Siemens SINUMERIK 808D User manual

Table of contents
Tables
Figures
SINUMERIK
SINUMERIK 808D ADVANCED
Diagnostics Manual
Diagnostics Manual
08/2013
6FC5398-6DP10-0BA1
Preface
Introduction 1
Operating in the "SYSTEM"
area 2
SINUMERIK 808D
ADVANCED alarms 3
System responses 4
SINAMICS V70 alarms 5
Data backup 6
Updating software 7
Appendix A A

Legal information- Warning notice system
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.
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:
Trademarks
All names identified by ® are registered trademarks of SiemensAG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described.
Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this
publication is reviewed regularly and any necessary corrections are included in subsequent editions.
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.
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.
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number:6FC5398-6DP10-0BA1
Ⓟ 08.2013 Technical data subject to change
Copyright © SiemensAG 2012 - 2013.
All rights reserved

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Table of contents
Table of c ontents
Preface.........................................................................................................................................................5
1 Introduction .................................................................................................................................................7
1.1 Structure of the Diagnostics Manual............................................................................................ 7
1.2 Alarm number ranges .................................................................................................................. 8
2 Operating in the "SYSTEM" area ................................................................................................................9
2.1 Operating area overview ............................................................................................................. 9
2.2 Setting start-up function............................................................................................................. 10
2.3 Setting system machine data .................................................................................................... 12
2.4 Configuring the drive system ..................................................................................................... 20
2.5 PLC diagnostics......................................................................................................................... 22
2.5.1 Screen layout ............................................................................................................................. 23
2.5.2 Operating options ...................................................................................................................... 24
2.5.3 Displaying information on the program blocks ........................................................................... 27
2.5.4 Displaying cross-references ...................................................................................................... 28
2.6 Setting the HMI display.............................................................................................................. 29
2.6.1 Setting the date and time ........................................................................................................... 29
2.6.2 Adjusting the screen brightness ................................................................................................ 30
2.7 Managing the system data ........................................................................................................ 31
2.8 Creating commissioning archives.............................................................................................. 33
2.9 Optimizing drive performance.................................................................................................... 34
2.10 Viewing the service info............................................................................................................. 36
2.10.1 Action log ................................................................................................................................... 37
2.10.2 Service MSG ............................................................................................................................. 37
2.10.3 Servo trace ................................................................................................................................ 40
2.10.4 Version/HMI details ................................................................................................................... 42
2.11 Configuring the Ethernet connection ......................................................................................... 46
2.12 Defining the maintenance planner............................................................................................. 52
2.13 Alarm display ............................................................................................................................. 53
3 SINUMERIK 808D ADVANCED alarms ....................................................................................................55
3.1 System error alarms .................................................................................................................. 55
3.2 NCK alarms ............................................................................................................................... 55
3.3 Drive alarms ............................................................................................................................ 333
3.4 PLC alarms.............................................................................................................................. 342
3.5 Cycle alarms............................................................................................................................ 346

Table of contents
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3.6 PLC user alarms...................................................................................................................... 434
4 System responses ...................................................................................................................................435
4.1 System reactions to SINUMERIK alarms ................................................................................ 435
4.2 Cancel criteria for alarms......................................................................................................... 438
5 SINAMICS V70 alarms ............................................................................................................................439
5.1 Overview of alarms.................................................................................................................. 439
5.2 Common faults and alarms...................................................................................................... 441
6 Data backup ............................................................................................................................................453
6.1 Overview of internal/external data backup............................................................................... 453
6.2 Internal data backup ................................................................................................................ 453
6.3 External data backup............................................................................................................... 455
6.3.1 External data backup in a data archive .................................................................................... 455
6.3.2 External data backup of files .................................................................................................... 457
6.3.3 External data backup in case of backlight failure ..................................................................... 458
6.3.4 External data backup through the RS232 interface ................................................................. 458
6.3.5 External data backup through the Ethernet interface .............................................................. 460
6.3.6 Loading externally backed-up data .......................................................................................... 462
7 Updating software ...................................................................................................................................465
A Appendix A ..............................................................................................................................................467
Index .......................................................................................................................................................471

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Preface
Applicable products
This manual is applicable to the following control systems:
Documentation components and target groups
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.
Control system Software version
SINUMERIK 808D ADVANCED T (Turning) V4.6
SINUMERIK 808D ADVANCED M (Milling) V4.6
Component Recommended target group
User documentation
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
Turning)
Programmers and operators of turning machines
Diagnostics Manual Mechanical and electrical designers, commissioning
engineers, machine operators, and service and maintenance
personnel
Manufacturer/service documentation
Commissioning Manual Installation personnel, commissioning engineers, and service
and maintenance personnel
Function Manual Mechanical and electrical designers, technical professionals
Parameter Manual Mechanical and electrical designers, technical professionals
PLC Subroutines Manual Mechanical and electrical designers, technical professionals,
and commissioning engineers

Preface
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6 Diagnostics Manual, 08/2013, 6FC5398-6DP10-0BA1
Technical support
EC Declaration of Conformity
The EC Declaration of Conformity for the EMC Directive can be found on the Internet at http:/
/support.automation.siemens.com
Here, enter the number15257461 as the search term or contact your local Siemens office.
Hotline:
•Global support hotline:
[phone]
•Support hotline in China:
[phone] (china)
Service and Support:
•Chinese Web site:
http://www.siemens.com.cn/808D
•Global Web site:
http://support.automation.siemens.com

1
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Introduction
1.1 Structure of the Diagnostics Manual
NCK / PLC alarms
The descriptions for the alarms can be found in the chapters:
•NCK alarms (Page 55)
•Drive alarms (Page 333)
•PLC alarms (Page 342)
•Cycle alarms (Page 346)
•SINAMICS V70 alarms (Page 439)
In each chapter, the alarm descriptions are sorted according to ascending alarm number.
There are gaps in the sequence.
Structure of the NCK / drive / PLC / cycle alarm descriptions
The descriptions of the alarms have the following layout:
Each alarm is uniquely identified using the <Alarm number> and the <Alarm text>.
The description of the alarms is classified according to the following categories:
•Explanation
•Response
See Chapter: System reactions to SINUMERIK alarms (Page 435)
•Remedy
•Program continuation
See Chapter: System reactions to SINUMERIK alarms (Page 435)
<Alarm No.>
Explanation:
Reaction:
Help:
Continue
program:
<Alarm text>

Introduction
1.2 Alarm number ranges
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Action list
The actions described in the NCK alarm texts ("Action %...") are explained in the following
Chapter:
See Chapter: Cancel criteria for alarms (Page 438)
Specification "%"
The specification "%" represents variables for an online parameter that is replaced on the
control with a corresponding value. Since 808D is a single-channel control system, "Channel
1" is always output.
Safety
1.2 Alarm number ranges
The following tables show an overview of all of the reserved number ranges for alarms /
messages.
NCK alarms / messages
NCK alarms (Page 55)
PLC alarms / messages
PLC alarms (Page 342)
DANGER
Please check the situation in the plant on the basis of the description of the active alarm(s).
Eliminate the causes for the occurrence of the alarms and acknowledge in the manner
indicated. Failure to observe this warning will place your machine, workpiece, stored settings
and possibly even your own safety at risk.
Note
In the alarm lists of this manual, only those number ranges are represented, which are valid
for the specified product.
002 000 - 009 999 General alarms
010 000 - 019 999 Channel alarms
020 000 - 029 999 Axis / spindle alarms
030 000 - 099 999 Functional alarms
400 000 - 499 999 General PLC alarms

2
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Operating in the "SYSTEM" area
2.1 Operating area overview
Softkey functions
Press the and keys on the PPU to enter the following operating area. This
operating area includes functions required for parameterizing and analyzing the NCK, the
PLC and the drive. The start screen displays the machine configuration data and softkeys
available. Depending on the functions selected, the horizontal and the vertical softkey bars
vary. The screenshot below uses the turning variant as an example.
     








①Sets the NC, PLC and drive start up modes ⑨Enters the corresponding password (manufacturer
password, and end user password) for different
access levels
②Sets the system machine data ⑩Changes the password as per the corresponding
access levels
③Configures the connected drives and motors ⑪Deletes the current password
④Provides PLC commissioning and diagnostics ⑫Selects the user interface language. Note that the HMI
is automatically restarted when a new language is
selected.
⑤Sets the system date and time and adjusts the
brightness of the screen ⑬Configures the access right for the remote control through the Ethernet connection
⑥Backs up and restores system data ⑭Switches to the ISO programming mode
⑦Creates and restores startup archives, data archive ⑮Saves the contents of the volatile memory into a non-
volatile memory area
⑧Performs the axis optimization

Operating in the "SYSTEM" area
2.2 Setting start-up function
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An extended horizontal softkey bar can be accessed via this key on the PPU. Two extended
horizontal softkeys are provided:
2.2 Setting start-up function
Functionality
This softkey allows you to choose the NC, PLC, and drive start-up modes. You can set up the
start-up modes by pressing the respective softkeys.
Selecting an NC restart mode
Proceed through the following steps to select an NC restart mode:
Views the service information
Defines the maintenance planner
+
1. Select the desired operating area.
2. Press this softkey.
3. Press this softkey to open the window for selecting the NC start-up
mode.
4. Select a desired mode with the cursor keys. Three NC start-up
modes are available:
5. Press this softkey to confirm your selection. The system then restarts
in the mode selected.
Note
You must stop the machine before selecting the NC start-up mode.

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Operating in the "SYSTEM" area
2.2 Setting start-up function
Selecting a PLC restart mode
Proceed through the following steps to select a PLC restart mode:
Selecting a drive restart mode
Proceed through the following steps to select an drive restart mode:
+
1. Select the desired operating area.
2. Press this softkey.
3. Press this softkey to open the window for selecting the PLC start-up
mode.
4. Select a desired mode with the cursor keys. Two PLC start-up
modes are available:
5. Use this key to select/deselect the PLC debugging.
6. Press this softkey to confirm your selection. The system then restarts
in the mode selected.
+
1. Select the desired operating area.
2. Press this softkey.
3. Press this softkey to open the window for selecting the drive start-up
mode.
4. Select a desired mode with the cursor keys. Two drive start-up
modes are available:
5. Press this softkey to confirm your selection, and then the drive list
window opens displaying all the connected drives.

Operating in the "SYSTEM" area
2.3 Setting system machine data
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2.3 Setting system machine data
Machine data structure
Any changes in the machine data have a substantial influence on the machine. The following
describes the machine data structure in detail:
6. Select all drives or one specific drive using the cursor keys.
7. Press this softkey to confirm your selection. The selected drive(s) will
restart in the mode selected.
No. Meaning
1 MD number
2Name
3 Value
4Unit
5 Effective im immediately
cf with confirmation
re after reset
po after power on
CAUTION
Machine damage
Incorrect parameterization may result in destruction of the machine.

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Operating in the "SYSTEM" area
2.3 Setting system machine data
Setting basic machine data
The SINUMERIK 808D ADVANCED provides two easy-to-use data lists for beginner users.
You can use the basic data list for quick access of common NC data and drive data.
Setting basic NC data
In the basic NC data list, the general, axis, and channel MD are integrated in one screen.
Proceed through the following steps to set the basic NC data:
+
1. Select the desired operating area.
2. Press this softkey, and the window of basic NC data opens by
default.
3. Locate the machine data which you desire to set.
You can also search for an MD using the following softkeys:
Searches for the desired number or the name (or a
part of the name) of the machine data
Continues searching for the next match
4. Enter the desired value in the blank and press this key to confirm.
5. Press this softkey to activate the modified value(s) after you finish
setting the machine data.
Further softkey operations are available for setting the basic NC
data:
Switches to the next axis
Switches to the previous axis
Resets the value of the selected MD to default
Undoes the modified values and recalls the lastly used
values

Operating in the "SYSTEM" area
2.3 Setting system machine data
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Setting basic drive data
Several common drive parameters are provided in the basic drive data list. Proceed through
the following steps to set the basic drive data:
+
1. Select the desired operating area.
2. Enter the window of basic drive data through the following softkey
operations:
→
3. Locate the parameter which you desire to set.
You can also search for a parameter using the following softkeys:
Searches for the desired number or the name (or a
part of the name) of the parameter
Continues searching for the next match
4. Enter the desired value in the blank and press this key to confirm.
5. Press this softkey to save the modified value(s) after you finish the
parameter setting.
Further softkey operations are available for setting the basic drive
data:
Switches to the next drive
Switches to the previous drive
Resets the value of the selected parameter to default
Undoes the modified values and recalls the lastly used
values

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Operating in the "SYSTEM" area
2.3 Setting system machine data
Setting machine data in expert list
All machine data are divided into five groups described as follows.
Setting general machine data
+
1. Select the desired operating area.
2. Enter the window of general machine data through the following
softkey operations:
→ →
3. Locate the machine data which you desire to set.
You can also search for an MD using the following softkeys:
Searches for the desired number or the name (or a
part of the name) of the machine data
Continues searching for the next match
4. Enter the desired value in the blank and press this key to confirm.
5. Press this softkey to activate the modified value(s) after you finish
setting the machine data.
Further softkey operations are available for setting the general
machine data:
Resets the value of the selected MD to default
Undoes the modified values and recalls the lastly used
values
Provides various display filters for the active machine
data group

Operating in the "SYSTEM" area
2.3 Setting system machine data
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Setting channel-specific machine data
+
1. Select the desired operating area.
2. Enter the window of channel-specific machine data through the
following softkey operations:
→ →
3. Locate the machine data which you desire to set.
You can also search for an MD using the following softkeys:
Searches for the desired number or the name (or a
part of the name) of the machine data
Continues searching for the next match
4. Enter the desired value in the blank and press this key to confirm.
5. Press this softkey to activate the modified value(s) after you finish
setting the machine data.
Further softkey operations are available for setting the channel-
specific machine data:
Resets the value of the selected MD to default
Undoes the modified values and recalls the lastly used
values
Provides various display filters for the active machine
data group

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Operating in the "SYSTEM" area
2.3 Setting system machine data
Setting axis-specific machine data
+
1. Select the desired operating area.
2. Enter the window of axis-specific machine data through the following
softkey operations:
→ →
3. Locate the machine data which you desire to set.
You can also search for an MD using the following softkeys:
Searches for the desired number or the name (or a
part of the name) of the machine data
Continues searching for the next match
4. Enter the desired value in the blank and press this key to confirm.
5. Press this softkey to activate the modified value(s) after you finish
setting the machine data.
Further softkey operations are available for setting the axis-specific
machine data:
Switches to the next axis
Switches to the previous axis
Resets the value of the selected MD to default
Undoes the modified values and recalls the lastly used
values
Provides various display filters for the active machine
data group

Operating in the "SYSTEM" area
2.3 Setting system machine data
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Setting drive machine data
+
1. Select the desired operating area.
2. Enter the window of drive machine data through the following softkey
operations:
→ →
3. Locate the machine data which you desire to set.
You can also search for an MD using the following softkeys:
Searches for the desired number or the name (or a
part of the name) of the machine data
Continues searching for the next match
4. Enter the desired value in the blank and press this key to confirm.
5. Press this softkey to save the modified value(s) after you finish
setting the machine data.
Further softkey operations are available for setting the drive machine
data:
Switches to the next drive
Switches to the previous drive
Resets the value of the selected MD to default
Undoes the modified values and recalls the lastly used
values
Provides various display filters for the active machine
data group

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Operating in the "SYSTEM" area
2.3 Setting system machine data
Setting display machine data
Checking MD by servo trace
By pressing this softkey, you can compare the defined machine data with the actual data and
adjust the parameters if necessary.
To learn more functions regarding the servo trace, refer to the Section "Servo trace (Page
40)".
References
You can find a description of the machine data in the following manufacturers' documents:
SINUMERIK 808D ADVANCED Parameter Manual
SINUMERIK 808D ADVANCED Function Manual
+
1. Select the desired operating area.
2. Enter the window of display machine data through the following
softkey operations:
→ →
3. Locate the machine data which you desire to set.
You can also search for an MD using the following softkeys:
Searches for the desired number or the name (or a
part of the name) of the machine data
Continues searching for the next match
4. Enter the desired value in the blank and press this key to confirm.
5. Press this softkey to activate the modified value(s) after you finish
setting the machine data.
Further softkey operations are available for setting the display
machine data:
Resets the value of the selected MD to default
Undoes the modified values and recalls the lastly used
values

Operating in the "SYSTEM" area
2.4 Configuring the drive system
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2.4 Configuring the drive system
Pressing this softkey opens the drive system configuration window where you can configure
the connected drives and motors.
Before starting the drive and motor configuration, you must ensure the Drive Bus addresses
are properly set (p0918) via the drive BOPs according to the instructions in the window
above.
Operating sequence
1. Press this softkey on the main screen of drive system configuration, and
the control system starts to identify the drives and motors connected.
After the identification finishes, a drive list with motor information displays
on the screen, for example:
Note: For a motor with an absolute encoder, the motor ID can be
identified automatically. For a motor with an incremental encoder,
however, you must configure it manually.
2. Select the motor to be configured using the cursor keys.