Siemens SINUMERIK 808D User manual

© Siemens AG 2017. All rights reserved
01/2017 1
SINUMERIK
SINUMERIK 808D, SINUMERIK 808D ADVANCED
Service Manual
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The
notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage
have no safety alert symbol. These notices shown below are graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of
injury to persons with a safety alert symbol may also include a warning relating to property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by
personnel qualified
for the specific task in accordance with
the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their
training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products
and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage,
installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any
problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed.

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Preface
Applicable products
This manual is valid for the following control systems:
Control system
Software version
SINUMERIK 808D ADVANCED T (Turning)
SINUMERIK 808D ADVANCED M (Milling)
V4.7.4: PPU161.3/PPU160.2 with spindle/feed servo system
SINUMERIK 808D (Turning)
SINUMERIK 808D (Milling)
V4.7.4: PPU141.2 with feed servo system
Documentation components and target audience
End-user documentation
Target audience
Programming and Operating Manual (Turning)
Programmers and operators of turning machines
Programming and Operating Manual (Milling)
Programmers and operators of milling machines
Programming and Operating Manual (ISO Turning/Milling)
Programmers and operators of turning/milling machines
Programming and Operating Manual (Manual Machine Plus
(MM+), Turning)
Programmers and operators of turning machines
Diagnostics Manual
Mechanical and electrical designers, commissioning engi-
neers, machine operators, and service and maintenance
personnel
Manufacturer/service documentation
Target audience
Commissioning Manual
Installation personnel, commissioning engineers, and ser-
vice and maintenance personnel
Function Manual
Mechanical and electrical designers, technical professionals
Parameter Manual
Mechanical and electrical designers, technical professionals
Service Manual
Mechanical and electrical designers, technical profession-
als, commissioning engineers, and service and maintenance
personnel
Readme file
Third-party software - Licensing terms and copyright information
My Documentation Manager (MDM)
Under the following link you will find information to individually compile your documentation based on the Siemens content:
www.siemens.com/mdm
Standard scope
This manual only describes the functionality of the standard version. Extensions or changes made by the machine tool
manufacturer are documented by the machine tool manufacturer.
Technical support
Country
Hotline
1)
Further service contact information:
•Worldwide Web site:
https://support.industry.siemens.com/cs/ww/en/
•Chinese Web site:
http://www.siemens.com.cn/808D
Germany
[phone]
China [phone]
1) You can find more hotline information at the worldwide Web site given above.
EC Declaration of Conformity
The EC Declaration of Conformity for the EMC Directive can be found on the Internet at
http://www.siemens.com/automation/service&support.
Here, enter the number "
67385845
" as the search term or contact your local Siemens office.

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Table of contents
Preface...................................................................................................................................................................2
1 Safety instructions ..................................................................................................................................................4
1.1 Fundamental safety instructions..............................................................................................................4
1.1.1 General safety instructions......................................................................................................................4
1.1.2 Handling electrostatic sensitive devices (ESD) .......................................................................................8
1.1.3 Industrial security ....................................................................................................................................8
1.1.4 Residual risks of power drive systems.....................................................................................................9
1.2 Carrying out of repairs.............................................................................................................................9
2 Service case overview ..........................................................................................................................................10
3 Service cases of the hardware/software faults .......................................................................................................11
3.1 System startup fault...............................................................................................................................12
3.2 PPU/HMI fault........................................................................................................................................12
3.3 MCP connection fault ............................................................................................................................13
3.4 MCP key press fault ..............................................................................................................................13
3.5 RS232 transmission fault (PPU160.2 only) ...........................................................................................14
3.6 Spindle fault...........................................................................................................................................15
3.7 Spindle encoder alarm...........................................................................................................................17
3.8 Handwheel fault.....................................................................................................................................17
3.9 Feed axis fault.......................................................................................................................................18
3.10 Axis moving direction fault.....................................................................................................................18
3.11 Positioning error ....................................................................................................................................19
3.12 Tool change fault...................................................................................................................................19
3.13 Overload................................................................................................................................................20
3.14 System crash during startup..................................................................................................................20
3.15 Hardware limit fault................................................................................................................................20
3.16 Reference point approach fault .............................................................................................................21
3.17 Drive alarm............................................................................................................................................22
3.18 Option activation failure after PPU replacement....................................................................................23
3.19 CNC lock alarms ...................................................................................................................................28
3.20 OEM PIN forgotten for CNC lock...........................................................................................................29
4 Service cases of the PLC alarms...........................................................................................................................31
4.1 General alarms......................................................................................................................................32
4.1.1 Alarm 700010........................................................................................................................................32
4.1.2 Alarm 700012........................................................................................................................................32
4.1.3 Alarm 700014........................................................................................................................................32
4.1.4 Alarm 700015........................................................................................................................................33
4.1.5 Alarm 700016........................................................................................................................................33
4.1.6 Alarm 700018........................................................................................................................................34
4.1.7 Alarm 700021........................................................................................................................................34
4.1.8 Alarm 700029........................................................................................................................................34
4.1.9 Alarm 700030........................................................................................................................................35
4.1.10 Alarm 700060........................................................................................................................................35
4.2 Specific milling alarms...........................................................................................................................36
4.2.1 Alarm 700019........................................................................................................................................36
4.2.2 Alarm 700020........................................................................................................................................36

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4.2.3 Alarm 700031........................................................................................................................................ 37
4.2.4 Alarm 700032........................................................................................................................................ 37
4.2.5 Alarm 700033........................................................................................................................................ 38
4.2.6 Alarm 700034........................................................................................................................................ 38
4.2.7 Alarm 700035........................................................................................................................................ 39
4.2.8 Alarm 700036........................................................................................................................................ 39
4.2.9 Alarm 700059........................................................................................................................................ 40
4.3 Specific turning alarms.......................................................................................................................... 40
4.3.1 Alarm 700013........................................................................................................................................ 40
4.3.2 Alarm 700017........................................................................................................................................ 41
4.3.3 Alarm 700022........................................................................................................................................ 41
4.3.4 Alarm 700023........................................................................................................................................ 42
4.3.5 Alarm 700024........................................................................................................................................ 42
4.3.6 Alarm 700025........................................................................................................................................ 42
4.3.7 Alarm 700026........................................................................................................................................ 43
4.3.8 Alarm 700028........................................................................................................................................ 43
5 Service cases of the NC program alarms ...............................................................................................................45
5.1 G81 deactivated in ISO mode............................................................................................................... 45
5.2 M10/M11 deactivated............................................................................................................................ 45
5.3 Thread cutting interruption .................................................................................................................... 45
5.4 Wrong zero offsets in ISO mode ........................................................................................................... 46
6 General NC program alarms..................................................................................................................................47
1
Safety instructions
1.1
Fundamental safety instructions
1.1.1
General safety instructions
DANGER
Danger to life due to live parts and other energy sources
Death or serious injury can result when live parts are touched.
•Only work on electrical devices when you are qualified for this job.
•Always observe the country-specific safety rules.
Generally, six steps apply when establishing safety:
1. Prepare for shutdown and notify all those who will be affected by the procedure.
2. Disconnect the machine from the supply.
–Switch off the machine.
–Wait until the discharge time specified on the warning labels has elapsed.
–Check that it really is in a no-voltage condition, from phase conductor to phase conductor and phase
conductor to protective conductor.
–Check whether the existing auxiliary supply circuits are de-energized.
–Ensure that the motors cannot move.
3. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or water.
4. Isolate or neutralize all hazardous energy sources by closing switches, grounding or short-circuiting or
closing valves, for example.
5. Secure the energy sources against switching on again.
6. Ensure that the correct machine is completely interlocked.
After you have completed the work, restore the operational readiness in the inverse sequence.

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WARNING
Danger to life through a hazardous voltage when connecting an unsuitable power supply
Touching live components can result in death or severe injury.
•Only use power supplies that provide SELV (Safety Extra Low Voltage) or PELV- (Protective Extra Low
Voltage) output voltages for all connections and terminals of the electronics modules.
WARNING
Danger to life when live parts are touched on damaged motors/devices
Improper handling of motors/devices can damage them.
For damaged motors/devices, hazardous voltages can be present at the enclosure or at exposed components.
•Ensure compliance with the limit values specified in the technical data during transport, storage and
operation.
•
Do not use any damaged motors/devices.
WARNING
Danger to life through electric shock due to unconnected cable shields
Hazardous touch voltages can occur through capacitive cross-coupling due to unconnected cable shields.
•As a minimum, connect cable shields and the cores of cables that are not used at one end at the grounded
housing potential.
WARNING
Danger to life due to electric shock when not grounded
For missing or incorrectly implemented protective conductor connection for devices with protection class I, high
voltages can be present at open, exposed parts, which when touched, can result in death or severe injury.
•
Ground the device in compliance with the applicable regulations.
WARNING
Danger to life due to electric shock when opening plug connections in operation
When opening plug connections in operation, arcs can result in severe injury or death.
•Only open plug connections when the equipment is in a no-
voltage state, unless it has been explicitly stated
that they can be opened in operation.
WARNING
Danger to life through electric shock due to the residual charge of the power component capacitors
Because of the capacitors, a hazardous voltage is present for up to 5 minutes after the power supply has been
switched off. Contact with live parts can result in death or serious injury.
•Wait for 5 minutes before you check that the unit really is in a no-voltage condition and start work.
NOTICE
Material damage due to loose power connections
Insufficient tightening torques or vibrations can result in loose electrical connections. This can result in damage due to fire,
device defects or malfunctions.
•Tighten all power connections with the specified tightening torques, e.g. line supply connection, motor connection, DC
link connections.
•
Check all power connections at regular intervals. This applies in particular after transport.
WARNING
Danger to life due to fire spreading if housing is inadequate
Fire and smoke development can cause severe personal injury or material damage.
•Install devices without a protective housing in a metal control cabinet (or protect the device by another equivalent
measure) in such a way that contact with fire is prevented.
•Ensure that smoke can only escape via controlled and monitored paths.

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WARNING
Danger to life from electromagnetic fields
Electromagnetic fields (EMF) are generated by the operation of electrical power equipment, such as transformers,
converters, or motors.
People with pacemakers or implants are at particular risk in the immediate vicinity of this equipment.
•
If you have a heart pacemaker or implant, maintain a minimum distance of 2 m from electrical power equipment.
WARNING
Danger to life from permanent-magnet fields
Even when switched off, electric motors with permanent magnets represent a potential risk for persons with heart
pacemakers or implants if they are close to converters/motors.
•If you have a heart pacemaker or implant, maintain a minimum distance of 2 m.
•When transporting or storing permanent-magnet motors always use the original packing materials with the warning
labels attached.
•Clearly mark the storage locations with the appropriate warning labels.
•
IATA regulations must be observed when transported by air.
WARNING
Danger to life through unexpected movement of machines when using mobile wireless devices or mobile phones
Using mobile wireless devices or mobile phones with a transmit power > 1 W closer than approx. 2 m to the components
may cause the devices to malfunction, influence the functional safety of machines therefore putting people at risk or
causing material damage.
•
Switch the wireless devices or mobile phones off in the immediate vicinity of the components.
WARNING
Danger to life due to the motor catching fire in the event of insulation overload
There is higher stress on the motor insulation thr
ough a ground fault in an IT system. If the insulation fails, it is possible that
death or severe injury can occur as a result of smoke and fire.
•Use a monitoring device that signals an insulation fault.
•Correct the fault as quickly as possible so the motor insulation is not overloaded.
WARNING
Danger to life due to fire if overheating occurs because of insufficient ventilation clearances
Inadequate ventilation clearances can cause overheating of components with subsequent fire and smoke. This can cause
severe injury or even death. This can also result in increased downtime and reduced service lives for devices/systems.
•
Ensure compliance with the specified minimum clearance as ventilation clearance for the respective component.
WARNING
Danger of an accident occurring due to missing or illegible warning labels
Missing or illegible warning labels can result in accidents involving death or serious injury.
•Check that the warning labels are complete based on the documentation.
•Attach any missing warning labels to the components, in the national language if necessary.
•
Replace illegible warning labels.
NOTICE
Device damage caused by incorrect voltage/insulation tests
Incorrect voltage/insulation tests can damage the device.
•Before carrying out a voltage/insulation check of the system/machine, disconnect the devices as all converters and
motors have been subject to a high voltage test by the manufacturer, and therefore it is not necessary to perform an
additional test within the system/machine.

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WARNING
Danger to life when safety functions are inactive
Safety functions that are inactive or that have not been adjusted accordingly can cause operational faults on machines that
could lead to serious injury or death.
•Observe the information in the appropriate product documentation before commissioning.
•Carry out a safety inspection for functions relevant to safety on the entire system, including all safety-related
components.
•Ensure that the safety functions used in your drives and automation tasks are adjusted and activated through
appropriate parameterizing.
•Perform a function test.
•Only put your plant into live operation once you have guaranteed that the functions relevant to safety are running
correctly.
Note
Important safety notices for Safety Integrated functions
If you want to use Safety Integrated functions, you must observe the safety notices in the Safety Integrated manuals.
WARNING
Danger to life or malfunctions of the machine as a result of incorrect or changed parameterization
As a result of incorrect or changed parameterization, machines can malfunction, which in turn can lead to injuries or death.
•Protect the parameterization (parameter assignments) against unauthorized access.
•Respond to possible malfunctions by applying suitable measures (e.g. EMERGENCY STOP or EMERGENCY OFF).
WARNING
Risk of injury caused by moving parts or parts that are flung out
Touching moving motor parts or drive output elements and loose motor parts that are flung out (e.g. feather keys) in
operation can result in severe injury or death.
•Remove any loose parts or secure them so that they cannot be flung out.
•Do not touch any moving parts.
•Safeguard all moving parts using the appropriate safety guards.
WARNING
Danger to life due to fire if overheating occurs because of insufficient cooling
Inadequate cooling can cause overheating resulting in death or severe injury as a result of smoke and fire. This can also
result in increased failures and reduced service lives of motors.
•
Comply with the specified coolant requirements for the motor.
WARNING
Danger to life due to fire as a result of overheating caused by incorrect operation
When incorrectly operated and in the case of a fault, the motor can overheat resulting in fire and smoke. This can result in
severe injury or death. Further, excessively high temperatures destroy motor components and result in increased failures
as well as shorter service lives of motors.
•Operate the motor according to the relevant specifications.
•Only operate the motors in conjunction with effective temperature monitoring.
•
Immediately switch off the motor if excessively high temperatures occur.
CAUTION
Risk of injury due to touching hot surfaces
In operation, the motor can reach high temperatures, which can cause burns if touched.
•Mount the motor so that it is not accessible in operation.
Measures when maintenance is required:
•Allow the motor to cool down before starting any work.
•
Use the appropriate personnel protection equipment, e.g. gloves.

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1.1.2
Handling electrostatic sensitive devices (ESD)
Electrostatic sensitive devices (ESD) are individual components, integrated circuits, modules or devices that may be
damaged by either electric fields or electrostatic discharge.
NOTICE
Damage through electric fields or electrostatic discharge
Electric fields or electrostatic discharge can cause malfunctions through damaged individual components,
integrated circuits, modules or devices.
•Only pack, store, transport and send electronic components, modules or devices in their original packaging
or in other suitable materials, e.g conductive foam rubber of aluminum foil.
•Only touch components, modules and devices when you are grounded by one of the following methods:
–Wearing an ESD wrist strap
–Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring
•Only place electronic components, modules or devices on conductive surfaces (table with ESD surface,
conductive ESD foam, ESD packaging, ESD transport container).
1.1.3
Industrial security
Note
Industrial security
Siemens provides products and solutions with industrial security functions that support the secure operati
on of plants,
systems, machines and networks.
In order to protect plants, systems, machines and networks against cyber threats, it is necessary to implement
– and
continuously maintain
– a holistic, state-of-the-art industrial security concept. Siemens pro
ducts and solutions only represent
one component of such a concept.
The customer is responsible for preventing unauthorized access to its plants, systems, machines and networks. Systems,
machines and components should only be connected to the enterprise network or the internet if and to the extent necessary
and with appropriate security measures (e.g. use of firewalls and network segmentation) in place.
Additionally, Siemens’ guidance on appropriate security measures should be taken into account. For more information about
industrial security, please visit:
Industrial security (
http://www.siemens.com/industrialsecurity).
Siemens’ products and solutions undergo continuous development to make them mor
e secure. Siemens strongly
recommends to apply product updates as soon as available and to always use the latest product versions. Use of product
versions that are no longer supported, and failure to apply latest updates may increase customer’s exposure to
cyber
threats.
To stay informed about product updates, subscribe to the Siemens Industrial Security RSS Feed at:
Industrial security (
http://www.siemens.com/industrialsecurity).
WARNING
Danger to life as a result of unsafe operating states resulting from software manipulation
Software manipulations (e.g. viruses, trojans, malware or worms) can cause unsafe operating states in your system that
may lead to death, serious injury, and property damage.
•Keep the software up to date.
•Incorporate the automation and drive components into a holistic, state-of-the-art industrial security concept for the
installation or machine.
•Make sure that you include all installed products into the holistic industrial security concept.
•Protect files stored on exchangeable storage media from malicious software by with suitable protection measures, e.g.
virus scanners.

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1.1.4
Residual risks of power drive systems
When assessing the machine- or system-related risk in accordance with the respective local regulations (e.g., EC Machinery
Directive), the machine manufacturer or system installer must take into account the following residual risks emanating from
the control and drive components of a drive system:
1. Unintentional movements of driven machine or system components during commissioning, operation, maintenance, and
repairs caused by, for example,
–Hardware and/or software errors in the sensors, control system, actuators, and cables and connections
–Response times of the control system and of the drive
–Operation and/or environmental conditions outside the specification
–Condensation/conductive contamination
–Parameterization, programming, cabling, and installation errors
–Use of wireless devices/mobile phones in the immediate vicinity of electronic components
–External influences/damage
–X-ray, ionizing radiation and cosmic radiation
2. Unusually high temperatures, including open flames, as well as emissions of light, noise, particles, gases, etc., can occur
inside and outside the components under fault conditions caused by, for example:
–Component failure
–Software errors
–Operation and/or environmental conditions outside the specification
–External influences/damage
3. Hazardous shock voltages caused by, for example:
–Component failure
–Influence during electrostatic charging
–Induction of voltages in moving motors
–Operation and/or environmental conditions outside the specification
–Condensation/conductive contamination
–External influences/damage
4. Electrical, magnetic and electromagnetic fields generated in operation that can pose a risk to people with a pacemaker,
implants or metal replacement joints, etc., if they are too close
5. Release of environmental pollutants or emissions as a result of improper operation of the system and/or failure to
dispose of components safely and correctly
6. Influence of network-connected communication systems, e.g. ripple-control transmitters or data communication via the
network
For more information about the residual risks of the drive system components, see the relevant sections in the technical user
documentation.
1.2
Carrying out of repairs
DANGER
Carrying out of repairs
Anywhere in the automation equipment where faults might cause physical injury or major material damage, in other words,
where faults could be dangerous, additional external precautions must be taken, or facilities must be provided, that
guarantee or enforce a safe operational state, even when there is a fault (e.g. using an independent limit value switch,
mechanical locking mechanisms, EMERGENCY STOP/EMERGENCY OFF devices).

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2
Service case overview
In this manual, the following four types of service cases are described:
Service cases of the hardware/software faults (Page 11)
Service cases of the PLC alarms (Page 31)
Service cases of the NC program alarms (Page 45)
General NC program alarms (Page 47)
Notes

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3
Service cases of the hardware/software faults
In this chapter, the following service cases are described:
Case 1
→
System startup fault (Page 12)
Case 2
→
PPU/HMI fault (Page 12)
Case 3
→
MCP connection fault (Page 13)
Case 4
→
MCP key press fault (Page 13)
Case 5
→
RS232 transmission fault (PPU160.2 only) (Page 14)
Case 6
→
Spindle fault (Page 15)
Case 7
→
Spindle encoder alarm (Page 17)
Case 8
→
Handwheel fault (Page 17)
Case 9
→
Feed axis fault (Page 18)
Case 10
→
Axis moving direction fault (Page 18)
Case 11
→
Positioning error (Page 19)
Case 12
→
Tool change fault (Page 19)
Case 13
→
Overload (Page 20)
Case 14
→
System crash during startup (Page 20)
Case 15
→
Hardware limit fault (Page 20)
Case 16
→
Reference point approach fault (Page 21)
Case 17
→
Drive alarm (Page 22)
Case 18
→
Option activation failure after PPU replacement (Page 23)
Case 19
→
CNC lock alarms (Page 28)
Case 20
→
OEM PIN forgotten for CNC lock (Page 29)
Note
In case of the necessity of replacing a defective PPU or a defective system CF card, both the PPU and the
CF card must be
replaced since the CF card always remains as an undetachable component of the PPU.

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3.1
System startup fault
Fault description
The control system cannot start up successfully after power-on; the PPU normally shows a black screen with no display at
all.
Diagnostic steps
1.
Check the status LED on the PPU panel.
•
If the status LED is lit, power off the control system and check whether
you have inserted the CF card properly. Then power on again and
observe whether you have eliminated the fault.
•
If the status LED is off, check the power supply interface (X1) on the
back of the PPU for the following:
–Whether the connection is loose
–Whether the 24 V terminal matches the interface
–Whether the 24
VDC power supply is available by measuring with a
multimeter
2.
Replacement and maintenance are necessary if the fault still exists after
the above operations, because probably the PPU is damaged.
3.2
PPU/HMI fault
Fault description
The HMI screen or the keys on the PPU are inactive.
Diagnostic steps
1.
Check whether the control system is in the crashed state. If yes, restart the control system and then check whether the
fault still exists.
2.
Replacement
and maintenance are necessary if the fault still exists after the above operations, because probably the
PPU is damaged.

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3.3
MCP connection fault
Fault description
●The MCP does not respond after power-on. All the status LEDs on the MCP are off and no operation is possible.
●All the status LEDs on the MCP are flashing all the time.
Note that the alarm 400003 may appear in the above cases.
Diagnostic steps
1.
Check whether the connection cable between the MCP and the PPU is in good condition and properly connected. You
may verify this by using a new cable.
2.
Check whether the PPU interface X30 or the MCP interface X10 is damaged or subject to bad contact. You may verify
this by using a new cable.
3.
Check the PLC programs since a PLC program fault can also cause the flashing of all the status LEDs on the MCP.
4.
Replacement and maintenance are necessary if the fault still exists after the above operations, because probably the
PPU or MCP is damaged.
3.4
MCP key press fault
Fault description
Some keys on the MCP have no response. A key press fault occurs normally in the following keys:
and
Diagnostic steps
+
1.
Select the system data operating area.
2.
Open the PLC
status monitoring window through the following softkey operations:
→

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3.
Check the PLC interface statu
s in the following window:
①
: Address of the key (DB1000.DBX3.5)
②
: Address of the key (DB1000.DBX3.3)
•
If the PLC status bit changes after you press the corresponding key, it suggests the key
functions correctly. In this case, make further observation to see if there are other alarms
or whether the PLC program is correct in a different position.
•
If the PLC status bit does not change after you press the c
orresponding key, replacement
and maintenance are necessary because the key is damaged.
3.5
RS232 transmission fault (PPU160.2 only)
Note
The RS232 interface is available on the PPU160.2 only.
Fault description
Data transmission is not possible via the RS232 interface.
Diagnostic steps
1.
Check the RS232 communication settings on the PPU for the following:
•
Whether the communication is activated
•
Whether the communication parameters match the PC terminal
•
Whether the X2 interface on the PPU is loose
•
Whether the cable of RS232 is damaged
•
Whether the RS232 interface of the PC terminal is damaged
2.
Replacement and maintenance are necessary if the fault still exists after the above inspection, because probably the
PPU is damaged.
Perform the following PPU operations to configure the RS232 communication settings:
●Using the RS232 interface to establish connection with PLC Programming Tool
+ → → →
●Using the RS232 interface to establish connection with the SinuComPCIN
→ →

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Make sure the communication settings are the same as those in the communication software on your PC.
Note
When using the SinuComPCIN, the RS232 inter
face must not be active for another application. This means, for example,
the RS232 interface must not be active through the following operation:
+ → → →
3.6
Spindle fault
Fault description
Case 1:
The spindle cannot move; the PPU screen shows the message of wa
iting for the spindle signal and no alarm
prompts.
Case 2:
The PPU shows the spindle speed values, but the spindle cannot move and no alarm prompts.
Case 3:
The spindle speed is not stable (varies during rotation).
Diagnostic steps
Case 1
1.
Check the s
ettings of machine data MD30200 (= 1: for the spindle with an encoder; = 0: for the spindle without an
encoder).
2.
If you use an analog spindle, check the spindle interface X54 on the back
of the PPU for the following:
•
Whether the interface is loose or damaged
•
Whether there is voltage output by measuring pins 1 and 9 of X54 with
a multimeter after starting the spindle
3.
Check whether the connection cables of the PPU, spindle drive, and encoder are in good condition.
4.
Check whether the settings of the following machine data are correct:
•
MD30130 = 1
•
MD30240: encoder type (= 1: for the spindle with motor encoder; = 2: for the spindle with an external encoder via
X60)
•
MD30134: spindle output polarity (= 0: dual polarity; = 1/2: single polarity, as the case may be)
•
MD32250 = 100/MD32260, consistent with the rated motor speed
5.
Check whether the spindle drive has a fault.
6.
Replacement and maintenance are necessary if the fault still exists after the above inspection, because probably the
PPU is damaged.

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Case 2
1.
Check whether the control system is in the program test state:
•
Check whether the status LED for program test on the MCP is lit
(it must be off)
•
Check whether the PRT icon appears in the program status bar
on the PPU screen (it must be deactivated)
2.
Perform the above diagnostic steps for case 1 to check the spindle if the fault still exists.
Case 3
1.
Check whether there is interference
between the connection cables. Make sure you route the power cables and signal
cables separately.
2.
If you use an analog spindle, check the interface X54 on the back of
the PPU for the following:
•
Whether the interface is loose or damaged
•
Whether the connections have bad contact
3.
Check whether the connection cable to the spindle drive is loose or whether the drive is damaged.

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3.7
Spindle encoder alarm
Fault description
The spindle cannot move, and the alarm 025000 appears on the screen at the same time.
Diagnostic steps
1.
If you use an external encoder for the spindle, check whether the spindle
encoder
interface X60 on the back of the PPU is loose or damaged.
2.
Check whether the connection cable of the spindle encoder is damaged or connected incorrectly.
3.
Check whether the settings of machine data MD30200 and MD30240 are correct as follows:
•
MD30200: number of encoders (= 1: for the spindle with an encoder; = 0: for the spindle without an encoder)
•
MD30240: encoder type (= 1: for the spindle with motor encoder; = 2: for the spindle with an external encoder via
X60)
4.
Check whether the spindle encoder is damaged. Replace the encoder with a new one and test it again.
5.
Replacement and maintenance are necessary if the fault still exists after the above inspection, because probably the
PPU is damaged.
3.8
Handwheel fault
Fault description
The handwheel is not available or cannot be assigned to an axis successfully.
Diagnostic steps
1.
Check whether the operating sequence is correct, and whether the feed
axis is selected for handwheel assignment in the handwheel mode.
Use the PLC to monitor and test the PLC input/output status of the selec
t-
ed axis traver
sing key.
2.
Check whether the connections on the
handwheel are correct, and observe if there are short circuits in adjacent con-
nections.
3.
Check the interface X10 on the back of the PPU for the following:
•
Whether the connection is loose
•
Whether the cable is damaged
•
Whether there is voltage output of 5 V at the interface (terminal 5/6)

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4.
Check whether the handwheel is damaged.
5.
Replacement and maintenance are necessary if the fault still exists after the above inspection, because probably the
PPU is damaged.
3.9
Feed axis fault
Fault description
The following fault cases may occur with the axes referenced:
Case 1:
The screen displays the movement values of the feed axis, but actually the axis does not move.
Case 2:
The actual traversing direction of the axis is opposite to the direction selected in operation or the direction
displayed on the PPU screen.
Diagnostic steps
Case 1
1.
Check whether the control system is in the program test state:
•
Check whether the status LED for program test on the MCP is lit
(it must be off)
•
Check whether the PRT icon appears in the program status bar
on the PPU screen (it must be deactivated)
2.
Check whether the mechanical coupling is loose.
3.
Check whether t
he connections between the control system and the drives are in good condition, and whether the
terminals on the drives are damaged.
4.
Replacement and maintenance are necessary if the fault still exists after the above inspection, because probably the
PPU is damaged.
Case 2
1.
Check whether the settings of machine data MD32100 and MD32110 are correct as follows:
•
MD32100: axis traversing direction (default value = 1, change to -1 as required)
•
MD32110: encoder position feedback polarity (default value = 1, change to -1 as required)
2.
For the SINUMERIK 808D control system, you should also check
the co
nnections of the terminals +DIR and -DIR on the drives.
3.10
Axis moving direction fault
Fault description
The axis can only move in one direction when the axis traversing keys are pressed in "JOG" mode, and the direction cannot
be changed.
Diagnostic steps
Check whether the corresponding drive is damaged.

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3.11
Positioning error
Fault description
The operating position of the machine coordinate system is not accurate.
Diagnostic steps
1.
Check whether the settings of
the following machine data are consistent with the actual mechanical parameters:
•
MD31030: pitch of leadscrew
•
MD31050/MD31060: denominator/numerator of the deceleration ratio
•
MD31020/MD31400 = 10000: encoder lines per revolution (SINUMERIK 808D only)
Note
: check whether there is frequency multiplication on the drive encoder.
2.
Check whether the turret is installed properly on the machine.
3.
Check whether the mechanical coupling is loose or the belt is slipping.
4.
Check whether it is necessary to adjust the compensation of the leadscrew pitch and/or the backlash.
3.12
Tool change fault
Fault description
Case 1:
The tool cannot be changed; the wrong tool is changed; the turret keeps rotating.
Case 2:
During the tool change, the tool arm does not go back to the home position.
Diagnostic steps
Case 1
1.
Check whether the phase sequence of the connection of the machine power supply/turret motor is correct.
2.
Check the interface of turret rotation signal output/turret in
-position signal input on the back of the PPU:
•
Whether it is damaged
•
Whether the wires are loose
•
Whether the terminals 1 and 10 are connected respectively to 24 V and 0 V
•
Whether the connection is wrong or different from the settings in the PLC program
3.
Check whether the wires between the tu
rret signal input/output interface on the back of the PPU and the turret are
loose or damaged.
4.
Check whether the turret signal encoder on the machine is damaged.
5.
Replacement and maintenance are necessary if the fault still exists after the above
inspection, because probably the
PPU is damaged.
Case 2
1.
Check the PLC output signals related to the tool arm positions.
2.
Check the PPU input signals related to the tool arm positions.
Note
This fault case may occur because the PLC control action
is influenced by the interference to the turret signal
reception/transmission, which is caused by the instable fluctuation of voltage and contactor arc.

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3.13
Overload
Fault description
The axis cannot move or moves difficultly because of overload (the drive may issue an overload alarm).
Diagnostic steps
1.
Check whether the guide lubrication is sufficient:
•
Whether the lubricating pipe/nozzle is blocked
•
Whether the lubrication interval time is set properly (the interval should not be too long)
2.
Stop the mac
hine and check whether the guides/screws are blocked by the machining waste. If so, it may need prop-
er cleaning.
3.
Check whether the connection of the shaft coupling is smooth and concentric.
3.14
System crash during startup
Fault description
The system loading process crashes during startup (usually the HMI freezes when it loads to 40%).
Diagnostic steps
1.
Power off and restart the control system. Check whether the fault is resolved.
2.
Power off the control system and check whether the CF card is inser
t-
ed correctly or has a faulty contact, and then power on again to check
whet
her the fault is resolved.
3.
Replacement and maintenance are necessary if the fault still exists after the above inspection, because probably the
PPU is damaged.
3.15
Hardware limit fault
Fault description
Case 1:
The hardware limit
switch alarm appears on the PPU.
Case 2:
The axis has crossed the hardware limit, but can still move without any alarm.
Diagnostic steps
Case 1
1.
Press and hold down the following key on the PPU while pressing the axis traversing key at the same time to make
the feed axis move in the opposite directio
n. The alarm can then be cleared when the axis moves away from the
hardware limit switch.
2.
Check the hardware limit switches on the machine if the fault still exists:
•
Check whether the hardware limit switch connection is good with a multimeter.
•
Check whether the hardware limit switches are damaged.