Siemens SINUMERIK 802S Setup guide

Diagnostics Guide 01/02 Edition
SINUMERIK 802S/802C

SINUMERIK 802S
SINUMERIK 802C
Diagnostics Guide
Valid as from
Control system Software version
SINUMERIK 802S 3
SINUMERIK 802C 3
01.2002 Edition
Alarms 1
Glossary / Abbrevia-
tions
2

SINUMERIK
Documentation
Printing history
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Status code in the “Remarks” column:
ANew documentation. . . . .
BUnrevised reprint with new Order No.. . . . .
CRevised edition with new status.. . . . .
If factual changes have been made on the page since the last edition, this is indicated by a new edition
coding in the header on that page.
Edition Order No. Remarks
02.99 6FC5598–2AA20–0BP0 A
04.00 6FC5598–2AA20–0BP1 C
01.02 6FC5598–3AA20–0BP2 C
This manual is part of the documentation on CD-ROM (DOCONCD)
Edition Order No. Remarks
11.02 6FC5298-6CA00–0BG3 C
Trademarks
SIMATICr, SIMATIC HMIr, SIMATIC NETr, SIROTECr, SINUMERIKr,SIMODRIVErand
MOTION-CONNECTrare Siemens trademarks. All other product and system names are registered
trademarks of their respective owners and must be treated accordingly.
Further information is available on the Internet under:
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The reproduction, transmission or use of this document or its
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created by patent grant or registration of a utility model or design,
are reserved.
Siemens AG 2002. All rights reserved.
Other functions not described in this documentation might be
executable in the control. This does not, however, represent an
obligation to supply such functions with a new control or when
servicing.
We have checked that the contents of this publication agree with the
hardware and software described herein. Nonetheless, differences
might exist and therefore we cannot guarantee that they are
completely identical. The information given in this publication is
reviewed at regular intervals and any corrections that might be
necessary are made in the subsequent printings. Suggestions for
improvement are welcome at all times.
Subject to change without prior notice.
Siemens–AktiengesellschaftOrder No. 6FC5598–3AA20–0BP2
Printed in the Federal Republic of Germany
3ls

01.02
© Siemens AG 2002 All Rights Reserved 6FC5598-3AA20-0BP2
SINUMERIK 802S/802C (DG) v
Preface
The present description is intended as a manual for the machine tool operator
so that he can:
- assess special events when operating the machine correctly
- learn the response of the equipment on special events
- use the provided possibilities to continue work after the special event
- follow the notes referring him to documentation with further information.
This Description includes the alarms that may occur in the following areas: NC
kernel (NCK), cycles and PLC.
Further alarms provided from the MMC area (Man Machine Communication)
can also occur. They are announced to the user in self-explaining alarm lines
on the operator panel. They are not subject of the Diagnostic Instructions. For
special cases in conjunction with the integrated PLC refer to literature on the
SIMATIC S7-300 system.
The alarms are sorted in the Diagnostic Instructions by ascending alarm num-
bers with spaces between them.
Danger
Please check the situation of the equipment carefully using the description of
the particular alarm occurred. Eliminate the causes of occurrence of the alarm
and acknowledge it as specified. Inattention could cause damage to machine,
workpiece, stored settings and - under certain circumstances - to your health.
Table 1_1 Alarm number ranges
000 000 - 009 999 General alarms
010 000 - 019 999 Channel alarms
020 000 - 029 999 Axis/spindle alarms
030 000 - 099 999 Functional alarms
060 000 - 064 999 SIEMENS cycle alarms
065 000 - 069 999 User cycle alarms
070 000 - 079 999 Manufacturer and OEM compile cycles
Scope
Sorting
Safety
NCK alarms

01.02
6FC5598-3AA20-0BP2 © Siemens AG 2002 All Rights Reserved
vi SINUMERIK 802S/802C (DG)
Table 1_2 Alarm number ranges (continued)
100 000 - 100 999 Basic system MMC0
101 000 - 101 999 Diagnosis
102 000 - 102 999 Services
103 000 - 103 999 Machine
104 000 - 104 999 Parameters
105 000 - 105 999 Programming
106 000 - 106 999 Reserve
107 000 - 107 999 OEM
110 000 - 110 999 reserved
120 000 - 120 999 reserved
Table 1_3 Alarm number ranges (continued)
300 000 - 399 999
Table 1_4 Alarm number ranges (continued)
400 000 - 499 999 General alarms
700 000 - 799 999 User range
MMC
alarms/messages
611D alarms
PLC
alarms/messages

01.02
© Siemens AG 2002 All Rights Reserved 6FC5598-3AA20-0BP2
SINUMERIK 802S/802C (DG) vii
Contents
ALARMS 1-9
1.1 Overview of NCK Alarms 1-10
1.2 Cycle Alarms 1-88
1.3 PLC Alarms 1-93
1.4 Action List 1-96
GLOSSARY / ABBREVIATIONS 2-105
2.1 Abbreviations 2-105
2.2 Glossary 2-111

01.02
6FC5598-3AA20-0BP2 © Siemens AG 2002 All Rights Reserved
viii SINUMERIK 802S/802C (DG)

01.02 1 Alarms
© Siemens AG 2002 All Rights Reserved 6FC5598-3AA20-0BP2
SINUMERIK 802S/802C (DG) 1-9
Alarms
The alarms listed in the following are system errors indicating internal error
conditions. The internal error number displayed together with the error mes-
sage provides the developer with important information on error cause and
error location.
These system errors will not be described in detail. As far as they occur on the
delivered control systems at all, please contact the following hotline, specifying
alarm number, alarm text and internal system error number contained in
the error message:
Hotline Germany
Siemens AG, A&D techsupport
Telephone: [phone]
Mailto: [e-mail]
Helpline
Telephone: [phone]
1
System errors

1 Alarms 01.02
6FC5598-3AA20-0BP2 © Siemens AG 2002 All Rights Reserved
1-10 SINUMERIK 802S/802C (DG)
1.1 Overview of NCK Alarms
System error %1
%1 = System error number
This alarm refers you to internal error conditions, which in conjunction with
the error number contained in the error message provide information on the
error cause and the error location.
Alarm display.
Please contact the hotline indicated in the beginning of this Manual and specify
the operating system error number.
Press the Clear key to clear the alarm. No further operation required.
Alarm pointer for this self-clearing alarm %1 is zero
%1 = Alarm number
The address used by the operating system for self-clearing alarms (zero
pointer) is not permitted for use in the system.
Alarm display.
Please contact the hotline indicated in the beginning of this Manual and specify
the operating system error number.
Press the Clear key to clear the alarm. No further operation required.
Alarm reaction from nck alarm is false projected
%1 = incorrect alarm number
The alarm response configured by the operating system is incorrect.
Alarm display
Interface signals are set
NC not ready for operation.
Please contact the hotline indicated in the beginning of this Manual and specify
the operating system error number.
Power ON
Operating system error %1
%1 = Operating system error
This alarm indicates that the operating system has detected a severe error in the
system.
Alarm display.
Interface signals are set.
NC not ready for operation.
1 002
Explanation
Response
Remedy
Program continua-
tion by
1 003
Explanation
Response
Remedy
Program continua-
tion by
1 004
Explanation
Response
Remedy
Program continua-
tion by
1 005
Explanation
Response

01.02 1 Alarms
© Siemens AG 2002 All Rights Reserved 6FC5598-3AA20-0BP2
SINUMERIK 802S/802C (DG) 1-11
NC Start inhibited.
NC Stop at alarm.
Please contact the hotline indicated in the beginning of this Manual and specify
the operating system error number.
Power ON
Channel %1 system error %2
%1 = Channel number
%2 = System error number
This alarm refers you to internal error conditions, which in conjunction with
the error number contained in the error message provide information on the
error cause and the error location.
Alarm display.
Interface signals are set.
NC not ready for operation.
NC Start inhibited.
NC Stop at alarm.
Please contact the hotline indicated in the beginning of this Manual and specify
the operating system error number.
Power ON
Channel %1 %3 system error %2
%1 = Channel number
%2 = System error number
%3 = Channel parameter: Block number, label
This alarm refers you to internal error conditions, which in conjunction with
the error number contained in the error message provide information on the
error cause and the error location.
Alarm display.
Interface signals are set.
Interpreter stop.
NC Start inhibited.
Please contact the hotline indicated in the beginning of this Manual and specify
the operating system error number.
Press the RESET key to clear the alarm. Restart part program.
Channel %1 system error %2
%1 = Channel number
%2 = System error number
This alarm refers you to internal error conditions, which in conjunction with
the error number contained in the error message provide information on the
error cause and the error location.
Alarm display.
Remedy
Program continua-
tion by
1 010
Explanation
Response
Remedy
Program continua-
tion by
1 011
Explanation
Response
Remedy
Program continua-
tion by
1 012
Explanation
Response

1 Alarms 01.02
6FC5598-3AA20-0BP2 © Siemens AG 2002 All Rights Reserved
1-12 SINUMERIK 802S/802C (DG)
Please contact the hotline indicated in the beginning of this Manual and specify
the operating system error number.
Press the Clear key to clear the alarm. No further operation required.
Channel %1 system error %2
%1 = Channel number
%2 = System error number
This alarm refers you to internal error conditions, which in conjunction with
the error number contained in the error message provide information on the
error cause and the error location.
Alarm display.
Interface signals are set.
NC Stop at alarm.
NC Start inhibited.
Please contact the hotline indicated in the beginning of this Manual and specify
the operating system error number.
Press the RESET key to clear the alarm. Restart part program.
Channel %1 axis %2 system error %3
%1 = Channel number
%2 = Axis number
%3 = System error number
This alarm refers you to internal error conditions, which in conjunction with
the error number contained in the error message provide information on the
error cause and the error location.
Alarm display.
Interface signals are set.
Channel not ready for operation.
Please contact the hotline indicated in the beginning of this Manual and specify
the operating system error number.
Press the RESET key to clear the alarm. Restart part program.
Channel %1 axis %2 system error %3
%1 = Channel number
%2 = Axis number
%3 = System error number
This alarm refers you to internal error conditions, which in conjunction with
the error number contained in the error message provide information on the
error cause and the error location.
Alarm display.
Interface signals are set.
Please contact the hotline indicated in the beginning of this Manual and specify
the operating system error number.
Remedy
Program continua-
tion by
1 014
Explanation
Response
Remedy
Program continua-
tion by
1 015
Explanation
Response
Remedy
Program continua-
tion by
1 016
Explanation
Response
Remedy

01.02 1 Alarms
© Siemens AG 2002 All Rights Reserved 6FC5598-3AA20-0BP2
SINUMERIK 802S/802C (DG) 1-13
Press the RESET key to clear the alarm. Restart part program.
Channel %1 axis %2 system error %3
%1 = Channel number
%2 = Axis number
%3 = System error number
This alarm refers you to internal error conditions, which in conjunction with
the error number contained in the error message provide information on the
error cause and the error location.
Alarm display.
Please contact the hotline indicated in the beginning of this Manual and specify
the operating system error number.
Press the Clear key to clear the alarm. No further operation required.
Floating point arithmetic error in channel %1 task %2 station %3 FPU
state: %4
%1 = Channel number
%2 = Task ID
%3 = Station priority
%4 = FPU state
The floating point arithmetic unit of the processor has detected an error.
Alarm display.
Interface signals are set.
Channel not ready for operation.
NC Stop at alarm.
NC Start inhibited.
Please contact the hotline indicated in the beginning of this Manual and specify
the operating system error number.
Press the RESET key to clear the alarm. Restart part program.
Floating point arithmetic error at address %3 in channel %1 task %2
FPU state %4
%1 = Channel number
%2 = Task ID
%3 = Code address of the operation which has caused the error
%4 = FPU state
Due to a calculation error, the floating point arithmetic unit of the processor
has initiated an exception.
Alarm display.
Interface signals are set.
Channel not ready for operation.
NC Stop at alarm.
NC Start inhibited.
Please contact the hotline indicated in the beginning of this Manual and specify
the operating system error number.
Program continua-
tion by
1 017
Explanation
Response
Remedy
Program continua-
tion by
1 018
Explanation
Response
Remedy
Program continua-
tion by
1 019
Explanation
Response
Remedy

1 Alarms 01.02
6FC5598-3AA20-0BP2 © Siemens AG 2002 All Rights Reserved
1-14 SINUMERIK 802S/802C (DG)
Press the RESET key to clear the alarm. Restart part program.
Sign of life monitoring: PLC not alive
The PLC must provide a sign of life within a certain period of time. If not, this
alarm is output. This alarm is also output as the consequence of a PLC stop
(PLC stop with programming tool, PLC stop from start-up switch, PLC stop
from alarm).
NC Start inhibited.
NC not ready for operation.
Mode group ('BAG') not ready for operation.
NC Stop at alarm.
Alarm display.
Interface signals are set.
If none of the cases mentioned above exists, please contact the hotline indi-
cated in the beginning of this Manual and specify the operating system error
number.
Power ON
PLC has not started up
The PLC must provide at least one sign of life within the defined period of
time after Power On.
NC Start inhibited.
NC not ready for operation.
Mode group ('BAG') not ready for operation.
NC Stop at alarm.
Alarm display.
Interface signals are set.
Please contact the hotline indicated in the beginning of this Manual.
Power ON
The actual service switch position forces the SRAM to be cleared at the
next Power on (general reset active)
The initialization switch is now set to General Reset. This forces the SRAM of
the module to be cleared when the module is reset next time. As a conse-
quence, the NC data memory gets lost.
Alarm display.
Interface signals are set.
Reset initialization switch to "1".
Press the Clear key to clear the alarm. No further operation required.
Emergency Stop
EMERGENCY STOP request is provided at the NCK/PLC interface
(V 26000000.1).
Program continua-
tion by
2 000
Explanation
Response
Remedy
Program continua-
tion by
2 001
Explanation
Response
Remedy
Program continua-
tion by
2 140
Explanation
Response
Remedy
Program continua-
tion by
3 000
Explanation

01.02 1 Alarms
© Siemens AG 2002 All Rights Reserved 6FC5598-3AA20-0BP2
SINUMERIK 802S/802C (DG) 1-15
NC Start inhibited.
NC Stop at alarm
Alarm display.
Interface signals are set.
Check whether an EMERGENCY STOP cam has been approached or an
EMERGENCY STOP button has been actuated. Check the PLC user program.
Eliminate the EMERGENCY STOP cause and acknowledge EMERGENCY
STOP via the PLC /NCK interface (V 26000000.2).
Press the RESET key to clear the alarm. Restart part program.
Internal emergency stop
This alarm is not displayed.
NC Start inhibited.
NC Stop at alarm.
No remedial action necessary.
Press the RESET key to clear the alarm. Restart part program.
Standard machine data loaded
Booting with standard values by:
•Operating action (e.g. start-up switch)
•MD 11200 INIT_MD
•Loss of retentive data
•Operating action "Booting with saved data", without data saving before-
hand
Alarm display
The specific data of the equipment on hand must be entered/loaded after the
standard machine data (MD) have been loaded automatically.
Press the Clear key to clear the alarm. Reload your own machine data.
Backup data loaded
The user data saved to FLASH have been loaded into the SRAM.
Alarm display
Reload your own machine data.
Press the RESET key to clear the alarm.
Response
Remedy
Program continua-
tion by
3001
Explanation
Response
Remedy
Program continua-
tion by
4 060
Explanation
Response
Remedy
Program continua-
tion by
4 062
Explanation
Response
Remedy
Program continua-
tion by

1 Alarms 01.02
6FC5598-3AA20-0BP2 © Siemens AG 2002 All Rights Reserved
1-16 SINUMERIK 802S/802C (DG)
Battery-backed memory is restored from backup copy (risk of loss
of data !)
During power-up, it has been detected that inconsistencies are possible in the
battery-backed memory.
The battery-backed memory was initialized using the last back-up copy. As a
result, the changes in the battery-backed memory, which have been made since
the last update of the backup copy, were lost. This may be caused by the fact
that the buffer time has been exceeded. Please make sure that the appropriate
on-time of your control system complies with the on-time required by the Start-
up Guide.
The current backup copy of the battery-backed memory was created using the
internal data backup carried out last using the softkey "Save data" in the HMI.
Alarm display
Interface signals are set.
NC Start inhibited
Restart the control system.
Machine data %1 (and may be others) not altered - permission level %2
needed
%1 = String: MD identifier
%2 = Write protection level of the MD
When executing a TOA file, you have tried to write into data whose protection
level is higher than the right to access currently set on the control. Your value
entry will be denied.
This alarm is only set when the first violation of the right to access is detected.
Alarm display.
Enter the password to set the required access level or delete the respective
machine data from the MD file.
Press the Clear key to clear the alarm. No further operation required.
%1 machine data could not be modified with permission level %2
%1 = Number of MD
%2 = Set user class
When executing a TOA file, you have tried to write into data whose protection
level is higher than the right to access currently set on the control. Your value
entry will be denied.
This alarm is output when alarm 4075 is acknowledged. It can only be cleared
by Power On.
Alarm display.
Set the required access level either using the key-operated switch or be entering
the password and/or delete the respective machine data from the MD file.
Power ON
4065
Explanation
Response
Remedy
Program continua-
tion by
4 075
Explanation
Response
Remedy
Program continua-
tion by
4 076
Explanation
Response
Remedy
Program continua-
tion by

01.02 1 Alarms
© Siemens AG 2002 All Rights Reserved 6FC5598-3AA20-0BP2
SINUMERIK 802S/802C (DG) 1-17
PLC cycle increased to %1 ms
The PLC cycle divider has not been set to an integer multiple of the IPO cycle
divider.
The divider (MD 10 074 PLC_IPO_TIME_RATIO) has been increased.
Alarm display.
Adapt machine data.
Power ON
Channel %1 data alteration from external not possible in current channel
state
%1 = Channel number
These data may not be entered during part program execution (e.g. setting data
for spindle speed limitation or for dry run feed).
Alarm display.
The data to be entered must be altered before starting the part program.
Press the Clear key to clear the alarm. No further operation required.
Declaration in machine data %1 index %2 is not allowed
%1 = String: MD identifier
%2 = Index in MD array
The values of the machine data in the array must be arranged in ascending
order.
NC not ready for operation.
NC Stop at alarm.
NC Start inhibited.
Alarm display.
Interface signals are set.
Correct MD
Press the RESET key to clear the alarm. Restart part program.
Machine data alteration will cause reorganization of buffered memory
(loss of data!)
An MD has been altered which configures the buffered memory. An NCK boot
with the altered data will reorganize the buffered memory and thus result in a
loss of all buffered user data (part programs, tool data, GUD, LEC, ..).
Alarm display.
If the control system contains user data which have not yet been backed up,
these data must be saved before the next NCK boot. The reorganization of the
memory can be avoided by resetting the altered MD to the value during the last
boot manually.
Press the Clear key to clear the alarm. No further operation required.
4 111
Explanation
Response
Remedy
Program continua-
tion by
4 230
Explanation
Response
Remedy
Program continua-
tion by
4 310
Explanation
Response
Remedy
Program continua-
tion by
4 400
Explanation
Response
Remedy
Program continua-
tion by

1 Alarms 01.02
6FC5598-3AA20-0BP2 © Siemens AG 2002 All Rights Reserved
1-18 SINUMERIK 802S/802C (DG)
Communication job not executed
The communication task (data exchange between NCK and MMC), e.g. load-
ing of an NC part program) cannot be executed due to insufficient memory.
Cause: too many parallel communication jobs.
Alarm display.
No remedial action possible - the operating action that resulted in the alarm
message must be repeated. Press Cancel to clear the alarm display.
Press the Clear key to clear the alarm. No further operation required.
Memory reorganized using standard machine data
The memory management could not realize the NC user memory mapping with
the values provided in the machine data, because the total memory is used by
the NC user both as a dynamic and a static memory (e.g. for the number of tool
offsets, number of directories and files, etc.) and is therefore not sufficient.
Alarm display.
Interface signals are set.
NC Start inhibited.
NC Stop at alarm.
Redefine NC memory mapping!
It is not possible to specify a certain MD as an alarm cause for the NC user
memory assignment. The MD that has caused the alarm must therefore be de-
termined on the base of the default values in the machine data and by modify-
ing the user-specific memory assignment step by step.
In most cases, not only an individual MD is selected too large, and it is there-
fore recommended to reduce the memory area in several MDs by a certain
fraction.
Press the RESET key to clear the alarm. Restart part program.
Machine data have been altered - now memory is reorganized
Machine data defining the NC user memory mapping have been altered. The
data management has re-mapped the memory with respect of the altered ma-
chine data.
Alarm display.
No remedial action required. Any user data needed must be re-entered.
Press the RESET key to clear the alarm. Restart part program.
NC memory is full
Too many part programs have been loaded. The job cannot be carried out.
This error may concern files of the NC file system (part of NC memory), such
as initialization files, NC programs, etc., during commissioning.
Alarm display.
Delete or unload files (e.g. part programs).
5 000
Explanation
Response
Remedy
Program continua-
tion by
6 000
Explanation
Response
Remedy
Program continua-
tion by
6 020
Explanation
Response
Remedy
Program continua-
tion by
6 500
Explanation
Response
Remedy

01.02 1 Alarms
© Siemens AG 2002 All Rights Reserved 6FC5598-3AA20-0BP2
SINUMERIK 802S/802C (DG) 1-19
Press the Clear key to clear the alarm. No further operation required.
Too many files in the NC memory
The number of files in the NC file system (part of NC memory has reached the
maximum.
Alarm display.
Delete or unload files (e.g. part programs).
Press the Clear key to clear the alarm. No further operation required.
Too many files in directory
The number of files in a directory of the NC memory has reached the maxi-
mum.
Alarm display.
Delete or unload files (e.g. part programs) in the directory concerned.
Press the Clear key to clear the alarm. No further operation required.
Too many directories in the NC memory
The number of directories in the NC file system (part of NC memory) has
reached the maximum.
Alarm display.
Delete or unload directories not needed (e.g. workpiece).
Press the Clear key to clear the alarm. No further operation required.
Data format not allowed
Invalid data have been entered in a file of the NC, e.g. binary data are loaded
into the NC as an ASCII file.
Alarm display.
Mark the file as binary data (e.g. extension: .BIN)
Press the Clear key to clear the alarm. No further operation required.
NC memory is full
The DRAM file system of the NCK is full. The job cannot be executed. Too
many system files have been created in the DRAM.
Alarm display
Start less „Process from External“ operations.
Press the Clear key to clear the alarm.
Program continua-
tion by
6 510
Explanation
Response
Remedy
Program continua-
tion by
6 530
Explanation
Response
Remedy
Program continua-
tion by
6 540
Explanation
Response
Remedy
Program continua-
tion by
6 560
Explanation
Response
Remedy
Program continua-
tion by
6 570
Explanation
Response
Remedy
Program continua-
tion by

1 Alarms 01.02
6FC5598-3AA20-0BP2 © Siemens AG 2002 All Rights Reserved
1-20 SINUMERIK 802S/802C (DG)
Machine data %1 reset, corresponding option is not set
%1 = String: MD identifier
An MD has been set which is locked by an option.
Alarm display.
To upgrade your CNC with the required option, contact either your machine
manufacturer or a sales engineer of AUT 2 of SIEMENS AG.
Press the Clear key to clear the alarm. No further operation required.
Channel %1 NC-start not possible with unreferenced axes (Cmd = %2).
%1 = Channel number
%2 = String (event name)
NC Start has been pressed either in MDA or AUTOMATIC mode, and at least
one axis to be referenced has not reached its reference point.
Alarm display.
Referencing start can be initiated either channel or axis-specifically.
1. Channel-specific reference-point approach: The rising edge of the
interface signal "Activate referencing" (V 32000001.0) starts an auto-
matic cycle which start the axes of the channel in the sequence of order
specified in the axis-specific MD 34 110 REFP_CYCLE_NR (axis order
for channel-specific referencing).
-1: Axis is not involved in channel-specific referencing, but must be
referenced for NC start.
0: Axis is not involved in channel-specific referencing, but must be
referenced for NC start
1-4: Starting sequence for channel-specific referencing (simultaneous
start with the same number.)
2. Axis-specific referencing: Press the direction key corresponding to the
approach direction specified in the axis-specific MD 34 010
REFP_CAM_DIR_IS_MINUS (Approach Reference Point in Minus
Direction).
Press NC START to clear the alarm and continue program execution.
Channel %1 Continue program with NC-Start
%1 = Channel number
After block search with calculation, the control system is in the desired state.
The program can now be started with NC Start or in the state first changed by
Overwrite/Jog.
Alarm display.
NC Stop at alarm.
Press NC Start.
Press NC START to clear the alarm and continue program execution.
8 040
Explanation
Response
Remedy
Program continua-
tion by
10 203
Explanation
Response
Remedy
Program continuation
by
10 208
Explanation
Response
Remedy
Program continua-
tion by