Preface

Fundamental safety
instructions 1

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

Spare parts and accessories 5

Service Manual

Appendix A

Valid for:
SINUMERIK 828D
SINUMERIK 828D BASIC

CNC software V4.7 SP2

03/2016
6FC5397-5DP40-5BA3
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.

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

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

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

NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be
used. A notice warning 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, 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 complied with. The information in the relevant documentation must be observed.

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

Siemens AG Document order number: 6FC5397-5DP40-5BA3 Copyright © Siemens AG 2010 - 2016.

Division Digital Factory Ⓟ 03/2016 Subject to change All rights reserved
Postfach 48 48
90026 NÜRNBERG
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 at: www.siemens.com/automation/support
(http://www.siemens.com/sinumerik/support)
● Ordering documentation/overview of documentation
● Additional links to download documents
● Using documentation online (finding and searching in manuals/information)
Please send email any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to: [email protected]
(mailto:[email protected])

mySupport-documentation
In the Siemens Industry Online Support, you can find information to compile your own individual
documentation based on Siemens content: www.siemens.com/sinumerik/docu (http://
www.siemens.com/sinumerik/docu)

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

Software and hardware

Service Manual, 03/2016, 6FC5397-5DP40-5BA3 3
Preface

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

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 at:
www.siemens.com/sinumerik/contact (http://www.siemens.com/sinumerik/contact)

EC Declaration of Conformity
The EC Declaration of Conformity for the EMC Directive can be found in the Internet under
the following link: Certificates (http://support.automation.siemens.com/WW/view/de/
10805517/134200)

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4 Service Manual, 03/2016, 6FC5397-5DP40-5BA3
Table of contents

Preface.........................................................................................................................................................3
1 Fundamental safety instructions...................................................................................................................9
1.1 General safety instructions.......................................................................................................9
1.2 Handling electrostatic sensitive devices (ESD)......................................................................13
1.3 Industrial security...................................................................................................................14
1.4 Residual risks of power drive systems...................................................................................15
2 System description.....................................................................................................................................17
2.1 System overview....................................................................................................................17
2.2 PPU versions.........................................................................................................................19
3 Service cases - software............................................................................................................................23
3.1 Backing up user data.............................................................................................................24
3.1.1 This is how you backup user data..........................................................................................24
3.1.2 This is how you load the user data backup............................................................................26
3.2 Generating a commissioning archive.....................................................................................29
3.2.1 This is how you generate a setup archive on an external data storage medium...................29
3.2.2 This is how you read a setup archive from an external data storage medium.......................32
3.2.3 This is how you generate a setup archive on the system CompactFlash card .....................34
3.2.4 This is how you read in a setup archive from the system CompactFlash card......................35
3.3 Software backup....................................................................................................................38
3.3.1 This is how you generate a software backup.........................................................................38
3.3.2 This is how you install a software backup..............................................................................41
3.4 Updating the software............................................................................................................46
3.5 Generating a boot system on the CompactFlash card...........................................................50
3.5.1 This is how you create a boot system....................................................................................50
3.5.2 This is how you install a software backup using the boot system..........................................53
3.6 Licensing................................................................................................................................56
3.6.1 Licensing after replacing the system CompactFlash Card.....................................................56
3.6.2 This is how you license a CNC option....................................................................................56
3.6.3 This is how you determine missing licenses/options..............................................................59
3.6.4 This is how you generated a new license key........................................................................60
3.6.5 This is how you display the actual license key.......................................................................62
3.7 Machine registration...............................................................................................................66
3.7.1 This is how you generate the machine logbook.....................................................................66
3.7.2 This is how you make a new entry in the logbook..................................................................68
3.7.3 This is how you save the machine identity.............................................................................70
3.7.4 This is how you send the machine identity.............................................................................72

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Table of contents

4 Service cases - hardware...........................................................................................................................73

4.1 Safety instructions for the hardware.......................................................................................75
4.1.1 Safety instructions for the hardware.......................................................................................75
4.2 PPU 2xy.3 .............................................................................................................................77
4.2.1 PPU status displays...............................................................................................................77
4.2.2 This is how you remove the PPU...........................................................................................79
4.2.3 This is how you install the PPU..............................................................................................80
4.3 Replacing the system CompactFlash Card............................................................................82
4.3.1 This is how you remove the system CompactFlash Card......................................................82
4.3.2 This is how you insert the system CompactFlash Card.........................................................83
4.4 Replacing the front cover.......................................................................................................85
4.4.1 This is how you remove the front cover.................................................................................85
4.4.2 This is how you install the front cover....................................................................................86
4.5 Machine control panels..........................................................................................................87
4.5.1 This is how you remove MCP 483 USB/MCP 310 USB.........................................................87
4.5.2 This is how you install the MCP 483 USB/MCP 310 USB ....................................................88
4.5.3 Status display MCP interface PN...........................................................................................89
4.5.4 This is how you remove the MCP interface PN......................................................................90
4.5.5 This is how you install the MCP interface PN........................................................................91
4.5.6 Status displays, MCP 483C PN.............................................................................................92
4.5.7 This is how you remove the MCP 483C PN...........................................................................93
4.5.8 This is how you install the MCP 483C PN .............................................................................95
4.5.9 Status displays MCP 310C PN..............................................................................................96
4.5.10 This is how you remove the MCP 310C PN...........................................................................97
4.5.11 This is how you install the MCP 310C PN .............................................................................99
4.5.12 This is how you replace the rotary switch............................................................................100
4.6 I/O modules..........................................................................................................................103
4.6.1 Status displays PP 72/48D PN.............................................................................................103
4.6.2 This is how you remove the PP 72/48D PN.........................................................................104
4.6.3 This is how you install the PP 72/48D PN ...........................................................................106
4.6.4 Status displays PP 72/48D 2/2A PN....................................................................................107
4.6.5 This is how you remove the PP 72/48D 2/2A PN.................................................................108
4.6.6 This is how you install the PP 72/48D 2/2A PN ..................................................................110
4.7 Expansion modules NX10.3 / NX15.3..................................................................................111
4.7.1 NX10.3 / NX15.3 status displays..........................................................................................111
4.7.2 NX10.3 / NX15.3 connections..............................................................................................112
4.7.3 This is how you remove the NX10.3 / NX15.3.....................................................................112
4.7.4 This is how you install the NX10.3 / NX15.3........................................................................114
4.8 Installing SINAMICS components........................................................................................115
4.8.1 Releasing with a screwdriver...............................................................................................115
4.8.2 Protective conductor connection and shield support............................................................115
4.9 Control Unit CU320-2 PN and CU310-2 PN........................................................................117
4.9.1 CU320-2 PN status displays................................................................................................117
4.9.2 CU320-2 PN connections.....................................................................................................120
4.9.3 This is how you remove the CU320-2 PN............................................................................121
4.9.4 This is how you install the CU320-2 PN...............................................................................122
4.9.5 CU310-2 PN status displays................................................................................................122

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 Table of contents

4.9.6 CU310-2 PN connections.....................................................................................................126

4.9.7 This is how you remove the CU310-2 PN............................................................................127
4.9.8 This is how you install the CU310-2 PN...............................................................................129
4.10 SINAMICS S120 Combi.......................................................................................................130
4.10.1 S120 Combi status displays.................................................................................................130
4.10.2 Connections, 3-axis module.................................................................................................132
4.10.3 Connections, 4-axis module.................................................................................................134
4.10.4 How to mount an S120 Combi Power Module.....................................................................135
4.10.5 This is how you attach the drip protection............................................................................137
4.10.6 This is how you remove the front panel...............................................................................138
4.10.7 This is how you open the DC link cover...............................................................................139
4.10.8 This is how you connect the DC link busbars and 24 V busbars ........................................142
4.10.9 To connect the second component......................................................................................145
4.10.10 This is how you remove the internal fan...............................................................................147
4.10.11 This is how you install the internal fan.................................................................................150
4.10.12 This is how you install the external fan................................................................................151
4.10.13 This is how you clean the heat sink of the S120 Combi.......................................................155
4.11 Motor Module Booksize Compact format.............................................................................159
4.11.1 Motor Module Booksize Compact status displays................................................................159
4.11.2 Motor Module connections...................................................................................................160
4.11.3 This is how you mount a Motor Module Booksize Compact................................................162
4.11.4 This is how you replace the fan on a Motor Module Booksize Compact..............................163
4.12 Single Motor Modules..........................................................................................................167
4.12.1 SMM status displays............................................................................................................167
4.12.2 SMM connections.................................................................................................................168
4.12.3 This is how you remove a Motor Module.............................................................................169
4.12.4 This is how you install a Motor Module................................................................................171
4.13 Double Motor Modules.........................................................................................................174
4.13.1 DMM status displays............................................................................................................174
4.13.2 DMM connections................................................................................................................175
4.13.3 This is how you remove a Motor Module.............................................................................176
4.13.4 This is how you install a Motor Module................................................................................178
4.14 Smart Line Modules.............................................................................................................181
4.14.1 SLM (< 16 kW) status displays.............................................................................................181
4.14.2 SLM (< 16 kW) connections.................................................................................................182
4.14.3 SLM (16 kW and higher) status displays..............................................................................183
4.14.4 SLM (16 kW and higher) connections..................................................................................184
4.14.5 This is how you remove an SLM..........................................................................................185
4.14.6 This is how you install an SLM.............................................................................................187
4.15 Active Line Modules.............................................................................................................189
4.15.1 ALM status displays.............................................................................................................189
4.15.2 ALM connections..................................................................................................................190
4.15.3 This is how you remove an ALM..........................................................................................191
4.15.4 This is how you install an ALM.............................................................................................193
4.16 Sensor Modules Cabinet......................................................................................................195
4.16.1 SMC10/SMC20 status displays............................................................................................195
4.16.2 SMC10/SMC20 connections................................................................................................196
4.16.3 This is how you remove an SMC10/SMC20........................................................................196
4.16.4 This is how you install an SMC10/SMC20...........................................................................198

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Table of contents

4.16.5 SMC30 status displays.........................................................................................................199

4.16.6 SMC30 connections.............................................................................................................200
4.16.7 This is how you remove an SMC30.....................................................................................200
4.16.8 This is how you install an SMC30........................................................................................202
4.16.9 SMC40 status displays.........................................................................................................203
4.16.10 SMC40 connections.............................................................................................................204
4.16.11 This is how you remove an SMC40.....................................................................................204
4.16.12 This is how you install an SMC40........................................................................................206
4.17 Sensor Modules External.....................................................................................................207
4.17.1 SME20 connections.............................................................................................................207
4.17.2 This is how you remove an SME20 and install it again........................................................207
4.17.3 SME25 connections.............................................................................................................208
4.17.4 This is how you remove an SME25 and install it again........................................................208
4.17.5 SME120 connections...........................................................................................................210
4.17.6 This is how you remove an SME120 and install it again......................................................210
4.17.7 SME125 connections...........................................................................................................211
4.17.8 This is how you remove an SME125 and install it again......................................................212
4.18 Terminal Modules.................................................................................................................213
4.18.1 TM54F status displays.........................................................................................................213
4.18.2 TM54F connections..............................................................................................................215
4.18.3 This is how you remove an TM54F......................................................................................216
4.18.4 This is how you install a TM54F...........................................................................................217
4.18.5 TM120 status displays.........................................................................................................217
4.18.6 TM120 safety instructions....................................................................................................218
4.18.7 TM120 connections..............................................................................................................219
4.18.8 This is how you remove a TM120 and install it again..........................................................220
4.19 Hub Modules........................................................................................................................221
4.19.1 DMC20 status displays........................................................................................................221
4.19.2 DMC20 connections.............................................................................................................222
4.19.3 This is how you remove a DMC20.......................................................................................222
4.19.4 This is how you install a DMC20..........................................................................................223
4.19.5 DME20 connections.............................................................................................................224
4.19.6 This is how you mount a DME20.........................................................................................225
4.19.7 Connection to X524 electronics power supply ....................................................................226
4.20 MODEM MD720...................................................................................................................227
4.20.1 Status displays MODEM MD720..........................................................................................227
4.20.2 Replace SIM card.................................................................................................................227
4.20.3 This is how you load the factory settings.............................................................................228
5 Spare parts and accessories....................................................................................................................231
A Appendix...................................................................................................................................................233
A.1 Information about third-party software used.........................................................................233
A.2 List of abbreviations.............................................................................................................235
A.3 Documentation overview......................................................................................................238
Index.........................................................................................................................................................239

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8 Service Manual, 03/2016, 6FC5397-5DP40-5BA3
Fundamental safety instructions 1
1.1 General safety instructions

DANGER
Danger to life due to live parts and other energy sources
Death or serious injury can result when live parts are touched.
● Only work on electrical devices when you are qualified for this job.
● Always observe the country-specific safety rules.
Generally, six steps apply when establishing safety:
1. Prepare for shutdown and notify all those who will be affected by the procedure.
2. Disconnect the machine from the supply.
– Switch off the machine.
– Wait until the discharge time specified on the warning labels has elapsed.
– Check that it really is in a no-voltage condition, from phase conductor to phase
conductor and phase conductor to protective conductor.
– Check whether the existing auxiliary supply circuits are de-energized.
– Ensure that the motors cannot move.
3. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or
water.
4. Isolate or neutralize all hazardous energy sources by closing switches, grounding or short-
circuiting or closing valves, for example.
5. Secure the energy sources against switching on again.
6. Ensure that the correct machine is completely interlocked.
After you have completed the work, restore the operational readiness in the inverse sequence.

WARNING
Danger to life through a hazardous voltage when connecting an unsuitable power supply
Touching live components can result in death or severe injury.
● Only use power supplies that provide SELV (Safety Extra Low Voltage) or PELV-
(Protective Extra Low Voltage) output voltages for all connections and terminals of the
electronics modules.

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Service Manual, 03/2016, 6FC5397-5DP40-5BA3 9
Fundamental safety instructions
1.1 General safety instructions

WARNING
Danger to life when live parts are touched on damaged devices
Improper handling of devices can cause damage.
For damaged devices, hazardous voltages can be present at the enclosure or at exposed
components; if touched, this can result in death or severe injury.
● Ensure compliance with the limit values specified in the technical data during transport,
storage and operation.
● Do not use any damaged devices.

WARNING
Danger to life through electric shock due to unconnected cable shields
Hazardous touch voltages can occur through capacitive cross-coupling due to unconnected
cable shields.
● As a minimum, connect cable shields and the cores of cables that are not used at one end
at the grounded housing potential.

WARNING
Danger to life due to electric shock when not grounded
For missing or incorrectly implemented protective conductor connection for devices with
protection class I, high voltages can be present at open, exposed parts, which when touched,
can result in death or severe injury.
● Ground the device in compliance with the applicable regulations.

WARNING
Danger to life due to fire spreading if housing is inadequate
Fire and smoke development can cause severe personal injury or material damage.
● Install devices without a protective housing in a metal control cabinet (or protect the device
by another equivalent measure) in such a way that contact with fire is prevented.
● Ensure that smoke can only escape via controlled and monitored paths.

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10 Service Manual, 03/2016, 6FC5397-5DP40-5BA3
 Fundamental safety instructions
1.1 General safety instructions

WARNING
Danger to life through unexpected movement of machines when using mobile wireless
devices or mobile phones
Using mobile wireless devices or mobile phones with a transmit power > 1 W closer than
approx. 2 m to the components may cause the devices to malfunction, influence the functional
safety of machines therefore putting people at risk or causing material damage.
● Switch the wireless devices or mobile phones off in the immediate vicinity of the
components.

WARNING
Danger to life due to fire if overheating occurs because of insufficient ventilation clearances
Inadequate ventilation clearances can cause overheating of components with subsequent
fire and smoke. This can cause severe injury or even death. This can also result in increased
downtime and reduced service lives for devices/systems.
● Ensure compliance with the specified minimum clearance as ventilation clearance for the
respective component.

WARNING
Danger to life when safety functions are inactive
Safety functions that are inactive or that have not been adjusted accordingly can cause
operational faults on machines that could lead to serious injury or death.
● Observe the information in the appropriate product documentation before commissioning.
● Carry out a safety inspection for functions relevant to safety on the entire system, including
all safety-related components.
● Ensure that the safety functions used in your drives and automation tasks are adjusted
and activated through appropriate parameterizing.
● Perform a function test.
● Only put your plant into live operation once you have guaranteed that the functions relevant
to safety are running correctly.

Note
Important safety notices for Safety Integrated functions
If you want to use Safety Integrated functions, you must observe the safety notices in the Safety
Integrated manuals.

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Service Manual, 03/2016, 6FC5397-5DP40-5BA3 11
Fundamental safety instructions
1.1 General safety instructions

WARNING
Danger to life or malfunctions of the machine as a result of incorrect or changed
parameterization
As a result of incorrect or changed parameterization, machines can malfunction, which in turn
can lead to injuries or death.
● Protect the parameterization (parameter assignments) against unauthorized access.
● Respond to possible malfunctions by applying suitable measures (e.g. EMERGENCY
STOP or EMERGENCY OFF).

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12 Service Manual, 03/2016, 6FC5397-5DP40-5BA3
 Fundamental safety instructions
1.2 Handling electrostatic sensitive devices (ESD)

1.2 Handling electrostatic sensitive devices (ESD)

Electrostatic sensitive devices (ESD) are individual components, integrated circuits, modules
or devices that may be damaged by either electric fields or electrostatic discharge.

NOTICE
Damage through electric fields or electrostatic discharge
Electric fields or electrostatic discharge can cause malfunctions through damaged individual
components, integrated circuits, modules or devices.
● Only pack, store, transport and send electronic components, modules or devices in their
original packaging or in other suitable materials, e.g conductive foam rubber of aluminum
foil.
● Only touch components, modules and devices when you are grounded by one of the
following methods:
– Wearing an ESD wrist strap
– Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring
● Only place electronic components, modules or devices on conductive surfaces (table with
ESD surface, conductive ESD foam, ESD packaging, ESD transport container).

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Fundamental safety instructions
1.3 Industrial security

1.3 Industrial security

Note
Industrial security
Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, solutions, machines, equipment and/or networks. They are
important components in a holistic industrial security concept. With this in mind, Siemens’
products and solutions undergo continuous development. Siemens recommends strongly that
you regularly check for product updates.
For the secure operation of Siemens products and solutions, it is necessary to take suitable
preventive action (e.g. cell protection concept) and integrate each component into a holistic,
state-of-the-art industrial security concept. Third-party products that may be in use should also
be considered. For more information about industrial security, visit Hotspot-Text (http://
www.siemens.com/industrialsecurity).
To stay informed about product updates as they occur, sign up for a product-specific
newsletter. For more information, visit Hotspot-Text (http://support.automation.siemens.com).

WARNING
Danger as a result of unsafe operating states resulting from software manipulation
Software manipulation (e.g. by viruses, Trojan horses, malware, worms) can cause unsafe
operating states to develop in your installation which can result in death, severe injuries and/
or material damage.
● Keep the software up to date.
You will find relevant information and newsletters at this address (http://
support.automation.siemens.com).
● Incorporate the automation and drive components into a holistic, state-of-the-art industrial
security concept for the installation or machine.
You will find further information at this address (http://www.siemens.com/
industrialsecurity).
● Make sure that you include all installed products into the holistic industrial security concept.

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14 Service Manual, 03/2016, 6FC5397-5DP40-5BA3
 Fundamental safety instructions
1.4 Residual risks of power drive systems

1.4 Residual risks of power drive systems

The control and drive components of a drive system are approved for industrial and commercial
use in industrial line supplies. Their use in public line supplies requires a different configuration
and/or additional measures.
These components may only be operated in closed housings or in higher-level control cabinets
with protective covers that are closed, and when all of the protective devices are used.
These components may only be handled by qualified and trained technical personnel who are
knowledgeable and observe all of the safety instructions on the components and in the
associated technical user documentation.
When assessing the machine's risk in accordance with the respective local regulations (e.g.,
EC Machinery Directive), the machine manufacturer must take into account the following
residual risks emanating from the control and drive components of a drive system:
1. Unintentional movements of driven machine components during commissioning, operation,
maintenance, and repairs caused by, for example,
– Hardware and/or software errors in the sensors, control system, actuators, and cables
and connections
– Response times of the control system and of the drive
– Operation and/or environmental conditions outside the specification
– Condensation/conductive contamination
– Parameterization, programming, cabling, and installation errors
– Use of wireless devices/mobile phones in the immediate vicinity of the control system
– External influences/damage
2. In the event of a fault, exceptionally high temperatures, including an open fire, as well as
emissions of light, noise, particles, gases, etc. can occur inside and outside the inverter,
e.g.:
– Component failure
– Software errors
– Operation and/or environmental conditions outside the specification
– External influences/damage
Inverters of the Open Type/IP20 degree of protection must be installed in a metal control
cabinet (or protected by another equivalent measure) such that contact with fire inside and
outside the inverter is not possible.
3. Hazardous shock voltages caused by, for example,
– Component failure
– Influence during electrostatic charging
– Induction of voltages in moving motors
– Operation and/or environmental conditions outside the specification
– Condensation/conductive contamination
– External influences/damage

Software and hardware

Service Manual, 03/2016, 6FC5397-5DP40-5BA3 15
Fundamental safety instructions
1.4 Residual risks of power drive systems

4. Electrical, magnetic and electromagnetic fields generated in operation that can pose a risk
to people with a pacemaker, implants or metal replacement joints, etc., if they are too close
5. Release of environmental pollutants or emissions as a result of improper operation of the
system and/or failure to dispose of components safely and correctly

Note
The components must be protected against conductive contamination (e.g. by installing them
in a control cabinet with degree of protection IP54 according to IEC 60529 or NEMA 12).
Assuming that conductive contamination at the installation site can definitely be excluded, a
lower degree of cabinet protection may be permitted.

For more information about residual risks of the components in a drive system, see the relevant
sections in the technical user documentation.

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16 Service Manual, 03/2016, 6FC5397-5DP40-5BA3
System description 2
2.1 System overview

Configuration with four axes (basic configuration)

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

&RPSDQ\QHWZRUN ,QGXVWULDO(WKHUQHW

6,180(5,.'

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600
600
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33'$31 1PH8 spindle

motor
1FK7 feed motor

1FK7 feed motor

Image 2-1 Configuration example 1: Basic configuration with four axes

Software and hardware

Service Manual, 03/2016, 6FC5397-5DP40-5BA3 17
System description
2.1 System overview

Configuration with S120 Combi and six axes

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

&RPSDQ\QHWZRUN ,QGXVWULDO(WKHUQHW

6,180(5,.'
1RQFURVVRYHU 02'(0
PRWRUFDEOH 0'
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§ &RQWURO6XSSO\0RGXOH
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9
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6XSSOHPHQWDU\
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Image 2-2 Configuration example 2: Maximum expansion stage with six axes and with Safety Integrated

Software and hardware

18 Service Manual, 03/2016, 6FC5397-5DP40-5BA3
 System description
2.2 PPU versions

2.2 PPU versions

Front of the PPU

 

   

 



 




  




  

①⑩ Front cover ⑧ Menu forward key

② Menu back key ⑨ 3/8" threads for additional components
③ Alphabetic key group ⑪ X127, Ethernet (service socket)
④ Control key group ⑫ Status LED: RDY, NC, CF
⑤ Hotkey group ⑬ X125, USB interface
⑥ Cursor key group ⑭ Slot for CompactFlash card with user
⑦ Numerical key group data

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Service Manual, 03/2016, 6FC5397-5DP40-5BA3 19
System description
2.2 PPU versions

Front of PPU version 290.3

   

① USB interface
② X127 Ethernet interface (service connection)
③ Qwerty keyboard
④ Control keys
⑤ Cursor keys
⑥ Keys to quickly select the operating area
⑦ Control keys
⑧ Numerical keys

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20 Service Manual, 03/2016, 6FC5397-5DP40-5BA3
 System description
2.2 PPU versions

Rear of the PPU

  





  

①② X122, X132 Digital inputs/outputs, drive

③④ X242, X252 Digital inputs/outputs for NC; control of the analog spindle (X252)
⑤ X143 Handwheels
⑥ M, T2, T1, T0 Measuring sockets
⑦ X1 Power supply
⑧ X135 USB interface: for MCP 310 USB, MCP 483 USB and for service
⑨ X130 Ethernet LAN
⑩ PN 1, PN 2 PLC I/O Interface
⑪ SYNC, FAULT Status LED
⑫ X100, X101, X102 DRIVE-CLiQ interfaces
⑬ X140 Serial interface RS232

Image 2-3 Interfaces at the rear of the PPU

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System description
2.2 PPU versions

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22 Service Manual, 03/2016, 6FC5397-5DP40-5BA3
Service cases - software 3
Introduction
The current versions of the software tools should be used for the subsequently described
service activities and for backing up the system and user data; these tools are supplied in the
SINUMERIK 828D toolbox DVD:
● SINUMERIK 828D boot system → configuration data
● SINUMERIK Integrate Access MyMachine /P2P
● SINUMERIK Integrate Lock MyCycles
● SINUMERIK Commissioning from CNC software V4.7
● PLC programming tool

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.
The directory name has the following structure: LOG_date_time
Example:
LOG_091102_083615 stands for a directory generated on 02.11.2009 at 8:36:15.
This therefore ensures that a directory is not overwritten by pressing CTRL + ALT + D several
times. The directory contains all of the logbook and debug information available in the system.

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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 NC data 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!

NOTICE
Data backup
The following procedure is recommended in order to avoid losing data.
● After making important changes, immediately backup data, e.g. after the
1st commissioning and the 2nd commissioning.
● While the data is being backed up, the control system must neither be operated, nor turned
off.

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.

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3.1 Backing up user data

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

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Service cases - software
3.1 Backing up user data

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

– A progress indicator indicate 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".

3.1.2 This is how you load the user data backup

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

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3.1 Backing up user data

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 Startup menu press the <SELECT> key.

You now go to the Startup menu:

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Service cases - software
3.1 Backing up user data

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

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

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

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

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 setup archive on an external data storage medium

Generating an archive on an external data carrier

Procedure:
1. Select the "Startup" operating area.

2. Press the menu forward key.

3. Press the "Setup archive" softkey.

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Service cases - software
3.2 Generating a commissioning archive

4. Activate "Create setup archive".

The "Create setup archive" 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 "OK" softkey to create the archive.

The "Create Archive: Select Archive" window opens.

7. Select the storage location of the archive:
– USER USB: USB-FlashDrive in slot X125 at the front
– User CF: CompactFlash Card in the slot at the front
8. Select a directory.
Example: User CF
- OR -

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3.2 Generating a commissioning archive

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

The "New Directory" window opens.

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

The directory is created subordinate to the selected folder.

11.Press the "OK" softkey.

The "Create archive: Name" window opens.

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

A file with format type *.ard is saved in the selected directory:

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3.2 Generating a commissioning archive

3.2.2 This is how you read a setup archive from an external data storage medium

Reading in an archive from an external data carrier

Procedure:
1. Select the "Startup" operating area.

2. Press the menu forward key.

3. Press the "Setup archive" softkey.

4. Press "OK".

The "Startup" window opens.

5. Activate "Read in setup archive".
6. Press "OK".

The "Select Setup archive" window opens and the data tree is displayed.

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3.2 Generating a commissioning archive

7. Select the required setup 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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Service cases - software
3.2 Generating a commissioning archive

3.2.3 This is how you generate a setup archive on the system CompactFlash card

Generating an archive on the system CompactFlash Card

Procedure:
1. Select the "Startup" operating area.

2. Press the menu forward key.

3. Press the "Setup archive" softkey.

4. Activate "Create setup archive".

The "Create setup archive" window opens.

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3.2 Generating a commissioning archive

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 "OK" softkey to create an archive.

The "Create 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 "Create archive: Name" window opens.

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

A file with the ARD format type is saved in the selected directory.

3.2.4 This is how you read in a setup archive from the system CompactFlash card

Reading in an archive from the system CompactFlash Card

A description is provided here how you read in a series setup archive in order to be able to
restore the previous state of the machine.

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Service cases - software
3.2 Generating a commissioning archive

Procedure:
1. Select the "Startup" operating area.

2. Press the menu forward key.

3. Press the "Setup archive" softkey.

4. Press "OK".

The "Create setup archive" window opens.

5. Activate "Read in setup archive".
6. Press "OK".

The "Select Setup archive" window opens and the data tree is displayed.

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3.2 Generating a commissioning archive

7. Select the required setup 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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Service cases - software
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 2 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 flash drive) with a minimum memory size of 2 GB is required.
Other data carriers are not permissible.

Generating the system software backup ("clone")

Procedure:
1. Switch the control on.
2. Perform an internal data backup (see also:This is how you backup user data (Page 24)).
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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3.3 Software backup

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

2. To call the "Startup menu", press the following keys in succession:

Menu reset key, HSK2 (horizontal SK2), VSK2 (vertical SK2)

Note
PPU with touch operation
To call the startup menu when powering up, there is an additional shortcut for all PPUs: "8"
→ "2" → "8"

3. The Startup menu is displayed:

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

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

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Service cases - software
3.3 Software backup

1. 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.
2. When starting to generate a backup, the following message is output:

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3.3 Software backup

3. Wait until the following message is displayed:

4. Withdraw the storage medium from the slot at the front panel of the control.
5. Switch the control off.
6. Switch the control on.
7. 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.

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 include a license key, and is not installed with the software update.
As an alternative, the license key for an already licensed card can be obtained through the
Internet: see also This is how you display the actual license key (Page 62)
When replacing a defective system CompactFlash Card, the license key must be requested
again: see also Licensing after replacing the system CompactFlash Card (Page 56)

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Service cases - software
3.3 Software backup

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:

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

2. To call the "Startup menu", press the following keys in succession:

Menu reset key, HSK2 (horizontal SK2), VSK2 (vertical SK2)

Note
PPU with touch operation
To call the startup menu when powering up, there is an additional shortcut for all PPUs: "8"
→ "2" → "8"

3. The Startup menu is displayed:

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 Service cases - software
3.3 Software backup

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

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

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

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Service cases - software
3.3 Software backup

7. Select the valid backup using the cursor keys.

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

9. The following message briefly appears: "Starting software update"
Then the screen goes dark for several seconds.
10.If a valid backup has been found, the following message is output:

If a valid backup was not selected, then the upgrade is canceled with the following message:
"Image file is corrupt!"
In this case, switch-off the control, withdraw the data carrier and repeat the procedure by
selecting a valid backup image.
11.Wait until the following message appears:

12.Switch the control off.

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

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3.3 Software backup

14.Switch the control on.

15.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 boot system must be generated on this card. (see also: This is how you create a
boot system (Page 50) )
In this case, the license key of the system CompactFlash Card should be transferred to the
control.

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Service cases - software
3.4 Updating the software

3.4 Updating 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 38)).
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 startup (see This is how you generate a setup archive on
an external data storage medium (Page 29)), 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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3.4 Updating the software

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

2. To call the "Startup menu", press the following keys in succession:

Menu reset key, HSK2 (horizontal SK2), VSK2 (vertical SK2)

Note
PPU with touch operation
To call the startup menu when powering up, there is an additional shortcut for all PPUs: "8"
→ "2" → "8"

3. The Startup menu is displayed:

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

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Service cases - software
3.4 Updating the software

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

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

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

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3.4 Updating the software

9. Wait until the following message is output:

10.Withdraw the storage medium from the slot.

11.Switch the control off.
12.Switch the control on.
13.The control boots normally.
Note
If the update is interrupted, then it must be restarted.
If the system CompactFlash Card is no longer identified as bootable system, then a boot
system must be generated on this card (see also: This is how you create a boot system
(Page 50)).
In this case, the license key of the system CompactFlash Card should be transferred to the
control.

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Service cases - software
3.5 Generating a boot system on the CompactFlash card

3.5 Generating a 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" is supplied on the toolbox CD of the SINUMERIK 828D, which in the scope
of delivery includes a boot system image:

Image 3-1 Toolbox selection

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

3.5.1 This is how you create a boot system

Precondition
The default path to install the boot system is:
C:\Program Files (x86)\Siemens\Toolbox 828D\V04070xx00\RecoverySys
The file name of the boot system is: minsys.img

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3.5 Generating a boot system on the CompactFlash card

With SINUMERIK Integrate Access MyMachine /P2P, the minsys.img file is copied to an empty
replacement card.
Precondition to write:
● SINUMERIK Integrate Access MyMachine /P2P is 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 program via "Start" → "Programs" → "SINUMERIK" → "Tools" → "Access
MyMachine P2P".
3. Press “Cancel" if you are prompted to establish the connection.
Note
An online connection to the control is not required to generate the boot system.

4. In the ""Options" menu, select the menu item "Write SINUMERIK 828D boot system...":

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

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Service cases - software
3.5 Generating a boot system on the CompactFlash card

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

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

Note
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:

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

9. In order to ensure that there are no read and write access operations to the
CompactFlash Card, when you remove the CompactFlash Card from the interchangeable
drive, select the Windows function "Safely remove hardware".

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 Service cases - software
3.5 Generating a boot system on the CompactFlash card

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

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

Note
Licenses
The 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 56)).
All system data and user data are overwritten with the system image.

Updating the software

After you have inserted the CompactFlash Card with the boot system as new system
CompactFlash card (see Replacing the system CompactFlash Card (Page 82)) 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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3.5 Generating a boot system on the CompactFlash card

3. Confirm the question with "Yes".

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

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

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

Then the screen goes dark for several seconds.

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3.5 Generating a boot system on the CompactFlash card

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

8. Wait until the following message is displayed:

9. Switch the control off.

10.Switch the control system back on again: The control boots normally.
Note
If the system was booted using a 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 startup (commissioning) file were generated.
● If a valid image is not found, the update is interrupted with the following message:
Image file is corrupt!
In this case, switch-off the control, withdraw the data carrier and carry out the procedure
again by selecting a valid file.

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3.6 Licensing

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 empty CompactFlash cards that have been released as replacement part can be used.
Only these CompactFlash cards are known in the licensing database.

In order to obtain a valid license key for the new, empty CompactFlash Card, contact the
SINUMERIK Hotline specifying the serial numbers of the two CompactFlash cards. The hotline
will immediately provide you with a new license key.

3.6.2 This is how 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 "Startup" 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"

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3.6 Licensing

Image 3-2 Licensing

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).

Note
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.

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3.6 Licensing

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
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.

Image 3-3 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.
1. Press the "OK" softkey to trigger a warm restart.
- OR -
2. Press the "Cancel" softkey to cancel the process.

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3.6 Licensing

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.

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.

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3.6 Licensing

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)
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.

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3.6 Licensing

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

2. Press the menu forward key.

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.

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3.6 Licensing

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.

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".

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3.6 Licensing

3. A window with the license key opens:

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

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3.6 Licensing

5. Press the "Display license key" softkey.

6. The actual license key is displayed as follows:

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3.7 Machine registration

3.7 Machine registration

Overview
The machine registration contains:
● Notification of the startup date (e.g. start of production)
● Notification of where the machine is located (final destination)
● Notification regarding the Siemens components and software versions installed
● Name of the machine OEM, the machine type and the machine number
This is how you register a machine:
● Create a machine logbook
● Create a new entry in the logbook
● Save the machine identity
● Send the machine identity

On-site service (OSS)

SINUMERIK 828D and the associated drive, motor and accessories from Siemens include an
on-site service (local service) for 24 months. The on-site service time is extended to 36 months
by registering the machine.
You can obtain additional information about the on-site service here Internet page
(www.siemens.com/automation/oss).

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

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 (if available)
● Contact data of the end customer
● Log of the service and diagnostic procedures that have already been carried out.

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3.7 Machine registration

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.

3. Press the "Details" softkey.

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

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3.7 Machine registration

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.

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 should be documented here after each service call.

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3.7 Machine registration

To make a logbook entry, proceed as follows:

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

2. Press the "Version" softkey.

3. Press the "Logbook" softkey.

4. Press the "New entry" softkey in order to make an entry in the logbook.

Complete the fields for the new logbook entry:

5. Press the "OK" softkey to save an entry in the logbook.

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

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3.7 Machine registration

1st Commissioning completed (commissioning at the machine OEM's fa‐

cility)
2nd commissioning completed (commissioning at the company operating
the machine/end user)

Note
Once saved, data can no longer be changed.

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.

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3.7 Machine registration

4. Press the "OK" softkey.

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.

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3.7 Machine registration

3.7.4 This is how you send the machine identity

Overview
To complete, transfer the configuration file (address data, logbook data, version data) of the
control to the final destination database via an Internet connection.
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.

Note
On-site service
The machine is registered by sending the machine identity. Only then is the full on-site service
period effective.

Send the machine identity

Preconditions:
● The commissioning status is saved in the logbook.
● The addresses data are entered/updated in the machine.
● The machine identity was saved and is available on the PC/PG.
● The PC/PG is connected with the Internet.
Please proceed as follows:
1. Open the Internet Browser on your PC/PG.
2. Go to the Internet page for the registration (http://www.siemens.com/sinumerik/register).
You can find instructions on how to transfer data on this Internet page. Follow these
instructions.

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

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

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Service cases - hardware

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Image 4-2 Supplementary components in the electrical cabinet

References
Information about the cause of faults and how they can be resolved can be found in the
following references:
● SINUMERIK 828D/SINAMICS S120 Diagnostics Manual "Alarms"
● SINUMERIK 828D/SINAMICS S120 List Manual "Parameter description"
● "EMC Installation Guideline" Configuration Manual.
● "Industrial security" Configuration Manual

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4.1 Safety instructions for the hardware

4.1 Safety instructions for the hardware

4.1.1 Safety instructions for the hardware

WARNING
Danger to life if the fundamental safety instructions and remaining risks are not carefully
observed
The non-observance of the fundamental safety instructions and residual risks stated in
Chapter 1 can result in accidents with severe injuries or death.
● Comply with the fundamental safety instructions.
● When assessing the risk, take into account residual risks.

DANGER
Danger to life through electric shock due to the residual charge of the DC link capacitors
As a result of the DC link capacitors, a hazardous voltage is present for up to 5 minutes after
the power supply has been switched off.
Contact with live parts results in death or serious injury.
● Do not open the protective cover of the device until 5 minutes have elapsed.
● Before starting any work, check that the system is in a completely no-voltage condition by
measuring all poles/phases, also to ground.
● Ensure that the associated warning plate in the appropriate language is attached.

WARNING
Danger to life through electric shock due to incorrectly installed DC link clips
Incorrectly installed DC link clips at the left-hand end of the drive line-up can cause an electric
shock.
● For all 50 mm wide modules (exception: Smart Line Module) remove the DC link clips,
including the bolts. Do not tighten the screws without the DC link clips.
● For all components that are 75 mm wide or wider, it is not permissible that the DC link
clips are moved to the left or removed.

WARNING
Danger to life through electric shock due to missing DC link side covers
There is a danger of an electric shock through contact when the side covers of the DC link
are missing.
● Mount the side covers that are provided on the first and last component in the drive line-
up.
● Order any missing side covers (order number: 6SL3162-5AA00-0AA0).

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4.1 Safety instructions for the hardware

NOTICE
Damage through electric fields or electrostatic discharge
Electric fields or electrostatic discharge can cause malfunctions through damaged individual
components, integrated circuits, modules or devices.
● Only pack, store, transport and send electronic components, modules or devices in their
original packaging or in other suitable materials, e.g conductive foam rubber of aluminum
foil.
● Only touch components, modules and devices when you are grounded by one of the
following methods:
– Wearing an ESD wrist strap
– Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring
● Only place electronic components, modules or devices on conductive surfaces (table with
ESD surface, conductive ESD foam, ESD packaging, ESD transport container).

NOTICE
Damage caused by loose plug connections and screw connections
Loose plug connections and screw connections can release themselves in operation.
● Ensure that all of the connectors and screws are correctly tightened or latched and inserted.

NOTICE
Damage caused by excessively low cooling clearances
Higher temperatures can occur if heat-generating components have excessively low cooling
clearances. This can damage the hardware.
● Ensure that the specified cooling clearances are complied with.

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4.2 PPU 2xy.3

4.2 PPU 2xy.3

4.2.1 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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Image 4-3 Vertical flap (detail)

LEDs and the slots for the CompactFlash card are not available on the front of the PPU 290.3.
The three LEDs located behind the front flap at the front 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

NOTICE
Damage to the CompactFlash card when it is withdrawn in operation
The CompactFlash card can be destroyed if it is withdrawn or inserted in operation.
Therefore, do not withdraw the CompactFlash card if an LED is lit.

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4.2 PPU 2xy.3

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 data
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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*) A PPU 24xy.3 does not have a port 1.

Image 4-4 Rear of the PPU

For diagnostic purposes, the RJ45 sockets, port 1 and port 2 are each equipped with a green
and a yellow LED. As a consequence, the following connection information of the PLC I/O
interface is displayed based on PROFINET:

Name Color State Meaning

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

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

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4.2 PPU 2xy.3

Name Color State Meaning

FAULT Red OFF For the maximum expansion level of the PLC I/O: The data ex‐
change 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 (Page 19).

4.2.2 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 complete system, carefully checked that it is in a no-voltage condition and
lock it out so that it cannot be switched on without the appropriate authorization.
2. Access the 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. Label all connectors/cables that are inserted in the module. Only then, can it be ensured
that the cables are not interchanged.
5. Withdraw the power supply X1.
6. Withdraw the digital input/output terminals X122, X132, X142.

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4.2 PPU 2xy.3

7. Withdraw the handwheel terminal X143.

8. Withdraw the RS232 cable, X140.
9. Withdraw the connected DRIVE-CLiQ cables X100 - X102.
10.Withdraw the connected Ethernet cable X130.
11.Withdraw the connected PROFINET cables PN1, PN2.
12.Remove the ground connection by releasing the grounding screw.
13.If required, release the strain relief.
14.Release the clips to remove the PPU from the operator panel. For the PPU 290.3, also
release the upper snap mechanism.
Please note that when removing the last upper clip, the PPU must be held from the front
so that it doesn't fall out of the mounting cutout!
15.Remove the system CompactFlash card from the control.
(refer to Chapter This is how you remove the system CompactFlash Card (Page 82))

4.2.3 This is how you install the PPU

Boundary condition
When replacing the PPU, then the MAC address of Ethernet interface X130 changes: Tell the
customer or the system administrator the new MAC address.

Installing

NOTICE
Installing the PPU
The following points must be carefully observed to correctly install the PPU:
● The maximum permissible tightening torque for the tensioning screws is 0.5 Nm - and
must not be exceeded.
● It is important that the seal is not damaged when installing so that the maximum degree
of protection that can be achieved is fulfilled. Therefore, center the PPU in the installation
cutout.
● Do not use suction grippers to lift the glass front to avoid damaging the glass front (only
for PPU 290.3).

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4.2 PPU 2xy.3

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 83))
2. Insert the PPU into the installation cutout from the front.

3. Tilt the PPU and press the snap mechanism to fit the device into the cutout (only for
PPU 290.3)

Make sure that the PPU sits firmly in the installation cutout and cannot fall out before you
secure the PPU at the rear using the tension jacks.
4. Fix the PPU in the installation cutout from the rear using the tension jacks by tightening the
setscrews:
5. Connect the ground connections and tighten.
6. Insert the PN1, PN2 interfaces that were withdrawn.
7. Insert the Ethernet cable that was withdrawn at X130.
8. Insert the DRIVE-CLiQ cable that was withdrawn at X100 – X102
9. Insert the handwheel terminal that was withdrawn at X143.
10.Insert the digital input/output terminals that were withdrawn at X122, X132, X142.
11.Reconnect power supply X1.
12.Retighten the strain relief assemblies.
13.Close the cabinet and switch-on the system again.
14.Read-in the available data backup.

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4.3 Replacing the system CompactFlash Card

4.3 Replacing the system CompactFlash Card

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

NOTICE
Damage to the CompactFlash card when it is withdrawn or inserted under voltage
The system CompactFlash card can be damaged if it is withdrawn or inserted under voltage.
● Switch-off the control power supply before inserting or removing the CompactFlash card.
● Before you touch the CompactFlash card, discharge yourself at the cabinet or at the
ground terminal.

Removing the system CompactFlash Card

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

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

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4.3 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. First, guide the metal cover at the rear into the rabbet and fix to the housing using the screw.

4.3.2 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.

NOTICE
Damage to the CompactFlash card when it is withdrawn or inserted under voltage
The system CompactFlash card can be damaged if it is withdrawn or inserted under voltage.
● Switch-off the control power supply before inserting or removing the CompactFlash card.
● Before you touch the CompactFlash card, discharge yourself at the cabinet or at the
ground terminal.

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4.3 Replacing the system CompactFlash Card

Inserting the system CompactFlash Card

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.

Procedure:
1. Release the screw (M3), and swing the metal cover to the side to remove it.
2. Gently insert the system CompactFlash Card into the slot until it clicks into place.

3. First, guide the metal cover at the rear into the rabbet and then tilt it into the end position.

4. Attach the metal cover to the housing using the screw.

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4.4 Replacing the front cover

4.4 Replacing the front cover

4.4.1 This is how you remove the front cover

Precondition
You must first remove the PPU before you remove the front cover, see This is how you remove
the PPU (Page 79).

Removing the front cover

Procedure:
1. Open the front cover.
2. Press the holding pins of the front cover through the openings at the rear. The tool that you
use may have a maximum width of 2 mm.

3. Remove the front cover.

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4.4 Replacing the front cover

4.4.2 This is how you install the front cover

Installing the front cover

Procedure:
1. Insert the springs and pins into the front cover.

Pin

Spring

Cover

Spring

Pin

2. Press in the pins and mount the front cover. The pins must snap into the PPU housing.

After you have installed the front cover, you can also possibly reinstall the PPU, see This is
how you install the PPU (Page 80).

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4.5 Machine control panels

4.5.1 This is how you remove MCP 483 USB/MCP 310 USB

Removing
If the machine control panel has a hardware defect, then it must be replaced by an identical
replacement part.
Precondition: The control cabinet is in a no-voltage condition, all of the connectors and cables
are labeled.
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. Use a multimeter to check that the system really is in a no-voltage condition (isolated from
the supply).
4. If it has not already been done, label all connectors that lead to the module now.
Only then, can it be ensured that the cables are not interchanged.
5. Remove the USB cable: ①
6. Release other cables (e.g. the Emergency Stop cable or from other command devices), if
available.
7. Remove the ground connection by releasing the grounding screw: ②
8. Release the tension jacks of the machine control panel to remove it from the control panel.

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① USB connection for communication with the PPU

② Ground connection
③ Slots for control devices (d = 16 mm)

Image 4-5 MCP 310 USB interfaces

① USB connection for communication with the PPU

② Ground connection
③ Slots for control devices (d = 16 mm)

Image 4-6 MCP 483 USB interfaces

4.5.2 This is how you install the MCP 483 USB/MCP 310 USB

Installing
Procedure:
1. Attach the tension jacks to fix the machine control panel and tighten them.
2. Connect the ground connection: ②

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3. Reconnect other cables (e.g. the Emergency Stop cable or from other command devices),
if available.
4. Reinsert the USB cable into the USB port: ①
5. Close the cabinet and switch-on the system again.

4.5.3 Status display MCP interface PN

LEDs for status display

For the MCP interface PN, the following LEDs provide information about the module status:

+ +

+ +

Image 4-7 Status display

Meaning of the LED H500 H501 H502 (red) H505 (red)

(green) (green) PN fault OVTemp
PowerOK PN Sync
Power OFF OFF OFF OFF OFF
Power ON (voltage is stable) ON OFF OFF OFF
Boot software runs and the system software ON ON ON OFF
is loaded
The system software is booting ON OFF OFF OFF
The system software is running, no commu‐ ON OFF OFF OFF
nication to the controller
STOP state: The system software is run‐ ON ON OFF OFF
ning, communication to the controller
RUN state: The system software is running, ON Flashes at OFF OFF
communication to the controller 0.5 Hz
Overtemperature alarm -- -- -- ON

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4.5.4 This is how you remove the MCP interface PN

Removing
If the module has a hardware defect, then it must be replaced by an identical part.
Precondition: The control cabinet is in a no-voltage condition, all of the connectors and cables
are labeled.

;; 6 6
; ;;

;;;
;;;;

;;

;;;;;
++
++
;

3URWHFWLYHFRQGXFWRU ; ; 6WUDLQUHOLHI;DQG
FRQQHFWLRQ01P ;

X1 24 VDC power supply

X2 / X3 PROFINET interfaces
X30 Interface for rotary switch feed override
X31 Interface for rotary switch spindle override
X40/X41 Digital inputs (24 V)
X51 / X52 / X55 Digital inputs (TTL)
X58 / X57 / X56 / X53 / Digital outputs (24 V)
X54
X60 / X62 Handwheel
X61 Reserved
X111 / X112 / X113 / Key and LED interfaces
X114
H500 / H501 / H502 / LEDs for status display
H505
S1 DIP switch for the MCP IP address
S2 DIP switch to transfer the handwheel pulse signals

Image 4-8 MCP Interface PN interfaces

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Procedure:
1. Switch-off the control: Completely switch off the system. Check that the system is in a no-
voltage condition and is locked-out so that it cannot be switched on again without the
appropriate authorization.
2. Access the operator panel or control cabinet in which the machine control panel is located.
3. If it has not already been done, label all connectors that are inserted in the module now.
Only then, can it be ensured that the cables are not interchanged.
4. Release the screw connection for power supply X1 and remove this.
5. Release the strain relief of the Ethernet cables.
6. Remove the Ethernet cables from interface X2/X3 (port 1/port 2).
7. Release other cables (e.g. rotary switch cable or cables for digital inputs and outputs), if
available.
8. Remove the ground connection by releasing the grounding screw.
9. Release the machine control panel by removing the 4 standard Torx screws T20/M4.
10.Note the set address of DIL switch S1.
11.Note the settings of the handwheel pulses at DIL switch S2.

4.5.5 This is how you install the MCP interface PN

Installing
Procedure:
1. Set DIL switches S1 and S2 of the new module to what you previously noted down.
2. Mount the new machine control panel using the 4 standard Torx screws T20/M4.
3. Connect the ground connection to the grounding screw.
4. Reconnect other cables (e.g. for the rotary switch and for the digital inputs and outputs).
5. Reinsert the Ethernet cables at interface X2/X3 (port 1/port 2)
6. Re-establish the strain relief for the Ethernet cables.
7. Reconnect power supply X1.
8. Close the cabinet and switch-on the system again.

Switches S1, S2

  
2))
21

6 6

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The switches S1-1 to S1-8 define the PROFINET address of the machine control panel. In
SINUMERIK 828D, the address "64" must always be assigned to the MCP.
Switches S1-9 and S1-10 must be set to "ON".

1 2 3 4 5 6 7 8 9 10 Meaning
ON ON ON
OFF OFF OFF OFF OFF OFF OFF PROFINET address "64"

The handwheel signal transfer type is set using switch S2-1.

S2-1 Meaning
ON Differential connection
OFF TTL interface

Note
Switch S2-2 is reserved for test purposes.

4.5.6 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 + + +

Image 4-9 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 con‐ ON OFF OFF
troller.

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

PowerOK PN Sync PN Fault
System software runs, communication to the con‐ ON ON OFF
troller, STOP state
System software runs, communication to the con‐ ON Flashes at OFF
troller, RUN state 0.5 Hz

4.5.7 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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Removing

    

        

① Ground terminal
② X30 Feedrate override
③ X31 Spindle override
④ X20 Port 1: Connection: PLC I/O interface based on PROFINET
X21 Port 2: Connection: PLC I/O interface based on PROFINET
⑤ Slot for Emergency Stop
⑥ Mounting slots for additional command devices
⑦ Customer-specific inputs and outputs
⑧ Cover plate
⑨ Ethernet cable strain relief
⑩ LED
⑪ S2 Switch for setting the MCP address
⑫ S1 Switch for setting the handwheel signal type
⑬ X60 Handwheel connection
X61 Reserved
⑭ X10 Power supply interface

Image 4-10 MCP 483C PN rear side

Procedure:
1. Switch-off the control: Completely switch off the system. Check that the system is in a no-
voltage condition and is locked-out so that it cannot be switched on again without the
appropriate authorization.
2. Access the operator panel/control cabinet in which the machine control panel is located.

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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 (⑭).
6. Release the strain relief of the Ethernet cable (⑨ )
7. Remove the Ethernet cables from the X20 / X21 interface ( port 1 / port 2 ) ( ④ )
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 ( ① ).
10.Release the machine control panel from the control panel by releasing the clips.
11.Note down the address set with DIP switch S1 (⑫) on the defective module.
12.Note down the setting of DIP switch S2 (⑪) on the defective module.

4.5.8 This is how you install the MCP 483C PN

Installing
Procedure:
1. Set switch S1 ( ⑫ ) on the new module as you previously noted down.
2. Set DIL switch S2 ( ⑪ ) of the new module to what you previously noted down.
3. Installing a new machine control panel.
4. Secure the clips to retain the machine control panel and tighten them.
5. Connect the ground connection ( ① ).
6. 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.
7. Reinsert the Ethernet cables at the X20/X21 interface (port 1/port 2) ( ④ ).
8. Re-establish the strain relief for the Ethernet cables (⑨).
9. Reconnect the power supply X10 ( ⑭ ).
10.Close the cabinet and switch-on the system again.

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Switch S2

6 + + +

Image 4-11 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 OFF OFF OFF OFF OFF OFF PROFINET address "64"

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

4.5.9 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

+ + +

Image 4-12 Status displays

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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 starts ON OFF OFF
System software runs, no communication to the con‐ ON OFF OFF
troller
System software runs, communication to the control‐ ON ON OFF
ler, STOP state
System software runs, communication to the control‐ ON Flashes at OFF
ler, RUN state 0.5 Hz

4.5.10 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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Removing

    

     

① Slot for Emergency Stop button or spindle override

② X10 Power supply interface
③ X60 Handwheel connection
④ X61 Reserved
⑤ S1 Switch for setting the handwheel signal type
⑥ S2 Switch for setting the MCP address
⑦ LED
⑧ Ethernet cable strain relief
⑨ X21 Port 2: PLC I/O interfaces based on PROFINET
⑩ X20 Port 1: PLC I/O interfaces based on PROFINET
⑪ Equipotential bonding
⑫ Feedrate override
⑬ Customer-specific inputs and outputs

Image 4-13 MCP 310C PN rear side

Procedure:
1. Switch-off the control: Completely switch off the system. Check that the system is in a no-
voltage condition and is locked-out so that it cannot be switched on again without the
appropriate authorization.
2. Access the operator panel or control cabinet in which the machine control panel is located.
3. Using a multimeter, check the X10 power supply to ensure that the system really is in a no-
voltage condition.

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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 (②).
6. Release the strain relief of the Ethernet cable (⑧)
7. Remove the Ethernet cables from the X20/X21 interface (port 1/port 2) (⑨, ⑩).
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 (⑪).
10.Release the machine control panel from the control panel by releasing the clips.
11.Note down the address set with DIP switch S1 (⑤) on the defective module.
12.Note down the setting of DIP switch S2 (⑥) on the defective module.

4.5.11 This is how you install the MCP 310C PN

Installing
Procedure:
1. Set switch S1 on the new module as you previously noted down.
2. Set DIL switch S2 of the new module to what you previously noted down.
3. Install the new machine control panel.
4. Secure the clips to retain the machine control panel and tighten them.
5. Connect the ground connection (⑪).
6. 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.
7. Reinsert the Ethernet cables at the X20/X21 interface (port 1/port 2) (⑨, ⑩).
8. Re-establish the strain relief for the Ethernet cables (⑧).
9. Reconnect the power supply X10 (②).
10.Close the cabinet and switch-on the system again.

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Switch S2

6

+ + +

Image 4-14 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 OFF OFF OFF OFF OFF OFF PROFINET address "64"

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

4.5.12 This is how you replace the rotary switch

Overview
For MCP 310C PN and MCP 483C PN machine control panels, you can replace a defective
rotary switch by a new one. The following rotary switches are installed in the machine control
panels:
● Rotary switch for the spindle control, rotary switch with 16 positions
● Rotary switch for the feedrate control, rotary switch with 23 positions
The activities that must be taken into account when replacing a rotary switch are subsequently
described.
Preconditions when replacing a rotary switch:
● The rotary switch is defective and must be replaced.
● The system is in a no voltage condition.

Note
For the machine control panel, use only electronic rotary switches.

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Removing a rotary switch

Procedure:
1. Pry off the cap ③ from the knob ② (snap on connection!).
2. Remove the nut of collet ① with a wrench (size 10).
3. Remove the complete knob ②.
4. Remove the lock nut ⑤ on the shaft of the rotary switch ④ with a wrench (size 14).
5. Remove the connector at the end of the rotary switch cable from the socket.
6. Remove the rotary switch.




① Nut of the collet

② Knob
③ Cap
④ Rotary switch shaft
⑤ Fastening nut
⑥ Scale

Image 4-15 Removing a rotary switch

Installing a rotary switch

Procedure:
1. Push the O-ring ① onto the shaft of the new rotary switch as a seal.
2. Insert the rotary switch into the front cutout so that pressure is applied to the O-ring.
3. Screw the lock nut ④ onto the rotary switch shaft from the front with a wrench (size 14)
(tightening torque: 3 Nm).
4. Connect the arrow ring ③ and knob ⑤.
5. Slide both parts onto the shaft of the rotary switch.
6. Align the arrow point on the ring with position "0" on the scale.
7. Tighten the collet nut of the knob by hand and using a torque wrench tighten to a torque of
2 Nm.

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8. Place the cap ② on the knob and snap it into position.

9. Fold and fasten the connecting cable ⑦ as shown in the diagram on the right.
      

① O-ring Detail diagram of the connector

② Cap
③ Arrow ring
④ Fastening nut
    
⑤ Knob
    
⑥ Connection plug
⑦ Connecting cable
⑧ Connection PCB

Image 4-16 Installing a rotary switch

Note
It is essential that the specified tightening torques are complied with.

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4.6 I/O modules

4.6.1 Status displays PP 72/48D PN

LEDs for status display

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

Image 4-17 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 soft‐ ON ON ON ON ON OFF
ware.
System software starts ON OFF OFF OFF OFF OFF
System software runs, no communication to the ON OFF OFF OFF OFF OFF
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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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

Image 4-18 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

4.6.2 This is how you remove the PP 72/48D PN

Overview
The activities necessary to replace the PP72/48D PN I/O module are described in the following.
If the PP 72/48D PN has a hardware defect, then this must be replaced by an identical module.
Preconditions:
● The I/O module is defective and must be replaced.
● The control cabinet is in a no-voltage condition, all of the connectors and cables are labeled.

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Removing

6 ++
352),1(7;
3RUW 3RUW

;

; ;

;



① Protective conductor connection

② Shield support

Image 4-19 PP 72/48D PN interfaces

Procedure:
1. Switch-off the control: Completely switch off the system. Check that the system is in a no-
voltage condition and is locked-out so that it cannot be switched on again without the
appropriate authorization.
2. Access the 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 PROFINET cables of interfaces X2.
8. Remove the PROFINET cables from interface X2 (port 1 and port 2).
9. Remove the shield support ②, if available.
10.Release the grounding screw ①, to remove the protective conductor.

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11.To remove the I/O module, release the fixing screws.

12.Note down the address set with DIP switch S1 on the defective module.

4.6.3 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".

Note
A new address only becomes effective after voltage OFF → ON.

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4.6.4 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:

Image 4-20 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 soft‐ ON ON ON ON ON OFF
ware.
System software starts ON OFF OFF OFF OFF OFF
System software runs, no communication to the ON OFF OFF OFF OFF OFF
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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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

Image 4-21 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

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

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

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4.6 I/O modules

Removing

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① Protective conductor connection

② Shield support

Image 4-22 PP 72/48D 2/2A PN interfaces

Procedure:
1. Switch-off the control: Completely switch off the system. Check that the system is in a no-
voltage condition and is locked-out so that it cannot be switched on again without the
appropriate authorization.
2. Access the 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. Insert connector X3 for the analog inputs/outputs.
7. Release the connectors of the ribbon cables (X111, X222, X333) on the module that are
used to connect the digital inputs and outputs.
8. Remove the strain relief of the PROFINET cables of interfaces X2.
9. Remove the PROFINET cables from interface X2 (port 1 and port 2).

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Service cases - hardware
4.6 I/O modules

10.Remove the shield support ②, if available.

11.Release the grounding screw ①, to remove the protective conductor.
12.To remove the I/O module, release the fixing screws.
13.Note down the address set with DIP switch S1 on the defective module.

4.6.6 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".

Note
A new address only becomes effective after voltage OFF → ON.

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4.7 Expansion modules NX10.3 / NX15.3

4.7 Expansion modules NX10.3 / NX15.3

4.7.1 NX10.3 / NX15.3 status displays

Status displays
The following status displays on the NX10.3 / NX15.3 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 / NX15.3 is presently booting.
Flashing light 0.5 Error when booting: e.g. the firmware cannot be loaded into the RAM.
Hz
Yellow Continuous light Firmware is being loaded into the RAM
Flashing light 0.5 Firmware cannot be loaded into the RAM.
Hz
Flashing light 2 Hz Firmware CRC error.
DP1, - OFF Electronics power supply outside the permissible tolerance range.
CU_LINK, NX10.3 / NX15.3 is not ready for operation.
H2
Green Continuous light CU_LINK is ready for communication and cyclic communication is running.
Flashing light 0.5 CU_LINK is ready for communication and no cyclic communication is running.
Hz
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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4.7 Expansion modules NX10.3 / NX15.3

4.7.2 NX10.3 / NX15.3 connections

Connections

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Image 4-23 NX10.3 / NX15.3 connections

4.7.3 This is how you remove the NX10.3 / NX15.3

Preconditions
The activities that are required when replacing an NX10.3 / NX15.3 are subsequently
described.
If the NX10.3 / NX15.3 has a hardware defect, then it must be replaced by an identical module.

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4.7 Expansion modules NX10.3 / NX15.3

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

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Image 4-24 Mounting aids

Procedure:
1. Switch off the complete system, carefully checked that it is in a no-voltage condition and
lock it out so that it cannot be switched on without the appropriate authorization.
2. Access the control cabinet where the NX10.3 / NX15.3 is located.
3. Use a multimeter to check that the NX module really is in a no-voltage condition.
4. Open the cover of the NX module.

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Service cases - hardware
4.7 Expansion modules NX10.3 / NX15.3

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 / NX15.3.
10.Release the screws attaching the NX10.3 / NX15.3 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.

4.7.4 This is how you install the NX10.3 / NX15.3

Installing
Procedure:
1. Screw the new NX10.3 / NX15.3 to the mounting plate.
– OR –
2. If the module was located to the left of the infeed, re-attach it here by first introducing the
NX10.3 / NX15.3 into the holder to the right and then press it down slightly to retain it.
3. Reconnect the protective conductor connection of the NX10.3 / NX15.3.
4. Insert the DRIVE-CLiQ cables that were previously withdrawn into sockets X100-X103.
5. Insert the digital input/output terminal X122 into the NX10.3 / NX15.3.
6. Reconnect the electronics power supply X124.
7. Now check that all of the cables have been reconnected.
8. Now close the cover of the NX10.3 / NX15.3.
9. Close the cabinet and switch-on the system again.

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4.8 Installing SINAMICS components

4.8 Installing SINAMICS components

4.8.1 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 (coun‐
ter-clockwise)

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

4.8.2 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.

WARNING
Incorrect machine operation as a result of incorrect shielding or inadmissible cable lengths
If the shielding procedures described and the specified cable lengths are not observed, the
machine may not operate properly.

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Service cases - hardware
4.8 Installing SINAMICS components

A typical shield connecting terminal for the shield support is shown in the following diagram:

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Image 4-25 Shield support and protective conductor connection

Shield connecting terminal from Weidmüller (http://catalog.weidmueller.com/catalog/Start.do)

Type: KLBLUE CO 1
Article number: 17533 11001

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

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4.9 Control Unit CU320-2 PN and CU310-2 PN

4.9 Control Unit CU320-2 PN and CU310-2 PN

4.9.1 CU320-2 PN status displays

Module status displays

Three LEDs at the front of the CU320-2 PN provide information about the state of the module.
They indicate the states when powering up and in operation:
● If an error occurs, the power-up is terminated and the LEDs indicate the cause of the error.
● At the end of an error-free power-up, all LEDs are switched off briefly.
● After power-up, the LEDs are controlled via the loaded software.

Response of the LEDs when powering up – loading software

LED State Remark

RDY PN OPT
Red Orange Orange Reset Hardware reset
RDY LED lights up red, all other LEDs light
up orange
Red Red Off BIOS loaded –
Red flash‐ Red Off BIOS error ● An error occurred while loading the
ing light 2 BIOS
Hz
Red flash‐ Red Off File error ● Memory card not inserted or faulty
ing light 2 Flashing ● Software on memory card not present
Hz light 2 Hz
or corrupted
Red Orange Off FW loading RDY LED lights up red, PN LED flashes
flashing orange without fixed frequency
light
Red Off Off FW loaded –
Off Red Off FW checked –
(no CRC error)
Red flash‐ Red flash‐ Off FW checked ● CRC error
ing light 0.5 ing light 0.5 (CRC error)
Hz Hz

Response of the LEDs when powering up – firmware

LED State Remark

RDY PN OPT
Orange Off Off Initializing –
Alternating Running See the table below

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4.9 Control Unit CU320-2 PN and CU310-2 PN

Response of the LEDs in operation

LED Color State Description, cause Remedy

RDY – OFF Electronics power supply is missing or outside per‐ Check power supply
(READY) missible tolerance range.
Green Continu‐ The component is ready for operation and cyclic –
ous light DRIVE-CLiQ communication is taking place.
Flashing Commissioning/reset –
light
0.5 Hz
Flashing Writing to the memory card –
light
2 Hz
Red Flashing General error Check parameterization/con‐
light figuration
2 Hz
Red/ Flashing Control Unit is ready for operation. Obtain licenses
green light However, there are no software licenses.
0.5 Hz
Orange Flashing Updating the firmware of the connected DRIVE- –
light CLiQ components
0.5 Hz
Flashing DRIVE-CLiQ component firmware update com‐ Perform a POWER ON of the
light plete. Wait for POWER ON for the components in affected component
2 Hz question.
Green/ Flashing Component detection via LED is activated –
Orange light (p0124[0]).
or 2 Hz Note:
Red/
Both options depend on the LED status when com‐
Orange
ponent recognition is activated via p0124[0] = 1.
PN – Off Cyclic communication has not (yet) taken place. –
PROFIdrive Note:
cyclic opera‐
PROFIdrive is ready for communication when the
tion
Control Unit is ready (see LED RDY).
Green Continu‐ Cyclic communication is taking place. –
ous light
Flashing Full cyclic communication is not yet taking place. –
light Possible causes:
0.5 Hz
● The controller is not transferring any setpoints.
● During isochronous operation, no global control
(GC) or a faulty global control (GC) is
transferred by the controller.
● "Shared Device" is selected (p8929=2) and only
one controller connected.
Red Flashing Bus fault, Adapt configuration between
light incorrect parameter assignment/configuration. controller and devices
0.5 Hz
Flashing Cyclic bus communication has been interrupted or Correct the fault
light could not be established.
2 Hz

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4.9 Control Unit CU320-2 PN and CU310-2 PN

LED Color State Description, cause Remedy

OPT – Off Electronics power supply is missing or outside per‐ Check power supply and/or
(OPTION) missible tolerance range. component
Component is not ready.
Option board not installed or no associated drive
object has been created.
Green Continu‐ Option Board is ready. –
ous light
Flashing Depends on the option board used. –
light
0.5 Hz
Red Flashing At least one fault is present on this component. Remove the fault and ac‐
light Option Board not ready (e.g. after switch-on). knowledge
2 Hz
RDY and PN Red Flashing Bus fault – communication has been interrupted Correct the fault
light
2 Hz
RDY and OPT Orange Flashing Firmware update in progress for connected Option –
light Board CBE20.
0.5 Hz

Status displays of Ethernet interfaces

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

Name Color State Meaning

Link Green Continuous 10 or 100 Mbit link available
light
Off Missing or faulty link
Activity Yellow Flashing Sending or receiving data
light
Off No activity

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Service cases - hardware
4.9 Control Unit CU320-2 PN and CU310-2 PN

4.9.2 CU320-2 PN connections

Connections

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X100 ... X102 DRIVE-CLiQ interfaces

X122, X132 Digital inputs/outputs
X124 Electronics power supply
X127 Ethernet (LAN)
X150 P1, PROFINET interfaces
X150 P2
X140 Serial interface (lower side)
T0, T1, T2 Measuring sockets (lower side)

Image 4-26 CU320-2 PN interface overview

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4.9 Control Unit CU320-2 PN and CU310-2 PN

PC board connector
Mounting a PC board connector in the measuring socket:

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The PC board connector can be purchased from: Phoenix Contact (https://

www.phoenixcontact.com/online/portal/pc)

4.9.3 This is how you remove the CU320-2 PN

Overview
The activities that are required when replacing a CU320-2 PN are subsequently described.
If the CU320-2 PN has a hardware defect, then it must be replaced by an identical module.
Preconditions:
● The module is defective and must be replaced.
● The control cabinet is in a no-voltage condition, all of the connectors and cables are labeled.

Removing
Procedure:
1. Switch off the complete system, carefully checked that it is in a no-voltage condition and
lock it out so that it cannot be switched on without the appropriate authorization.
2. Access the control cabinet where the CU320-2 PN is located.
3. Open the cover of the CU320-2 PN.

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Service cases - hardware
4.9 Control Unit CU320-2 PN and CU310-2 PN

4. Use a multimeter to check that the CU320-2 PN really is in a no-voltage condition.

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 DRIVE-CLiQ cables X100 - X103.
8. Withdraw the Profinet cable.
9. Withdraw all other cables, if available.
10.Remove the protective conductor connection of the CU320-2 PN.
11.Release the screws attaching the CU320-2 PN to the mounting plate.
12.Remove the CompactFlash card.

4.9.4 This is how you install the CU320-2 PN

Installing
Procedure:
1. Screw the new CU320-2 PN onto the mounting plate.
2. Reconnect the protective conductor connection of the CU320-2 PN.
3. First insert the PROFINET cable that was previously withdrawn.
4. Insert the DRIVE-CLiQ cables that were previously withdrawn into sockets X100-X103.
5. Insert all other cables, if available.
6. Reconnect the electronics power supply X124.
7. Now check that all of the cables have been reconnected.
8. Insert the CompactFlash card.
9. Close the cover of the CU320-2 PN.
10.Close the cabinet and switch-on the system again.

4.9.5 CU310-2 PN status displays

Module status displays

Four LEDs at the front of the CU310-2 PN provide information about the state of the module.
They indicate the states when powering up and in operation:
● If an error occurs, the power-up is terminated and the LEDs indicate the cause of the error.
● At the end of an error-free power-up, all LEDs are switched off briefly.
● After power-up, the LEDs are controlled via the loaded software.

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4.9 Control Unit CU320-2 PN and CU310-2 PN

Response of the LEDs when powering up – loading software

LED State Remark

RDY COM OUT>5V MOD
Orange Orange Orange Orange POWER ON All LEDs light up for approx. 1 s
Red Red Off Off Hardware reset After pressing the RESET button
the LEDs light up for approx. 1 s
Red Red Off Off BIOS loaded -
Red Red Off Off BIOS error An error occurred while loading the
Flashing light 2 BIOS
Hz
Red Red Off Off File error Memory card not inserted or faulty
Flashing light 2 Flashing light 2 Software on memory card not
Hz Hz present or corrupted

Response of the LEDs when powering up – firmware

LED State Remark

RDY COM OUT>5V MOD
Red Orange Off Off Firmware load‐ COM-LED flashing without fixed
ing flashing frequency
Red Off Off Off Firmware loa‐ -
ded
Off Red Off Off Firmware -
check
(no CRC error)
Red Red Off Off Firmware CRC is incorrect
Flashing light Flashing light check
0.5 Hz 0.5 Hz (CRC error)
Orange Off Off Off Firmware initi‐ -
alization

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Service cases - hardware
4.9 Control Unit CU320-2 PN and CU310-2 PN

Response of the LEDs in operation

LED Color State Description / cause Remedy

RDY - Off Electronics power supply is missing or outside Check the power sup‐
(READY) permissible tolerance range. ply
Continuous light The unit is ready for operation. -
Green Cyclic DRIVE-CLiQ communication is in progress.
Flashing light 0.5 Commissioning/reset -
Hz
Flashing light 2 Hz Writing to the memory card. -
Red Flashing light General error Check parameter as‐
2 Hz signment/configuration
Red/green Flashing light The Control Unit is ready for operation, but there Install the missing li‐
0.5 Hz are no software licenses. censes.
Flashing light Updating the firmware of the DRIVE-CLiQ com‐ -
Orange 0.5 Hz ponents.
Flashing light DRIVE-CLiQ component firmware update com‐ Switch on the compo‐
2 Hz pleted. Waiting for POWER ON of the correspond‐ nent.
ing component.
Green/Or‐ Flashing light Recognition of the component via LED is activa‐ -
ange 2 Hz ted (see SINAMICS S120/S150 List Manual.)
or Note:
Red/Or‐
Both options depend on the LED status when
ange
component recognition is activated.
COM - Off Cyclic communication has not (yet) taken place. -
Note:
PROFIdrive is ready for communication when the
Control Unit is ready (see LED: RDY).
Continuous light Cyclic communication is taking place. -
Green Flashing light Full cyclic communication is not yet taking place. -
0.5 Hz Possible causes:
● The controller is not transferring any setpoints.
● During isochronous operation, no GC (Global
Control) or a faulty GC is transferred by the
controller.
Flashing light The PROFIBUS master is sending a faulty param‐ Modify the configura‐
Red 0.5 Hz eter assignment or the configuration file is corrup‐ tion between master/
ted. controller and Control
Unit.
Flashing light Cyclic bus communication has been interrupted Rectify the bus com‐
2 Hz or could not be established. munication fault.
MOD - Off - -
OUT > 5 V - Off - -
Orange Continuous light The voltage of the electronics power supply for
the measuring system is 24 V. 1)
1)
Make sure that the encoder connected is designed for a 24 V supply. Connecting a 5 V encoder to a 24 V supply can
destroy the encoder electronics.

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4.9 Control Unit CU320-2 PN and CU310-2 PN

Status displays of PROFINET interfaces

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

Name Color State Meaning

Link Green Continuous 10 or 100 Mbit link available
light
Off Missing or faulty link
Activity Yellow Flashing Sending or receiving data
light
Off No activity

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Service cases - hardware
4.9 Control Unit CU320-2 PN and CU310-2 PN

4.9.6 CU310-2 PN connections

Connections

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X22 Serial interface

X23 Encoder interface HTL/TTL/SSI
X100 DRIVE-CLiQ interface
X120 Fail-safe digital inputs/connection for the temperature sensor
X121 Digital inputs/digital outputs
X124 Electronics power supply
X127 LAN (Ethernet)
X130 Digital input/fail-safe digital output
X131 Digital input/output/analog input
X150 P1 PROFINET interfaces
X150 P2

Image 4-27 Interface overview of the CU310-2 PN

Note
The PROFIBUS address switch on the CU310-2 PN has no function.

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4.9 Control Unit CU320-2 PN and CU310-2 PN

4.9.7 This is how you remove the CU310-2 PN

Overview
The activities that are required when replacing a CU310-2 PN are subsequently described.
If the CU310-2 PN has a hardware defect, then it must be replaced by an identical module.
Preconditions:
● The module is defective and must be replaced.
● The control cabinet is in a no-voltage condition, all of the connectors and cables are labeled.

Removing
Procedure:
1. Switch off the complete system, carefully checked that it is in a no-voltage condition and
lock it out so that it cannot be switched on without the appropriate authorization.
2. Access the control cabinet where the CU310-2 PN is located.
3. Use a multimeter to check that the CU310-2 PN really is in a no-voltage condition.
4. If it has not already been done, label all connectors and cables that lead to the module now.
Only then, can it be ensured that the cables are not interchanged.
5. Withdraw the electronics power supply X124.
6. Withdraw the DRIVE-CLiQ cable X100.
7. Withdraw all other cables, if available.
8. Remove the protective conductor connection of the CU310-2 PN.

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Service cases - hardware
4.9 Control Unit CU320-2 PN and CU310-2 PN

9. Press the blue locking latch downward (see arrow).

Image 4-28 Removing the CU310-2 PN from the PM340

10.Remove the Control Unit toward the front.

11.Remove the CompactFlash card.

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4.9 Control Unit CU320-2 PN and CU310-2 PN

4.9.8 This is how you install the CU310-2 PN

Installing
Procedure:
1. Place the Control Unit on the PM340.

Image 4-29 Mounting the CU310-2 PN on the PM340

2. Push the Control Unit back until it latches in the blue locking latch.
3. Reconnect the protective conductor connection of the CU310-2 PN.
4. Insert the DRIVE-CLiQ cable that was previously withdrawn into socket X100.
5. Insert all other cables, if available.
6. Reconnect the electronics power supply X124.
7. Now check that all of the cables have been reconnected.
8. Insert the CompactFlash card.
9. Close the cabinet and switch-on the system again.

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4.10 SINAMICS S120 Combi

4.10 SINAMICS S120 Combi

4.10.1 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 permissi‐ Connect/test the electronics pow‐
ble tolerance range. er 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 DRIVE- Check the line supply voltage.
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 acknowl‐
Note: edge
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/Or‐ - Component recognition using LED is activated (p0124) -
ange Note:
or
Both options depend on the LED status when module
Red/Orange
recognition is activated via p0124 = 1.

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DANGER
Danger to life through electric shock due to the residual charge of the DC link capacitors
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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4.10.2 Connections, 3-axis module

Connections

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

Image 4-31 S120 Combi 3 axis Power Module

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4.10.3 Connections, 4-axis module

Connections, S120 Combi with 4 axes

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EP terminal The shield support is included in the accessories pack (Weidmüller, type KLBÜ 3-8 SC).

Image 4-33 S120 Combi 4 axis Power Module

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4.10.4 How to mount an S120 Combi Power Module

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

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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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Image 4-34 Installing an S120 Combi Power Module

4. Connect the protective conductor.

See also: Protective conductor connection and shield support (Page 115)
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

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4.10.5 This is how you attach the drip protection

Attaching the drip protection

To prevent liquids from dripping into the module from the top, a drip protection assembly is
available; this is provided as standard in the scope of supply for the 4-axis version. For the
other S120 Combi Power Modules, drip protection assembly can be ordered as spare part
(Page 231).
Attach the drip protection assembly to the top of the S120 Combi Power Module:

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Image 4-35 S120 Combi Power Modules with drip protection

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4.10 SINAMICS S120 Combi

4.10.6 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
Danger to life through electric shock
A hazardous voltage is still present for up to 5 minutes after the power supply has been
switched off.
● Remove the front plate only after 5 minutes have passed.

Procedure:
1. Use a Torx T20 or slotted 1.2 x 6 screwdriver as tool.
2. Remove the two Torx-slotted screws at the front.

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3. Release the front cover by slightly pressing upwards

4. Remove the front plate.

4.10.7 This is how you open the DC link cover

Opening the DC link cover

To electrically connect additional components, the front cover of the S120 Combi must already
have been removed.

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The DC link busbars are located under the DC link cover.

DANGER
Danger to life through electric shock due to the residual charge of the DC link capacitors
As a result of the DC link capacitors, a hazardous voltage is present for up to 5 minutes after
the power supply has been switched off.
Contact with live parts results in death or serious injury.
● Do not open the protective cover of the device until 5 minutes have elapsed.
● Before starting any work, check that the system is in a completely no-voltage condition by
measuring all poles/phases, also to ground.
● Ensure that the associated warning plate in the appropriate language is attached.

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

2. Remove the DC link cover.

3. Remove the DC link side cover.

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4.10.8 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.

Note
When commissioning a drive line-up the following must be observed
The following points must be complied with before commissioning the drive line-up:
● 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.

Note
Attach the touch protection for the DC link busbars
After removing the additional components, before recommissioning the system, the touch
protection of the DC link busbars on the S120 Combi power module must be reinstalled. The
touch protection can be ordered as a spare part.

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

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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!
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.

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4.10.9 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:

Note
Before commissioning a drive line-up the following must be observed
The following points must be complied with before commissioning the drive line-up:
● The DC link side cover is inserted at the outer component (touch protection).
● The protective covers of the connected components are closed.

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


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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

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4. Install the lower DC link busbar:

– Release the screws

– Turn over the DC link bridge.
– Observe the sequence when tightening the screws
5. Install the upper DC link busbar:

– Release the screws

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

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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 covers of both components.

4.10.10 This is how you remove the internal fan

Removing the internal fan

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

DANGER
Danger to life through live parts and components
Death or serious injury can result when live parts are touched.
● Switch off the power supply before replacing the fan (400 V AC). A hazardous voltage is
still present for up to 5 minutes after the power supply has been switched off.
● Before removing the component, carefully ensure that it is in a no-voltage condition.

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4.10 SINAMICS S120 Combi

Procedure:
1. Remove the S120 Combi front cover (see also: This is how you remove the front panel
(Page 138)).
2. Remove the Torx-slotted screw of the fan cover.

3. Remove the fan cover,

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

Opened fan compartment:

5. Withdraw the fan.

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4.10.11 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.

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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 138) )

4.10.12 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 135)).

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

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4.10 SINAMICS S120 Combi

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.

Image 4-36 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 module in the specified sequence (step ① to step ④):

Image 4-37 Step ①

Image 4-38 Step ②

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4.10 SINAMICS S120 Combi

Image 4-39 Step ③

Image 4-40 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 (arrow
1 to arrow 5):

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Boundary condition
It is important that the reinforcement plates must always be installed when operating the S120
Combi with the external fan unit:

WRONG: CORRECT:
S120 Combi and external fan unit without rein‐ S120 Combi and external fan unit with instal‐
forcement plates led reinforcement plates

Note
Shutdown as a result of excessively high temperature if the reinforcement plates are missing
Operation without the reinforcement plates is not permissible.
If the reinforcement plates are incorrectly fixed, this can result in an excessively high heat sink
temperature and cause the S120 Combi to prematurely trip.

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

Cleaning the heat sink

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

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4.10 SINAMICS S120 Combi

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.

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

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

The air baffle plate has been removed.

The heat sink can now be cleaned:

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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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4.11 Motor Module Booksize Compact format

4.11 Motor Module Booksize Compact format

4.11.1 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 permissi‐ –-
ble 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 DRIVE- Check the line supply voltage.
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 ac‐
Note: knowledge
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 POW‐ Carry out a POWER ON
(2 Hz) ER 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
Danger to life through electric shock due to the residual charge of the DC link capacitors
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 Motor Module Booksize Compact format

4.11.2 Motor Module connections

Single Motor Module connections

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Double Motor Module connections

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4.11 Motor Module Booksize Compact format

4.11.3 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

 
① Mounting wall
② Screw M6 x 16
③ Plain washer
④ Spring washer
⑤ Nut

Image 4-43 Motor Module Booksize Compact

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4.11 Motor Module Booksize Compact format

4.11.4 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.

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

DANGER
Danger to life through live parts and components
Death or serious injury can result when live parts are touched.
● Switch off the power supply before replacing the fan (400 V AC). A hazardous voltage is
still present for up to 5 minutes after the power supply has been switched off.
● Before removing the component, carefully ensure that it is in a no-voltage condition.

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4.11 Motor Module Booksize Compact format

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

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

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3. Carefully withdraw the fan.

4. Release the connector before you withdraw it.

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.

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4.11 Motor Module Booksize Compact format

3. Install the fan.

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

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4.12 Single Motor Modules

4.12 Single Motor Modules

4.12.1 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 voltage.
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 ac‐
Note: knowledge.
The LED is controlled irrespective of the corresponding
messages being reconfigured.
Green/red (0.5 – Firmware is being downloaded. –
Hz)
Green/red (2 - Firmware download has been completed. Wait for POW‐ Carry out a POWER ON.
Hz) ER 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
Danger to life through electric shock due to the residual charge of the DC link capacitors
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 Single Motor Modules

4.12.2 SMM connections

Connections

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4.12 Single Motor Modules

4.12.3 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
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
Danger to life through electric shock due to the residual charge of the DC link capacitors
As a result of the DC link capacitors, a hazardous voltage is present for up to 5 minutes after
the power supply has been switched off.
Contact with live parts results in death or serious injury.
● Do not open the protective cover of the device until 5 minutes have elapsed.
● Before starting any work, check that the system is in a completely no-voltage condition by
measuring all poles/phases, also to ground.
● Ensure that the associated warning plate in the appropriate language is attached.

1. 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).
2. Withdraw the 24 V terminal adapter.

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4.12 Single Motor Modules

3. 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).

-XPSHUSOXJ

'&3

'&

4. Withdraw the red 24 V jumper plug.

5. Release the Torx screws of the DC link.

7RU[ 7 7RU[ 7

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4.12 Single Motor Modules

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

7. Release the screws that are used to retain the motor module to the mounting plate.
8. Remove the protective conductor connection of the Motor Module.
9. Remove the Motor Module from the control cabinet.

4.12.4 This is how you install a Motor Module

Installing

DANGER
Danger to life through electric shock due to the residual charge of the DC link capacitors
As a result of the DC link capacitors, a hazardous voltage is present for up to 5 minutes after
the power supply has been switched off.
Contact with live parts results in death or serious injury.
● Do not open the protective cover of the device until 5 minutes have elapsed.
● Before starting any work, check that the system is in a completely no-voltage condition by
measuring all poles/phases, also to ground.
● Ensure that the associated warning plate in the appropriate language is attached.

Procedure:
1. Screw the new 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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4.12 Single Motor Modules

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

7RU[ 7

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

   

7RU[ 7 7RU[ 7

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.
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.

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4.12 Single Motor Modules

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.

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4.13 Double Motor Modules

4.13 Double Motor Modules

4.13.1 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 DRIVE- Check the line supply voltage.
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 ac‐
Note: knowledge
The LED is controlled irrespective of the corresponding
messages being reconfigured.
Green/red (0.5 – Firmware is being downloaded. –
Hz)
Green/red (2 - Firmware download has been completed. Wait for POW‐ Carry out a POWER ON.
Hz) ER 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
Danger to life through electric shock due to the residual charge of the DC link capacitors
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 Double Motor Modules

4.13.2 DMM connections

Connections

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Image 4-45 Double Motor Module (DMM)

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4.13 Double Motor Modules

4.13.3 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
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
Danger to life through electric shock due to the residual charge of the DC link capacitors
As a result of the DC link capacitors, a hazardous voltage is present for up to 5 minutes after
the power supply has been switched off.
Contact with live parts results in death or serious injury.
● Do not open the protective cover of the device until 5 minutes have elapsed.
● Before starting any work, check that the system is in a completely no-voltage condition by
measuring all poles/phases, also to ground.
● Ensure that the associated warning plate in the appropriate language is attached.

1. 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).
2. Withdraw the 24 V terminal adapter.

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4.13 Double Motor Modules

3. 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).

-XPSHUSOXJ

'&3

'&

4. Withdraw the red 24 V jumper plug.

5. Release the Torx screws of the DC link.

7RU[ 7 7RU[ 7

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4.13 Double Motor Modules

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

7. Release the screws that are used to retain the motor module to the mounting plate.
8. Remove the protective conductor connection of the Motor Module.
9. Remove the Motor Module from the control cabinet.

4.13.4 This is how you install a Motor Module

Installing

DANGER
Danger to life through electric shock due to the residual charge of the DC link capacitors
As a result of the DC link capacitors, a hazardous voltage is present for up to 5 minutes after
the power supply has been switched off.
Contact with live parts results in death or serious injury.
● Do not open the protective cover of the device until 5 minutes have elapsed.
● Before starting any work, check that the system is in a completely no-voltage condition by
measuring all poles/phases, also to ground.
● Ensure that the associated warning plate in the appropriate language is attached.

Procedure:
1. Screw the new 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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4.13 Double Motor Modules

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

7RU[ 7

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

   

7RU[ 7 7RU[ 7

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.
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.

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4.13 Double Motor Modules

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.

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4.14 Smart Line Modules

4.14 Smart Line Modules

4.14.1 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 per‐ –-
missible 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 termi‐
nal:
-- Continuous DC link voltage in the permissible tolerance range. --
yellow light
-- Continuous Line supply faults: DC link voltage outside the permis‐ Check the line supply voltage.
red light sible tolerance range.

DANGER
Danger to life through electric shock due to the residual charge of the DC link capacitors
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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4.14 Smart Line Modules

4.14.2 SLM (< 16 kW) connections

Connections

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Image 4-46 SLM connections

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4.14 Smart Line Modules

4.14.3 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 permis‐ –
sible 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 (0.5 Hz) – Firmware is being downloaded. –
Green/red (2 Hz) - Firmware download has been completed. Wait for POW‐ Carry out a POWER
ER 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
Danger to life through electric shock due to the residual charge of the DC link capacitors
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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4.14 Smart Line Modules

4.14.4 SLM (16 kW and higher) connections

Connections

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Image 4-47 Connections,SLM ≥ 16 kW

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4.14 Smart Line Modules

4.14.5 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
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
Danger to life through electric shock due to the residual charge of the DC link capacitors
As a result of the DC link capacitors, a hazardous voltage is present for up to 5 minutes after
the power supply has been switched off.
Contact with live parts results in death or serious injury.
● Do not open the protective cover of the device until 5 minutes have elapsed.
● Before starting any work, check that the system is in a completely no-voltage condition by
measuring all poles/phases, also to ground.
● Ensure that the associated warning plate in the appropriate language is attached.

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

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4.14 Smart Line Modules

3. 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

'&3

'&

4. Withdraw the red 24 V jumper plug.

5. Release the Torx screws of the DC link.

7RU[ 7

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

7. Release the screws that are used to retain the module to the mounting plate.
8. Remove the protective conductor connection of the module.
9. Remove the module from the control cabinet.

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4.14 Smart Line Modules

4.14.6 This is how you install an SLM

Installing

DANGER
Danger to life through electric shock due to the residual charge of the DC link capacitors
As a result of the DC link capacitors, a hazardous voltage is present for up to 5 minutes after
the power supply has been switched off.
Contact with live parts results in death or serious injury.
● Do not open the protective cover of the device until 5 minutes have elapsed.
● Before starting any work, check that the system is in a completely no-voltage condition by
measuring all poles/phases, also to ground.
● Ensure that the associated warning plate in the appropriate language is attached.

Procedure:
1. Screw the new 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.


0

'&3

'&

2EVHUYHWKHVHTXHQFH
 
ZKHQWLJKWHQLQJ

7RU[ 7
1P

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Service cases - hardware
4.14 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.

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4.15 Active Line Modules

4.15 Active Line Modules

4.15.1 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 (0.5 Hz) - Firmware is being downloaded. –
Green/red (2 Hz) - Firmware download has been completed. Wait for POW‐ Carry out a POWER
ER ON. ON.
Green/orange or – Component recognition via LED is activated (p0124). –
red/orange Note:
Both options depend on the LED status when module rec‐
ognition is activated via p0124 = 1.

DANGER
Danger to life through electric shock due to the residual charge of the DC link capacitors
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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Service cases - hardware
4.15 Active Line Modules

4.15.2 ALM connections

Connections

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Image 4-48 ALM connections

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4.15 Active Line Modules

4.15.3 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
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
Danger to life through electric shock due to the residual charge of the DC link capacitors
As a result of the DC link capacitors, a hazardous voltage is present for up to 5 minutes after
the power supply has been switched off.
Contact with live parts results in death or serious injury.
● Do not open the protective cover of the device until 5 minutes have elapsed.
● Before starting any work, check that the system is in a completely no-voltage condition by
measuring all poles/phases, also to ground.
● Ensure that the associated warning plate in the appropriate language is attached.

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

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4.15 Active Line Modules

3. 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

'&3

'&

4. Withdraw the red 24 V jumper plug.

5. Release the Torx screws of the DC link.

7RU[ 7

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

7. Release the screws that are used to retain the module to the mounting plate.
8. Remove the protective conductor connection of the module.
9. Remove the module from the control cabinet.

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4.15 Active Line Modules

4.15.4 This is how you install an ALM

Installing

DANGER
Danger to life through electric shock due to the residual charge of the DC link capacitors
As a result of the DC link capacitors, a hazardous voltage is present for up to 5 minutes after
the power supply has been switched off.
Contact with live parts results in death or serious injury.
● Do not open the protective cover of the device until 5 minutes have elapsed.
● Before starting any work, check that the system is in a completely no-voltage condition by
measuring all poles/phases, also to ground.
● Ensure that the associated warning plate in the appropriate language is attached.

Procedure:
1. Screw the new 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.


0

'&3

'&

2EVHUYHWKHVHTXHQFH
 
ZKHQWLJKWHQLQJ

7RU[ 7
1P

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Service cases - hardware
4.15 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.

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4.16 Sensor Modules Cabinet

4.16 Sensor Modules Cabinet

4.16.1 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 cy‐ –
clic DRIVE-CLiQ communication is taking
place.
Orange Continuous light DRIVE-CLiQ communication is being estab‐ –
lished.
Red Continuous light This component has at least one fault. Remove and acknowl‐
Note: edge fault.
The LED is controlled irrespective of the corre‐
sponding 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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Service cases - hardware
4.16 Sensor Modules Cabinet

4.16.2 SMC10/SMC20 connections

Connections

;

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X500 DRIVE-CLiQ
X520 Encoder system interface
X524 Electronics power supply

Image 4-49 SMC10/SMC20 connections

4.16.3 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.

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4.16 Sensor Modules Cabinet

Removing

6ZLYHOWKHPRGXOHWRWKHIURQW

0RXQWLQJVOLGH

3XVKWKHOXJGRZQZDUGV

Image 4-50 Removing the SMC10/SMC20

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.

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

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4.16 Sensor Modules Cabinet

4.16.4 This is how you install an SMC10/SMC20

Installing
Procedure:
1. Place the component on the mounting rail.
2. Then, swivel the component on the mounting rail so that the mounting catches click into
place at the rear.
3. Slide the component along the mounting rail to either the left or right up to its final position.
4. Screw on the protective conductor connection.
5. Screw on the encoder connecting cable to X520 and X521 / X531, if required, also the
shield connection.
6. Insert the DRIVE-CLiQ cable at X500.
7. Insert connector X524 for the electronics power supply.
Note
The 50 mm ventilation clearances above and below the components must be observed.

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4.16.5 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 establish‐ –
ed.
Red Continuous light This component has at least one fault. Remove and acknowl‐
Note: edge fault.
The LED is controlled irrespective of the corre‐
sponding messages being reconfigured.
Green/red Flashes at 0.5 Hz Firmware is being downloaded. –
Flashes at 2 Hz Firmware download has been completed. 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 oper‐
ate 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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4.16 Sensor Modules Cabinet

4.16.6 SMC30 connections

Connections

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X500 DRIVE-CLiQ
X524 Electronics power supply
X520, X521, Encoder system interfaces: HTL, TTL, with track monitoring SSI
X531

Image 4-51 Connections SMC30

4.16.7 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.

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4.16 Sensor Modules Cabinet

Removing

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Image 4-52 SMC30 removal

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

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4.16 Sensor Modules Cabinet

4.16.8 This is how you install an SMC30

Installing

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Procedure:
1. Place the component on the mounting rail.
2. Then, swivel the component on the mounting rail so that the mounting catches click into
place at the rear.
3. Slide the component along the mounting rail to either the left or right up to its final position.
4. Screw on the protective conductor connection.
5. Screw on the encoder connecting cable to X520 or X521 / X531, if required, also the shield
connection.
6. Insert the DRIVE-CLiQ cable at X500.
7. Insert connector X524 for the electronics power supply.
Note
The 50 mm ventilation clearances above and below the components must be observed.

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4.16 Sensor Modules Cabinet

4.16.9 SMC40 status displays

Status displays
The Sensor Module Cabinet-Mounted SMC40 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 –
READY tolerance range.
Green Continu‐ The component is ready for operation and cyclic DRIVE-CLiQ –
ous light communication is taking place.
Orange Continu‐ DRIVE-CLiQ communication is being established. –
ous light
Red Continu‐ At least one fault is present in this component. Remedy and acknowl‐
ous light Note: edge fault
The LED is controlled irrespective of the corresponding mes‐
sages being reconfigured.
Green/red Flashing Firmware download has been completed. Wait for POWER Carry out a POWER
light ON. ON
2 Hz
Green/ Flashing Component recognition via LED is activated (p0144) –
orange light Note:
or Both options depend on the LED status when module recog‐
Red/ nition is activated via p0144 = 1.
orange

Each channel has a multifunction LED.

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4.16 Sensor Modules Cabinet

4.16.10 SMC40 connections

Connections

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X500/1, DRIVE-CLiQ
X500/2
X520/1, Encoder system interfaces with multifunction LED per channel
X520/2
X524 Electronics power supply

Image 4-54 Connections SMC40

4.16.11 This is how you remove an SMC40

Overview
The activities that must be taken into account when replacing an SMC40 are subsequently
described.
If an SMC40 has a hardware defect, then it must be replaced by an identical module.
Preconditions:
● The module is defective and must be replaced.
● The control cabinet is in a no-voltage condition, all of the connectors and cables are labeled.

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4.16 Sensor Modules Cabinet

Removing

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Image 4-55 SMC40 removal

Procedure:
1. Before withdrawing it, label the connector X524 for the electronics power supply.
2. Unscrew the encoder connecting cables X520/x.
3. Label the DRIVE-CLiQ cables X500/x and withdraw them.
4. Release the protective conductor connection and write the position designation on the cable.
5. Slide the lug downwards.
6. Swivel the module to the front to remove it.
Note
The 50 mm ventilation clearances above and below the components must be observed.

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4.16 Sensor Modules Cabinet

4.16.12 This is how you install an SMC40

Installing

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Image 4-56 SMC40 installation

Procedure:
1. Place the component on the mounting rail.
2. Then, swivel the component on the mounting rail so that the mounting catches click into
place at the rear.
3. Slide the component along the mounting rail to either the left or right up to its final position.
4. Screw on the protective conductor connection.
5. Screw on the encoder connecting cables X520/x.
6. Insert the DRIVE-CLiQ cables at X500/x.
7. Insert connector X524 for the electronics power supply.
Note
The 50 mm ventilation clearances above and below the components must be observed.

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4.17 Sensor Modules External

4.17 Sensor Modules External

4.17.1 SME20 connections

Connections

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Image 4-57 Connections SME20

4.17.2 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
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.

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4.17 Sensor Modules External

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.

Note
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.

4.17.3 SME25 connections

Connections

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Image 4-58 Connections SME25

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

Overview
The activities that must be taken into account when replacing an SME25 are subsequently
described.

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4.17 Sensor Modules External

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
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.

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

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4.17 Sensor Modules External

4.17.5 SME120 connections

Connections
Requirements: The control cabinet is in a no-voltage condition, all of the connectors and cables
are labeled.

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X100 Encoder system interfaces, tightening torque: 3.5 Nm
X200 Temperature sensor input, tightening torque: 2 Nm
X300 Hall sensor input, tightening torque: 3.5 Nm
X500 DRIVE-CLiQ

Image 4-59 SME120 connections

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

Removing
Procedure:
1. Release the encoder connecting cable X100 of the SME120.
2. Withdraw the DRIVE-CLiQ cable from X500 of the SME120.
3. Release the Hall sensor input X300 of the SME120.
4. Release the temperature sensor input X200 of the SME120.
5. Release the protective conductor connection of the SME120.
6. Remove the defective SME120 module.

Installing
Procedure:
1. Now install the new SME120 module.
2. Screw on the protective conductor connection.
3. Reconnect the temperature sensor at X200.

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4. Reconnect the Hall sensor at X300.

5. Reconnect the encoder connecting cable.
6. Connect the DRIVE-CLiQ cable.
Note
Connections/cables
The maximum DRIVE-CLiQ cable length is 100 m.
The maximum encoder cable length is 3 m.
In order to guarantee the degree of protection, all of the plug connectors must be correctly
screwed and snapped into place.

4.17.7 SME125 connections

Connections
Requirements: The control cabinet is in a no-voltage condition, all of the connectors and cables
are labeled.

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X200 Temperature sensor input, tightening torque: 2 Nm
X500 DRIVE-CLiQ

Image 4-60 SME125 connections

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4.17 Sensor Modules External

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

Removing
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.

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

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4.18 Terminal Modules

4.18 Terminal Modules

4.18.1 TM54F status displays

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

State Description, cause Remedy

RDY L1+, L2+ L3+
Off –- –- Electronics power supply is missing or outside permissible –-
tolerance range.
Continuous –- –- The component is ready for operation and cyclic DRIVE- –-
green light CLiQ communication is taking place.
Orange con‐ –- –- DRIVE-CLiQ communication is being established. –-
tinuous light
Continuous –- –- At least one fault is present in this component. Remove and ac‐
red light Note: knowledge fault.
The LED is controlled irrespective of the corresponding
messages being reconfigured.
Green / red –- –- Firmware is being downloaded. –-
flashing light
0.5 Hz
Flashing light –- –- Firmware download has been completed. Wait for POWER Carry out a
2 Hz ON POWER ON.
Green/or‐ –- –- Component recognition via LED is activated (p0154). –-
ange Note:
Flashing light Both options depend on the LED status when activated via
- OR - p0154 = 1.
Red/orange
Flashing light
–- On –- The sensor power supply that can be dynamized is func‐ –-
tioning fault-free.
–- Continuous –- There is a fault in the sensor power supply that can be –-
red light dynamized.
–- –- On The sensor power supply is operating fault-free. --
–- –- Continuous There is a fault in the sensor power supply. --
red light

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4.18 Terminal Modules

Fail-safe inputs / double inputs

LED state Description, cause Remedy

F_DI z
(Input x, (x+1)+, (x+1)-)
LED x LED x+1 NC contact / NC contact 1): (z = 0..9, x = 0, 2, ..18) –-
Continuous – Red Different signal states at inputs x and 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)
Continuous – Red Identical signal states at inputs x and x+1
light – – No signal at input x and a signal at input x+1
–
LED x LED x+1 NC contact / NC contact 1): (z = 0..9, x = 0, 2, ..18) –-
Continuous Green Green One signal at input x and one signal at input x+1
light Green Green NC contact / NO contact 1): (z = 0..9, x = 0, 2, ..18)
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.

Single digital inputs, not fail-safe

LED state Description, cause Remedy

DI x
– Off No signal at digital input x (x = 20..23) –
Green Continuous Signal at digital input x –
light

Fail-safe digital outputs with associated readback channel

LED state Description, cause Remedy

F_DO y (0+..3+, 0-..3-)
Green Continuous Output y (y=0 .. 3) has a signal –
light
Read back input DI 2y for output F_DO y (y = 0..3) for test stop.
The state of the LEDs 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 light Both output lines y+ and y- have no signal –

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4.18 Terminal Modules

4.18.2 TM54F connections

Connections

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X501, X500 DRIVE-CLiQ interfaces

X524 Electronics power supply
RDY LEDs for status display
X521, X531 Fail-safe digital inputs DI and dynamic power supply
X522, X532 Fail-safe digital inputs DI
X523, X525, X533, Fail-safe digital outputs DO
X535
X520 Sensor power supply
X514 Power supply for digital outputs and sensors

Image 4-61 TM54F connections

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4.18 Terminal Modules

4.18.3 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.

Removing

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Image 4-62 TM54F removal

Procedure:
1. Label connectors X514 and X524 for the sensor and electronics power supply prior to
withdrawing them.
2. Withdraw the connected DRIVE-CLiQ cables X500 and X501 and write the slot designation
on the cable.
3. Label the connected connectors X520 - X535 for digital inputs and outputs prior to
withdrawing them.

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4.18 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.
Note
The 50 mm ventilation clearances above and below the components must be observed.

4.18.4 This is how you install a TM54F

Installing
Procedure:
1. Place the component on the mounting rail.
2. Then, swivel the component on the mounting rail so that the mounting catches click into
place at the rear.
3. Slide the component along the mounting rail to either the left or right up to its final position.
4. Screw on the protective conductor connection.
5. 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.
Note
The 50 mm ventilation clearances above and below the components must be observed.

4.18.5 TM120 status displays

Status displays
The Terminal Module TM120 has the following status displays, which provide information about
the module state:

State Description, cause Remedy

RDY
- Off Electronics power supply is missing or outside permissible toler‐ Check the power sup‐
ance range. ply.
Green Continuous The component is ready for operation and cyclic DRIVE-CLiQ com‐ --
light munication is taking place.

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4.18 Terminal Modules

State Description, cause Remedy

RDY
Orange Continuous DRIVE-CLiQ communication is being established. --
light
Red Continuous At least one fault is present in this component. Remove and acknowl‐
light Note: edge fault.
The LED is controlled irrespective of the corresponding messages
being reconfigured.
Green/red Flashing light Firmware is being downloaded. --
0.5 Hz
Flashing light Firmware download has been completed. Wait for POWER ON Carry out a POWER
2 Hz ON.
Green/ Component recognition via LED is activated (p0154). --
orange Flashing light Note:
or 2 Hz Both options depend on the LED status when activated via p0154
red/
= 1.
orange

4.18.6 TM120 safety instructions

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

Note
Shielding
Connecting cables to temperature sensors must always be installed with shielding. The cable
shield must be connected to the ground potential at both ends over a large surface area.
Temperature sensor cables that are routed together with the motor cable must be twisted in
pairs and shielded separately.

Note
If sensors other than those specified are connected, this may result in incorrect measured
values.

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4.18 Terminal Modules

4.18.7 TM120 connections

Connections

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X500, X501 DRIVE-CLiQ interfaces

RDY LEDs for status display
X521 Inputs for the temperature sensor
X524 Electronics power supply

Image 4-63 TM120 connections

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4.18 Terminal Modules

4.18.8 This is how you remove a TM120 and install it again

Removing
Procedure:
1. First shift the mounting slide downward at the lug to release the interlocking with the
mounting rail.
2. Then swivel the component toward the front so that you can remove it upward from the
mounting rail.


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WKHIURQW

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Image 4-64 Removing the TM120

Installing
Procedure:
1. Slightly tilt the component backward and attach it to the mounting rail using the catch.
2. Swivel the component on the mounting rail until you hear the mounting slide at the rear
latch into position.
3. Slide the component along the mounting rail to either the left or right up to its final position.

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4.19 Hub Modules

4.19 Hub Modules

4.19.1 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 cy‐ –
clic DRIVE-CLiQ communication is taking
place.
Orange Continuous light DRIVE-CLiQ communication is being establish‐ –
ed.
Red Continuous light This component has at least one fault. Remove and acknowl‐
Note: edge fault.
The LED is controlled irrespective of the corre‐
sponding messages being reconfigured.
Green/red Flashes at 0.5 Hz Firmware is being downloaded. –
Flashes at 2 Hz Firmware download has been completed. Wait 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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4.19 Hub Modules

4.19.2 DMC20 connections

Connections

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X500 ... X505 DRIVE-CLiQ interfaces

X524 Electronics power supply

Image 4-65 Connections DMC20

4.19.3 This is how you remove a DMC20

Removing
Precondition: The control cabinet is in a no-voltage condition, all of the connectors and cables
are labeled.
Procedure:
1. Before withdrawing it, label the connector X524 for the electronics power supply.
2. Withdraw the connected DRIVE-CLiQ cables X500 – X505 and write the slot designation
on the cable.
3. Release the protective conductor connection and write the position designation on the
cable.

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4.19 Hub Modules

4. First shift the mounting slide downwards at the lug ① to release the interlocking with the
mounting rail.

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0RXQWLQJVOLGH

Image 4-66 Removing the DMC20

5. Swivel the module to the front to remove it from the mounting rail ②.

4.19.4 This is how you install a DMC20

Installing

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

Procedure:
1. Place the component on the mounting rail.
2. Then, swivel the component on the mounting rail so that the mounting catches click into
place at the rear.
3. Slide the component along the mounting rail to either the left or right up to its final position.
4. Screw on the protective conductor connection.
5. Screw on the encoder connecting cable to X520.

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4.19 Hub Modules

6. Insert the DRIVE-CLiQ cable at X500 – X505.

7. Insert connector X524 for the electronics power supply.

4.19.5 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.

;
;

;

; ;

;
;

;

X500 ... X505 DRIVE-CLiQ interfaces

X524 Electronics power supply

Image 4-67 DME20 connections

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 Service cases - hardware
4.19 Hub Modules

4.19.6 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.
 

0RXQWLQJVXUIDFH

 
 


 
0
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Image 4-68 DME20 dimensions

2. Drill the holes with Ø5.3 or M5 threads.

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

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Service cases - hardware
4.19 Hub Modules

4.19.7 Connection to X524 electronics power supply

Secondary conditions for DMC20 with UL approval

Pin assignment of the cable for connection to X524:

Pin Designation Technical specifications

 1 (brown) Electronics power supply The supply voltage of 20.4 V – 28.8
2 (white) Electronics power supply V refers to the terminal voltage at the
  
DME20.
3 (black) Electronics ground
 The cable cross-section and the
4 (blue) Electronics ground power supply cable length should be
5 (gray) Not connected observed:
● Pins 1 and 2 are internally
jumpered.
● Pins 3 and 4 are internally
jumpered.

Address where the cables can be sourced

The following cables can be sourced through: Phoenix Contact (https://
www.phoenixcontact.com/online/portal/pc)

Pre-assembled cables Cables to be assembled by the user

Sensor/actuator cable, 5-pole, free cable end at Cable ring, PUR/PVC black, 5-pole
the M12-SPEEDCON straight socket Conductor colors: brown/white/blue/black/gray
Length of cable: 2, 5, 10, 15 m (up to 100 m on Cable length: 100 m
request)
Conductor cross-section: 5 x 0.75 mm²
SAC-5P-xxx-186/FS SCO
SAC-5P-100.0-186/0.75
Article number: 1535590
Connector:
Sensor/actuator connector, socket, straight, 5-pin,
M12, A-coded
Screw connection, metal knurl, Pg9 cable gland
SACC-M12FS-5CON-PG9-M
Article number: 1681486

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 Service cases - hardware
4.20 MODEM MD720

4.20 MODEM MD720

4.20.1 Status displays MODEM MD720

LED status
The modem has three LEDs, which provide information about the operating state:

MODEM MD720 LED State Meaning

All in common Flash on and off in a fast se‐ Device starts
quence Service mode
Slow flashing in synchronism Loading a firmware file
Flash on and off in a slow se‐ Error
quence
Fast flashing in synchronism
STATUS Slow flashing Waiting for PIN input
Fast flashing PIN error/ SIM error
QUALITY Slow flashing Logging into a 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
ON Field strength very good
OFF Waiting for PIN
CONNECT Flashing Terminal mode activated

Reference
You can find information about the MODEM MD720 (Article number: 6NH9720-3AA01-0XX0)
at: MODEM MD720 (https://support.industry.siemens.com/cs/document/73513752)

4.20.2 Replace SIM card

Removing the modem

To remove the module, proceed as follows:
1. Ensure that the module has been disconnected from the power supply.
2. Remove the MODEM MD720 from the mounting rail.

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Service cases - hardware
4.20 MODEM MD720

Replace SIM card

Use a mini SIM card, 15 x 25 mm.
Proceed as follows to replace the SIM card:
1. Release the slide for the SIM card at the rear of the MODEM MD720 by gently pressing
the release button.

6,0FDUGVORWZLWKVOLGH
WRDFFHSWWKH6,0FDUG

5HOHDVHEXWWRQWRUHMHFW

Image 4-69 MODEM MD720, rear side

2. Withdraw the slide from the housing and remove the SIM card.
3. Insert the new SIM card into the slide.
4. Move the slide into the housing until it gently latches into place.
5. Mount the MODEM MD720 on the mounting rail.

Note
Replacing the SIM card and PIN
When changing the SIM card, do not forget to change the PIN in your control.
If you are using a lot of SIM cards, it may make sense to set all SIM cards, e.g. with one cellular
phone to the same PIN.
The device also operates with SIM cards, where the PIN prompt is deactivated. In this case,
when establishing a connection, the prompt to enter a PIN is skipped.

4.20.3 This is how you load the factory settings

Restoring the factory settings

If you press the SET key for longer than 4 seconds until the LED "CONNECT" lights up, then
the MODEM MD720 configuration is reset to the default values set in the factory.

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 Service cases - hardware
4.20 MODEM MD720

When resetting, the consequences are as follows:

● An established connection is interrupted.
● The MODEM MD720 is restarted.
● The SIM card PIN is cleared. It is no longer possible to read out the logbook.

3DSHUFOLS

Image 4-70 MODEM MD720: SET key

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Service cases - hardware
4.20 MODEM MD720

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230 Service Manual, 03/2016, 6FC5397-5DP40-5BA3
Spare parts and accessories 5
Order data for accessories
The following accessories are available:

Component Article number

USB flash drive 16 GB, bootable USB 3.0 6ES7648-0DC60-0AA0

CompactFlash card 8 GB, empty as user memory 6FC5313-6AG00-0AA0

CompactFlash Card 2 GB, empty 6FC5313-5AG00-0AA2

Compatibility of CompactFlash cards

For SINUMERIK 828D, only the memory card (2 GB) with Article number
6FC5313-5AG00-0AA2 is permitted.
SINUMERIK control system supports the file systems FAT16 and FAT32 for
CompactFlash cards. You may need to format the memory card if you want to ensure the
compatibility of the memory card with the SINUMERIK, or if you wish to use a memory card
from another device. Formatting the memory card will permanently delete all data on it.
● If you cannot use a memory card with SINUMERIK, then it possibly involves a memory card
that has not been formatted for this control system (e.g. Ext3 Linux file system), or a memory
card with a defective file system or an incorrect memory card type.
● Insert the memory card carefully and the right way round into the memory card slot (observe
indicators such as arrow or similar). This way you avoid mechanical damage to the memory
card or the device.
● Do not remove the memory card while it is being accessed. This can damage the memory
card and the SINUMERIK as well as the data on the memory card.
Only use memory cards that have been approved by Siemens for use with SINUMERIK. Even
though SINUMERIK follows general industry standards for memory cards, it is possible that
memory cards from some manufacturers will not function perfectly in this device or are not
completely compatible with it (you can obtain information on compatibility from the memory
card manufacturer or supplier).

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Service Manual, 03/2016, 6FC5397-5DP40-5BA3 231
Spare parts and accessories

Ordering data for S120 Combi spare/replacement parts

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

Component Article number

S120 Combi front cover 6SL3161-3GP00-0AA0
S120 Combi guide frame for DRIVE-CLiQ cables 6SL3161-3EP00-0AA0
S120 Combi DC link lateral cover 6SL3161-3AP00-0AA0
S120 Combi internal fan with holder and data sheet 6SL3161-0JP00-0AA0
S120 Combi external fan module 6SL3161-0EP00-0AA0
S120 Combi drip protection 6SL3161-3DP00-0AA0
For the S120 Combi with 4 axes, this is provided in the pack of accessories
when shipped from the factory; for all other S120 Combi versions this must
be ordered and retrofitted.
S120 Combi set of connecting terminals /Terminal Kit 6SL3161-8AP00-0AA0
● 24 V plug connector
● Terminal for the motor holding brake
● 4 DRIVE-CLiQ blanking covers
● 2 terminals (4-pole) for X12/X13
● 2 terminals (4-pole) for X21/X22
● 5 shield connecting terminals for motor cables
● Shield connection terminal for EP signal cables

Ordering address
You can find accessories and spare parts for the components in the Internet at: Siemens
Spares on Web (https://b2b-extern.automation.siemens.com/spares_on_web)

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232 Service Manual, 03/2016, 6FC5397-5DP40-5BA3
Appendix A
A.1 Information about third-party software used
Copyright 1995 Sun Microsystems, Inc.
Printed in the United States of America.
All Rights Reserved.
This software product (LICENSED PRODUCT), implementing the Object Management
Group's "Internet Inter-ORB Protocol", is protected by copyright and is distributed under the
following license restricting its use. Portions of LICENSED PRODUCT may be protected by
one or more U.S. or foreign patents, or pending applications.
LICENSED PRODUCT is made available for your use provided that you include this license
and copyright notice on all media and documentation and the software program in which this
product is incorporated in whole or part. You may copy, modify, distribute, or sublicense the
LICENCED PRODUCT without charge as part of a product or software program developed by
you, so long as you preserve the functionality of interoperating with the Object Management
Group's "Internet Inter-ORB Protocol" version one. However, any uses other than the foregoing
uses shall require the express written consent of Sun Microsystems, Inc.
The names of Sun Microsystems, Inc. and any of its subsidiaries or affiliates may not be used
in advertising or publicity pertaining to distribution of the LICENSED PRODUCT as permitted
herein. This license is effective until terminated by Sun for failure to comply with this license.
Upon termination, you shall destroy or return all code and documentation for the LICENSED
PRODUCT.
LICENSED PRODUCT IS PROVIDED AS IS WITH NO WARRANTIES OF ANY KIND
INCLUDING THE WARRANTIES OF DESIGN, MERCHANTIBILITY AND FITNESS FOR A
PARTICULAR PURPOSE, NONINFRINGEMENT, OR ARISING FROM A COURSE OF
DEALING, USAGE OR TRADE PRACTICE.
LICENSED PRODUCT IS PROVIDED WITH NO SUPPORT AND WITHOUT ANY
OBLIGATION ON THE PART OF SUN OR ANY OF ITS SUBSIDIARIES OR AFFILIATES TO
ASSIST IN ITS USE, CORRECTION, MODIFICATION OR ENHANCEMENT. SUN OR ANY
OF ITS SUBSIDIARIES OR AFFILIATES SHALL HAVE NO LIABILITY WITH RESPECT TO
THE INFRINGEMENT OF COPYRIGHTS, TRADE SECRETS OR ANY PATENTS BY
LICENSED PRODUCT OR ANY PART THEREOF.
IN NO EVENT WILL SUN OR ANY OF ITS SUBSIDIARIES OR AFFILIATES BE LIABLE FOR
ANY LOST REVENUE OR PROFITS OR OTHER SPECIAL, INDIRECT AND
CONSEQUENTIAL DAMAGES, EVEN IF SUN HAS BEEN ADVISED OF THE POSSIBILITY
OF SUCH DAMAGES.
Use, duplication, or disclosure by the government is subject to restrictions as set forth in
subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at
DFARS 252.227-7013 and FAR 52.227-19.
SunOS, SunSoft, Sun, Solaris, Sun Microsystems and the Sun logo are trademarks or
registered trademarks of Sun Microsystems, Inc.

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Service Manual, 03/2016, 6FC5397-5DP40-5BA3 233
Appendix
A.1 Information about third-party software used

SunSoft, Inc.
2550 Garcia Avenue
Mountain View, California 94043
Copyright (c) 1991 by AT&T.
Permission to use, copy, modify, and distribute this software for any purpose without fee is
hereby granted, provided that this entire notice is included in all copies of any software which
is or includes a copy or modification of this software and in all copies of the supporting
documentation for such software.
THIS SOFTWARE IS BEING PROVIDED "AS IS", WITHOUT ANY EXPRESS OR IMPLIED
WARRANTY. IN PARTICULAR, NEITHER THE AUTHOR NOR AT&T MAKES ANY
REPRESENTATION OR WARRANTY OF ANY KIND CONCERNING THE
MERCHANTABILITY OF THIS SOFTWARE OR ITS FITNESS FOR ANY PARTICULAR
PURPOSE.
This product includes software developed by the University of California, Berkeley and its
contributors.
QLocale's data is based on Common Locale Data Repository v1.6.1.

Note
You can find additional information on the product DVD in the Readme_OSS file about the
third-party software used.

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234 Service Manual, 03/2016, 6FC5397-5DP40-5BA3
 Appendix
A.2 List of abbreviations

A.2 List of abbreviations

Abbreviation Meaning Explanation

ALM Active Line Module
ASCII American Standard Code for Information Inter‐ American coding standard for the exchange of in‐
change formation
AUTO "Automatic" operating mode
BAG Mode group
OPI Operator Panel Interface
BERO Proximity limit switch with feedback oscillator
BICO Binector Connector Interconnection technology for the drive
CEC Cross Error Compensation
CNC Computerized Numerical Control Computerized numerical control
dbSI drive based Safety Integrated Safety functions integrated in the drive
DB Data Block in the PLC
DBB Data Block Byte in the PLC
DBW Data Block Word in the PLC
DBX Data Block Bit in the PLC
DDE Dynamic Data Exchange Dynamic Data Exchange
DDS Drive Data Set Drive Data Set
DIN Deutsche Industrie Norm
DO Drive object Drive Object
DRAM Dynamic Random Access Memory Dynamic memory block
DRF Differential Resolver Function Differential resolver function (handwheel)
DRY DRY run DRY run feedrate
EDS Encoder Data Set Encoder data set
ESR Extended Stop and Retract
FIFO First In - First Out Method of storing and retrieving data in a memory
GUD Global User Data Global user data
HD Hard Disk Hard disk
Hardware Hardware
HSC High-Speed Cutting
IME Input Method Editor Entering Asian characters
INC Increment Increment
INI Initializing Data Initializing data
IGBT Insulated Gate Bipolar Transistor
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 Leadscrew error compensation
LED Light Emitting Diode Light-emitting diode
LUD Local User Data Local user data
MB Megabyte

Software and hardware

Service Manual, 03/2016, 6FC5397-5DP40-5BA3 235
Appendix
A.2 List of abbreviations

Abbreviation Meaning Explanation

MCP Machine Control Panel Machine control panel
MD Machine data
MDA "Manual Data Automatic" operating mode Manual input
MDS Motor Data Set Motor data set
MCS Machine Coordinate System
MLFB Machine-Readable Product Code
MPF Main Program File Main program (NC part program)
MAIN Main program Main program (OB1, PLC)
MPI Multi Point Interface Multi-Point Interface
NCK Numerical Control Kernel Numerical control kernel
NCU Numerical Control Unit NCK hardware unit
WO Work Offset
OEM Original Equipment Manufacturer
PCU Programmable Control Unit
PI Program Instance
PG Programming device
PLC Programmable Logic Control Programmable logic controller
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 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 Real-time clock
SBL Single Block 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 Aktive Identifier for machine data
TO Tool Offset Tool offset
TOA Tool Offset Active Identifier (file type) for tool offsets
VPM Voltage Protection Module
VSM Voltage Sensing Module
WCS Workpiece Coordinate System
TMMG Tool Magazine Management

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236 Service Manual, 03/2016, 6FC5397-5DP40-5BA3
 Appendix
A.2 List of abbreviations

Abbreviation Meaning Explanation

TM Tool Management
ZOA Zero Offset Active Identifier (file type) for work offset data

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Service Manual, 03/2016, 6FC5397-5DP40-5BA3 237
Appendix
A.3 Documentation overview

A.3 Documentation overview

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238 Service Manual, 03/2016, 6FC5397-5DP40-5BA3
Index

B F
Backing up log files, 23 Fan, internal
Motor Module Booksize Compact, 163
S120 Combi, 147
C Front cover
installing, 86
CompactFlash Card, 231
removing, 85
Connections
ALM, 190
CU310-2 PN, 126
CU320-2 PN, 120
L
DMC20, 222 LED status
DME20, 224 CU310-2 PN, 122
DMM, 175 CU320-2 PN, 117
DMM Booksize Compact, 161 Front of the PPU, 77
NX10.3 / NX15.3, 112 MCP 483C PN, 92
S120 Combi 3 axes, 132 MCP 310C PN, 96
S120 Combi 4 axes, 134 MODEM MD720, 227
SLM ≥ 16kW, 184 NX10.3 / NX15.3, 111
SLM 5kW, 10kW, 182 Rear of the PPU, 78
SMC10, 196 S120 Combi Power Modules, 130
SMC20, 196 TM120, 217
SMC30, 200 TM54F, 213
SME120, 210 License key, 56
SME125, 211 Control, 63
SME20, 207 Web License Manager, 63
SME25, 208 Licenses
SMM, 168 Save as backup, 62
SMM Booksize Compact, 160 Licensing a CNC option, 56
TM120, 219 Logbook entry, 68
TM54F, 215
Creating a boot system, 51
M
Machine identity, 66
D Sending, 72
Data backup, 46 Machine logbook, 66
Machine registration, 66

E
End user final destination data
O
Configuration file, 72 On-site service, 66
Enter, 66

P
PPU version 290.3, 20
Protective conductor connection, 115

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Service Manual, 03/2016, 6FC5397-5DP40-5BA3 239
Index

R
Removing MCP 310 USB, 87
Removing MCP 310C PN, 97
Removing MCP 483 USB, 87
Removing MCP 483C PN, 93
Removing the MCP Interface PN, 90
Rotary switch
Replacing, 100

S
S120 Combi
Cleaning the heat sink, 155
DC link cover, 139
Drip protection, 137
installing an internal fan, 150
Remove the air baffle plate, 155
Removing the internal fan, 147
Spare parts, 232
Safety instructions
S120 Combi, 138
Terminal Module TM120, 218
Shield support, 115
Spare parts, S120 Combi, 232
Switch
S1 on the I/O module, 106, 110
S2 on the MCP 310C PN, 100
S2 on the MCP 483C PN, 96

U
USB FlashDrive, 46, 231

W
Web License Manager, 58

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