 147

Table of contents
Hardware and Software
Service Manual, 03/2011, 6FC5397-5DP40-0BA0 9
4.9.4 This is how you replace the fan on a Motor Module Booksize Compact...................................148
4.10 Single Motor Modules ................................................................................................................151
4.10.1 SMM status displays ..................................................................................................................151
4.10.2 SMM connections ......................................................................................................................152
4.10.3 This is how you remove a Motor Module...................................................................................153
4.10.4 This is how you install a Motor Module......................................................................................155
4.11 Double Motor Modules...............................................................................................................158
4.11.1 DMM status displays..................................................................................................................158
4.11.2 DMM connections ......................................................................................................................159
4.11.3 This is how you remove a Motor Module...................................................................................160
4.11.4 This is how you install a Motor Module......................................................................................162
4.12 Smart Line Modules ...................................................................................................................165
4.12.1 SLM (< 16 kW) status displays ..................................................................................................165
4.12.2 SLM (< 16 kW) connections.......................................................................................................166
4.12.3 SLM (16 kW and higher) status displays ...................................................................................167
4.12.4 SLM (16 kW and higher) connections........................................................................................168
4.12.5 This is how you remove an SLM................................................................................................169
4.12.6 This is how you install an SLM...................................................................................................171
4.13 Active Line Modules...................................................................................................................173
4.13.1 ALM status displays ...................................................................................................................173
4.13.2 ALM connections .......................................................................................................................174
4.13.3 This is how you remove an ALM................................................................................................175
4.13.4 This is how you install an ALM...................................................................................................177
4.14 Sensor Modules Cabinet............................................................................................................179
4.14.1 SMC10/SMC20 status displays .................................................................................................179
4.14.2 SMC10/SMC20 connections......................................................................................................180
4.14.3 This is how you remove an SMC10/SMC20..............................................................................181
4.14.4 This is how you install an SMC10/SMC20.................................................................................182
4.14.5 SMC30 status displays ..............................................................................................................183
4.14.6 SMC30 connections...................................................................................................................184
4.14.7 This is how you remove an SMC30 ...........................................................................................185
4.14.8 This is how you install an SMC30..............................................................................................187
4.15 Sensor Modules External...........................................................................................................189
4.15.1 SME20 connections ...................................................................................................................189
4.15.2 This is how you remove an SME20 and install it again .............................................................189
4.15.3 SME25 connections ...................................................................................................................190
4.15.4 This is how you remove an SME25 and install it again .............................................................191
4.15.5 SME120 connections .................................................................................................................192
4.15.6 This is how you remove an SME120 and install it again ...........................................................193
4.15.7 SME125 connections .................................................................................................................194
4.15.8 This is how you remove an SME125 and install it again ...........................................................194
4.16 Terminal Modules ......................................................................................................................196
4.16.1 TM54F status displays ...............................................................................................................196
4.16.2 TM54F connections ...................................................................................................................198
4.16.3 This is how you remove an TM54F............................................................................................198
4.16.4 This is how you install a TM54F.................................................................................................200
4.17 Hub Modules..............................................................................................................................201
4.17.1 DMC20 status displays ..............................................................................................................201

Table of contents
Hardware and Software
10 Service Manual, 03/2011, 6FC5397-5DP40-0BA0
4.17.2 DMC20 connections.................................................................................................................. 202
4.17.3 This is how you remove a DMC20 ............................................................................................ 202
4.17.4 This is how you install a DMC20............................................................................................... 204
4.17.5 DME20 connections .................................................................................................................. 205
4.17.6 This is how you mount a DME20 .............................................................................................. 206
4.17.7 Connection to X524 electronics power supply.......................................................................... 207
5 Spare parts and accessories ................................................................................................................. 209
5.1 Spare parts for the S120 Combi ............................................................................................... 210
A ESD guidelines ...................................................................................................................................... 211
A.1 RI suppression measures ......................................................................................................... 211
A.2 ESD measures .......................................................................................................................... 212
B Appendix................................................................................................................................................ 213
B.1 List of abbreviations .................................................................................................................. 213
B.2 Documentation overview........................................................................................................... 216
Index...................................................................................................................................................... 217

Hardware and Software
Service Manual, 03/2011, 6FC5397-5DP40-0BA0 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, 03/2011, 6FC5397-5DP40-0BA0
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, 03/2011, 6FC5397-5DP40-0BA0 13
System description 2
2.1 System overview
System design
The following configuration shows a typical example with SINAMICS S120 booksize:
3/&,2LQWHUIDFHEDVHG
RQ352),1(7
&RPSDQ\QHWZRUN,QGXVWULDO(WKHUQHW
,QGXFWLRQPRWRU
6\QFKURQRXV
PRWRU
6\QFKURQRXV
PRWRU
6\QFKURQRXV
PRWRU
[KDQGZKHHO
3HHUWRSHHU
3*3&
QRQFURVVHG
PRGHPFDEOH
6/0
6,1$870'
'5,9(&/L4
6,1$0,&66
60&
6,180(5,.'
0&331
33'31
33'$31
600 600 600 600
Figure 2-1 Configuration example 1: Basic configuration with 4 axes

System description
2.1 System overview
Hardware and Software
14 Service Manual, 03/2011, 6FC5397-5DP40-0BA0
The following configuration shows the maximum expansion stage with SINAMICS S120
Combi:
%UDNLQJUHVLVWRU
8SWR
/LQHDUVFDOHV
2SWLRQDO
/LQHILOWHU
6HUYRPRWRU6SLQGOHPRWRU 6HUYRPRWRU 6HUYRPRWRU 6HUYRPRWRU6HUYRPRWRU
6XSSOHPHQWDU\
VSLQGOH
/LQHUHDFWRU
0RWRUFDEOH
77/VSLQGOHHQFRGHU
3/&,2LQWHUIDFHEDVHG
RQ352),1(7
&RPSDQ\QHWZRUN,QGXVWULDO(WKHUQHW
[KDQGZKHHO
3HHUWRSHHU
3*3&
QRQFURVVHG
PRGHPFDEOH
9
$&
%UDNLQJ0 RGXOH

&RQWURO6XSSO\0RGXOH

'RXEOH0RWRU0RGXOH%RRNVL]H&RPSDFW

'5,9(&/L4
'5,9(&/L4
'0&'0(
70)
6,1$0,&6
6&RPEL
3RZHU0RGXOH
6,180(5,.'
0&331
33'31
33'$31
Figure 2-2 Configuration example 2: Maximum expansion stage with 6 axes and with Safety Integrated

System description
2.2 System versions horizontal and vertical
Hardware and Software
Service Manual, 03/2011, 6FC5397-5DP40-0BA0 15
2.2 System versions horizontal and vertical
Front of the PPU versions 26x.2 and 28x.2




 








 








① Protective cover for user interfaces
② Menu back key
③ Alphabetic key group
④ Control key group
⑤ Hotkey group
⑥ Cursor key group

System description
2.2 System versions horizontal and vertical
Hardware and Software
16 Service Manual, 03/2011, 6FC5397-5DP40-0BA0
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 LED: RDY, NC, CF
⑬ X125 USB interface
⑭ Slot for CompactFlash Card with user data
Figure 2-3 System versions
Rear of the PPU 26x.2 and 28x.2












① ② X122, X132 Digital inputs/outputs, drive
③ ④ X242, X252 Digital inputs/outputs, NC
⑤ X143 Handwheels
⑥ M, T2, T1, T0 Measuring sockets
⑦ X1 Power supply
⑧ X135 USB interface: For service purposes only
⑨ X130 Ethernet LAN
⑩ PN 1, PN 2 PLC I/O Interface
⑪ SYNC, FAULT Status LEDs
⑫ X100, X101, X102 DRIVE-CLIQ interfaces
⑬ X140 Serial interface RS232
Figure 2-4 Interfaces on the rear side of the PPU

System description
2.3 System versions, BASIC T and BASIC M
Hardware and Software
Service Manual, 03/2011, 6FC5397-5DP40-0BA0 17
2.3 System versions, BASIC T and BASIC M
Front panel of the SINUMERIK 828D BASIC T with interfaces




 








 








① ⑩ Protective cover for user interfaces
② Menu back key
③ Alphabetic key group
④ Control key group

System description
2.3 System versions, BASIC T and BASIC M
Hardware and Software
18 Service Manual, 03/2011, 6FC5397-5DP40-0BA0
⑤ Hotkey group
⑥ Cursor key group
⑦ Numerical block
⑧ Menu forward key
⑨ 3/8" threads for additional components
⑪ X127 Ethernet (service socket)
⑫ Status LED: RDY, NC, CF
⑬ X125 USB interface
⑭ Slot for CompactFlash Card with user data
Figure 2-5 System versions

System description
2.3 System versions, BASIC T and BASIC M
Hardware and Software
Service Manual, 03/2011, 6FC5397-5DP40-0BA0 19
Rear of the PPU 24x.2












① ② X122, X132 Digital inputs/outputs, drive
③ ④ X242, X252 Digital inputs/outputs, NC
⑤ X143 Handwheels
⑥ M, T2, T1, T0 Measuring sockets
⑦ X1 Power supply
⑧ X135 USB interface: For service purposes only
⑨ X130 Ethernet LAN
⑩ PN PLC I/O Interface
⑪ SYNC, FAULT Status LEDs
⑫ X100, X101, X102 DRIVE-CLIQ interfaces
⑬ X140 Serial interface RS232
Figure 2-6 Interfaces at the rear

System description
2.3 System versions, BASIC T and BASIC M
Hardware and Software
20 Service Manual, 03/2011, 6FC5397-5DP40-0BA0