828D_SH_0310_en (2).pdf

Hardware and Software Hardware and Software _ SINUMERIK SINUMERIK 828D SINUMERIK SINUMERIK 828D Hardware and SoftwareHardware and Software Service ManualService Manual Valid for:CNC software for SINUMERIK 828D V2.6 03/201003/2010 6FC5397-5DP20-0BA0 Preface Preface Safety notes Safety notes 1 1 System description System description 2 2 Service cases-software Service cases-software 3 3 Service cases-hardware Service cases-hardware 4 4 Spare parts and accessoriesSpare parts and accessories 5 5 ESD guidelines ESD guidelines A A Appendix Appendix B B Legal information Legal information Legal information Warning notice system Legal information Warning notice system This manual contains notices you have to observe in order to ensure your personal safety,as well as to prevent damage to property.The notices referring to your personal safety are highlighted in the manual by a safety alert symbol,notices referring only to property damage have no safety alert symbol.These notices shown below are graded according to the degree of danger.DANGER DANGER indicates that death or severe personal injury willwill result if proper precautions are not taken.WARNING WARNING indicates that death or severe personal injury maymay result if proper precautions are not taken.CAUTION CAUTION with a safety alert symbol,indicates that minor personal injury can result if proper precautions are not taken.CAUTION CAUTION without a safety alert symbol,indicates that property damage can result if proper precautions are not taken.NOTICE NOTICE indicates that an unintended result or situation can occur if the corresponding information is not taken into account.If more than one degree of danger is present,the warning notice representing the highest degree of danger will be used.A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.Qualified Personnel Qualified Personnel The product/system described in this documentation may be operated only by personnel qualifiedpersonnel qualified for the specific task in accordance with the relevant documentation for the specific task,in particular its warning notices and safety instructions.Qualified personnel are those who,based on their training and experience,are capable of identifying risks and avoiding potential hazards when working with these products/systems.Proper use of Siemens products Proper use of Siemens products Note the following:WARNING WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation.If products and components from other manufacturers are used,these must be recommended or approved by Siemens.Proper transport,storage,installation,assembly,commissioning,operation and maintenance are required to ensure that the products operate safely and without any problems.The permissible ambient conditions must be adhered to.The information in the relevant documentation must be observed.Trademarks Trademarks All names identified by are registered trademarks of the Siemens AG.The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.Disclaimer of Liability Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described.Since variance cannot be precluded entirely,we cannot guarantee full consistency.However,the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.Siemens AG Industry Sector Postfach 48 48 90026 NRNBERG GERMANY order number:6FC5397-5DP20-0BA0 04/2010 Copyright Siemens AG 2010.Technical data subject to change Hardware and Software Service Manual,03/2010,6FC5397-5DP20-0BA0 3 PrefacePreface SINUMERIK documentation SINUMERIK documentation The SINUMERIK documentation is organized in three parts:General documentation User documentation Manufacturer/service documentation Information on the following topics is available under the link(http:/ documentation Here you can find an up-to-date overview of publications.Downloading documentation Links to more information for downloading files from Service&Support.Researching documentation online Information on DOConCD and direct access to the publications in DOConWEB.Customizing documentation based on Siemens content using My Documentation Manager(MDM)(http:/ Documentation Manager provides you with a range of features for generating your own machine documentation.Training and FAQs Information on our range of training courses and FAQs(frequently asked questions)is available via the page navigation.Target group Target group This document addresses maintenance and service personnel.Benefits Benefits Based on the Service Manual,the target group can correctly and safely perform service and maintenance work.Utilization phase:Maintenance and service phase Standard version Standard version This documentation only describes the functionality of the standard version.Extensions or changes made by the machine manufacturer are documented by the machine manufacturer.Other functions not described in this documentation might be executable in the control.However,no claim can be made regarding the availability of these functions when the equipment is first supplied or in the event of servicing.Preface Hardware and Software 4 Service Manual,03/2010,6FC5397-5DP20-0BA0 Further,for the sake of simplicity,this documentation does not contain all detailed information about all types of the product and cannot cover every conceivable case of installation,operation or maintenance.Questions about this documentation Questions about this documentation If you have any queries(suggestions,corrections)in relation to this documentation,please send a fax or e-mail to the following address:Fax:+49 9131 98 2176 A fax form is available at the end of this document.E-mail(mailto:)SINUMERIK Internet address(http:/ Service&Support If you have any technical questions,please contact our hotline:Europe/Africa Europe/Africa PhonePhone+49 180 5050 222 FaxFax+49 180 5050 223 0.14/min from the German fixed-line network;cell phone charges may vary.Internet(http:/ Americas PhonePhone+1 423 262 2522 FaxFax+1 423 262 2200 E-mail(mailto:)Asia/Pacific Asia/Pacific PhonePhone+86 1064 75 75 75 FaxFax+86 1064 74 74 74 E-mail(mailto:)Note Note Country-specific telephone numbers for technical support are provided on the Internet(http:/ Hardware and Software Service Manual,03/2010,6FC5397-5DP20-0BA0 5 EC Declaration of Conformity EC Declaration of Conformity The EC Declaration of Conformity for the EMC Directive can be found on the Internet(http:/)under the Product Order No.15257461 or at the relevant branch office of the I DT MC Division of Siemens AG.CompactFlash cards for users:CompactFlash cards for users:The SINUMERIK CNC supports the file systems FAT16 and FAT32 for CompactFlash cards.You may need to format the memory card if you want to use a memory card from another device or if you want to ensure the compatibility of the memory card with the SINUMERIK.However,formatting the memory card will permanently delete all data on it.Do not remove the memory card while it is being accessed.This can lead to damage of the memory card and the SINUMERIK as well as the data on the memory card.If you cannot use a memory card with the SINUMERIK,it is probably because the memory card is not formatted for the control system(e.g.Ext3 Linux file system),the memory card file system is faulty or it is the wrong type of memory card.Insert the memory card carefully with the correct orientation into the memory card slot(take note of arrows,etc.).This way you avoid mechanical damage to the memory card or the device.Only use memory cards that have been approved by Siemens for use with SINUMERIK.Even though the SINUMERIK keeps to the general industry standards for memory cards,it is possible that memory cards from some manufacturers will not function perfectly in this device or are not completely compatible with it(you can obtain information on compatibility from the memory card manufacturer or supplier).The CompactFlash card from SanDisk CompactFlash 5000 Industrial Grade has been approved for SINUMERIK(Order Number 6FC5313-5AG00-0AA0).Preface Hardware and Software 6 Service Manual,03/2010,6FC5397-5DP20-0BA0 Hardware and Software Service Manual,03/2010,6FC5397-5DP20-0BA0 7 Table of contents Table of contents Preface.3 1 Safety notes.11 2 System description.13 Preface.3 1 Safety notes.11 2 System description.13 2.1 System overview.13 2.2 System versions.14 3 Service cases-software.17 3 Service cases-software.17 3.1 Backing up user data.18 3.1.1 This is how you backup user data.18 3.1.2 This is how you load the user data backup.21 3.2 Series commissioning.23 3.2.1 This is how you generate a series commissioning archive on an external data carrier.23 3.2.2 This is how you import a series commissioning archive from an external data carrier.26 3.2.3 This is how you generate a series commissioning archive on the system CompactFlash Card.27 3.2.4 This is how you import a series commissioning archive from the system CompactFlash Card.29 3.3 Software backup.32 3.3.1 This is how you generate a software backup.32 3.3.2 This is how you install a software backup.36 3.4 Software update.40 3.4.1 This is how you update the software.40 3.5 Mini boot system on the CompactFlash Card.44 3.5.1 This is how you generate a mini boot system.44 3.5.2 This is how you install a software backup using the mini boot system.48 3.6 Licensing.51 3.6.1 Licensing after replacing the system CompactFlash Card.51 3.6.2 This is how you license a CNC option.51 3.6.3 How to determine the license requirement.53 3.6.4 This is how you generated a new license key.54 3.6.5 This is how you display the actual license key.57 3.7 Enter the final end user data(EUNA).60 3.7.1 This is how you generate the machine logbook.60 3.7.2 This is how you make a new entry in the logbook.62 3.7.3 This is how you save the machine identity.64 3.7.4 This is how you send the end user final destination data.66 4 Service cases-hardware.69 4 Service cases-hardware.69 4.1 PPU26x/PPU28x.71 4.1.1 Status displays at the PPU.71 4.1.2 This is how you remove the PPU.73 4.1.3 This is how you install the PPU.74 4.2 Replacing the system CompactFlash Card.76 Table of contents Hardware and Software 8 Service Manual,03/2010,6FC5397-5DP20-0BA0 4.2.1 This is how you remove the system CompactFlash Card.76 4.2.2 This is how you insert the system CompactFlash Card.78 4.3 SINAUT modem.81 4.3.1 LED status displays.81 4.3.2 This is how you insert the SIM card.82 4.3.3 This is how you load the factory settings.88 4.4 Machine control panels.89 4.4.1 Status displays MCP 310C PN.89 4.4.2 This is how you remove the MCP 310C PN.90 4.4.3 This is how you install the MCP 310C PN.92 4.4.4 Status displays,MCP 483C PN.93 4.4.5 This is how you remove the MCP 483C PN.94 4.4.6 This is how you install the MCP 483C PN.96 4.5 I/O modules.98 4.5.1 Status displays PP 72/48D PN.98 4.5.2 This is how you remove the PP 72/48D PN.99 4.5.3 This is how you install the PP 72/48D PN.101 4.5.4 Status displays PP 72/48D 2/2A PN.102 4.5.5 This is how you remove the PP 72/48D 2/2A PN.103 4.5.6 This is how you install the PP 72/48D 2/2A PN.105 4.6 Expansion module NX10.106 4.6.1 Status displays on the NX10.106 4.6.2 This is how you remove the NX10.106 4.6.3 This is how you install the NX10.108 4.7 Single Motor Modules.109 4.7.1 SMM status displays.109 4.7.2 SMM connections.110 4.7.3 This is how you remove a Motor Module.111 4.7.4 This is how you install a Motor Module.113 4.8 Double Motor Modules.115 4.8.1 DMM status displays.115 4.8.2 DMM connections.116 4.8.3 This is how you remove a Motor Module.117 4.8.4 This is how you install a Motor Module.119 4.9 Smart Line Modules.121 4.9.1 SLM(16 kW)status displays.121 4.9.2 SLM(16 kW)connections.122 4.9.3 SLM(16 kW and higher)status displays.123 4.9.4 SLM(16 kW and higher)connections.124 4.9.5 This is how you remove an SLM.125 4.9.6 This is how you install an SLM.127 4.10 Active Line Modules.129 4.10.1 ALM status displays.129 4.10.2 ALM connections.130 4.10.3 This is how you remove an ALM.131 4.10.4 This is how you install an ALM.133 4.11 SMC20/SMC30.135 4.11.1 SMC20 status displays.135 4.11.2 SMC20 connections.136 4.11.3 This is how you remove an SMC20.136 4.11.4 This is how you install an SMC20.138 Table of contents Hardware and Software Service Manual,03/2010,6FC5397-5DP20-0BA0 9 4.11.5 SMC30 status displays.139 4.11.6 SMC30 connections.140 4.11.7 This is how you remove an SMC30.140 4.11.8 This is how you install an SMC30.142 4.12 SME20/SME25.144 4.12.1 SME20 connections.144 4.12.2 This is how you remove an SME20 and install it again.144 4.12.3 SME25 connections.145 4.12.4 This is how you remove an SME25 and install it again.146 4.13 DMC20.147 4.13.1 DMC20 status displays.147 4.13.2 DMC20 connections.148 4.13.3 This is how you remove a DMC20.148 4.13.4 This is how you install a DMC20.150 5 Spare parts and accessories.151 A ESD guidelines.153 5 Spare parts and accessories.151 A ESD guidelines.153 A.1 RI suppression measures.153 A.2 ESD measures.154 B Appendix.155 B Appendix.155 B.1 List of abbreviations.155 B.2 Feedback on the documentation.159 B.3 Documentation overview.163 Index.165 Index.165 Table of contents Hardware and Software 10 Service Manual,03/2010,6FC5397-5DP20-0BA0 Hardware and Software Service Manual,03/2010,6FC5397-5DP20-0BA0 11 Safety notesSafety notes 1 1 The following notices are intended firstly for your personal safety and secondly to prevent damage occurring to the product described or any connected devices and machines.Non-observance of the warnings can result in severe personal injury or property damage.DANGER DANGER Only appropriately qualified personnel may commission/start-up SINUMERIK equipment.The personnel must take into account the information provided in the technical customer documentation for the product,and be familiar with and observe the specified danger and warning notices.When electrical equipment and motors are operated,the electrical circuits automatically conduct a dangerous voltage.When the system is operating,dangerous axis movements may occur throughout the entire work area.A potential fire hazard exists due to the energy being transferred in the equipment and the work materials used.All work on the electrical system must be performed after the system has been switched off and disconnected from the power supply.DANGER DANGER Proper transportation,expert storage,installation and mounting,as well as careful operation and maintenance are essential for this SINUMERIK device to operate correctly and reliably.The details in the catalogs and proposals also apply to the design of special equipment versions.In addition to the danger and warning information provided in the technical customer documentation,the applicab