siemens 828D User Manual

SINUMERIK

SINUMERIK 828D PPU

Manual

Preface

Safety notes	1
System description	2
Application planning	3
Installing	4
Rulesforpermittedtopologies	5
Interface description	6
Connectable components	7
Technical data	8
Spare parts and accessories	9
Appendix	A

Valid for: SINUMERIK 828D PPU 24x.3 BASIC PPU 26x.3 PPU 28x.3

01/2014

6FC5397-2DP40-3BA3

Legal information

Warning notice system

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.

DANGER

indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING

indicates that death or severe personal injury may result if proper precautions are not taken.

CAUTION

indicates that minor personal injury can result if proper precautions are not taken.

NOTICE

indicates that property damage can result if proper precautions are not taken.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning ofinjuryto persons with a safety alert symbol may also include a warning relating toproperty damage.

Qualified Personnel

The product/system described in this documentation may be operated only by personnel qualified for the specific taskinaccordancewiththerelevantdocumentation,inparticularitswarningnoticesandsafetyinstructions.Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.

Proper use of Siemens products

Note the following:

WARNING

Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks

All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of Liability

We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AG	Order number: 6FC5397-2DP40-3BA3	Copyright © Siemens AG 2009 - 2014.
Industry Sector	01/2014 Technical data subject to change	All rights reserved
Postfach 48 48
90026 NÜRNBERG
GERMANY

Preface

SINUMERIK documentation

The SINUMERIK documentation is organized into the following categories:

●General documentation

●User documentation

●Manufacturer/service documentation

Additional information

You can find information on the following topics under the link (www.siemens.com/ motioncontrol/docu):

●Ordering documentation / current documentation overview

●Additional links to download documents

●Using documentation online (finding and searching in manuals/information)

Please send any questions about the technical documentation (e.g. suggestions for improvement, corrections) to the following address: (mailto:[e-mail])

My Documentation Manager (MDM)

Under the following link you will find information to individually compile OEM-specific machine

documentation based on the Siemens content: MDM (www.siemens.com/mdm)

Training

For information about the range of training courses, refer to:

●SITRAIN (www.siemens.com/sitrain) - training courses from Siemens for automation products, systems and solutions

●SinuTrain (www.siemens.com/sinutrain) - training software for SINUMERIK

FAQs

You can find Frequently Asked Questions in the Service&Support pages under Product

Support (www.siemens.com/automation/service&support).

PPU	3
Manual, 01/2014, 6FC5397-2DP40-3BA3

Preface

SINUMERIK

You can find information on SINUMERIK under the following link: (www.siemens.com/ sinumerik)

Target group

This documentation is intended for manufacturers of machine tools, particularly:

●Project engineers, electricians and installers

●Maintenance and service personnel

Benefits

The information in this manual facilitates installation and connection of the SINUMERIK 828D numerical control.

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.

Further, for the sake of simplicity, this documentation does not contain all detailed information aboutalltypesoftheproductandcannotcovereveryconceivablecaseofinstallation,operation or maintenance.

Technical support

Country-specific telephone numbers for technical support are provided in the Internet under "Contact" (www.siemens.com/automation/service&support).

EC Declaration of Conformity

The EC declaration of conformity for the EMC directive can be found in the Internet (http:// support.automation.siemens.com/WW/view/de/10805517/134200).

4	PPU
	Manual, 01/2014, 6FC5397-2DP40-3BA3

Table of contents

	Preface.........................................................................................................................................................		3
1	Safety notes..................................................................................................................................................		9
	1.1	Danger notices..............................................................................................................................	9
	1.2	ESD notices.................................................................................................................................	11
2	System description.....................................................................................................................................		13
	2.1	Controller features.......................................................................................................................	13
	2.2	PPU version 24x.3 BASIC...........................................................................................................	15
	2.3	PPU versions 26x.3 and 28x.3....................................................................................................	18
	2.4	Operator controls and display elements......................................................................................	21
	2.5	Type plate....................................................................................................................................	22
	2.6	System overview.........................................................................................................................	24
	2.7	Connectable components............................................................................................................	26
	2.8	Ordering data..............................................................................................................................	27
	2.9	CompactFlash Cards...................................................................................................................	29
	2.9.1	CompactFlash card system.........................................................................................................	29
	2.9.2	Inserting the system CompactFlash Card...................................................................................	30
	2.9.3	CompactFlash card for user data................................................................................................	32
3	Application planning...................................................................................................................................		35
	3.1	Secondary electrical conditions...................................................................................................	35
	3.1.1	Protective Separation as per EN 61800-5-1................................................................................	35
	3.1.2	Grounding concept......................................................................................................................	35
	3.1.3	RI suppression measures............................................................................................................	37
	3.2	Climatic and mechanical environmental conditions.....................................................................	39
	3.2.1	Ambient conditions......................................................................................................................	39
	3.2.2	Transport and Storage Conditions..............................................................................................	39
	3.2.3	Operating Conditions...................................................................................................................	40
	3.3	Recycling and disposal................................................................................................................	41
4	Installing.....................................................................................................................................................		43
	4.1	Mounting positions......................................................................................................................	43
	4.2	Dimension drawings....................................................................................................................	50
5	Rules for permitted topologies....................................................................................................................		53
	5.1	Topology rules for S120 Combi...................................................................................................	53
	5.2	Topology rules for S120 Booksize...............................................................................................	54
	5.3	Topology rules for Safety Integrated functions............................................................................	58

PPU	5
Manual, 01/2014, 6FC5397-2DP40-3BA3

Table of contents

	5.4	Topology example without Safety Integrated functions...............................................................	59
	5.5	Topology example with Safety Integrated functions....................................................................	63
6	Interface description...................................................................................................................................		67
	6.1	Interface overview.......................................................................................................................	67
	6.2	Power supply connection............................................................................................................	69
	6.2.1	Requirements for the power supply.............................................................................................	69
	6.2.2	Connecting the power supply......................................................................................................	71
	6.3	Ethernet.......................................................................................................................................	71
	6.4	PLC I/O Interface based on PROFINET .....................................................................................	73
	6.4.1	Addressing the I/O modules........................................................................................................	75
	6.5	Digital inputs/outputs...................................................................................................................	76
	6.5.1	Terminal connection diagram......................................................................................................	81
	6.5.2	Example: Connecting an inductive proximity switch (BEROs) .................................................	82
	6.5.3	Technical data ............................................................................................................................	83
	6.6	DRIVE-CLiQ................................................................................................................................	84
	6.6.1	DRIVE-CLiQ interface.................................................................................................................	84
	6.6.2	SINAMICS components..............................................................................................................	86
	6.7	Handwheel..................................................................................................................................	87
	6.8	USB.............................................................................................................................................	89
	6.9	RS 232 serial interface................................................................................................................	90
7	Connectable components...........................................................................................................................		93
	7.1	MCP 483C PN.............................................................................................................................	93
	7.1.1	Operator controls and display elements......................................................................................	94
	7.1.2	Mounting......................................................................................................................................	97
	7.1.3	Connecting..................................................................................................................................	98
	7.1.4	Parameterization.......................................................................................................................	104
	7.1.5	Technical data...........................................................................................................................	107
	7.1.6	Spare parts and accessories.....................................................................................................	108
	7.2	MCP 310C PN...........................................................................................................................	111
	7.2.1	Operator controls and display elements....................................................................................	113
	7.2.2	Mounting....................................................................................................................................	116
	7.2.3	Connecting................................................................................................................................	118
	7.2.4	Parameterization.......................................................................................................................	123
	7.2.5	Technical data...........................................................................................................................	126
	7.2.6	Spare parts and accessories.....................................................................................................	127
	7.3	MCP Interface PN.....................................................................................................................	130
	7.3.1	Mounting....................................................................................................................................	133
	7.3.2	Connection................................................................................................................................	134
	7.3.3	Parameter assignment..............................................................................................................	146
	7.3.4	Technical data...........................................................................................................................	148
	7.4	Electronic handwheel................................................................................................................	148
	7.4.1	Description................................................................................................................................	148
	7.4.2	Mounting....................................................................................................................................	151
	7.4.3	Connection................................................................................................................................	152

6	PPU
	Manual, 01/2014, 6FC5397-2DP40-3BA3

			Table of contents
	7.4.4	Technical specifications............................................................................................................	153
	7.4.5	Spare parts and accessories.....................................................................................................	154
	7.5	Mini handheld unit.....................................................................................................................	154
	7.5.1	Description................................................................................................................................	154
	7.5.2	Mounting....................................................................................................................................	157
	7.5.3	Connecting................................................................................................................................	160
	7.5.4	Parameterization.......................................................................................................................	162
	7.5.5	Technical data ..........................................................................................................................	163
	7.5.6	Spare parts and accessories.....................................................................................................	164
	7.6	PP 72/48D PN...........................................................................................................................	166
	7.6.1	Description................................................................................................................................	166
	7.6.2	Mounting....................................................................................................................................	169
	7.6.3	Connecting................................................................................................................................	171
	7.6.3.1	X1 power supply........................................................................................................................	172
	7.6.3.2	X2 PROFINET...........................................................................................................................	173
	7.6.3.3	X111, X222 and X333 pin assignment......................................................................................	174
	7.6.3.4	Specification of the digital inputs...............................................................................................	177
	7.6.3.5	Specification of the digital outputs.............................................................................................	178
	7.6.4	Parameter assignment..............................................................................................................	179
	7.6.4.1	Input / output images.................................................................................................................	179
	7.6.4.2	Diagnostics via input image.......................................................................................................	181
	7.6.5	Technical data...........................................................................................................................	183
	7.7	PP 72/48D 2/2A PN...................................................................................................................	184
	7.7.1	Description................................................................................................................................	184
	7.7.2	Assembling................................................................................................................................	187
	7.7.3	Connection................................................................................................................................	189
	7.7.3.1	X1 power supply........................................................................................................................	190
	7.7.3.2	X2 PROFINET...........................................................................................................................	193
	7.7.3.3	X111, X222 and X333 pin assignment......................................................................................	194
	7.7.3.4	Specification of the digital inputs...............................................................................................	197
	7.7.3.5	Specification of the digital outputs.............................................................................................	198
	7.7.3.6	Analog X3 inputs/outputs..........................................................................................................	199
	7.7.4	Assigning parameters................................................................................................................	203
	7.7.4.1	Input / output images.................................................................................................................	203
	7.7.4.2	Diagnostics via input image.......................................................................................................	205
	7.7.4.3	Assigning parameters to the analog inputs / outputs................................................................	207
	7.7.4.4	Analog value representation......................................................................................................	209
	7.7.4.5	Examples...................................................................................................................................	212
	7.7.5	Technical data...........................................................................................................................	213
	7.8	NX10.3......................................................................................................................................	214
	7.8.1	Description................................................................................................................................	214
	7.8.2	Mounting....................................................................................................................................	217
	7.8.3	Connecting................................................................................................................................	219
	7.8.4	Technical Data..........................................................................................................................	223
8	Technical data..........................................................................................................................................		225
9	Spare parts and accessories....................................................................................................................		227
	9.1	SINAUT modem........................................................................................................................	227
	9.2	PN/PN coupler...........................................................................................................................	229

PPU	7
Manual, 01/2014, 6FC5397-2DP40-3BA3

Table of contents

	9.2.1	Principle of operation .................................................................................................................	229
	9.2.2	Configuration .............................................................................................................................	230
	9.3	SENTRON PAC3200/PAC4200 ................................................................................................	233
	9.4	SITOP power supply .................................................................................................................	235
	9.5	Terminal strip converter .............................................................................................................	236
A	Appendix	...................................................................................................................................................	237
	A.1	Abbreviations .............................................................................................................................	237
	A.2 ............................................................................	Documentation overview SINUMERIK 828D	239
	Index.........................................................................................................................................................		241

8	PPU
	Manual, 01/2014, 6FC5397-2DP40-3BA3

Safety notes	1

1.1Danger notices

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. Nonobservance of the warnings can result in severe personal injury or property damage.

DANGER

Qualified personnel

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

Supply voltage

External power supply units for supplying components of the drive control must have safety isolation from circuits with dangerous voltages (DVC A according to EN 61800-5-1; SELV/ PELV).Inadditiononlypowerunitswithcontrolcircuitsthathavesafetyisolationfromcircuits with dangerous voltages may be connected.

PPU	9
Manual, 01/2014, 6FC5397-2DP40-3BA3

Safety notes

1.1 Danger notices

DANGER

Commissioning and operation of the devices

Proper transportation, expert storage, installation and mounting, as well as careful operation and maintenance are essential for this SINUMERIK device to operate correctly and reliably.

The details in the catalogs and proposals also apply to the design of special equipment versions.

In addition to the danger and warning information provided in the technical customer documentation, the applicable national, local, and system-specific regulations and requirements must be taken into account.

Only class DVC A protective extra-low voltages (PELVs) may be connected to connections and terminals up to 60 V DC in accordance with EN 61800-5-1.

Should it be necessary to test or take measurements on live equipment, then the specifications and procedural instructions defined in Accident Prevention Regulation BGV A2 must be adhered to, in particular § 8 "Permissible deviations when working on live components". Suitable electric tools should be used.

DANGER

Carrying out of repairs

Repairs to devices that we have supplied may only be carried out by Siemens Customer Service or by repair centers authorized by Siemens.

When replacing parts or components, only use those parts that are included in the spare parts list.

EMERGENCY STOP/EMERGENCY OFF devices according to EN 60204-1 (VDE 0113 Part 1)mustremainactiveinallmodesoftheautomationequipment.ResettingtheEMERGENCY STOP/EMERGENCY OFF device must not cause an uncontrolled or undefined restart.

Anywhere in the automation equipment where faults might cause physical injury or major material damage, in other words, where faults could be dangerous, additional external precautions must be taken, or facilities must be provided, that guarantee or enforce a safe operational state, even when there is a fault (e.g. using an independent limit value switch, mechanical locking mechanisms, EMERGENCY STOP/EMERGENCY OFF devices).

10	PPU
	Manual, 01/2014, 6FC5397-2DP40-3BA3

Safety notes

1.2 ESD notices

1.2ESD notices

NOTICE

Handling ESD modules:

The modules contain electrostatically sensitive devices. Discharge yourself of electrostatic energy before touching the components. The easiest way to do this is to touch a conductive, grounded object immediately beforehand (for example, bare metal parts of control cabinet or the protective ground contact of a socket outlet).

●When handling electrostatically sensitive devices, make sure that operator, workplace and packing material are properly grounded.

●Generally, electronic modules must not be touched unless work has to be carried out on them. When handling PC boards make absolutely sure that you do not touch component pins or printed conductors.

●Touch components only if:

–you are constantly grounded via an ESD arm band,

–ESD shoes or ESD shoe grounding strips if there is an ESD floor.

●Boards/modules must only be placed on conductive surfaces (table with ESD surface, conductive ESD foam, ESD packaging, ESD transport container).

●Keep modules away from visual display units, monitors or TV sets (minimum distance from screen 10 cm).

●Do not bring ESD-sensitive modules into contact with chargeable and highly-insulating materials, such as plastic, insulating table tops or clothing made of synthetic materials.

●Measurements on modules are allowed only if:

–The measuring instrument is properly earthed (e.g., protective conductor) or

–Beforemeasuringwithafloatingmeasuringinstrument,theprobeisbrieflydischarged (e.g., touch the bare metal parts of the control housing).

PPU	11
Manual, 01/2014, 6FC5397-2DP40-3BA3

System description	2

2.1Controller features

Features

The SINUMERIK 828D is a tailor-made CNC solution for milling and turning machines in the medium performance range.

SINUMERIK828Disapanel-basedCNC(panelprocessingunit).ACNC,PLC,operatorpanel and axis control for six drives (standard) are combined in a single unit. This design provides a high degree of robustness by eliminating the need for hardware interfaces between the CNC electronics board and the operator panel. In order to guarantee that operation is as lowmaintenance as possible, there are no wearing parts such as fans or back-up batteries.

●CNC operator panel with tailor-made system software versions for turning and milling technologies. PPU 28x, PPU 26x and PPU 24x BASIC

●Two operator panel versions for horizontal and vertical operator panel housings.

●Integrated full QWERTY CNC keyboard with mechanical short-stroke keys.

This enables the user to enter text for part-program names or tool identifiers and plain-text language commands directly, without using the keys of the second input level (shift key). The keys have IP65 degree of protection.

●USB, CompactFlash card and Ethernet interface on the operator panel front.

●Additional Ethernet interface on the rear of the CNC for a permanent factory network.

●PLC I/O Interface based on PROFINET for the connection of PLC I/O devices and a machine control panel.

●PP 72/48D PN and PP 72/48D 2/2A PN as PLC I/O module.

●Three handwheels can be connected.

●Optional GSM modem connection possible.

●Up to six axes/spindles for milling applications and up to eight axes/spindles for turning applications.

●One machining channel / mode group.

●IntegratedPLCbasedontheSIMATICS7-200commandsetwithladderlogicprogramming.

●Standardized 3/8" threads are embedded in the upper edges of the operator panel. These threads can be used for attaching commercially available additional components such as holders for diagrams or similar.

Control system versions

The SINUMERIK 828D is available in different versions (horizontal or vertical; turning or milling).

The SINUMERIK 828D is available in the following versions:

PPU	13
Manual, 01/2014, 6FC5397-2DP40-3BA3

System description

2.1Controller features

●PPU 240.3 BASIC (vertical operator panel)

●PPU 241.3 BASIC (horizontal operator panel)

●PPU 260.3 (vertical operator panel)

●PPU 261.3 (horizontal operator panel)

●PPU 280.3 (vertical operator panel)

●PPU 281.3 (horizontal operator panel)

Quantity structure

The following table shows the quantity structures for the different control versions:

Function		PPU 240.3 / 241.3		PPU 260.3 / 261.3		PPU 280.3 / 281.3
		BASIC
		Turning	Milling	Turning	Milling	Turning	Milling
Non-volatile memory (NVRAM):
●	For OEM data	512 KB	512 KB	512 KB	512 KB	512 kB	512 kB
●	For user data	3 MB	3 MB	5 MB	5 MB	8 MB	8 MB
Number of axes/spindles		3	4	3	4	3	4
Maximum number of axes/spindles		5	5	6	6	6 / 8 *	6
Maximum number of axes with drive-		5	5	6	6	6 / 8 *	6
based Safety Integrated
Axis expansion with NX10.3		--	--	--	1	1	1
Number of DRIVE-CLiQ interfaces		3	3	3	3	3	3
Maximum number of I/O modules		3	3	4	4	5	5
(digital/analog)

Note

Axis extensions for PPU 28x.3

With the help of a NX10.3, the following extensions can be connected:

●The maximum number of axes can be increased to eight, six of which can be connected to the PPU and two to the NX10.3.

●One high-speed spindle (e.g. 24,000 rpm with four pole pairs) can be connected to the NX10.3 and five axes to the PPU.

14	PPU
	Manual, 01/2014, 6FC5397-2DP40-3BA3

System description

2.2 PPU version 24x.3 BASIC

2.2PPU version 24x.3 BASIC

Front side of the PPU 24x.3 BASIC

PPU	15
Manual, 01/2014, 6FC5397-2DP40-3BA3

System description

2.2 PPU version 24x.3 BASIC

Front cover Menu back key

Alphabetic key group Control key group Hotkey group Cursor key group Numerical block Menu forward key

3/8" threads for additional components X127 Ethernet (service socket)

Status LED: RDY, NC, CF X125 USB interface

Slot for CompactFlash card with user data

Figure 2-1 System versions

16	PPU
	Manual, 01/2014, 6FC5397-2DP40-3BA3

System description

2.2 PPU version 24x.3 BASIC

Rear side of the PPU 24x.3 BASIC

	X122, X132	Digital inputs/outputs, drive
	X242, X252	Digital inputs/outputs for NC; controller of the analog spindle (X252)
	X143	Handwheels
	M, T2, T1, T0	Measuring sockets
	X1	Power supply
	X135	USB interface: For service purposes only
	X130	Ethernet LAN
	PN	PLC I/O Interface
	SYNC, FAULT	Status LEDs

X100, X101, X102 DRIVE-CLiQ interfaces

X140

Serial interface RS232

Figure 2-2 Interfaces at the rear

PPU	17
Manual, 01/2014, 6FC5397-2DP40-3BA3

System description

2.3 PPU versions 26x.3 and 28x.3

2.3PPU versions 26x.3 and 28x.3

Front of the PPU versions 26x.3 and 28x.3

18	PPU
	Manual, 01/2014, 6FC5397-2DP40-3BA3

System description

2.3 PPU versions 26x.3 and 28x.3

Front cover Menu back key

Alphabetic key group Control key group Hotkey group Cursor key group Numerical block Menu forward key

3/8" threads for additional components Front cover

X127 Ethernet (service socket) Status LED: RDY, NC, CF

X125 USB interface

Slot for CompactFlash card with user data

Figure 2-3 System versions

PPU	19
Manual, 01/2014, 6FC5397-2DP40-3BA3

System description

2.3 PPU versions 26x.3 and 28x.3

Rear of the PPU versions 26x.3 and 28x.3

X122, X132	Digital inputs/outputs, drive
X242, X252	Digital inputs/outputs for NC; controller of the analog spindle (X252)
X143	Handwheels
M, T2, T1, T0	Measuring sockets
X1	Power supply
X135	USB interface: For service purposes only
X130	Ethernet LAN
PN 1, PN 2	PLC I/O Interface
SYNC, FAULT	Status LEDs
X100, X101, X102	DRIVE-CLiQ interfaces
X140	Serial interface RS232

Figure 2-4 Interfaces at the rear of the PPU

20	PPU
	Manual, 01/2014, 6FC5397-2DP40-3BA3

System description

2.4 Operator controls and display elements

2.4Operator controls and display elements

TFT color display

The TFT color display has a diagonal size of 10.4" (PPU 26x.3/28x.3) or 8.4" (PPU 24x.3). The resolution is 800 x 600 pixels. The softkeys are arranged in an 8 + 8 layout; this makes the CNC easy to operate using only a very small number of menu levels.

Note

Pixel error acc. to DIN EN ISO 13406-2 Class II.

Keyboard

Several keys and key pads are installed on the operator panel front:

●The alphabetic key group contains the letters A ... Z and the space character for entering text.

●The numeric key group contains the digits 0 - 9, arithmetic/special characters and the decimal point for entering numeric characters and operators.

●The cursor key group is used to navigate on the screen.

●The control key group includes special functions.

●The area changeover displays the operating areas.

●The menu forward key allows the horizontal softkey bar to be extended in the same menu.

●The softkeys call up functions that are available on screen via a menu bar.

●The machine area key switches directly into the "Machine" operating area.

●The menu back key returns to the superordinate menu, one window is closed.

The keys used on the operator panel front along with the corresponding function keys on the PC keyboard are shown in the following overview:

Key

Function corresponds to PC

Key

Function corresponds to PC

key function

key function

Esc

End

F11

Backspace

F12

Tabulator

Spaces

(only for internal keyboard

changeover)

PPU	21
Manual, 01/2014, 6FC5397-2DP40-3BA3

System description

2.5 Type plate

Key

Function corresponds to PC

Key

Function corresponds to PC

key function

key function

Home

CTRL key

Page up

ALT key

Page down

Delete

Cursor up

Insert

Cursor left

Enter

Cursor right

F9

Cursor down

F10

5 (in numeric key group)

A ... Z

A ... Z

<Shift> F9

<Shift> F10

2.5Type plate

Type plates

The PPU type plate is located on the rear side.

Note

The contents of the individual type plate fields on the current controller may differ from those described in this Manual (e.g. updated product status, approvals and identifications not yet issued, etc.).

The following images display all the information required to uniquely identify a PPU.

22	PPU
	Manual, 01/2014, 6FC5397-2DP40-3BA3

System description

2.5 Type plate

&RPSRQ QW Q P

$UWLFO QXP	U
6 UL O QXP	U
,' QXP	U

+: Y UVLRQ

Figure 2-5 Horizontal PPU type plate

&RPSRQ QW Q P
$UWLFO QXP	U
6 UL O QXP	U
,' QXP	U

+: Y UVLRQ

Figure 2-6 Vertical PPU type plate

Note

MAC addresses

The MAC addresses printed on the type plate of the PPU are required for configuring the PLC I/O Interface communications networks based on PROFINET and Industrial Ethernet.

There is a similar situation for the machine control panels and the I/O modules.

PPU	23
Manual, 01/2014, 6FC5397-2DP40-3BA3

System description

2.6 System overview

2.6System overview

Configuration with four axes (basic configuration)

The following configuration shows a typical example with SINAMICS S120 booksize:

&RPS Q\ QHWZRUN ,QGXVWUL O (W HUQHW

6,180(5,. '

3HHU WR SHHU

1XOO PRGHP

F OH

6,1$87 0'

3* 3&

'5,9( &/L4

3/& , 2 LQWHUI FH VHG

[ QGZ HHO

RQ 352),1(7

6,1$0,&6 6

0&3 31

60&

							6/0	600	600	600	600

33 ' 31

6\QF URQRXV PRWRU

	33 ' $ 31		6\QF URQRXV PRWRU
		$V\QF URQRXV PRWRU

6\QF URQRXV PRWRU

Figure 2-7 Configuration example 1: Basic configuration with four axes

24	PPU
	Manual, 01/2014, 6FC5397-2DP40-3BA3

System description

2.6 System overview

Configuration with S120 Combi and six axes

The following configuration shows the maximum expansion stage with SINAMICS S120 Combi:

&RPS Q\ QHWZRUN ,QGXVWUL O (WKHUQHW

6,180(5,. '

1XOO PRGHP F OH

3HHU WR SHHU

3* 3&

33 ' 31

[ K QGZKHHO

3/& , 2 LQWHUI FH VHG

RQ 352),1(7

33 ' $ 31

70 )

'0& '0(

8S WR ILYH

0&3 31

'5,9( &/L4

/LQH U VF OHV

		6,1$0,&6
77/ VSLQGOH HQFRGHU		6 &RP L	♣ 'RX OH 0RWRU 0RGXOH %RRNVL]H &RPS FW
		3RZHU 0RGXOH	♣ &RQWURO 6XSSO\ 0RGXOH
			♣ %U NLQJ 0 RGXOH %U NLQJ UHVLVWRU
2SWLRQ	O
/LQH ILOWHU		/LQH UH FWRU

$& 9

0RWRU F OH

'5,9( &/L4

6SLQGOH PRWRU

6HUYR PRWRU

6HUYR PRWRU

6HUYR PRWRU

6HUYR PRWRU

6HUYR PRWRU

6XSSOHPHQW

U\

VSLQGOH

Figure 2-8 Configuration example 2: Maximum expansion stage with six axes and with Safety Integrated

PPU	25
Manual, 01/2014, 6FC5397-2DP40-3BA3

System description

2.7 Connectable components

2.7Connectable components

Component overview

The following components can be connected to the PPU:

●Machine Control Panel MCP 310C PN, MCP 483C PN

Contains the keys and switches required for the operation of a machine (turning or milling machine).

●Interface module MCP Interface PN

The MCP Interface PN module enables customer-specific machine control panels to be connected. Further, a 3rd handwheel can be connected via the module.

●Handwheels

A maximum of three handwheels can be connected.

●Mini handheld unit

A mini HHU can be integrated into the SINUMERIK 828D system using a connection kit.

●I/O modules PP 72/48D PN / PP 72/48D 2/2A PN

The modules are used to connect digital as well as analog inputs and outputs. To supply the module and the outputs, an external power supply unit (24 VDC) is required, which provides safety isolation from dangerous voltages.

●GSM modem

ConnectionofaSINAUTMD720-3GSMmodemforsendingandreceivingSMSmessages (Easy Message) via the serial RS232 interface.

●PN/PN coupler

A PN/PN coupler can be connected in order to link a SINUMERIK 828D to PROFINET networks.

●SENTRON PAC 3200/PAC 4200

The connection of a SENTRON PAC 3200 / PAC 4200 makes available functions for increasing the energy efficiency of machine tools.

SINAMICS S120 drive system

Only the SINAMICS S120 Line Modules and Motor Modules are used for drive control. Motor Modules can be used to connect servo motors as type 1FK7, 1FT7, and 1PH8 feed and main spindle motors. Type 1FW6 torque motors can also be connected.

See also

Connectable components (Page 93)

SINAMICS components (Page 86)

●Rules for permitted topologies (Page 53)

●Interface description (Page 67)

26	PPU
	Manual, 01/2014, 6FC5397-2DP40-3BA3

System description

2.8 Ordering data

2.8Ordering data

Ordering data of the components

SINUMERIK 828D is generally marketed in sales packages with drives, motors and accessories. For orders, please contact your local Siemens sales representative.

Table 2-1		Components
Designation			Article number
Panel Processing Unit without system software
● PPU 241.3 BASIC horizontal			6FC5370-3AA30-0AA0
● PPU 240.3 BASIC vertical			6FC5370-4AA30-0AA0
●	PPU 261.3 horizontal		6FC5370-5AA30-0AA0
●	PPU 260.3 vertical		6FC5370-6AA30-0AA0
●	PPU 281.3 horizontal		6FC5370-7AA30-0AA0
●	PPU 280.3 vertical		6FC5370-8AA30-0AA0
CompactFlash card with system software and license
● For PPU 241.3 / PPU 240.3: Turning			6FC5835-1GY40- YA0
● For PPU 241.3 / PPU 240.3: Milling			6FC5835-2GY40- YA0
● For PPU 261.3 / PPU 260.3: Turning			6FC5834-1GY40- YA0
● For PPU 261.3 / PPU 260.3: Milling			6FC5834-2GY40- YA0
● For PPU 281.3 / PPU 280.3: Turning			6FC5833-1GY40- YA0
● For PPU 281.3 / PPU 280.3: Milling			6FC5833-2GY40- YA0
Axis extension:
● Numeric Control Extension NX10.3			6SL3040-1NC00-0AA0
Machine control panels:
●	MCP 483C PN		6FC5303-0AF22-0AA1
●	MCP 310C PN		6FC5303-0AF23-0AA1
Interface module
●	MCP Interface PN		6FC5303-0AF03-0AA0
Mini handheld unit:
● With spiral connection cable			6FX2007-1AD03
●	With straight cable		6FX2007-1AD13
I/O modules:
● PP 72/48D PN (digital)			6FC5311-0AA00-0AA0
● PP 72/48D 2/2A PN (analog)			6FC5311-0AA00-1AA0

PPU	27
Manual, 01/2014, 6FC5397-2DP40-3BA3

System description

2.8 Ordering data

Spare parts

Table 2-2	Spare parts
Designation		Article number
Set of tensioners (9 units)		6FC5248-0AF14-0AA0
CompactFlash card (empty), 2 GB		6FC5313-5AG00-0AA2
Front flap with fastening		6FC5348-2AA00-0AA0

Accessories

Table 2-3	Accessories
Designation		Article number
SENTRON PAC3200 Power Monitoring Device		7KM2112-0BA00-3AA0
SENTRON PAC4200 Power Monitoring Device		7KM4212-0BA00-3AA0
PROFINET Switched Ethernet expansion module		7KM9300-0AE00-0AA0
SINAUT MD720-3 GSM/GPRS MODEM		6NH9720-3AA00
SINAUT ANT 794-4MR ANTENNA		6NH9860-1AA00
RS232 modem cable		6NH7701-5AN
SIMATIC DP PN/PN coupler		6ES7158-3AD00-0XA0
Terminal strip converter, 50-pin		6EP5406-5AA00
Cable set comprising:		6EP5306-5BG00
● 6 m ribbon cable, 50-pin
● 8 insulation displacement connectors, 50-pin
IP20 PLC I/O interface connecting cable (corresponds to		6FX2002-1DC00-...
DRIVE-CLiQ signal cable)
Blanking plates for the DRIVE-CLiQ interface		6SL3066-4CA00-0AA0
USB flash drive, 8 GB		6ES7648-0DC50-0AA0
CompactFlash card (empty as user memory), 8 GB		6FC5313-6AG00-0AA0
Stabilized power supply SITOP lite 10 A		6EP1334-1LB00
24 VDC, 1-phase
Stabilized power supply SITOP smart 10 A		6EP1334-2BA01
24 VDC, 1-phase
Stabilized power supply PSU100S 20 A		6EP1336-2BA10
24 VDC, 1-phase
Stabilized power supply PSU300S 10 A		6EP1434-2BA10
24 VDC, 3-phase
Stabilized power supply PSU300S 20 A		6EP1436-2BA10
24 VDC, 3-phase

28	PPU
	Manual, 01/2014, 6FC5397-2DP40-3BA3

System description

2.9 CompactFlash Cards

2.9CompactFlash Cards

2.9.1CompactFlash card system

Overview

The PPU has two slots for CompactFlash cards:

●The slot for the user CompactFlash card is located at the front behind the front flap.

●The slot for the system CompactFlash card with the system software is at the rear.

CompactFlash card with system software

The system CompactFlash card is shipped in a bootable condition. It is not supplied with the PPU and must be ordered as a separate component.

The system CompactFlash card is essential for the operation of the PPU.

In addition to the technology-specific system software for SINUMERIK 828D and the firmware for SINAMICS, the system CompactFlash card also contains:

●Version information (serial number, version, type designation)

●Licensekey:AllowstheCompactFlashcardtobeinsertedintoanotherPPUwithouthaving to change the licenses.

Note the following when using a system CompactFlash card:

●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.

●Insertthememorycardcarefullyandtherightwayroundintothememorycardslot(observe indicatorssuchasarroworsimilar).Thiswayyouavoidmechanicaldamagetothememory card or the device.

PPU	29
Manual, 01/2014, 6FC5397-2DP40-3BA3

System description

2.9CompactFlash Cards

●Only use memory cards that have been approved by Siemens for use with SINUMERIK. Even though SINUMERIK follows general industry standards for memory cards, it is possible that memory cards from some manufacturers will not function perfectly in this device or are not completely compatible with it (you can obtain information on compatibility from the memory card manufacturer or supplier).

●For SINUMERIK 828D, only the memory card (2 GB) with order number 6FC5313-5AG00-0AA2 is permitted.

NOTICE

CompactFlash card system

●The CompactFlash card always comes formatted! You must not reformat it under any circumstances!

●To ensure that the system CompactFlash card functions properly, the card must not be repartitioned.

●In the event of a defect, the system software card must be replaced.

For information about restoring your system using an empty CompactFlash card, refer to the Service Manual.

2.9.2Inserting the system CompactFlash Card

Slot and mounting position

M3 screw Metal cover Slot

The CompactFlash card has an edge on the opposite side to the pins. This edge must always be on the right when inserting the card.

30	PPU
	Manual, 01/2014, 6FC5397-2DP40-3BA3