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Siemens SINUMERIK 808D Service Manual

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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.
© Siemens AG 2017. All rights reserved
01/2017
1

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   Summary of Contents for Siemens SINUMERIK 808D

  • Page 1 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.
  • Page 2: Preface

    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.
  • Page 3: Table Of Contents

    Table of contents Preface ................................... 2 Safety instructions ..............................4 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 Carrying out of repairs ..........................
  • Page 4: Safety Instructions

    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 Specific turning alarms .......................... 40 4.3.1 Alarm 700013 ............................
  • Page 5 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 •...
  • Page 6 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.
  • Page 7 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. •...
  • Page 8: Handling Electrostatic Sensitive Devices (esd)

    Note Industrial security Siemens provides products and solutions with industrial security functions that support the secure operation 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 –...
  • Page 9: Residual Risks Of Power Drive Systems

    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.
  • Page 10: Service Case Overview

    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 Service Manual...
  • Page 11: Service Cases Of The Hardware/software Faults

    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 →...
  • Page 12: System Startup Fault

    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 Check the status LED on the PPU panel. If the status LED is lit, power off the control system and check whether •...
  • Page 13: Mcp Connection Fault

    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.
  • Page 14: Rs232 Transmission Fault (ppu160.2 Only)

    Check the PLC interface status 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.
  • Page 15: Spindle Fault

    Make sure the communication settings are the same as those in the communication software on your PC. Note When using the SinuComPCIN, the RS232 interface must not be active for another application. This means, for example, the RS232 interface must not be active through the following operation: →...
  • Page 16 Case 2 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 •...
  • Page 17: Spindle Encoder Alarm

    Spindle encoder alarm Fault description The spindle cannot move, and the alarm 025000 appears on the screen at the same time. Diagnostic steps 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. Check whether the connection cable of the spindle encoder is damaged or connected incorrectly.
  • Page 18: Feed Axis Fault

    • MD32110: encoder position feedback polarity (default value = 1, change to -1 as required) • For the SINUMERIK 808D control system, you should also check the connections 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"...
  • Page 19: Positioning Error

    • 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. Check whether the turret is installed properly on the machine.
  • Page 20: Overload

    3.13 Overload Fault description The axis cannot move or moves difficultly because of overload (the drive may issue an overload alarm). Diagnostic steps 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) •...
  • Page 21: Reference Point Approach Fault

    Case 2 Check whether the hardware limit switch wire is short-circuited with the high level signal. Check whether the hardware limit switches are damaged. 3.16 Reference point approach fault Fault description Case 1: Press the desired axis traversing key, the position values displayed on the PPU do not change and the axis does not move.
  • Page 22: Drive Alarm

    Case 4 Check whether the deceleration switches cannot bounce back. Check whether there is connection fault of the deceleration switches. Case 5 Check whether the machine data MD34000 is set correctly (the deceleration switches are not available when MD34000 = 0). Case 6 Check whether the machine approaching switch and its related connections are damaged.
  • Page 23: Option Activation Failure After Ppu Replacement

    After the initial power up of the control system with the new PPU, you are recommended to import an existing commissioning archive created with the previous PPU. You must first contact the Siemens Hotline to unassign the licenses of the options, and then proceed through the following steps to reactivate the options on the new PPU: Select the system data operating area.
  • Page 24 → Then you can find the serial number of CF card in the following dialog box: Go to the Web License Manager (http://www.siemens.com/automation/license) on a comput- er with Internet access, and login via "Direct access". Follow the instructions in the Web License Manager to assign the licenses of your purchased options to the new PPU.
  • Page 25 Enter the data required in the dialog box, for example: ① The software version 4.7 SP4 must be selected for the SINUMERIK 808D/SINUMERIK 808D ADVANCED control system. ② Serial number of the new CF card, which can be found on the PPU HMI through the following operations: →...
  • Page 26 Click this button to save the activation data in the form of .clc file. Store the .clc file in a USB memory stick or a connected network drive. Open the license key dialog box through the following PPU operations: → →...
  • Page 27 ● Case 2: A commissioning archive created after the CNC lock function is activated is imported after the PPU replacement. In this case, alarm 8062 is displayed and NC start disabled. The cause of the alarm is the new serial numbers of the new control system hardware and new CF card.
  • Page 28: Cnc Lock Alarms

    Find the desired deactivation file and press this softkey to import. If no error occurs when importing the deactivation file, the CNC lock function is deactivated. To activate the CNC lock function again, a new activation file (.clc) appropriate for the control system must be created by the machine manufacturer or dealer and imported into the control system.
  • Page 29: Oem Pin Forgotten For Cnc Lock

    Remedy The machine manufacturer or dealer must contact the Siemens Hotline and provide the following information to unlock the machine: ● License certificate (CoL) for the option of the CNC lock function ●...
  • Page 30 Notes Service Manual 01/2017...
  • Page 31: Service Cases Of The Plc Alarms

    Service cases of the PLC alarms In this chapter, the following service cases are described: General alarms Case 1 → Alarm 700010 (Page 32) Case 2 → Alarm 700012 (Page 32) Case 3 → Alarm 700014 (Page 32) Case 4 →...
  • Page 32: General Alarms

    General alarms 4.1.1 Alarm 700010 Alarm description It is not a fault, but a reminder that the handwheel is activated and assigned to an axis. PLC information PLC address: DB1600.DBX1.2 Subroutine: MINI_HHU (SBR 41) Remedy No special action is required. The alarm will disappear after deactivating the handwheel function/unassigning the handwheel. 4.1.2 Alarm 700012 Name of alarm...
  • Page 33: Alarm 700015

    4.1.4 Alarm 700015 Alarm description The control cannot receive the gear level signal/the control receives the wrong gear level signal. PLC information PLC address: DB1600.DBX1.7 Subroutine: GearChg1_Auto (SBR 49) Remedy ● Check the related parts of the gear level signal as follows: –...
  • Page 34: Alarm 700018

    4.1.6 Alarm 700018 Alarm description The motor of the cooling system is overloaded. The coolant function cannot be used normally, and the control system issues an alarm. PLC information PLC address: DB1600.DBX2.2 Subroutine: COOLING (SBR 44) Remedy ● Check whether the overload protection switch of the cooling motor works. ●...
  • Page 35: Alarm 700030

    Remedy Check the preset service maintenance plan and make the relevant preparations. Select the system data operating area. Press this key on the PPU to access the extended softkeys. Enter the main screen of service planning. Press this softkey on the PPU to cancel the alarm. 4.1.9 Alarm 700030 Alarm description...
  • Page 36: Specific Milling Alarms

    Remedy Press this key on the PPU to cancel the alarm, and the program will continue. You can also press this key on the MCP to cancel the alarm. Note: The program execution is also reset in this case. Specific milling alarms 4.2.1 Alarm 700019 Alarm description...
  • Page 37: Alarm 700031

    4.2.3 Alarm 700031 Alarm description The system detects that the magazine is neither in the spindle position nor in the original position. The tool change action stops in this case. PLC information PLC address: DB1600.DBX3.7 Subroutine: DISK_MGZ_M (SBR 60) Remedy ●...
  • Page 38: Alarm 700033

    4.2.5 Alarm 700033 Alarm description The magazine moving key is pressed when the magazine or the spindle is not ready. The magazine cannot move in this case. PLC information PLC address: DB1600.DBX4.1 Subroutine: DISK_MGZ_M (SBR 60) Remedy Press this key on the MCP to cancel the alarm. Note The magazine cannot move in the following cases: The spindle is rotating.
  • Page 39: Alarm 700035

    4.2.7 Alarm 700035 Alarm description The tool release time exceeds the monitoring time, which results in the failure of spindle tool release. PLC information PLC address: DB1600.DBX4.3 Subroutine: DISK_MGZ_M (SBR 60) Remedy ● Check the interface X101 on the back of the PPU for the following: –...
  • Page 40: Alarm 700059

    Note Press the following key on the MCP to cancel the alarm after eliminating the faults. 4.2.9 Alarm 700059 Alarm description The part program cannot be executed without closing the safety door. PLC information PLC address: DB1600.DBX7.3 Subroutine: AUX_MCP (SBR 20) Remedy Check whether the safety door is closed (if using the safety door control key on •...
  • Page 41: Alarm 700017

    Remedy Check whether the chuck control key on the MCP is activated (the indicator is • lit). Check whether the workpiece is clamped in the chuck on the machine. • Check the interface X102 on the back of the PPU for the following: •...
  • Page 42: Alarm 700023

    4.3.4 Alarm 700023 Alarm description The program is incorrect. The programmed tool position number is larger than the maximum tool position number. PLC information PLC address: DB1600.DBX2.7 Subroutine: MAIN (OB1) Remedy Check the content of the part program, and edit the program according to the actual number of tools created. 4.3.5 Alarm 700024 Alarm description...
  • Page 43: Alarm 700026

    4.3.7 Alarm 700026 Alarm description This alarm appears because no tool position is detected within the time limit. PLC information PLC address: DB1600.DBX3.2 Subroutine: MAIN (OB1) Remedy ● Check the turret encoder to see whether the turret signal interface is damaged. ●...
  • Page 44 Notes Service Manual 01/2017...
  • Page 45: Service Cases Of The Nc Program Alarms

    Service cases of the NC program alarms In this chapter, the following service cases are described: Case 1 → G81 deactivated in ISO mode (Page 45) Case 2 → M10/M11 deactivated (Page 45) Case 3 → Thread cutting interruption (Page 45) Case 4 →...
  • Page 46: Wrong Zero Offsets In Iso Mode

    Wrong zero offsets in ISO mode Fault description The zero offset activated in ISO mode cannot be reset to zero after the control system is switched back to Siemens mode. Remedy Select the machining operating area. Switch to "MDA" mode.
  • Page 47: General Nc Program Alarms

    General NC program alarms For more information about the general NC program alarms, refer to the SINUMERIK 808D/SINUMERIK 808D ADVANCED Diagnostics Manual. Notes Service Manual 01/2017...
  • Page 48 Notes 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.

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Sinumerik 808d advanced

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