Siemens SINUMERIK 840C Setup guide

SINUMERIK 840C
SIMODRIVE 611-D
Diagnostics Guide 09.2001 Edition
User Documentation

Valid for
09.2001 Edition
SINUMERIK 840C
SIMODRIVE 611–D
DiagnosticsGuide
Alarms 1
Diagnostics on the PLC 2
Error Display on CPU 3
Errors with Function Macros 4
Parameterization Errors
Spindle/Axis 5
Control Drive
SINUMERIK 840C/CE
(Standard/Export version) SIMODRIVE 611–D
Software Version Software Version
1.x
2.x
3.x 1.x
4.x 2.x
5.x 3.x
6.x 4.x
6.4 5.x

SINUMERIKdocumentation
Printing history
Brief details of this edition and previous editions are listed below.
The status of each edition is shown by the code in the “Remarks”column.
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
09.95 6FC5198–5AB40–0BP0 A
04.96 6FC5198–5AB40–0BP1 C
08.96 6FC5198–5AB40–0BP2 C
07.97 6FC5198–6AB40–0BP0 C
01.99 6FC5198–6AB40–0BP1 C
09.01 6FC5198–6AB40–0BP2 C
This manual is included in the documentation on CD–ROM (DOCONCD)
Edition Order No. Remarks
11.01 6FC5 198–6CA00–0BG2 C
Trademarks
SIMATICR, SIMATIC HMIR, SIMATIC NETR, SIROTECR, SINUMERIKRand SIMODRIVERare trademarks
of Siemens AG. All other product and system names are registered trademarks of their respective
companies and must be treated accordingly.
For further informationvisit our Internet address:
http://www.ad.siemens.de/sinumerik
This publication was produced with Interleaf V 7
The reproduction, transmission or use of this document or its
contents is not permitted wihout express written authority. Offenders
will be liable for damages. All rights, including rights created by patent
grant or registration of a utility model or design, are reserved.
Siemens AG 1996–2001. All rights reserved.
Other functions not decribed 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 document correspond to
the hardware and software described. Nonetheless, differences might
exist and therefore we cannot guarantee that they are completely
identical. The information contained in this document is, however,
reviewed regularly and any necessary changes will be included in the
next edition. We welcome suggestions for improvement.
Subject to change without prior notice.
Siemens–AktiengesellschaftOrder No. 6FC 5198–6AB40–0BP2
Printed in the Federal Republic of Germany

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SINUMERIK 840C / SIMODRIVE 611–D (DA)
Preliminary notes
This Guide serves as a reference work. It allows the machine tool user:
Sto assess irregularities during operation at the machine correctly
Sto obtain information about the response of the system to the irregularity
Sto make use of the options for continuing operation after the irregularity
Scope This description lists the diagnostics options of the PLC and the alarms of the
MMC, NCK, servo and drive (SIMODRIVE 611–D) areas.
Sequence In the Diagnostics Guide the alarms are sorted in ascending order of alarm num-
bers. The numbers are not necessarily contiguous.
Safety
!Danger
Please assess the condition of your plant carefully against
the description of the alarm that has occurred. Eliminate
the cause of the alarm and acknowledge it as described.
If alarms are ignored, danger to the machine, workpiece,
stored settings, and in certain cases, to your health, could
result.
!Warning
This warning notice means that loss of life, severe personal
injury or substantial material damage can result if the
appropriate precautions are not taken.
!Caution
This warning notice (with warning triangle) means that
a minor personal injury can result if the appropriate pre-
cautions are not taken.
Caution
This warning notice (without warning triangle) means that a
material damage can result if the appropriate precautions
are not taken.
Notice
This warning notice means that an undesired event or an
undesired state can result if the appropriate notices are not
observed.

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Contents
1 Alarms 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Alarm groups 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Alarm numbers/cancellation of alarms 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Display of the alarms in the alarm line 1–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Display of the alarms as dialog box 1–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 Priority of alarms 1–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5.1 Alarm description 1–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 Dialog text 1–223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.1 Notes for the operator 1–223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.2 Listing of dialog texts 1–223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Diagnostics on the PLC 2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Error numbers (ACCU 3 high byte, DB 1 DW 160) 2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Additional error information (ACCU 3 low byte, DB 1 DW 161–163) 2–7. . . . . . . . . . . . . .
3 Error Display on CPU 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Errors with Function Macros 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Parameterization Errors Spindle/Axis 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SINUMERIK 840C / SIMODRIVE 611–D (DA)
1 Alarms
1.1 Alarm groups
NC alarms The alarms are divided into alarm groups.
SGeneral alarms
SComputer link alarms
SAxis-specific alarms
SSpindle-specific alarms
SChannel-specific alarms
At POWER ON RESET (switching on control), all
NC alarms are cancelled.
The CANCEL alarms can be deleted in the asso-
ciated operating area only.
PLC alarms
The PLC alarms are assigned error numbers
6000 to 9999. The alarm text, alarm action and
deletion conditions are configured by the ma-
chine manufacturer.
MMC alarms
MMC alarms do not interrupt an active NC
program. The alarms are acknowledged
automatically provided the correct sequence of
operations is adhered to or via softkeys.
1 Alarms
9.1.1 Alarmgruppen

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1.2 Alarm numbers/cancellation of alarms
Alarm number Kind of alarm
1General alarms
2 to 15 General alarms
16 to 36 Computer link alarms
43 to 110 General alarms
1000 to 1211
1240 to 1251 Axis-specific alarms
1280 to 1371 Axis-specific alarms
1440 to 1971 Axis-specific alarms
2000 to 2193 General alarms
2250 to 2263 Spindle-specific alarms
2270 to 2273 Spindle-specific alarms
2280 to 2283 Spindle-specific alarms
3000 to 3220 General alarms
4000 to 4299
5000 to 5299 Cycle alarms
6000 to 9999 PLC error messages or PLC operational messages
10000 to 12031 Axis-specific alarms
20000 to 20309 Spindle-specific alarms
100000 to 169999 MMC alarms
200000 to 209999 PLC dialogs
210000 to 219999 Free area
300000 to 399999 611D alarms
1 Alarms
1.2 Alarmnumbers/cancellation of alarms

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SINUMERIK 840C / SIMODRIVE 611–D (DA)
Key Effect of cancelling alarms
Acknowledgement
An active NC program is not aborted but only stopped.
After eliminating the error, it is possible to continue execution of the NC pro-
gram from the point at which it was stopped.
Reset
Execution of an active NC program is aborted. After eliminating the error, the
NC program must be restarted.
POWER ON Execution of the active NC program is aborted. After eliminating the error, the
NC program must be restarted and the reference points must be reapproa-
ched.
Caution! On switching off the control, the contents of the NCK part program
memory are lost.
POWER ON means switching off the control and switching it on again.
Please note the information provided by the machine tool manufacturer.
1 Alarms
1.2 Alarmnumbers/cancellation of alarms

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1.3 Display of the alarms in the alarm line
Messages from the monitoring system are displayed in the alarm line. Existing
comments are overwritten by alarm texts. The alarm line is the second display
line from the top.
Machine Parameter Programm. Services Diagnosis
AUTOMATIC Program stop M. grp.: 1
Channel: 1
POWER
ON
Actual
values Distances to
go Program pointer
%1234 N1234
L1234 N1234P12
X 10.789
Y 5.231
Z 210.643
100.000
10.000
200.000
Alarm line Delete error condition
There are three types of display representation for alarm messages: Types A, B
and C.
Example of display Alarm display in sequence order
representation Type A:
Machine Parameter Programm. Services Diagnosis
10243 ORD 5 X Illegal pulse multiplication
max. 6 characters for alarm number
max. 5 characters for ordinal number
The ordinal number shows the order
in which the alarms have occurred.
max. 40 characters
for explanatory text
(for single-line alarm)
max. 100 characters
(for two-line alarm)
1 Alarms
1.3 Display of the alarms in the alarm line

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Example of display Alarm display in block number order
representation Type B:
Machine Parameter Programm. Services Diagnosis
3000 1 N0045 General programming error
max. 5 characters for alarm number
max. 5 characters for block number
E.g.: the error has occurred in block N0045.
max. 38 characters
for explanatory text
(for single-line alarm)
1 character for channel number
Example of display
representation Type C:
Machine Parameter Programm. Services Diagnosis
6000 Hydraulic oil min.
max. 4 characters for alarm number max. 47 characters
for explanatory text
(for single-line alarm)
1 Alarms
1.3 Display of the alarms in the alarmline

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1.4 Display of the alarms as dialog box
The machine tool manufacturer can configure whether the alarm messages are
displayed in the alarm line or in a dialog box. MMC messages are displayed as a
dialog box.
There are 3 types of dialog box:
Dialog box with The dialog must be acknowledged from a configured application.
empty softkey bar
Fig. 1.1 Example 1 dialog box
1 Alarms
1.4 Display of the alarms as dialog box

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SINUMERIK 840C / SIMODRIVE 611–D (DA)
Dialog box with OK The dialog box can be acknowledged with the OK key.
softkey
Fig. 1.2 Example 2 dialog box
Dialog box with The dialog box can either be acknowledged with the OK key or it can be
OK softkey and with the HIDE softkey without being acknowledged.
HIDE softkey
Fig. 1.3 Example 3 dialog box
1 Alarms
1.4 Display of the alarms as dialog box

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1.5 Priority of alarms
Only one alarm can be displayed in the alarm line and the following priorities
apply:
Priority
range Alarm type
0 – 100 Power on
101 – 200 Reset
201 – 300 Cancel
301 – 500 Message
301 – 500 PLC alarm
1000 Diagnosis
Within the alarm groups, the priority is in accordance with the alarm number or
priority range, i.e. the lowest alarm number/priority range has the highest priority.
The alarm priorities can be configured by the machine tool manufacturer.
An arrow on the right in the alarm line indicates that further alarms exist. These
alarms are displayed if you select the alarm overview display in the DIAGNOSIS
area.
1.5.1 Alarm description
The alarms are described in a uniform style. The column alarm heading boxes
show the alarm number, alarm text and the means of cancellation.
Alarm number Alarm text Means of
cancel.
Scan: Specifies in which state the alarm occurs.
Effect: Specifies the sphere of influence of processing.
Explanation: States the reasons for the alarm.
Remedy: Instructions for eliminating the alarm state.
1 Alarms
1.5.1 Alarm description

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SINUMERIK 840C / SIMODRIVE 611–D (DA)
1 Battery: Data loss at power off! Acknowledgement key
POWER ON
Cyclic
Data is not battery-backed after power off.
During operation: Do not interrupt the production process. Data will be lost if the control is switched off.
Run-up: Data has been lost. Obligatory re-installation is activated.
Backup battery is empty.
Replace the battery when the control is switched on
If data has been lost the whole NCK/PLC unit must be re-installed.
2 Overtemperature Acknowledgement key
POWER ON
Cyclic
The second temperature monitoring threshold has been triggered because the ambient temperature is too high.
NC program is not interrupted.
Safe functioning of the hardware can no longer be guaranteed, serious damage to hardware may result.
Processing is not interrupted directly. A contact is opened on the CSB which the NC user must use to take the
appropriate measures.
A low temperature level will eliminate the error.
Switch off control (hardware damage possible).
3 Fan failure Acknowledgement key
POWER ON
Cyclic
Fan monitoring is triggered because of incorrect fan functioning.
Safe functioning of the hardware can no longer be guaranteed, serious damage to hardware may result.
Processing is not interrupted directly. A contact is opened on the CSB which the NC user must use to take the
appropriate measures.
Eliminate the fan fault, e.g. by replacing the fan.
Switch off control (hardware damage possible).
4 System of units not allowed POWER ON
SPOWER ON
SAfter modification of NC machine data
SInterlocking of NC READY
SInterlocking of NC START
SInterlocking of Mode Group Ready
SMachining stops
An illegal combination of machine data MD 18000 display resolution and MD 5002 input resolution has been
selected. Both data must use the same system of units
For rotary axes with a position control resolution smaller than = 0.5 10–4 degrees, the function bit “High-reso-
lution rotary axis”must be set.
Check and correct machine data combinations. Then cancel the alarm with POWER ON.
5 Power failure protection / data loss Acknowledgement key
POWER ON
The power failure protection integrated in the software could not be executed correctly because of a hardware
fault.
Data loss in the NCK unit.
Obligatory re-installation is activated.
The whole NCK unit must be re-installed.
Eliminate hardware fault.
Scan
Effect
Explanation
Remedy
Scan
Effect
Explanation
Remedy
Scan
Effect
Explanation
Remedy
Scan
Effect
Exlanation
Remedy
Scan
Effect
Explanation
Remedy
1 Alarms
1.5.1 Alarm description

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1–10 SINUMERIK 840C / SIMODRIVE 611–D (DA)
6 Start-up due to system error Acknowledgement key
POWER ON
Start-up of the control shows that a fatal error was present before reset/power off (e.g. obligatory re-installation is
activated. Alarm 5 can be set in conjunction with alarm 6. EPROM error, DRAM error, processor exceptions).
Re-installation is necessary as data loss or corruption is to be expected (no data consistency).
The NCK unit must be completely re-installed.
Cause of error can be eliminated as follows:
a) Replace hardware
b) Report the software error leading to the processor exception to the manufacturer of the control.
7 15 V undervoltage Acknowledgement key
POWER ON
Cyclic
Activates 15V voltage monitoring
Safe operation of the NC is no longer possible so NC Ready is cancelled.
Eliminate hardware fault
8 Wrong axis/spindle assignment POWER ON
SAfter modification of machine data
SOn POWER ON
SInterlocking of NC START
SRemoval of Mode Group Ready
SNC Ready relay drops out
SMachining stops
The NC machine data for axis assignment MD200* or spindle assignment MD400* have been input incorrectly or
transposed.
If error in MD 461* C axis definition:
SC axis must not be fictitious (MD 564*, bit 6)
SC axis must be defined (MD 564*, bit 7)
SMode group numbers of C axis and spindle must be same
(MD 360*, MD 453*)
Check and correct machine data for axis and spindle assignment.
Cancel alarm with POWER ON.
9 Not enough memory for UMS POWER ON
SAt POWER ON in normal mode, not in start-up mode
None
The RAM area reserved on the NC is too small for the UMS address lists for the modified system area.
Describe fewer elements (displays/texts) in modified system area (merge).
Applies up to SW 2 only
9 Overflow in altered system area POWER ON
Whenpowering up the control
The UMS does not function
In the UMS, an altered system area has been configured that exceeds the memory area.
Configure UMS properly
Applies as from SW 4
Scan
Effect
Explanation
Remedy
Scan
Effect
Explanation
Remedy
Scan
Effect
Explanation
Remedy
Scan
Effect
Explanation
Remedy
Note
Scan
Effect
Explanation
Remedy
Note
1 Alarms
1.5.1 Alarm description

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10 UMS error POWER ON
SAt POWER ON
SInterlocking of NC START
The UMS loaded in NCK has a faulty internal structure.
Reinstall UMS on hard disk.
Applies up to SW 2 only
10 Startup after software upgrade POWER ON
SAt POWER ON
SThe NCK–internal static memory has been deleted.
There are two causes for the alarm:
–A new NCK software version has been loaded (only when booting for the first time after software upgrade)
–The NCK–internal static RAM has failed (e.g. because of an empty back–up battery); alarm 5 is then dis-
played additionally.
The complete NCK unit must be started up again.
Applies as from SW 6
11 Undervoltage on secondary side Cancel
POWER ON
Cyclic
Short circuit on secondary side or overloading of 5V voltage
Caution: The error may have been signalled during initial start-up without the error being present (hardware wi-
ring).
When the error occurs the shutdown routine is activated to achieve a safe state.
Restart:
Data loss has occurred, obligatory re-installation is activated
Eliminate the hardware error
Re-install
20 Cam activation wrong POWER ON
POWER ON
SInterlocking of NC start
SInterlocking of Mode Group Ready
Software cams can only be used for linear axes.
Correct the PLC user program
26 Part program block >120 char. V.24 POWER ON
SOn reading data into the NC via the computer link
SComputer link transmission interrupted
SLast block declared invalid
The part program block that has been read in contains more than 120 characters. Only the characters actually
stored are counted (no spaces, no CR, etc.)
Divide the block into two or more blocks. The number of the faulty block is displayed.
Applies up to SW 2 only
Scan
Effect
Explanation
Remedy
Note
Scan
Effect
Explanation
Remedy
Note
Scan
Effect
Explanation
Remedy
Scan
Effect
Explanation
Remedy
Scan
Effect
Explanation
Remedy
Note
1 Alarms
1.5.1 Alarm description
07/97

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27 Data input disabled V.24 POWER ON
SOn reading data into the NC via the computer link
No data has been read in
SThe “Cycle lock”interface signal (DB 48 D0.11) is present
SAn attempt has been made to read in NC machine data in normal mode
SAn attempt has been made to transfer UMS data to the NC although the UMS was not enabled or not plugged
in.
SReset DB 48 DW 0 bit 11 via PLC STATUS
SEnter new NC machine data
Applies up to SW 2 only
29 Block >254 characters V.24 POWER ON
SOn reading tool data into the NC via the computer link
SComputer link transmission interrupted
SLast block declared invalid
The block read in has more than 254 characters (counting all characters read in, including blanks, CR, LF, etc.)
Divide the block into two or more blocks. The number of the faulty block is displayed.
Applies up to SW 2 only
30 Part program memory overflow V.24 POWER ON
SWhilereading programs in via the computer link of the NC
SComputer link transmission interrupted
SLast block declared invalid
The maximum memory space for part programs is already assigned
SDelete old programs to release memory for the reading in of new programs. The number of the faulty block is
displayed.
Applies up to SW 2 only
31 No more part program input V.24 POWER ON
SOn reading in via computer link
No data has been read in
The part program memory available has been used up.
SRead and delete old part programs no longer required in order to provide more memory.
Applies up to SW 2 only
32 Data format error V.24 POWER ON
SOn reading data into the NC via the computer link
SComputer link transmission interrupted
SLast block declared invalid
SThe number of decades used after an address is not permissible
SThe decimal point occurs in the wrong place
SPart programs or subroutines are not defined or concluded correctly (check header)
Check the program to be read in. The number of the faulty block is displayed.
Applies up to SW 2 only
Scan
Effect
Explanation
Remedy
Note
Scan
Effect
Explanation
Remedy
Note
Scan
Effect
Explanation
Remedy
Note
Scan
Effect
Explanation
Remedy
Note
Scan
Effect
Explanation
Remedy
Note
1 Alarms
1.5.1 Alarm description