Sinumerik 808D Service Guide

Transcription

1 Training manual Sinumerik 808D Service Guide Verion

2 Note Service guide 808D

3 Lit For Service cae of hardware Go to page 7 Service cae of For Go to page 23 PLC alarm For Service cae of NC program alarm Pleae refer to the alarm handbook End Service guide

4 Note Service guide 808D turning and milling

5 Service cae of hardware For normal hardware, we provide the baic ervice diagnotic tep and detecting procedure which are only for Siemen ervice engineer, OEM ervice engineer and Siemen authorized ervice engineer. Cae 7 Spindle encoder alarm Go to page 12 Cae 1 Startup cannot log into the ytem Go to page 7 Cae 8 Handwheel Go to page 12 Cae 2 Battery alarm Go to page 7 Cae 9 Feed axi Go to page 13 Cae 3 MCP i not available Go to page 8 Cae 10 Change of direction i not poible Go to page 14 Cae 4 MCP button pre Go to page 9 Cae 11 Poitioning error Go to page 14 Cae 5 RS232 tranmiion Go to page 10 Cae 12 Tool change i not poible Go to page 15 Cae 6 Spindle Go to page 11 Cae 13 Startup proce Go to page 15 crahe 808D turning and milling Page 5 Service guide

6 Service cae of hardware Cae 14 Hardware limit witch Go to page 16 Cae 15 Startup can t go to REF. point Go to page 16 Cae 16 PPU/HMI Go to page 18 Cae 17 Drive alarm Go to page 18 Cae 18 Overload Go to page 20 End Service guide Page 6 808D turning and milling

7 Service cae of hardware Startup cannot log into the ytem Fault decription: Cannot log into the ytem after power on; normally black creen, no diplay at all. Diagnotic tep Check the power indicator light on the PPU panel: If the indicator light i on: Power off and check whether the CF card i inerted correctly, then power on and retart, oberve whether the i eliminated. If the indicator light i off: Check the X1 power plug interface on the back of the PPU 1. Whether the connection i looe. 2. Whether the 24 V terminal matche the interface. 3. Whether 24 VDC i available by meauring with a multi- meter. Battery alarm Fault decription: The ytem iue a battery alarm. tput. Diagnotic tep Replace the battery when the ytem iue the alarm Remove the battery and replace it,in the power-on tate. Note Battery: Lithium 3V DC 950mAH Life time: 3 year Order number: 6FC5247-0AA18-0AA0. Battery alarm number : Thi alarm indicate that the battery power of the ytem i low. In thi cae, replace the battery within ix week, otherwie it may caue data lo. Replacement and maintenance are neceary if the till exit after the above inpection, becaue it i probable that the PPU i damaged. Battery alarm number : Thi alarm indicate that the battery power of the ytem will oon be ued up. In thi cae, replace the battery immediately, otherwie it may caue data lo. 808D turning and milling Page 7 Service guide

8 Service cae of hardware MCP i not available Fault decription: 1. MCP doe not repond after power on, all the indicator light are off and all the operation are not available. 2. All the indicator light of MCP are flahing all the time. Diagnotic tep Check the connection between the MCP and the PPU 1. Whether the connection are diconnected. 2. Whether the connection are damaged or have a y contact. (Check whether the i reolved by replacement with a new wire.) Check whether the interface of X30 on the back of the PPU i damaged or there i a y contact.(check whether the i reolved by replacement with a new wire.) Check whether the interface of X10 on the back of themcp i damaged or there i a y contact.(check whether the i reolved by replacement with a new wire.) Note: In thi cae, the alarm number on the PPU may be A PLC program can alo caue flahing of all the MCP indicator light. In thi cae, check whether there i problem in the PLC program. Replacement and maintenance are neceary if the till exit after the above inpection, becaue it i probable that the PPU or MCP i damaged. Service guide Page 8 808D turning and milling

9 Service cae of hardware MCP button pre Fault decription: Some button on the MCP do not repond. (Common button with : "Cycle tart" button and "Reet" button.) Diagnotic tep Check the tate of the PLC input/output. Note: The tep for entering the PLC tatu monitoring interface on the PPU: 1. Pre the Machine button on the PPU. 2. Pre the Shift+ Alarm button at the ame time. 3. Pre the PLC oftkey on the PPU. 4. Pre the PLC tatu oftkey on the PPU. + If the PLC tatu bit correponding to the button change If the PLC tatu bit correponding to the button doe not change Example of PLC tatu monitoring MCP button function correctly. In thi cae, make further obervation to ee if there are other alarm or whether the PLC program i correct in a different poition. Replacement and maintenance are neceary becaue the MCP button are damaged. Addre of the Reet button: DB1000.DBX3.5 Addre of the Cycle tart button: DB1000.DBX D turning and milling Page 9 Service guide

10 Service cae of hardware RS232 tranmiion Fault decription: Data communication i not poible via RS232. Diagnotic tep Check the RS232 communication etting on the PPU 1. Whether the communication i activated. 2. Whether the communication parameter match the PC terminal. 3. Whether the X2 interface on the PPU panel i looe. 4. Whether the cable of RS232 i damaged. 5. Whether the RS232 interface of the PC terminal i damaged. Replacement and maintenance are neceary if the till exit after the above inpection, becaue it i probable that the PPU i damaged. Note: When you ue WINPCIN, pleae make ure that STEP 7 i cloed otherwie thi may caue a communication. Note: The tep for entering the RS232 communication interface on the PPU: a. Uing RS232 to etablih the PLC programming tool connection 1. Pre the Machine button on the PPU. 2. Pre the Shift+ Alarm button at the ame time 3. Pre the PLC button on the PPU. 4. Pre the STEP 7 connect oftkey on the PPU. 5. Pre the "Connect. ON" oftkey on the PPU after etting up the communication data. b. Uing RS232 to etablih the WINPCIN connection 1. Pre the Program management button on the PPU. 2. Pre the RS232 oftkey on the PPU. 3. Pre the Setup oftkey on the PPU. 4. Adjut the "Communication etting" parameter until they are exactly the ame a the configuration parameter in the computer communication oftware. Pleae make ure that STEP7 i cloed (OFF) before uing WINPCIN! + Service guide Page D turning and milling

11 Service cae of hardware Fault decription: 1. The pindle cannot move, the PPU creen how the waiting for pindle ignal and the creen ha no alarm prompt. 2. The creen ha pindle value, but the actual pindle cannot move and the creen ha no alarm prompt. 3. The pindle angle of rotation i not teady (varie during rotation). Diagnotic tep Cae1 Spindle If the i:the pindle cannot move, the PPU creen how the waiting for pindle ignal. Check the etting of machine data MD30200 (pindle i et to 1 if it ha an encoder, otherwie 0). Check the pindle interface of X54 on the back of the PPU 1. Whether the interface i looe or damaged. 2. Meaure pin 1 and 9 of X54 with a multi-meter after tarting the pindle, then oberve if there i voltage output. Check whether the connection cable between the PPU, pindle and encoder i good. Check whether the etting of machine data MD30130/MD30240/MD30134/ MD32250/MD32260/MD35150 are correct. 1. MD30130 = 1 / MD30240 = 2 2. MD pindle output polarity (et between 0 ~ 2 ) 0-dual polarity, 1/2-ingle polarity (depend on the actual ituation) 3. MD32250 = 100 / MD32260, it i conitent with actual motor rated peed. Check whether the pindle converter how a or not. Replacement and maintenance are neceary if the till exit after the above inpection, becaue it i probable that the PPU i damaged. If the i:the creen ha pindle value, but the actual pindle cannot move. Check whether there i an interference between the connection (it i better to eparate thicker and thinner wire). 808D turning and milling Page 11 Service guide Cae2 Pleae check whether the PPU i in the program tet tate. 1. Whether the indicator light of the "Program tet" key on MCP i on or not (it hould not be on). 2. Whether the "PRT" indicator on the PPU creen i activated or not (it hould not be acti- Ue the diagnotic tep of "Cae1" mentioned above to check the pindle if the till exit. Cae3 If the i:the pindle angle of rotation i not teady (varie during rotation) Check the interface of X54 on the back of the PPU 1.Whether the interface i looe. 2.Whether the connection have a y contact. Pleae check whether the connection of the pindle converter i looe or whether the converter i damaged.

12 Service cae of hardware Spindle encoder alarm Fault decription: The pindle cannot move, and the alarm appear on the creen at the ame time. Diagnotic tep Check the pindle encoder interface on the back of the PPU. Check whether the connection of the PPU pindle encoder i damaged or the connection i correct. Check whether the etting of machine data MD30200/MD30240 in the PPU are correct. 1. MD30200: Spindle i et to 1 if it ha an encoder, otherwie MD30240=2 Handwheel Fault decription: Handwheel i not available / axi i not elected. Diagnotic tep Check whether the proce i correct, and confirm whether the feed axi ha been elected for operation in the "Handwheel" tate. Ue the PLC input/output for monitoring the axi inpection with the elected key. Check whether the connection on the handwheel are correct, and oberve if there are hort-circuit to adjacent connection. Check the X10 interface on the front of the PPU. 1. Whether the connection i looe. 2. Whether the connection i damaged. 3. Check the X10 interface (terminal 5/6) and oberve if there i 5 V output. Check whether the pindle encoder i damaged, replace it with a new encoder and tet it again. Check whether the handwheel i damaged. X10 HANDWHEEL Replacement and maintenance are neceary if the till exit after the above inpection, becaue it i probable that the PPU i damaged. Replacement and maintenance are neceary if the till exit after the above inpection, becaue it i probable that the PPU i damaged. Service guide Page D turning and milling

13 Service cae of hardware Feed axi Fault decription: The ytem ha completed the tate of returning to the reference point 1. The creen can diplay feed axi data, but the actual machine cannot move 2. The actual direction of motion i oppoite to the operational direction of the machine / i oppoite to the direction of creen diplay. Cae2 If the i: The actual direction of motion i oppoite to the operational direction of the machine / i oppoite to the direction of creen diplay. Check whether the connection of the direction key on the V60 drive are correct. Check whether the wiring of terminal + DIR / - DIR i correct depending on the actual ituation. Diagnotic tep Cae1 If the i:the creen can diplay feed axi data, but the actual machine cannot move. Pleae check whether the PPU i in the program tet tate. 1. Whether the indicator light of the "Program tet" button on the MCP i on (it hould not be on). 2. Whether the "PRT" indicator on the PPU creen i activated (it hould not be activated). Check whether the etting of machine data MD32100 / MD32110 are correct. MD32100:Axi revere key (The implied value = 1. It i permitted to change to -1 according to the actual ituation.) MD32110:Encoder poition feedback polarity key (The implied value = 1. It i permitted to change to -1 according to the actual ituation.) Check whether the mechanical coupling i looe. Check whether the connection between the axi ignal and the drive i good, and whether the pin on the V60 are tight/damaged. Check whether there are alarm on the drive if uing a third-party drive. Replacement and maintenance are neceary if the till exit after the above inpection, becaue it i probable that the PPU i damaged. 808D turning and milling Page 13 Service guide

14 Service cae of hardware Change of direction i not poible Fault decription: The machine can only move in one direction when the Shaft + (or haft-) key i ued in "Manual" mode, and the direction cannot be changed. Diagnotic tep Check whether the drive i damaged. If uing a third-party drive, it i neceary to verify the compatibility between the ytem and the drive. Poitioning error Fault decription: The operating poition of the machine coordinate ytem i not accurate. Diagnotic tep Check whether the etting of machine parameter MD31030/MD31050/ MD31060/MD31020/MD31400 are conitent with the actual mechanical parameter. 1. MD31030 leadcrew pitch value torage 2. MD31050/MD31060 haft deceleration rate 3. MD31020 = MD31400 encoder line number (et to when uing the V60 drive) Note: Check whether there i play on the drive encoder. Check the drive parameter. Do not et up the deceleration rate parameter in the drive. Check whether the machine intallation i table. Check whether the mechanical coupling i looe / the belt i lipping. Check whether it i neceary to adjut the compenation of the leadcrew pitch and the backlah. Service guide Page D turning and milling

15 Service cae of hardware Tool change Fault decription: Machine cannot change tool / tool change error / tool keep rotating. Diagnotic tep Check whether the connected equence of machine ource / tool motor i correct. Check the tool rotation ignal output on the back of the PPU / input point interface of the tool ignal in place 1. Whether it i damaged. 2. Whether the wire i looe. 3. Terminal no. 1/10 i connected to 24 V / 0 V. 4. Whether the connection i correct or different in the etting of PLC program. Check whether the wire between the tool ignal input /output point on the back of the PPU and the connection between the tool are looe or damaged. Check whether the ignal code wheel of the machine i damaged. Replacement and maintenance are neceary if the till exit after the above inpection, becaue it i probably the of the PPU Connected interface Startup proce crahe Fault decription: The ytem loading proce crahe during tartup (uually it freeze when loading at 40%). Diagnotic tep Power off and retart. Check whether the i reolved. Power off and check whether the CF card i inerted correctly or ha a y contact, then power on again to check whether the i reolved. Power off and pre the "Selection" button on the PPU during power-up to open the menu, then elect "Startup with de data". Note: All machine data i lot during thi operation. Pleae enure that there i an appropriate backup. Replacement and maintenance are neceary if the till exit after the above inpection, becaue it i probable that the PPU i damaged. 808D turning and milling Page 15 Service guide

16 Service cae of hardware Hardware limit Fault decription: 1. Hardware limit witch alarm appear on the PPU. 2. The machine ha croed the hardware limit witch, but can till move, no alarm. Diagnotic tep If the i: Hardware Cae1 limit witch alarm appear on the PPU. Pre the "Reet" button on the PPU and pre the direction key controlling the feed haft movement on the PPU at the ame time to make the feed axi move in the oppoite direction and break away from the hardware limit witch. The alarm can then be cleared. The hardware limit witche on the machine mut be checked if thee method do not reolve the. 1. Ue a multi-meter to check whether the hardware limit witch connection i good. 2. Check whether the hardware limit witche are damaged. Cae2 If the i:the machine ha croed the hardware limit witch, but can till move, no alarm. Check whether the hardware limit witch connection i hort-circuited with the high level. Check whether the hardware limit witche are damaged. Startup can t go to REF. point Fault decription: 1. Pre the axi + (or axi-) key, the creen coordinate do not change and the machine doe not move. 2. Pre the axi + (or axi-) key, creen coordinate change but the machine doe not move. 3. Pre the axi + (or axi-) key, the machine can move until the hardware limit witch alarm appear. 4. Pre the axi + (or axi-) key, the machine i alway moving in the oppoite direction. 5. Pre the axi + (or axi-) key, the machine move only a hort ditance. 6. Pre the axi + (or axi-) key, the machine alarm appear after exiting the lowdown witch. 7. Pre the axi + (or axi-) key, the tart point and automatic proceing program are running normally, but the ytem doe not repond when returning to the reference point. Diagnotic tep Cae1 If the i:pre the axi + (or axi-) key, the creen coordinate do not change and the machine doe not move. Check if there i an alarm number on the PPU creen, continue operation after eliminating the alarm via the "Reet" key. The machine data i lot if the alarm number /004062/ appear; in thi cae, it i neceary to back up the data and retart after power-off to check whether the ha been eliminated. Service guide Page D turning and milling

17 Service cae of hardware Cae2 If the i:pre the axi + (or axi-) key, creen coordinate change but the machine doe not move. Cae5 If the i:pre the axi + (or axi-) key, the machine move only a hort ditance. Check whether the PPU i in the program tet tate. 1. Whether the indicator light of the "Program tet" key on MCP i on (it hould not be on). 2. Whether the "PRT" indicator on the PPU creen i activated (it hould not be activated). Check whether the etting of machine data MD30130/MD30240/ MD30350 are correct. 1. Feed axi MD30130=2 / MD30240=3 2. MD30350=0 Check whether the etting of machine data MD34000 are correct (the machine deceleration witche are not available when 34000=0). Cae6 If the i:pre the axi + (or axi-) key, the machine alarm appear after exiting the lowdown witch. Check whether the machine approaching witch and it related connection are damaged. Check whether the etting of machine data MD34060 are correct. Cae3 If the i:pre the axi + (or axi-) key, the machine can move until the hardware limit witch alarm appear. Check whether the encoder correponding to the feed axi and it related connection are damaged. Check whether the machine deceleration witche and their related connection are broken. Cae4 If the i:pre the axi + (or axi-) key, the machine i alway moving in the oppoite direction. Check whether the machine deceleration witche can bounce. Cae7 If the i:pre the axi + (or axi-) key, the tart point and automatic proceing program are running normally, but the ytem doe not repond when returning to the reference point. Check whether the etting of machine data MD30200 are correct (it cannot return to the reference point when 30200=0). Check whether the machine deceleration witche and their related connection are broken. 808D turning and milling Page 17 Service guide

18 Service cae of hardware PPU/HMI Drive alarm Thi ection dicue only the Siemen SINAMICS V60 drive Fault decription: PPU button i defect / HMI creen i defect Diagnotic tep Check whether it i in the crahed tate. If o, power off and on, then check whether the till exit. Replacement and maintenance are neceary if the till exit after the above operation, becaue it i probable that the PPU i damaged. Fault decription: The ytem iue a drive-related alarm. The V60 drive alo iue an alarm, the common alarm number are A05/ A06/A07/A08/A09 Diagnotic tep A05 alarm IGBT overcurrent appear when power i obtained from the line upply / appear during motor operation. Check the U, V, W, PE connection on the drive 1. Whether connection among different phae are hort-circuited. 2. Whether the grounding connection i incorrect or ha bad grounding. 3. Whether the connection i damaged. Power on again and oberve whether the till exit after verification. If the till exit after the above operation, check the inulation of the motor and ee if it i damaged. The motor can be changed when neceary. Then power on again and oberve whether the till exit. Replacement and maintenance are neceary if the till exit after the above operation, becaue it i probable that the drive i damaged. Service guide Page D turning and milling

19 Service cae of hardware A06 alarm Internal chip overcurrent appear when power i obtained from the line upply / appear during motor operation. Check the U, V, W, PE connection on the drive 1. Whether connection between different phae are hort-circuited. 2. Whether a U, V, W phae i diconnected. 3. Whether the grounding connection i incorrect or ha bad grounding. 4. Whether the connection i damaged. Power on again and oberve whether the till exit after verification. If the till exit after the above operation, check the inulation of the motor and ee if it i damaged. The motor can be changed when neceary. Then power on again and oberve whether the till exit. Replacement and maintenance are neceary if the till exit after the above operation, becaue it i probable that the drive i damaged. A07 alarm The ground circuit i hort-circuited appear when power i obtained from the line upply / appear during motor operation. Check the U, V, W, PE connection on the drive 1. Whether connection among different phae are hort-circuited. Power on again and oberve whether the till exit after verification. Replacement and maintenance are neceary if the till exit after the above operation, becaue it i probable that the IGBT module in the drive i damaged. A08 alarm The encoder U/V/W connection are incorrect. Check the ignal cable between the motor and the drive (the encoder from the drive to the motor) 1. Whether the internal cable connection have y contact. 2. Whether the cable hielding i poor. 3. Whether the hielded ground cable i connected correctly. Power on again and oberve whether the till exit after verification. The interface circuit of the encoder mut be checked if the till exit after the above operation. Replacement and maintenance are neceary if the till exit after the above operation, becaue it i probable that the encoder on the drive i damaged. A09 alarm The encoder TTL ha pule. Check the ignal cable between the motor and the drive (the encoder from the drive to the motor) 1. Whether the connection of the encoder cable i correct. 2. Whether the internal cable connection have y contact. 3. Whether the cable hielding i poor. 4. Whether the hielded ground cable i connected correctly. Power on again and oberve whether the till exit after verification. The interface circuit of the encoder mut be checked if the till exit after the above operation. Replacement and maintenance are neceary if the till exit after the above operation, becaue it i probable that the encoder in the drive i damaged. 808D turning and milling Page 19 Service guide

20 Service cae of hardware Overload Fault decription: The machine cannot move or move difficultly becaue of overload (the drive may iue an overload alarm). Diagnotic tep Check whether the guide lubrication i ufficient 1. Whether the tubing/nozzle i unimpeded. 2. Whether the etting of the lubrication interval time i ufficient (the interval hould not be too long). Stop the machine and check whether the guide / the crew are blocked by the machining wate. If o, it may need proper cleaning. Check the connection of the haft coupling 1. Whether the connection i too tight. 2. Whether the connection i concentric. Service guide Page D turning and milling

21 Note 808D turning and milling Page 21 Service guide

22 Note Service guide Page D turning and milling

23 Service cae of PLC alarm We provide guidance in analyzing and diagnoing alarm caued by the tandard PLC in the 808D which are only for Siemen ervice engineer, OEM ervice engineer and Siemen authorized ervice engineer. Cae 6 Go to page T & M general alarm Cae Go to page 29 Cae Go to page 26 Cae Go to page 29 Cae Go to page 26 Cae Go to page 30 Cae Go to page 27 Cae Go to page 30 Cae Go to page 27 Cae Go to page 31 End Cae Go to page D turning and milling Page 23 Service guide

24 Service cae of PLC alarm Specific milling alarm Cae Go to page 35 Cae Go to page 32 Cae Go to page 35 Cae Go to page 32 Cae Go to page 36 End Cae Go to page 33 Cae Go to page 33 Cae Go to page 34 Cae Go to page 34 Service guide Page D turning and milling

25 Service cae of PLC alarm Specific turning alarm Cae Go to page 40 Cae Go to page 37 Cae Go to page 40 Cae Go to page 37 End Cae Go to page 38 Cae Go to page 38 Cae Go to page 39 Cae Go to page D turning and milling Page 25 Service guide

26 Service cae of PLC alarm HHU i active Spindle in braking progre Addre of PLC: DB1600.DBX1.2 Name of ubprogram: MINI_HHU(SBR 41) Addre of PLC: DB1600.DBX1.4 Name of ubprogram: SPINDLE(SBR 42) It i not a, the alarm act a a reminder and point out that the handwheel i activated. (Condition for the alarm to appear: The handwheel function ha been activated and the axi election operation i already in progre.) Proceing method No pecial action i required; the alarm will diappear after cancellation of the handwheel function / cancellation of the handwheel election. It i not a, the alarm act a a reminder and point out that the pindle i braking. Proceing method Pleae wait for the end of pindle braking, the alarm will diappear. Service guide Page D turning and milling

27 Service cae of PLC alarm Gear-change timeout Gear level poition error Addre of PLC: DB1600.DBX1.6 Name of ubprogram: GearChg1_Auto(SBR 49) Fault, the pindle hift time i beyond the permitted limit. Proceing method Check whether the gear-change monitoring time i et too low. Check whether the pindle gearbox ha mechanical problem. Addre of PLC: DB1600.DBX1.7 Name of ubprogram: GearChg1_Auto(SBR 49) Fault, the control cannot accept the gear level ignal / the control accept the wrong gear level ignal. Proceing method Check the related part of the gear level ignal 1.Ue PLC monitoring to detect if there i an input ignal at the gear level ignal relevant input point. 2.Check whether the input terminal of the interface on the back of the PPU are damaged/looe or the wiring i damaged. Check whether the pindle gearbox ha mechanical problem. 808D turning and milling Page 27 Service guide

28 Service cae of PLC alarm Drive not ready Addre of PLC: DB1600.DBX2.0 Name of ubprogram: EMG_STOP(SBR 33) Fault, the drive i not ready for operation or preparation. Note: Thi alarm alway appear for an "emergency top". Proceing method Check whether an emergency top alarm ha caued thi alarm. Check the drive 1. Whether the terminal of X6 i tight / wiring i looe or diconnected / 65 enable and M24 pin are ed. 2. Whether a drive alarm exit / no tartup. 3. Whether the drive i damaged. Cooling motor overload Addre of PLC: DB1600.DBX2.2 Name of ubprogram: COOLING(SBR 44) Fault, cooling motor overload, cooling fluid function cannot be ued normally, the ytem iue an alarm. Proceing method Check whether the cooling motor' overload protection witch i operable. Check the terminal of X102 on the back of the PPU 1. Whether the connection of pin 7 i looe/diconnected. 2. Confirm that pin 10 i connected normally with 0 V. Service guide Page D turning and milling

29 Service cae of PLC alarm Lubricant liquid poition in low level Approach ref point again after rot. monitoring Addre of PLC: DB1600.DBX2.5 Name of ubprogram: LUBRICAT(SBR 45) Addre of PLC: DB1600.DBX3.3 Name of ubprogram: AXIS_CTL(SBR 46) Fault, the lubricating oil level in the oil box i lower than the lowet et value and thi reult in the alarm; it may caue mechanical damage if not corrected in time. Proceing method Check whether the lubricating oil level i too low and add lubricating oil in time. Check the relevant terminal on the back of the PPU 1. Whether the input point i damaged/looe. 2. Whether pin10 i connected normally with 0 V. Fault caued by a drive tage lo (thi uually occur during motor highpeed operation ). The reult i that the running program i terminated and the reference point are lot. Proceing method Check the +24 V, Z-M, M24 of the X6 cable on the drive 1.Whether the connection i correct. 2.Whether the connection ha been cut / damaged. Power on again and oberve whether the i eliminated after power off. You can reduce the machining peed in the permitted range. Replacement and maintenance are neceary if the occur frequently, becaue it i probable that the drive ha a problem. 808D turning and milling Page 29 Service guide

30 Service cae of PLC alarm Reminding information for 1t ervice plan Addre of PLC: DB1600.DBX3.5 Name of ubprogram: PI_SERVICE(SBR 46) It i not a, the alarm act a a reminder. The appearance of thi alarm how that the reminding information for the 1t ervice plan which i et ahead of time i arriving. Proceing method Alarm for 1t ervice plan Addre of PLC: DB1600.DBX3.6 Name of ubprogram: PI_SERVICE(SBR 46) It i not a, the alarm act a a reminder. The appearance of thi alarm how that the reminding information for the 1t ervice plan which i et ahead of time ha arrived, pleae execute the relevant ervice plan immediately. Proceing method Check the predetermined ervice maintenance plan and make the relevant preparation. Pre the "Tak completed" oftkey on the PPU to eliminate the alarm. Pre the "Tak completed" oftkey on the "Service plan" interface after executing the relevant ervice plan to eliminate the alarm. Note: The tep on the "Service plan" interface are a follow 1. Pre the Shift + Diagnoi button at the ame time. 2. Pre the Service plan oftkey on the PPU. + Service guide Page D turning and milling

31 Service cae of PLC alarm Channel not in reet, change PRT not poible. Addre of PLC: DB1600.DBX7.4 Name of ubprogram: MCP_NCK(SBR 37) Fault, the "Program tet" oftkey to change thi tate i not available during the program operation o the ytem mut firt be witched to the "Reet" tate. 处理方法 Proceing method Pre the "Alarm cancel" button to cancel the alarm, the program will continue. You can alo pre the "Reet" button to cancel the alarm. (Note: the implemented program i alo reet at thi time.) 808D turning and milling Page 31 Service guide

32 Service cae of PLC alarm Coolant liquid poition in low level Lubricating motor overload Addre of PLC: DB1600.DBX2.3 Name of ubprogram: COOLING(SBR 44) Fault, the coolant liquid poition in the machine i lower than the lowet et value and thi alarm i iued; it can caue mechanical damage if not corrected in time. Proceing method Check whether the lubricating oil level i too low and add lubricating oil in time. Check terminal X102 on the back of the PPU 1. Whether the connection of pin 6 i looe/ diconnected. 2. Whether pin10 ha been connected normally to 0 V. addre of PLC :DB1600.DBX2.4 Name of ubprogram: LUBRICAT(SBR 45) Fault, lubricating motor overload, lubricating fluid function cannot be ued normally, the ytem iue an alarm. Proceing method Check whether the motor' lubricating overload protection witch i operable or not. Check the relevant terminal on the back of the PPU 1. Whether the input point i damaged/looe. 2. Whether pin 10 i connected normally to 0 V. Service guide Page D turning and milling

33 Service cae of PLC alarm Magazine not in pindle po. or original po. Addre of PLC: DB1600.DBX3.7 Name of ubprogram: DISK_MGZ_M(SBR 60) Fault, the magazine i not in the pindle poition or the original poition, the changing of tool i topped at thi time. Proceing method Check terminal X101 on the back of the PPU 1. Ue the PLC tatu monitoring to detect the input tate of I1.3 / I Whether the connection of pin 5 and pin 6 are looe/diconnected. 3. Whether pin 10 i connected normally to 0 V. Check whether the magazine air preure i low. Check whether the tet witche of the magazine extruion limit and withdrawal limit are y. Note: Pre the "Reet" button to eliminate the alarm after the magazine ha returned to the correct poition. Magazine in pindle po. and original po. Addre of PLC: DB1600.DBX4.0 Name of ubprogram: DISK_MGZ_M(SBR 60) Fault, the ytem detect that the magazine i in the pindle poition and the original poition; the action of the magazine i topped at thi time. Proceing method Check terminal X101 on the back of the PPU 1. Ue the PLC tatu monitoring to detect the input tate of I1.3 / I Whether the connection of pin 5 and pin 6 are looe/ diconnected. 3. Whether pin 10 i connected normally to 0 V. Check whether the tet witche of the magazine extruion limit and withdrawal limit are y. Note: Pre the "Reet" button to eliminate the alarm after the magazine ha returned to the correct poition. 808D turning and milling Page 33 Service guide

34 Service cae of PLC alarm Magazine turn key when magazine or p. not ready Addre of PLC: DB1600.DBX4.1 Name of ubprogram: DISK_MGZ_M(SBR 60) Fault, the "Move magazine" button i preed when the magazine or the pindle i not ready; the reult i that the magazine cannot move. Block earch, tool in pindle <> programmed tool Addre of PLC: DB1600.DBX4.2 Name of ubprogram: DISK_MGZ_M(SBR 60) Fault, the pindle tool number i not equal to the program tool number; the reult i that an alarm i iued and the program cannot be executed. Proceing method Pre the "Reet" button to cancel the alarm, then continue. Note:The magazine cannot be moved in the following cae 1. The pindle i turning in the poitive direction. 2. The magazine i executing the forward rotation / revere rotation command. 3. The pindle i executing the tool-releae command. 4. The emergency top tate i activated. Proceing method Make ure that you have ued the correct "Program earch" method to retart the program. Check whether the tool number election in the current program which i to be activated i conitent with the current pindle load tool. Cancel thi alarm by preing the Reet button after making ure that the entire information i correct. Service guide Page D turning and milling

35 Service cae of PLC alarm Spindle not reach tool-releae po. in time Addre of PLC: DB1600.DBX4.3 Name of ubprogram: DISK_MGZ_M(SBR 60) Fault, the tool-releae proce take longer than the monitoring time; thi reult in the failure of the pindle tool releae. Spindle not reach tool-lock po. in time Addre of PLC: DB1600.DBX4.4 Name of ubprogram: DISK_MGZ_M(SBR 60) Fault, the tool-lock proce take longer than the monitoring time; thi reult in the failure of the pindle tool lock. Proceing method Check terminal X101 on the back of the PPU 1. Ue the PLC tatu monitoring to detect the input tate of I Whether the connection of pin 7 are looe/ diconnected? Check whether the etting of the tool-releae monitoring timer (T19) in the PLC i correct. Check whether the air preure i ufficient. Check whether the pindle tool-releae witch i normal. Note: Pre the "Reet" button to eliminate the alarm after eliminating the actual. Proceing method Check terminal X101 on the back of the PPU 1. Ue the PLC tatu monitoring to detect the input tate of I Whether the connection of pin 8 are looe/diconnected. 3. Whether pin 10 i connected normally to 0 V. Check whether the etting of the tool-lock monitoring timer (T20) in PLC i reaonable. Check whether the air preure i ufficient. Check whether the pindle tool-lock witch i normal. Note: Pre the "Reet" button to eliminate the alarm after eliminating the actual. 808D turning and milling Page 35 Service guide

36 Service cae of PLC alarm Safety door not cloed, NC tart not poible. Addre of PLC: DB1600.DBX7.3 Name of ubprogram: AUX_MCP(SBR 20) Fault, running the program without cloing the afety door; the reult i that the program cannot be executed. Proceing method Check whether the afety door i cloed (if uing the afety door control key on the MCP, pleae check whether thi button i activated). If the afety door ha been cloed, pleae check the following: Check terminal X102 on the back of the PPU 1. Whether the connection of pin 7 are looe/ diconnected. Check whether the door-cloed limit witch i normal. Note: Pre the "Reet" button to eliminate the alarm after eliminating the actual. Service guide Page D turning and milling

37 Service cae of PLC alarm Operation while chuck i not locked Addre of PLC: DB1600.DBX1.5 Name of ubprogram: Lock_ unlock _T(SBR 56) Fault, the chuck i not locked tightly and the cycle tart a well a the pindle forward/revere operation i not permitted. Proceing method Check whether the MCP "Chuck open" indicator light i on. Check whether the actual machine part are clamped in the chuck. Check terminal X102 on the back of the PPU 1. Whether the connection of pin 5 are looe/ diconnected. 2. Whether pin 10 i connected normally to 0 V. Operate chuck when p. or part prog. i running Addre of PLC: DB1600.DBX2.1 Name of ubprogram: MAIN(OB1) Fault, no "Chuck open" operation when pindle or program i running. Proceing method The caue the iuing of thi alarm. Pleae notice that there i no chuck operation when the pindle / program i running. Pre the "Alarm cancel" button to cancel the alarm, the action will continue. You can alo pre the "Reet" button to cancel the alarm. (Note: The action i alo reet at thi time.) 小 808D turning and milling Page 37 Service guide

38 Service cae of PLC alarm Turret motor overload Programmed tool num. > max. tool number Addre of PLC: DB1600.DBX2.6 Name of ubprogram: MAIN(OB1) Fault, the turret motor i overloaded, the function cannot be ued normally, the ytem iue the alarm; the reult i that all operation are not available. Proceing method Check whether the motor overload protection witch I operable. Addre of PLC: DB1600.DBX2.7 Name of ubprogram: MAIN(OB1) Fault, becaue the program i incorrect. Proceing method Check the content of the machining program, then et the program tool number according to actual ituation. Check terminal X102 on the back of the PPU 1. Whether the connection of pin 2 are looe/ diconnected. 2. Whether pin 10 i connected normally with 0 V. Service guide Page D turning and milling

39 Service cae of PLC alarm Max. tool number etting error No poition ignal from turret Addre of PLC: DB1600.DBX3.0 Name of ubprogram: MAIN(OB1) Fault, the etting of the max. tool number in the ytem i not correct. The correct etting number i:4 or 6 Proceing method Check whether the etting of parameter MD14510[20] (max. tool number) are correct. Addre of PLC: DB1600.DBX3.1 Name of ubprogram: MAIN(OB1) Fault, no poition ignal can be detected from the turret. Proceing method Check the tool code wheel 1.Whether the tool ignal point i damaged. 2.Whether the tool itelf i y. Check the correponding terminal of the I/O interface on the back of the PPU 1. Whether the connection are diconnected/looe. 2. Whether the terminal are damaged/looe? 3. Whether the point of mon. terminal i connected normally to 0 V. 808D turning and milling Page 39 Service guide

40 Service cae of PLC alarm Not able to find expected tool in monitor time Tool i not locked Addre of PLC: DB1600.DBX3.2 Name of ubprogram: MAIN(OB1) Fault, the alarm appear becaue no tool poition i detected in the time limit. Proceing method Check the tool code wheel 1.Whether the tool ignal point i damaged. 2.Whether the tool itelf i y. Check the correponding terminal of the I/O interface on the back of the PPU 1. Whether the connection are diconnected/looe. 2. Whether the terminal are damaged/looe. 3. Whether the point of the mon. terminal are connected normally to 0 V. Check whether the etting of MD14510[22] are correct (the value can be increaed appropriately). Addre of PLC: DB1600.DBX3.4 Name of ubprogram: Turret3_CODE_T(SBR 53) Fault, the tool-locked ignal i not in the ytem and therefore the tool i not locked tightly. Proceing method Check the tool-locked ignal 1.Whether the relevant input terminal on the back of the PPU are looe/ damaged. 2.Whether the connection of relevant input terminal on the back of the PPU are damaged/diconnected. 3. Ue the PLC monitoring to detect whether the correponding input point of thi ignal ha input ignal. Service guide Page D turning and milling

41 Note 808D turning and milling Page 41 Service guide

42 Everything ever wanted to know about SINUMERIK 808D: 808/Page/inumerik-808.apx Everything about hopfloor manufacturing: Everything about the SINUMERIK Manufacturing Excellence portfolio of ervice: Information about CNC training: Siemen AG Indutry Sector Motion Control Sytem P.O.Box ERLANGEN GERMANY Subject to change without prior notice Order No.: Dipotelle WÜ/35557 WERK WS Printed in Germany Siemen AG 2012 The information provided in thi brochure contain merely general decription or characteritic of performance which in actual cae of ue do not alway apply a decribed or which may change a a reult of further development of the product. An obligation to provide the repective characteritic hall only exit if exprely agreed in the term of contract. All product deignation may be trademark or product name of Siemen AG or upplier companie whoe ue by third partie for their own purpoe could violate the right of the owner.