Made to specification on the shopfloor.

Made to specification for the shopfloor.

SINUMERIK 828D
Answers for industry.
Contents

Hardware 03 – 07

Applications 08 – 09

CNC functions 10 – 13

Operation, programming, technology 14 – 21

Communication 22 – 23

Service and commissioning functions 24 – 25

Drives and motors 26 – 27

PLC, system overview, accessories 28 – 29

Technical information 30 – 31
 Enabled for Scalable sturdy CNC
communication: Heavy duty: Optimal view: operator panel:

Front ports Panel front made from 10.4” TFT color display Two versions with different
(IP65 degree of protection) die-cast magnesium performance capabilities
• RJ45 Ethernet • PPU 260/261
• USB 2.0 • PPU 280/281
• Compact Flash (CF) Card

3 Hardware
Low-maintenance: User-friendly: Clever: Optimally connected:

• No battery (non-volatile • Full QWERTY keyboard 3/8” thread for additional Rear side ports
data buffer thanks to • Hard keys with protective components • USB 2.0
NV-RAM technology) foil • RJ45 Ethernet
• No hard disk • IP65 degree of protection • DRIVE-CLiQ
• No fan • PLC I/O Interface
• RS 232 C
• NC inputs/outputs

Hardware 4
Compact, strong, simple…
…simply perfect!

By devising the SINUMERIK 828D, we have managed to develop a panel-based CNC

that is tailor-made for use in milling and turning machines. The product combines

CNC, PLC, operating and axis control functions for six CNC measuring circuits into one

compact unit, which is designed to fit any operator panel housing. Despite its compact

dimensions, the SINUMERIK 828D is a real powerhouse. Equipped with premium

CNC functions such as the ability to execute kinematic transformations or powerful

tool management, the product leaves nothing to be desired…and all without being

unnecessarily complicated. The SINUMERIK 828D is ideal for the shopfloor thanks to

its unique graphical user interface. Users can quickly commission, operate, program,

service and maintain machines and tasks without the need for extensive training.

Hardware 5
SINUMERIK 828D: One system,
two versions, many advantages. Dimensions (W x H x D): 483 x 220 x 105 mm

The SINUMERIK 828D is available in two versions that offer different performance levels, which means it can be perfectly

adapted to suit the power requirements of the machine. There are separate software versions for milling and turning

applications. These provide the maximum possible number of machine presets, thereby helping to keep commissioning

times to a minimum.

Enabled for communications Heavy duty Compact and user-friendly

The SINUMERIK 828D is equipped with The operator panel front of the Thanks to its mounting dimensions,
all the latest communications ports. The SINUMERIK 828D is made from heavy the SINUMERIK 828D can even be built
Compact Flash (CF) Card, USB and service duty die-cast magnesium. This ensures into highly compact operator panel hous-
ports are located behind the flap on the that the SINUMERIK 828D remains in ings. Despite its small dimensions, the
operator panel front, from where they good condition even if subjected to SINUMERIK 828D features a 10.4” color
can be directly accessed. The flap can harsh operating conditions. The hard display along with a full QWERTY key-
even be closed once a CF Card has been keys on the CNC keyboard are covered board and offers maximum user-friend-
inserted. in embossed foil to provide perfect pro- liness.
tection against moisture.

6 Hardware
 Dimensions (W x H x D): 310 x 380 x 105 mm

Low-maintenance Scalable Versions of the SINUMERIK 828D

The SINUMERIK 828D has no hard disk The SINUMERIK 828D is available with Standard version
and no fan. Thanks to the removal of both a horizontal and a vertical operator PPU 260 (vertical operator panel layout)
these parts, which are subject to wear, panel layout. Both operator panel orien- PPU 261 (horizontal operator panel layout)
the SINUMERIK 828D is relatively easy tations are available in conjunction with
to maintain and easy to service. In addi- two different performance ratings. As a Performance version
tion, no battery is required and the use result, the SINUMERIK 828D can be per- PPU 280 (vertical operator panel layout)
of NV-RAM does away with the need for fectly matched to the installation location PPU 281 (horizontal operator panel layout)
backup. as well as the power requirements.

Hardware 7
 Milling machines:
Setting up and getting started.

The SINUMERIK 828D is perfect for equipping vertical Straightforward operation.

Across the board.
and straightforward horizontal milling centers featuring
As well as being suitable for use with mill-
up to six CNC measuring circuits. And thanks to the new ing spindles and geometry axes (X-, Y-,
and Z-axes), the CNC can be used to oper-
Advanced Surface motion control function it can also be ate other machine units as an alternative.

used in tool- and moldmaking applications. These include:

• CNC rotary table (C-axis) for machining

on two stations
• CNC reversible clamping device (A-axis)
for milling and hole machining on
cylindrical workpieces
• CNC gantry axes (gantry operation)
• Inclinable heads or swivel tables for
milling and hole machining in statically
rotated machining planes
• CNC-controlled tool changer

8 Applications
 Turning machines:
Guaranteed to turn out well.

Another application for the SINUMERIK 828D is the control Flexible use

of turning machines. The functional scope has been tailored Besides being suitable for use with lathe
spindles and geometry axes (X- and Z-
for horizontal and vertical turning centers equipped with one axes), as an alternative the product can be
used to operate other machine units:
machining channel and up to eight CNC measuring circuits.
• Power tools, peripheral C-axis mode, and
Y-axis (orthogonal or diagonal) for end
face and surface machining
• Counterspindle with synchronous
spindle function for two-sided workpiece
machining
• Tailstock axis (with travel to fixed stop
function)
• CNC-controlled turret

Applications 9
Accuracy:
This compact powerhouse is raising the bar.

Y (nm)
Conventional interpolation
1(nm)

Position Speed Current Int. encoder

X (nm)
control control control resolution

Y (nm)

0.001(nm)

SINUMERIK + SINAMICS
X (nm)
80-bit NANOFP Accuracy

Workpiece accuracy is not just determined by the machine’s mechanical system. The CNC also contributes significantly to

the precision of the workpieces produced. The SINUMERIK 828D, a real powerhouse among compact CNCs, offers a variety

of top-notch CNC functions to ensure the necessary precision.

The ultimate in accuracy Maximum contour precision Integrated thermal compensation

SINUMERIK and SINAMICS are equipped Thanks to the dynamic feedforward The integrated thermal compensation fea-
with 80-bit NANOFP Accuracy. As a result, control feature, following errors in the ture balances out any potential tempera-
accuracy of well under a nanometer can machine can be calculated as early as ture changes in the machine and ensures
be achieved. This precision is not just set point output and compensated for in constant workpiece precision.
available for closed-loop position control advance. This way, maximum contour
but also for current regulation and closed- precision can be achieved.
loop speed control, as well as within the
context of drive sensor evaluation. Deviation detection

Easy on mechanical systems Contour deviations can be almost com-

pletely eliminated during axis reversal
Your machine’s mechanical system is thanks to the integrated quadrant error
protected thanks to an intelligent jerk compensation feature. This results in a
limitation feature. Smooth acceleration perfect workpiece surface, even at the
and deceleration prolong the service life kinds of critical quadrant transitions that
of the machine, thereby increasing its are associated with circular paths. Natu-
productivity. rally, the SINUMERIK 828D also compen-
sates for mechanical inaccuracy in the ball
screw.

10 CNC functions
Advanced Surface technology:
Unique performance for moldmaking workpieces.

Conventional CNC with Advanced Surface

Machining time: 48 min. Velocity Machining time: 33 min.

The manufacture of moldmaking workpieces has always been one of the biggest challenges for a CNC. The

SINUMERIK 828D is able to rise to this challenge thanks to its Advanced Surface technology, a unique method

of calculation which aims to improve workpiece surfaces while significantly reducing machine time.

Perfect surfaces Minimal machining time Only needs to be optimized once

The SINUMERIK 828D can even cope with Advanced Surface technology guarantees The system needs to be optimized only
inadequate CNC block sequences in mold- the shortest possible machining times, once in order for the tolerant filter algo-
making programs. Innovative “look-ahead” as well. A completely new kind of motion rithms that form part of the Advanced
mathematical algorithms calculate the control is able to calculate optimum Surface technology to guarantee optimum
forwards and backwards path motions smoothing of the surface, thereby en- workpiece surfaces and the shortest pos-
identically. In this way, perfectly smooth suring that the tool remains within the sible machining times.
workpiece surfaces can be achieved when optimum speed range at all times.
carrying out line-by-line milling for molds.

CNC functions 11
Transformations:
Full orientation in all machining planes.

Whether you are machining the front face or peripheral surface of rotating parts, or dealing with milled workpieces in

rotated planes, the SINUMERIK 828D is able to transform the machining plane to ensure exactly the right position. This

is all done automatically – without the need for CAD/CAM systems or a pocket calculator.

C-axis utilized to full advantage Diagonal boreholes handled with ease

Your turning machine’s spindle for C-axis The SINUMERIK 828D remains calm
mode is more than just a positioning axis. under pressure, coping easily with milling
With the SINUMERIK 828D’s TRANSMIT machines that are equipped with a swiv-
function, power tools can be used to eling table or inclinable head. Due to its
carry out any boring and milling pro- integrated swivel cycle, boring and mill-
cesses you require on the end face of the ing processes can be carried out in any
tool. statically rotated workpiece plane – with-
out the need for a CAM system or pocket
The ultimate in peripheral surface calculator.
machining
Counterspindle machining made easy
The SINUMERIK 828D controls peripheral
surface machining perfectly, whether Having difficulties programming work-
used on turning or milling machines. piece transfer from the main spindle to
Slots with parallel walls can even be the counterspindle? The SINUMERIK 828D’s
machined when the tool offset is acti- integrated counterspindle cycle makes
vated. Geometry axes can be easily pro- this process really easy and there is no
grammed using the processing interface. need for the user to have any special
The CNC takes care of everything else. G-code knowledge.

12 CNC functions
Tool management:
Everything at a glance, everything under control.

Tool management made easy. The SINUMERIK 828D features a command center for all tool and magazine tasks so that

the machining process is never interrupted. If the tool is at the end of its service life, the SINUMERIK 828D will send a text

message (SMS) as necessary – thanks to the Easy Message technology.

Everything at a glance Simply brilliant Powerful

The SINUMERIK 828D‘s tool management The SINUMERIK 828D does not just rec- The SINUMERIK 828D can manage up to
system presents tool data and position ognize tools in the tool magazine. Simply 256 tools with 512 cutting data records.
information on one screen so there is no create a tool in the tool list and it is ready Naturally, the SINUMERIK 828D monitors
need to keep switching screens. The tool to be programmed and simulated. At the tool service life and makes replacement
type is presented in the form of a picto- touch of a button, the tool management tools available, as needed. Is the tool you
gram. Both primary and secondary cut- function will search for a suitable maga- want missing from the tool magazine? No
ting edges are indicated for turning tools. zine location. Assign relevant names problem. The SINUMERIK 828D requests
Therefore, process stability can be guaran- for the tools, then call the tool name a manual change and machining can con-
teed simply by looking at the tool table. in the CNC part program and the tinue right away.
SINUMERIK 828D will automatically
take care of everything else for you.

CNC functions 13
Animated Elements: Perfectly animated
operation and programming.

What do the parameters that are input daily into a CNC actually do? The answer is obvious: they are responsible for the machine’s

movements. Static help screens can only illustrate these movements to a limited extent. That is why the SINUMERIK 828D offers

a completely new and highly convenient method of input support: Animated Elements. This input support completely redefines

graphic programming and operation thanks to a unique display involving sequences of moving pictures.

Setup combined with process stability Accurate programming

Need to determine the workpiece zero What is helical immersion in a milled

using a circular spigot? What is the pocket or how do you tell the difference
positioning sequence for the tracer and between chip removal and chip breakage
how does the CNC withdraw it? This is during deep-hole drilling? In such situa-
where the Animated Elements technol- tions, a static help screen would simply
ogy comes in: a short sequence of mov- show you a collection of arrows that
ing pictures shows you the trace process would be very hard to understand. Not so
while ensuring 100% process reliability. with Animated Elements. This technology
illustrates the motional sequence per-
fectly and with 100% accuracy.

14 Operation, programming, technology

Input assistance: It’s the little things
that make everyday life more bearable.

Today’s PCs couldn’t be more user-friendly. For example, they offer fantastic support in terms of data input. But what

about CNCs? Do you sometimes find yourself wondering whether you have been transported back in time? You won’t with

SINUMERIK 828D. With features such as cursor text, context-sensitive online help and clearly structured menu assistance,

you will realize that you are truly in the present.

Well structured Always helpful

The SINUMERIK 828D’s user interface is For every text box on the operating
divided into clearly structured control screens, the SINUMERIK 828D automati-
areas. Control areas such as the CNC editor cally provides help in the form of cursor
or machining parameters can be accessed text. The SINUMERIK 828D has a com-
at the touch of a button thanks to the plete help system for more detailed
direct keys on the operator panel. information, just like a PC at home.

Easy-to-use A global player

The SINUMERIK 828D is operated by The SINUMERIK 828D allows names of

means of eight horizontal and eight ver- part programs and CNC comments to be
tical soft keys. This arrangement means input in pictographic languages. Chinese
that all the operating screens can be or Korean characters can easily be gen-
accessed with just a few key presses. erated with the integrated keyboard so
every user imme-diately feels at ease.

Operation, programming, technology 15

programGUIDE:
Less machining time – more output.

Every second of machining time counts when manufacturing workpieces in large batch sizes. That is why the

SINUMERIK 828D boasts a flexible CNC programming language with readable high-level language elements.

Thanks to programGUIDE, you can combine this flexibility with the convenience of powerful technology cycles.

Maximum flexibility Quick and convenient to program

The pairing of DIN/ISO language state- The text-based CNC editor, with many
ments with CNC high-level language helpful functions such as “Find and
elements provides the maximum in flexi- Replace,” enables flexible CNC programs
bility and guarantees minimal machining to be generated quickly.
time. In addition, the SINUMERIK 828D programGUIDE allows you to integrate
can understand other CNC programs from the SINUMERIK 828D’s technology cycles
other manufacturers due to the online into your CNC programs. With just a
ISO dialect interpreter. few keystrokes, you can tap into the
full performance capability of the
SINUMERIK 828D – effortlessly and
with perfect support from Animated
Elements.

16 Operation, programming, technology

ShopMill and ShopTurn:
Simple, step-by-step programming.

When it comes to manufacturing small batches or individual parts, programming time is the key factor for ensuring

productivity. Here, the SINUMERIK 828D is in its element. With ShopMill/ShopTurn sequence programming, the

SINUMERIK 828D boasts the most straightforward CNC program editor in the world. Programming takes place

without the need for DIN/ISO knowledge in technological steps that are easy to understand.

Simple and clear Always in the picture

Processes such as drilling, centering, All geometric elements in the CNC pro-
grooving or pocket milling are displayed gram are displayed true-to-scale thanks
in the form of steps. This makes the CNC to the dynamic broken-line graphics.
programs – even those used for com- Throughout the entire program, the
plex machining processes – extremely broken-line graphics adapt automatically
compact and easy to read. Associated to the geometric input. Even if elements
steps are automatically linked and can are changed or added, they are displayed
be assigned any position pattern. This perfectly on the screen, without simula-
unique level of programming conve- tion. Naturally, CNC simulation is also
nience ensures the shortest possible available in ShopMill/ShopTurn sequence
programming times even in the case of programming. However, this will not be
demanding machining tasks. required until the end of the process and,
when it is, optimum process stability will
also be ensured.

Operation, programming, technology 17

Technology cycles:
Suitable for every type of program.

Whether you have programGUIDE or ShopMill/ShopTurn sequencing, you have the

full range of technology cycles, position patterns and geometries at your disposal.

For every standard geometry in every

position Little helpers For maximum precision

Circular pockets, thread undercuts, deep- Programming of the counterspindle not The SINUMERIK 828D ensures continued
hole drilling and a whole lot more: the always easy? It is with the SINUMERIK 828D. workpiece accuracy during the machining
SINUMERIK 828D offers a unique assort- An ingeniously straightforward cycle process with an assortment of measuring
ment of technology cycles for standard enables the counterspindle to be man- cycles.
geometries – including engraving cycles. aged without the need for CNC language
The technology cycles are assigned to commands. Even sloping surfaces can be
machining positions using a large assort- programmed with ease. The machining
ment of ready-made position patterns. In plane can be rotated just how the user
addition, this also applies to the front and wants with the integrated swivel cycle,
peripheral surfaces of turned workpieces without the need for CAD systems or a
or rotated planes in the case of milled pocket calculator.
workpieces.

18 Operation, programming, technology

 Worried about complex contours of
In good shape Pockets with islands required? rotation?

Even complex contours can be gener- The integrated geometry processor The machining of complex inside con-
ated directly on the CNC thanks to the makes it easy to generate pocket and tours is a particular challenge for any
integrated geometry processor. Partially- island contours. The SINUMERIK 828D CNC. Even complex geometries with relief
defined contour elements are calculated generates tool paths automatically. To cuts can be machined. You can choose
automatically. Grinding stock allowance achieve maximum productivity, parts can whether you want to turn the contour in
required for turned workpieces? All you be rough machined with a large milling the conventional way or plunge-cut it.
have to do is input the allowance. The tool. Optional identification of residual Contour machining can also be config-
SINUMERIK 828D will take care of any addi- material enables targeted remachining ured exactly as you wish. This means you
tional calculations. In addition, DXF files of the residual corners using a smaller can choose the right tool and the best
can also be processed offline. Simply use a milling tool. This feature can also be used cutting values for each subsegment. The
CAD reader to convert your DXF files into on turning machines equipped with live geometric tracking function takes care
the SINUMERIK geometric format. tools. of the optional identification of residual
material automatically.

Operation, programming, technology 19

CNC simulation:
Maximum process stability guaranteed.

Ensuring machine productivity is partly a question of preparing well for the machining process. The SINUMERIK 828D’s

powerful CNC simulation feature helps in this regard. And not just by a brilliant simulation display. The calculation of the

machining time provides the ideal basis for determining workpiece costs.

Maximum process stability In all circumstances Optimum view guaranteed

The SINUMERIK 828D’s simulation Any CNC that is available on the market Worried about detailed machining? Not
feature guarantees maximum process today is capable of generating simula- a problem for the SINUMERIK 828D. The
stability because it uses the actual geo- tions in top and side view. But what about user can zoom in to the smallest corners
metrical data of the tools installed on the simulations involving kinematic transfor- of the CNC simulation without having to
machine. Therefore, the SINUMERIK 828D mations? Even here, the SINUMERIK 828D restart it. In addition, the simulation can
doesn’t just look good, it shows an exact shows what it is made of. Whether it is be interrupted at any time and controlled
image of the desired machining process. being used for front and peripheral sur- in terms of speed. As a result, even the
faces in the case of turning machines or smallest detail is not overlooked.
rotated machining planes in the case of
milling machines, the SINUMERIK 828D
can simulate machining whatever the
circumstances.

20 Operation, programming, technology

Machine setup made easy.

Particularly within the context of job shop manufacturing (small batch production), machines frequently need to be reset.

Tracer processes for workpiece setup or process measurement for the establishment of tool geometries are provided in a

format tailored to the user’s requirements.

Everything as it should be Perfectly aligned Perfectly equipped

Blanks often need to be shaped prior to All you need to do is trace the edge, The SINUMERIK 828D makes it really
machining. The SINUMERIK 828D does corner or boreholes and the system will easy to quickly determine the tool length.
not require any additional CNC part pro- determine the clamping position includ- Whether you are determining the tool
gram for this purpose. A workpiece can ing the workpiece‘s basic rotation. The geometry by “scratching” or using a tool
be face milled or face turned simply by SINUMERIK 828D offers a variety of measurement system, all you need to
setting the relevant parameters in setup measurement variants – even for sloping do is press a button and the geometry
mode. Simply select NC Start and off you workpiece surfaces. will be stored in the CNC’s tool offset
go. Want to bore clamping jaws? The memory.
SINUMERIK 828D can also do this at the
touch of a button.

Operation, programming, technology 21

User memory and data transfer:
All data under control.

Text message (SMS), USB and Ethernet – the SINUMERIK 828D uses the

latest methods of communication to guarantee data transfer at all times.

Unlimited user memory Got your notebook handy?

The SINUMERIK 828D is already equipped to the front Ethernet port of the The days of laborious serial data trans-
with a basic 3 or 5 MB user memory. If SINUMERIK 828D and you‘re online. fer are over. The RCS Commander is a
this memory capacity is not sufficient, The CNC also offers a user-friendly PC powerful and free PC tool which can be
then memory can be expanded by insert- tool in the form of the RCS Commander. used to easily transfer data to the CNC
ing a Compact Flash (CF) Card into the and using the Drag and Drop method. A
front port. Already networked? treat for service technicians: the CNC’s
screen contents can be easily viewed on
Perfect diagnostics The SINUMERIK 828D can be integrated a PC using the RCS Commander. Simply
into any company network via a 100Base-T connect the RCS Commander to the front
Need quick and easy service? The Ethernet port. And all without the need Ethernet port. The network configura-
SINUMERIK 828D is available to you from for additional software protocols. Simply tion will automatically pick up the
anywhere. The remote diagnostics func- connect, configure and get on the infor- SINUMERIK 828D. No expertise in net-
tion enables remote operation as well as mation superhighway. working is required.
supporting file transfer. The contents of
the CNC screen are displayed directly on
the workstation where the remote diag-
nostics are being carried out. Simply con-
nect a modem that supports the required
data transfer method (analog, ISDN, etc.)

22 Communication
Easy Message:
Always informed, wherever you are.

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Easy Message is an innovative modern communications function. It represents a new way of increasing machine

productivity – regardless of where you are. Get a hold of the process information relating to your machine very easily –

by text message (SMS) on your mobile phone.

Just install a SIM card and you’re

ready to go! The right information for each person Perfect service

All you need to use Easy Message is the Easy Message offers a user administra- There is an increasing focus on all aspects
optional mobile communications modem tion feature to ensure that each person of machine tool customer service and
and a SIM card of your choice. This means involved is supplied with exactly the support. Easy Message also provides an
you are free to choose the mobile phone information they need. This means that excellent platform in this respect. As well
contract that suits you best. The mobile machine operators can obtain information as error messages, maintenance informa-
communications modem relies on the about the status of the current machining tion from the service planner can be sent
globally-established GSM mobile commu- operation, whereas information about tool via text message (SMS), too. Impress your
nications standard – naturally with quad- wear can be transmitted directly to mem- customers with extremely short customer
band technology. The associated mobile bers of the tool planning team. In addi- support waiting times with the help of
communications antenna guarantees opti- tion, you can send any text (SMS) message Easy Message.
mum quality of transmission even in harsh you want to directly from the CNC part
industrial environments. program. This means that the sky is the
limit when it comes to flexibility.

Communication 23
Easy Extend:
Expand your machine at the touch of a button.

0QUJPOT 0QUJPOT

How difficult is it to subsequently install an optional component on your machine? With a SINUMERIK 828D, it’s really easy.

Easy Extend provides a simple way of carrying out the necessary groundwork at the factory prior to commissioning optional

machine units. Once installed on-site, everything runs automatically…and at the touch of a button.

Easy-to-add machine components All maintenance tasks under control

The SINUMERIK 828D allows you to carry The SINUMERIK 828D helps you monitor
out the necessary groundwork for any any essential maintenance intervals asso-
optional machine components, which ciated with your machine on the basis of
might later be added at the request of the service planner. The best thing about
your customers, as early as the commis- this is that you don’t need to configure
sioning stage. With Easy Extend, any nec- any user displays of your own. Simply
essary system parameters, such as those enter the desired maintenance interval
required for attaching a dividing unit into the service planner (the time left until
(A-axis), can be stored in a script file. All the coolant reservoir needs to be changed,
the on-site service technician needs to do for example). The SINUMERIK 828D auto-
is install a SINAMICS power unit, if neces- matically informs the operator about
sary. Then the machine components to the pending maintenance work. In addi-
be installed can be selected. Easy Extend tion, there is no need for you to define
automatically installs the necessary sys- any maintenance intervals for the
tem parameters. The component is ready SINUMERIK 828D itself. The fact that
for use at the touch of a button. there is no wear on parts (such as a hard
disk or fan) means that maintenance
tasks are not required.
24 Service and commissioning functions
Easy Archive: Commissioning and service –
well prepared and quickly executed.

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We aim for straightforward commissioning and straightforward service. Simply unpack and turn on your SINUMERIK 828D.

You will find that the parameters have already been set to allow straightforward and reliable commissioning. And if you

ever need to upgrade your application in the field, this can be done with Easy Archive, which requires no expert knowledge.

Easy Archive is an ingenious process, which enables you to upgrade seamlessly without losing your momentum.

Perfectly prepared Suitable for your own data

The SINUMERIK 828D’s interface data is Easy Archive guarantees problem-free You can also use Easy Archive for your
pre-defined on delivery and ready for a machine operation in conjunction with own application data, for example in the
typical machine application. This means all user data, such as CNC part programs PLC. Simply categorize your application
commissioning can be carried out rather or tool data, as well as the geometric data by assigning one of the Easy Archive
quickly. machine data that was originally input. data classes and you will soon be enjoy-
And the great thing about Easy Archive is ing the benefits of the SINUMERIK 828D’s
Software upgrading made easy that you don’t need any software tools. innovative approach to archiving.
Easy Archive can be controlled via the
The SINUMERIK 828D features a brand- SINUMERIK 828D user interface.
new data management process. Easy
Archive allows you to upgrade the
machine’s interface data in the field with-
out having to back up your customers’
user data and the individual machine set-
tings (such as reference positions or com-
pensation data) in advance. Use your test
machine to create an upgrade archive.

Service and commissioning functions 25

Drives and motors:
For powerful machine tool applications.

Everyone has a tendency to focus exclusively on the CNC. But what is it that actually gets the machine going? Correct: the com-

ponents hard at work behind the scenes – the drives and motors. Thanks to SINAMICS, the SINUMERIK 828D runs in top form.

SINUMERIK and SINAMICS, the perfectly coordinated motion control system consisting of CNC, drive and motors guarantees

perfect workpiece surfaces and extremely short machining times, thereby delivering maximum productivity.

Superb dynamic performance and

perfect surfaces Flexible and energy-efficient DRIVE-CLiQ: simply plug and play

SINAMICS S120 provides a unique closed- SINAMICS S120 can be used in all line If you are searching for the perfect “infor-
loop position control process for the tough- system configurations (TN, IT, IT) with mation superhighway” in a device, you
est dynamic response requirements in a voltage range of between 380 V and need to look no further than SINAMICS,
the form of Dynamic Servo Control (DSC). 480 V without the need for an additional which is equipped with DRIVE-CLiQ. The
An adaptive current controller helps to series transformer. Incidentally, 70% of electronic name plates of all connected
ensure maximum motor performance. As all machine tools happen to be oper- components, including motors and en-
a result, impressive acceleration values can ated within this voltage range. Thanks to coders, are detected automatically. This is
be achieved, thereby increasing machine energy recovery, it is not just your control achieved with a single data protocol. All
productivity significantly. The intelligent cabinet that will be able to keep its cool components are networked using just one
filter functions mean that the natural reso- at full infeed power. In these times of cable type – simply and clearly. Therefore,
nances of the machine can be almost com- constantly increasing energy prices, the commissioning of the drive system is child’s
pletely suppressed. This, combined with money you will save on power costs will play. Want to add new components later
high-precision, three-phase detection of give you additional peace-of-mind. on? No sweat: SINAMICS automatically
the actual value and actual position value recognizes the new drive components –
acquisition in the sub-nanometer range, simply plug and play.
ensures that perfectly smooth workpiece
surfaces can be achieved.

26 Drives and motors

Superb dynamic performance Sheer power Optimal actual value acquisition

Whatever your requirements – whether Maximum spindle speed and machine SINAMICS motors are equipped with
high static torques, high maximum cutting performance, as well as minimal state-of-the-art encoder technology.
speeds, perfectly smooth running char- ramp-up time, ensure optimum produc- High-precision optical encoders with a
acteristics, additional holding brakes or tivity. SINAMICS main spindle motors pro- resolution of up to 24 bits ensure maxi-
whatever else you might need – the 1FK7 vide the ideal platform for any demand- mum contour precision and positioning
and 1FT7 SINAMICS servomotor series ing spindle solution. The main spindle accuracy. In addition, the absolute value
are perfectly suited to any task. With motors on offer range from standard sensors do not require expensive back-
their high degree of protection, strong motors with asynchronous and synchro- up batteries. This is not just good news
bearings and vibration-free design, the nous technology to built-in motors that for your wallet, but also for the environ-
synchronous servomotors provide a reli- are directly integrated into the machine’s ment. If necessary, the encoders can
able drive source for your machine. High- mechanical system. Of course, there is be replaced quickly and easily thanks to
quality magnet materials give the system also a wide power spectrum available. the intelligent coupling technology, and
a very high power density. As a result, without any need for adjustment. This
extremely small motor dimensions can be makes them very easy to service.
supported and even very tight installa-
tion conditions can be overcome.

Drives and motors 27

PLC: A systematic approach to automation.

The PLC interface control has a decisive role to play in terms of increasing productivity. Machining downtimes (when changing

tools, for example) need to be kept to a minimum. That is why the SINUMERIK 828D is equipped with an interface control that

is designed help your machine achieve maximum output.

Quick to program Plug and Play Straightforward diagnostics

The PLC can be programmed easily and The SINUMERIK 828D automatically rec- If a mechanism of the machine ever “jams,”
logically using universally established lad- ognizes the PLC I/O modules. This makes the SINUMERIK 828D is even perfectly
der diagram technology (Ladder Steps) – commissioning and subsequent expansion equipped to deal with this. A PLC viewer
either with a PLC programming tool really easy, without the need for expensive integrated into the SINUMERIK 828D’s user
on a PC or a PLC editor integrated into configuration work or additional configur- interface enables the user to determine the
SINUMERIK 828D’s user interface in case ing tools. source of the error as quickly as possible.
of minor extensions.
Incredibly fast Easy interfacing
Optimal I/O modules
The SINUMERIK 828D’s PLC is capable of With an optional PN/PN Interface the
Especially designed input/output modules processing 24,000 logic instructions in SINUMERIK 828D can communicate with
are available for the SINUMERIK 828D. their entirety within a time scale that is additional automation modules such as
These modules have 72 digital inputs and guaranteed to remain constant. In the case a roboter or connect to a supervisory PLC
48 digital outputs as well as two analog of time-critical process signals, an addi- network. Plug & Play without tedious con-
inputs and outputs, which are of course tional servo synchronous high-speed PLC figuration efforts.
isolated to ensure the best possible process task accelerates the response time. This is
stability. a real advantage in terms of productivity.

28 PLC, system overview, accessories

System overview

Factory network
Service interface SINUMERIK 828D (Ethernet TCP/IP)
(Ethernet TCP/IP)
RS232 C SMS modem

PC/PG
PC

DRIVE CLiQ DMC20

linear scales
Modem router MCP
SINAMICS S120

NX10
(T version only)

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

Handheld unit PN/PN coupler Asynchronous motor Synchronous motor Asynchronous motor

SINUMERIK, SINAMICS and their accessory components are a well-rehearsed team. Top-notch communication

This perfectly coordinated motion control system guarantees optimum workpiece The intelligent PLC and drive interfaces
guarantee top-notch communication. The
quality combined with minimal machining time. SINUMERIK 828D detects the operating
state of all connected components. This
makes it really easy to perform diagnostics
on the entire system.

Siemens accessories

Add Siemens components to your system.

These components are perfectly matched
to one another and guarantee maximum
machine availability. We offer an extensive
range of components such as machine
control panels and user handwheels. With
our Motion Connect products, we also
offer a large assortment of high-quality
cables and connections that are measured
to the exact centimeter, if required.

29 PLC, system overview, accessories

Technical data (Excerpt)
PPU 260/261 PPU 280/281
Turning Milling Turning Milling
System performance
Basic quantity of axes/spindles/auxiliary axes 3 4 3 4
Each additional axis/spindle
Each additional axis/spindle
Maximum configuration axes/spindles/auxiliary axes 6 6 8 6
Maximum number of interpolating axes 4 4 4 4
Maximum number of machining channels 1 1 1 1
Minimum block cycle time ~6ms ~2ms ~6ms ~1ms
CNC user memory (extendable by user-CF-card) 3 MByte 3 MByte 5 MByte 5 MByte
CNC Functions
Tool management with monitoring of tool life and workpiece count
Replacement tools
Maximum number of tools/cutting edges 128/256 128/256 256/512 256/512
Number of settable zero-offsets 100 100 100 100
Safety Integrated ¸ ¸ ¸ ¸
Asynchronous subroutines ASUB
Synchronized actions and high-speed auxiliary function output
Acceleration with jerk limitation
Look Ahead (number of blocks) 1 100 1 150
Compressor for 3-axis machining – –
Advanced Surface – –
A, B, C spline interpolation
TRANSMIT and peripheral surface transformation
Travel to fixed stop
Travel to fixed stop with Force Control
Inclined axis for nonorthogonal Y-axis – – –
Synchronous spindle function for subspindle (CP Static) – – –
Synchronous spindle function multiedge turning (CP Basic) – –
Pair of synchronized axes Gantry
Temperature compensation
Bidirectional leadscrew error compensation
Multi-dimensional sag compensation
Master/slave for drives – –
Analysis of internal drive values – –

¸ in preparation standard (basic scope) CNC option – not available

Technical information 30
 PPU 260/261 PPU 280/281
Turning Milling Turning Milling
CNC Programming and Operation
Programming language (DIN 66025 and high-level language expansion)
Online ISO dialect interpreter
Technology cycles for drilling and milling
Technology cycles for turning – –
Residual material detection and machining
Programming support for technology cycles (programGUIDE)
ShopTurn/ShopMill machining step programming
Measuring cycles for drilling/milling and turning
Simulation in plane display
Simulation in 3-D display
Simultaneous recording (real-time simulation of current machining operation)
Extended operator functions for complex turning and milling
tasks
Contour handwheel
Network drive management
Remote diagnostics function RCS Host
PLC Functions
Integrated PLC based on SIMATIC S7-200
PLC periphery modules PP 72/48D PN, PP 72/48D 2/2A PN
Ladder viewer and add-on editor on board
Processing time per PLC command 0.025µs 0.025µs 0.02µs 0.02µs
Maximum number of PLC ladder steps 24,000 24,000 24,000 24,000
Servo-synchronous High Speed PLC Task
Reaction time to process events (terminal to terminal) ~7.5ms ~7.5ms ~4.5ms ~4.5ms
Maximum number of digital inputs/outputs 288/192 288/192 360/240 360/240
Maximum number of analogue inputs/outputs 8/8 8/8 10/10 10/10
PN/PN coupler
Commissioning and Service Functions
Easy Screen easy creation of user screens
(OA Runtime License from 5 user screens)
Service Planner planner for maintenance tasks
Easy Extend management of machine components
Easy Archive data archiving

standard (basic scope) CNC option – not available

Technical information 31
Get more information
Everything you need to know about SINUMERIK CNC equipment:
www.siemens.com/sinumerik

Everything you need to know about shopfloor production:

www.siemens.com/cnc4you

Everything you need to know about our service portfolio

SINUMERIK Manufacturing Excellence at:
www.siemens.com/sinumerik/manufacturing-excellence

Information on training sessions:

www.siemens.com/sinumerik/training

The information provided in this brochure contains

merely general descriptions or characteristics of
Siemens AG Subject to change without prior notice
performance which in actual case of use do not always
Industry Sector Order No.: E20001-A840-P610-X-7600 apply as described or which may change as a result of
Drive Technologies Dispo 06311 further development of the products. An obligation to
P.O. Box 31 80 WÜ/17743 GD.MC.10.TIGE.52.9.01 WS 02091. provide the respective characteristics shall only exist if
91050 ERLANGEN Printed in Germany expressly agreed in the terms of contract.
GERMANY © Siemens AG 2009 All product designations may be trademarks or product
names of Siemens AG or supplier companies whose use
www.siemens.com/sinumerik by third parties for their own purposes could violate the
rights of the owners.