Page 1 ___________________ Hardware and Software Preface ___________________ Safety notes ___________________ System description SINUMERIK ___________________ Service cases - software SINUMERIK 828D ___________________ Hardware and Software Service cases - hardware ___________________ Spare parts and accessories Service Manual ___________________ ESD guidelines ___________________ Appendix Valid for: SINUMERIK 828D: PPU 24x.2 BASIC T...
Page 2 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.
Page 3: Preface
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...
Page 4 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.
Page 5 (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,...
Page 6 Preface Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 7: Table Of Contents
Table of contents Preface ..............................3 Safety notes............................. 11 System description ..........................13 System overview ..........................13 System versions horizontal and vertical ..................15 System versions, BASIC T and BASIC M..................17 Service cases - software.......................... 21 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...
Page 8 Table of contents 4.1.2 This is how you remove the PPU....................77 4.1.3 This is how you install the PPU....................78 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 SINAUT modem ..........................
Page 9 Table of contents 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...
Page 10 Table of contents 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 ................
Page 11: Safety Notes
Safety notes 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.
Page 12 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.
Page 13: System Description
System description System overview System design The following configuration shows a typical example with SINAMICS S120 booksize: Figure 2-1 Configuration example 1: Basic configuration with 4 axes Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 14 System description 2.1 System overview The following configuration shows the maximum expansion stage with SINAMICS S120 Combi: Figure 2-2 Configuration example 2: Maximum expansion stage with 6 axes and with Safety Integrated Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 15: System Versions Horizontal And Vertical
System description 2.2 System versions horizontal and vertical 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...
Page 16 System description 2.2 System versions horizontal and vertical 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...
Page 17: System Versions, Basic T And Basic M
System description 2.3 System versions, BASIC T and BASIC M 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...
Page 18 System description 2.3 System versions, BASIC T and BASIC M 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...
Page 19 System description 2.3 System versions, BASIC T and BASIC M 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 Power supply ⑧...
Page 20 System description 2.3 System versions, BASIC T and BASIC M Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 21: Service Cases - Software
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 –...
Page 22: Backing Up User Data
Service cases - software 3.1 Backing up user data 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.
Page 23 Service cases - software 3.1 Backing up user data 4. This is followed by the "Query" to backup data: Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 24 Service cases - software 3.1 Backing up user data 5. Press the "OK" softkey to backup the data. – A progress indicator indicates the status of the data backup. – After the data backup has been successfully completed, the following message is output: 6.
Page 25: This Is How You Load The User Data Backup
Service cases - software 3.1 Backing up user data 3.1.2 This is how you load the user data backup NOTICE If this function is activated, the actual system data is replaced by the data backup. Procedure Proceed as follows to load the internal data backup: 1.
Page 26 Service cases - software 3.1 Backing up user data 3. Using the arrow key, select the menu item "Reload saved user data". 4. Confirm that the backup is loaded by pressing the key <INPUT>. 5. Confirm the confirmation prompt by pressing the <INPUT> key. Are you sure you want to reload saved user data?"...
Page 27: Generating A Commissioning Archive
Service cases - software 3.2 Generating a commissioning archive Generating a commissioning archive Overview A commissioning archive is used to completely backup all of the data required for the machine function. A commissioning archive can be generated on an external data carrier, e.g. USB-FlashDrive or CompactFlash card at the front panel of the control as well as on the system CompactFlash Card.
Page 28 Easy Archive  Select all of the components, unless it is known that individual components do not deviate from the Siemens standard.  Select all data classes, unless only certain data (e.g. INDIVIDUAL) are to be backed 6. Press the "Generate archive" softkey.
Page 29 Service cases - software 3.2 Generating a commissioning archive 9. Press the "New directory" softkey to generate a new directory. The "New Directory" window opens. 10. Enter the required name and confirm with "OK." The directory is created subordinate to the selected folder. 11.
Page 30: This Is How You Import A Series Commissioning Archive From An External Data Carrier
Service cases - software 3.2 Generating a commissioning archive 3.2.2 This is how you import a series commissioning archive from an external data carrier Reading in an archive from an external data carrier Procedure: 1. Select the "Start-up" operating area. 2.
Page 31 Service cases - software 3.2 Generating a commissioning archive 7. Select the required commissioning archive (ARD). Example: User CF 8. Press "OK". A query is displayed, here you can see the most important data of the selected archive to be certain that it is OK. 9.
Page 32: This Is How You Generate A Series Commissioning Archive On The System Compactflash Card
Service cases - software 3.2 Generating a commissioning archive 3.2.3 This is how you generate a series commissioning archive on the system CompactFlash Card Generating an archive on the system CompactFlash Card Procedure: 1. Select the "Start-up" operating area. 2. Press the menu forward key. 3.
Page 33 Easy Archive  Select all of the components, unless it is known that individual components do not deviate from the Siemens standard.  Select all data classes, unless only certain data (e.g. INDIVIDUAL) are to be backed 6. Press the "Generate archive" softkey.
Page 34: This Is How You Import A Series Commissioning Archive From The System Compactflash Card
Service cases - software 3.2 Generating a commissioning archive 3.2.4 This is how you import a series commissioning archive from the system CompactFlash Card Reading in an archive from the system CompactFlash Card A description is provided here how you read in a series commissioning archive in order to be able to restore the previous state of the machine.
Page 35 Service cases - software 3.2 Generating a commissioning archive 7. Select the required commissioning archive (ARD). Example: "Archives" → "Manufacturer" 8. Press "OK". A window with the data of the selected archive is displayed. 9. Data is read in when pressing "OK". 10.
Page 36: Software Backup
Service cases - software 3.3 Software backup Software backup 3.3.1 This is how you generate a software backup Overview With "Create software backup", a function is provided to generate a backup of the system software including all of the user data saved on the system card. This backup represents the "Backup"...
Page 37 Service cases - software 3.3 Software backup 5. Press the <SELECT> key, "Normal startup" is the default setting. 6. Now press the following keys in succession: Menu reset key, HSK2 (horizontal SK2), VSK2 (vertical SK2) 7. The Startup menu is displayed: 8.
Page 38 Service cases - software 3.3 Software backup 11. Press the <INPUT> key to start the backup. The software first checks whether a backup was already generated on the card and outputs a message. The backup can now be overwritten or the process interrupted by making the appropriate operator action.
Page 39 Service cases - software 3.3 Software backup 13. Wait until the following message is displayed: 14. Withdraw the storage medium from the slot at the front panel of the control. 15. Switch the control off. 16. Switch the control on. 17.
Page 40: This Is How You Install A Software Backup
Service cases - software 3.3 Software backup 3.3.2 This is how you install a software backup Overview A backup previously generated is loaded into the control using the function "Install software update/backup". All system and user data are overwritten with the software backup image. Note Licenses The backup does not contain a license key;...
Page 41 Service cases - software 3.3 Software backup 4. The Startup menu is displayed: 5. Using the cursor keys, select the menu item "Install software update/backup". 6. Press the <INPUT> key to confirm your selection: 7. Insert the storage medium with the backup in the slot and confirm with "Yes" by using the cursor keys to make the selection: Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 42 Service cases - software 3.3 Software backup 8. Select the valid backup using the cursor keys. 9. Press the <Input> key to confirm your selection. 10. The following message briefly appears: " " Starting software update Then the screen goes dark for several seconds. 11.
Page 43 Service cases - software 3.3 Software backup 15. Switch the control on. 16. The control boots normally. Note If the procedure is interrupted, then it must be restarted. If the system CompactFlash Card is no longer identified as a bootable CompactFlash Card, then a mini boot system must be generated on this card.
Page 44: Software Update
Service cases - software 3.4 Software update Software update 3.4.1 This is how you update the software Data backup If a system update is necessary, then the system data must be backed up so that no data is lost in the case of a problem. In this case, we recommend to perform two types of data backup.
Page 45 Service cases - software 3.4 Software update 2. Press the <SELECT> key, "Normal startup" is the default setting. 3. Now press the following keys in succession: Menu reset key, HSK2 (horizontal SK2), VSK2 (vertical SK2) 4. The setup menu is displayed: 5.
Page 46 Service cases - software 3.4 Software update 7. Use the cursor keys to select "Yes". 8. Select the update image (*.tgz) on the storage medium and confirm with <INPUT>. 9. The software update is started: The following message appears while the update is running: Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 47 Service cases - software 3.4 Software update 10. Wait until the following message is output: 11. Withdraw the storage medium from the slot. 12. Switch the control off. 13. Switch the control on. 14. The control boots normally. NOTICE If the update is interrupted, then it must be restarted. If the system CompactFlash Card is no longer identified as bootable system, then a mini boot system must be generated on this card (see also: This is how you generate a mini boot system (Page 48)).
Page 48: Mini Boot System On The Compactflash Card
CompactFlash Card as it is without any additional preparation. Mini boot system image "Configuration data" are supplied on the toolbox CD of the SINUMERIK 828D, which include in the scope of delivery of mini boot system image: Figure 3-2...
Page 49 Service cases - software 3.5 Mini boot system on the CompactFlash Card Precondition to write: ● RCS Commander has been installed. ● SW package: Configuration data from the Toolbox has been installed. ● CompactFlash card is a replacement card. Installing the boot system on an empty card Procedure: 1.
Page 50 Service cases - software 3.5 Mini boot system on the CompactFlash Card 6. If several versions of the toolbox are installed on the PC, you obtain the following selection: 7. All of the identified interchangeable drives are displayed, here in the example, the CompactFlash Card is identified as drive F:\.
Page 51 Service cases - software 3.5 Mini boot system on the CompactFlash Card 8. Confirm the selection of the target drive with "OK". By pressing the "Write" button, the image is transferred to the target drive. NOTICE While the data is being transferred, do not switch-off the PC and do not remove the CompactFlash Card.
Page 52: This Is How You Install A Software Backup Using The Mini Boot System
Service cases - software 3.5 Mini boot system on the CompactFlash Card 3.5.2 This is how you install a software backup using the mini boot system Overview If a CompactFlash Card with a mini boot system is used as system CompactFlash Card, the system software or a previously generated software backup must still be transferred.
Page 53 Service cases - software 3.5 Mini boot system on the CompactFlash Card 3. Confirm the question with "Yes". 4. Insert the CompactFlash Card or a USB-FlashDrive with the image into the slot on the front panel of the control. 5. Confirm the selection with the <INPUT> key. 6.
Page 54 Service cases - software 3.5 Mini boot system on the CompactFlash Card 7. If a valid image has been found, the following message is output: 8. Wait until the following message is displayed: 9. Switch the control off. 10. Switch the control system back on again: The control boots normally. Note If the system was booted using a mini boot system, there is no valid license key on the system CompactFlash Card.
Page 55: Licensing
Access level 1 (password: Manufacturer). Licensing CNC options If an additional CNC option is to be activated at a SINUMERIK 828D, then this CNC option must be licensed at the machine and is only valid for this CompactFlash Card. Hardware and Software...
Page 56 Service cases - software 3.6 Licensing Proceed as follows to access the "licenses" dialog box: 1. Select the "Start-up" operating area. 2. Press the menu forward key. 3. Press the "Licenses" softkey. The "Licensing" window opens. Using the vertical softkeys, you can execute the following actions: –...
Page 57: This Is How You Determine Missing Licenses/Options
To conclude the assignment, the license key must be entered at the control via the user interface. See also The license database administered by Siemens can only be accessed using the Web License Manager (http://www.siemens.com/automation/license). NOTICE The NC start function is suppressed if a CNC option, for which no valid license key has been entered, is additionally activated.
Page 58: This Is How You Generated A New License Key
Service cases - software 3.6 Licensing 3. Press the "Missing lic./opt." softkey in order to display all options that are licensed. In the "Set" column, you can deselect the options that you do not require. Figure 3-4 Licensing (example) 4. Press the softkey "Set option according to license", to activate all of the options contained in the license key.
Page 59 3. Press the "Licenses" softkey. 4. Press the "Overview" softkey and note down the serial number of the system CompactFlash Card. 5. At your PG/PC, establish a connection to the Web License Manager (http://www.siemens.com/automation/license) Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 60 Service cases - software 3.6 Licensing 6. Log on via "Direct access". Follow additional instructions in the Web License Manager: 7. After completing the assignment process, enter the license key displayed in the Web License Manager into the "Licensing" dialog box in SINUMERIK Operate. Note License key via e-mail If you have an e-mail address, you have the option (checkbox) of receiving the license...
Page 61: This Is How You Display The Actual License Key
Service cases - software 3.6 Licensing 3. Press the "Licenses" softkey. 4. Press the "Overview” softkey. If you receive the license key via the Web License Manager, enter the license key manually in the field "You can enter a new license key here". 5.
Page 62 Service cases - software 3.6 Licensing Displaying the actual license key in the Internet In order to view the actual license key of the control, using the serial number, it is possible display the license key via the Internet. The serial number is on the system CompactFlash Card - or can be displayed at the control as described above.
Page 63 Service cases - software 3.6 Licensing 4. In the menu, select "Hardware serial number" and enter the serial number of the system CompactFlash Card. 5. Press the "Display license key" softkey. 6. The actual license key is displayed as follows: Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 64: Enter The Final End User Data (Euna)
Service cases - software 3.7 Enter the final end user data (EUNA) Enter the final end user data (EUNA) Precondition To change the end user final destination data (EUNA), the following access rights must be available: ● Softkey "Manufacturer" : Access level 1 (password: Manufacturer) ●...
Page 65 Service cases - software 3.7 Enter the final end user data (EUNA) 3. Press the "Details" softkey. The data associated with the machine are displayed in the "Machine logbook": 4. Press the "Change" softkey to open the "Machine identity" dialog box. 5.
Page 66: This Is How You Make A New Entry In The Logbook
Note Contact data Using the "Import data" softkey, templates with contact data can be imported to simplify data entry; these templates are available through Siemens sales partners. 3.7.2 This is how you make a new entry in the logbook Generating a new logbook entry In order to log service and diagnostic procedures at the machine, make an entry in the machine logbook.
Page 67 Service cases - software 3.7 Enter the final end user data (EUNA) 3. Press the "Logbook" softkey. 4. Press the "New entry" softkey in order to make an entry in the logbook. Complete the fields for the new logbook entry: 5.
Page 68: This Is How You Save The Machine Identity
Service cases - software 3.7 Enter the final end user data (EUNA) 3.7.3 This is how you save the machine identity Saving the machine identity Note Ensure that the machine identity that has been entered is correct before saving in order that no incorrect information is saved.
Page 69: This Is How You Send The End User Final Destination Data
Service cases - software 3.7 Enter the final end user data (EUNA) The data are pre-assigned so that a change is not necessary. The "Name" text field is pre-assigned as follows: <Machine name/Number>+<Number of the CompactFlash Card> You now have the opportunity of changing this name. You can enter a comment in the "Comments"...
Page 70 ● The PC/PG is connected with the Internet. Please proceed as follows: 1. Open the Internet Browser on your PC/PG. 2. Connection with EUNA (http://www.siemens.com/sinumerik/register). 3. Select a language and enter an e-mail address: Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 71 9. If no other files are to be uploaded, press the softkey "continue >". 10. Complete the upload by pressing the "Save" softkey. Note Contact persons worldwide If it was not possible to transfer the file, then please contact your local Siemens officeContact (http://www.automation.siemens.com/partner) in sales. Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 72 Service cases - software 3.7 Enter the final end user data (EUNA) Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 73: Service Cases - Hardware
Information about the cause of faults and how they can be resolved can be found in the following references: ● SINUMERIK 828D/SINAMICS S120 Diagnostics Manual "Alarms" /828D_DA/ ● SINUMERIK 828D/SINAMICS S120 List Manual "Parameter description" /828D_LH2/ Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 74: Ppu 24X.2/26X.2/28X.2
Service cases - hardware 4.1 PPU 24x.2/26x.2/28x.2 PPU 24x.2/26x.2/28x.2 4.1.1 PPU status displays Status displays front side On the front side of the PPU, the following status displays provide information about the module state: Figure 4-2 Vertical flap (detail) The three LEDs located behind the protective flap on the front side of the PPU have the following significance: Name Color...
Page 75 Service cases - hardware 4.1 PPU 24x.2/26x.2/28x.2 The RJ45 socket is equipped with one green and one yellow LED. As a consequence, the following information of the PLC I/O interface is displayed based on PROFINET: Name Color State Meaning Link Green 100 MBit link available Missing or faulty link...
Page 76 PLC I/O is not being used. SYNC *) Green Task system of the SINUMERIK 828D is not synchronized to the send clock of the PLC I/O interface based on PROFINET IO. An internal substitute clock of the same size as the send clock will be generated.
Page 77: This Is How You Remove The Ppu
Service cases - hardware 4.1 PPU 24x.2/26x.2/28x.2 4.1.2 This is how you remove the PPU Precondition For this description, it is assumed that the PPU has been completely connected. Removing This description applies to both versions (vertical/horizontal). Procedure: 1. Switch-off the control: Completely switch off the system. Check that the system is in a no- voltage condition and is locked-out so that it cannot be switched on again without the appropriate authorization.
Page 78: This Is How You Install The Ppu
Service cases - hardware 4.1 PPU 24x.2/26x.2/28x.2 4.1.3 This is how you install the PPU Installing Procedure: 1. Now, install the system CompactFlash Card into the new PPU. (refer to Chapter This is how you insert the system CompactFlash Card (Page 81)) 2.
Page 79: Replacing The System Compactflash Card
Service cases - hardware 4.2 Replacing the system CompactFlash Card Replacing the system CompactFlash Card 4.2.1 This is how you remove the system CompactFlash Card Overview If service is required, it may be necessary to replace the system CompactFlash Card of the control.
Page 80 Service cases - hardware 4.2 Replacing the system CompactFlash Card 3. Move the metal cover to the side and remove it. 4. Remove the system CompactFlash Card from the side. 5. Fix the metal cover by first locating at the rear and then tilting it into the end position. Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 81: This Is How You Insert The System Compactflash Card
Service cases - hardware 4.2 Replacing the system CompactFlash Card 6. Fix the metal cover to the housing using the screw. Note When removing the system CompactFlash Card, carefully ensure that neither the screw nor the system CompactFlash Card falls into the PPU or the machine. PPU as replacement part Note For a PPU as replacement part (spare part), a system CompactFlash Card is not supplied.
Page 82 Service cases - hardware 4.2 Replacing the system CompactFlash Card Inserting the system CompactFlash Card Procedure: 1. Release the screw (M3). 2. Move the metal cover to the side and withdraw it. 3. Gently insert the system CompactFlash Card into the slot until it clicks into place. Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 83 Service cases - hardware 4.2 Replacing the system CompactFlash Card 4. Reattach the metal cover by first locating it at the rear and then tilting it into the end position. 5. Fix the metal cover to the housing using the screw. Note When inserting the system CompactFlash Card, carefully ensure that neither the screw nor the system CompactFlash Card falls into the PPU or the machine.
Page 84: Sinaut Modem
Service cases - hardware 4.3 SINAUT modem SINAUT modem 4.3.1 LED status displays Validity This description is valid for the GPRS/GSM modem MD720-3, hardware version 3.x. You can find additional information in the System Manual SINAUT MD720-3 in the Chapter "Service functions".
Page 85: This Is How You Insert The Sim Card
Service cases - hardware 4.3 SINAUT modem 4.3.2 This is how you insert the SIM card CAUTION Risk of damage to sensitive components due to static electricity This activity must always be carried out by trained personnel. Open the module Proceed as follows to open the module: 1.
Page 86 Service cases - hardware 4.3 SINAUT modem 1. Using a suitable object, press one of the two opening lugs carefully so that the fastener opens. 2. Remove the rear section of the housing. 3. The SIM card holder can be seen on the printed circuit board: ①...
Page 87 Service cases - hardware 4.3 SINAUT modem Inserting the SIM card NOTICE When handling SIM cards, carefully observe its safety instructions. When changing the SIM card, do not forget to change the PIN in your control. If you are using a lot of SIM cards, it may make sense to set all SIM cards, e.g. with one cellular phone to the same PIN.
Page 88 Service cases - hardware 4.3 SINAUT modem The slot for the SIM card in the upper section is shown in white in the following diagram: 3. Insert the SIM card into the upper section of the SIM card holder so that the contact surface is at the bottom and the sloped corner of the SIM card points towards the front of the device.
Page 89 Service cases - hardware 4.3 SINAUT modem 5. Press the upper section of the SIM card holder downwards. Ensure that the sloped corner of the SIM card clicks into place. 6. Using your fingernail or a suitable object, slide the upper section of the SIM card holder approximately 2 mm in the direction of the arrow to the right in order to lock the SIM card holder.
Page 90 Service cases - hardware 4.3 SINAUT modem 8. Then assemble the two housing sections again. To do this, locate the printed circuit board in the upper and lower rails inside the rear section of the housing. ① Rail for the printed circuit board 9.
Page 91: This Is How You Load The Factory Settings
Service cases - hardware 4.3 SINAUT modem 4.3.3 This is how you load the factory settings Loading the factory settings Figure 4-5 MD720-3: Front view If you press the SET key for longer than 4 seconds until the LED "C" starts to light up, then the SINAUT MD720-3 configuration is reset to the default values set in the factory.
Page 92: Machine Control Panels
Service cases - hardware 4.4 Machine control panels Machine control panels 4.4.1 Status displays MCP 310C PN LEDs for status display For the MCP 310C PN there are 3 LEDs in a row (H1-H3), which provide information about the module state: Figure 4-7 Status displays H1 (green)
Page 93: This Is How You Remove The Mcp 310C Pn
Service cases - hardware 4.4 Machine control panels 4.4.2 This is how you remove the MCP 310C PN Overview The activities that must be taken into account when replacing a machine control panel are subsequently described. If the machine control panel has a hardware defect, then it must be replaced by an identical replacement part.
Page 94 Slot for Emergency Stop button or spindle override ② Power supply interface ③ Handwheel connection *) ④ Handwheel connection *) ⑤ Switch: for SINUMERIK 828D, no function ⑥ Switch ⑦ LEDs ⑧ Ethernet cable strain relief ⑨ Port 2: PLC I/O interfaces based on PROFINET ⑩...
Page 95: This Is How You Install The Mcp 310C Pn
Service cases - hardware 4.4 Machine control panels Procedure: 1. Switch-off the control: Completely switch off the system. Check that the system is in a no- voltage condition and is locked-out so that it cannot be switched on again without the appropriate authorization.
Page 96: Status Displays, Mcp 483C Pn
Switch S2 Switch S2 defines the IP address of the machine control panel: Device name mcp-pn64 For SINUMERIK 828D, the IP address = 192.168.214.64 must always be assigned to the MCP. 4.4.4 Status displays, MCP 483C PN LED status displays...
Page 97: This Is How You Remove The Mcp 483C Pn
Service cases - hardware 4.4 Machine control panels H1 (green) H2 (green) H3 (red) PowerOK PN Sync PN Fault Power Off Power On (voltage is stable) Boot software runs and loads the system software. System software runs. System software runs, no communication to the controller.
Page 98 ⑨ Ethernet cable strain relief ⑩ LEDs ⑪ Switch ⑫ Switch: for SINUMERIK 828D, has no function ⑬ Handwheel connection *) Handwheel connection *) ⑭ Power supply interface Handwheels are directly connected to the PPU: Do not wire X60/X61 Figure 4-11...
Page 99: This Is How You Install The Mcp 483C Pn
Service cases - hardware 4.4 Machine control panels Procedure: 1. Switch-off the control: Completely switch off the system. Check that the system is in a no- voltage condition and is locked-out so that it cannot be switched on again without the appropriate authorization.
Page 100 Figure 4-12 Switch S2 Switch S2 defines the IP address of the machine control panel: Device name mcp-pn64 For SINUMERIK 828D, the IP address = 192.168.214.64 must always be assigned to the MCP. Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 101: I/O Modules
Service cases - hardware 4.5 I/O modules I/O modules 4.5.1 Status displays PP 72/48D PN LEDs for status display The following LEDs on the I/O module provide information about the module state: Figure 4-13 Switch S1 and LEDs H1 to H6 H1 (green) H2 (green) H3 (red)
Page 102: This Is How You Remove The Pp 72/48D Pn
Service cases - hardware 4.5 I/O modules LEDs at port 1 and port 2 There are 2 LEDs at port 1 and port 2 for diagnostics of the PLC I/O interfaces based on PROFINET. Figure 4-14 Port 1 and port 2 LED for communication at the RJ45 connector.
Page 103 Service cases - hardware 4.5 I/O modules Removing Figure 4-15 Rear of the PP 72/48D PN NOTICE Electro-static discharge (ESD) Before you touch the module, discharge yourself at the cabinet or at the ground terminal. Procedure: 1. Switch-off the control: Completely switch off the system. Check that the system is in a no- voltage condition and is locked-out so that it cannot be switched on again without the appropriate authorization.
Page 104: This Is How You Install The Pp 72/48D Pn
Service cases - hardware 4.5 I/O modules 7. Remove the strain relief of the communication cables to interfaces X2. 8. Remove the communication cables from interface X2 (port 1 and port 2). 9. Remove the ground connection by releasing the grounding screw. 10.
Page 105: Status Displays Pp 72/48D 2/2A Pn
Service cases - hardware 4.5 I/O modules 4.5.4 Status displays PP 72/48D 2/2A PN LEDs for status display The following LEDs on the I/O module provide information about the module state: Figure 4-16 Switch S1 and LEDs H1 to H6 H1 (green) H2 (green) H3 (red)
Page 106 Service cases - hardware 4.5 I/O modules LEDs at port 1 and port 2 There are 2 LEDs at port 1 and port 2 for diagnostics of the PLC I/O interfaces based on PROFINET. Figure 4-17 Port 1 and port 2 LED for communication at the RJ45 connector.
Page 107: This Is How You Remove The Pp 72/48D 2/2A Pn
Service cases - hardware 4.5 I/O modules 4.5.5 This is how you remove the PP 72/48D 2/2A PN Overview The activities necessary when replacing the PP 72/48D 2/2A PN I/O module are described in the following. If the PP 72/48D 2/2A PN has a hardware defect, then it must be replaced by an identical module.
Page 108 Service cases - hardware 4.5 I/O modules Removing Figure 4-18 Rear of PP 72/48D 2/2A PN NOTICE Electro-static discharge (ESD) Before you touch the module, discharge yourself at the cabinet or at the ground terminal. Procedure: 1. Switch-off the control: Completely switch off the system. Check that the system is in a no- voltage condition and is locked-out so that it cannot be switched on again without the appropriate authorization.
Page 109: This Is How You Install The Pp 72/48D 2/2A Pn
Service cases - hardware 4.5 I/O modules 8. Remove the communication cables from interface X2 (port 1 and port 2). 9. Remove the ground connection by releasing the grounding screw. 10. To remove the I/O module, release the fixing screws. 11.
Page 110: Expansion Module Nx10.3
Service cases - hardware 4.6 Expansion module NX10.3 Expansion module NX10.3 4.6.1 NX10.3 status displays Status displays The following status displays on the NX10.3 provide information about the module state: Color State Description RDY, H1 Electronics power supply outside the permissible tolerance range. Green Continuous light Component is ready.
Page 111: Nx10.3 Connections
Service cases - hardware 4.6 Expansion module NX10.3 4.6.2 NX10.3 connections Connections Figure 4-19 NX10.3 connections Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 112: This Is How You Remove The Nx10.3
Service cases - hardware 4.6 Expansion module NX10.3 4.6.3 This is how you remove the NX10.3 Preconditions The activities that are required when replacing an NX10.3 are subsequently described. If the NX10.3 has a hardware defect, then it must be replaced by an identical module. ●...
Page 113: This Is How You Install The Nx10.3
Service cases - hardware 4.6 Expansion module NX10.3 NOTICE Electro-static discharge (ESD) Before you touch the component, discharge yourself at the cabinet or at the ground terminal. Procedure: 1. Switch-off the control: Completely switch off the system. Check that the system is in a no- voltage condition and is locked-out so that it cannot be switched on again without the appropriate authorization.
Page 114 Service cases - hardware 4.6 Expansion module NX10.3 7. Now check that all of the cables have been re-connected. 8. Now close the cover cap of the NX10. 9. Close the cabinet and switch-on the system again. CAUTION Ensure that all of the connectors and screws are correctly tightened or latched and inserted.
Page 115: Installing Sinamics Components
Service cases - hardware 4.7 Installing SINAMICS components Installing SINAMICS components 4.7.1 Releasing with a screwdriver The new protective covers for the DC link on the SINAMICS S120 components feature a new interlock mechanism, which is really easy to operate using a slot-head screwdriver (1 x 5.5).
Page 116: Protective Conductor Connection And Shield Support
Service cases - hardware 4.7 Installing SINAMICS components 4.7.2 Protective conductor connection and shield support Shield support and protective conductor connection It is always advisable to use shielded wiring for the digital inputs and outputs. DANGER If the shielding procedures described and the specified cable lengths are not observed, the machine may not operate properly.
Page 117: Sinamics S120 Combi
Service cases - hardware 4.8 SINAMICS S120 Combi SINAMICS S120 Combi 4.8.1 S120 Combi status displays Status displays The SINAMICS S120 Combi has two LEDs to display the status of the components. The software assigns a priority to the status signals from the individual components. The most important and most informative status is output for the complete S120 Combi.
Page 118 Service cases - hardware 4.8 SINAMICS S120 Combi DANGER DC link voltage Hazardous DC link voltages may be present at any time regardless of the state of the "DC LINK" LED. The warning information on the components must be carefully observed! Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 119: Connections, 3-Axis Module
Service cases - hardware 4.8 SINAMICS S120 Combi 4.8.2 Connections, 3-axis module Connections Figure 4-22 S120 Combi 3 axis Power Module Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 120 Service cases - hardware 4.8 SINAMICS S120 Combi View from the top The shield connection terminal is included in the accessories pack (Weidmüller, type KLBÜ 3-8 SC). Figure 4-23 S120 Combi 3 axis Power Module View from below Figure 4-24 S120 Combi 3 axis Power Module Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 121: Connections, 4-Axis Module
Service cases - hardware 4.8 SINAMICS S120 Combi 4.8.3 Connections, 4-axis module Connections, S120 Combi with 4 axes Figure 4-25 S120 Combi 4 axis Power Module Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 122 Service cases - hardware 4.8 SINAMICS S120 Combi View from the top The shield connection terminal is included in the accessories pack (Weidmüller, type KLBÜ 3-8 SC). Figure 4-26 S120 Combi 4 axis Power Module View from below Figure 4-27 S120 Combi 4 axis Power Module Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 123: How To Mount An S120 Combi Power Module
Service cases - hardware 4.8 SINAMICS S120 Combi 4.8.4 How to mount an S120 Combi Power Module Precondition The reinforcement plates are installed in order to mount an S120 Combi Power Module. Mounting Procedure: 1. Mount the self-clinching flush head studs M6. 2.
Page 124: This Is How You Remove The Front Panel
Service cases - hardware 4.8 SINAMICS S120 Combi 4. Connect the protective conductor. See also: Protective conductor connection and shield support (Page 116) 5. Connect the following connections with the associated screw-type terminals: X1: Line supply connection X2 to X4: Motor connection for the S120 Combi with 3 axes X2 to X5: Motor connection for the S120 Combi with 4 axes 4.8.5 This is how you remove the front panel...
Page 125 Service cases - hardware 4.8 SINAMICS S120 Combi 3. Release the front cover by slightly pressing upwards 4. Remove the front plate. Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 126: This Is How You Open The Dc Link Cover
Service cases - hardware 4.8 SINAMICS S120 Combi 4.8.6 This is how you open the DC link cover Removing the front plate of the S120 Combi To electrically connect additional components, the front cover of the S120 Combi must already have been removed. The DC link busbars are located under the DC link cover.
Page 127 Service cases - hardware 4.8 SINAMICS S120 Combi 2. Remove the DC link cover. 3. Remove the DC link side cover. Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 128: This Is How You Connect The Dc Link Busbars And 24 V Busbars
Service cases - hardware 4.8 SINAMICS S120 Combi 4.8.7 This is how you connect the DC link busbars and 24 V busbars Connecting additional components The following steps are necessary to connect a component to the DC link and the 24 V busbars of the S120 Combi.
Page 129 Service cases - hardware 4.8 SINAMICS S120 Combi 4. Install the lower DC link busbar as shown in the following diagram: 5. Install the upper DC link busbar as shown in the following diagram: – Release the screws – Remove the plastic cap on the DC link bridge –...
Page 130: To Connect The Second Component
Service cases - hardware 4.8 SINAMICS S120 Combi 6. Install the red 24 V connectors in accordance with the supplied description of the component to be connected. 7. Close the protective cover of the connected component. 8. Mount the front plate on the S120 Combi. 4.8.8 To connect the second component Connecting a second component...
Page 131 Service cases - hardware 4.8 SINAMICS S120 Combi Procedure: 1. Use a suitable tool to open the protective cover of the component to be connected 2. Remove the DC link side covers of both components at the connection location 3. To connect the DC link busbars you will need the following tool: Screwdriver: Torx T20 Tightening torque: 1.8 Nm 4.
Page 132 Service cases - hardware 4.8 SINAMICS S120 Combi 5. Install the upper DC link busbar: – Release the screws – Turn over the DC link bridge. – Observe the sequence when tightening the screws 6. Install the red 24 V connectors in accordance with the supplied description of the component to be connected.
Page 133: This Is How You Remove The Internal Fan
Service cases - hardware 4.8 SINAMICS S120 Combi 4.8.9 This is how you remove the internal fan Removing the internal fan NOTICE When replacing the fan, you must observe the ESD regulations. Only qualified personnel are permitted to install spare parts! DANGER Risk of electric shock Before replacing the fan, the power supply (400 V AC) must be switched off.
Page 134 Service cases - hardware 4.8 SINAMICS S120 Combi 3. Remove the fan cover, 4. Remove the cable connector by gently pressing the interlock and connector together. Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 135 Service cases - hardware 4.8 SINAMICS S120 Combi Opened fan compartment: 5. Withdraw the fan. Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 136: This Is How You Install The Internal Fan
Service cases - hardware 4.8 SINAMICS S120 Combi 4.8.10 This is how you install the internal fan Installing a new internal fan Procedure: 1. Before installing the fan, note the direction of the airflow: The arrows on the fan must match the following diagram! The arrows on the fan show the direction of the airflow.
Page 137 Service cases - hardware 4.8 SINAMICS S120 Combi Mounting accessories Number Designation Specification Self-clinching flush head M4, steel, strength class 8.8, zinc-plated, length: 15 mm studs M4, steel, strength class 8, zinc-plated Installing Procedure: 1. Mount the self-clinching flush head studs - position 1) in the following part of the diagram: The zero line shown runs at the height of the upper bolts used to mount the S120 Combi.
Page 138 Service cases - hardware 4.8 SINAMICS S120 Combi 3. Mount the fan unit in the specified sequence (steps 1 to 4). Step 1: Step 2: Step 3: Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 139 Service cases - hardware 4.8 SINAMICS S120 Combi Step 4: 4. Initially tighten the nuts by hand with 0.5 Nm. 5. Then tighten the nuts with a tightening torque of 1.8 Nm in the specified sequence 1 to 5 (arrows). Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 140 Service cases - hardware 4.8 SINAMICS S120 Combi Boundary condition The reinforcement plates must always be installed when operating the S120 Combi with the external fan unit. WRONG: CORRECT: S120 Combi and external fan unit without S120 Combi and external fan unit with reinforcement plates installed reinforcement plates CAUTION...
Page 141: This Is How You Clean The Heat Sink Of The S120 Combi
Service cases - hardware 4.8 SINAMICS S120 Combi 4.8.12 This is how you clean the heat sink of the S120 Combi Cleaning the heat sink The S120 Combi heat sink should be cleaned at regular intervals using either compressed air or high-pressure water jets. To clean the heat sink, the air baffle plate at the rear of the S120 Combi must be removed.
Page 142 Service cases - hardware 4.8 SINAMICS S120 Combi Screws: Slotted or cross slot M4 x 10, DIN EN ISO 7046-1/2 3. Remove the air baffle plate in the direction of the arrow. The air baffle plate has been removed. Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 143 Service cases - hardware 4.8 SINAMICS S120 Combi The heat sink can now be cleaned: 4. After cleaning the heat sink, the air baffle plate is reinstalled in the reverse sequence. Tightening torque for the screws: 1.8 Nm. Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 144: Motor Module Booksize Compact Format
Service cases - hardware 4.9 Motor Module Booksize Compact format Motor Module Booksize Compact format 4.9.1 Motor Module Booksize Compact status displays Status displays The Motor Module has the following status displays, which provide information about the module state: LED state Description, cause Remedy DC LINK...
Page 145: Motor Module Connections
Service cases - hardware 4.9 Motor Module Booksize Compact format 4.9.2 Motor Module connections Single Motor Module connections Figure 4-30 SMM Booksize Compact format (example 5 A) Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 146 Service cases - hardware 4.9 Motor Module Booksize Compact format Double Motor Module connections Figure 4-31 DMM Booksize Compact format (example 2 x 5 A) Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 147: This Is How You Mount A Motor Module Booksize Compact
Service cases - hardware 4.9 Motor Module Booksize Compact format 4.9.3 This is how you mount a Motor Module Booksize Compact Installing Note the tightening torques for hexagonal combination screws or hexagon screws with spring lock washer and flat washer. Procedure: 1.
Page 148: This Is How You Replace The Fan On A Motor Module Booksize Compact
Service cases - hardware 4.9 Motor Module Booksize Compact format 4.9.4 This is how you replace the fan on a Motor Module Booksize Compact Removing the fan The instructions are valid for a module width of 50 mm. NOTICE When replacing the fan, you must observe the ESD regulations. Only qualified personnel are permitted to install spare parts! DANGER Risk of electric shock...
Page 149 Service cases - hardware 4.9 Motor Module Booksize Compact format 2. Remove the fan cover at the lower side of the Motor Module by releasing the snap hooks. 3. Carefully withdraw the fan. 4. Release the connector before you withdraw it. Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 150 Service cases - hardware 4.9 Motor Module Booksize Compact format Installing the fan Procedure: 1. Before installing the fan, observe the direction of the airflow: The arrow on the fan must point toward the cooling ribs. 2. Insert the cable connector until it latches into place. 3.
Page 151: Single Motor Modules
Service cases - hardware 4.10 Single Motor Modules 4.10 Single Motor Modules 4.10.1 SMM status displays Status displays The Motor Module has the following status displays, which provide information about the module state: LED state Description, cause Remedy DC LINK The electronics power supply is missing or outside the –...
Page 152: Smm Connections
Service cases - hardware 4.10 Single Motor Modules 4.10.2 SMM connections Connections Figure 4-33 Single Motor Module (SMM) Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 153: This Is How You Remove A Motor Module
Service cases - hardware 4.10 Single Motor Modules 4.10.3 This is how you remove a Motor Module Overview The activities required when replacing a Motor Module are subsequently described. If a Motor Module has a hardware defect, then it must be replaced by an identical module. Preconditions: ●...
Page 154 Service cases - hardware 4.10 Single Motor Modules 7. Open the protective cover of the DC link voltage of the defective module as well as the adjacent module - if available - using a suitable tool (e.g. a screwdriver). 8. Withdraw the 24 V terminal adapter. 9.
Page 155: This Is How You Install A Motor Module
Service cases - hardware 4.10 Single Motor Modules 12. Open the DC link busbars of the two modules. 13. Release the screws that are used to retain the motor module to the mounting plate. 14. Remove the protective conductor connection of the Motor Module. 15.
Page 156 Service cases - hardware 4.10 Single Motor Modules 4. Release the Torx screws and connect the DC link busbar. 5. Tighten the Torx screws of the DC link busbars, observe the correct sequence. 6. Place the red jumper plug on the electronics busbar until it clicks into place. 7.
Page 157 Service cases - hardware 4.10 Single Motor Modules 9. Reconnect motor connections X1 and X2 - if available - to the module. 10. Insert the DRIVE-CLiQ cables that were previously withdrawn into sockets X200 - X202. 11. Reinsert the enable terminals X21 and X22 - if available - into the module. 12.
Page 158: Double Motor Modules
Service cases - hardware 4.11 Double Motor Modules 4.11 Double Motor Modules 4.11.1 DMM status displays Status displays The Motor Module has the following status displays, which provide information about the module state: LED state Description, cause Remedy DC LINK The electronics power supply is missing or outside the –...
Page 159: Dmm Connections
Service cases - hardware 4.11 Double Motor Modules 4.11.2 DMM connections Connections Figure 4-34 Double Motor Module (DMM) Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 160: This Is How You Remove A Motor Module
Service cases - hardware 4.11 Double Motor Modules 4.11.3 This is how you remove a Motor Module Overview The activities required when replacing a Motor Module are subsequently described. If a Motor Module has a hardware defect, then it must be replaced by an identical module. Preconditions: ●...
Page 161 Service cases - hardware 4.11 Double Motor Modules 7. Open the protective cover of the DC link voltage of the defective module as well as the adjacent module - if available - using a suitable tool (e.g. a screwdriver). 8. Withdraw the 24 V terminal adapter. 9.
Page 162: This Is How You Install A Motor Module
Service cases - hardware 4.11 Double Motor Modules 12. Open the DC link busbars of the two modules. 13. Release the screws that are used to retain the motor module to the mounting plate. 14. Remove the protective conductor connection of the Motor Module. 15.
Page 163 Service cases - hardware 4.11 Double Motor Modules 4. Release the Torx screws and connect the DC link busbar. 5. Tighten the Torx screws of the DC link busbars, observe the correct sequence. 6. Place the red jumper plug on the electronics busbar until it clicks into place. 7.
Page 164 Service cases - hardware 4.11 Double Motor Modules 9. Reconnect motor connections X1 and X2 - if available - to the module. 10. Insert the DRIVE-CLiQ cables that were previously withdrawn into sockets X200 - X202. 11. Reinsert the enable terminals X21 and X22 - if available - into the module. 12.
Page 165: Smart Line Modules
Service cases - hardware 4.12 Smart Line Modules 4.12 Smart Line Modules 4.12.1 SLM (< 16 kW) status displays Status displays The 5 kW and 10 kW Smart Line Modules have the following status displays, which provide information about the module state: LED state Description, cause Remedy...
Page 166: Slm (< 16 Kw) Connections
Service cases - hardware 4.12 Smart Line Modules 4.12.2 SLM (< 16 kW) connections Connections Figure 4-35 SLM connections Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 167: Slm (16 Kw And Higher) Status Displays
Service cases - hardware 4.12 Smart Line Modules 4.12.3 SLM (16 kW and higher) status displays Status displays The Smart Line Modules ≥ 16 kW have the following status displays, which provide information about the module state: LED state Description, cause Remedy DC LINK Electronics power supply is missing or outside...
Page 168: Slm (16 Kw And Higher) Connections
Service cases - hardware 4.12 Smart Line Modules 4.12.4 SLM (16 kW and higher) connections Connections Figure 4-36 Connections,SLM ≥ 16 kW Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 169: This Is How You Remove An Slm
Service cases - hardware 4.12 Smart Line Modules 4.12.5 This is how you remove an SLM Overview The activities that must be taken into account when replacing a Smart Line Module (SLM) are subsequently described. If a module has a hardware defect, then it must be replaced by an identical module. Preconditions: ●...
Page 170 Service cases - hardware 4.12 Smart Line Modules 9. Using a multimeter (set the measuring range to 1000 V DC) at the points DCP/DCN, check that the DC link voltage is in a no-voltage condition. Only continue with the work when it has been absolutely ensured that no voltage is present (no-voltage condition has been established).
Page 171: This Is How You Install An Slm
Service cases - hardware 4.12 Smart Line Modules 4.12.6 This is how you install an SLM Installing DANGER Risk of electric shock A hazardous voltage is present for up to 5 minutes after the power supply has been switched off. The protective cover must not be opened until this time has elapsed. The warning information on the components must be carefully observed! Procedure: 1.
Page 172 Service cases - hardware 4.12 Smart Line Modules 7. Place the 24 V terminal adapter on the electronics power supply busbar until it clicks into place. 8. Close the protective cover of the DC link voltage. 9. Reconnect the line supply connection X1 at the module. 10.
Page 173: Active Line Modules
Service cases - hardware 4.13 Active Line Modules 4.13 Active Line Modules 4.13.1 ALM status displays Status displays The Active Line Module (ALM) has the following status displays, which provide information about the module status: LED state Description, cause Remedy DC LINK Electronics power supply is missing or outside –...
Page 174: Alm Connections
Service cases - hardware 4.13 Active Line Modules 4.13.2 ALM connections Connections Figure 4-37 ALM connections Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 175: This Is How You Remove An Alm
Service cases - hardware 4.13 Active Line Modules 4.13.3 This is how you remove an ALM Overview The activities that must be taken into account when replacing an Active Line Module (ALM) are subsequently described. If a module has a hardware defect, then it must be replaced by an identical module. Preconditions: ●...
Page 176 Service cases - hardware 4.13 Active Line Modules 9. Using a multimeter (set the measuring range to 1000 V DC) at the points DCP/DCN, check that the DC link voltage is in a no-voltage condition. Only continue with the work when it has been absolutely ensured that no voltage is present (no-voltage condition has been established).
Page 177: This Is How You Install An Alm
Service cases - hardware 4.13 Active Line Modules 4.13.4 This is how you install an ALM Installing DANGER Risk of electric shock A hazardous voltage is present for up to 5 minutes after the power supply has been switched off. The protective cover must not be opened until this time has elapsed. The warning information on the components must be carefully observed! Procedure: 1.
Page 178 Service cases - hardware 4.13 Active Line Modules 7. Place the 24 V terminal adapter on the electronics power supply busbar until it clicks into place. 8. Close the protective cover of the DC link voltage. 9. Reconnect the line supply connection X1 at the module. 10.
Page 179: Sensor Modules Cabinet
Service cases - hardware 4.14 Sensor Modules Cabinet 4.14 Sensor Modules Cabinet 4.14.1 SMC10/SMC20 status displays Status displays Sensor Modules Cabinet-Mounted SMC10 and SMC20 have the following status displays, which provide information about the module state: Color State Description, cause Remedy Electronics power supply is missing or outside –...
Page 180: Smc10/Smc20 Connections
Service cases - hardware 4.14 Sensor Modules Cabinet 4.14.2 SMC10/SMC20 connections Connections Figure 4-38 SMC10/SMC20 connections Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 181: This Is How You Remove An Smc10/Smc20
Service cases - hardware 4.14 Sensor Modules Cabinet 4.14.3 This is how you remove an SMC10/SMC20 Overview The activities that must be taken into account when replacing an SMC10 or SMC20 are subsequently described. If the SMC10 or SMC20 has a hardware defect, then it must be replaced by an identical module.
Page 182: This Is How You Install An Smc10/Smc20
Service cases - hardware 4.14 Sensor Modules Cabinet Procedure: 1. Withdraw the electronics power supply connector X524 and label. 2. Unscrew the encoder connecting cable at X520 or X521 / X531, if required, also the shield connection. 3. Withdraw the DRIVE-CLiQ cable X500 and write the slot designation on the cable. 4.
Page 183: Smc30 Status Displays
Service cases - hardware 4.14 Sensor Modules Cabinet 4.14.5 SMC30 status displays Status displays The Sensor Module Cabinet-Mounted SMC30 has the following status displays, which provide information about the module state: Color State Description, cause Remedy Electronics power supply is missing or outside –...
Page 184: Smc30 Connections
Service cases - hardware 4.14 Sensor Modules Cabinet 4.14.6 SMC30 connections Connections Figure 4-40 Connections SMC30 Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 185: This Is How You Remove An Smc30
Service cases - hardware 4.14 Sensor Modules Cabinet 4.14.7 This is how you remove an SMC30 Overview The activities that must be taken into account when replacing an SMC30 are subsequently described. If an SMC30 has a hardware defect, then it must be replaced by an identical module. Preconditions: ●...
Page 186 Service cases - hardware 4.14 Sensor Modules Cabinet NOTICE Electro-static discharge (ESD) Before you touch the module, discharge yourself at the cabinet or at the ground terminal. Procedure: 1. Before withdrawing it, label the connector X524 for the electronics power supply. 2.
Page 187: This Is How You Install An Smc30
Service cases - hardware 4.14 Sensor Modules Cabinet 4.14.8 This is how you install an SMC30 Installing Figure 4-42 Installing SMC30 Procedure: 1. Place the components on the mounting rail. 2. Then, swivel the components on the mounting rail so that the mounting catches click into place at the rear.
Page 188 Service cases - hardware 4.14 Sensor Modules Cabinet CAUTION The 50 mm clearances above and below the components must be observed. Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 189: Sensor Modules External
Service cases - hardware 4.15 Sensor Modules External 4.15 Sensor Modules External 4.15.1 SME20 connections Connections Figure 4-43 Connections SME20 4.15.2 This is how you remove an SME20 and install it again Overview The activities that must be taken into account when replacing an SME20 are subsequently described.
Page 190: Sme25 Connections
Service cases - hardware 4.15 Sensor Modules External Procedure: 1. Release the encoder connecting cable of the SME20. 2. Withdraw the DRIVE-CLiQ cable from the SME20. 3. Release the protective conductor connection of the SME20. 4. Remove the defective SME20. Installing Procedure: 1.
Page 191: This Is How You Remove An Sme25 And Install It Again
Service cases - hardware 4.15 Sensor Modules External 4.15.4 This is how you remove an SME25 and install it again Overview The activities that must be taken into account when replacing an SME25 are subsequently described. If an SME25 has a hardware defect, then it must be replaced by an identical module. Preconditions: ●...
Page 192: Sme120 Connections
Service cases - hardware 4.15 Sensor Modules External CAUTION Cables The maximum DRIVE-CLiQ cable length is 100 m. The maximum encoder cable length is 3 m. In order to guarantee the degree of protection, all of the plug connectors must be correctly screwed into place or snapped into place.
Page 193: This Is How You Remove An Sme120 And Install It Again
Service cases - hardware 4.15 Sensor Modules External 4.15.6 This is how you remove an SME120 and install it again Removing NOTICE Electro-static discharge (ESD) Before you touch the module, discharge yourself at the ground terminal. Procedure: 1. Release the encoder connecting cable X100 of the SME120. 2.
Page 194: Sme125 Connections
Service cases - hardware 4.15 Sensor Modules External 4.15.7 SME125 connections Overview The activities that must be taken into account when replacing an Sensor Module External SME125 are subsequently described. If an SME125 has a hardware defect, then it must be replaced by an identical module. Preconditions: ●...
Page 195 Service cases - hardware 4.15 Sensor Modules External Installing Procedure: 1. Now install the new SME125 module. 2. Screw on the protective conductor connection. 3. Reconnect the temperature sensor at X200. 4. Reconnect the encoder connecting cable. 5. Connect the DRIVE-CLiQ cable. CAUTION The maximum DRIVE-CLiQ cable length is 100 m.
Page 196: Terminal Modules
Service cases - hardware 4.16 Terminal Modules 4.16 Terminal Modules 4.16.1 TM54F status displays Status displays The Terminal Module TM54F has the following status displays, which provide information about the module state: Color State Description, cause Remedy Electronics power supply is missing or outside permissible –...
Page 197 Service cases - hardware 4.16 Terminal Modules Color State Description, cause Remedy Fail-safe inputs / double inputs F_DI z – (input x, NC contact / NC contact : (z = 0..9, x = 0, 2, ..18) (x+1)+, – Continuous Different signal states at input x and x+1 (x+1)-) light –...
Page 198: Tm54F Connections
Service cases - hardware 4.16 Terminal Modules 4.16.2 TM54F connections Connections Figure 4-47 TM54F connections 4.16.3 This is how you remove an TM54F Overview The activities that must be taken into account when replacing an TM54F are subsequently described. If a TM54F has a hardware defect, then it must be replaced by an identical module. Preconditions: ●...
Page 199 Service cases - hardware 4.16 Terminal Modules Removing Figure 4-48 TM54F removal NOTICE Electro-static discharge (ESD) Before you touch the module, discharge yourself at the cabinet or at the ground terminal. Procedure: 1. Label connectors X514 and X524 for the sensor and electronics power supply prior to withdrawing them.
Page 200: This Is How You Install A Tm54F
Service cases - hardware 4.16 Terminal Modules 4. Release the protective conductor connection and write the position designation on the cable. 5. If necessary, unscrew the shield connection. 6. Slide the lug downwards. 7. Swivel the module to the front to remove it. CAUTION The 50 mm clearances above and below the components must be observed.
Page 201: Hub Modules
Service cases - hardware 4.17 Hub Modules 4.17 Hub Modules 4.17.1 DMC20 status displays Status displays The DRIVE-CLiQ Hub Module DMC20 has the following status displays, which provide information about the module state: Color State Description, cause Remedy Electronics power supply is missing or outside –...
Page 202: Dmc20 Connections
Service cases - hardware 4.17 Hub Modules 4.17.2 DMC20 connections Connections Figure 4-49 Connections DMC20 4.17.3 This is how you remove a DMC20 Overview The activities that must be taken into account when replacing a DMC20 are subsequently described. If a DMC20 has a hardware defect, then it must be replaced by an identical module. Preconditions: ●...
Page 203 Service cases - hardware 4.17 Hub Modules Removing Figure 4-50 DMC20 removal NOTICE Electro-static discharge (ESD) Before you touch the module, discharge yourself at the cabinet or at the ground terminal. Procedure: 1. Before withdrawing it, label the connector X524 for the electronics power supply. 2.
Page 204: This Is How You Install A Dmc20
Service cases - hardware 4.17 Hub Modules 4.17.4 This is how you install a DMC20 Installing Procedure: 1. Place the components on the mounting rail. 2. Then, swivel the components on the mounting rail so that the mounting catches click into place at the rear.
Page 205: Dme20 Connections
Service cases - hardware 4.17 Hub Modules 4.17.5 DME20 connections Connections The component has degree of protection IP67 and is especially suitable for applications which require DRIVE-CLiQ nodes to be removed in groups, without interrupting the DRIVE- CLiQ line and therefore the data exchange. Figure 4-51 DME20 connections Hardware and Software...
Page 206: This Is How You Mount A Dme20
Service cases - hardware 4.17 Hub Modules 4.17.6 This is how you mount a DME20 Mounting Procedure: 1. Place the drilling pattern on the mounting surface. The mounting surfaces must be bare metal. Figure 4-52 DME20 dimensions 2. Drill the holes with Ø5.3 or M5 threads. 3.
Page 207: Connection To X524 Electronics Power Supply
Service cases - hardware 4.17 Hub Modules 4.17.7 Connection to X524 electronics power supply Specifications for using the DME20 with UL approval Pin assignment of the cable for connection to X524: Designation Technical specifications 1 (brown) Electronics power supply The connection voltage of 20.4 V – 28.8 V refers to the (terminal) voltage at the 2 (white) Electronics power supply...
Page 208 Service cases - hardware 4.17 Hub Modules Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 209: Spare Parts And Accessories
Order data for accessories The following accessories are available: Component Order No. Description CompactFlash Card (empty) 1 GB 6FC5313-5AG00-0AA1 for SIMOTION / SINUMERIK USB FlashDrive 2 GB 6ES7648-0DC40-0AA0 USB2.0, bootable See also SiemensSpares-on-web (https://b2b-extern.automation.siemens.com/spares_on_web) Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 210: Spare Parts For The S120 Combi
5 shield connection terminals for motor cables Shield connection terminal for EP signal cables Available spare parts You will find spare parts for all of the other components and modules in the Internet under: Available spare parts (http://support.automation.siemens.com/WW/view/en/16612315) Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 211: Esd Guidelines
● Signal cables and load cables must be routed at the greatest possible distance from one another. ● Only use Siemens signal cables for connecting to and from the NC or PLC. ● Signal cables may not be routed close to strong external magnetic fields (e.g. motors and transformers).
Page 212: Esd Measures
ESD guidelines A.2 ESD measures ESD measures CAUTION The modules contain electrostatically sensitive devices. Discharge yourself of electrostatic energy before touching the electronic modules. The easiest way to do this is to touch a conductive, grounded object immediately beforehand (for example, bare metal parts of control cabinet or the protective ground contact of a socket outlet).
Page 213: Appendix
Appendix List of abbreviations Abbreviation Meaning Explanation Active Line Module ASCII American Standard Code for Information Interchange AUTO "Automatic" operating mode Mode group BERO Proximity limit switch with feedback oscillator BICO Binector Connector Interconnection technology for the drive Cross Error Compensation Computerized Numerical Control Data Block in the PLC Data Block Byte in the PLC...
Page 214 Appendix B.1 List of abbreviations Abbreviation Meaning Explanation Light Emitting Diode Local User Data MAIN Main program Main program (OB1, PLC) Megabyte Machine Control Panel Machine Coordinate System Machine data "Manual Data Automatic" operating mode Manual input MLFB Machine-Readable Product Code Main Program File Main program (NC part program) Multi Point Interface...
Page 215 Appendix B.1 List of abbreviations Abbreviation Meaning Explanation Tool Offset Active Identifier (file type) for tool offsets Voltage Protection Module Voltage Sensing Module Workpiece Coordinate System Work Offset Zero Offset Active Identifier (file type) for work offset data Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 216: Documentation Overview
Appendix B.2 Documentation overview Documentation overview Hardware and Software Service Manual, 03/2011, 6FC5397-5DP40-0BA0...
Page 217: Index
Index Fan, internal Motor Module Booksize Compact, 148 Backing up log files, 21 S120 Combi, 133 CompactFlash Card, 209 LED status Connections Front of the PPU, 74 ALM, 174 MCP 310C PN, 92 DMC20, 202 MCP 483C PN, 96 DME20, 205 NX10.3, 110 DMM, 159 Rear of the PPU, 75...
Page 218 Index Removing the internal fan, 133 Spare parts, 210 Safety information S120 Combi modules, 126 S120 Combi Modules, 124 Shield support, 116 Shielded cables, 211 SIM card, 85 SINAUT modem, 85 Spare parts, S120 Combi, 210 Switch S1 on the I/O module, 104, 109 S2 on the MCP 310C PN, 96 S2 on the MCP 483C PN, 100 USB FlashDrive, 44, 209...

Siemens sinumerik 828d Service Manual

1 Safety Notes

2 System Description

3 Service Cases - Software

4 Service Cases - Hardware

5 Spare Parts and Accessories

Appendix

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