Hardware and Software ___________________

Preface

___________________
Safety notes 1

___________________
System description 2
SINUMERIK
___________________
Service cases - software 3
SINUMERIK 828D
Hardware and Software ___________________
Service cases - hardware 4

___________________
Spare parts and accessories 5
Service Manual
A
___________________
ESD guidelines

B
___________________
Appendix

Valid for:

SINUMERIK 828D:
PPU 24x.2 BASIC T
PPU 24x.2 BASIC M
PPU 26x.2
PPU 28x.2

Software:
CNC software V4.3

03/2011
6FC5397-5DP40-0BA0
Legal information
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.

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

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

CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.

CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.

NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation for the specific task, in particular its warning notices and
safety instructions. Qualified personnel are those who, based on their training and experience, are capable of
identifying risks and avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:

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

Trademarks
All names identified by are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

Siemens AG Order number: 6FC5397-5DP40-0BA0 Copyright Siemens AG 2011.

Industry Sector 03/2011 Technical data subject to change
Postfach 48 48
90026 NRNBERG
GERMANY
Preface

SINUMERIK documentation
The SINUMERIK documentation is organized in the following categories:
General documentation
User documentation
Manufacturer/service documentation

Additional information
You can find information on the following topics under the link
(http://www.siemens.com/motioncontrol/docu):
Ordering documentation/overview of documentation
Additional links to download documents
Using documentation online (finding and searching in manuals/information)
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following address:
(mailto:[email protected])

My Documentation Manager (MDM)

Under the following link you will find information to individually compile OEM-specific
machine documentation based on the Siemens content: MDM
(http://www.siemens.com/mdm)

Training
For information about the range of training courses, refer to:
SITRAIN (www.siemens.com/sitrain) - training courses from Siemens for automation
products, systems and solutions
SinuTrain (www.siemens.com/sinutrain) - training software for SINUMERIK

FAQs
You can find Frequently Asked Questions in the Service&Support pages under Product
Support (www.siemens.com/automation/service&support).

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

Hardware and Software

Service Manual, 03/2011, 6FC5397-5DP40-0BA0 3
Preface

Target group
This document addresses maintenance and service personnel.

Benefits
Based on the Service Manual, the target group can correctly and safely perform service and
maintenance work.
Utilization phase: Maintenance and service phase

Standard version
This documentation only describes the functionality of the standard version. Extensions or
changes made by the machine manufacturer are documented by the machine manufacturer.
Other functions not described in this documentation might be executable in the control. This
does not, however, represent an obligation to supply such functions with a new control or
when servicing.
Further, for the sake of simplicity, this documentation does not contain all detailed
information about all types of the product and cannot cover every conceivable case of
installation, operation or maintenance.

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

EC Declaration of Conformity
The EC declaration of conformity for the EMC directive can be found in the Internet
(www.siemens.com/automation/service&support).
Here, enter the number 15257461 as the search term or contact your local Siemens office.

CompactFlash Cards
The SINUMERIK CNC supports the file systems FAT16 and FAT32 for
CompactFlash cards. You may need to format the memory card if you want to use a
memory card from another device or if you want to ensure the compatibility of the
memory card with the SINUMERIK. However, formatting the memory card will
permanently delete all data on it.
Do not remove the memory card while it is being accessed. This can lead to damage of
the memory card and the SINUMERIK as well as the data on the memory card.

Hardware and Software

4 Service Manual, 03/2011, 6FC5397-5DP40-0BA0
 Preface

If you cannot use a memory card with the SINUMERIK, it is probably because the
memory card is not formatted for the control system (e.g. Ext3 Linux file system), the
memory card file system is faulty or it is the wrong type of memory card.
Insert the memory card carefully with the correct orientation into the memory card slot
(take note of arrows, etc.). This way you avoid mechanical damage to the memory card or
the device.
Only use memory cards that have been approved by Siemens for use with SINUMERIK.
Even though the SINUMERIK keeps to the general industry standards for memory cards,
it is possible that memory cards from some manufacturers will not function perfectly in
this device or are not completely compatible with it (you can obtain information on
compatibility from the memory card manufacturer or supplier).
For SINUMERIK 828D, only the memory card (1 GB) with order number 6FC5313-
5AG00-0AA1 is permitted.

Hardware and Software

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

Hardware and Software

6 Service Manual, 03/2011, 6FC5397-5DP40-0BA0
Table of contents

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

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Service Manual, 03/2011, 6FC5397-5DP40-0BA0 7
Table of contents

4.1.2 This is how you remove the PPU................................................................................................ 77

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

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8 Service Manual, 03/2011, 6FC5397-5DP40-0BA0
 Table of contents

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

Hardware and Software

Service Manual, 03/2011, 6FC5397-5DP40-0BA0 9
Table of contents

4.17.2 DMC20 connections.................................................................................................................. 202

4.17.3 This is how you remove a DMC20 ............................................................................................ 202
4.17.4 This is how you install a DMC20............................................................................................... 204
4.17.5 DME20 connections .................................................................................................................. 205
4.17.6 This is how you mount a DME20 .............................................................................................. 206
4.17.7 Connection to X524 electronics power supply .......................................................................... 207
5 Spare parts and accessories ................................................................................................................. 209
5.1 Spare parts for the S120 Combi ............................................................................................... 210
A ESD guidelines ...................................................................................................................................... 211
A.1 RI suppression measures ......................................................................................................... 211
A.2 ESD measures .......................................................................................................................... 212
B Appendix................................................................................................................................................ 213
B.1 List of abbreviations .................................................................................................................. 213
B.2 Documentation overview........................................................................................................... 216
Index...................................................................................................................................................... 217

Hardware and Software

10 Service Manual, 03/2011, 6FC5397-5DP40-0BA0
Safety notes 1
The following notices are intended firstly for your personal safety and secondly to prevent
damage occurring to the product described or any connected devices and machines. Non-
observance of the warnings can result in severe personal injury or property damage.

DANGER

Only appropriately qualified personnel may commission/start-up SINUMERIK equipment.

The personnel must take into account the information provided in the technical customer
documentation for the product, and be familiar with and observe the specified danger and
warning notices.
When electrical equipment and motors are operated, the electrical circuits automatically
conduct a dangerous voltage.
When the system is operating, dangerous axis movements may occur throughout the entire
work area.
A potential fire hazard exists due to the energy being transferred in the equipment and the
work materials used.
All work on the electrical system must be performed after the system has been switched off
and disconnected from the power supply.

DANGER

Proper transportation, expert storage, installation and mounting, as well as careful

operation and maintenance are essential for this SINUMERIK device to operate correctly
and reliably.
The details in the catalogs and proposals also apply to the design of special equipment
versions.
In addition to the danger and warning information provided in the technical customer
documentation, the applicable national, local, and system-specific regulations and
requirements must be taken into account.
Only class DVC A protective extra-low voltages (PELVs) may be connected to connections
and terminals up to 60 V DC in accordance with EN 61800-5-1.
Should it be necessary to test or take measurements on live equipment, then the
specifications and procedural instructions defined in Accident Prevention Regulation BGV
A2 must be adhered to, in particular 8 "Permissible deviations when working on live
components". Suitable electric tools should be used.

Hardware and Software

Service Manual, 03/2011, 6FC5397-5DP40-0BA0 11
Safety notes

DANGER

Repairs to devices that have been supplied by our company may only be carried out by
SIEMENS customer service or by repair centers authorized by SIEMENS.
When replacing parts or components, only use those parts that are included in the spare
parts list.
EMERGENCY STOP/EMERGENCY OFF devices according to EN 60204-1 (VDE 0113
Part 1) must remain active in all modes of the automation equipment. Resetting the
EMERGENCY STOP/EMERGENCY OFF device must not cause an uncontrolled or
undefined restart.
Anywhere in the automation equipment where faults might cause physical injury or major
material damage, in other words, where faults could be dangerous, additional external
precautions must be taken, or facilities must be provided, that guarantee or enforce a safe
operational state, even when there is a fault (e.g. using an independent limit value switch,
mechanical locking mechanisms, EMERGENCY STOP/EMERGENCY OFF devices).

DANGER

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

Hardware and Software

12 Service Manual, 03/2011, 6FC5397-5DP40-0BA0
System description 2
2.1 System overview

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

&RPSDQ\QHWZRUN,QGXVWULDO(WKHUQHW

6,180(5,.'

3HHUWRSHHU

QRQFURVVHG
PRGHPFDEOH
6,1$870'
3*3&

'5,9(&/L4

3/&,2LQWHUIDFHEDVHG
[KDQGZKHHO RQ352),1(7
6,1$0,&66

0&331
60&
600

600
600
600
6/0

33'31

6\QFKURQRXV
PRWRU

33'$31 6\QFKURQRXV
PRWRU
,QGXFWLRQPRWRU

6\QFKURQRXV
PRWRU

Figure 2-1 Configuration example 1: Basic configuration with 4 axes

Hardware and Software

Service Manual, 03/2011, 6FC5397-5DP40-0BA0 13
System description
2.1 System overview

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

&RPSDQ\QHWZRUN,QGXVWULDO(WKHUQHW

6,180(5,.'
QRQFURVVHG
PRGHPFDEOH
3HHUWRSHHU

3*3&

33'31
[KDQGZKHHO

3/&,2LQWHUIDFHEDVHG
RQ352),1(7
33'$31
70)

'0&'0( 8SWR
0&331
/LQHDUVFDOHV

'5,9(&/L4

6,1$0,&6
6&RPEL  'RXEOH0RWRU0RGXOH%RRNVL]H&RPSDFW
77/VSLQGOHHQFRGHU 3RZHU0RGXOH
 &RQWURO6XSSO\0RGXOH
 %UDNLQJ0 RGXOH %UDNLQJUHVLVWRU

2SWLRQDO
/LQHILOWHU /LQHUHDFWRU

$&
9
0RWRUFDEOH

'5,9(&/L4

6SLQGOHPRWRU 6HUYRPRWRU 6HUYRPRWRU 6HUYRPRWRU 6HUYRPRWRU 6HUYRPRWRU

6XSSOHPHQWDU\
VSLQGOH

Figure 2-2 Configuration example 2: Maximum expansion stage with 6 axes and with Safety Integrated

Hardware and Software

14 Service Manual, 03/2011, 6FC5397-5DP40-0BA0
 System description
2.2 System versions horizontal and vertical

2.2 System versions horizontal and vertical

Front of the PPU versions 26x.2 and 28x.2

 

   

 










 




  

Protective cover for user interfaces

Menu back key
Alphabetic key group
Control key group
Hotkey group
Cursor key group

Hardware and Software

Service Manual, 03/2011, 6FC5397-5DP40-0BA0 15
System description
2.2 System versions horizontal and vertical

Numerical block
Menu forward key
3/8" threads for additional components
Protective cover for user interfaces
X127 Ethernet (service socket)
Status LED: RDY, NC, CF
X125 USB interface
Slot for CompactFlash Card with user data

Figure 2-3 System versions

Rear of the PPU 26x.2 and 28x.2

  





  

X122, X132 Digital inputs/outputs, drive

X242, X252 Digital inputs/outputs, NC
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 on the rear side of the PPU

Hardware and Software

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

2.3 System versions, BASIC T and BASIC M

Front panel of the SINUMERIK 828D BASIC T with interfaces

 

   

 










 

 

  

Protective cover for user interfaces

Menu back key
Alphabetic key group
Control key group

Hardware and Software

Service Manual, 03/2011, 6FC5397-5DP40-0BA0 17
System description
2.3 System versions, BASIC T and BASIC M

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 2-5 System versions

Hardware and Software

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

Rear of the PPU 24x.2

  





  

X122, X132 Digital inputs/outputs, drive

X242, X252 Digital inputs/outputs, NC
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 2-6 Interfaces at the rear

Hardware and Software

Service Manual, 03/2011, 6FC5397-5DP40-0BA0 19
System description
2.3 System versions, BASIC T and BASIC M

Hardware and Software

20 Service Manual, 03/2011, 6FC5397-5DP40-0BA0
Service cases - software 3
Overview
The following software tools should be used for the subsequently described service activities
and to backup system and user data:
Toolbox CD V2.6 SINUMERIK 828D with the following contents:
PLC Programming Tool for Integrated PLC
Commissioning software for SINAMICS S120
Recovery system
RCS Commander V2.6 SP1

Backing up log files

If system problems occur, then it is necessary to backup all of the existing log files in order to
provide these to the hotline for diagnostics. There is a special shortcut key for this function:
CTRL + ALT + D

This function generates a directory on the User CF card or on the front USB. If both are
available, then the directory is created in both storage media.

Example
The directory name has the following structure: LOG_Date_Time
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 the logbook and debug information available in
the system.

Hardware and Software

Service Manual, 03/2011, 6FC5397-5DP40-0BA0 21
Service cases - software
3.1 Backing up user data

3.1 Backing up user data

3.1.1 This is how you backup user data

Application
A backup of the data in the complete memory is generated with the "Save data" function.
This data backup must be performed for every control that has been commissioned in order
to be able to quickly restore the control system in the case of data loss. If the "Create
software backup" function is used, then it is essential to backup the memory data.
With the data backup, a copy of the limited buffered memory is stored in the permanent
memory. Backup of selected data (e.g. only machine data and no workpiece programs) is
not possible.
Data can be backed up without a password: i.e. always!

Note
Data backup
After making important changes to the data, immediately backup data, e.g. after the
1st commissioning and the 2nd commissioning.

Backing up data
Preconditions:
The control system has powered up.
The power supply voltage is guaranteed during the data backup.
Proceed as follows to generate the internal data backup:
1. Press the <MENU SELECT> key.

2. Select the "Start-up" operating area.

3. Press the "Save data" softkey.

Hardware and Software

22 Service Manual, 03/2011, 6FC5397-5DP40-0BA0
 Service cases - software
3.1 Backing up user data

4. This is followed by the "Query" to backup data:

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5. Press the "OK" softkey to backup the data.

A progress indicator indicates the status of the data backup.

After the data backup has been successfully completed, the following message is
output:

6. Confirm this message with "OK".

NOTICE

While the data is being backed up, the control system must neither be operated, nor turned
off.

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3.1.2 This is how you load the user data backup

NOTICE

If this function is activated, the actual system data is replaced by the data backup.

Procedure
Proceed as follows to load the internal data backup:
1. The following display is shown when booting after power-on:

2. To start the Setup menu, press the <SELECT> key.

You now go to the Setup menu:

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3. Using the arrow key, select the menu item "Reload saved user data".

4. Confirm that the backup is loaded by pressing the key <INPUT>.

5. Confirm the confirmation prompt by pressing the <INPUT> key.

Are you sure you want to reload saved user data?"

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".

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3.2 Generating a commissioning archive

3.2 Generating a commissioning archive

Overview
A commissioning archive is used to completely backup all of the data required for the
machine function.
A commissioning archive can be generated on an external data carrier, e.g. USB-FlashDrive
or CompactFlash card at the front panel of the control as well as on the system
CompactFlash Card.

Note
Data must always be backed up before a machine is delivered. Only then can it be ensured
that in the case of service, the delivery condition of the machine can be restored.
In addition, it may be necessary to generate a commissioning archive before service
activities are started. This means that it can be guaranteed that the actual state of the
machine can be restored after the activities have been completed.

3.2.1 This is how you generate a series commissioning archive on an external data
carrier

Generating an archive on an external data carrier

Procedure:
1. Select the "Start-up" operating area.

2. Press the menu forward key.

3. Press the "Series startup" softkey.

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4. Activate "Series startup".

The "Create Series Startup" window opens.

5. Select the desired control components.

Note
Easy Archive
Select all of the components, unless it is known that individual components do not
deviate from the Siemens standard.
Select all data classes, unless only certain data (e.g. INDIVIDUAL) are to be backed
up.

6. Press the "Generate archive" softkey.

The "Generate 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
8. Select a directory.
Example: User CF
- OR -

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9. Press the "New directory" softkey to generate a new directory.

The "New Directory" window opens.

10.Enter the required name and confirm with "OK."

The directory is created subordinate to the selected folder.

11.Press the "OK" softkey.

The "Generate 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:

Figure 3-1 Generating an archive

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3.2.2 This is how you import a series commissioning archive from an external data
carrier

Reading in an archive from an external data carrier

Procedure:
1. Select the "Start-up" operating area.

2. Press the menu forward key.

3. Press the "Series startup" softkey.

4. Press "OK".

The "Series Start-up" window opens.

5. Activate "Read in series startup".
6. Press "OK".

The "Select Startup Archive" window opens and the data tree is displayed.

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7. Select the required commissioning archive (ARD).

Example: User CF

8. Press "OK".

A query is displayed, here you can see the most important data of the selected archive to
be certain that it is OK.
9. Data is read in when pressing "OK".

10.In the case of errors or problems, import can be terminated by pressing the "Cancel"
softkey.

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3.2.3 This is how you generate a series commissioning archive on the system
CompactFlash Card

Generating an archive on the system CompactFlash Card

Procedure:
1. Select the "Start-up" operating area.

2. Press the menu forward key.

3. Press the "Series startup" softkey.

4. Activate "Series startup".

The "Create Series Startup" window opens.

5. Select the desired control components.

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Note
Easy Archive
Select all of the components, unless it is known that individual components do not
deviate from the Siemens standard.
Select all data classes, unless only certain data (e.g. INDIVIDUAL) are to be backed
up.

6. Press the "Generate archive" softkey.

The "Generate Archive: Select Archive" window opens.

7. Select the storage location of the archive:
"Archives": Internal memory on the CompactFlash Card system
8. Select a directory.
Example: "Archives" "Manufacturer"
- OR -
9. Press the "New directory" softkey to generate a new directory.

The "New Directory" window opens.

10.Enter the required name and confirm with "OK."

The directory is created subordinate to the selected folder.

11.Press the "OK" softkey.

The "Generate 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.

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3.2.4 This is how you import a series commissioning archive from the system
CompactFlash Card

Reading in an archive from the system CompactFlash Card

A description is provided here how you read in a series commissioning archive in order to be
able to restore the previous state of the machine.
Procedure:
1. Select the "Start-up" operating area.

2. Press the menu forward key.

3. Press the "Series startup" softkey.

4. Press "OK".

The "Series Start-up" window opens.

5. Activate "Read in series startup".
6. Press "OK".

The "Select Startup Archive" window opens and the data tree is displayed.

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7. Select the required commissioning archive (ARD).

Example: "Archives" "Manufacturer"

8. Press "OK".

A window with the data of the selected archive is displayed.

9. Data is read in when pressing "OK".

10.In the case of errors or problems, import can be terminated by pressing the "Cancel"
softkey.

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3.3 Software backup

3.3 Software backup

3.3.1 This is how you generate a software backup

Overview
With "Create software backup", a function is provided to generate a backup of the system
software including all of the user data saved on the system card. This backup represents the
"Backup" of the machine.

Note
Memory size: At least 1 GB
The backup does not contain a license key, in order to guarantee use for series production.
To generate the backup of the system software ("clone"), a storage medium
(CompactFlash Card or USB-FlashDrive) with a minimum memory size of 1 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 22)).
A correct, complete backup is only generated using the internal data backup.
3. Switch the control off.
4. Switch-on the control again, as the backup can only be generated when the control boots.
After the control has been switched-on, the following display appears:

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5. Press the <SELECT> key, "Normal startup" is the default setting.

6. Now press the following keys in succession:
Menu reset key, HSK2 (horizontal SK2), VSK2 (vertical SK2)

7. The Startup menu is displayed:

8. Using the cursor keys, select the menu item "Create software backup".
9. Press the <INPUT> key to confirm your selection:

10.Insert a storage medium into the slot on the front panel.

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11.Press the <INPUT> key to start the backup.

The software first checks whether a backup was already generated on the card and
outputs a message. The backup can now be overwritten or the process interrupted by
making the appropriate operator action.
12.When starting to generate a backup, the following message is output:

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13.Wait until the following message is displayed:

14.Withdraw the storage medium from the slot at the front panel of the control.
15.Switch the control off.
16.Switch the control on.
17.The control boots normally.

Note
Note that when the system software is transferred, no license key for the software of the
CNC options is transferred.

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3.3 Software backup

3.3.2 This is how you install a software backup

Overview
A backup previously generated is loaded into the control using the function "Install software
update/backup". All system and user data are overwritten with the software backup image.

Note
Licenses
The backup does not contain a license key; a valid license key must be available on the
control.
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 61)
When replacing a defective system CompactFlash Card, the license key must be requested
again: See also Licensing after replacing the system CompactFlash Card (Page 55)

Installing the software backup

Procedure:
1. Switch-on the control again, as the backup can only be generated when the control boots.
After the control has been switched-on, the following is displayed:

2. Press the <SELECT> key, "Normal startup" is the default setting.

3. Now press the following keys in succession:
Menu reset key, HSK2 (horizontal SK2), VSK2 (vertical SK2)

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4. The Startup menu is displayed:

5. Using the cursor keys, select the menu item "Install software update/backup".

6. Press the <INPUT> key to confirm your selection:

7. Insert the storage medium with the backup in the slot and confirm with "Yes" by using the
cursor keys to make the selection:

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8. Select the valid backup using the cursor keys.

9. Press the <Input> key to confirm your selection.

10.The following message briefly appears: "Starting software update"

Then the screen goes dark for several seconds.

11.If a valid backup has been found, the following message is output:

If no valid backup was selected, the upgrade is interrupted 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.
12.Wait until the following message appears:

13.Switch the control off.

14.Withdraw the storage medium from the slot at the front panel of the control.

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15.Switch the control on.

16.The control boots normally.

Note
If the procedure is interrupted, then it must be restarted.
If the system CompactFlash Card is no longer identified as a bootable CompactFlash
Card, then a mini boot system must be generated on this card. (See also: This is how you
generate a mini boot system (Page 48) )
In this case, the license key of the system CompactFlash Card should be transferred to
the control.

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3.4 Software update

3.4 Software update

3.4.1 This is how you update the software

Data backup
If a system update is necessary, then the system data must be backed up so that no data is
lost in the case of a problem.
In this case, we recommend to perform two types of data backup.
1. Generate an image of the system CompactFlash Card ("clone", see also: This is how you
generate a software backup (Page 36)).
A backup is generated just in case an error occurs during the update. This means that it
is then possible to restore the "old system".
2. Generate an archive for series commissioning (see This is how you generate a series
commissioning archive on an external data carrier (Page 27)), in order to 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.
The image for the update is saved on the CompactFlash card.
The CompactFlash card is inserted in the slot on the front panel of the control.
Procedure:
1. Switch-on the control again, as the image can only be generated when booting. After the
control has been switched-on, the following display appears:

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2. Press the <SELECT> key, "Normal startup" is the default setting.

3. Now press the following keys in succession:
Menu reset key, HSK2 (horizontal SK2), VSK2 (vertical SK2)

4. The setup menu is displayed:

5. Use the cursor keys to select the menu item "Install software update/backup".
6. Press the <INPUT> key to confirm your selection.

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7. Use the cursor keys to select "Yes".

8. Select the update image (*.tgz) on the storage medium and confirm with <INPUT>.

9. The software update is started: The following message appears while the update is
running:

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10.Wait until the following message is output:

11.Withdraw the storage medium from the slot.

12.Switch the control off.
13.Switch the control on.
14.The control boots normally.

NOTICE

If the update is interrupted, then it must be restarted.

If the system CompactFlash Card is no longer identified as bootable system, then a mini
boot system must be generated on this card (see also: This is how you generate a mini
boot system (Page 48)).
In this case, the license key of the system CompactFlash Card should be transferred to
the control.

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3.5 Mini boot system on the CompactFlash Card

3.5 Mini boot system on the CompactFlash Card

Application
If the system CompactFlash Card hardware is defective, then it must be replaced. The
replacement card is an empty CompactFlash Card without any system software and without
any user software and cannot be used as system CompactFlash Card as it is without any
additional preparation.

Mini boot system image

"Configuration data" are supplied on the toolbox CD of the SINUMERIK 828D, which include
in the scope of delivery of mini boot system image:

Figure 3-2 Toolbox selection

This program must be installed in order that the image of the mini boot system is installed on
the PC/PG.

3.5.1 This is how you generate a mini boot system

Precondition
The default path to install the mini-boot system is:
C:\Program Files\Siemens\Toolbox 828D\V02060xx00\RecoverySys

The file name of the boot system is: minsys.img

The minsys.img file is copied to an empty replacement card using the RCS commander.

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3.5 Mini boot system on the CompactFlash Card

Precondition to write:
RCS Commander has been installed.
SW package: Configuration data from the Toolbox has been installed.
CompactFlash card is a replacement card.

Installing the boot system on an empty card

Procedure:
1. Insert the CompactFlash Card into the card reader.
2. Start the RCS Commander via "Start" "Programs" "RCS Commander".

Note
An online connection to the control is not required to generate the boot system.

3. If you are prompted to establish the connection, press "Cancel".

4. In the "View" menu, select the menu item "Expert view".

The following, additional "NC commissioning" menu is displayed:

5. Select menu item "Generate 828D boot system".

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3.5 Mini boot system on the CompactFlash Card

6. If several versions of the toolbox are installed on the PC, you obtain the following
selection:

7. All of the identified interchangeable drives are displayed, here in the example, the
CompactFlash Card is identified as drive F:\.

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8. Confirm the selection of the target drive with "OK". By pressing the "Write" button, the
image is transferred to the target drive.

NOTICE

While the data is being transferred, do not switch-off the PC and do not remove the
CompactFlash Card.

Data transfer is displayed using a progress bar:

9. The following message is output if data transfer was successfully completed:

10.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".

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3.5 Mini boot system on the CompactFlash Card

3.5.2 This is how you install a software backup using the mini boot system

Overview
If a CompactFlash Card with a mini boot system is used as system CompactFlash Card, the
system software or a previously generated software backup must still be transferred.

Note
Licenses
The mini boot system does not contain a license key, a valid license key must be transferred
to the control. When replacing a system CompactFlash Card, this must be requested again
(see also: This is how you license a CNC option (Page 55)).
All system data and user data are overwritten with the system image.

Updating the software

After you have inserted the CompactFlash Card with the mini boot system as new system
CompactFlash Card (see Replacing the system CompactFlash Card (Page 79)) proceed as
follows:
1. Switch the control on. When booting, the following display appears:

2. Press the <INPUT> key to confirm your selection.

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3. Confirm the question with "Yes".

4. Insert the CompactFlash Card or a USB-FlashDrive with the image into the slot on the
front panel of the control.

5. Confirm the selection with the <INPUT> key.

6. The following message briefly appears: "Starting software update"

Then the screen goes dark for several seconds.

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7. If a valid image has been found, the following message is output:

8. Wait until the following message is displayed:

9. Switch the control off.

10.Switch the control system back on again: The control boots normally.

Note
If the system was booted using a mini boot system, there is no valid license key on the
system CompactFlash Card. This must be transferred again.

Result
The 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 series 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 selecting a valid file.

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3.6 Licensing

3.6.1 Licensing after replacing the system CompactFlash Card

Application
The license key of the SINUMERIK 828D is linked with the system CompactFlash Card. If
the system CompactFlash Card is replaced for a SINUMERIK 828D, the license key loses its
validity and the system is only ready with some significant restrictions.
This situation can occur for a defective hardware of the system CompactFlash Card.

Validity of the license key

The following data are required in order to obtain a valid license key after replacing the
system CompactFlash Card: The serial number of the defective and the new
CompactFlash Card.

Note
Only CompactFlash Cards can be used that were released as spare part as only these are
known to the license database.

In order to obtain a valid license key for the new 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 you license a CNC option

Precondition
You require at least one authorization to set or reset a CNC option:
Access level 1 (password: Manufacturer).

Licensing CNC options

If an additional CNC option is to be activated at a SINUMERIK 828D, then this CNC option
must be licensed at the machine and is only valid for this CompactFlash Card.

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3.6 Licensing

Proceed as follows to access the "licenses" dialog box:

1. Select the "Start-up" operating area.

2. Press the menu forward key.

3. Press the "Licenses" softkey.

The "Licensing" window opens. Using the vertical softkeys, you can execute the following
actions:
Display a serial number: "Overview"
"Display all options":
Display "Missing licenses"
"Exp. license requirement"
"Read in the license key"

Figure 3-3 Licensing

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Web License Manager

Licenses that are purchased are assigned via the Internet.
By using the Web License Manager, you can assign licenses to hardware in a standard Web
browser. To conclude the assignment, the license key must be entered at the control via the
user interface.

See also
The license database administered by Siemens can only be accessed using the Web
License Manager (http://www.siemens.com/automation/license).

NOTICE

The NC start function is suppressed if a CNC option, for which no valid license key has
been entered, is additionally activated. 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 can be selected for this control.
2. Activate or deactivate the required options in the "Set" column:
Mark the checkbox
Enter the number of options

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3. Press the "Missing lic./opt." softkey in order to display all options that are licensed. In the
"Set" column, you can deselect the options that you do not require.

Figure 3-4 Licensing (example)

4. Press the softkey "Set option according to license", to activate all of the options contained
in the license key. Confirm the following confirmation prompt with "OK".
5. To activate new selected options, press the "Reset (po)" softkey. A safety prompt
appears.
6. Press the "OK" softkey to trigger a warm restart.
- OR -
7. 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 via the
user interface.
As a consequence, a valid license key can be generated at any time worldwide for options
that have been additionally purchased.

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Preconditions
The following preconditions must be met in order to assign a license to a piece of hardware
via direct access and user interface:
Hardware serial number
A PC/PG with Internet connection and browser is available.
The login data for direct access (e.g. per CoL (Certificate of License)) is available:
License number
Delivery note number

Note
Hardware serial number
Ensure that the serial number of 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 your PG/PC, establish a connection to the Web License Manager

(http://www.siemens.com/automation/license)

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6. Log on via "Direct access".

Follow additional instructions in the Web License Manager:

7. After completing the assignment process, enter the license key displayed in the Web
License Manager into the "Licensing" dialog box in SINUMERIK Operate.

Note
License key via e-mail
If you have an e-mail address, you have the option (checkbox) of receiving the license
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.

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3. Press the "Licenses" softkey.

4. Press the "Overview softkey.

If you receive the license key via the Web License Manager, enter the license key
manually in the field "You can enter a new license key here".
5. Press the <INPUT> key.

If the license key is valid, the message "License key set" is displayed.

3.6.5 This is how you display the actual license key

Overview
The following options are available to display the actual license of the control:
Directly at 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 "Start-up" operating area.

2. Press the menu forward key.

3. Press the "Licenses" softkey to display the control licenses.

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3.6 Licensing

Displaying the actual license key in the Internet

In order to view the actual license key of the control, using the serial number, it is possible
display the license key via the Internet. The serial number is on the system
CompactFlash Card - or can be displayed at the control as described above.
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:

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3.6 Licensing

4. In the menu, select "Hardware serial number" and enter the serial number of the system
CompactFlash Card.

5. Press the "Display license key" softkey.

6. The actual license key is displayed as follows:

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3.7 Enter the final end user data (EUNA)

3.7 Enter the final end user data (EUNA)

Precondition
To change the end user final destination data (EUNA), the following access rights must be
available:
Softkey "Manufacturer" : Access level 1 (password: Manufacturer)
Softkey "Dealer" : Access level 2 (password: Service)
Softkey "End user": Access level 3 (password: User)

Repair and Service Contract (RSC)

SINUMERIK offers an electronic logbook in which all of the activities relating to the Repair
and Service Contract (RSC) are saved.
After the service call has been completed, the control data are checked and are transferred
to the EUNA database for update.

3.7.1 This is how you generate the machine logbook

Machine data
The following data are saved in the control in the "Machine logbook":
Contact data of the manufacturer (OEM)
Contact data of the dealer
Contact data of the end customer
Log of the service and diagnostic procedures that have already been carried out.
During a service call, the data should be checked as to whether it is correct.

Open the "Machine identity" dialog box

Procedure:
1. Select the "Diagnostics" operating area using the following key:

2. Press the "Version" softkey to open the "Version data" dialog box.

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3.7 Enter the final end user data (EUNA)

3. Press the "Details" softkey.

The data associated with the machine are displayed in the "Machine logbook":

4. Press the "Change" softkey to open the "Machine identity" dialog box.
5. Select, for example, the "End user" softkey to check and complete the contact data of the
end user.

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3.7 Enter the final end user data (EUNA)

Note
Contact data
Using the "Import data" softkey, templates with contact data can be imported to simplify
data entry; these templates are available through Siemens sales partners.

3.7.2 This is how you make a new entry in the logbook

Generating a new logbook entry

In order to log service and diagnostic procedures at the machine, make an entry in the
machine logbook. The activities performed are logged here after each service call.
To make a logbook entry, proceed as follows:
1. Select the "Diagnostics" operating area using the following key:

2. Press the "Version" softkey.

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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.

For the following activities, two additional softkeys are available, which generate pre-
configured logbook entries:

1st commissioning completed

2nd commissioning completed

NOTICE

Once saved, data can no longer be changed.

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3.7 Enter the final end user data (EUNA)

3.7.3 This is how you save the machine identity

Saving the machine identity

Note
Ensure that the machine identity that has been entered is correct before saving in order that
no incorrect information is saved.

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 version information: Select Archive" window opens. Select a directory.
4. Press the "OK" softkey.

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3.7 Enter the final end user data (EUNA)

The data are pre-assigned so that a change is not necessary.

The "Name" text field is pre-assigned as follows:

<Machine name/Number>+<Number of the CompactFlash Card>
You now have the opportunity of changing this name.
You can enter a comment in the "Comments" 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.

3.7.4 This is how you send the end user final destination data

Overview
The configuration file (address data, logbook data, version data) of the control can be sent to
the EUNA database (End User Notification Administration) via an Internet connection.

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3.7 Enter the final end user data (EUNA)

This means that the service organization has the possibility of obtaining a profile about the
history of the control without having to go to the machine. Therefore, service can be more
effectively carried-out as all of the relevant information is available.

Sending the end user final destination data

Preconditions:
The commissioning status is saved in the logbook.
The machine identity has been 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. Connection with EUNA (http://www.siemens.com/sinumerik/register).
3. Select a language and enter an e-mail address:

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3.7 Enter the final end user data (EUNA)

4. In the following dialog box, select the configuration files:

5. To open a navigation window, press the "XML Upload" softkey.

6. Select the files of the machine identity that you wish to transfer to EUNA.
7. Now confirm using the softkey "Upload file ...".
8. After the upload, other files can also be uploaded.
During the upload, the files are checked and a log is displayed for each file that has been
transferred.
9. If no other files are to be uploaded, press the softkey "continue >".
10.Complete the upload by pressing the "Save" softkey.

Note
Contact persons worldwide
If it was not possible to transfer the file, then please contact your local Siemens
officeContact (http://www.automation.siemens.com/partner) in sales.

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Overview
The sequence in the chapter of the hardware components corresponds to the following
criteria:
Components at the machine
Components in the control cabinet

Component overview

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Figure 4-1 Components in the control 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" /828D_DA/
SINUMERIK 828D/SINAMICS S120 List Manual "Parameter description" /828D_LH2/

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4.1 PPU 24x.2/26x.2/28x.2

4.1 PPU 24x.2/26x.2/28x.2

4.1.1 PPU status displays

Status displays front side

On the front side of the PPU, the following status displays provide information about the
module state:

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Figure 4-2 Vertical flap (detail)

The three LEDs located behind the protective flap on the front side of the PPU have the
following significance:

Name Color State Meaning

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

CAUTION

If the LED is lit, the CompactFlash Card must not be removed!

Non-compliance can result in damage to the CompactFlash Card.

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4.1 PPU 24x.2/26x.2/28x.2

The RJ45 socket is equipped with one green and one yellow LED. As a consequence, the
following information of the PLC I/O interface is displayed based on PROFINET:

Name Color State Meaning

Link Green ON 100 MBit link available
OFF Missing or faulty link
Activity Yellow ON Sending or receiving
OFF No activity

Status displays, rear

At the rear of the PPU, the following status displays provide information about the module
state:

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31

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;
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*) For a PPU 24x.2, port 1 is not available.

Figure 4-3 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 MBit link available
OFF Missing or faulty link
Activity Yellow ON Sending or receiving
OFF No activity

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4.1 PPU 24x.2/26x.2/28x.2

There are 2 additional LEDs "FAULT" and "SYNC" next to port 1, which apply to both ports:

Name Color State Meaning

FAULT Red OFF For the maximum expansion level of the PLC I/O: The data
exchange to all configured IO devices runs without errors.
Is lit Bus fault:
No physical connection to a subnet/switch
Incorrect transmission rate
Full duplex transmission is not activated.
Flashing If the PN fault LED flashes red, there is no fault. The maximum
(2 Hz) expansion level of the PLC I/O is not being used.
SYNC *) Green OFF Task system of the SINUMERIK 828D is not synchronized to the
send clock of the PLC I/O interface based on PROFINET IO. An
internal substitute clock of the same size as the send clock will
be generated.
Is lit Task system of the SINUMERIK 828D has synchronized to the
clock of the PLC I/O interface based on PROFINET IO, data is
being exchanged.
Flashing Task system of the SINUMERIK 828D has synchronized to the
(0.5 Hz) 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:
System versions horizontal and vertical (Page 15)
System versions, BASIC T and BASIC M (Page 17)

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4.1 PPU 24x.2/26x.2/28x.2

4.1.2 This is how you remove the PPU

Precondition
For this description, it is assumed that the PPU has been completely connected.

Removing
This description applies to both versions (vertical/horizontal).
Procedure:
1. Switch-off the control: Completely switch off the system. Check that the system is in a no-
voltage condition and is locked-out so that it cannot be switched on again without the
appropriate authorization.
2. Access the control panel/control cabinet where the PPU is installed.
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.
5. Only then, can it be ensured that the cables are not interchanged.
6. Withdraw the power supply X1.
7. Withdraw the digital input/output terminals X122, X132, X142.
8. Withdraw the handwheel terminal X142.
9. Withdraw the RS232 cable, X140.
10.Withdraw the connected DRIVE-CLiQ cable X100 X102
11.Withdraw the connected Ethernet cable X130
12.Withdraw the connected PN interfaces PN1, PN2
13.Remove the ground connection by releasing the grounding screw.
14.If required, release the strain relief.
15.Release the PPU from the operator panel by releasing the clips.
16.Remove the system CompactFlash Card from the control.
(refer to Chapter This is how you remove the system CompactFlash Card (Page 79))

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4.1 PPU 24x.2/26x.2/28x.2

4.1.3 This is how you install the PPU

Installing
Procedure:
1. Now, install the system CompactFlash Card into the new PPU.
(refer to Chapter This is how you insert the system CompactFlash Card (Page 81))
2. Installing a new PPU.
3. Attach and tighten the clips to fix the PPU.
4. Connect the ground connections and tighten.
5. Insert the PN1, PN2 interfaces that were withdrawn.
6. Insert the Ethernet cable that was withdrawn at X130.
7. Insert the DRIVE-CLiQ cable that was withdrawn at X100 X102
8. Insert the handwheel terminal that was withdrawn at X142.
9. Insert the digital input/output terminals that were withdrawn at X122, X132, X142.
10.Reconnect power supply X1.
11.Retighten the strain relief assemblies.
12.Close the cabinet and switch-on the system again.
13.Read-in the available data backup.

Note
Changing the MAC address
When replacing the PPU, then the MAC address of Ethernet interface X130 changes:
Notify the customer or the system administrator of the new MAC address.

CAUTION

Ensure that all of the connectors and screws are correctly tightened or latched and
inserted.

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4.2 Replacing the system CompactFlash Card

4.2 Replacing the system CompactFlash Card

4.2.1 This is how you remove the system CompactFlash Card

Overview
If service is required, it may be necessary to replace the system CompactFlash Card of the
control. This is the case if, e.g. the system CompactFlash Card or the PPU is defective.

CAUTION
Electro-static discharge (ESD)
The system CompactFlash card must only be inserted or removed in a no-current
condition.
Before you touch the CompactFlash Card, discharge yourself at the cabinet or at the
ground terminal.

Removing the system CompactFlash Card

Procedure:
1. Switch-off the power supply of the control and the control cabinet.
2. Release the screw (M3).

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4.2 Replacing the system CompactFlash Card

3. Move the metal cover to the side and remove it.

4. Remove the system CompactFlash Card from the side.

5. Fix the metal cover by first locating at the rear and then tilting it into the end position.

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6. Fix the metal cover to the housing using the screw.

Note
When removing the system CompactFlash Card, carefully ensure that neither the screw
nor the system CompactFlash Card falls into the PPU or the machine.

PPU as replacement part

Note
For a PPU as replacement part (spare part), a system CompactFlash Card is not supplied.

4.2.2 This is how you insert the system CompactFlash Card

Precondition
The control cabinet and the PPU are in a no-voltage condition or the PPU has already been
removed.

CAUTION
Electro-static discharge (ESD)
The system CompactFlash card must only be inserted or removed in a no-current
condition.
Before you touch the CompactFlash Card, discharge yourself at the cabinet or at the
ground terminal.

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4.2 Replacing the system CompactFlash Card

Inserting the system CompactFlash Card

Procedure:
1. Release the screw (M3).

2. Move the metal cover to the side and withdraw it.

3. Gently insert the system CompactFlash Card into the slot until it clicks into place.

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4. Reattach the metal cover by first locating it at the rear and then tilting it into the end
position.

5. Fix the metal cover to the housing using the screw.

Note
When inserting the system CompactFlash Card, carefully ensure that neither the screw
nor the system CompactFlash Card falls into the PPU or the machine.

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4.3 SINAUT modem

4.3 SINAUT modem

4.3.1 LED status displays

Validity
This description is valid for the GPRS/GSM modem MD720-3, hardware version 3.x. You
can find additional information in the System Manual SINAUT MD720-3 in the Chapter
"Service functions".

LED status
The device has 3 LEDs, which provide information about the operating state:

S (Status)
Q (Quality)
C (Connect)

LED State Meaning

S, Q, C Common Flash on and off in a fast sequence Booting
Slow flashing in synchronism Service mode
Flash on and off in a slow sequence Update
Fast flashing in synchronism Error
S (Status) Slow flashing Waiting for PIN input
Fast flashing PIN error/ SIM error
Q (Quality) Slow flashing Logging into GSM network
Flashes 1 time with interval Field strength inadequate
Flashes 2 times with interval Field strength adequate
Flashes 3 times with interval Field strength good
Always ON Field strength very good
OFF Waiting for PIN
C (Connect) Flashing Terminal mode activated

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4.3 SINAUT modem

4.3.2 This is how you insert the SIM card

CAUTION
Risk of damage to sensitive components due to static electricity
This activity must always be carried out by trained personnel.

Open the module

Proceed as follows to open the module:
1. Ensure that the module has been disconnected from the power supply.
2. You must open the housing of the SINAUT MD720-3 in order to insert the SIM card.
A fastener with opening lug is located at the upper and lower side of the housing.

Opening lug
Opening lug

Figure 4-4 SINAUT modem

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1. Using a suitable object, press one of the two opening lugs carefully so that the fastener
opens.

2. Remove the rear section of the housing.

3. The SIM card holder can be seen on the printed circuit board:

SIM card holder

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Inserting the SIM card

NOTICE

When handling SIM cards, carefully observe its safety instructions.

When changing the SIM card, do not forget to change the PIN in your control.
If you are using a lot of SIM cards, it may make sense to set all SIM cards, e.g. with one
cellular phone to the same PIN.

Proceed as follows to insert the SIM card:

1. Using your fingernail or a suitable object, slide the upper section of the SIM card holder
approximately 2 mm in the direction of the arrow to the left so that the upper section can
be flipped up.

2. Flip up the upper section of the SIM card holder so that you can insert the SIM card into
this section.

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The slot for the SIM card in the upper section is shown in white in the following diagram:

3. Insert the SIM card into the upper section of the SIM card holder so that the contact
surface is at the bottom and the sloped corner of the SIM card points towards the front of
the device.

4. Insert the SIM card far enough so that the upper section of the SIM card holder can again
be flipped downwards.

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5. Press the upper section of the SIM card holder downwards. Ensure that the sloped corner
of the SIM card clicks into place.

6. Using your fingernail or a suitable object, slide the upper section of the SIM card holder
approximately 2 mm in the direction of the arrow to the right in order to lock the SIM card
holder.

7. The SIM card is then firmly locked in the SIM card holder:

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4.3 SINAUT modem

8. Then assemble the two housing sections again. To do this, locate the printed circuit
board in the upper and lower rails inside the rear section of the housing.

Rail for the printed circuit board

9. Press the two housing sections together so that the lugs of the fasteners click into place
at the top and bottom.

Result
SIM card is ready; screw the SINAUT modem together again.

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4.3.3 This is how you load the factory settings

Loading the factory settings

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Figure 4-5 MD720-3: Front view

If you press the SET key for longer than 4 seconds until the LED "C" starts to light up, then
the SINAUT MD720-3 configuration is reset to the default values set in the factory.

3DSHUFOLS

Figure 4-6 MD720-3: SET key

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4.4 Machine control panels

4.4 Machine control panels

4.4.1 Status displays MCP 310C PN

LEDs for status display

For the MCP 310C PN there are 3 LEDs in a row (H1-H3), which provide information about
the module state:

6

+ + +

Figure 4-7 Status displays

LED H1 (green) H2 (green) H3 (red)

PowerOK PN Sync 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 on off off
controller
System software runs, communication to the on on off
controller, STOP state
System software runs, communication to the on Flashes at off
controller, RUN state 0.5 Hz

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4.4 Machine control panels

4.4.2 This is how you remove the MCP 310C PN

Overview
The activities that must be taken into account when replacing a machine control panel are
subsequently described.
If the machine control panel has a hardware defect, then it must be replaced by an identical
replacement part.
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.

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4.4 Machine control panels

Removing

    

     

Slot for Emergency Stop button or spindle override

X10 Power supply interface
X60 Handwheel connection *)
X61 Handwheel connection *)
S1 Switch: for SINUMERIK 828D, no function
S2 Switch
LEDs
Ethernet cable strain relief
X21 Port 2: PLC I/O interfaces based on PROFINET
X20 Port 1: PLC I/O interfaces based on PROFINET
Equipotential bonding
Feedrate override
Customer-specific inputs and outputs
*) Handwheels are directly connected to the PPU: Do not wire X60/X61.

Figure 4-8 MCP 310C PN rear side

NOTICE
Electro-static discharge (ESD)
Before you touch the machine control panel, discharge yourself at the cabinet or at the
ground terminal.

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4.4 Machine control panels

Procedure:
1. Switch-off the control: Completely switch off the system. Check that the system is in a no-
voltage condition and is locked-out so that it cannot be switched on again without the
appropriate authorization.
2. Access the operator panel or control cabinet in which the machine control panel is
located.
3. Using a multimeter, check the X10 power supply to ensure that the system really is 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 X10 ().
6. Release the strain relief of the Ethernet cable ()
7. Remove the Ethernet cables from the X20/X21 interface (port 1/port 2) (, ).
8. Release other cables (e.g. the Emergency Stop cable or the button from the mini
handheld unit or from other command devices), if available.
9. Remove the ground connection by releasing the grounding screw ().
10.Release the machine control panel from the control panel by releasing the clips.
11.Note down the set address S2 () at the DIL switch of the defective module.

4.4.3 This is how you install the MCP 310C PN

Installing
Procedure:
1. Set DIL switch S2 of the new module to what you previously noted down.
2. Install the new machine control panel.
3. Secure the clips to retain the machine control panel and tighten them.
4. Connect the ground connection ().
5. Reconnect the other cables (e.g. the Emergency Stop cable or the button from the mini
handheld unit or from other command devices), if available.
6. Reinsert the Ethernet cables at the X20/X21 interface (port 1/port 2) (, ).
7. Re-establish the strain relief for the Ethernet cables ().
8. Reconnect the power supply X10 ().
9. Close the cabinet and switch-on the system again.

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4.4 Machine control panels

DIP switch S2

6

+ + +

Figure 4-9 Switch S2

Switch S2 defines the IP address of the machine control panel:

1 2 3 4 5 6 7 8 9 10 Device name
on on
on off on off off off off off mcp-pn64

For SINUMERIK 828D, the IP address = 192.168.214.64 must always be assigned to the MCP.

4.4.4 Status displays, MCP 483C PN

LED status displays

For the MCP 483C PN there are 3 LEDs in a row (H1 - H3), which provide information about
the module state:

6 + + +

Figure 4-10 Status displays

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4.4 Machine control panels

LED H1 (green) H2 (green) H3 (red)

PowerOK PN Sync 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 on off off
controller.
System software runs, communication to the on on off
controller, STOP state
System software runs, communication to the on Flashes at off
controller, RUN state 0.5 Hz

4.4.5 This is how you remove the MCP 483C PN

Overview
The activities that must be taken into account when replacing a machine control panel are
subsequently described.
If the machine control panel has a hardware defect, then it must be replaced by an identical
replacement part.
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.

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4.4 Machine control panels

Removing

    

        

Ground terminal
X30 Feedrate override
X31 Spindle override
X20 Port 1: Connection: PLC I/O interface based on PROFINET
X21 Port 2: Connection: PLC I/O interface based on PROFINET
Slot for Emergency Stop
Mounting slots for additional command devices
Customer-specific inputs and outputs
Cover plate
Ethernet cable strain relief
LEDs
S2 Switch
S1 Switch: for SINUMERIK 828D, has no function
X60 Handwheel connection *)
X61 Handwheel connection *)
X10 Power supply interface
*) Handwheels are directly connected to the PPU: Do not wire X60/X61

Figure 4-11 MCP 483C PN rear side

NOTICE
Electro-static discharge (ESD)
Before you touch the machine control panel, discharge yourself at the cabinet or at the
ground terminal.

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4.4 Machine control panels

Procedure:
1. Switch-off the control: Completely switch off the system. Check that the system is in a no-
voltage condition and is locked-out so that it cannot be switched on again without the
appropriate authorization.
2. Access the operator panel/control cabinet in which the machine control panel is located.
3. Using a multimeter, check the X10 power supply to ensure that the system really is 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 X10 ().
6. Release the strain relief of the Ethernet cable ()
7. Remove the Ethernet cables from the X20 / X21 interface (port 1/port 2) ()
8. Release other cables (e.g. the Emergency Stop cable or the button from the mini
handheld unit or from other command devices), if available.
9. Remove the ground connection by releasing the grounding screw ().
10.Release the machine control panel from the control panel by releasing the clips.
11.Note down the set address S2 () at the DIL switch of the defective module.

4.4.6 This is how you install the MCP 483C PN

Installing
Procedure:
1. Set DIL switch S2 () of the new module to what you previously noted down.
2. Installing a new machine control panel.
3. Secure the clips to retain the machine control panel and tighten them.
4. Connect the ground connection ().
5. Reconnect the other cables (e.g. the Emergency Stop cable or the button from the mini
handheld unit or from other command devices), if available.
6. Reinsert the Ethernet cables at the X20/X21 interface (port 1/port 2) ().
7. Re-establish the Ethernet cable strain relief ().
8. Reconnect the power supply X10 ().
9. Close the cabinet and switch-on the system again.

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4.4 Machine control panels

Switch S2

6 + + +

Figure 4-12 Switch S2

Switch S2 defines the IP address of the machine control panel:

1 2 3 4 5 6 7 8 9 10 Device name
on on
on off on off off off off off mcp-pn64

For SINUMERIK 828D, the IP address = 192.168.214.64 must always be assigned to the MCP.

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4.5 I/O modules

4.5 I/O modules

4.5.1 Status displays PP 72/48D PN

LEDs for status display

The following LEDs on the I/O module provide information about the module state:

Figure 4-13 Switch S1 and LEDs H1 to H6

H1 (green) H2 (green) H3 (red) H4 (green) H5 (green) H6

PowerOK PN Sync PN Fault Diag1 Diag2 OVTemp
Power Off off off off off off off
Power On (voltage is stable) on off off off off off
Boot software runs and loads the system on on on on on off
software.
System software runs on off off off off off
System software runs, no communication to on off off off off off
the controller.
System software runs, communication to the on on off off off off
controller, STOP state
System software runs, communication to the on Flashes at off off off off
controller, RUN state 0.5 Hz
Overtemperature alarm -- -- -- -- -- on

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4.5 I/O modules

LEDs at port 1 and port 2

There are 2 LEDs at port 1 and port 2 for diagnostics of the PLC I/O interfaces based on
PROFINET.

\HOORZ

JUHHQ

Figure 4-14 Port 1 and port 2

LED for communication at the RJ45 connector.

Name Color State Meaning

Link Green ON 100 MBit link available
OFF Missing or faulty link
Activity Yellow ON Sending or receiving
OFF No activity

4.5.2 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 connectors and cables are
labeled.

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4.5 I/O modules

Removing

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Figure 4-15 Rear of the PP 72/48D PN

NOTICE
Electro-static discharge (ESD)
Before you touch the module, discharge yourself at the cabinet or at the ground terminal.

Procedure:
1. Switch-off the control: Completely switch off the system. Check that the system is in a no-
voltage condition and is locked-out so that it cannot be switched on again without the
appropriate authorization.
2. Access the control cabinet where the module is located.
3. Using a multimeter, check the X1 power supply to ensure that the system really is 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. Release the connectors of the ribbon cables (X111, X222, X333) on the module that are
used to connect the digital inputs and outputs.

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4.5 I/O modules

7. Remove the strain relief of the communication cables to interfaces X2.

8. Remove the communication cables from interface X2 (port 1 and port 2).
9. Remove the ground connection by releasing the grounding screw.
10.To remove the I/O module, release the fixing screws.
11.Note down the address set with DIP switch S1 on the defective module.

4.5.3 This is how you install the PP 72/48D PN

Installing
Procedure:
1. Set DIP switch S1 of the new module as you previously noted down.
2. Install the new I/O module.
3. Connect the ground connection.
4. Connect the communication cables at interface X2 (port 1 and port 2).
5. Re-establish the strain relief for the communication cables.
6. Re-insert the connectors 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 off off off off pp72x48pn6
on off on off off off off off pp72x48pn5

The switch positions 9 and 10 guarantee the PROFINET functionality of the module and must always be switched "on".

NOTICE

A new address only becomes effective after voltage OFF ON.

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4.5 I/O modules

4.5.4 Status displays PP 72/48D 2/2A PN

LEDs for status display

The following LEDs on the I/O module provide information about the module state:

Figure 4-16 Switch S1 and LEDs H1 to H6

H1 (green) H2 (green) H3 (red) H4 (green) H5 (green) H6

PowerOK PN Sync PN Fault Diag1 Diag2 OVTemp
Power Off off off off off off off
Power On (voltage is stable) on off off off off off
Boot software runs and loads the system on on on on on off
software.
System software runs on off off off off off
System software runs, no communication to on off off off off off
the controller.
System software runs, communication to the on on off off off off
controller, STOP state
System software runs, communication to the on Flashes at off off off off
controller, RUN state 0.5 Hz
Overtemperature alarm -- -- -- -- -- on

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4.5 I/O modules

LEDs at port 1 and port 2

There are 2 LEDs at port 1 and port 2 for diagnostics of the PLC I/O interfaces based on
PROFINET.

\HOORZ
JUHHQ

Figure 4-17 Port 1 and port 2

LED for communication at the RJ45 connector.

Name Color State Meaning

Link Green ON 100 MBit link available
OFF Missing or faulty link
Activity Yellow ON Sending or receiving
OFF No activity

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4.5 I/O modules

4.5.5 This is how you remove the PP 72/48D 2/2A PN

Overview
The activities necessary when replacing the PP 72/48D 2/2A PN I/O module are described in
the following.
If the PP 72/48D 2/2A PN has a hardware defect, then it must be replaced by an identical
module.
Preconditions:
The I/O module is defective and must be replaced.
The control cabinet is in a no-voltage condition, all of the connectors and cables are
labeled.

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4.5 I/O modules

Removing

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;

*URXQGLQJVFUHZ

Figure 4-18 Rear of PP 72/48D 2/2A PN

NOTICE
Electro-static discharge (ESD)
Before you touch the module, discharge yourself at the cabinet or at the ground terminal.

Procedure:
1. Switch-off the control: Completely switch off the system. Check that the system is in a no-
voltage condition and is locked-out so that it cannot be switched on again without the
appropriate authorization.
2. Access the control cabinet where the module is located.
3. Using a multimeter, check the X1 power supply to ensure that the system really is 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. 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 communication cables to interfaces X2.

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8. Remove the communication cables from interface X2 (port 1 and port 2).
9. Remove the ground connection by releasing the grounding screw.
10.To remove the I/O module, release the fixing screws.
11.Note down the address set with DIP switch S1 on the defective module.

4.5.6 This is how you install the PP 72/48D 2/2A PN

Installing
Procedure:
1. Set DIP switch S1 of the new module as you previously noted down.
2. Install the new I/O module.
3. Connect the ground connection.
4. Connect the communication cables at interface X2 (port 1 and port 2).
5. Re-establish the strain relief for the communication cables.
6. Re-insert the connectors 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 off off off off pp72x48pn6
on off on off off off off off pp72x48pn5

The switch positions 9 and 10 guarantee the PROFINET functionality of the module and must always be switched "on".

NOTICE

A new address only becomes effective after voltage OFF ON.

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4.6 Expansion module NX10.3

4.6 Expansion module NX10.3

4.6.1 NX10.3 status displays

Status displays
The following status displays on the NX10.3 provide information about the module state:

LED Color State Description

RDY, H1 - OFF Electronics power supply outside the permissible tolerance range.
Green Continuous light Component is ready.
Flashing light 2 Hz Writing to CompactFlash Card.
Red Continuous light There is at least one fault (e.g., RESET, watchdog monitoring, basic system
fault).
NX10.3 is presently booting.
Flashing light Error when booting: e.g. the firmware cannot be loaded into the RAM.
0.5 Hz
Yellow Continuous light Firmware is being loaded into the RAM
Flashing light Firmware cannot be loaded into the RAM.
0.5 Hz
Flashing light 2 Hz Firmware CRC error.
DP1, - OFF Electronics power supply outside the permissible tolerance range.
CU_LINK, NX10.3 is not ready for operation.
H2
Green Continuous light CU_LINK is ready for communication and cyclic communication is running.
Flashing light CU_LINK is ready for communication and no cyclic communication is
0.5 Hz running.
Red Continuous light At least one CU_LINK fault is present.
CU_LINK is not ready for operation (e.g., after switching on).

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4.6 Expansion module NX10.3

4.6.2 NX10.3 connections

Connections

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Figure 4-19 NX10.3 connections

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4.6 Expansion module NX10.3

4.6.3 This is how you remove the NX10.3

Preconditions
The activities that are required when replacing an NX10.3 are subsequently described.
If the NX10.3 has a hardware defect, then it must be replaced by an identical module.
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

6SDFHUV

&XWRXWVIRU
ODWHUDOPRXQWLQJ

Figure 4-20 Mounting aids

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4.6 Expansion module NX10.3

NOTICE
Electro-static discharge (ESD)
Before you touch the component, discharge yourself at the cabinet or at the ground
terminal.

Procedure:
1. Switch-off the control: Completely switch off the system. Check that the system is in a no-
voltage condition and is locked-out so that it cannot be switched on again without the
appropriate authorization.
2. Access the control cabinet where the NX10.3 is located.
3. Use a multimeter to check that the system really is in a no-voltage condition (isolated
from the supply).
4. Open the cover cap of the NX10.3 module.
5. 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.
6. Withdraw the electronics power supply X124.
7. Withdraw the digital input/output terminal X122.
8. Withdraw any connected DRIVE-CLiQ cables X100 - X103.
9. Remove the protective conductor connection of the NX10.3.
10.Release the screws retaining the NX10.3 to the mounting plate.
OR
11.If the module is located to the left of the infeed, remove the module by first pulling it
upwards and then removing it towards the left.

4.6.4 This is how you install the NX10.3

Installing
Procedure:
1. Screw the new NX10 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 into the holder to the right and then press it down slightly to retain it.
3. Reconnect the protective conductor connection of the NX10.
4. Insert the DRIVE-CLiQ cables that were previously withdrawn into sockets X100-X103.
5. Insert the digital input/output terminal X122 into the NX10.
6. Reconnect the electronics power supply X124.

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4.6 Expansion module NX10.3

7. Now check that all of the cables have been re-connected.

8. Now close the cover cap of the NX10.
9. Close the cabinet and switch-on the system again.

CAUTION

Ensure that all of the connectors and screws are correctly tightened or latched and
inserted.

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4.7 Installing SINAMICS components

4.7 Installing SINAMICS components

4.7.1 Releasing with a screwdriver

The new protective covers for the DC link on the SINAMICS S120 components feature a
new interlock mechanism, which is really easy to operate using a slot-head screwdriver
(1 x 5.5).

Table 4- 1 Opening the protective cover for the DC link using a screwdriver

Protective cover with new interlock To open the protective cover, use the Opened protective cover
mechanism screwdriver to turn the interlock screw
a little, in the direction of the arrow
(counter-clockwise)

To lock, press the protective cover back on until you hear the interlock engage.

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4.7 Installing SINAMICS components

4.7.2 Protective conductor connection and shield support

Shield support and protective conductor connection

It is always advisable to use shielded wiring for the digital inputs and outputs.

DANGER

If the shielding procedures described and the specified cable lengths are not observed, the
machine may not operate properly.

NOTICE

Only use screws with a permissible insertion length of 4-6 mm.

The following diagram shows typical shield-connection terminals for the shield supports:

3URWHFWLYHFRQGXFWRU 6KLHOGWHUPLQDO
FRQQHFWLRQ
01P

Connecting terminal Weidmller

Type: KLBLUE CO 1
order number: 17533 11001

Figure 4-21 Shield support and protective conductor connection

See also
Weidmller website (http://www.weidmueller.com)

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4.8 SINAMICS S120 Combi

4.8 SINAMICS S120 Combi

4.8.1 S120 Combi status displays

Status displays
The SINAMICS S120 Combi has two LEDs to display the status of the components. The
software assigns a priority to the status signals from the individual components. The most
important and most informative status is output for the complete S120 Combi.
The status is immediately output if any component develops a fault. The ready to run
indication is only issued if all of the components have signaled that they are ready to run.
The LED statuses for the S120 Combi are described in the following table. The status
display always refers to the entire module.

State Description, cause Remedy

RDY DC LINK
Off Off Electronics power supply is missing or outside Connect/test the electronics
permissible tolerance range. power supply
Green Off The 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 Check the line supply voltage.
DRIVE-CLiQ communication is taking place.
The DC link voltage is too high.
Orange Orange DRIVE-CLiQ communication is being established. -
Red - This component has at least one fault. Remove the fault and
Note: acknowledge
The LED is controlled irrespective of the corresponding
messages being reconfigured.
Green/Red - Firmware is being downloaded.
(0.5 Hz)
Green/Red - Firmware has been downloaded. Carry out a POWER ON
(2 Hz) Wait for POWER ON.
Green/Orange - Component recognition using LED is activated (p0124) -
or Note:
Red/Orange
Both options depend on the LED status when module
recognition is activated via p0124 = 1.

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4.8 SINAMICS S120 Combi

DANGER
DC link voltage
Hazardous DC link voltages may be present at any time regardless of the state of the
"DC LINK" LED. The warning information on the components must be carefully observed!

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4.8 SINAMICS S120 Combi

4.8.2 Connections, 3-axis module

Connections
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Figure 4-22 S120 Combi 3 axis Power Module

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4.8 SINAMICS S120 Combi

View from the top

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1) The shield connection terminal is included in the accessories pack (Weidmller, type KLB 3-8 SC).

Figure 4-23 S120 Combi 3 axis Power Module

View from below

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Figure 4-24 S120 Combi 3 axis Power Module

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4.8 SINAMICS S120 Combi

4.8.3 Connections, 4-axis module

Connections, S120 Combi with 4 axes

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Figure 4-25 S120 Combi 4 axis Power Module

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4.8 SINAMICS S120 Combi

View from the top

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1) The shield connection terminal is included in the accessories pack (Weidmller, type KLB 3-8 SC).

Figure 4-26 S120 Combi 4 axis Power Module

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Figure 4-27 S120 Combi 4 axis Power Module

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4.8 SINAMICS S120 Combi

4.8.4 How to mount an S120 Combi Power Module

Precondition
The reinforcement plates are installed in order to mount an S120 Combi Power Module.

Mounting
Procedure:
1. Mount the self-clinching flush head studs M6.
2. Position the S120 Combi Power Module and initially tighten the M6 nuts by hand with
0.5 Nm.
3. Then tighten the nuts in the specified sequence 1 to 4 with 10 Nm.

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Figure 4-28 Installing an S120 Combi Power Module

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4.8 SINAMICS S120 Combi

4. Connect the protective conductor.

See also: Protective conductor connection and shield support (Page 116)
5. Connect the following connections with the associated screw-type terminals:
X1: Line supply connection
X2 to X4: Motor connection for the S120 Combi with 3 axes
X2 to X5: Motor connection for the S120 Combi with 4 axes

4.8.5 This is how you remove the front panel

Removing the front plate of the S120 Combi

To electrically connect additional components, the front cover of the S120 Combi must be
removed.

DANGER
Risk of electric shock
A hazardous voltage is still present for up to 5 minutes after the power supply has been
switched off.
The front cover must not be opened until this time has elapsed.

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.

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4.8 SINAMICS S120 Combi

3. Release the front cover by slightly pressing upwards

4. Remove the front plate.

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4.8.6 This is how you open the DC link cover

Removing the front plate of the S120 Combi

To electrically connect additional components, the front cover of the S120 Combi must
already have been removed.
The DC link busbars are located under the DC link cover.

DANGER
Risk of electric shock
A hazardous voltage is still present for up to 5 minutes after the power supply has been
switched off.
The front cover must not be opened until this time has elapsed.

Procedure:
1. Remove the Torx-slotted screw of the DC link cover.

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2. Remove the DC link cover.

3. Remove the DC link side cover.

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4.8.7 This is how you connect the DC link busbars and 24 V busbars

Connecting additional components

The following steps are necessary to connect a component to the DC link and the 24 V
busbars of the S120 Combi.

CAUTION

Before commissioning the drive line-up, it must be ensured that following items are
complied with:
The 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.

CAUTION

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 reinstalled.
The touch protection can be ordered as a spare part.

Procedure:
1. Use a suitable tool to open the protective cover of the component to be connected
2. Remove the DC link side cover at the connection location.


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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

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4. Install the lower DC link busbar as shown in the following diagram:

5. Install the upper DC link busbar as shown in the following diagram:

Release the screws

Remove the plastic cap on the DC link bridge
Turn over the DC link bridge.
Observe the sequence when tightening the screws!

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6. Install the red 24 V connectors in accordance with the supplied description of the
component to be connected.

7. Close the protective cover of the connected component.

8. Mount the front plate on the S120 Combi.

4.8.8 To connect the second component

Connecting a second component

A second component is connected as follows to the DC link busbars and the 24 V busbars:

CAUTION
DC link
Before commissioning the drive line-up, it must be ensured that following items are
complied with:
The DC link side cover is inserted at the outer component (touch protection).
The protective covers of the connected components are closed.

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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


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3. To connect the DC link busbars you will need the following tool:
Screwdriver: Torx T20
Tightening torque: 1.8 Nm
4. Install the lower DC link busbar:

Release the screws

Turn over the DC link bridge.
Observe the sequence when tightening the screws

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5. Install the upper DC link busbar:

Release the screws

Turn over the DC link bridge.
Observe the sequence when tightening the screws
6. Install the red 24 V connectors in accordance with the supplied description of the
component to be connected.

7. Close the protective covers of both components.

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4.8.9 This is how you remove the internal fan

Removing the internal fan

NOTICE

When replacing the fan, you must observe the ESD regulations.
Only qualified personnel are permitted to install spare parts!

DANGER
Risk of electric shock
Before replacing the fan, the power supply (400 V AC) must be switched off. A hazardous
voltage is still present for up to 5 minutes after the power supply has been switched off.
Before removing the component, check that the system is in a no-voltage condition!

Procedure:
1. Remove the S120 Combi front cover (see also: This is how you remove the front panel
(Page 124)).
2. Remove the Torx-slotted screw of the fan cover.

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3. Remove the fan cover,

4. Remove the cable connector by gently pressing the interlock and connector together.

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Opened fan compartment:

5. Withdraw the fan.

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4.8.10 This is how you install the internal fan

Installing a new internal fan

Procedure:
1. Before installing the fan, note the direction of the airflow:
The arrows on the fan must match the following diagram!

The arrows on the fan show the direction of the airflow.

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.
5. Attach the Torx-slotted screw to the fan cover.
6. Install the front panel and tighten the front screws.
(see Chapter: This is how you remove the front panel (Page 124))

4.8.11 This is how you install the external fan

Preparation
The external fan unit is always installed above the S120 Combi in the control 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 123)).

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Mounting accessories

Number Designation Specification

5 Self-clinching flush head M4, steel, strength class 8.8, zinc-plated, length: 15 mm
studs
5 Nut M4, steel, strength class 8, zinc-plated

Installing
Procedure:
1. Mount the self-clinching flush head studs - position 1) in the following part of the diagram:
The zero line shown runs at the height of the upper bolts used to mount the S120 Combi.

Figure 4-29 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

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3. Mount the fan unit in the specified sequence (steps 1 to 4).

Step 1:

Step 2:

Step 3:

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Step 4:

4. Initially tighten the nuts by hand with 0.5 Nm.

5. Then tighten the nuts with a tightening torque of 1.8 Nm in the specified sequence 1 to 5
(arrows).

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Boundary condition
The reinforcement plates must always be installed when operating the S120 Combi with the
external fan unit.

WRONG: CORRECT:
S120 Combi and external fan unit without S120 Combi and external fan unit with
reinforcement plates installed reinforcement plates

CAUTION
Reinforcement plates
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.

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4.8.12 This is how you clean the heat sink of the S120 Combi

Cleaning the heat sink

The S120 Combi heat sink should be cleaned at regular intervals using either compressed
air or high-pressure water jets. To clean the heat sink, the air baffle plate at the rear of the
S120 Combi must be removed.
Procedure:
1. The screws are accessible from the rear.

2. To remove the air baffle plate on the S120 Combi, release the fixing screws through the
holes in the reinforcement plates.

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Screws: Slotted or cross slot M4 x 10, DIN EN ISO 7046-1/2

3. Remove the air baffle plate in the direction of the arrow.

The air baffle plate has been removed.

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The heat sink can now be cleaned:

4. After cleaning the heat sink, the air baffle plate is reinstalled in the reverse sequence.
Tightening torque for the screws: 1.8 Nm.

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4.9 Motor Module Booksize Compact format

4.9 Motor Module Booksize Compact format

4.9.1 Motor Module Booksize Compact status displays

Status displays
The Motor Module has the following status displays, which provide information about the
module state:

LED state Description, cause Remedy

RDY DC LINK
OFF OFF Electronics power supply is missing or outside -
permissible tolerance range.
Green --- The 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 Check the line supply
DRIVE-CLiQ communication is taking place. voltage.
The DC link voltage is too high.
Orange Orange DRIVE-CLiQ communication is being established. -
Red -- This component has at least one fault. Remove the fault and
Note: acknowledge
The LED is controlled irrespective of the corresponding
messages being reconfigured.
Green / Red -- Firmware is being downloaded. -
(0.5 Hz)
Green / Red -- Firmware download has been completed. Wait for Carry out a POWER ON
(2 Hz) POWER ON.
Green/Orange -- Component recognition via LED is activated (p0124). -
or Note:
Red/Orange
Both options depend on the LED status when module
recognition is activated via p0124 = 1.

DANGER
DC link voltage
Hazardous DC link voltages may be present at any time regardless of the state of the
"DC LINK" LED. The warning information on the components must be carefully observed!

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4.9.2 Motor Module connections

Single Motor Module connections

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4.9 Motor Module Booksize Compact format

Double Motor Module connections

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4.9.3 This is how you mount a Motor Module Booksize Compact

Installing
Note the tightening torques for hexagonal combination screws or hexagon screws with
spring lock washer and flat washer.
Procedure:
1. Initially tighten the screws by hand with 0.5 Nm.
2. Tighten the screws in the specified sequence 1 to 4 with 6 Nm.




3
4
5

 
Mounting wall
Screw M6 x 16
Plain washer
Spring washer
Nut
Figure 4-32 Motor Module Booksize Compact

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4.9.4 This is how you replace the fan on a Motor Module Booksize Compact

Removing the fan

The instructions are valid for a module width of 50 mm.

NOTICE

When replacing the fan, you must observe the ESD regulations.
Only qualified personnel are permitted to install spare parts!

DANGER
Risk of electric shock
Switch off the power supply (400 V AC) before replacing the fan. A hazardous voltage is
still present for up to 5 minutes after the power supply has been switched off.
Before removing the component, check that the system is in a no-voltage condition!

Procedure:
1. Remove the Motor Module from the drive line-up.

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2. Remove the fan cover at the lower side of the Motor Module by releasing the snap hooks.

3. Carefully withdraw the fan.

4. Release the connector before you withdraw it.

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Installing the fan

Procedure:
1. Before installing the fan, observe the direction of the airflow: The arrow on the fan must
point toward the cooling ribs.

2. Insert the cable connector until it latches into place.

3. Install the fan.
Notice! Do not crush the connection cables!
4. Attach the fan cover.

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4.10 Single Motor Modules

4.10.1 SMM status displays

Status displays
The Motor Module has the following status displays, which provide information about the
module state:

LED state Description, cause Remedy

RDY DC LINK
OFF OFF The electronics power supply is missing or outside the
permissible tolerance range.
Green OFF The 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- Check the line supply
CLiQ communication is taking place. voltage.
The DC link voltage is too high.
Orange Orange DRIVE-CLiQ communication is being established.
Red This component has at least one fault. Remove the fault and
Note: acknowledge.
The LED is controlled irrespective of the corresponding
messages being reconfigured.
Green/red Firmware is being downloaded.
(0.5 Hz)
Green/red - Firmware download has been completed. Wait for Carry out a POWER ON.
(2 Hz) POWER ON.
Green/orange Component recognition via LED is activated (p0124).
or red/orange Note:
Both options depend on the LED status when module
recognition is activated via p0124 = 1.

DANGER
DC link voltage
Hazardous DC link voltages may be present at any time regardless of the state of the
"DC Link" LED. The warning information on the components must be carefully observed!

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4.10 Single Motor Modules

4.10.2 SMM connections

Connections

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4.10.3 This is how you remove a Motor Module

Overview
The activities required when replacing a Motor Module are subsequently described.
If a Motor Module has a hardware defect, then it must be replaced by an identical module.
Preconditions:
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

NOTICE
Electro-static discharge (ESD)
Before you touch the module, discharge yourself at the cabinet or at the ground terminal.

Procedure:
1. Switch-off the control: Completely switch off the system. Check that the system is in a no-
voltage condition and is locked-out so that it cannot be switched on again without the
appropriate authorization.
2. Access the control cabinet where the infeed module is located.
3. 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.
4. Withdraw the enable terminals X21 (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
Risk of electric shock
A hazardous voltage is present for up to 5 minutes after the power supply has been
switched off. The protective cover must not be opened until this time has elapsed.
The warning information on the components must be carefully observed!

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7. Open the protective cover of the DC link voltage of the defective module as well as the
adjacent module - if available - using a suitable tool (e.g. a screwdriver).
8. Withdraw the 24 V terminal adapter.
9. Using a multimeter (set the measuring range to 1000 V DC) at the points DCP/DCN,
check that the DC link voltage is in a no-voltage condition.
Only continue with the work when it has been absolutely ensured that no voltage is
present (a no-voltage condition has been established).

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10.Withdraw the red 24 V jumper plug.

11.Release the Torx screws of the DC link.

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12.Open the DC link busbars of the two modules.

13.Release the screws that are used to retain the motor module to the mounting plate.
14.Remove the protective conductor connection of the Motor Module.
15.Remove the Motor Module from the control cabinet.

4.10.4 This is how you install a Motor Module

Installing

DANGER
Risk of electric shock
A hazardous voltage is present for up to 5 minutes after the power supply has been
switched off. The protective cover must not be opened until this time has elapsed.
The warning information on the components must be carefully observed!

Procedure:
1. Screw the new Motor Module to the mounting plate.
2. Reconnect the protective conductor connection of the Motor Module.
3. Open the protective cover of the DC link voltage using a suitable tool (e.g. a screwdriver).

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4. Release the Torx screws and connect the DC link busbar.

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5. Tighten the Torx screws of the DC link busbars, observe the correct sequence.

   

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6. Place the red jumper plug on the electronics busbar until it clicks into 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.

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9. Reconnect motor connections X1 and X2 - if available - to the module.

10.Insert the DRIVE-CLiQ cables that were previously withdrawn into sockets X200 - X202.
11.Reinsert the enable terminals X21 and X22 - if available - into the module.
12.Check whether all of the cables have been re-connected.
13.Close the cabinet and switch-on the system again.

CAUTION

Ensure that all of the connectors and screws are correctly tightened and latched or
inserted.

WARNING

The components must only be operated when the protective cover of the DC link is closed.
Damaged components must not be used.

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4.11 Double Motor Modules

4.11 Double Motor Modules

4.11.1 DMM status displays

Status displays
The Motor Module has the following status displays, which provide information about the
module state:

LED state Description, cause Remedy

RDY DC LINK
OFF OFF The electronics power supply is missing or outside the
permissible tolerance range.
Green OFF The 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 Check the line supply
DRIVE-CLiQ communication is taking place. voltage.
The DC link voltage is too high.
Orange Orange DRIVE-CLiQ communication is being established.
Red This component has at least one fault. Remove the fault and
Note: acknowledge
The LED is controlled irrespective of the corresponding
messages being reconfigured.
Green/red Firmware is being downloaded.
(0.5 Hz)
Green/red - Firmware download has been completed. Wait for Carry out a POWER ON.
(2 Hz) POWER ON.
Green/orange Component recognition via LED is activated (p0124).
or red/orange Note:
Both options depend on the LED status when module
recognition is activated via p0124 = 1.

DANGER
DC link voltage
Hazardous DC link voltages may be present at any time regardless of the state of the
"DC Link" LED. The warning information on the components must be carefully observed!

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4.11.2 DMM connections

Connections

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4.11 Double Motor Modules

4.11.3 This is how you remove a Motor Module

Overview
The activities required when replacing a Motor Module are subsequently described.
If a Motor Module has a hardware defect, then it must be replaced by an identical module.
Preconditions:
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

NOTICE
Electro-static discharge (ESD)
Before you touch the module, discharge yourself at the cabinet or at the ground terminal.

Procedure:
1. Switch-off the control: Completely switch off the system. Check that the system is in a no-
voltage condition and is locked-out so that it cannot be switched on again without the
appropriate authorization.
2. Access the control cabinet where the infeed module is located.
3. 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.
4. Withdraw the enable terminals X21 (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
Risk of electric shock
A hazardous voltage is present for up to 5 minutes after the power supply has been
switched off. The protective cover must not be opened until this time has elapsed.
The warning information on the components must be carefully observed!

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7. Open the protective cover of the DC link voltage of the defective module as well as the
adjacent module - if available - using a suitable tool (e.g. a screwdriver).
8. Withdraw the 24 V terminal adapter.
9. Using a multimeter (set the measuring range to 1000 V DC) at the points DCP/DCN,
check that the DC link voltage is in a no-voltage condition.
Only continue with the work when it has been absolutely ensured that no voltage is
present (a no-voltage condition has been established).

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10.Withdraw the red 24 V jumper plug.

11.Release the Torx screws of the DC link.

7RU[7 7RU[7

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4.11 Double Motor Modules

12.Open the DC link busbars of the two modules.

13.Release the screws that are used to retain the motor module to the mounting plate.
14.Remove the protective conductor connection of the Motor Module.
15.Remove the Motor Module from the control cabinet.

4.11.4 This is how you install a Motor Module

Installing

DANGER
Risk of electric shock
A hazardous voltage is present for up to 5 minutes after the power supply has been
switched off. The protective cover must not be opened until this time has elapsed.
The warning information on the components must be carefully observed!

Procedure:
1. Screw the new Motor Module to the mounting plate.
2. Reconnect the protective conductor connection of the Motor Module.
3. Open the protective cover of the DC link voltage using a suitable tool (e.g. a screwdriver).

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4. Release the Torx screws and connect the DC link busbar.

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5. Tighten the Torx screws of the DC link busbars, observe the correct sequence.

   

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6. Place the red jumper plug on the electronics busbar until it clicks into 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.

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4.11 Double Motor Modules

9. Reconnect motor connections X1 and X2 - if available - to the module.

10.Insert the DRIVE-CLiQ cables that were previously withdrawn into sockets X200 - X202.
11.Reinsert the enable terminals X21 and X22 - if available - into the module.
12.Check whether all of the cables have been re-connected.
13.Close the cabinet and switch-on the system again.

CAUTION

Ensure that all of the connectors and screws are correctly tightened and latched or
inserted.

WARNING

The components must only be operated when the protective cover of the DC link is closed.
Damaged components must not be used.

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4.12 Smart Line Modules

4.12 Smart Line Modules

4.12.1 SLM (< 16 kW) status displays

Status displays
The 5 kW and 10 kW Smart Line Modules have the following status displays, which provide
information about the module state:

LED state Description, cause Remedy

RDY DC LINK
- OFF Electronics power supply is missing or outside -
permissible tolerance range.
Continuous -- Component is ready. --
green light
Continuous -- Precharging not yet complete. --
yellow light Bypass relay has dropped-out.
EP terminals are not supplied with 24 V DC.
Continuous -- Overcurrent trip due to overtemperature. Diagnose fault via output terminals
red light and acknowledge via input
terminal:
-- Continuous DC link voltage in the permissible tolerance range. --
yellow light
-- Continuous Line supply faults: DC link voltage outside the Check the line supply voltage.
red light permissible tolerance range.

DANGER
DC link voltage
Hazardous DC link voltages may be present at any time regardless of the state of the
"DC Link" LED. It must be checked that it really is in a no-voltage condition.
The warning information on the components must be carefully observed!

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4.12 Smart Line Modules

4.12.2 SLM (< 16 kW) connections

Connections

;;
7HUPLQDOV

;; ;
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b9WHUPLQDODGDSWHU

8QORFNLQJ (OHFWURQLFSRZHU
SURWHFWLYHFRYHU VXSSO\

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3URWHFWLYHFRYHU

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FRQGXFWRU /LQHVXSSO\FRQQHFWLRQ
FRQQHFWLRQ
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Figure 4-35 SLM connections

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4.12 Smart Line Modules

4.12.3 SLM (16 kW and higher) status displays

Status displays
The Smart Line Modules 16 kW have the following status displays, which provide
information about the module state:

LED state Description, cause Remedy

RDY DC LINK
OFF OFF Electronics power supply is missing or outside
permissible tolerance range.
Green OFF The 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 Check the line supply
DRIVE-CLiQ communication is taking place. voltage.
The DC link voltage is too high.
Orange Orange DRIVE-CLiQ communication is being established.
Red This component has at least one fault. Remove the fault and
Note: acknowledge
The LED is controlled irrespective of the corresponding
messages being reconfigured.
Green/red (0.5 Hz) Firmware is being downloaded.
Green/red (2 Hz) - Firmware download has been completed. Wait for Carry out a POWER
POWER ON. ON
Green/orange Component recognition via LED is activated (p0124).
or Note:
Red/orange Both options depend on the LED status when module
recognition is activated via p0124 = 1.

DANGER
DC link voltage
Hazardous DC link voltages may be present at any time regardless of the state of the
"DC Link" LED. The warning information on the components must be carefully observed!

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4.12 Smart Line Modules

4.12.4 SLM (16 kW and higher) connections

Connections

;
7HUPLQDO

;;
;
'5,9(&/L4
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;
b9WHUPLQDODGDSWHU
8QORFNLQJ
SURWHFWLYHFRYHU (OHFWURQLFSRZHU
VXSSO\

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EXVEDUV
SURWHFWLYHFRYHU

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8 9 :

7\SHSODWH

3URWHFWLYH
;
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/LQHVXSSO\
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Figure 4-36 Connections,SLM 16 kW

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4.12 Smart Line Modules

4.12.5 This is how you remove an SLM

Overview
The activities that must be taken into account when replacing a Smart Line Module (SLM)
are subsequently described.
If a module has a hardware defect, then it must be replaced by an identical module.
Preconditions:
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

NOTICE
Electro-static discharge (ESD)
Before you touch the module, discharge yourself at the cabinet or at the ground terminal.

Procedure:
1. Switch-off the control: Completely switch off the system. Check that the system is in a no-
voltage condition and is locked-out so that it cannot be switched on again without the
appropriate authorization.
2. Access the control cabinet where the infeed module is located.
3. If it has not already been done, label all connectors/cables that lead to the module now.
Only then, can it be ensured 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
Risk of electric shock
A hazardous voltage is present for up to 5 minutes after the power supply has been
switched off. The protective cover must not be opened until this time has elapsed.
The warning information on the components must be carefully observed!

7. Open the protective cover of the DC link voltage using a suitable tool (e.g. a screwdriver).
8. Withdraw the 24 V terminal adapter.

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4.12 Smart Line Modules

9. Using a multimeter (set the measuring range to 1000 V DC) at the points DCP/DCN,
check that the DC link voltage is in a no-voltage condition. Only continue with the work
when it has been absolutely ensured that no voltage is present (no-voltage condition has
been established).

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10.Withdraw the red 24 V jumper plug.

11.Release the Torx screws of the DC link.

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12.Open the DC link busbars of the two modules.

13.Release the screws that are used to retain the module to the mounting plate.
14.Remove the protective conductor connection of the module.
15.Remove the module from the control cabinet.

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4.12 Smart Line Modules

4.12.6 This is how you install an SLM

Installing

DANGER
Risk of electric shock
A hazardous voltage is present for up to 5 minutes after the power supply has been
switched off. The protective cover must not be opened until this time has elapsed.
The warning information on the components must be carefully observed!

Procedure:
1. 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 Torx screws of the DC link busbars, observe the correct sequence.
6. Place the red jumper plug on the electronics busbar until it clicks into place.


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4.12 Smart Line Modules

7. Place the 24 V terminal adapter on the electronics power supply busbar until it clicks into
place.
8. Close the protective cover of the DC link voltage.
9. Reconnect the line supply connection X1 at the module.
10.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.

CAUTION

Ensure that all of the connectors and screws are correctly tightened and latched or
inserted.

WARNING

The components must only be operated when the protective cover of the DC link is closed.
Damaged components must not be used.

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4.13 Active Line Modules

4.13 Active Line Modules

4.13.1 ALM status displays

Status displays
The Active Line Module (ALM) has the following status displays, which provide information
about the module status:

LED state Description, cause Remedy

RDY DC LINK
OFF OFF Electronics power supply is missing or outside
permissible tolerance range.
Green OFF The 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- Check the line supply
CLiQ communication is taking place. voltage.
The DC link voltage is too high.
Orange Orange DRIVE-CLiQ communication is being established.
Red This component has at least one fault. Remove the fault and
Note: acknowledge.
The LED is controlled irrespective of the corresponding
messages being reconfigured.
Green/red - Firmware is being downloaded.
(0.5 Hz)
Green/red (2 Hz) - Firmware download has been completed. Wait for Carry out a POWER
POWER ON. ON.
Green/orange or Component recognition via LED is activated (p0124).
red/orange Note:
Both options depend on the LED status when module
recognition is activated via p0124 = 1.

DANGER
DC link voltage
Hazardous DC link voltages may be present at any time regardless of the state of the
"DC Link" LED. The warning information on the components must be carefully observed!

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4.13 Active Line Modules

4.13.2 ALM connections

Connections

;
7HUPLQDO

;;
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;
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FRYHU (OHFWURQLFV
SRZHUVXSSO\

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Figure 4-37 ALM connections

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4.13 Active Line Modules

4.13.3 This is how you remove an ALM

Overview
The activities that must be taken into account when replacing an Active Line Module (ALM)
are subsequently described.
If a module has a hardware defect, then it must be replaced by an identical module.
Preconditions:
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

NOTICE
Electro-static discharge (ESD)
Before you touch the module, discharge yourself at the cabinet or at the ground terminal.

Procedure:
1. Switch-off the control: Completely switch off the system. Check that the system is in a no-
voltage condition and is locked-out so that it cannot be switched on again without the
appropriate authorization.
2. Access the control cabinet where the infeed module is located.
3. If it has not already been done, label all connectors/cables that lead to the module now.
Only then, can it be ensured 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
Risk of electric shock
A hazardous voltage is present for up to 5 minutes after the power supply has been
switched off. The protective cover must not be opened until this time has elapsed.
The warning information on the components must be carefully observed!

7. Open the protective cover of the DC link voltage using a suitable tool (e.g. a screwdriver).
8. Withdraw the 24 V terminal adapter.

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4.13 Active Line Modules

9. Using a multimeter (set the measuring range to 1000 V DC) at the points DCP/DCN,
check that the DC link voltage is in a no-voltage condition. Only continue with the work
when it has been absolutely ensured that no voltage is present (no-voltage condition has
been established).

-XPSHUSOXJ

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10.Withdraw the red 24 V jumper plug.

11.Release the Torx screws of the DC link.

7RU[7

12.Open the DC link busbars of the two modules.

13.Release the screws that are used to retain the module to the mounting plate.
14.Remove the protective conductor connection of the module.
15.Remove the module from the control cabinet.

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4.13 Active Line Modules

4.13.4 This is how you install an ALM

Installing

DANGER
Risk of electric shock
A hazardous voltage is present for up to 5 minutes after the power supply has been
switched off. The protective cover must not be opened until this time has elapsed.
The warning information on the components must be carefully observed!

Procedure:
1. 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 Torx screws of the DC link busbars, observe the correct sequence.
6. Place the red jumper plug on the electronics busbar until it clicks into place.


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4.13 Active Line Modules

7. Place the 24 V terminal adapter on the electronics power supply busbar until it clicks into
place.
8. Close the protective cover of the DC link voltage.
9. Reconnect the line supply connection X1 at the module.
10.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.

CAUTION

Ensure that all of the connectors and screws are correctly tightened and latched or
inserted.

WARNING

The components must only be operated when the protective cover of the DC link is closed.
Damaged components must not be used.

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4.14 Sensor Modules Cabinet

4.14 Sensor Modules Cabinet

4.14.1 SMC10/SMC20 status displays

Status displays
Sensor Modules Cabinet-Mounted SMC10 and SMC20 have the following status displays,
which provide information about the module state:

LED Color State Description, cause Remedy

RDY - OFF Electronics power supply is missing or outside
permissible tolerance range.
Green Continuous light The component is ready for operation and
cyclic DRIVE-CLiQ communication is taking
place.
Orange Continuous light DRIVE-CLiQ communication is being
established.
Red Continuous light This component has at least one fault. Remove and
Note: acknowledge fault.
The LED is controlled irrespective of the
corresponding messages being reconfigured.
Green/red Flashes at Firmware is being downloaded.
0.5 Hz
Flashes at 2 Hz Firmware download has been completed. Carry out a POWER ON.
Wait for POWER ON
Green/orange or Flashing Component recognition via LED is activated
red/orange (p0144)
Note:
Both options depend on the LED status when
module recognition is activated via p0144 = 1.

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4.14 Sensor Modules Cabinet

4.14.2 SMC10/SMC20 connections

Connections

;
'5,9(&/L4LQWHUIDFH

;
(OHFWURQLFVSRZHUVXSSO\

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;
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Figure 4-38 SMC10/SMC20 connections

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4.14 Sensor Modules Cabinet

4.14.3 This is how you remove an SMC10/SMC20

Overview
The activities that must be taken into account when replacing an SMC10 or SMC20 are
subsequently described.
If the SMC10 or SMC20 has a hardware defect, then it must be replaced by an identical
module.
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

6ZLYHOWKHPRGXOHWRWKHIURQW

0RXQWLQJVOLGH

3XVKWKHOXJGRZQZDUGV

Figure 4-39 Removing the SMC10/SMC20

NOTICE
Electro-static discharge (ESD)
Before you touch the module, discharge yourself at the cabinet or at the ground terminal.

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4.14 Sensor Modules Cabinet

Procedure:
1. Withdraw the electronics power supply connector X524 and label.
2. Unscrew the encoder connecting cable at X520 or X521 / X531, if required, also the
shield connection.
3. Withdraw the DRIVE-CLiQ cable X500 and write the slot designation on the cable.
4. 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.

CAUTION

The 50 mm clearances above and below the components must be observed.

4.14.4 This is how you install an SMC10/SMC20

Installing
Procedure:
1. Place the components on the mounting rail.
2. Then, swivel the components on the mounting rail so that the mounting catches click into
place at the rear.
3. Slide the components along the mounting rail to either the left or right up to their 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.

CAUTION

The 50 mm clearances above and below the components must be observed.

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4.14 Sensor Modules Cabinet

4.14.5 SMC30 status displays

Status displays
The Sensor Module Cabinet-Mounted SMC30 has the following status displays, which
provide information about the module state:

LED Color State Description, cause Remedy

RDY - OFF Electronics power supply is missing or outside
permissible tolerance range.
Green Continuous light The component is ready and cyclic
DRIVE-CLiQ communication is taking place.
Orange Continuous light DRIVE-CLiQ communication is being
established.
Red Continuous light This component has at least one fault. Remove and
Note: acknowledge fault.
The LED is controlled irrespective of the
corresponding messages being reconfigured.
Green/red Flashes at 0.5 Hz Firmware is being downloaded.
Flashes at 2 Hz Firmware download has been completed. Carry out a POWER
Wait for POWER ON ON.
Green/orange Flashing Component recognition via LED is activated
or red/orange (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.
Power supply 5 V
Orange Continuous light Electronics power supply for measuring system -
available.
Power supply > 5 V.
Notice:
It must be ensured that it is permissible to
operate the connected encoder with a 24 V
power supply. If an encoder that is designed for
a 5 V supply is operated with a 24 V supply, this
can destroy the encoder electronics.

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4.14 Sensor Modules Cabinet

4.14.6 SMC30 connections

Connections

3UHVVOXJGRZQZDUGV

;
'5,9(&/L4LQWHUIDFH

;
(OHFWURQLFVSRZHUVXSSO\

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;
(QFRGHUV\VWHPLQWHUIDFH
+7/77/ZLWKWUDFNPRQLWRULQJ66,

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V\VWHPLQWHUIDFHV
+7/77/ZLWKWUDFN
PRQLWRULQJ66,

;

6KLHOG
3URWHFWLYHJURXQG FRQQHFWLRQ
FRQQHFWLRQ
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Figure 4-40 Connections SMC30

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4.14 Sensor Modules Cabinet

4.14.7 This is how you remove an SMC30

Overview
The activities that must be taken into account when replacing an SMC30 are subsequently
described.
If an SMC30 has a hardware defect, then it must be replaced by an identical module.
Preconditions:
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

6ZLYHOWKHPRGXOHWRWKHIURQW

0RXQWLQJVOLGH

5RWDWHDVFUHZGULYHUZLWKDZLGHEODGHWRPP
LQWKHVORWRIWKHPRXQWLQJVOLGHWKURXJKrRU
DOWHUQDWLYHO\SUHVVWKHOXJGRZQZDUGV

Figure 4-41 SMC30 removal

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4.14 Sensor Modules Cabinet

NOTICE
Electro-static discharge (ESD)
Before you touch the module, discharge yourself at the cabinet or at the ground terminal.

Procedure:
1. Before withdrawing it, label the connector X524 for the electronics power supply.
2. 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.

CAUTION

The 50 mm clearances above and below the components must be observed.

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4.14 Sensor Modules Cabinet

4.14.8 This is how you install an SMC30

Installing

5RWDWHDVFUHZGULYHUZLWKDZLGHEODGHWR
PPLQWKHVORWRIWKHPRXQWLQJVOLGHWKURXJKr
RUDOWHUQDWLYHO\SUHVVWKHOXJGRZQZDUGV

Figure 4-42 Installing SMC30

Procedure:
1. Place the components on the mounting rail.
2. Then, swivel the components on the mounting rail so that the mounting catches click into
place at the rear.
3. Slide the components along the mounting rail to either the left or right up to their 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.

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4.14 Sensor Modules Cabinet

CAUTION

The 50 mm clearances above and below the components must be observed.

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4.15 Sensor Modules External

4.15 Sensor Modules External

4.15.1 SME20 connections

Connections

(QFRGHUV\VWHP 3URWHFWLYHJURXQG
LQWHUIDFH FRQQHFWLRQ
SROH 01P

'5,9(&/L4
LQWHUIDFH

Figure 4-43 Connections SME20

4.15.2 This is how you remove an SME20 and install it again

Overview
The activities that must be taken into account when replacing an SME20 are subsequently
described.
If an 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

NOTICE
Electro-static discharge (ESD)
Before you touch the module, discharge yourself at the cabinet or at the ground terminal.

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4.15 Sensor Modules External

Procedure:
1. Release the encoder connecting cable of the SME20.
2. Withdraw the DRIVE-CLiQ cable from the SME20.
3. Release the protective conductor connection of the SME20.
4. Remove the defective SME20.

Installing
Procedure:
1. Now install the new SME20.
2. Screw on the protective conductor connection.
3. Reconnect the encoder connecting cable.
4. Connect the DRIVE-CLiQ cable.

CAUTION
Connections/cables
Only measuring systems where the measuring system power supply is not grounded may
be connected.
The maximum DRIVE-CLiQ cable length is 100 m.
The maximum encoder cable length is 3 m.
In order to guarantee the degree of protection, all of the plug connectors must be correctly
screwed into place or snapped into place.

4.15.3 SME25 connections

Connections
(QFRGHUV\VWHP 3URWHFWLYHJURXQGFRQQHFWLRQ
LQWHUIDFH 01P
SROH

'5,9(&/L4LQWHUIDFH

Figure 4-44 Connections SME25

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4.15 Sensor Modules External

4.15.4 This is how you remove an SME25 and install it again

Overview
The activities that must be taken into account when replacing an SME25 are subsequently
described.
If an SME25 has a hardware defect, then it must be replaced by an identical module.
Preconditions:
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

NOTICE
Electro-static discharge (ESD)
Before you touch the module, discharge yourself at the cabinet or at the ground terminal.

Procedure:
1. Release the encoder connecting cable of the SME25.
2. Withdraw the DRIVE-CLiQ cable from the SME25.
3. Release the protective conductor connection of the SME25.
4. Remove the 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.

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4.15 Sensor Modules External

CAUTION
Cables
The maximum DRIVE-CLiQ cable length is 100 m.
The maximum encoder cable length is 3 m.
In order to guarantee the degree of protection, all of the plug connectors must be correctly
screwed into place or snapped into place.

4.15.5 SME120 connections

Overview
The activities that must be taken into account when replacing an Sensor Module External
SME120 are subsequently described.
If the SME120 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.

Connections

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Figure 4-45 SME120 connections

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4.15 Sensor Modules External

4.15.6 This is how you remove an SME120 and install it again

Removing

NOTICE
Electro-static discharge (ESD)
Before you touch the module, discharge yourself at the ground terminal.

Procedure:
1. Release the encoder connecting cable X100 of the SME120.
2. 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 the new SME120 module.
2. Screw on the protective conductor connection.
3. Reconnect the temperature sensor at X200.
4. Reconnect the Hall sensor at X300.
5. Reconnect the encoder connecting cable.
6. Connect the DRIVE-CLiQ cable.

CAUTION

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.

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4.15 Sensor Modules External

4.15.7 SME125 connections

Overview
The activities that must be taken into account when replacing an Sensor Module External
SME125 are subsequently described.
If an SME125 has a hardware defect, then it must be replaced by an identical module.
Preconditions:
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.

Connections

3URWHFWLYHFRQGXFWRUFRQQHFWLRQ ;WHPSHUDWXUHVHQVRULQSXW
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Figure 4-46 SME125 connections

4.15.8 This is how you remove an SME125 and install it again

Removing

NOTICE
Electrostatic discharge (ESD)
Before you touch the module, discharge yourself at the ground terminal.

Procedure:
1. Release the encoder connecting cable X100 of the SME125
2. Withdraw the DRIVE-CLiQ cable from X500 of the SME125.
3. Release the temperature sensor input X200 of the SME125.
4. Release the protective conductor connection of the SME125.
5. Remove the defective SME125 module.

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Installing
Procedure:
1. Now install the new SME125 module.
2. Screw on the protective conductor connection.
3. Reconnect the temperature sensor at X200.
4. Reconnect the encoder connecting cable.
5. Connect the DRIVE-CLiQ cable.

CAUTION

The maximum DRIVE-CLiQ cable length is 100 m.

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.

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4.16 Terminal Modules

4.16 Terminal Modules

4.16.1 TM54F status displays

Status displays
The Terminal Module TM54F has the following status displays, which provide information
about the module state:

LED Color State Description, cause Remedy

RDY - Off Electronics power supply is missing or outside permissible
tolerance range.
Green Continuous The component is ready for operation and cyclic DRIVE-
light CLiQ communication is taking place.
Orange Continuous DRIVE-CLiQ communication is being established.
light
Red Continuous At least one fault is present in this component. Correct and
light Note: acknowledge
The LED is activated irrespective of whether the fault
corresponding messages have been reconfigured.
Green/red Flashing Firmware is being downloaded.
light 0.5 Hz
Flashing Firmware download has been completed. Wait for POWER Carry out a
light 2 Hz ON POWER ON
Green/orange Flashing Component recognition via LED is activated (p0154).
or light Note:
Red/orange Both options depend on the LED status when component
recognition is activated via p0154 = 1.
L1+, L2+, On The sensor power supply that can be dynamized is
functioning fault-free.
Red Continuous There is a fault in the sensor power supply that can be
light dynamized.
L3+ On Sensor power supply is functioning fault-free.
Red Continuous There is a fault in the sensor power supply.
light
LED Color State Description, cause Remedy

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LED Color State Description, cause Remedy

Fail-safe inputs / double inputs
F_DI z LED LED
(input x, x x+1 NC contact / NC contact 1): (z = 0..9, x = 0, 2, ..18)
(x+1)+, Red Continuous Different signal states at input x and x+1
(x+1)-) light
No signal at input x and no signal at input x+1
NC contact / NO contact 1): (z = 0..9, x = 0, 2, ..18)
Red Continuous Same signal states at input x and x+1
light
No signal at input x and a signal at input x+1
LED LED
x x+1 NC contact / NC contact 1): (z = 0..9, x = 0, 2, ..18)
Green Green Continuous A signal at input x and a signal at input x+1
light
NC contact / NO contact 1): (z = 0..9, x = 0, 2, ..18)
Green Green Continuous A signal at input x and no signal at input x+1
light
1) Inputs x+1 (DI 1+, 3+, .. 19+) can be set 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.

LED Color State Description, cause Remedy

Single digital inputs, not fail-safe
DI x Off No signal at digital input x (x = 20..23)
Green Continuous Signal at digital input x
light
Fail-safe digital outputs with associated readback channel
F_DO y Green Continuous Output y (y=0 .. 3) has a signal
(0+..3+, light
0-..3-)
Readback input DI 2y for output F_DO y (y = 0..3) for test stop.
The status of the LEDs also depends on the type of external circuit.
DI 2y Off One of the two output lines y+ or y- or both lines of output y
have a signal
Green Continuous Both output lines y+ and y- have no signal
light

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4.16 Terminal Modules

4.16.2 TM54F connections

Connections

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Figure 4-47 TM54F connections

4.16.3 This is how you remove an TM54F

Overview
The activities that must be taken into account when replacing an TM54F are subsequently
described.
If a TM54F has a hardware defect, then it must be replaced by an identical module.
Preconditions:
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.

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4.16 Terminal Modules

Removing

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Figure 4-48 TM54F removal

NOTICE
Electro-static discharge (ESD)
Before you touch the module, discharge yourself at the cabinet or at the ground terminal.

Procedure:
1. Label connectors X514 and X524 for the sensor and electronics power supply prior to
withdrawing them.
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.

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4.16 Terminal Modules

4. Release the protective conductor connection and write the position designation on the
cable.
5. If necessary, unscrew the shield connection.
6. Slide the lug downwards.
7. Swivel the module to the front to remove it.

CAUTION

The 50 mm clearances above and below the components must be observed.

4.16.4 This is how you install a TM54F

Installing
Procedure:
1. Place the components on the mounting rail.
2. Then, swivel the components on the mounting rail so that the mounting catches click into
place at the rear.
3. Slide the components along the mounting rail to either the left or right up to their final
position.
4. Screw on the protective conductor connection.
5. If necessary, screw on the shield connection.
6. Insert 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.

CAUTION

The 50 mm clearances above and below the components must be observed.

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4.17 Hub Modules

4.17 Hub Modules

4.17.1 DMC20 status displays

Status displays
The DRIVE-CLiQ Hub Module DMC20 has the following status displays, which provide
information about the module state:

LED Color State Description, cause Remedy

RDY - Off Electronics power supply is missing or outside
permissible tolerance range.
Green Continuous light The component is ready for operation and
cyclic DRIVE-CLiQ communication is taking
place.
Orange Continuous light DRIVE-CLiQ communication is being
established.
Red Continuous light This component has at least one fault. Remove and
Note: acknowledge fault.
The LED is controlled irrespective of the
corresponding messages being reconfigured.
Green/red Flashes at 0.5 Hz Firmware is being downloaded.
Flashes at 2 Hz Firmware download has been completed. Wait Carry out a POWER ON.
for POWER ON
Green/orange Flashing Component recognition via LED is activated
or red/orange (p0154).
Note:
Both options depend on the LED status when
activated via p0154 = 1.

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4.17 Hub Modules

4.17.2 DMC20 connections

Connections

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Figure 4-49 Connections DMC20

4.17.3 This is how you remove a DMC20

Overview
The activities that must be taken into account when replacing a DMC20 are subsequently
described.
If a DMC20 has a hardware defect, then it must be replaced by an identical module.
Preconditions:
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.

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4.17 Hub Modules

Removing

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3UHVV
OXJGRZQZDUGV

Figure 4-50 DMC20 removal

NOTICE
Electro-static discharge (ESD)
Before you touch the module, discharge yourself at the cabinet or at the ground terminal.

Procedure:
1. Before withdrawing it, label the connector X524 for the electronics power supply.
2. 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.
4. Slide the lug downwards.
5. Swivel the module to the front to remove it.

CAUTION

The 50 mm clearances above and below the components must be observed.

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4.17 Hub Modules

4.17.4 This is how you install a DMC20

Installing
Procedure:
1. Place the components on the mounting rail.
2. Then, swivel the components on the mounting rail so that the mounting catches click into
place at the rear.
3. Slide the components along the mounting rail to either the left or right up to their final
position.
4. Screw on the protective conductor connection.
5. Screw on the encoder connecting cable to X520.
6. Insert the DRIVE-CLiQ cable at X500 X505.
7. Insert connector X524 for the electronics power supply.

CAUTION

The 50 mm clearances above and below the components must be observed.

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4.17 Hub Modules

4.17.5 DME20 connections

Connections
The component has degree of protection IP67 and is especially suitable for applications
which require DRIVE-CLiQ nodes to be removed in groups, without interrupting the DRIVE-
CLiQ line and therefore the data exchange.

;
;

;

; ;

;
;

;

Figure 4-51 DME20 connections

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4.17.6 This is how you mount a DME20

Mounting
Procedure:
1. Place the drilling pattern on the mounting surface.
The mounting surfaces must be bare metal.


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Figure 4-52 DME20 dimensions

2. Drill the holes with 5.3 or M5 threads.

3. Tighten the component with a tightening torque of 6.0 Nm.

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4.17.7 Connection to X524 electronics power supply

Specifications for using the DME20 with UL approval

Pin assignment of the cable for connection to X524:

Pin Designation Technical specifications

1 (brown) 1) Electronics power supply The connection voltage of 20.4 V 28.8 V

2 (white) 1) Electronics power supply refers to the (terminal) voltage at the
   DME20.
3 (black) 1) Electronics ground
 This must be observed when selecting the
4 (blue) 1) Electronics ground cable cross-section and supply cable
5 (gray) 1) Not connected internally length:
Pins 1 and 2: jumpered internally
Pins 3 and 4: jumpered internally

1) The colors stated refer to the cable specified above

Pre-assembled cables
Phoenix Contact (www.phoenixcontact.com)
Sensor/actuator cable, 5-pole, variable cable
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

Cables to be assembled by the user

Cable Connector
Cable ring, PUR/PVC black, 5-pole Sensor/actuator connector, socket, straight, 5-pin, M12, A-coded
Conductor colors: brown/white/blue/black/gray Screw connection, metal knurl,
Length of cable: 100 m Cable gland Pg9
SAC-5P-100.0-186/0.75 SACC-M12FS-5CON-PG9-M
order number: 1535590 order number: 1681486
Phoenix Contact (www.phoenixcontact.com)

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Spare parts and accessories 5
Order data for accessories
The following accessories are available:

Component Order No. Description

CompactFlash Card (empty) 1 GB 6FC5313-5AG00-0AA1 for SIMOTION / SINUMERIK
USB FlashDrive 2 GB 6ES7648-0DC40-0AA0 USB2.0, bootable

See also
SiemensSpares-on-web (https://b2b-extern.automation.siemens.com/spares_on_web)

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Spare parts and accessories
5.1 Spare parts for the S120 Combi

5.1 Spare parts for the S120 Combi

S120 Combi spare parts list

An overview of the available S120 Combi spare parts is provided in the table below:

Designation MLFB
S120 Combi front cover 6SL3161-3FP00-0AA0
S120 Combi guiding frame for DRIVE-CLiQ cables 6SL3161-3EP00-0AA0
S120 Combi DC link lateral cover 6SL3161-3AP00-0AA0
S120 Combi internal fan 6SL3161-0IP00-0AA0
S120 Combi external fan unit 6SL3161-0EP00-0AA0
S120 Combi accessories pack 6SL3161-8AP00-0AA0
Contents:
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 connection terminals for motor cables
Shield connection terminal for EP signal cables

Available spare parts

You will find spare parts for all of the other components and modules in the Internet under:
Available spare parts (http://support.automation.siemens.com/WW/view/en/16612315)

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ESD guidelines A
A.1 RI suppression measures

Shielded signal cables

To ensure safe, interference-free system operation, it is essential to use the cables specified
in the individual diagrams. Both ends of the shield must always be conductively connected to
the equipment housing.
Exception:
If third-part devices are connected (printers, programming devices, etc.), you can also use
standard shielded cables, which are connected at one end.
These external devices may not be connected to the control during normal operation.
However, if the system cannot be operated without them, then the cable shields must be
connected at both ends. Furthermore, the external device must be connected to the control
via an equipotential bonding cable.

Rules for routing cables

In order to achieve the best-possible noise immunity for the complete system (control, power
section, machine) the following EMC measures must be observed:
Signal cables and load cables must be routed at the greatest possible distance from one
another.
Only use Siemens signal cables for connecting to and from the NC or PLC.
Signal cables may not be routed close to strong external magnetic fields (e.g. motors and
transformers).
Pulse-carrying HC/HV cables must always be laid completely separate from all other
cables.
If signal cables cannot be laid at a sufficient distance from other cables, then they must
be installed in shielded cable ducts (metal).
The clearance (interference injection area) between the following lines must be kept to a
minimum:
Signal cable and signal cable
Signal lead and associated equipotential bonding lead
Equipotential bonding lead and protective conductor routed together

See also
For further information about radio interference suppression measures and the connecting
shielded leads:
Configuration Manual, EMC Guidelines

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ESD guidelines
A.2 ESD measures

A.2 ESD measures

CAUTION

The modules contain electrostatically sensitive devices. Discharge yourself of electrostatic

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

NOTICE
Handling ESDS modules:
When handling electrostatically sensitive devices, make sure that operator, workplace
and packing material are properly grounded.
Generally, electronic modules may 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.
Components may only be touched under the following conditions:
You are permanently grounded by means of an ESD armband.
You are wearing ESD boots or ESD boots with grounding strips in conjunction with
ESD flooring.
Boards/modules must only be placed on conductive surfaces (table with ESDS surface,
conductive ESDS foam, ESDS packaging, ESDS transport container).
Exceptions:
Modules with their own power supply units (e.g. batteries) are an exception. These may not
be placed on conductive surfaces, as this might result in short circuits and thus destroy the
component on the module.
Never place modules in the vicinity of display units, monitors, or television sets
(minimum distance to the 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 may only be carried out on modules under the following conditions:
The measuring device is grounded (via a protective conductor).
When floating measuring equipment is used, the probe is briefly discharged before
making measurements (e.g. a bare-metal control housing is touched).

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Appendix B
B.1 List of abbreviations

Abbreviation Meaning Explanation

ALM Active Line Module
ASCII American Standard Code for Information
Interchange
AUTO "Automatic" operating mode
BAG Mode group
BERO Proximity limit switch with feedback oscillator
BICO Binector Connector Interconnection technology for the drive
CEC Cross Error Compensation
CNC Computerized Numerical Control
DB Data Block in the PLC
DBB Data Block Byte in the PLC
dbSI drive based Safety Integrated Safety functions integrated in the drive
DBW Data Block Word in the PLC
DBX Data Block Bit in the PLC
DDE Dynamic Data Exchange
DIN Deutsche Industrie Norm [German Industry Standard]
DO Drive object
DRAM Dynamic Random Access Memory Dynamic memory block
DRF Differential Resolver Function Differential resolver function (handwheel)
DRY DRY run DRY run feedrate
ESR Extended Stop and Retract
FIFO First In - First Out Method of storing and retrieving data in a memory
GUD Global User Data
HD Hard Disk
HSC High-Speed Cutting
HW Hardware
IGBT Insulated Gate Bipolar Transistor
IME Input Method Editor Entering Asian characters
INC Increment
INI Initializing Data
IPO Interpolator
IRT Isochronous Real Time Isochronous communication
ISO International Standardization Organisation International Standards Organization
JOG "Jogging" operating mode Jogging via the direction keys
LEC Leadscrew Error Compensation

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Appendix
B.1 List of abbreviations

Abbreviation Meaning Explanation

LED Light Emitting Diode
LUD Local User Data
MAIN Main program Main program (OB1, PLC)
MB Megabyte
MCP Machine Control Panel
MCS Machine Coordinate System
MD Machine data
MDA "Manual Data Automatic" operating mode Manual input
MLFB Machine-Readable Product Code
MPF Main Program File Main program (NC part program)
MPI Multi Point Interface
NCK Numerical Control Kernel
NCU Numerical Control Unit NCK hardware unit
OEM Original Equipment Manufacturer
OPI Operator Panel Interface
PCU Programmable Control Unit
PG Programming device
PI Program Instance
PLC Programmable Logic Control
POU Program organization unit in the PLC user program
PPU Panel Processing Unit Panel-based control
PZD Process data for drives
QEC Quadrant Error Compensation
REF POINT "Reference point approach" in JOG mode
REPOS "Repositioning" in JOG mode
RPA R-Parameter Active Memory area on the NCK for R parameter
numbers
RTC Real Time Clock
SBL Single Block
SBR Subroutine Subroutine (PLC)
SD Setting Data
SDB System Data Block
SEA Setting Data Active Identifier (file type) for setting data
SK Softkey
SLM Smart Line Module
SPF Subprogram file Subprogram (NC)
SRAM Static Random Access Memory Static memory block
SW Software
TEA Testing Data Active Identifier for machine data
TM Tool Management
TMMG Tool Magazine Management
TO Tool Offset

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 Appendix
B.1 List of abbreviations

Abbreviation Meaning Explanation

TOA Tool Offset Active Identifier (file type) for tool offsets
VPM Voltage Protection Module
VSM Voltage Sensing Module
WCS Workpiece Coordinate System
WO Work Offset
ZOA Zero Offset Active Identifier (file type) for work offset data

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Appendix
B.2 Documentation overview

B.2 Documentation overview

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Index

F
B Fan, internal
Backing up log files, 21 Motor Module Booksize Compact, 148
S120 Combi, 133

C
L
CompactFlash Card, 209
Connections LED status
ALM, 174 Front of the PPU, 74
DMC20, 202 MCP 310C PN, 92
DME20, 205 MCP 483C PN, 96
DMM, 159 NX10.3, 110
DMM Booksize Compact, 146 Rear of the PPU, 75
NX10.3, 111 S120 Combi Power Modules, 117
S120 Combi 3 axes, 119 SINAUT MD720-3, 84
S120 Combi 4 axes, 121 License key, 55
SLM 16kW, 168 Control, 61
SLM 5kW, 10kW, 166 Web License Manager, 62
SMC10, 180 Licenses
SMC20, 180 Save as backup, 61
SMC30, 184 Licensing a CNC option, 55
SME120, 192 Logbook entry, 66
SME125, 194
SME20, 189
SME25, 190 M
SMM, 152 Mini boot system, 49
SMM Booksize Compact, 145
TM54F, 198
P
D Protective conductor connection, 116
Data backup, 44
R
E Repair and Service Contract (RSC), 64
RI suppression measures, 211
EMC measures, 211 Rules for routing cables, 211
End User Notification Administration (EUNA), 64
ESD measures, 212
EUNA S
Configuration file, 69
Machine identity, 64 S120 Combi
Machine logbook, 64 Cleaning the heat sink, 141
Installing an internal fan, 136
Remove the air baffle plate, 141

Hardware and Software

Service Manual, 03/2011, 6FC5397-5DP40-0BA0 217
Index

Removing the internal fan, 133

Spare parts, 210
Safety information
S120 Combi modules, 126
S120 Combi Modules, 124
Shield support, 116
Shielded cables, 211
SIM card, 85
SINAUT modem, 85
Spare parts, S120 Combi, 210
Switch
S1 on the I/O module, 104, 109
S2 on the MCP 310C PN, 96
S2 on the MCP 483C PN, 100

U
USB FlashDrive, 44, 209

W
Web License Manager, 62

Hardware and Software

218 Service Manual, 03/2011, 6FC5397-5DP40-0BA0