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Siemens SINUMERIK 828D Turning, Software And Hardware Service Manual

The Siemens SINUMERIK 828D Turning product is an advanced CNC system used for turning operations. With its user-friendly interface, it allows operators to efficiently control and monitor the machining process. For detailed instructions and guidance, you can download the free user manual from our website, manualshive.com.

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Boundary condition

It is important that the reinforcement plates must always be installed when operating the S120 

Combi with the external fan unit: 

WRONG: 
S120 Combi and external fan unit without rein‐

forcement plates

CORRECT: 
S120 Combi and external fan unit with instal‐

led reinforcement plates

Note
Shutdown as a result of excessively high temperature if the reinforcement plates are missing
Operation without the reinforcement plates is not permissible. 
If the reinforcement plates are incorrectly fixed, this can result in an excessively high heat sink 

temperature and cause the S120 Combi to prematurely trip.

4.10.13

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.

Service cases - hardware
4.10 SINAMICS S120 Combi

Software and hardware

162

Service Manual, 08/2018, 6FC5397-5DP40-6BA1

Summary of Contents for SINUMERIK 828D Turning

Page 1: ...id for SINUMERIK 828D PPU 27x 4 SINUMERIK 828D PPU 290 4 CNC system software V4 8 SP4 08 2018 6FC5397 5DP40 6BA1 Preface Fundamental safety instructions 1 System description 2 Service cases software 3 Service cases hardware 4 Spare parts and accessories 5 Appendix A ...

Page 2: ...ose 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...

Page 3: ...the following address mailto docu motioncontrol siemens com mySupport Documentation At the following address https support industry siemens com My ww en documentation you can find information on how to create your own individual documentation based on Siemens content and adapt it for your own machine documentation Training At the following address http www siemens com sitrain you can find informat...

Page 4: ...Note regarding the General Data Protection Regulation Siemens observes standard data protection principles in particular the principle of privacy by design That means that this product does not process store any personal data only technical functional data e g time stamps If a user links this data with other data e g a shift schedule or stores personal data on the same storage medium e g hard driv...

Page 5: ... 4 This is how you read in a setup archive from the system CompactFlash card 41 3 3 Software backup 44 3 3 1 This is how you generate a software backup 44 3 3 2 This is how you install a software backup 47 3 4 Updating the software 52 3 5 Generating a boot system on the CompactFlash card 56 3 5 1 This is how you create a boot system 56 3 5 2 This is how you install a software backup using the boot...

Page 6: ...terface PN 98 4 5 6 Status displays MCP 483C PN 99 4 5 7 This is how you remove the MCP 483C PN 100 4 5 8 This is how you install the MCP 483C PN 102 4 5 9 Status displays MCP 310C PN 103 4 5 10 This is how you remove the MCP 310C PN 104 4 5 11 This is how you install the MCP 310C PN 106 4 5 12 This is how you replace the rotary switch 107 4 6 I O modules 110 4 6 1 Status displays PP 72 48D PN 110...

Page 7: ...le Booksize Compact format 166 4 11 1 Motor Module Booksize Compact status displays 166 4 11 2 Motor Module connections 167 4 11 3 This is how you mount a Motor Module Booksize Compact 169 4 11 4 This is how you replace the fan on a Motor Module Booksize Compact 170 4 12 Single Motor Modules 174 4 12 1 SMM status displays 174 4 12 2 SMM connections 175 4 12 3 This is how you remove a Motor Module ...

Page 8: ...ME125 and install it again 218 4 18 Terminal Modules 220 4 18 1 TM54F status displays 220 4 18 2 TM54F connections 222 4 18 3 This is how you remove an TM54F 223 4 18 4 This is how you install a TM54F 224 4 18 5 TM120 status displays 224 4 18 6 TM120 safety instructions 225 4 18 7 TM120 connections 226 4 18 8 This is how you remove a TM120 and install it again 227 4 19 Hub Modules 228 4 19 1 DMC20...

Page 9: ...Index 245 Table of contents Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 9 ...

Page 10: ...Table of contents Software and hardware 10 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 11: ...any of the power connections and the protective conductor connection 5 Check whether the existing auxiliary supply circuits are de energized 6 Ensure that the motors cannot move 7 Identify all other dangerous energy sources e g compressed air hydraulic systems or water Switch the energy sources to a safe state 8 Check that the correct drive system is completely locked After you have completed the ...

Page 12: ...here is no ground connection For missing or incorrectly implemented protective conductor connection for devices with protection class I high voltages can be present at open exposed parts which when touched can result in death or severe injury Ground the device in compliance with the applicable regulations WARNING Spread of fire from built in devices In the event of fire outbreak the enclosures of ...

Page 13: ...d minimum clearance as ventilation clearance for the respective component WARNING Unexpected movement of machines caused by inactive safety functions Inactive or non adapted safety functions can trigger unexpected machine movements that may result in serious injury or death Observe the information in the appropriate product documentation before commissioning Carry out a safety inspection for funct...

Page 14: ...malfunction which in turn can lead to injuries or death Protect the parameterization parameter assignments against unauthorized access Handle possible malfunctions by taking suitable measures e g emergency stop or emergency off Fundamental safety instructions 1 1 General safety instructions Software and hardware 14 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 15: ...ort and send electronic components modules or devices in their original packaging or in other suitable materials e g conductive foam rubber of aluminum foil Only touch components modules and devices when you are grounded by one of the following methods Wearing an ESD wrist strap Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring Only place electronic components modules...

Page 16: ...but are only intended to provide support for typical tasks As the user you yourself are responsible for ensuring that the products described are operated correctly Application examples do not relieve you of your responsibility for safe handling when using installing operating and maintaining the equipment Fundamental safety instructions 1 3 Warranty and liability for application examples Software ...

Page 17: ...or network segmentation are in place For additional information on industrial security measures that may be implemented please visit Industrial security http www siemens com industrialsecurity Siemens products and solutions undergo continuous development to make them more secure Siemens strongly recommends that product updates are applied as soon as they are available and that the latest product v...

Page 18: ...c state of the art industrial security concept for the installation or machine Make sure that you include all installed products into the holistic industrial security concept Protect files stored on exchangeable storage media from malicious software by with suitable protection measures e g virus scanners Protect the drive against unauthorized changes by activating the know how protection drive fun...

Page 19: ...s gases etc can occur inside and outside the components under fault conditions caused by for example Component failure Software errors Operation and or environmental conditions outside the specification External influences damage 3 Hazardous shock voltages caused by for example Component failure Influence during electrostatic charging Induction of voltages in moving motors Operation and or environ...

Page 20: ...Fundamental safety instructions 1 5 Residual risks of power drive systems Software and hardware 20 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 21: ...ypical example with SINAMICS S120 booksize 0RWRU FDEOHV HHG PRWRUV 6SLQGOH PRWRU 0 600 600 600 600 6 1 0 6 60 6 1 0 6 6 RRNVL H 352 1 7 6 027 6 6 6 027 6 0 3 5 9 L4 6 180 5 0 3 86 33 31 33 31 Figure 2 1 Configuration example 1 Basic configuration with four axes Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 21 ...

Page 22: ...RU LQH UHDFWRU 2SWLRQDO OLQH ILOWHU 0RWRUV 0RWRU FDEOHV 0 3 86 3352 1 7 6 027 6 6 9 9 30 8 6 1 0 6 6 RPEL 6 180 5 31 8 31 3 5 9 L4 6 027 6 0 3 Figure 2 2 Configuration example 2 Basic expansion stage with 4 axes and 2 auxiliary axes System description 2 1 System overview Software and hardware 22 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 23: ...EOHV 77 VSLQGOH HQFRGHU UDNLQJ UHVLVWRU UDNLQJ 0RGXOH RQWURO 6XSSO 0RGXOH RXEOH 0RWRU 0RGXOH RRNVL H RPSDFW HHG PRWRUV RQQHFWLRQ HQFRGHU V VWHP 6SLQGOH PRWRU 6 1 0 6 6 RPEL 3RZHU 0RGXOH 352 1 7 6 027 6 6 6 027 6 0 3 3 3 02 0 0 9 5 9 L4 6 1 0 6 0 6 180 5 0 3 31 33 31 33 31 6 1 0 6 70 Figure 2 3 Configuration example 3 Maximum expansion stage with 6 axes and with Safety Integrated System description...

Page 24: ...face X127 Ethernet interface service connection Qwerty keyboard Keys to quickly select the operating area Cursor keypad Numerical keys Control keys System description 2 2 PPU versions Software and hardware 24 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 25: ...keys QWERTY keyboard Status LED RDY NC CF Control keys Slot for CompactFlash card Keys to quickly select the operating area X125 USB interface Cursor keypad X127 Ethernet interface service connection System description 2 2 PPU versions Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 25 ...

Page 26: ...X1 Power supply X135 X145 USB interface for MCP 310 USB MCP 483 USB MCP 416 USB and for service X130 Ethernet LAN PN 1 PN 2 PLC I O Interface SYNC FAULT Status LED X100 X101 X102 DRIVE CLiQ interfaces X140 Serial interface RS232 Figure 2 4 Interfaces at the rear of the PPU System description 2 2 PPU versions Software and hardware 26 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 27: ...er CompactFlash card or on the USB flash drive front If both are available then the directory is created in both storage media The directory name has the following structure LOG_date_time Example LOG_091102_083615 stands for a directory generated on 02 11 2009 at 8 36 15 This therefore ensures that a directory is not overwritten by pressing CTRL ALT D several times The directory contains all of th...

Page 28: ... com sinumerik docu http www siemens com sinumerik docu Further information www siemens com sinumerik support http www siemens com sinumerik support Siemens Industry Online Support provides further information such as FAQs product information forum contributions Service cases software Software and hardware 28 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 29: ...ograms is not possible Data can be backed up without a password i e always NOTICE Data backup The following procedure is recommended in order to avoid losing data After making important changes immediately backup data e g after the 1st commissioning and the 2nd commissioning While the data is being backed up the control system must neither be operated nor turned off Data backup using the Save data...

Page 30: ...4 This is followed by the Query to backup data Service cases software 3 1 Backing up user data Software and hardware 30 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 31: ... CompactFlash card siemens sinumerik sys_cache archive savedata ard The archive is overwritten with a new version every time the Save data button is pressed Automatic data backup As opposed to the Save data function which has to be triggered manually a backup of the NC data memory is generated automatically every time the NC restarts This automatic backup is performed after the following actions T...

Page 32: ...f the manual data backup is more recent than the automatic data backup then the manual data backup is loaded instead of the automatically created data backup The system only attempts to load an existing manual data backup if no valid automatic data backup is available If this process also fails then the NCK default data are loaded 3 1 2 This is how you load the user data backup Note If this functi...

Page 33: ...roceed as follows 1 The following display is shown when booting after power on 2 To start the Startup menu press the SELECT key You now go to the Startup menu Service cases software 3 1 Backing up user data Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 33 ...

Page 34: ...nt to reload saved user data Note Booting If data is lost from the buffer memory the data saved in the permanent memory will automatically be reloaded to the memory at POWER ON If the control boots with the backed up data the following message is displayed 4062 Data backup copy has been loaded Service cases software 3 1 Backing up user data Software and hardware 34 Service Manual 08 2018 6FC5397 5...

Page 35: ...s on the system CompactFlash Card Note Memory size of the data storage medium that can be connected The memory size of the data storage medium that can be connected is not restricted It is only important that these are FAT FAT16 or FAT32 types Only the first partition is used With its own formatting tool Windows can only format data storage medium up to 32 GB in FAT32 In these cases 32 GB in order...

Page 36: ...emens standard Select all data classes unless only certain data e g INDIVIDUAL are to be backed up 6 Press the OK softkey to create the archive The Create Archive Select Archive window opens 7 Select the storage location of the archive USER USB USB FlashDrive in slot X125 at the front User CF CompactFlash Card in the slot at the front Service cases software 3 2 Generating a commissioning archive S...

Page 37: ...rm with OK The directory is created subordinate to the selected folder 11 Press the OK softkey The Create archive Name window opens 12 Enter the required name and confirm with OK A file with format type ard is saved in the selected directory Service cases software 3 2 Generating a commissioning archive Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 37 ...

Page 38: ...rtup operating area 2 Press the menu forward key 3 Press the Setup archive softkey 4 Press OK The Startup window opens 5 Activate Read in setup archive 6 Press OK The Select Setup archive window opens and the data tree is displayed Service cases software 3 2 Generating a commissioning archive Software and hardware 38 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 39: ...rtant data of the selected archive to be certain that it is OK 9 Data is read in when pressing OK 10 In the case of errors or problems import can be terminated by pressing the Cancel softkey Service cases software 3 2 Generating a commissioning archive Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 39 ...

Page 40: ...actFlash Card Procedure 1 Select the Startup operating area 2 Press the menu forward key 3 Press the Setup archive softkey 4 Activate Create setup archive The Create setup archive window opens Service cases software 3 2 Generating a commissioning archive Software and hardware 40 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 41: ...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 Press the OK softkey The Create archive Name window opens 12 Enter the required name and confirm with OK A file with the ARD format type is saved in the selected directory 3 2 4 This is how you read in a setup archive from the syst...

Page 42: ...e softkey 4 Press OK The Create setup archive window opens 5 Activate Read in setup archive 6 Press OK The Select Setup archive window opens and the data tree is displayed Service cases software 3 2 Generating a commissioning archive Software and hardware 42 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 43: ... data of the selected archive is displayed 9 Data is read in when pressing OK 10 In the case of errors or problems import can be terminated by pressing the Cancel softkey Service cases software 3 2 Generating a commissioning archive Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 43 ...

Page 44: ... medium CompactFlash card or USB flash drive with a minimum memory size of 2 GB is required Other data carriers are not permissible Generating the system software backup clone Procedure 1 Switch the control on 2 Perform an internal data backup see also This is how you backup user data Page 29 A correct complete backup is only generated using the internal data backup 3 Switch the control off 4 Swit...

Page 45: ... To call the startup menu when powering up there is an additional shortcut for all PPUs 8 2 8 3 The Startup menu is displayed 4 Using the cursor keys select the menu item Create software backup 5 Press the INPUT key to confirm your selection 6 Insert a storage medium into the slot on the front panel Service cases software 3 3 Software backup Software and hardware Service Manual 08 2018 6FC5397 5DP...

Page 46: ...the card and outputs a message The backup can now be overwritten or the process interrupted by making the appropriate operator action 2 When starting to generate a backup the following message is output Service cases software 3 3 Software backup Software and hardware 46 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 47: ...function Install software update backup All system and user data are overwritten with the software backup image Note Licenses The backup does not include a license key and is not installed with the software update As an alternative the license key for an already licensed card can be obtained through the Internet see also This is how you display the actual license key Page 68 When replacing a defec...

Page 48: ...Normal startup is the default setting 2 To call the Startup menu press the following keys in succession Menu reset key HSK2 horizontal SK2 VSK2 vertical SK2 Note PPU with touch operation To call the startup menu when powering up there is an additional shortcut for all PPUs 8 2 8 3 The Startup menu is displayed Service cases software 3 3 Software backup Software and hardware 48 Service Manual 08 20...

Page 49: ...Press the INPUT key to confirm your selection 6 Insert the storage medium with the backup in the slot and confirm with Yes by using the cursor keys to make the selection Service cases software 3 3 Software backup Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 49 ...

Page 50: ...id backup was not selected then the upgrade is canceled with the following message Image file is corrupt In this case switch off the control withdraw the data carrier and repeat the procedure by selecting a valid backup image 11 Wait until the following message appears 12 Switch the control off 13 Withdraw the storage medium from the slot at the front panel of the control Service cases software 3 ...

Page 51: ...nger identified as a bootable CompactFlash Card then a boot system must be generated on this card see also This is how you create a boot system Page 56 In this case the license key of the system CompactFlash Card should be transferred to the control Service cases software 3 3 Software backup Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 51 ...

Page 52: ...o restore the machine specific data The control is booted using a tgz file on the storage medium CompactFlash Card or USB FlashDrive in the slot at the front panel of the control Note Backup and archive the data of the control system to an external data carrier before booting Observe the information in the update instructions Updating the control Preconditions The control system is switched off Th...

Page 53: ...PU with touch operation To call the startup menu when powering up there is an additional shortcut for all PPUs 8 2 8 3 The Startup menu is displayed 4 Using the cursor keys select the menu item Install software update backup 5 Press the INPUT key to confirm your selection Service cases software 3 4 Updating the software Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 53 ...

Page 54: ...age tgz on the storage medium and confirm with INPUT 8 The software update is started The following message appears while the update is running Service cases software 3 4 Updating the software Software and hardware 54 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 55: ...t must be restarted If the system CompactFlash Card is no longer identified as bootable system then a boot system must be generated on this card see also This is how you create a boot system Page 56 In this case the license key of the system CompactFlash Card should be transferred to the control Service cases software 3 4 Updating the software Software and hardware Service Manual 08 2018 6FC5397 5...

Page 56: ...pplied on the toolbox CD of the SINUMERIK 828D which in the scope of delivery includes a boot system image Figure 3 1 Toolbox selection This program must be installed in order that the image of the boot system is installed on the PC PG 3 5 1 This is how you create a boot system Precondition The default path to install the boot system is C Program Files x86 Siemens Toolbox 828D V04070xx00 RecoveryS...

Page 57: ...h Card into the card reader 2 Start the program via Start Programs SINUMERIK Tools Access MyMachine P2P 3 Press Cancel if you are prompted to establish the connection Note An online connection to the control is not required to generate the boot system 4 In the Options menu select the menu item Write SINUMERIK 828D boot system 5 If several versions of the toolbox are installed on the PC you obtain ...

Page 58: ...d do not remove the CompactFlash Card Data transfer is displayed using a progress bar 8 The following message is output if data transfer was successfully completed 9 In order to ensure that there are no read and write access operations to the CompactFlash Card when you remove the CompactFlash Card from the interchangeable drive select the Windows function Safely remove hardware Service cases softw...

Page 59: ...d this must be requested again see also This is how you license a CNC option Page 62 All system data and user data are overwritten with the system image Updating the software After you have inserted the CompactFlash Card with the boot system as new system CompactFlash card see Replacing the system CompactFlash Card Page 88 proceed as follows 1 Switch the control on When booting the following displ...

Page 60: ...ont panel of the control 5 Confirm the selection with the INPUT key 6 The following message briefly appears Starting software update Then the screen goes dark for several seconds Service cases software 3 5 Generating a boot system on the CompactFlash card Software and hardware 60 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 61: ...he following cases are possible The control boots and is ready for operation if when generating the system image the internal data backup and also a startup commissioning file were generated If a valid image is not found the update is interrupted with the following message Image file is corrupt In this case switch off the control withdraw the data carrier and carry out the procedure again by selec...

Page 62: ...nly empty CompactFlash cards that have been released as replacement part can be used Only these CompactFlash cards are known in the licensing database In order to obtain a valid license key for the new empty CompactFlash Card contact the SINUMERIK Hotline specifying the serial numbers of the two CompactFlash cards The hotline will immediately provide you with a new license key 3 6 2 This is how yo...

Page 63: ...ey The Licensing window opens Using the vertical softkeys you can execute the following actions Display a serial number Overview Display all options Display Missing licenses Exp license requirement Read in the license key Figure 3 2 Licensing Service cases software 3 6 Licensing Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 63 ...

Page 64: ...is suppressed if a CNC option for which no valid license key has been entered is additionally activated This means that the machine can only operate on a severely restricted basis if an attempt is made to use an unlicensed CNC option 3 6 3 This is how you determine missing licenses options Determining the license requirement Procedure 1 Press the All options softkey to list all the options that ca...

Page 65: ... softkey to trigger a warm restart OR 2 Press the Cancel softkey to cancel the process 3 6 4 This is how you generated a new license key Assigning the license to hardware In order to simplify licensing for the technician licenses are assigned to the hardware in a Standard Web Browser using the Web License Manager To conclude the assignment the license key must be entered manually on the control vi...

Page 66: ...f the hardware displayed is the one you want to make the assignment for The assignment of a license to a piece of hardware cannot be reversed via the Web License Manager Generating a license key Procedure 1 Select the Start up operating area 2 Press the menu forward key 3 Press the Licenses softkey 4 Press the Overview softkey and note down the serial number of the system CompactFlash Card 5 At yo...

Page 67: ...K Operate Note License key via e mail If you have an e mail address you have the option checkbox of receiving the license key by e mail Entering the license key The newly purchased license key is entered into the control Procedure 1 Select the Start up operating area 2 Press the menu forward key 3 Press the Licenses softkey Service cases software 3 6 Licensing Software and hardware Service Manual ...

Page 68: ...the SINUMERIK control Without control in the Internet You require the serial number of the system CompactFlash Card in order to display the actual key in the Internet This is displayed at the control in the Licenses dialog box or can be read from the system CompactFlash Card Displaying the actual license key at the control Proceed as follows to display the license key at the control 1 Select the S...

Page 69: ... key via the Internet The serial number is on the system CompactFlash Card or can be displayed at the control as described above 1 Go to the Internet page of the Web License Manager 2 Press the menu item Display license key 3 A window with the license key opens Service cases software 3 6 Licensing Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 69 ...

Page 70: ... 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 Service cases software 3 6 Licensing Software and hardware 70 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 71: ...is extended to 36 months by registering the machine You can obtain additional information about the on site service here SIOS_OSS www siemens com automation oss Precondition To change the end user final destination data the following access rights must be available Softkey Manufacturer Access level 1 password Manufacturer Softkey Dealer Access level 2 password Service Softkey End user Access level...

Page 72: ...the Diagnostics operating area using the following key 2 Press the Version softkey to open the Version data dialog box 3 Press the Details softkey The data associated with the machine are displayed in the Machine logbook Service cases software 3 7 Machine registration Software and hardware 72 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 73: ...o 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 The activities performed should be documented here after each service call Service cases software 3 7 Machine registration Softwar...

Page 74: ...on softkey 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 Press the OK softkey to save an entry in the logbook Service cases software 3 7 Machine registration Software and hardware 74 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 75: ...machine identity Note Ensure that the machine identity that has been entered is correct before saving in order that no incorrect information is saved In order to save the machine identity address data version data and logbook externally on a data carrier proceed as follows 1 Select the Diagnostics operating area using the following key 2 Press the Version softkey 3 Press the Save softkey The Save ...

Page 76: ...portunity of changing this name You can enter a comment in the Comments text field Select the following options Version data TXT Output of the version data in the text format Configuration data XML All information about the machine identity 5 Press the OK softkey to start saving the data Service cases software 3 7 Machine registration Software and hardware 76 Service Manual 08 2018 6FC5397 5DP40 6...

Page 77: ...fective Send the machine identity Preconditions The commissioning status is saved in the logbook The addresses data are entered updated in the machine The machine identity was saved and is available on the PC PG The PC PG is connected with the Internet Please proceed as follows 1 Open the Internet Browser on your PC PG 2 Go to the Internet page for the registration http www siemens com sinumerik r...

Page 78: ...ample LOG_171102_083615 stands for a directory created on 02 11 2017 at 8 36 15 This therefore ensures that a directory is not overwritten by pressing CTRL ALT D several times The directory contains all of the logbook and debug information available in the system 3 8 1 3 Backing up log data as ZIP file Backing up all log data using a special softkey in the Diagnostics operating area Diagnostics Al...

Page 79: ...nts at the machine Components in the control cabinet 6 1 0 6 6 RPEL D LV PRGXOH D LV PRGXOH 6 VWHP FRPSRQHQWV 1XPHULF RQWURO WHQVLRQV 6HQVRU 0RGXOHV 60 60 60 60 60 0RWRU 0RGXOHV 6LQJOH 0RWRU 0RGXOHV RXEOH 0RWRU 0RGXOHV RQWURO 8QLWV 8 8 8 0 0 70 70 1 1 Figure 4 1 Components in the control cabinet Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 79 ...

Page 80: ... components in the electrical cabinet References 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 SINUMERIK 828D SINAMICS S120 List Manual Parameter description EMC Installation Guideline Configuration Manual Industrial security Configuration Manual Service cases hardware Software and ...

Page 81: ...measuring all poles phases also to ground Ensure that the associated warning plate in the appropriate language is attached WARNING Danger to life through electric shock due to incorrectly installed DC link clips Incorrectly installed DC link clips at the left hand end of the drive line up can cause an electric shock For all 50 mm wide modules exception Smart Line Module remove the DC link clips in...

Page 82: ...oring Only place electronic components modules or devices on conductive surfaces table with ESD surface conductive ESD foam ESD packaging ESD transport container NOTICE Damage caused by loose plug connections and screw connections Loose plug connections and screw connections can release themselves in operation Ensure that all of the connectors and screws are correctly tightened or latched and inse...

Page 83: ...eaning RDY Green Is lit NC Ready and PLC in run mode Yellow Is lit PLC in stop mode Flashing Booting Red Is lit NC in stop mode When booting if NC Ready is not yet available Critical fault power off on necessary NC Yellow Cyclic flashing NC operation CF Yellow Is lit User CompactFlash Card being accessed NOTICE Damage to the CompactFlash card when it is withdrawn in operation The CompactFlash card...

Page 84: ...f the PPU the following status displays provide information about the module state 3RUW 3RUW 86 DQG WKHUQHW 1 Figure 4 4 Rear of the PPU For diagnostic purposes the RJ45 sockets port 1 and port 2 are each equipped with a green and a yellow LED As a consequence the following connection information of the PLC I O interface is displayed based on PROFINET Name Color State Meaning Link Green ON 100 MBi...

Page 85: ...of the SINUMERIK 828D has synchronized to the clock of the PLC I O interface based on PROFINET IO data is being exchanged Flashing 0 5 Hz Task system of the SINUMERIK 828D has synchronized to the clock of the PLC I O interface based on PROFINET IO data is being cyclically exchanged See also Additional connections at the rear of the PPU Page 24 4 2 2 This is how you remove the PPU Precondition For ...

Page 86: ... out of the mounting cutout 15 Remove the system CompactFlash card from the control refer to Chapter This is how you remove the system CompactFlash Card Page 88 4 2 3 This is how you install the PPU Boundary condition When replacing the PPU then the MAC address of Ethernet interface X130 changes Tell the customer or the system administrator the new MAC address Installing NOTICE Installing the PPU ...

Page 87: ...ut from the rear using the tension jacks by tightening the setscrews 5 Connect the ground connections and tighten 6 Insert the PN1 PN2 interfaces that were withdrawn 7 Insert the Ethernet cable that was withdrawn at X130 8 Insert the DRIVE CLiQ cable that was withdrawn at X100 X102 9 Insert the handwheel terminal that was withdrawn at X143 10 Insert the digital input output terminals that were wit...

Page 88: ...d can be damaged if it is withdrawn or inserted under voltage Switch off the control power supply before inserting or removing the CompactFlash card Before you touch the CompactFlash card discharge yourself at the cabinet or at the ground terminal Removing the system CompactFlash Card Note When removing the system CompactFlash Card carefully ensure that neither the screw nor the system CompactFlas...

Page 89: ...n or the PPU has already been removed NOTICE Damage to the CompactFlash card when it is withdrawn or inserted under voltage The system CompactFlash card can be damaged if it is withdrawn or inserted under voltage Switch off the control power supply before inserting or removing the CompactFlash card Before you touch the CompactFlash card discharge yourself at the cabinet or at the ground terminal S...

Page 90: ... M3 and swing the metal cover to the side to remove it 2 Gently insert the system CompactFlash Card into the slot until it clicks into place 3 First guide the metal cover at the rear into the rabbet and then tilt it into the end position 4 Attach the metal cover to the housing using the screw Service cases hardware 4 3 Replacing the system CompactFlash Card Software and hardware 90 Service Manual ...

Page 91: ...how you remove the PPU Page 85 Removing the front cover Procedure 1 Open the front cover 2 Press the holding pins of the front cover through the openings at the rear The tool that you use may have a maximum width of 2 mm 3 Remove the front cover Service cases hardware 4 4 Replacing the front cover Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 91 ...

Page 92: ...pring Spring Pin 2 Press in the pins and mount the front cover The pins must snap into the PPU housing After you have installed the front cover you can also possibly reinstall the PPU see This is how you install the PPU Page 86 Service cases hardware 4 4 Replacing the front cover Software and hardware 92 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 93: ... Access the operator panel control cabinet in which the machine control panel is located 3 Use a multimeter to check that the system really is in a no voltage condition isolated from the supply 4 If it has not already been done label all connectors that lead to the module now Only then can it be ensured that the cables are not interchanged 5 Remove the USB cable 6 Release other cables e g the Emer...

Page 94: ... the PPU Figure 4 5 MCP 310 USB interfaces 0 3 86 USB connection for communication with the PPU Protective conductor connection Slots for control devices d 16 mm Interface X51 X52 X55 Figure 4 6 MCP 483 USB interfaces Service cases hardware 4 5 Machine control panels Software and hardware 94 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 95: ...10 USB MCP 416 USB Installing Procedure 1 Attach the tension jacks to fix the machine control panel and tighten them 2 Connect the ground connection 3 Reconnect other cables e g the Emergency Stop cable or from other command devices if available 4 Re insert the USB cable into the USB port 5 Close the cabinet and switch on the system again Service cases hardware 4 5 Machine control panels Software ...

Page 96: ...tem software is running no commu nication to the controller ON OFF OFF OFF STOP state The system software is run ning communication to the controller ON ON OFF OFF RUN state The system software is running communication to the controller ON Flashes at 0 5 Hz OFF OFF Overtemperature alarm ON 4 5 4 This is how you remove the MCP interface PN Removing If the module has a hardware defect then it must b...

Page 97: ...pulse signals Figure 4 9 MCP Interface PN interfaces 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 2 Access the operator panel or control cabinet in which the machine control panel is located 3 If it has not already been done label ...

Page 98: ... new machine control panel using the 4 standard Torx screws T20 M4 3 Connect the ground connection to the grounding screw 4 Reconnect other cables e g for the rotary switch and for the digital inputs and outputs 5 Reinsert the Ethernet cables at interface X2 X3 port 1 port 2 6 Re establish the strain relief for the Ethernet cables 7 Reconnect power supply X1 8 Close the cabinet and switch on the s...

Page 99: ...LED H1 green PowerOK H2 green PN Sync H3 red PN Fault Power OFF OFF OFF OFF Power ON voltage is stable ON OFF OFF Boot software runs and loads the system software ON ON ON System software runs ON OFF OFF System software runs no communication to the con troller ON OFF OFF System software runs communication to the con troller STOP state ON ON OFF System software runs communication to the con troller...

Page 100: ...e machine control panel has a hardware defect then it must be replaced by an identical replacement part Preconditions The module is defective and must be replaced The control cabinet is in a no voltage condition all of the connectors and cables are labeled Service cases hardware 4 5 Machine control panels Software and hardware 100 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 101: ... Handwheel connection X61 Reserved X10 Power supply interface Figure 4 11 MCP 483C PN rear side 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 2 Access the operator panel control cabinet in which the machine control panel is located ...

Page 102: ...ting of DIP switch S2 on the defective module 4 5 8 This is how you install the MCP 483C PN Installing Procedure 1 Set switch S1 on the new module as you previously noted down 2 Set DIL switch S2 of the new module to what you previously noted down 3 Installing a new machine control panel 4 Secure the clips to retain the machine control panel and tighten them 5 Connect the ground connection 6 Recon...

Page 103: ...the module state 6 Figure 4 13 Status displays LED H1 green PowerOK H2 green PN Sync H3 red PN Fault Power OFF OFF OFF OFF Power ON voltage is stable ON OFF OFF Boot software runs and loads the system software ON ON ON System software starts ON OFF OFF System software runs no communication to the con troller ON OFF OFF System software runs communication to the control ler STOP state ON ON OFF Syst...

Page 104: ...e machine control panel has a hardware defect then it must be replaced by an identical replacement part Preconditions The module is defective and must be replaced The control cabinet is in a no voltage condition all of the connectors and cables are labeled Service cases hardware 4 5 Machine control panels Software and hardware 104 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 105: ...cific inputs and outputs Figure 4 14 MCP 310C PN rear side 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 2 Access the operator panel or control cabinet in which the machine control panel is located 3 Using a multimeter check the X10...

Page 106: ...he setting of DIP switch S2 on the defective module 4 5 11 This is how you install the MCP 310C PN Installing Procedure 1 Set switch S1 on the new module as you previously noted down 2 Set DIL switch S2 of the new module to what you previously noted down 3 Install the new machine control panel 4 Secure the clips to retain the machine control panel and tighten them 5 Connect the ground connection 6...

Page 107: ... following rotary switches are installed in the machine control panels Rotary switch for the spindle control rotary switch with 16 positions Rotary switch for the feedrate control rotary switch with 23 positions The activities that must be taken into account when replacing a rotary switch are subsequently described Preconditions when replacing a rotary switch The rotary switch is defective and mus...

Page 108: ...rotary switch Procedure 1 Push the O ring onto the shaft of the new rotary switch as a seal 2 Insert the rotary switch into the front cutout so that pressure is applied to the O ring 3 Screw the lock nut onto the rotary switch shaft from the front with a wrench size 14 tightening torque 3 Nm 4 Connect the arrow ring and knob 5 Slide both parts onto the shaft of the rotary switch 6 Align the arrow ...

Page 109: ...il diagram of the connector Cap Arrow ring Fastening nut Knob Connection plug Connecting cable Connection PCB Figure 4 17 Installing a rotary switch Note It is essential that the specified tightening torques are complied with Service cases hardware 4 5 Machine control panels Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 109 ...

Page 110: ...stable ON OFF OFF OFF OFF OFF Boot software runs and loads the system soft ware ON ON ON ON ON OFF System software starts ON OFF OFF OFF OFF OFF System software runs no communication to the controller ON OFF OFF OFF OFF OFF System software runs communication to the controller STOP state ON ON OFF OFF OFF OFF System software runs communication to the controller RUN state ON Flashes at 0 5 Hz OFF OF...

Page 111: ... receiving OFF No activity 4 6 2 This is how you remove the PP 72 48D PN Overview The activities necessary to replace the PP72 48D PN I O module are described in the following If the PP 72 48D PN has a hardware defect then this must be replaced by an identical module Preconditions The I O module is defective and must be replaced The control cabinet is in a no voltage condition all of the connector...

Page 112: ... voltage condition 4 If it has not already been done label all connectors that lead to the module now Only then can it be ensured that the cables are not interchanged 5 Withdraw the power supply X1 6 Release the connectors of the ribbon cables X111 X222 X333 on the module that are used to connect the digital inputs and outputs 7 Remove the strain relief of the PROFINET cables of interfaces X2 8 Re...

Page 113: ...333 on the module that are used to connect the digital inputs and outputs 7 Reconnect power supply X1 8 Close the cabinet and switch on the system again DIP switch S1 Setting of switch S1 1 2 3 4 5 6 7 8 9 10 Device name ON ON ON OFF OFF ON OFF OFF OFF OFF pp72x48pn9 OFF OFF OFF ON OFF OFF OFF OFF pp72x48pn8 ON ON ON OFF OFF OFF OFF OFF pp72x48pn7 OFF ON ON OFF OFF OFF OFF OFF pp72x48pn6 ON OFF ON...

Page 114: ... ON OFF OFF OFF OFF OFF Boot software runs and loads the system soft ware ON ON ON ON ON OFF System software starts ON OFF OFF OFF OFF OFF System software runs no communication to the controller ON OFF OFF OFF OFF OFF System software runs communication to the controller STOP state ON ON OFF OFF OFF OFF System software runs communication to the controller RUN state ON Flashes at 0 5 Hz OFF OFF OFF ...

Page 115: ...g OFF No activity 4 6 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 Preconditions The I O module is defective and must be replaced The control cabinet is in a no voltage condition all of the ...

Page 116: ...s in a no voltage condition 4 If it has not already been done label all connectors that lead to the module now Only then can it be ensured that the cables are not interchanged 5 Withdraw the power supply X1 6 Insert connector X3 for the analog inputs outputs 7 Release the connectors of the ribbon cables X111 X222 X333 on the module that are used to connect the digital inputs and outputs 8 Remove t...

Page 117: ...ors of the ribbon cables X111 X222 X333 on the module that are used to connect the digital inputs and outputs 7 Reconnect power supply X1 8 Close the cabinet and switch on the system again DIP switch S1 Setting of switch S1 1 2 3 4 5 6 7 8 9 10 Device name ON ON ON OFF OFF ON OFF OFF OFF OFF pp72x48pn9 OFF OFF OFF ON OFF OFF OFF OFF pp72x48pn8 ON ON ON OFF OFF OFF OFF OFF pp72x48pn7 OFF ON ON OFF ...

Page 118: ... firmware cannot be loaded into the RAM Yellow Continuous light Firmware is being loaded into the RAM Flashing light 0 5 Hz Firmware cannot be loaded into the RAM Flashing light 2 Hz Firmware CRC error DP1 CU_LINK H2 OFF Electronics power supply outside the permissible tolerance range NX10 3 NX15 3 is not ready for operation Green Continuous light CU_LINK is ready for communication and cyclic comm...

Page 119: ...SODWH V 6KLHOG FRQQHFWLRQ 5 3 Figure 4 24 NX10 3 NX15 3 connections 4 7 3 This is how you remove the NX10 3 NX15 3 Preconditions The activities that are required when replacing an NX10 3 NX15 3 are subsequently described If the NX10 3 NX15 3 has a hardware defect then it must be replaced by an identical module Service cases hardware 4 7 Expansion modules NX10 3 NX15 3 Software and hardware Service...

Page 120: ...te system carefully checked that it is in a no voltage condition and lock it out so that it cannot be switched on without the appropriate authorization 2 Access the control cabinet where the NX10 3 NX15 3 is located 3 Use a multimeter to check that the NX module really is in a no voltage condition 4 Open the cover of the NX module Service cases hardware 4 7 Expansion modules NX10 3 NX15 3 Software...

Page 121: ...X10 3 NX15 3 Installing Procedure 1 Screw the new NX10 3 NX15 3 to the mounting plate OR 2 If the module was located to the left of the infeed re attach it here by first introducing the NX10 3 NX15 3 into the holder to the right and then press it down slightly to retain it 3 Reconnect the protective conductor connection of the NX10 3 NX15 3 4 Insert the DRIVE CLiQ cables that were previously withd...

Page 122: ...of the arrow coun ter clockwise Opened protective cover To lock press the protective cover back on until you hear the interlock engage 4 8 2 Protective conductor connection and shield contact Shield contact and productive conductor connection It is always advisable to use shielded wiring for the digital inputs and outputs NOTICE Incorrect machine operation as a result of incorrect shielding or ina...

Page 123: ...mple Connections Shield connection terminal http www weidmueller com int home from Weidmüller Type KLBLUE CO 1 Article No 17533 11001 Note Only use screws with a permissible insertion length of 4 6 mm Service cases hardware 4 8 Installing SINAMICS components Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 123 ...

Page 124: ...all other LEDs light up orange Red Red Off BIOS loaded Red flash ing light 2 Hz Red Off BIOS error An error occurred while loading the BIOS Red flash ing light 2 Hz Red Flashing light 2 Hz Off File error Memory card not inserted or faulty Software on memory card not present or corrupted Red Orange flashing light Off FW loading RDY LED lights up red PN LED flashes orange without fixed frequency Red...

Page 125: ...t 2 Hz Component detection via LED is activated p0124 0 Note Both options depend on the LED status when com ponent recognition is activated via p0124 0 1 PN PROFIdrive cyclic opera tion Off Cyclic communication has not yet taken place Note PROFIdrive is ready for communication when the Control Unit is ready see LED RDY Green Continu ous light Cyclic communication is taking place Flashing light 0 5...

Page 126: ...ed Flashing light 2 Hz Bus fault communication has been interrupted Correct the fault RDY and OPT Orange Flashing light 0 5 Hz Firmware update in progress for connected Option Board CBE20 Status displays of Ethernet interfaces The RJ45 sockets are 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 and the LA...

Page 127: ... 3URWHFWLYH FRQGXFWRU FRQQHFWLRQ 0 1P 3 3 7 7 7 0 1P X100 X102 DRIVE CLiQ interfaces X122 X132 Digital inputs outputs X124 Electronics power supply X127 Ethernet LAN X150 P1 X150 P2 PROFINET interfaces X140 Serial interface lower side T0 T1 T2 Measuring sockets lower side Figure 4 27 CU320 2 PN interface overview Service cases hardware 4 9 Control Unit CU320 2 PN and CU310 2 PN Software and hardwa...

Page 128: ...ust be replaced by an identical module Preconditions The module is defective and must be replaced The control cabinet is in a no voltage condition all of the connectors and cables are labeled Removing Procedure 1 Switch off the complete system carefully checked that it is in a no voltage condition and lock it out so that it cannot be switched on without the appropriate authorization 2 Access the c...

Page 129: ...ert the PROFINET cable that was previously withdrawn 4 Insert the DRIVE CLiQ cables that were previously withdrawn into sockets X100 X103 5 Insert all other cables if available 6 Reconnect the electronics power supply X124 7 Now check that all of the cables have been reconnected 8 Insert the CompactFlash card 9 Close the cover of the CU320 2 PN 10 Close the cabinet and switch on the system again 4...

Page 130: ... Off File error Memory card not inserted or faulty Software on memory card not present or corrupted Response of the LEDs when powering up firmware LED State Remark RDY COM OUT 5V MOD Red Orange Off Off Firmware load ing COM LED flashing without fixed flashing frequency Red Off Off Off Firmware loa ded Off Red Off Off Firmware check no CRC error Red Flashing light 0 5 Hz Red Flashing light 0 5 Hz O...

Page 131: ...hen component recognition is activated COM Off Cyclic communication has not yet taken place Note PROFIdrive is ready for communication when the Control Unit is ready see LED RDY Green Continuous light Cyclic communication is taking place Flashing light 0 5 Hz Full cyclic communication is not yet taking place Possible causes The controller is not transferring any setpoints During isochronous operat...

Page 132: ...O interfaces is displayed based on PROFINET Name Color State Meaning Link Green Continuous light 10 or 100 Mbit link available Off Missing or faulty link Activity Yellow Flashing light Sending or receiving data Off No activity Service cases hardware 4 9 Control Unit CU320 2 PN and CU310 2 PN Software and hardware 132 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 133: ...r the temperature sensor Digital inputs digital outputs X124 Electronics power supply X127 LAN Ethernet X130 X131 Digital input fail safe digital output Digital input output analog input X150 P1 X150 P2 PROFINET interfaces Figure 4 28 Interface overview of the CU310 2 PN Note The PROFIBUS address switch on the CU310 2 PN has no function Service cases hardware 4 9 Control Unit CU320 2 PN and CU310 ...

Page 134: ...t out so that it cannot be switched on without the appropriate authorization 2 Access the control cabinet where the CU310 2 PN is located 3 Use a multimeter to check that the CU310 2 PN really is in a no voltage condition 4 If it has not already been done label all connectors and cables that lead to the module now Only then can it be ensured that the cables are not interchanged 5 Withdraw the elec...

Page 135: ...re 4 29 Removing the CU310 2 PN from the PM340 10 Remove the Control Unit toward the front 11 Remove the CompactFlash card Service cases hardware 4 9 Control Unit CU320 2 PN and CU310 2 PN Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 135 ...

Page 136: ...connection of the CU310 2 PN 4 Insert the DRIVE CLiQ cable that was previously withdrawn into socket X100 5 Insert all other cables if available 6 Reconnect the electronics power supply X124 7 Now check that all of the cables have been reconnected 8 Insert the CompactFlash card 9 Close the cabinet and switch on the system again Service cases hardware 4 9 Control Unit CU320 2 PN and CU310 2 PN Soft...

Page 137: ...e component is ready for operation and cyclic DRIVE CLiQ communication is taking place Orange The component is ready for operation and cyclic DRIVE CLiQ communication is taking place The DC link voltage is present Red The component is ready for operation and cyclic DRIVE CLiQ communication is taking place The DC link voltage is too high Check the line supply voltage Orange Orange DRIVE CLiQ commun...

Page 138: ...pacitors 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 Service cases hardware 4 10 SINAMICS S120 Combi Software and hardware 138 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 139: ...QRW DVVLJQHG QRW DVVLJQHG 0RWRU FRQQHFWLRQ 1P 9 SOXJ FRQQHFWRU HDW VLQN OHFWURQLF SRZHU VXSSO DQG OLQN EXVEDUV 6KLHOG FRQQHFWLRQ WHUPLQDOV PP 1P 6KLHOG SODWH RQQHFWLRQ IRU PRWRU KROGLQJ EUDNH DQ FRQQHFWLRQ Figure 4 31 S120 Combi 3 axis Power Module Service cases hardware 4 10 SINAMICS S120 Combi Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 139 ...

Page 140: ...nal is included in the accessories pack Weidmüller type KLBÜ 3 8 SC Figure 4 32 S120 Combi 3 axis Power Module View from below HDW VLQN UDNH FRQQHFWLRQ 6KLHOG FRQQHFWLRQ WHUPLQDOV Figure 4 33 S120 Combi 3 axis Power Module Service cases hardware 4 10 SINAMICS S120 Combi Software and hardware 140 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 141: ...JXLGH IUDPH 0RWRU FRQQHFWLRQ 9 WHUPLQDO DGDSWHU HDW VLQN OHFWURQLFV SRZHU VXSSO DQG OLQN EXVEDUV 6KLHOG SODWH 0RWRU KROGLQJ EUDNH FRQQHFWLRQ PP 1P 1P 1P EP terminal The shield support is included in the accessories pack Weidmüller type KLBÜ 3 8 SC Figure 4 34 S120 Combi 4 axis Power Module Service cases hardware 4 10 SINAMICS S120 Combi Software and hardware Service Manual 08 2018 6FC5397 5DP40 6B...

Page 142: ...ries pack Weidmüller type KLBÜ 3 8 SC View from below HDW VLQN UDNH FRQQHFWLRQ 6KLHOG FRQQHFWLQJ WHUPLQDOV 4 10 4 How to mount an S120 Combi Power Module Precondition The reinforcement plates are installed in order to mount an S120 Combi Power Module Service cases hardware 4 10 SINAMICS S120 Combi Software and hardware 142 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 143: ...IDQ VXEDVVHPEO DVKHU 0 QXW Figure 4 35 Installing an S120 Combi Power Module 4 Connect the protective conductor See also Protective conductor connection and shield contact Page 122 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 Se...

Page 144: ...ly for the 4 axis version For the other S120 Combi Power Modules drip protection assembly can be ordered as Spare parts and accessories Page 237 Attach the drip protection assembly to the top of the S120 Combi Power Module 6 RPEL 3RZHU 0RGXOHV ULS SURWHFWLRQ Figure 4 36 S120 Combi Power modules with drip protection Service cases hardware 4 10 SINAMICS S120 Combi Software and hardware 144 Service M...

Page 145: ...rough electric shock A hazardous voltage is still present for up to 5 minutes after the power supply has been switched off Remove the front plate only after 5 minutes have passed Procedure 1 Use a Torx T20 or slotted 1 2 x 6 screwdriver as tool 2 Remove the two Torx slotted screws at the front Service cases hardware 4 10 SINAMICS S120 Combi Software and hardware Service Manual 08 2018 6FC5397 5DP4...

Page 146: ...his is how you open the DC link cover Opening the DC link cover To electrically connect additional components the front cover of the S120 Combi must already have been removed Service cases hardware 4 10 SINAMICS S120 Combi Software and hardware 146 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 147: ...switched off Contact with live parts results in death or serious injury Do not open the protective cover of the device until 5 minutes have elapsed Before starting any work check that the system is in a completely no voltage condition by measuring all poles phases also to ground Ensure that the associated warning plate in the appropriate language is attached Service cases hardware 4 10 SINAMICS S1...

Page 148: ... the Torx slotted screw of the DC link cover 2 Remove the DC link cover 3 Remove the DC link side cover Service cases hardware 4 10 SINAMICS S120 Combi Software and hardware 148 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 149: ...outer DC link side cover is inserted at the connected component The protective cover of the connected component is closed The front cover of the S120 Combi has been reinstalled Note Attach the touch protection for the DC link busbars After removing the additional components before recommissioning the system the touch protection of the DC link busbars on the S120 Combi power module must be reinstal...

Page 150: ...UV OLQN EXVEDUV 0RWRU 0RGXOH RRNVL H RPSDFW 6 RPEL 0 3 1 3 Use the following tool to install the DC link busbar Screwdriver Torx T20 or slotted 1 2 x 6 Tightening torque 1 8 Nm 4 Install the lower DC link busbar as shown in the following diagram Service cases hardware 4 10 SINAMICS S120 Combi Software and hardware 150 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 151: ...rve 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 7 Close the protective cover of the connected component 8 Mount the front plate on the S120 Combi Service cases hardware 4 10 SINAMICS S120 Combi Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 151 ...

Page 152: ...ent touch protection The protective covers of the connected components are closed 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 9 EXVEDUV OLQN EXVEDUV 0RWRU 0RGXOH RRNVL H RPSDFW 3 1 0 0RWRU 0RGXOH RRNVL H RPSDFW 3 To connect the DC link busbars you will need the following...

Page 153: ...ve the sequence when tightening the screws 5 Install the upper DC link busbar Release the screws Turn over the DC link bridge Observe the sequence when tightening the screws Service cases hardware 4 10 SINAMICS S120 Combi Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 153 ...

Page 154: ...el are permitted to install spare parts DANGER Danger to life through live parts and components Death or serious injury can result when live parts are touched Switch off the power supply before replacing the fan 400 V AC A hazardous voltage is still present for up to 5 minutes after the power supply has been switched off Before removing the component carefully ensure that it is in a no voltage con...

Page 155: ...r see also This is how you remove the front panel Page 145 2 Remove the Torx slotted screw of the fan cover 3 Remove the fan cover Service cases hardware 4 10 SINAMICS S120 Combi Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 155 ...

Page 156: ...onnector by gently pressing the interlock and connector together Opened fan compartment 5 Withdraw the fan Service cases hardware 4 10 SINAMICS S120 Combi Software and hardware 156 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 157: ... the fan must match the following diagram The arrows on the fan show the direction of the airflow 2 Insert the fan The connecting cables must not be crushed 3 Insert the plug connector The connector must audibly click into place 4 Close the fan cover Service cases hardware 4 10 SINAMICS S120 Combi Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 157 ...

Page 158: ...trol cabinet Make an installation cut out in the control cabinet panel The position depends on the installation cut out for the S120 Combi see Chapter How to mount an S120 Combi Power Module Page 142 Mounting accessories Number Designation Specification 5 Self clinching flush head studs M4 steel strength class 8 8 zinc plated length 15 mm 5 Nut M4 steel strength class 8 zinc plated Service cases h...

Page 159: ... used to mount the S120 Combi Figure 4 37 Section from the drilling pattern and installation cut out for the external fan unit 2 Connect the power supply cables of the fan unit to the S120 Combi Power Module Cable A to terminal X12 Cable B to terminal X13 Service cases hardware 4 10 SINAMICS S120 Combi Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 159 ...

Page 160: ...an module in the specified sequence step to step Figure 4 38 Step Figure 4 39 Step Figure 4 40 Step Service cases hardware 4 10 SINAMICS S120 Combi Software and hardware 160 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 161: ...uts by hand with 0 5 Nm 5 Then tighten the nuts with a tightening torque of 1 8 Nm in the specified sequence arrow 1 to arrow 5 Service cases hardware 4 10 SINAMICS S120 Combi Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 161 ...

Page 162: ... the reinforcement plates is not permissible If the reinforcement plates are incorrectly fixed this can result in an excessively high heat sink temperature and cause the S120 Combi to prematurely trip 4 10 13 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...

Page 163: ...affle plate on the S120 Combi release the fixing screws through the holes in the reinforcement plates Screws Slotted or cross slot M4 x 10 DIN EN ISO 7046 1 2 Service cases hardware 4 10 SINAMICS S120 Combi Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 163 ...

Page 164: ...e plate in the direction of the arrow The air baffle plate has been removed The heat sink can now be cleaned Service cases hardware 4 10 SINAMICS S120 Combi Software and hardware 164 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 165: ...eat sink the air baffle plate is reinstalled in the reverse sequence Tightening torque for the screws 1 8 Nm Service cases hardware 4 10 SINAMICS S120 Combi Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 165 ...

Page 166: ...nge Orange DRIVE CLiQ communication is being established Red This component has at least one fault Note The LED is controlled irrespective of the corresponding messages being reconfigured Remove the fault and ac knowledge Green Red 0 5 Hz Firmware is being downloaded Green Red 2 Hz Firmware download has been completed Wait for POW ER ON Carry out a POWER ON Green Orange or Red Orange Component rec...

Page 167: ... FRYHU 8QORFNLQJ SURWHFWLYH FRYHU 7HUPLQDO OHFWURQLFV SRZHU VXSSO OLQN EXVEDUV 0RWRU FRQQHFWLRQ 0RWRU EUDNH FRQQHFWLRQ b b 5 9 L4 Figure 4 42 SMM Booksize Compact format example 5 A Service cases hardware 4 11 Motor Module Booksize Compact format Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 167 ...

Page 168: ...LQDOV OHFWURQLFV SRZHU VXSSO OLQN EXVEDUV 0RWRU FRQQHFWLRQ 0RWRU EUDNH FRQQHFWLRQ 0RWRU FRQQHFWLRQ 0RWRU EUDNH FRQQHFWLRQ b b 5 9 L4 Figure 4 43 DMM Booksize Compact format example 2 x 5 A Service cases hardware 4 11 Motor Module Booksize Compact format Software and hardware 168 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 169: ...flat washer Procedure 1 Initially tighten the screws by hand with 0 5 Nm 2 Tighten the screws in the specified sequence 1 to 4 with 6 Nm 1 2 3 4 5 Mounting wall Screw M6 x 16 Plain washer Spring washer Nut Figure 4 44 Motor Module Booksize Compact Service cases hardware 4 11 Motor Module Booksize Compact format Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 169 ...

Page 170: ...r to life through live parts and components Death or serious injury can result when live parts are touched Switch off the power supply before replacing the fan 400 V AC A hazardous voltage is still present for up to 5 minutes after the power supply has been switched off Before removing the component carefully ensure that it is in a no voltage condition Service cases hardware 4 11 Motor Module Book...

Page 171: ...m the drive line up 2 Remove the fan cover at the lower side of the Motor Module by releasing the snap hooks Service cases hardware 4 11 Motor Module Booksize Compact format Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 171 ...

Page 172: ...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 Service cases hardware 4 11 Motor Module Booksize Compact format Software and hardware 172 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 173: ...ll the fan Notice Do not crush the connection cables 4 Attach the fan cover Service cases hardware 4 11 Motor Module Booksize Compact format Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 173 ...

Page 174: ...ge DRIVE CLiQ communication is being established Red This component has at least one fault Note The LED is controlled irrespective of the corresponding messages being reconfigured Remove the fault and ac knowledge Green red 0 5 Hz Firmware is being downloaded Green red 2 Hz Firmware download has been completed Wait for POW ER ON Carry out a POWER ON Green orange or red orange Component recognition...

Page 175: ...RQ 0 1P 8QORFNLQJ SURWHFWLYH FRYHU 7HUPLQDO OHFWURQLFV SRZHU VXSSO OLQN EXVEDUV 0RWRU FRQQHFWLRQ V 5 9 L4 9 MXPSHU XQGHU WKH SURWHFWLYH FRYHU Figure 4 45 Single Motor Module SMM Service cases hardware 4 12 Single Motor Modules Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 175 ...

Page 176: ...21 and X22 if available 5 Withdraw the connected DRIVE CLiQ cables X200 X202 6 Release the fixing screw Torx and remove the motor connection X1 and X2 if available DANGER Danger to life through electric shock due to the residual charge of the DC link capacitors As a result of the DC link capacitors a hazardous voltage is present for up to 5 minutes after the power supply has been switched off Cont...

Page 177: ...ontinue with the work when it has been absolutely ensured that no voltage is present a no voltage condition has been established 3 XPSHU SOXJ 4 Withdraw the red 24 V jumper plug 5 Release the Torx screws of the DC link 7RU 7 7RU 7 Service cases hardware 4 12 Single Motor Modules Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 177 ...

Page 178: ...ply has been switched off Contact with live parts results in death or serious injury Do not open the protective cover of the device until 5 minutes have elapsed Before starting any work check that the system is in a completely no voltage condition by measuring all poles phases also to ground Ensure that the associated warning plate in the appropriate language is attached Procedure 1 Screw the new ...

Page 179: ... place 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 motor connections X1 and X2 if available to the module 10 Insert the DRIVE CLiQ cables that were previously withdrawn into sockets X200 X202 Service cases hardware 4 12 Single Motor Modules Software and hardware Service Manual 08...

Page 180: ...vailable into the module 12 Check whether all of the cables have been re connected 13 Close the cabinet and switch on the system again Service cases hardware 4 12 Single Motor Modules Software and hardware 180 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 181: ...ge DRIVE CLiQ communication is being established Red This component has at least one fault Note The LED is controlled irrespective of the corresponding messages being reconfigured Remove the fault and ac knowledge Green red 0 5 Hz Firmware is being downloaded Green red 2 Hz Firmware download has been completed Wait for POW ER ON Carry out a POWER ON Green orange or red orange Component recognition...

Page 182: ...LRQ 0RWRU FRQQHFWLRQ 7 SH SODWH 3URWHFWLYH FRQGXFWRU FRQQHFWLRQ 0 1P 7HUPLQDOV 8QORFNLQJ SURWHFWLYH FRYHU V 5 9 L4 9 MXPSHU XQGHU WKH SURWHFWLYH FRYHU Figure 4 46 Double Motor Module DMM Service cases hardware 4 13 Double Motor Modules Software and hardware 182 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 183: ...21 and X22 if available 5 Withdraw the connected DRIVE CLiQ cables X200 X202 6 Release the fixing screw Torx and remove the motor connection X1 and X2 if available DANGER Danger to life through electric shock due to the residual charge of the DC link capacitors As a result of the DC link capacitors a hazardous voltage is present for up to 5 minutes after the power supply has been switched off Cont...

Page 184: ...ontinue with the work when it has been absolutely ensured that no voltage is present a no voltage condition has been established 3 XPSHU SOXJ 4 Withdraw the red 24 V jumper plug 5 Release the Torx screws of the DC link 7RU 7 7RU 7 Service cases hardware 4 13 Double Motor Modules Software and hardware 184 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 185: ...ply has been switched off Contact with live parts results in death or serious injury Do not open the protective cover of the device until 5 minutes have elapsed Before starting any work check that the system is in a completely no voltage condition by measuring all poles phases also to ground Ensure that the associated warning plate in the appropriate language is attached Procedure 1 Screw the new ...

Page 186: ... place 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 motor connections X1 and X2 if available to the module 10 Insert the DRIVE CLiQ cables that were previously withdrawn into sockets X200 X202 Service cases hardware 4 13 Double Motor Modules Software and hardware 186 Service Manua...

Page 187: ...vailable into the module 12 Check whether all of the cables have been re connected 13 Close the cabinet and switch on the system again Service cases hardware 4 13 Double Motor Modules Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 187 ...

Page 188: ...red light Overcurrent trip due to overtemperature Diagnose fault via output terminals and acknowledge via input termi nal Continuous yellow light DC link voltage in the permissible tolerance range Continuous red light Line supply faults DC link voltage outside the permis sible tolerance range Check the line supply voltage DANGER Danger to life through electric shock due to the residual charge of t...

Page 189: ...SO OLQN EXVEDUV LQH VXSSO FRQQHFWLRQ 3URWHFWLYH FRQGXFWRU FRQQHFWLRQ 0 1P 8QORFNLQJ SURWHFWLYH FRYHU b9 WHUPLQDO DGDSWHU 7HUPLQDOV 5 9 L4 Figure 4 47 SLM connections Service cases hardware 4 14 Smart Line Modules Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 189 ...

Page 190: ...ge DRIVE CLiQ communication is being established Red This component has at least one fault Note The LED is controlled irrespective of the corresponding messages being reconfigured Remove the fault and acknowledge Green red 0 5 Hz Firmware is being downloaded Green red 2 Hz Firmware download has been completed Wait for POW ER ON Carry out a POWER ON Green orange or Red orange Component recognition ...

Page 191: ...3URWHFWLYH FRQGXFWRU FRQQHFWLRQ 0 1P 7 SH SODWH 7HUPLQDO 5 9 L4 SURWHFWLYH FRYHU V b9 WHUPLQDO DGDSWHU 8QORFNLQJ SURWHFWLYH FRYHU b b 6KLHOG FRQQHFWLRQ SODWH 9 8 Figure 4 48 Connections SLM 16 kW Service cases hardware 4 14 Smart Line Modules Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 191 ...

Page 192: ...sured that the cables are not interchanged 4 Withdraw the enable terminals X21 5 Withdraw the connected DRIVE CLiQ cables X200 X202 6 Withdraw the line supply connection X1 DANGER Danger to life through electric shock due to the residual charge of the DC link capacitors As a result of the DC link capacitors a hazardous voltage is present for up to 5 minutes after the power supply has been switched...

Page 193: ... been established 3 XPSHU SOXJ 4 Withdraw the red 24 V jumper plug 5 Release the Torx screws of the DC link 7RU 7 6 Open the DC link busbars of the two modules 7 Release the screws that are used to retain the module to the mounting plate 8 Remove the protective conductor connection of the module 9 Remove the module from the control cabinet Service cases hardware 4 14 Smart Line Modules Software an...

Page 194: ...asuring all poles phases also to ground Ensure that the associated warning plate in the appropriate language is attached Procedure 1 Screw the new module to the mounting plate 2 Reconnect the protective conductor connection of the module 3 Open the protective cover of the DC link voltage using a suitable tool e g a screwdriver 4 Release the Torx screws and connect the DC link busbar 5 Tighten the ...

Page 195: ...ection X1 at the module 10 Insert the DRIVE CLiQ cables that were previously withdrawn into sockets X200 X202 11 Reinsert the enable terminals X21 at the module 12 Check whether all of the cables have been re connected 13 Close the cabinet and switch on the system again Service cases hardware 4 14 Smart Line Modules Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 195 ...

Page 196: ...ange DRIVE CLiQ communication is being established Red This component has at least one fault Note The LED is controlled irrespective of the corresponding messages being reconfigured Remove the fault and acknowledge Green red 0 5 Hz Firmware is being downloaded Green red 2 Hz Firmware download has been completed Wait for POW ER ON Carry out a POWER ON Green orange or red orange Component recognitio...

Page 197: ... FRYHU 8QORFNLQJ SURWHFWLYH FRYHU b9 WHUPLQDO DGDSWHU 7HUPLQDO OHFWURQLFV SRZHU VXSSO OLQN EXVEDUV LQH VXSSO FRQQHFWLRQ 6KLHOG FRQQHFWLRQ SODWH 5 9 L4 Figure 4 49 ALM connections Service cases hardware 4 15 Active Line Modules Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 197 ...

Page 198: ...sured that the cables are not interchanged 4 Withdraw the enable terminals X21 5 Withdraw the connected DRIVE CLiQ cables X200 X202 6 Withdraw the line supply connection X1 DANGER Danger to life through electric shock due to the residual charge of the DC link capacitors As a result of the DC link capacitors a hazardous voltage is present for up to 5 minutes after the power supply has been switched...

Page 199: ... been established 3 XPSHU SOXJ 4 Withdraw the red 24 V jumper plug 5 Release the Torx screws of the DC link 7RU 7 6 Open the DC link busbars of the two modules 7 Release the screws that are used to retain the module to the mounting plate 8 Remove the protective conductor connection of the module 9 Remove the module from the control cabinet Service cases hardware 4 15 Active Line Modules Software a...

Page 200: ...asuring all poles phases also to ground Ensure that the associated warning plate in the appropriate language is attached Procedure 1 Screw the new module to the mounting plate 2 Reconnect the protective conductor connection of the module 3 Open the protective cover of the DC link voltage using a suitable tool e g a screwdriver 4 Release the Torx screws and connect the DC link busbar 5 Tighten the ...

Page 201: ...ection X1 at the module 10 Insert the DRIVE CLiQ cables that were previously withdrawn into sockets X200 X202 11 Reinsert the enable terminals X21 at the module 12 Check whether all of the cables have been re connected 13 Close the cabinet and switch on the system again Service cases hardware 4 15 Active Line Modules Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 201 ...

Page 202: ... DRIVE CLiQ communication is being estab lished Red Continuous light This component has at least one fault Remove and acknowl edge fault Note The LED is controlled irrespective of the corre sponding messages being reconfigured Green red Flashes at 0 5 Hz Firmware is being downloaded Flashes at 2 Hz Firmware download has been completed Wait for POWER ON Carry out a POWER ON Green orange or red oran...

Page 203: ...ties 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 Preconditions The module is defective and must be replaced The control cabinet is in a no voltage condition all of the connectors and cables are labeled Service cases hardware 4 16 Sensor Modules Cabinet Softwar...

Page 204: ...also the shield connection 3 Withdraw the DRIVE CLiQ cable X500 and write the slot designation on the cable 4 Release the protective conductor connection and write the position designation on the cable 5 Push the lug downwards 6 Swivel the module to the front Note The 50 mm ventilation clearances above and below the components must be observed Service cases hardware 4 16 Sensor Modules Cabinet Sof...

Page 205: ... or right up to its final position 4 Screw on the protective conductor connection 5 Screw on the encoder connecting cable to X520 and X521 X531 if required also the shield connection 6 Insert the DRIVE CLiQ cable at X500 7 Insert connector X524 for the electronics power supply Note The 50 mm ventilation clearances above and below the components must be observed Service cases hardware 4 16 Sensor M...

Page 206: ...s at 0 5 Hz Firmware is being downloaded Flashes at 2 Hz Firmware download has been completed Wait for POWER ON Carry out a POWER ON Green orange or red orange Flashing Component recognition via LED is activated p0144 Note Both options depend on the LED status when module recognition is activated via p0144 1 OUT 5 V OFF Electronics power supply is missing or outside permissible tolerance range Pow...

Page 207: ...e 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 The module is defective and must be replaced The control cabinet is in a no voltage condition all of the connectors and cables are labeled Service cases hardware 4 16 Sensor Modules Cabi...

Page 208: ...ics power supply 2 Screw on the encoder connecting cable to X520 or X521 X531 if required also the shield connection 3 Release the protective conductor connection and write the position designation on the cable 4 Slide the lug downwards 5 Swivel the module to the front to remove it Note The 50 mm ventilation clearances above and below the components must be observed Service cases hardware 4 16 Sen...

Page 209: ... at the rear 3 Slide the component along the mounting rail to either the left or right up to its final position 4 Screw on the protective conductor connection 5 Screw on the encoder connecting cable to X520 or X521 X531 if required also the shield connection 6 Insert the DRIVE CLiQ cable at X500 7 Insert connector X524 for the electronics power supply Note The 50 mm ventilation clearances above an...

Page 210: ...on is being established Red Continu ous light At least one fault is present in this component Note The LED is controlled irrespective of the corresponding mes sages being reconfigured Remedy and acknowl edge fault Green red Flashing light 2 Hz Firmware download has been completed Wait for POWER ON Carry out a POWER ON Green orange or Red orange Flashing light Component recognition via LED is activ...

Page 211: ...an SMC40 Overview The activities that must be taken into account when replacing an SMC40 are subsequently described If an SMC40 has a hardware defect then it must be replaced by an identical module Preconditions The module is defective and must be replaced The control cabinet is in a no voltage condition all of the connectors and cables are labeled Service cases hardware 4 16 Sensor Modules Cabine...

Page 212: ...tronics power supply 2 Unscrew the encoder connecting cables X520 x 3 Label the DRIVE CLiQ cables X500 x and withdraw them 4 Release the protective conductor connection and write the position designation on the cable 5 Slide the lug downwards 6 Swivel the module to the front to remove it Note The 50 mm ventilation clearances above and below the components must be observed Service cases hardware 4 ...

Page 213: ...ting catches click into place at the rear 3 Slide the component along the mounting rail to either the left or right up to its final position 4 Screw on the protective conductor connection 5 Screw on the encoder connecting cables X520 x 6 Insert the DRIVE CLiQ cables at X500 x 7 Insert connector X524 for the electronics power supply Note The 50 mm ventilation clearances above and below the componen...

Page 214: ...SME20 has a hardware defect then it must be replaced by an identical module Preconditions The module is defective and must be replaced The control cabinet is in a no voltage condition all of the connectors and cables are labeled Removing 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 ...

Page 215: ...rotection all of the plug connectors must be correctly screwed into place or snapped into place 4 17 3 SME25 connections Connections 3URWHFWLYH JURXQG FRQQHFWLRQ 0 1P 5 9 L4 LQWHUIDFH QFRGHU V VWHP LQWHUIDFH SROH Figure 4 59 Connections SME25 4 17 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 ...

Page 216: ...defective SME25 Installing Procedure 1 Now install the new SME25 2 Screw on the protective conductor connection 3 Reconnect the encoder connecting cable 4 Connect the DRIVE CLiQ cable Note Connections 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 pl...

Page 217: ...20 and install it again Removing Procedure 1 Release the encoder connecting cable X100 of the SME120 2 Withdraw the DRIVE CLiQ cable from X500 of the SME120 3 Release the Hall sensor input X300 of the SME120 4 Release the temperature sensor input X200 of the SME120 5 Release the protective conductor connection of the SME120 6 Remove the defective SME120 module Installing Procedure 1 Now install th...

Page 218: ...ntrol cabinet is in a no voltage condition all of the connectors and cables are labeled 3URWHFWLYH FRQGXFWRU FRQQHFWLRQ 0 1P PPt X100 Encoder system interfaces tightening torque 3 5 Nm X200 Temperature sensor input tightening torque 2 Nm X500 DRIVE CLiQ Figure 4 61 SME125 connections 4 17 8 This is how you remove an SME125 and install it again Removing Procedure 1 Release the encoder connecting ca...

Page 219: ...econnect the temperature sensor at X200 4 Reconnect the encoder connecting cable 5 Connect the DRIVE CLiQ cable Note Connections 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 and snapped into place Service cases hardware 4 17 Sensor Modules External Soft...

Page 220: ... corresponding messages being reconfigured Remove and ac knowledge fault Green red flashing light 0 5 Hz Firmware is being downloaded Flashing light 2 Hz Firmware download has been completed Wait for POWER ON Carry out a POWER ON Green or ange Flashing light OR Red orange Flashing light Component recognition via LED is activated p0154 Note Both options depend on the LED status when activated via p...

Page 221: ...et individually via parameter p10040 TM54F p10040 TM54F 0 Input x 1 is an NC contact p10040 TM54F 1 Input x 1 is an NO contact Factory setting p10040 TM54F 0 for all inputs x 1 Single digital inputs not fail safe LED state Description cause Remedy DI x Off No signal at digital input x x 20 23 Green Continuous light Signal at digital input x Fail safe digital outputs with associated readback channe...

Page 222: ...s display X521 X531 X522 X532 Fail safe digital inputs DI and dynamic power supply Fail safe digital inputs DI X523 X525 X533 X535 Fail safe digital outputs DO X520 Sensor power supply X514 Power supply for digital outputs and sensors Figure 4 62 TM54F connections Service cases hardware 4 18 Terminal Modules Software and hardware 222 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 223: ...ZQZDUGV 6ZLYHO PRGXOH WR WKH IURQW 0RXQWLQJ VOLGH Figure 4 63 TM54F removal Procedure 1 Label connectors X514 and X524 for the sensor and electronics power supply prior to withdrawing them 2 Withdraw the connected DRIVE CLiQ cables X500 and X501 and write the slot designation on the cable 3 Label the connected connectors X520 X535 for digital inputs and outputs prior to withdrawing them 4 Release ...

Page 224: ...ert the connectors for the digital inputs and outputs at X520 X535 7 Insert the DRIVE CLiQ cables at X500 and X501 8 Insert the connectors for the sensor and electronics power supply at X514 and X524 Note The 50 mm ventilation clearances above and below the components must be observed 4 18 5 TM120 status displays Status displays The Terminal Module TM120 has the following status displays which pro...

Page 225: ...pend on the LED status when activated via p0154 1 4 18 6 TM120 safety instructions Note The 50 mm ventilation clearances above and below the components must be observed Note Shielding Connecting cables to temperature sensors must always be installed with shielding The cable shield must be connected to the ground potential at both ends over a large surface area Temperature sensor cables that are ro...

Page 226: ...OG FRQWDFW 5 X500 X501 DRIVE CLiQ interfaces RDY LEDs for status display X521 Inputs for the temperature sensor X524 Electronics power supply Figure 4 64 TM120 connections Service cases hardware 4 18 Terminal Modules Software and hardware 226 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 227: ...QWLQJ VOLGH 6ZLYHO WKH PRGXOH WRZDUG WKH IURQW Figure 4 65 Removing the TM120 Installing Procedure 1 Slightly tilt the component backward and attach it to the mounting rail using the catch 2 Swivel the component on the mounting rail until you hear the mounting slide at the rear latch into position 3 Slide the component along the mounting rail to either the left or right up to its final position Se...

Page 228: ... DRIVE CLiQ communication is being establish ed Red Continuous light This component has at least one fault Remove and acknowl edge fault Note The LED is controlled irrespective of the corre sponding messages being reconfigured Green red Flashes at 0 5 Hz Firmware is being downloaded Flashes at 2 Hz Firmware download has been completed Wait for POWER ON Carry out a POWER ON Green orange or red oran...

Page 229: ...is in a no voltage condition all of the connectors and cables are labeled Procedure 1 Before withdrawing it label the connector X524 for the electronics power supply 2 Withdraw the connected DRIVE CLiQ cables X500 X505 and write the slot designation on the cable 3 Release the protective conductor connection and write the position designation on the cable Service cases hardware 4 19 Hub Modules Sof...

Page 230: ...above and below the components must be maintained Procedure 1 Place the component on the mounting rail 2 Then swivel the component on the mounting rail so that the mounting catches click into place at the rear 3 Slide the component along the mounting rail to either the left or right up to its final position 4 Screw on the protective conductor connection 5 Screw on the encoder connecting cable to X...

Page 231: ... 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 X500 X505 DRIVE CLiQ interfaces X524 Electronics power supply Figure 4 68 DME20 connections Service cases hardware 4 19 Hub Modules Software and hardware Service Manual 08 2018 6FC5397 5DP40 6BA1 231 ...

Page 232: ...face The mounting surfaces must be bare metal R U 0 0RXQWLQJ VXUIDFH Figure 4 69 DME20 dimensions 2 Drill the holes with Ø5 3 or M5 threads 3 Tighten the component with a tightening torque of 6 0 Nm Service cases hardware 4 19 Hub Modules Software and hardware 232 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 233: ...cables can be sourced The following cables can be sourced through Phoenix Contact https www phoenixcontact com online portal pc Pre assembled cables Cables to be assembled by the user Sensor actuator cable 5 pole free cable end at the M12 SPEEDCON straight socket Length of cable 2 5 10 15 m up to 100 m on request SAC 5P xxx 186 FS SCO Cable ring PUR PVC black 5 pole Conductor colors brown white bl...

Page 234: ...times with interval Flashes 3 times with interval ON OFF Logging into a GSM network Field strength inadequate Field strength adequate Field strength good Field strength very good Waiting for PIN CONNECT Flashing Terminal mode activated Reference You can find information about the MODEM MD720 Article number 6NH9720 3AA01 0XX0 at SIOS_Modem_MD720 https support industry siemens com cs de en view 7351...

Page 235: ...cing the SIM card and PIN 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 The device also operates with SIM cards where the PIN prompt is deactivated In this case when establishing a connection the prompt to enter a PIN is skipped 4 20 3 This is how you ...

Page 236: ...n is interrupted The MODEM MD720 is restarted The SIM card PIN is cleared It is no longer possible to read out the logbook 3DSHU FOLS Figure 4 71 MODEM MD720 SET key Service cases hardware 4 20 MODEM MD720 Software and hardware 236 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 237: ...RIK then it possibly involves a memory card that has not been formatted for this control system e g Ext3 Linux file system or a memory card with a defective file system or an incorrect memory card type Insert the memory card carefully and the right way round into the memory card slot observe indicators such as arrow or similar This way you avoid mechanical damage to the memory card or the device D...

Page 238: ... must be ordered and retrofitted 6SL3161 3DP00 0AA0 S120 Combi set of connecting terminals Terminal Kit 24 V plug connector Terminal for the motor holding brake 4 DRIVE CLiQ blanking covers 2 terminals 4 pole for X12 X13 2 terminals 4 pole for X21 X22 5 shield connecting terminals for motor cables Shield connection terminal for EP signal cables 6SL3161 8AP00 0AA0 Spare parts and accessories MCP US...

Page 239: ...LiQ Drive Component Link with IQ EMC Electromagnetic compatibility EN European standard ESD Electro Static Discharge elektrostatische Entladung GSM Global System for Mobile Communications Worldwide standard for wireless transmission of voice data fax and text messages SMS LEDs Light emitting diode light emitting diode display MAC Media Access Control MCP Machine control panel Machine control panel...

Page 240: ...per revolution SRAM Static Random Access Memory Static memory battery backed NV SRAM Non Volatile Static Random Access Memory Non volatile memory USB Universal Serial Bus Bus system for connecting additional devices to a computer VDE Association of Electrical Engineering Electronics and Information Technology Germany Appendix A 1 Abbreviations Software and hardware 240 Service Manual 08 2018 6FC53...

Page 241: ... documentation for the LICENSED PRODUCT LICENSED PRODUCT IS PROVIDED AS IS WITH NO WARRANTIES OF ANY KIND INCLUDING THE WARRANTIES OF DESIGN MERCHANTIBILITY AND FITNESS FOR A PARTICULAR PURPOSE NONINFRINGEMENT OR ARISING FROM A COURSE OF DEALING USAGE OR TRADE PRACTICE LICENSED PRODUCT IS PROVIDED WITH NO SUPPORT AND WITHOUT ANY OBLIGATION ON THE PART OF SUN OR ANY OF ITS SUBSIDIARIES OR AFFILIATE...

Page 242: ...CERNING THE MERCHANTABILITY OF THIS SOFTWARE OR ITS FITNESS FOR ANY PARTICULAR PURPOSE This product includes software developed by the University of California Berkeley and its contributors QLocale s data is based on Common Locale Data Repository v1 6 1 Note You can find additional information on the product DVD in the Readme_OSS file about the third party software used Appendix A 2 Information ab...

Page 243: ...PHQW 0DQXDO 6HUYLFH 0DQXDO RPPLVVLRQLQJ 0DQXDO XQFWLRQ 0DQXDO 6DIHW QWHJUDWHG DWDORJ 1 6DOHV URFKXUH 6 180 5 6 LVW 0DQXDO 0DFKLQH GDWD QWHUIDFH VLJQDOV 9DULDEOHV 6 VWHP 0DQXDO WUO QHUJ RQILJXUDWLRQ 0DQXDO 0 LQVWDOODWLRQ JXLGHOLQH QGXVWULDO VHFXULW URVV V VWHP GRFXPHQWDWLRQ LVW 0DQXDO 3DUDPHWHU 6DOHV URFKXUH 6 180 5 6DOHV URFKXUH 6 180 5 6 180 5 6 1 0 6 6 6 180 5 VO 6 180 5 VO 6 180 5 6 180 5 6 180...

Page 244: ...Appendix A 3 Documentation overview SINUMERIK 828D Software and hardware 244 Service Manual 08 2018 6FC5397 5DP40 6BA1 ...

Page 245: ...up 52 automatic 31 Manual 29 E End user final destination data Configuration file 77 Enter 71 F Fan internal Motor Module Booksize Compact 170 S120 Combi 154 Front cover installing 92 removing 91 L LED status CU310 2 PN 129 CU320 2 PN 124 Front of the PPU 83 MCP 483C PN 99 MCP 310C PN 103 MODEM MD720 234 NX10 3 NX15 3 118 Rear of the PPU 84 S120 Combi Power Modules 137 TM120 224 TM54F 220 License ...

Page 246: ...k 162 DC link cover 146 Drip protection 144 installing an internal fan 157 Remove the air baffle plate 162 Removing the internal fan 154 Spare parts 238 Safety instructions S120 Combi 145 Terminal Module TM120 225 Service contact person 27 Shield contact 122 Spare parts S120 Combi 238 Switch S1 on the I O module 113 117 S2 on the MCP 310C PN 107 S2 on the MCP 483C PN 102 T Technical support 27 U U...

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