SINUMERIK

The powerful CNC platform for machine tools

siemens.com/sinumerik

Contents
SINUMERIK a CNC in a class of its own SINUMERIK 828D family SINUMERIK 840D sl family SINUMERIK MDynamics SINUMERIK Operate the graphical user interface Innovative measuring cycles and more Complete machining with SINUMERIK CNC SINAMICS S120 drives 04 06 08 10 12 14 16 18 Powerful motors Solutions for the control cabinet SINUMERIK Ctrl-Energy Everything for safety SINUMERIK Integrate SINUMERIK Manufacturing Excellence More information about service and support Technical information overview 22 26 27 28 30 31 32 34

Always the ideal CNC

With SINUMERIK, Siemens offers you an integrated and seamless system platform for machine tool automation used in various metalcutting industries and technologies. The SINUMERIK concept: one CNC system, many options from the CNC through drives and motors up to the complete control cabinet. SINUMERIK is easy-to-operate and offers you innovative functions and technology cycles for even more cost-effective manufacturing. The programming methods always precisely fit your requirements no matter if youre machining small or large series, simple or complex parts.

In a class of its own SINUMERIK CNC

SINUMERIK is a standard system platform used to automate machine tools and offers you cost-effective solutions for every machining technology and industry.

The SINUMERIK system platform The SINUMERIK system platform has different versions to meet the widest range of needs when it comes to equipping machine tools SINUMERIK 828D BASIC T and BASIC M for standard turning and milling machines, the compact SINUMERIK 828D as well as the premium SINUMERIK 840D sl CNC. Modularity for the perfect solution The modular SINUMERIK system offers a high degree of flexibility and openness for every machine application and manufacturing environment. The combination of state-ofthe-art operator panel, PCU, a high performance NCU that meets your particular need, our SINAMICS S120 drive as well as innovative motors, offers you plenty of options. Customers can perfectly harmonize and coordinate the components with each another precisely tailored to the demands of the machine tool builder and the final location of the machine.

SINUMERIK CNCs are designed to machine simple as well as complex parts in individual and series production across every technology. As a result, the ideal automation solution is available for each and every application. SINUMERIK is used globally in every metalcutting industry and reliably meets your every need when it comes to ruggedness, optimum usability and flexibility, as well as outstanding performance.

Compact class CNC SINUMERIK 828D BASIC T and BASIC M Applications Standard turning and milling machines Compact panel CNC with a horizontal and vertical operator panel layout

Compact class CNC SINUMERIK 828D

Premium class CNC SINUMERIK 840D sl

Turning and milling machines

Ideal for the widest range of machining technologies Modular, scalable CNC as universal control Available in three performance versions

Design

Compact panel CNC with a horizontal and vertical operator panel layout Available in two performance versions Up to 8 axes/spindles 1 machining channel

Output

Up to 5 axes/spindles 1 machining channel

Up to 93 axes/spindles Up to 10 machining channels

SINUMERIK 828D the CNC family for turning and milling machines
Service interface (Ethernet TCP/IP) SINUMERIK 828D RS232 C GSM/GPRS modem PC/PG Factory network (Ethernet TCP/IP)

PC

PC/PG DRIVE-CLiQ SINAMICS S120 TM54F NX10 (only version T) DMC20 Encoder system connection

Modem router

MCP

PLC I/O interface

Handwheel

PP 72/48D PN PP 72/48D 2/2A PN

Mini handheld unit

PN/PN coupler

Main spindle motor

Servomotor

Main spindle motor

The SINUMERIK 828D BASIC T / BASIC M and the SINUMERIK 828D CNCs have been specifically designed for turning and milling machine applications. In a panel-based CNC system, CNC, PLC, operator control and axis control for up to six CNC measuring circuits are combined in a very compact unit, which fits into every operator panel housing. In spite of its compact dimensions, the SINUMERIK 828D family is an absolute powerhouse, which fulfills every need CNC functions such as kinematic transformation or powerful tool management are already integrated. Performance and functionality for a diverse range of applications In the milling version, vertical and horizontal machining centers with up to 6 axes/spindles can be equipped. Thanks to SINUMERIK MDynamics and Advanced Surface, SINUMERIK 828D is also suitable for machining mold workpieces. The turning version offers up to 8 axes/spindles. This means that single-channel inclined bed lathes can be equipped with a counter-spindle and a Y-axis. As a result of the intelligent technology functions, milling and drilling operations can be performed without restriction at face and peripheral surfaces. With SINUMERIK 828D BASIC, the 828D-series can also be used for standard turning and milling machines with up to 5 axes/spindles.

SINUMERIK 828D BASIC / SINUMERIK 828D Minimum space requirements Complete package with 8.4/10.4 TFT, full QWERTY keyboard, USB, Ethernet, etc. Low-maintenance no hard disk, battery or fan 80-bit NANOFP technology Advanced Surface intelligent motion control SINUMERIK Operate user interface Fully graphical CNC and DIN programming User-friendly commissioning and expandability Text message (SMS)-based process monitoring Animated Elements graphical user support with moving image sequences and context-sensitive online help

Compact and user-friendly Thanks to its small dimensions, the SINUMERIK 828D family is even suitable for compact operator panel housings. It offers the highest degree of user-friendliness, features either an 8.4 or 10.4 color display and comes standard with a full QWERTY keyboard. Scalability The SINUMERIK 828D family is available in both a horizontal and vertical operator panel layout. With the SINUMERIK 828D BASIC, as well as two performance versions of the SINUMERIK 828D, a wide range of machine performance levels can be precisely addressed. Rugged The operator panel front of the SINUMERIK 828D BASIC and SINUMERIK 828D are manufactured from an extremely rugged die-cast magnesium that can stand up to the harshest application conditions. The CNC keyboards mechanical keys are located behind an embossed foil and are optimally protected against moisture and humidity.

Communicative SINUMERIK 828D BASIC and SINUMERIK 828D are equipped with state-of-the-art communication interfaces Compact Flash (CF) card, USB and the service interface are accessible from the front of the operator panel, directly behind the flap, which can be closed even if a Compact Flash card is inserted. Low maintenance The SINUMERIK 828D family is especially low maintenance and service friendly it has no fans and hard disks parts that are typically prone to wear. Additionally, a battery is not required, and by using NV-RAM memories, buffering can be eliminated.

SINUMERIK 840D sl the powerful CNC family for the widest range of applications
HT8 handheld unit Operator panel front with TCU Industrial PC PCU 50.3 Industrial Ethernet

PROFIBUS DRIVE-CLiQ

SINAMICS S120 and SINUMERIK 840D sl SV

SINAMICS S120 single axis(es)

Expansion, SINUMERIK NX15

SINAMICS S120 (for high power ratings)

Servomotors

Servomotor(s)

Main spindle motor

SINUMERIK 840D sl is a universal and flexible CNC system for up to 93 axes in the same mechanical design as our SINAMICS S120 drive. Its a distributed, scalable and open CNC system that can be networked. With a wide range of functions it is admirably suited for almost any technology and sets the standard when it comes to dynamic performance, precision and network integration. Open and flexible user interface and CNC An essential feature of the SINUMERIK 840D sl the distributed system architecture, fully-integrated into the mechanical design and communication structure of SINAMICS S120. Hardware and software can be scaled independently of one another. In conjunction with hubs, the internal drive communication based upon DRIVE-CLiQ significantly reduces machine wiring costs. Additionally, you benefit from an extremely flexible operating concept based upon thin client units. This modularity allows you to implement innovative machines that are perfectly tailored to your particular application. SINUMERIK 840D sl is available in various performance versions.
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SINUMERIK 840D sl BASIC With SINUMERIK 840D sl BASIC based upon the SINAMICS S120 Combi drive system SINUMERIK 840D sl facilitates the entry into the modular and flexible premium class for machines with up to six axes. This is a costoptimized solution for machines that require the extensive functionality and the outstanding performance of the SINUMERIK 840D sl.

SINUMERIK 840D sl BASIC / SINUMERIK 840D sl For up to 93 axes/spindles in 10 machining channels 80-bit NANOprecision 7.5/10/12/15/19 TFT operator panel fronts SINUMERIK Operate graphical user interface Animated Elements graphical user support based upon moving image sequences and a context-sensitive online help SINUMERIK MDynamics 3 axes/5 axes technology packages Several operator panels can be connected to one CNC Tool management functions SINUMERIK Safety Integrated safety functions

SINUMERIK 840D sl type 1A The modular and scalable SINUMERIK 840D sl system platform for sophisticated machines, together with the SINAMICS S120 drive platform, provides you with the usual level of performance and the ability to control up to 31 axes. SINUMERIK 840D sl type 1B A new performance class of the SINUMERIK 840D sl with enhanced performance through multi-core technology and a more powerful PLC offers an even higher precision based upon the innovative SINAMICS S120 drive platform, as well as the highest control dynamics for the best surface results when machining. With NCU link, it is possible to expand the system to be able to control a maximum of 93 NC axes. Additional special axes can be implemented using the CU 320-2. The optimized HMI and graphical performance increases the operating efficiency and the speed for the machine operator when simulating workpieces.

High degree of of versatility The system platform offers comprehensive options for every machining technology and innovative functions for machine tools. SINUMERIK 840D sl can be used around the world for milling, turning, drilling, grinding, laser machining, nibbling, punching and even on multi-tasking machines. The SINUMERIK 840D sl is the first-choice in machining applications that include mold-and-die, high-speed cutting, wood and glass, composites, power generation, medical part manufacturing, handling, transfer lines, rotary cycle machines, large series production and shopfloor environments. The SINUMERIK 840D sl is comprised of the operator panel, PCU, a high-performance NCU based upon your application needs, the SINAMICS S120 drive system and innovative motors. It offers you a wealth of options, which means that you can tailor your machine to match your requirements.

Data handling program handling

SINUMERIK 828D compact class CNC for 3 axis-/3+2 axis machining

SINUMERIK 840D sl premium class CNC for 3 axis/3+2 axis as well as 5-axis machining

SINAMICS

SINUMERIK MDynamics made for perfect milling

With SINUMERIK MDynamics, milling technology packages comprised of CNC hardware, intelligent CNC functions and CAD/CAM solutions are available for SINUMERIK controls in the compact and premium classes. SINUMERIK MDynamics SINUMERIK 828D compact class CNC for 3 axis/3+2 axis machining SINUMERIK 828D integrates a technology package for 3-axis milling machines, and can handle every milling and drilling application and naturally, in any swiveled workpiece planes and on cylindrical workpieces. SINUMERIK MDynamics SINUMERIK 840D sl premium class CNC for 3-axis/3+2 axis and 5-axis machining With the SINUMERIK 840D sl you can select between the two SINUMERIK MDynamics technology packages one for three axes and the other for five axes. The packages can be expanded by additional functions to precisely meet your machining needs.

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CAD/CAM/postprocessor connection Setup

Programming

Technology cycles, automatic measuring High-Speed Cutting cycles (HSC) functions

Advanced Surface

HMI functions

SINUMERIK MDynamics

Functions in detail SINUMERIK 828D 3 axis/3+2-axis machining Functions included in the package Advanced Surface User memory on a user Compact Flash (CF) card 3 axis/3+2-axis machining Advanced Surface User memory on a user Compact Flash (CF) card Spline interpolation Transmit and peripheral surface transformation Automatic measuring cycles 3-D simulationsimultaneous recording ShopMill/ShopTurnmachining step programming Residual material detection SINUMERIK 840D sl 5-axis machining Advanced Surface User memory on a user Compact Flash (CF) card Spline interpolation Transmit and peripheral surface transformation Automatic measuring cycles 3-D simulation-simultaneous recording ShopMill/ShopTurnmachining step programming Residual material detection 5-axis machining package 3-D tool radius compensation Measuring kinematics Volumetric Compensation System (VCS)

Spline interpolation Transmit and peripheral surface transformation Automatic measuring cycles 3-D simulation-simultaneous recording ShopMill/ShopTurnmachining step programming Residual material detection Expanded machining functions

Optional functions

Measuring kinematics Volumetric Compensation System (VCS)

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The SINUMERIK Operate user interface

The SINUMERIK Operate graphical user interface is transparent and can be intuitively used. This combines simple usability, functionality and technology for efficient operator control and programming. In addition, SINUMERIK Operate allows machining step programming and high-level language programming to be linked under one system interface. The result very fast, rational and intuitive NC programming using a standard interface for SINUMERIK CNC.

The look-and-feel is the same whether youre milling or turning Intelligent SINUMERIK Operate functions support the operator in the simplest ways during day-to-day work for example, screenshots using the CTRL+P key combination. The optimum display employing the modern Windows style is user oriented. The new user interface sets a new standard, also when it comes to graphical support. Animated Elements are a helpful function, as they can graphically simulate machining steps in an animated way before the machining step is actually executed. Practical tooltips make operation even more straightforward.

Technology cycles aligned for every programming type Circular pockets, thread recesses and deep hole drilling SINUMERIK offers you a unique range of technology cycles for standard geometries, including an engraving cycle. The allocation to the machine position is realized simply using a wide range of pre-configured position patterns. You also benefit from these for face or peripheral workpiece surfaces being turned or in the swiveled planes for workpieces being milled.

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Programming the way you like it

SINUMERIK Operate offers unique programming methods for every application. These include the ShopMill/ ShopTurn machining step programming, as well as programGUIDE, the SINUMERIK high-level programming language. Innovative technology cycles are also available.

ShopMill/ShopTurn machine step programming

programGUIDE DIN/ISO G-Code programming with cycle support

Machining step programming with ShopMill and ShopTurn In addition to programGUIDE, ShopMill and ShopTurn offer you unique machining step programming for the shortest programming times. This makes it the perfect answer for the individual and small batch production. Machining steps are clearly shown without requiring any knowledge about G-code Technology functions with geometrical elements can be simply cascaded The workpiece is dynamically displayed during programming Graphical machining step editor and geometry computer to simply enter the workplace contours Powerful 3D CNC simulation SINUMERIK high-level language with programGUIDE CNC programming for the highest degree of productivity SINUMERIK programGUIDE high-level language stands for DIN/ISO G-code programming with new cycle support and is perfect for average and large batch production. This means that programGUIDE offers the maximum degree of flexibility, short machining times and the highest productivity. programGUIDE with graphical cycle support screens including tooltip and Animated Elements CNC language with high-level programming instructions and ASCII editor Dynamic dotted line graphics for cycle masks Wide selection of standard drilling, milling and turning cycles Contour computer including cycles for contour milling and residual material detection Powerful 3D CNC simulation Online ISO dialect interpreter available

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Innovative measuring cycles and workpiece simulation

SINUMERIK provides you with graphical support when measuring workpieces, tools and the kinematics during the process with a competitive range of practical cycles. Five-axis workpiece simulation of our system platform offers you a higher degree of safety and reliability and checks options during workpiece programming.

Innovative measuring cycles for workpiece and tool management in automatic mode Using automatic measurements at the machine, SINUMERIK measuring cycles guarantee the quality of the machined parts: Powerful cycles to automatically measure workpieces and tools Automatic measuring cycle in programGUIDE and ShopMill/ShopTurn Input screen forms with graphical support and automatic logging of the measurement results SINUMERIK measuring cycles are also available in the SINUMERIK Operate style, with Animated Elements in different programming types, such as programGUIDE or ShopMill.

Innovative measuring cycles with kinematic measuring function CYCLE996 (for SINUMERIK 840D sl) CYCLE996 measure kinematics was developed to measure multi-axis kinematics. It is easy-to-use and does not require any additional measuring equipment. Probing with the calibration ball uses a 3D probe and the Measure kinematics cycle in three ball positions. The cycle can be directly called from the NC program. When compared to conventional measurements, CYCLE996 offers significant time savings with outstanding measurement accuracy. CNC simulation workpiece simulation for multi-side machining The 3D simulation with a three-level view and volume model of the machined part including simultaneous recording in automatic mode also ensures a higher degree of security. The blank can be entered and simulation speed can be regulated using softkeys. SINUMERIK 840D sl offers help and security during programming and simultaneously during five-axis machining. Programming can be immediately checked using the wide range of different workpiece views during simulation. You can zoom in and out cuts can be placed on the swiveled planes even during five-axis simultaneous machining.

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Efficient operation thanks to Animated Elements and state-of-the-art tool and program management
Parameters that are entered into the CNC control on a daily basis result in machine motion. Using static help screens, they can only be displayed with some restrictions. Animated Elements offers you a completely new level of convenience when entering data. They completely redefine the term graphic programming and operation thanks to a unique display with moving image sequences. The clear and transparent tool and program management also provides support.

Reliable setup and programming How can a workpieces zero-point be determined using a circular spigot? In which sequence must the probe be positioned and how does the CNC retract the probe? Animated Elements makes this quite easy a short moving image sequence shows you the probing procedure, and you can also see a motion sequence as an example. For instance, helical plunging into a milled pocket or when making the distinction between chip removal and chip breaking during deep-hole drilling. In this instance, a static help screen would only provide a multitude of arrows that are difficult to interpret. Tool and program management made easy SINUMERIK CNC offers state-of-the-art transparent tool and program management functionality. The tool list has a configurable display and can be intuitively operated and displayed using context-sensitive functions and selfexplanatory symbols for efficient management of tool data. Using innovative program management, workpiece sub-directories can be created on local drives and external storage media can be accessed. Users benefit as they can quickly check the program, have convenient data transfer and can easily handle programming.

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Cost-effective machining of complex workpieces on multi-tasking machines

Complex workpieces require cost-effective production techniques and innovative CNC solutions. SINUMERIK CNCs support multi-tasking machines when machining workpieces in one operation. SINUMERIK has all of the functions to manufacture parts on a machining center also when changing between different technologies. The SINUMERIK Operate graphical user interface offers integrated turning functions for milling, milling functions for turning, and supports all of the usual kinematics and multi-tools for even more cost-effective production.

Simple operation of multi-tasking machines As a standard, SINUMERIK has innovative functions to operate multi-tasking machines, such as mill-turning turn-milling machines, which makes part manufacturing easier and more cost-effective in just one machining operation. The SINUMERIK Operate graphical user interface offers integrated turning functionality for milling, and integrated milling functionality for turning; this is complemented by innovative measuring cycles in the Animated Elements design. The usability and look-and-feel are completely identical, even when switching between different technologies. Tool management facilitates simple handling of every tool, as well as multi-tools in a standard user interface. Programming in programGUIDE has been supplemented by functions such as the aligning and positioning of turning and milling tools, as well as turning and milling cycles including contour programming. Its now possible to simulate multi-tasking programs, leading to an even higher machining efficiency. User-friendly solution for multi-channel machines A display for several channels is included in the wide range of functions to achieve simple operability. When milling, via a second channel, handling modules or tool changes can be controlled and displayed, for example. This offers you an even higher degree of flexibility and cost-efficiency during production. Using the programSYNC option, multi-channel machining operations can be simply and efficiently synchronized. When using simulation in conjunction with SINUMERIK 840D sl, multi-channel machining can also be visualized in an excellent way. As a result, multi-channel machining operations can be programmed even more efficiently Create the structure of the part programs Fill the individual machining steps (blocks) Simulate part programs Run-in part programs (either channel by channel or spindle by spindle) New block building function programSYNC including the option of forming blocks.
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Efficient tool management For efficient tool data management, including all of the details, SINUMERIK Operate has extended the tool management function for milling, drilling and turning tools. Tool and magazine data are shown on a screen with all of the associated details. All of the tool parameters are available also for combined technologies. All tool types including turning tools are displayed using clear and transparent symbols. In addition, complex tools, which make tool changing superfluous and facilitate higher productivity during production, are supported by SINUMERIK CNC for use in multi-tasking machines. Maximum productivity and flexibility in programming With programGUIDE and ShopMill/ShopTurn, SINUMERIK Operate has innovative functions for complex workpiece programming and offers maximum productivity and flexibility thanks to innovative technology cycles.

Innovative functions for programming complex workpieces using programGUIDE Kinematic cycle Alignment of the turning and milling tool and swiveling of the coordinate system for turning or milling.

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Design Drive type

Blocksize AC/AC device, single-axis 0.37 90 kW (0.5 120 HP)

Combi AC/AC device, multi-axis 16 ... 20 kW (22 30 HP)

Booksize

Chassis

Modular DC/AC system, multi-axis

Power ranges

1.6 107 kW (2 145 HP)

110 250 kW (150 338 HP)

SINAMICS S120 the flexible, modular drive system for demanding tasks
With SINAMICS S120, we offer you the perfect solution platform for high-performance applications in industrial machine and plant construction a modular system that permits the highest degree of flexibility. An entire foundation of components and functions that are coordinated with one another to allow tailored solutions to be implemented, to individually address the particular application area. The modular SINAMICS system is the optimum platform to implement individual solutions.

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High productivity and modularity SINAMICS S120 for the coordinated motion control of your machine high performance multi-axis configurations with modular multi-axis or independent single-axis modules. The modular system covers the power range extending from 0.12 all the way up to 300 kW. In conjunction with SINUMERIK CNC, the SINAMICS S120 is the perfect basis for modular plant and machine concepts in the power range up to 250 kW. Engineering costs are significantly reduced using standard and integrated engineering tools.

The new SINAMICS S120 Combi a drive class all by itself SINAMICS S120 Combi offers the usual SINAMICS functionality in an integrated drive concept, tailored for compact turning and milling machines. Sporting a multitude of technical highlights, SINAMICS S120 Combi sets new standards in this class of drives.

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SINAMICS S120 drives fast and precise in every application

Internal air cooling External air cooling 7080% 100% 2030% 2030% Cold Plate cooling 7080%

SINAMICS S120 booksize drives offer you optimum cooling solutions in three cooling types

Water or convection

Reliable Numerous intelligent protection functions of the SINAMICS S120 guarantee optimum system availability. All power modules are short-circuit, ground fault and over-voltage-proof. An intelligent combination of sensors and algorithms monitors the temperature of the power units, therefore avoiding thermal overload. Compact and transparent As a result of its compact design, SINAMICS S120 can be installed in the smallest control cabinets. All connections are easy to access, thereby reducing installation costs. Data and power cables are strictly separated. Using DRIVECLiQ, CNC, drives and motors communicate with one and the same data protocol. As a result, you can network all of the components with just one cable type.

Automatic configuration With DRIVE-CLiQ, SINAMICS S120 has an optimum data highway. The components of the SINAMICS S120 drive control integrated in the SINUMERIK CNC are automatically identified using the electronic type plates for fast and reliable commissioning. SINAMICS automatically identifies the drive configuration when drive components are subsequently added plug-and-play as it should be. Highest dynamic performance With DSC (Dynamic Servo Control) SINAMICS S120 offers a unique closed-loop position control technique to facilitate the highest dynamic performance of the spindle and feed motors. An adaptive current controller helps to optimally utilize the performance of the motors. The productivity of your machine is significantly increased thanks to the acceleration values that can be attained. The SINAMICS S120 Active Line Modules keep the DC link voltage absolutely constant even when line voltage fluctuates. The acceleration time of the spindle can therefore be significantly reduced, further increasing the productivity of your machine.

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Type range according to dimension Motor modules in the booksize format Internal, external air cooling and Cold Plate cooling 3 A up to 200 A
A= 3 10 20 30 40 50 60 70 80 90 100 110 120 130

Motor modules in the chassis format

140

150

160

170

180

190

200

210

220

230

240

250

Internal air cooling 210 A to 490 A

130

140

150

160

170

180

190

200

210

230

250

270

290

310

330

350

370

390

410

430

450

470

490

Single-axis drives in the blocksize format Internal air cooling 1.3 A up to 178 A
A= 1.3 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250

Perfect surface quality SINAMICS S120 facilitates a perfect workpiece quality. Natural resonance points of the machine can be almost completely suppressed using the intelligent filter functions in the closed-loop control. Teamed up with the high accuracy three-phase current actual value sensing, allows you to achieve perfect workpiece surfaces. A high-resolution position actual value sensing in the nanometer range ensures high precision contour machining thus guaranteeing absolutely smooth workpiece surfaces. Flexible connection to the line supply SINAMICS S120 is designed for connection to line supplies in the range from 380 V up to 480 V, therefore covering as standard 70 percent of the voltage levels used worldwide. Energy efficiency Using the multi-axis concept and energy recovery based on Smart Line and Active Line modules, SINAMICS S120 reduces the energy usage. Up to the full regenerative power, no unnecessary heat is generated in the control cabinet. With the intelligent compensation of capacitive

and inductive reactive currents, SINAMICS S120 monitors that neither unnecessary energy losses occur in the line supply nor current harmonics. This not only prevents other loads from being negatively influenced, but further reduces the heat generated in the control cabinets. Optimum cooling solutions for the power electronics Booksize format power modules are available in three cooling types Internal air cooling the power loss of the power unit is dissipated in the control cabinet. External cooling the power loss of the power unit is cooled using a heat sink that extends through the mounting plate in a separate cooling chamber or outside the cabinet. Cold plate cooling the power loss of the power unit is dissipated to an external liquid heat sink via a thermal interface at the rear of the module.

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Powerful motors for each and every application

1FK7 HI

1FT7

Whether high standstill torques or rated powers, high maximum speeds or dynamic performance, air- or watercooling our extensive portfolio of motors offers you the optimum type for every drive application over a wide power range. These include synchronous and induction servomotors, as well as highly innovative linear and rotary direct drives. 1FK7 servomotors for standard applications Our 1FK7 motors can be universally used in a high degree of protection with their extended torque range of up to 150 Nm and cover a wide variety of machining applications. They have stall torques that lie between 0.18 and 48 Nm and rated speeds of between 2000 and 6000 rpm. Three motor versions that offer the best torque to rotor moment of inertia ratio are available. 1FK7 High Dynamic with its extremely low rotor moment of inertia is capable of extremely high acceleration rates. 1FK7 Compact addresses a wide spectrum of applications as a result of its well-balanced ratio between torque and intrinsic moment of inertia. 1FK7 High Inertia has rugged control properties even with high and variable load moments of inertia. 1FT7 servomotors for high-performance applications with 400 percent overload capability and high encoder resolutions up to 24-bits With their outstanding smooth running properties, we recommend our new 1FT7 synchronous servomotors for demanding applications involving state-of-the-art machine tool construction. The motors are available with either air- or water-cooling. They cover rated speeds extending from 1500 up to 6000 rpm and stall torques from 2 up to 125 Nm are very compact and equipped with a newly developed encoder coupling. This protects the encoder to a high degree from surge loads. 1FT7 motors have a crossover profile that permits simple installation, and now also from the rear. They also sport a connector that can be rotated with a quick release mechanism that simplifies connection for faster installation and reduced service times.

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1FN3

1FW6

Direct drives for the highest precision and dynamic performance 1FN3/1FN6 linear motors The essential advantage of linear direct drives effects involving elasticity, play and friction are almost completely avoided, as well as natural oscillations in the drive train. This allows the highest degree of dynamic performance and precision to be achieved in motion control applications. Teamed up with the SINAMICS S120 drive system, we can offer you an optimum drive system to address every requirement of the machine tool industry. Our 1FN3 and 1FN6 linear motors set themselves apart as a result of the highest traversing velocity of up to 800 m/ min, extreme dynamic performance and outstanding precision. 1FN3 motors have an IP65 degree of protection and permit maximum forces of up to 20,700 N. 1FN6 motors have degrees of protection IP23 up to IP65 and maximum forces up to 8000 N. Neither of the series has mechanical transmission elements such as ballscrews or belts. 1FW6 torque motors Our torque motors are perfectly suited for rotary axes with extremely high torques, and they can be directly integrated into the machine. They run with the highest precision and dynamic performance, as elasticity and play in the drive train are avoided and the total mass and frictional forces can be minimized. Additionally, they set themselves apart due to their high availability as they have no mechanical transmission elements that can wear. Yet another advantage their compact design and the low number of components mean that they take up a minimum amount of space. 1FW6 torque motors are the first choice for use in rotary cyclic machines, rotary tables, swivel and rotary axes, revolver and drum indexing units, dynamic tool magazines and spindles in milling machines. These torque motors have torques up to 10,900 Nm.

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Powerful motors for machine tool applications

Whether belt drive, hollow shaft motor, built-in motor or integrated motor spindle the main spindles of turning, milling and grinding machines can be driven in a wide variety of ways. The main spindle drive represents an essential component of your machines productivity, machining performance, production precision and machine availability.

1PH8

Optional sensor module with DRIVE-CLiQ for WEISS spindles Its easy to connect WEISS spindles to the SINAMICS drive and SINUMERIK CNC the Weiss spindle DRIVE-CLiQ is a new sensor module that enormously reduces cabling costs and simplifies and accelerates machine commissioning. This means that the rotary encoder signals, analog clamping state, digital piston position interrogation as well as the motor temperature can now be simply transferred from the spindle to SINAMICS and SINUMERIK. SINUMERIK option integrated spindle monitor to supplement the WEISS spindle DRIVE-CLiQ Using this option, machine users can quickly an easily call up information about the spindle state on the HMI using various screen forms. The integrated spindle monitor responds to questions regarding operating time, load with reference to power, torque and speed, the number of tool changes and the actual tool clamping state.

The dynamic powerhouse for main drives 1PH8 motor range The 1PH8 is a compact series of induction motors with power ratings up to 300 kW and squirrel-cage rotors in IP55/IP65. This series expands the power range of the well-proven 1PH/1PM series, and offers the optimum version for every application. The motors are available with forced-ventilation or water-cooling, with solid or hollow shaft, as well as a wide range of bearing designs and various encoder types for closed-loop speed control and highprecision positioning. Additional features of this motor type include outstanding power and vibration quality, concentricity up to 10 m, high dynamic performance (short acceleration times), maximum speeds up to 20,000 rpm. Water-cooled 1PH8 motors especially come into their own where extreme ambient conditions prevail, such as high temperatures, dust, dirt or aggressive atmospheres, which rule out air-cooling. The same is true in processes, in which the environment cannot tolerate any negative thermal effects.

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1PH2

1FE1

2SP1

Hybrid spindle

Built-in induction motors 1PH2 motors for direct drives 1PH2 built-in motors are liquid-cooled three-phase induction motors. They are used if, as a result of the compact design, the motor must be integrated into the machine. The workpiece is machined with the highest degree of precision without the effect of transverse drive forces as a result of the smooth and precise spindle operation. These motors have power ratings of between 7.5 and 30.9 kW. Synchronous built-in motors Main spindle synchronous motors highly-dynamic performance and extremely compact 1FE1 built-in motors are compact, water-cooled synchronous motors that are supplied as components the stator and the rotor. They have maximum speeds of up to 40,000 rpm and power ratings up to 104 kW (S1 duty). They are available in the two main versions high-torque and high-speed. Permanent-magnet motor spindles (PE spindles) increase the power density and cost-efficiency of CNC machines. They are used wherever the shortest acceleration times are demanded, but also the highest requirements relating to machining quality, precision and smooth running operation.

Motor spindles with a high control dynamic performance The advantages of motor spindles include stiff, compact design, the highest power density, as well as lower total weight and frictional forces. They can be deployed without using additional mechanical transmission elements, such as belts and gearboxes. This permits the shortest machining times and a high control dynamic performance. They facilitate a high production precision as the spindle position and speed are directly acquired. Our portfolio has the following series Standard motor spindles for milling machines for use in vertical and horizontal machine designs Motor spindles for milling, drilling, turning and grinding Motor spindles that we have specifically developed according to individual customer specifications Hybrid spindle This newly-developed motor spindle that is suitable for speeds up to 24,000 rpm. It can replace or supplement indirect spindle drive solutions in vertical machining centers. Its innovative design allows the productivity and machining quality of these machines to be increased.

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Solutions for the control cabinet

Today, state-of-the-art automation is hardly conceivable without flexible, distributed solutions solutions that are tailored to your specific demands and result in significant cost-savings. In addition to cost-effective CNC and drive systems, Siemens also offers the complete range of services for cabinet building. These range from support and development, through building of the equipment, up to supply and support during the commissioning phase.

Competent control cabinet building Our control cabinets are built to a high level of industrial quality in Chemnitz, Germany. Services offered include the checking of collision and free space in 3D design layouts, as well as automated checks and testing. When required, our customers can obtain complete modules, including switching devices, cable harnesses, pneumatic and hydraulic components. They are supported by order centers and production teams that are assigned to specific customers. The highest degree of flexibility is secured by employing customer-specific logistic modules, flexible production capacities and production areas, as well as change management in every process phase.

Experienced in engineering We provide our customers with consulting services regarding the designing and dimensioning of equipment in compliance with the relevant standards for drive technology, control systems, operational control and safety. We engineer, carry-out design-to-cost projects and where required, changeover customer documentation to UL or other technologies. Additionally, we provide support when selecting and optimizing suitable cabinet climate control systems. In addition to calculations and simulation routines, we also carry-out checks by making measurements in our own heat laboratory with load simulation. Our recommendation control cabinet certification As your partner, we recommend that you certify your control cabinets. This is for quality assurance reasons and to secure the productivity of your machine or system. Additional advantages for you include repair and service contracts, minimized production downtimes, as well as reduced spare part requirements. We can certify individual control cabinets and standard control cabinets no matter if the control cabinets are built in our factory or at your facility.

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SINUMERIK Ctrl-Energy Energy savings through the simple touch of a button

As a CNC technology leader, we provide powerful and technically-sophisticated functions to increase the energy efficiency of your machine. To supplement the functions that can be called from the graphical user interface, SINUMERIK Ctrl-Energy offers an extensive
Drive and motor components PC software solutions

portfolio of energy-efficient systems, solutions and services.

SINUMERIK Ctrl-Energy CNC and drive functions SINUMERIK Manufacturing Excellence services

Ctrl-E Energy analysis Using the Energy Analysis function, the CNC not only acquires the energy usage of the drive system, but of the entire machine. This allows machine users to analyze their energy usage for each workpiece, and if required, to optimize the machining strategy. Operators can visualize the energy consumption by simply pressing the Ctrl + E shortcut key. Ctrl-E profile Ctrl-E Efficient standby provides machine tool builders a configuring platform to control the energy-saving modes of the machine. This means that loads can be specifically shutdown when the machine is at a standstill. The operator can very quickly and simply influence the energy-saving modes using the Ctrl + E shortcut key.

With a wide range of drive and motor components, CNC and drive functions, PC software solutions, as well as SINUMERIK Manufacturing Excellence services, SINUMERIK Ctrl-Energy sets new standards for the energy efficiency of machine tools.

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Its safe to say more safety

If it involves the safety of man and machine, then SINUMERIK makes no compromises. Safety Integrated is a comprehensive safety package to protect people and machines. However, your data is also reliably protected by employing increased NC hardware and software security.

Well-conceived safety concept By using Safety Integrated, your machine can be safely and practically operated under all of the required operating conditions for example during setup and test modes with the protective door open. Safety functions fulfill the requirements according to Safety Integrity Level SIL 2 of IEC 61508 and according to Performance Level PL d in compliance with EN ISO 13849. As a result, all of the main requirements specified in the EC Machinery Directive can be simply and cost-effectively implemented Functions to safely monitor velocity and standstill Functions to safely segregate working zones and protected areas and for area identification* All of the safety-relevant signals can be directly connected via PROFIBUS with the PROFIsafe protocol and logically combined internally*

Reliable data protection Your data is also permanently protected: The complete security of NC hardware and software guarantees protection and long-term stability in your manufacturing environment. The hardened PC controller hardware (PCU) is based upon a type-tested, standard IT security configuration. At an early stage, intelligent components, especially control systems, are subject to simulated attacks, and a weak point analysis is performed to test the system design and identify possible IT security gaps. The result Windows XP-based PCUs, configured as type-tested highsecurity workstation. SINUMERIK offers reliable protection by using the latest virus scanners and an activated and optimally configured firewall. Immune to attacks The hardened NC software of SINUMERIK 840D sl is based on embedded LINUX. The operating system of the NCUs in SINUMERIK has been immunized using the hardening process for complete protection against malware which can damage Windows systems. Additionally, a firewall in the system kernel with optimized and pre-configured package filters, so that the CNC can be used as a firewall to protect all of the communication networks behind it.

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* for SINUMERIK 840D sl

Intelligent fire protection solutions with Sinorix al-deco PLUS

Sinorix al-deco PLUS your advantages at a glance Highest degree of safety for man, machine and the environment Unique personal protection complying with the latest Machinery Directive VdS-certified valves and self-monitoring components are used Insensitive to technical disturbances Online monitoring for fast intervention All of the system data are recorded as a safety-relevant verification Redundant monitoring of all safetyrelevant functions Efficiency based on well-proven control standards

European legislation specifies fire protection for machine tools and their associated equipment that represent a fire risk. Using Sinorix al-deco PLUS, we offer an intelligent fire extinguishing system that provides the highest degree of safety for man, machine and the environment over the complete lifecycle of the machine. Here, safety-related components for personal protection are employed with which Sinorix al-deco PLUS fulfills the high requirements of EU legislation. You can find additional information online: www.siemens.com/sinorix Safe machine operation With Sinorix al-deco PLUS, fire detection and extinguishing are realized completely pneumatically without any electric power supply and independent of the machine. As a result, Sinorix al-deco PLUS is insensitive to technical disturbances and does not respond incorrectly. This secures continuous machine operation and reduces overall maintenance costs no special maintenance work is required in order to keep high operational safety. Unique personal protection Sinorix al-deco PLUS fire extiguishing systems for equipment correspond to the highest safety requirements in-line with the latest Machinery Directive 2006/42/EC. This is achieved using lines and pipes that are protected twice in conjunction with redundant and self-monitoring components. This technology means that a machine can only be operated after a positive system check and only releases the machine door after fire extinguishing has been inhibited and checked. Reliable environmental protection The fire extinguishing agent used by Sinorix al-deco PLUS is a pure natural gas, therefore not electrically conductive and chemically inert. This means that no harmful reaction products are released when it comes into contact with fire and it is environmentally-friendly.

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SINUMERIK Integrate integrating the CNC into your company processes

From development and procurement up to production and sales integrating machine and production data into the workflow is becoming increasingly more important. Integrating the machine tool into your company processes is an essential pre-requisite to achieve lean and efficient production. SINUMERIK Integrate has six modules that provide a comprehensive portfolio for the integration of machine tools into communication, engineering and manufacturing processes within the machining environment.

SINUMERIK Integrate
Integration into SINUMERIK Machine development Customizing Know-how protection

Create-it! Generating and adapting interfaces in SINUMERIK Operate Generating your own compile cycles within the framework of Open Architecture

Engineering Production

Lock-it! Know-how protection for SINUMERIK Run-it!

Integration into production

Communication Production and logistics Service and maintenance

Runtimes to run individual screen user interfaces with SINUMERIK within the framework of Open Architecture Running your own compile cycles on the NC kernel and the drives as well as the virtual NC kernel (VNCK) Manage-it! Organization and management of NC programs and tools

Analyze-it! Functions for condition-based maintenance Analytical functions based upon key parameters

Access-it! Programming interfaces to the machine tool and the server Remote access to the machine for diagnostics

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SINUMERIK Manufacturing Excellence our portfolio of services for machines and processes
If you want to optimize your production, then you must evaluate your machines as a whole. Only then can the optimum package of measures take effect in every phase of the lifecycle. SINUMERIK Manufacturing Excellence provides you with the needed support, with a combination of products, solutions and services. Corresponding to the individual requirements of machines and processes, selected modules from this package of services are used, which when required, can also be specifically adapted. Advantages for the machine tool builder Shorter machine development times Cost-optimized machine development Improved machine service Machines with optimum dynamic performance Opens up new potential for offering services Lower warranty costs Advantages for the machine tool end-user Lower workpiece machining costs Optimized processes Improved productivity and availability Optimized quality

Machine Development Simulation and commissioning of machines Shortens machine development times Manufacturing IT Functions for planning and carrying out production Optimizes processes and increases transparency in the machine environment

Condition Monitoring Functions for condition-based maintenance Reduces machine downtimes Extended Machine Contracts Lump-sum contracts for personnel and materials with agreed upon response times Secures the availability of machines and systems Productivity Improvement Optimization of machine processes Reduces cycle times and improves the quality

Machine Retrofit Modernization of the automation and mechanical system Extends the machine service life Service & Support Comprehensive service, e.g. replacement parts and on-site service Secures a high availability of machines and systems

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Machine tool service and support

Whether you require a service technician, expert advice or even a spare part during the complete lifecycle of your machine or system, we can offer you the support you need. One of the main pillars to guaranteeing high machine and system availability is through the range of services we provide through our local service organization, including spare parts and repair. Our field service technicians can even offer you services for the commissioning and maintenance of your machines. Just ask.

During production, you'll also benefit from Spare parts supply Replacement and repair of components Component checking/diagnostics Component upgrade service General overhaul of components Ask your regional service person about all of the services we can provide.

Service and support your advantages at a glance: Can be reached 24/7 365 days a year Specialists are there for you locally around the world Highly-available spare parts Favorably-priced replacement parts Service and support your advantages at a glance: Europe: Germany +49 180 5050 222 America: USA +1 847 640 1595 Asia: China +86 1064 719 990 www.siemens.com/automation/service&support

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Even more information about SINUMERIK

We can offer you more than just first-class products within the framework of our SINUMERIK system platform and systems for the widest range of requirements. We can comprehensively and expertly support you in every tasks when it comes to machine tools. Global technology competence Technology and Application Centers Our Technology and Application Centers (TAC) are important information platforms and meeting points for machine tool builders and end-users. Here, we have the opportunity to demonstrate our systems, solutions and services through training classes and events. Find more information online: www.siemens.com/cnc4you.

Duplicate headline as the one below! With SinuTrain, we offer you PC-based training for the SINUMERIK CNC. In addition to the classic courses and seminars, we online learning modules, learning software and technical books. In-line with what is required in the real world and perfectly tailored to the various training levels, we offer everything for your learning success from basic training, to programming and operation, up to full training classes for machine tool professionals. Find more information online: www.siemens.com/sinutrain.

Documentation just a mouse click away Using our DOConWEB service, you can research our documentation online with full text search and index search through the list of contents. Additionally, you can compile your own individual documentation quickly and easily to meet your needs. Find more information online: www.siemens.com/automation/doconweb.

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Technical information overview

828D Configuration Mechanical design Axes / spindles / NCU link, up to Channels up to Mode groups up to CNC user memory up to User memory on the PCU 50.3 hard disk Operating components Operator panel fronts, TFT display Operator panel fronts, TFT display, touch Machine control panels / handheld terminals / handwheels Axis functions Acceleration with jerk limitation Travel to end stop / with Force Control Spindle functions Various thread cutting functions Oriented spindle stop Flying axis synchronization Interpolation 80-bit NANOFP technology (floating point accuracy) Interpolating axes, up to Universal interpolator NURBS (non-uniform rational B-splines) Three-axis compressor / five-axis compressor Spline interpolation Advanced Surface Couplings Following axes Inclined axis Synchronous spindle / multi-edge (CP basic / static) Synchronous axis pair (gantry axes) Leading value coupling / curve table interpolation / electronic gear (without code tables / CP Basic / Comfort / Expert) Electronic gear (with curve tables / CP Expert) Transformations Transmit and peripheral surface transformation (e.g. parallel slot wall) Transformation for machine-specific kinematics Measuring functions / measuring cycles Measuring during setup Measuring cycles / logging measuring results Synchronous motion actions Asynchronous sub-routines Synchronous actions and fast help function output including three synchronous functions Positioning axes and spindles using synchronous actions / / * / / 4 20 / / / 10 / / 7.5/10/12/15/19 15 / Panel 6(M), 8(T) 1 1 5 MB Drive 31 / 93 10 10 15 Mbyte 12 Gbyte 840D sl

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Standard (basic scope)

CNC option

not available

* not available in all versions

828D Programming Programming language (DIN 66025 and high-level language expansion) Online ISO dialect interpreter Technology cycles for drilling / milling and turning Programming support for geometry and cycles (programGUIDE) Programming support with Animated Elements" Manual Machine / machining step programming ShopMill / ShopTurn Simulation Simulation for turning and milling in a surface representation Simulation in 3-D view Simultaneous recording (real-time simulation of the current machining) Tools Tool management / tool monitoring Tool management functions (TDI) Communication / data management Data storage Compact Flash card / USB device Manage network drives (Ethernet) Data storage on the PCU hard drive Operator control Expanded operating functions for complex turning and milling operations Several operator panels connected to a CNC Compensation Temperature compensation Sag compensation Compensation in space (VCS plus) Oscillation suppression (Vibration Extinction VIBX) Open Architecture Simple configuration of user screens / Easy Screen (Run MyScreens) Integrating screens, software and technological know-how (Create MyHMI) PLC Integrated SIMATIC PLC Maximum PLC memory in Kbyte / operations Processing time, typical in ms / kilo operations Distributed peripherals (I/O) via PROFIBUS DP / PROFINET Safety functions Safety Integrated (Safe Torque Off, Safe Brake Control, Safe Stop 1) SINUMERIK Safety Integrated Commission functions Auto Servo Tuning (AST) / Automatic speed and position controller optimization Diagnostic functions Alarms and messages Remote diagnostics Standard (basic scope) CNC option not available S7-200 / 24,000 0.02 / / / / /

840D sl

S7-300 1536 / 0.03 /

* not available in all versions

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Everything you ever wanted to know about SINUMERIK CNC: www.siemens.com/sinumerik Everything about shopfloor manufacturing: www.siemens.com/cnc4you Everything about the SINUMERIK Manufacturing Excellence portfolio of services: www.siemens.com/sinumerik/manufacturing-excellence Information about CNC training: www.siemens.com/sinumerik/training

Siemens AG Industry Sector Motion Control Systems P.O. Box 31 80 91050 ERLANGEN GERMANY

Subject to change without prior notice Order No.: E20001-A1490-P610-X-7600 Dispo 06311 W/37269 STAN.52.2.01 WS 11113.0 Printed in Germany Siemens AG 2011

The information in this brochure only provides a general description and performance features. For a specific application, this information will not always be applicable in the form described here. The required performance features are only binding if they have been expressly agreed upon in the form of a written contract. All product designations could be trademarks or product names of Siemens AG or other companies, which, if used by third parties, could infringe the rights of their owners.