Alarm Sinumerik 808 D

Training handbook
SINUMERIK 808D Service
guide
Version: 05.2012
www.siemens.com.cn/808D
List
For
Service case of
hardware fault
Go to page 5
For
Service case of
PLC alarm
Go to page 23
For
Service case of
NC program
alarm
Please refer to the

alarm handbook
End
808D turning and milling
Service guide
Service case
of hardware
fault
For normal hardware faults, we provide the basic service diagnostic steps
and detecting procedures which are only for Siemens service engineers,
OEM service engineers and Siemens authorized service engineers.
Startup
cannot
log into
the system
Go to page 7
Battery
alarm
Go to page 7
Case 3
MCP is not
available
Go to page 8
Case 4
MCP
button
press fault
Go to page 9
Case 5
RS232
transmission
fault
Go to page 10
Case 6
Spindle
fault
Go to page 11
Case 1
Case 2
page 5
Case 7
Spindle
encoder
alarm
Go to page 12
Case 8
Handwheel
fault
Go to page 12
Case 9
Feed axis
fault
Go to page 13
Case 10
Change of
direction
is not
possible
Go to page 14
Case 11
Positioning
error
Go to page 14
Case 12
Tool change
is not possible
Go to page 15
Case 13
Startup
process
crashes
Go to page 15
Service guide
Service case
of hardware
fault
Case 14
Hardware
limit switch
fault
Go to page 16
Case 15
Startup
cannot return to
the reference
point
Go to page 16
Case 16
PPU/HMI
fault
Go to page 18
Case 17
Drive
alarm
Go to page 18
Case 18
Overload
Go to page 20
End
Service guide
page 6

Service case
of hardware
fault
Battery
alarm
,
Fault description:
Fault description:
Cannot
display at all.
Startup
cannot
log into the
system
log
into
the system
after power on; normally black
screen, no
The system issues a battery alarm.
PPU X1
,
Diagnostic steps
1.
2. 24v
Replace the battery when the system

Check the power indicator light on the PPU panel: 3. DC24V
issues the alarm shortage of electricity.
,,
Diagnostic steps
If the indicator light is off:

If the indicator light is on:
Remove the battery and replace it in
Power
off
and check whether
Check the X1 power plug interface
on
,
the power-on state.
the CF card is inserted correctly,
the back of the PPU
,
002100
then power
on and
1. Whether
the connection is loose.
restart,
observe
whether the
PPU X1
2. Whether
the
24 V terminal matches
,
fault ,,
is eliminated.
interface.
1. the
24 VDC is available by
2. 3.
24vWhether
with a DC24V
multi- meter.
3. measuring
Battery alarm number 002100: This alarm indicates that the battery
power of
the system002101
is low. In this case, replace the battery within six
weeks,
otherwise it may cause data loss.
, () ,
002100
6
Battery alarm number 002101: This alarm indicates that the battery
case, replace the battery
power of the system will soon be used up. In this

002101
immediately, otherwise it may cause data loss.
after
Replacement
and maintenance are necessary if the
fault
still exists
,
()
,
the above
inspection, because it is probable that the PPU is damaged.
page 7
Service guide
Service case
of hardware
fault
MCP is not
available
Diagnostic steps
MCP
PPU
MCP
PPU
Check the connections between the MCP and the PPU
1.
1. Whether
the connections are disconnected.
1.
2. Whether the connections are damaged or have a faulty contact.
2.
(Check2.
whether the fault is resolved by replacement with a new wire.)
Check whether the interface of

Check whether the interface of
X10 on the back of theMCP is
X30 on the back of the PPU is
PPUor
X30
MCP
X10is
damaged
is a
faulty
damaged
or there
a faulty
contact.
there
PPU
X30contact.
MCP
X10
(Check whether the fault is

(Check whether the fault is
resolved by replacement with a

resolved by replacement with a
new wire.)
new wire.)
description:
1.Fault
,
1.
MCP
MCP
,
,
,
1. MCP does not respond after
power
on, all the indicator lights
are off and all the operations are

not available.
2. MCP
2. MCP
2.
All the indicator lights of MCP
are flashing all the time.

Note:
In this
case,
the alarm number on the
PPU may be 400003.
A PLC
program fault can MCP
also cause
flashing of all the MCP indicator
PLC
,
PLC
lights. PLC
In this
case, check whetherMCP
there,
is problem in the PLC program.
PLC
Replacement and maintenance are necessary if the fault still exists after
the above inspection, because it is probable that the PPU or MCP is
,
PPU MCP ,
damaged.
, PPU MCP ,
Service
guide
8
page
808D turning and

milling
Service case
of hardware
fault
MCP
Note:
The
steps
for entering
the PLC status monitoring interface on
the PPU:
1. PPU
1.Press theMachinebutton on the PPU.
button
press fault
Fault description:
Some
buttons on the MCP do not respond.
MCP
(Common buttons with faults: "Cycle

start" button and "Reset" button.)
(
/)
Diagnostic steps
Check the state of the PLC input/output.

If the PLC status bit corresponding to If the PLC status bit corresponding
the buttons changes
to the buttons does not

change
,
MCP buttons function
correctly. In
this case, make further observation
to see if there are other

alarms or whether the PLC program
is correct in a different position.
,
Replacement and maintenance
are necessary because the MCP
buttons are damaged.
2.Press theShift+
Alarmbuttons
at the
2.
PPU
+
same time.
3.
PPU
PLC on the PPU.
3.Press
thePLCsoftkey
4.Press the soft key ofstate of PLCon PPU.
4. PPU PLC
PLC
Example
of PLC
status monitoring
Address
of the Reset
button:
DB1000.DBX3.5

Address of the Cycle start
button: DB1000.DBX3.3
page 9
Service guide
Service case
of hardware
fault
RS232
Note: The steps for entering the RS232

communication interface on the PPU:
transmission
fault
.
.

a. Using RS232 to establish the PLC programming tool connection
Fault description:
1. theMachinebutton
PPU
1. Press
on the PPU.
Data communication is not possible via RS232.
2.
PPUAlarm
buttons+at
the same time
2. Press
theShift+
RS232
Diagnostic steps
3. Press
on the PPU.
3. thePLCbutton
PPU PLC
4. Press theSTEP 7 connectsoftkey on the PPU.
4. PPU STEP7
Check
the
RS232RS232
communication
PPU
settings on the PPU
1.
Whether
the
communication
is activated.
1.
2. Whether the communication
parameters match the PC terminal.
2.
PC
5. Press theConnect. ONsoftkey on the PPU

5.,
PPUdata.
after
setting up the communications
STEP7
3. Whether the X2 interface on the PPU panel is loose.
b. Using RS232 to establish the WINPCIN connection
PPU X2
.
.
1. Press
theProgram
management
button
on the PPU.
4. Whether the cable of RS232 is damaged.
1. theRS232softkey
PPU
2. Press
on the PPU.
RS232
3. Press
on
the PPU.
2. theSetupsoftkey
PPU RS232
5. Whether the RS232 interface of the PC terminal is damaged.
settings
4. Adjust
theCommunications
3. PPU

parameters until they are exactly the same
as the configuration parameters in the
4.
computer communication software.
PC
RS232
Replacement
and
maintenance
are necessary if the fault still exists after
the above inspection, because it is probable that the PPU is damaged.
,
(PPU)
Note: When you use WINPCIN, please make sure that STEP
7 is,
closed otherwise this may cause a communication fault.
Service guide

,
,
page 10
Please make sure that STEP7 is

(OFF)
closed
before
using
WINPCIN
!

(
)!
()
!
Service case
of hardware
fault
Spindle
fault
1. / PPU ,
2.,,
Fault
description:
3.()
1. The
spindle cannot move, the PPU screen shows the waiting for spindle
1.
/ PPU
,
signal
and the screen
has no
alarm prompt.
2. The
screen has spindle values, but the actual spindle cannot move and
2.,,
the screen has no alarm prompt.
1
/ PPU
3.()
3. The spindle angle of rotation is not steady (varies during rotation).
steps
MD30200 ,
Diagnostic
,
(PPU) ,
Check
whether the spindle converter shows a fault or not.
, (PPU) ,
2 ,
If the fault isThe screen has spindle values, but the actual
Case2
spindle cannot move.
PPU
Please check whether the PPU is in the program
1.MCP
2
test
state.,
1.
Whether the indicator light of the
Program
testkey
on MCP is on or not (it
2.PPU
PRT
PPU
should not be on).
1.MCP
2. Whether thePRTindicator on the PPU
screen
is activated or not (it should not be acti2.PPU
PRT
Use
the diagnostic
steps ofCase1mentioned
,
above
to check the spindle if the fault still
exists.
If
the fault isThe spindle /cannot
move, the PPU screen shows
1PPU
PPU
Case1
X54
the waiting for spindle signal.
1.
Check
the settingsMD30200
of machine
data MD30200 (spindle,is set
to 1 if it has
an
2.
X54 1
encoder,
otherwise 0).
9,
Check
thePPU
spindle
interface ofX54
X54 on the back of the PPU
If the fault isThe spindle angle of rotation is not steady (varies
Case3
3 ()
,
1.
1. Whether
the interface is loose or damaged.
during rotation)
2. Measure
pins
1
and
9
of
X54
with
a
multi-meter
after
2.
X54 1
Check whether there is an interference between the connections (it is
starting the spindle, then observe if there is voltage output.
()
9,
better to separate thicker and thinner wires).
MD30130
/ MD30240
/ MD30134
/ MD32250 / MD32260 /
Check
whether the
connection
cable between
the PPU,
3 ()
spindle
and encoder
is good.
the
PPU
X54
on the back of the PPU
MD35150
Check
interface
of X54

1.MD30130=1
/ MD30240=2
Check
whether the
settings of machine data MD30130/MD30240/MD30134/
1.
1.Whether
the interface is loose.
()
MD32250/MD32260/MD35150
are correct.
2.MD30134
(
02
)
2.Whether
the connections have a faulty contact.
2.
MD30130 / MD30240
/ MD30134
/ MD32250 / MD32260 /
1. MD30130
= 1 //MD30240
=2
0
,1
2
()
PPU X54
MD35150
2. MD30134 - spindle output polarity (set between 0 ~ 2 )

Please check whether the connection of the spindle converter is
3.MD32250=100
/ MD32260
1.MD30130=1
/ MD30240=2
1.
/
0-dual
polarity, 1/2-single
polarity (depends on the actual situation)
loose or whether the converter is damaged.
2.MD30134
(
02 )
3. MD32250
= 100
/ MD32260, it is consistent
with actual motor rated
2.
speed.
0
,1 / 2
()
3.MD32250=100 / MD32260
/
page 11
Service guide
case
Service
of
hardware
fault
025000
encoder
alarm
/
Handwheel
fault
,
Fault
description:
PPU
025000
move, and
The
spindle
cannot
,
Fault
description:
/
,
Handwheel
available / axis is not selected.
is/not
screen at the same time.
Diagnostic steps
PLC PLC /
Check whether the process is correct, and confirm
,
whether
the feed axis has been selected for
,
,
operation
in theHandwheelstate.
,
Spindle
X60
the
025000
alarm
appears
on the
025000
Diagnostic
steps
PPU
the
PPU
X60
Check
spindle
encoder interface on
X60
the
back
of the PPU.
PPU MD30200 / MD30240
1.MD30200 1, 0
Check whether the connection of
the PPU spindle

2.MD30240=2

encoder
is damaged or the connection is
correct.
Use PLC
the
input/output for monitoring
axis inspection
PLC the
/
PPU
X10PLC
the
PLC
PLC /
with
selected
key.
1.
Check whether the connections on the handwheel are correct, and observe
2.
,
if,
there are5short-circuits
adjacent connections.
3. X10
/ 6 5Vto
Check
whetherMD30200
the settings
of machine
data MD30200 / MD30240 in the
PPU
/ MD30240
PPU MD30200 / MD30240
PPU
X10
Check
the
X10
interface
on the front of the PPU.
,
PPU are correct.
PPU
X10
1.MD30200
1,
1.
Whether
the
connection
is loose.
1, an
1.
encoder, otherwise00.
1.1.MD30200
MD30200: Spindle is set to 1 if it has
1.
2.MD30240=2
2. Whether the connection is damaged.
2.2.MD30240=2
MD30240=2
2.
2.
3.
Check the X10 interface (terminal 5/6) and
3.
X10
55/ /6
5V
, (PPU) ,
is 5 V output.
observe
if there
3.
X10
6
5V
,
(PPU)
,
Check whether the spindle encoder is damaged, replace it with a new
Check whether the handwheel is damaged.
Replacement and maintenance are necessary if the fault still exists after the
and
are necessary
if the fault still exists after
Replacement
maintenance
above inspection, because it is probable that the PPU is damaged.

,
(PPU)
,
,
, (PPU) ,
,(PPU)
(PPU),
,
encoder
and test it again.
,
,
page 12
Service guide
Service case
of hardware
fault
Feed axis
fault
Case2
If the fault is: The actual direction of motion is opposite to the
2
operational direction of the machine / is opposite
to the direction
/
of screen display.
Fault description:
Check whether the connections of the direction
the V60 drive are correct.
V60on
1. The screen can display feed axis data, but the actual machine cannot move keys
whether the wiring of terminal + DIR / 2. The actual direction of motion is opposite to the operational direction of Check
DR
/
DR depending
DIR is correct
on the actual situation.
the machine / is opposite to the direction of screen display.
1.,
The system has completed the state of returning to the reference point
2. /
Diagnostic steps
MD32100 / MD32110
Check whether the settings of machine data MD32100 / MD32110 are

Case1 If the fault isThe screen can display feed axis data, but theMD32100( =1, 1)
correct.
actual machine cannot move.
MD32110(
=1,
1 ,
MD32100Axis reverse key (The implied value
= 1. It is permitted 1)
to
Please check whether the PPU is in the program
change to -1 according to the actual situation.)
test state.
MD32110Encoder position feedback polarity key (The implied value
Whether the indicator light of the
PPU1.
= 1. It is permitted to change to -1 according to the actual situation.)
"Program test" button on the MCP is on (it
1.MCP
should not be on).
2. Whether the "PRT" indicator on the PPU

screen is activated (it should not be activated).
2.PPU PRT
Check whether the mechanical coupling is loose.
Check whether the connection between the axis signal and the drive is
good, and whether the pins on the V60 are tight/damaged.
Check whether there are alarms on the drive if using a third-party drive.
V60
after the
Replacement and maintenance are
necessary if the fault still /exists
,
page 13
Service guide
Service case
of hardware
fault
Change of
direction
is not
possible
Positioning
error
Fault description:
Fault description:
The machine can only move in one direction when the Shaft + (or shaft-)
key is used in "Manual" mode, and the direction cannot be changed.
The operating position of the machine coordinate system is not accurate.

Diagnostic steps
Diagnostic steps
Check whether the drive is damaged.
If using a third-party drive, it is necessary to verify the compatibility between
the system and the drive.
Check whether the settings of machine parameters MD31030/MD31050/

MD31060/MD31020/MD31400 are consistent with the actual mechanical
parameters.
1. MD31030 leadscrew pitch value storage
2. MD31050/MD31060 shaft deceleration rate
3. MD31020 = MD31400 encoder line number (set to 10000 when
using the V60 drive)
Note: Check whether there is play on the drive encoder.
Check the drive parameters. Do not set up the deceleration rate parameters
in the drive.
Check whether the machine installation is stable.
Check whether the mechanical coupling is loose / the belt is slipping.
Check whether it is necessary to adjust the compensation of the leadscrew
pitch and the backlash.
Service guide
page 14
Service case
of hardware
fault
Tool change
is not possible
Startup process
crashes
/ /
,( 40% )
Fault description:
Fault description:
The
system
loading process crashes during startup (usually
it freezes
,(
40% )
when loading at 40%).
Machine cannot
change tools / tool
change error
/ tools keep rotating.
/
/
Diagnostic steps
Check whether
the connected sequence of machine source / tool motor is
correct.
tool rotation signal output/

on the back of the PPU /
Check
PPUthe
input points interface of the tool signal in place

1.
PPU /
1. Whether it is
damaged.
2. Whether the 1.
wire is loose.
2.
3. Terminal
no. 2.
1/1024V
is connected
3.
1 / 10
/ 0V to 24 V / 0 V.
4. Whether the 3.
connection
correct
or /different
1 / 10is
24V
0V in the settings
4.
of PLC program. PLC
Diagnostic steps
,
Power
off
and
restart. Check whether the fault is resolved.
,
Power off
and check
whether the

,
CF
card is inserted correctly or
contact, then power

has
a faulty
on
again to check whether the
fault
is resolved.
Connected
off and press theSelection
,
PPU
Power
, PPU
button
on the PPU during power-up
interface
Check whether the wires between the tool signal input /

to open the menu, then select
output
point on
the back
of the PPU and the connections
Startup
with default data.
between the tools are loose or damaged.
4. PLC
,
,
Note:
All machine data is lost ,
during
this operation.
Please
ensure that there is an appropriate

Replacement and
maintenance are necessary if the fault still exists
after,backup.
,
()
, (PPU) ,
the above inspection,
because it is probably the fault of()
the PPU.
,
,
Check whether the signal code wheel of the machine is damaged.
,
(PPU) ,
the
page 15
Service guide
Service case
of hardware
fault
Startup cannot
return to the
reference point
Hardware limit
switch fault
Fault description:
Fault description:
1. Hardware limit switch alarm appears on the PPU.

2. The machine has crossed the hardware limit switch, but can still move, no
alarm.
1. Press the axis + (or axis-) key, the screen coordinates do not change and
the machine does not move.
2. Press the axis + (or axis-) key, screen coordinates change but the machine
does not move.
3. Press the axis + (or axis-) key, the machine can move until the hardware
limit switch alarm appears.
4. Press the axis + (or axis-) key, the machine is always moving in the opposite
direction.
5. Press the axis + (or axis-) key, the machine moves only a short distance.
6. Press the axis + (or axis-) key, the machine alarm 20002 appears after exiting
the slowdown switch.
7. Press the axis + (or axis-) key, the start point and automatic processing
program are running normally, but the system does not respond when returning
to the reference point.
Diagnostic steps
If the fault is: Hardware
limit switch alarm appears
on the PPU.
Press the "Reset" button on the PPU and press the direction key controlling
the feed shaft movement on the PPU at the same time to make the
feed axis move in the opposite direction and break away from the hardware
limit switch. The alarm can then be cleared.
Case1
The hardware limit switches on the machine must be checked if these

methods do not resolve the fault.
1. Use a multi-meter to check whether the hardware limit switch connection is good.
2. Check whether the hardware limit switches are damaged.
Case2
If the fault isThe machine has crossed the hardware limit

switch, but can still move, no alarm.
Check whether the hardware limit switch connection is short-circuited

with the high level.
Check whether the hardware limit switches are damaged.
Service guide
Diagnostic steps
If the fault isPress the axis + (or axis-) key, the screen coordinates
do not change and the machine does not move.
Check if there is an alarm number on the PPU screen, continue operation
after eliminating the alarm via theResetkey.
Case1
The machine data is lost if the alarm numbers 004060/004062/004065

appear; in this case, it is necessary to back up the data and restart after
power-off to check whether the fault has been eliminated.
page 16
Service case
of hardware
fault
Case2
If the fault isPress the axis + (or axis-) key, screen coordinates
change but the machine does not move.
Case5
Check whether the settings of machine data MD34000 are correct (the
machine deceleration switches are not available when 34000=0).
Check whether the PPU is in the program test

state.
1. Whether the indicator light of the
"Program test" key on MCP is on (it should not
be on).
2. Whether the "PRT" indicator on the PPU
screen is activated (it should not be activated).
Case6
Check whether the settings of machine data MD34060 are correct.

Check whether the encoder corresponding to the feed axis and its related
connections are damaged.
If the fault isPress the axis + (or axis-) key, the machine can
move until the hardware limit switch alarm appears.
Check whether the machine deceleration switches and their related

connections are broken.
Case4
If the fault isPress the axis + (or axis-) key, the machine alarm
20002 appears after exiting the slowdown switch.
Check whether the machine approaching switch and its related connections
are damaged.
Check whether the settings of machine data MD30130/MD30240/

MD30350 are correct.
1. Feed axis MD30130=2 / MD30240=3
2. MD30350=0
Case3
If the fault isPress the axis + (or axis-) key, the machine moves
only a short distance.
If the fault isPress the axis + (or axis-) key, the machine is always
moving in the opposite direction.
Case7
If the fault isPress the axis + (or axis-) key, the start point and
automatic processing program are running normally, but the
system does not respond when returning to the reference point.
Check whether the settings of machine data MD30200 are correct (it
cannot return to the reference point when 30200=0).
Check whether the machine deceleration switches can bounce.

Check whether the machine deceleration switches and their related
connections
are broken.
page 17
Service guide
Service case
of hardware
fault
PPU/HMI
fault
Drive
alarm
This section discusses only the Siemens

SINAMICS V60 drive
Fault description:
Fault description:
PPU
button is defect / HMI screen is defect
The system
issues a drive-related alarm.
The V60 drive also issues an alarm, the common alarm numbers are A05/
A06/A07/A08/A09
Diagnostic steps
PLC
PLC
Diagnostic steps
Check whether it is in the crashed state. If so, power off and on, then
PLC DB1600.DBX1.2
check whether the fault still exists.
PLC DB1600.DBX1.4
IGBT overcurrent appears when power is obtained from

SPINDLESBR 42
A05 alarm
the line supply / appears during motor operation.
MINI_HHUSBR 41
Replacement and maintenance are necessary if the fault still exists after the
above operation, because it is probable that the PPU is damaged.
,,
()
Check the U, V, W, PE connections on the drive

1. Whether connections among different phases are short-circuited.
2. Whether the grounding connection is incorrect or has bad grounding.

3. Whether
the connection is damaged.
,,
Power on again and observe whether the fault still exists after verification.
If the fault still exists after the above operation, check the insulation of the
motor and see if it is damaged. The motor can be changed when necessary.
Then power on again and observe whether the fault still exists.
Replacement
and maintenance are necessary if the fault still exists after
,
,
the above operation, because it is probable that the drive is damaged.
Service guide
page 18
Service case
of hardware
fault
Internal chip overcurrent appears when power is obtained

A06 alarm
A06 from
/
/
the line supply
appears during motor
operation.
connections are incorrect.
Check the signal cable between the motor and the drive (the encoder
from
the drive to the motor)
()
1.
Whether the internal cable connections have faulty contacts.
2. Whether the cable shielding is poor.
3. Whether the shielded ground cable is connected correctly.
Power
on again and observe whether the fault still exists after verification.
1. Whether
connections
between different phases
are short-circuited.
2. Whether
a U,
V, W phase is disconnected.
3. Whether
the grounding connection is
incorrect or has bad grounding.
4. Whether the connection is damaged.
The interface circuit of the encoder must be checked if the fault still exists
after the above operation.
Power on again and observe whether the

fault still exists after verification.
If the fault
still exists after the above operation, check the insulation of the
,,
motor and
see if it is damaged. The motor can be changed when necessary.
,
Then power on again and observe whether the fault still exists.
,,
the above
operation, because it is probable that the drive is damaged.
A07 alarm The ground circuit is short-circuited appears when

power is obtained from the line supply / appears during
motor operation.
A07
TheUencoder
U/V/W
A08
alarm
A08
/ V / W
the
above operation, because it is probable that the encoder on the drive
,,
is
damaged.
A09 alarm The encoder TTL has pulse faults.
A09
cable
TTL
Check
the signal
between the motor and the drive (the encoder
from the drive to the motor)
()
1.
Whether the connection of the encoder cable is correct.
2.
Whether the internal cable connections have faulty contacts.
3.
Whether the cable shielding is poor.
4. Whether the shielded ground cable is connected correctly.

1. Whether
connections
among different phases are short-circuited.
The
interface circuit of the encoder must be checked if the fault still exists
after the above operation.
the above operation, because it is probable that the IGBT module in the
,
drive is ,
damaged.
,
Replacement
the above operation, because it is probable that the encoder in the drive
is,,
damaged.
Replacement
808D
turning
and milling
page
19
Service
guide
Service case
of hardware
fault
Overload
Fault description:
The machine cannot move or moves difficultly because of overload (the
drive may issue an overload alarm).
Diagnostic steps
Check whether the guide lubrication is sufficient
1. Whether the tubing/nozzle is unimpeded.
2. Whether the setting of the lubrication interval time is sufficient (the
interval should not be too long).
Stop the machine and check whether the guides / the screw are blocked by
the machining waste. If so, it may need proper cleaning.
Check the connection of the shaft coupling
1. Whether the connection is too tight.
2. Whether the connection is concentric.
Service guide
page 20
Notes
page 21
Service guide
Notes
Service guide
page 22
Service case
of PLC alarm
We provide guidance in analyzing and diagnosing alarms caused by the

standard PLC in the 808D which are only for Siemens service engineers,
OEM service engineers and Siemens authorized service engineers.
Turning/milling
general alarms
Case 1
Case 2
Case 3
Case 4
Case 5
700010
700012
700014
700015
700016
Case 6
700018
Go to page 28
Case 7
700021
Go to page 29
Case 8
700027
Go to page 29
Case 9
700029
Go to page 30
Case 10
700030
Go to page 30
Case 11
700060
Go to page 31
Go to page 26
Go to page 26
Go to page 27
Go to page 27
Go to page 28
End
page 23
Service guide
Service case
of PLC alarm
Specific
milling
alarms
Case 1
700019
Go to page 32
Case 2
700020
Go to page 32
Case 3
700031
Go to page 33
Case 4
700032
Go to page 33
Case 5
700033
Go to page 34
Case 6
700034
Go to page 34
Service guide
Case 7
700035
Go to page 35
Case 8
700036
Go to page 35
Case 9
700059
Go to page 36
End
page 24
Service case
of PLC alarm
Specific
turning
alarms
Case 1
700013
Go to page 37
Case 2
700017
Go to page 37
Case 3
700022
Go to page 38
Case 4
700023
Go to page 38
Case 5
700024
Go to page 39
Case 6
700025
Go to page 39
Case 7
700026
Go to page 40
Case 8
700028
Go to page 40
End
page 25
Service guide
case
Service
of PLC alarm
700010
Name
of alarm:
HHU is active
PLC information
PLC
PLCAddress
of PLC: DB1600.DBX1.2
Name of subprogram: MINI_HHU(SBR 41)
DB1600.DBX1.2
PLCPLC
DB1600.DBX1.2
MINI_HHUSBR
MINI_HHUSBR
4141
Alarm comment
It
is not a fault, the alarm acts as a reminder and points out that the
handwheel is activated.
,,
,,
(Conditions for the alarm to appear: The handwheel function has been
()
()
activated
and the axis selection operation is already in progress.)
Processing method
No
special action is required; the alarm will disappear after cancellation
700012
Name
of alarm:
Spindle in braking progress
PLC information
Address
of
PLC: DB1600.DBX1.4
PLC PLC
Name of subprogram: SPINDLE(SBR 42)
DB1600.DBX1.4
PLCPLC
DB1600.DBX1.4
SPINDLESBR
SPINDLESBR
4242
Alarm comment
It
is not
a fault, the alarm acts as a reminder and points out that the spindle
is braking.
,,
,,
,
,
Processing method
Please
wait for the end of spindle braking, the alarm will disappear.
of the handwheel function / cancellation of the handwheel selection.
,
,
,
,
Service guide
page 26
Service case
of PLC alarm
700014
700015
Name of alarm:
Name
of alarm:
Gear-change timeout
PLC information
PLC information
PLCAddress
Name of subprogram: GearChg1_Auto(SBR 49)
PLC
Address
PLC
PL
PLCDB1600.DBX1.2
DB1600.DBX1.4
PLC
SPINDLESBR 41
42
MINI_HHUSBR
PL
Name of subprogram: GearChg1_Auto(SBR 49)
PLC DB1600.DBX1.2
MINI_HHUSBR 41
Alarm comment
Alarm comment
Fault, the spindle shift time is beyond the permitted limit.
Fault,
the control cannot accept the gear level signal / the control accepts
the wrong gear level signal.
,,
,,
,
()
,,
()
Check the related parts of the gear level signal
Check whether the gear-change monitoring time of MD14510[x] is set too
1.Use
PLC monitoring to detect if there is an input signal at the gear level
signals relevant input points.

,
,
the back of the
2.Check
whether the input terminals of
the interface on
PPU are damaged/loose or the wiring is damaged.
Check whether the spindle gearbox has mechanical problems.
Processing method
Processing method
Check whether the spindle gearbox has mechanical problems.
Gear level position error
low.
page 27
Service guide

Service case
of PLC
alarm
700018

700016
Name of alarm:
Drives not ready
PLC information
PLC information
PLC PLC

PLC PLC

PLC
PLC
Address
PLC
PLC
DB1600.DBX2.2
PLC
Name
ofDB1600.DBX2.2
subprogram: COOLING(SBR 44)
PLC DB1600.DBX2.2
PLC
DB1600.DBX1.2
PLC
DB1600.DBX1.44444
COOLINGSBR
COOLINGSBR
PLCAddress
DB1600.DBX2.0
PLC
DB1600.DBX2.0
NamePLC
of subprogram:
EMG_STOP(SBR 33)
LC DB1600.DBX2.0
PLC DB1600.DBX1.2
EMG_STOPSBR
3333
EMG_STOPSBR
EMG_STOPSBR
33
Alarm comment
MINI_HHUSBR
41
Cooling motor overload
LC
Name
of alarm:
Fault, the drive is not ready for operation or preparation.

,
Note:,
This
alarm always appears for an "emergency stop".
Processing method
PLC
COOLINGSBR
44 41
Alarm
comment
MINI_HHUSBR
SPINDLESBR
42
PLC
Fault, cooling motor overload, cooling fluid function cannot be used

,,,
,,,
normally,
the system issues an alarm.
,,,
,,
,,
Check whether the cooling motor's overload protection switch is operable.
()
,
Processing method
,,
Check whether an emergency stop alarm has caused this alarm.
()
Check the drive
1. Whether the terminal of X6 is tight / wiring is loose
Check
thePPU
terminal
of
X102
PPU
X102
X102on the back of the PPU

1.X61.X6
/
65 /
/and
65
or disconnected
/ 65 enable
M24 pins are /faulted.
1. Whether
connection
pin 7 is loose/disconnected.
1.
7
/
1.
7the
/ of
M24
aM24
2. Whether
drive
alarm exists / no startup.
pin
100V
is connected
normally with 0 V.
2. Confirm
that
PPU
2.
10 X102
2.
10
0V
X6
/
65
2.
/
2.
//
3. Whether
the drive is damaged.
,
,
,
1. 7 /
2. 10 0V
3.
3.
M24
/
Service guide
page 28
of PLC alarm
700021
Service case
700027
Name of alarm:
Name of
alarm:
Lubricant liquid position in low level
Approach ref point again after rot.
PLC
monitoring
PLC
PLC information
PLC DB1600.DBX2.5
PLC DB1600.DBX3.3
PLC information
AXIS_CTLSBR 46
LUBRICATSBR 45
Address of PLC:
PLC DB1600.DBX2.5
PLC
AddressPLC
of PLC:
DB1600.DBX3.3
Name ofPLC
subprogram:
AXIS_CTL(SBR 46)
DB1600.DBX1.2
Name of subprogram: LUBRICAT(SBR 45)
PLC
DB1600.DBX1.2
Alarm comment
MINI_HHUSBR 41
,,,
Processing,,
method
()
Check whether the lubricating oil level is too low and add lubricating oil in
PPU
time.
1. /
,()
Fault caused by a drive stage loss (this usually occurs during motor
,
highspeed operation ).
The result
is that
the running program is terminated and the
reference
points are lost.
Fault, the lubricating

oil level in the oil box is lower than the lowest set
value and this results in the alarm; it may cause mechanical damage if
not corrected
in
time.
Check the relevant

terminals on the back of the PPU
2. 10 0V
1. Whether
the input point is damaged/loose.
2. Whether pin10 is connected normally with 0 V.
PLC DB1600.DBX1.4
Alarm MINI_HHUSBR
comment
41 42
SPINDLESBR
,,
X6 24V 24
()
1.
,
of the X6 cable on the drive
Check 2.
the +24 V, Z-M,/M24
,,
Processing method
1.Whether the connection is correct.

the connection has been cut / damaged.
2.Whether
Power
on again and observe whether the fault is eliminated after power off.
,

,
,
You can
reduce the machining speed in the permitted range.
,,
Replacement and maintenance are necessary if the fault occurs frequently,
because it is probable
that
the drive
has a problem.
page 29
Service guide
Service case
of PLC alarm
700029
PLC
Name of alarm:
PLC
PLCReminding
DB1600.DBX3.5
information
PLC
for
1st service plan
PI_SERVICESBR
46
PLC
DB1600.DBX3.5
PLCPLC
DB1600.DBX3.5
PI_SERVICESBR
46
information
PI_SERVICESBR
46
PLC
700030
PLC
Name
of alarm:
PLC
PLCfor
DB1600.DBX3.6
Alarm
1st service plan
PLC
PI_SERVICESBR
46
PLC
DB1600.DBX3.6
PLC information
PLC DB1600.DBX3.6
PI_SERVICESBR
46
Address
PI_SERVICESBR
46
PLC
PLC
MINI_HHUSBR 41
,
Alarm comment
,
,
,
It is not a fault, the alarm acts as a reminder. The appearance of this
,
alarm shows that the reminding information for the 1st service plan which
PLC
DB1600.DBX1.4
PLC
DB1600.DBX1.2
,
Alarm
comment
SPINDLESBR
42
MINI_HHUSBR
41
,
,
It is
not a fault, the alarm acts as a reminder. The appearance of this
,
,
alarm shows that the reminding information for the 1st service plan which
,
is
set
ahead of time has arrived, please execute the relevant service plan
Address of PLC: DB1600.DBX3.5

PLC
DB1600.DBX1.2
Name
of subprogram: PI_SERVICE(SBR 46)
is set ahead of time is arriving.
,
,,
Processing method
preparations.
,
()
,
Press
theTask completedsoftkey on theService
,
plan
interface after executing the relevant service
plan to eliminate the alarm.
Note: The steps on the "Service plan" interface are as follows
time.
same
PPU
+
2.1.
PressPPU
theService
plansoftkey
on the PPU.
2.
Service
guide
PLC
,
, ,
1.
Press
theShift
+ Diagnosis
buttons
at the
1.
PPU
+
+
PLC
,
,,
,,
Processing
method
to eliminate the alarm.
immediately.
()
,
Check
the predetermined service maintenance plan and make the relevant
,
PPU
PPU
Task completedsoftkey on the PPU
Press
PPU the
Name of subprogram: PI_SERVICE(SBR 46)
+
1. PPU +
+
2. PPU
2. PPU
page
30
Service case
of PLC alarm
700060
,
PRT
,
PRT
Name
of alarm:
PLC
Channel
not in reset, change PRT not possible.
PLC
PLC
DB1600.DBX7.4
PLC
information
MCP_NCKSBR
37
PLC
DB1600.DBX7.4
PLC
PLC
MCP_NCKSBR
37
Address
PLC
DB1600.DBX1.2
Name
of
subprogram:
MCP_NCK(SBR
37)
PLC DB1600.DBX1.4
SPINDLESBR 42
MINI_HHUSBR 41
Alarm comment
,,
,
Fault,
theProgram testsoftkey to
,,
change
this state is not available
during the program operation so the
system
must first be switched to the
,,
Resetstate.
()
,,
,
Processing method
Press theAlarm cancelbutton to cancel the alarm,
,
,
the program will continue.
You can also press theResetbutton to cancel the alarm.
(Note: the implemented program is also reset at this time.)
page 31
Service guide
Service case
of PLC alarm
700019
700020
Name of alarm:
Name
of alarm:
Coolant liquid position
in low level
Lubricating motor overload
PLC information
PLC information
of
PLC
DB1600.DBX2.4
PLC
PLC
name of subroutineLUBRICATSBR 45
PLC

PLC
DB1600.DBX1.2
Name
of subprogram: COOLING(SBR 44)
PL
PLC
DB1600.DBX1.4
PLC
DB1600.DBX1.2
Alarm
comment
SPINDLESBR
42
MINI_HHUSBR
41
MINI_HHUSBR 41
Alarm comment
PL
Fault, lubricating motor overload, lubricating fluid function cannot be used

normally, the system issues an alarm.
Fault, the coolant liquid position in the machine is lower than the lowest
set value and this alarm is issued; it can cause mechanical damage if not
corrected in time.
,,
Processing method
()
Processing
method
,,
,,
,
()
Check
whether the motor's lubricating overload protection switch is
operable or not.
Check whether the lubricating oil level is too low and add
lubricating oil in time.
Check terminal X102 on the back of the PPU
Check the relevant terminals on the back of the PPU

1. Whether the input point is damaged/loose.
2. Whether pin 10 is connected normally to 0 V.
,

disconnected.
,
,
1. Whether the connection of pin 6 is loose/
2. Whether pin10 has been connected normally to 0 V.
Service guide
page 32
Service case
of PLC alarm
700031
700032
Name of alarm:
Name of alarm:
PLC Magazine not in spindle pos. or original pos.

PLC
PLC
Magazine
PLC in spindle pos. and original pos.
PLC DB1600.DBX3.7
PLC information
DB1600.DBX3.7
PLC PLC
PLC
DISK_MGZ_MSBR
60 60
DISK_MGZ_MSBR
PLC PLC
DB1600.DBX3.7
DB1600.DBX3.7
Name of subprogram: DISK_MGZ_M(SBR 60)
DISK_MGZ_MSBR
DISK_MGZ_MSBR
60 60
PLC DB1600.DBX4.0
PLC information
DB1600.DBX4.0
PLC PLC
PLC
DISK_MGZ_MSBR
60 60
DISK_MGZ_MSBR
Address
PLC PLC
DB1600.DBX4.0
DB1600.DBX4.0
DISK_MGZ_MSBR
DISK_MGZ_MSBR
60 60
,,
,,
Fault, the magazine is not in the spindle position or the original position,
the changing of tool is stopped at this time.

,,
,,
Processing method
,
,
Fault, the system detects that the magazine is in the spindle position and
the
original position; the action of the magazine is stopped at this time.
,
,
Processing method

PPUCheck
X101
X101
on the back of the PPU
PPUterminal
X101
1. Use
the PLC status
monitoring
to detect the input
1.1.
PLC
I1.3
/ I1.3
I1.4 /
PLC
I1.4
state
of
I1.3 / I1.4

PPU
PPU
X101X101
2.
5
2.
5 6
2. Whether
the connections/ of
pin 5 and pin 6 are
1.
1.
PLC
I1.3 /I1.3
I1.4/
I1.4
3.
10PLC
0V
loose/disconnected.
3.
10
0V
10 is connected
normally to 0 V.
2.
2.
53.Whether
56
6 pin
/
/
Check
whether
the
magazine
air pressure is low.
3.
3.
10
10
0V
0V
Check
PPU terminal
X101
X101
onX101
the back of the PPU
PPU
1.
PLC
I1.3 / I1.3
I1.4
1.1.
Use
the
PLC
status
monitoring
to /
detect
the
PLC
I1.4
state
of
I1.3 / X101
I1.4 X101
input
PPU
PPU
2.
5
/
2.2.
Whether
the6connections
of pin
5 and pin 6
1.
1.
PLC10PLC
I1.3 /I1.3
I1.4/
I1.4
3.
0V
are
loose/disconnected.
3.
10
0V
2.
5 56 pin
6
/
/ to 0 V.
3.2.
Whether
10
is connected
normally
3.
3.
10
10the
0V
0V
Check
whether
test
switches
of the magazines extrusion limit and
Alarm comment
Check whether the test switches of the magazines extrusion limit and
withdrawal limit are faulty.
Note: Press the "Reset" button to eliminate the alarm after the
magazine has returned

to the
correct position.
808D turning
and milling
Alarm comment
withdrawal limit are faulty.
Note:
Press the "Reset" button to eliminate the alarm after the
magazine has returned to the correct position.
page
33
Service
guide
Service case
of PLC alarm
700033
700034
Name of alarm:
,
,
,
Magazine turn key when magazine
,
or sp. not ready
Name of alarm:
,
,
,
Block
search, tool in spindle <> programmed tool
PLC
PLC
DB1600.DBX4.1
PLC
PLCAddress
DB1600.DBX4.1
DB1600.DBX4.1
Name
of subprogram: DISK_MGZ_M(SBR
PLC
DB1600.DBX4.1
DISK_MGZ_MSBR
60
DISK_MGZ_MSBR
DISK_MGZ_MSBR
60
6060)
DISK_MGZ_MSBR
60
Alarm comment
PLC
DB1600.DBX4.2
PLC
PLCDB1600.DBX4.2
DB1600.DBX4.2
Address
Name
of
subprogram: DISK_MGZ_M(SBR 60)
PLC
DB1600.DBX4.2
DISK_MGZ_MSBR
60
DISK_MGZ_MSBR
DISK_MGZ_MSBR
60
60
DISK_MGZ_MSBR
60
Alarm comment
PLC
PLC information
PLC
PLC
PLC
Fault, theMove magazinebutton is pressed when the magazine or the
,
,
,
spindle is not ready; the result is that the magazine cannot move.
,
Processing method
Press theResetbutton to cancel the alarm, then continue.
,
,
,
NoteThe magazine cannot be moved in the following cases
,
1. The spindle is turning in the positive direction.

2. The magazine is executing the forward rotation / reverse rotation
command.
3.
The spindle is executing the tool-release command.
4. The emergency stop state is activated.
Service guide
PLC
information
PLC
PLC
PLC
Fault, the spindle tool number is not equal to the program tool number;
,
,
,
the
result is that an alarm is issued and the program cannot be executed.
,
,
,
,
,
Processing method
Make sure that you have used the correct "Program search" method to
restart
the program.
Check whether the tool number selection in the current program which is to
be
activated is consistent with the current spindle load tool.
Cancel
this alarm by pressing theResetbutton after making sure that the
,
,
,
entire information is correct.
,
page 34
Service case
of PLC alarm
700035
700036
Name of alarm
Name of alarm
Spindle not reach tool-release pos. in time
Spindle not reach tool-lock pos. in time
PLC information
PLC information


Alarm comment
Alarm comment
Fault, the tool-release process takes longer than the monitoring time; this
results in the failure of the spindle tool release.
Fault, the tool-lock process takes longer than the monitoring time; this
results in the failure of the spindle tool lock.
Processing method
Processing method

1. Use the PLC status monitoring to detect the input
state of I1.5
2. Whether the connections of pin 7 are loose/
disconnected?

1. Use the PLC status monitoring to detect the
input state of I1.6.
2. Whether the connections of pin 8 are loose/disconnected.
3. Whether pin 10 is connected normally to 0 V.
Check whether the setting of the tool-release monitoring

timer (T19) in the PLC is correct.
Check whether the setting of the tool-lock monitoring

timer (T20) in PLC is reasonable.
Check whether the air pressure is sufficient.

Check whether the spindle tool-release switch is normal.
Note: Press theResetbutton to eliminate the alarm after eliminating
the actual fault.
Check whether the air pressure is sufficient.

Check whether the spindle tool-lock switch is normal.
Note: Press the "Reset" button to eliminate the alarm after eliminating
the actual fault.
page 35
Service guide
Service case
of PLC alarm
700059
,
Safety door not closed, NC start
not possible.
PLC
PLC information
PLC
PLCAddress
DB1600.DBX4.1
Name of subprogram: AUX_MCP(SBR 60
20)
DISK_MGZ_MSBR
PLC DB1600.DBX4.2
DISK_MGZ_MSBR 60
Name of alarm:
Alarm comment
Fault, running the program without closing the safety door; the result is
,
that the program cannot be executed.
,
,
Check whether the safety door is closed (if using
Processing method
the safety door control key on the MCP, please

,
check whether this button is activated).
If the safety door has been closed, please check the following:
1. Whether the connections of pin 7 are loose/disconnected.
Check
whether the door-closed limit switch is normal.
Note: Press theResetbutton to eliminate the alarm
after eliminating the

actual fault.
Service guide
page 36
Service case
of PLC alarm
700013
700017
,
Name
of alarm
Operate
chuck when sp. or part prog. is running
,
Name
of alarm
Operation while chuck is not locked
PLC
PLC
PLC information
PLC DB1600.DBX1.5
Address
of PLC: DB1600.DBX1.5_TSBR 56
Lock_unlock
Name of subprogram: Lock_ unlock _T(SBR 56)
PLC information
PLC DB1600.DBX2.1
Address
MAINOB1
Name of subprogram: MAIN(OB1)
Alarm comment
,,
Fault, the chuck is not locked tightly and the cycle start as well as the
spindle forward/reverse operation is not permitted.
Processing
method
Alarm comment
,
Fault, noChuck openoperation when spindle or program is running.
Processing method
Check
the MCP "Chuck open" indicator light
whether
MCP
is on.
Check
whether the actual machine parts are clamped in the chuck.

PPUthe
X102of pin 5 are loose/

1.
Whether
connections
1. 5 /
disconnected.
2.2.
Whether pin1010
is connected
normally to 0 V.
0V
808D
turning and milling
The
fault causes the issuing of this alarm. Please notice
that there is no
,
chuck operation when the spindle / program is running.
Press theAlarm cancelbutton to cancel the

alarm,
the action will continue.
,
You can also press theResetbutton to cancel the alarm.

(Note: The action is also reset at this time.)
page
37
Service
guide
Service case
of PLC alarm
700022
700023
,
,
Name
of alarm:
,
,
Programmed
tool num. > max. tool number
PLC
Name
of alarm:
,
Turret
motor overload
PLC
PLC
PLC
PLC information
PLC information
PLC
PLC
PLC
PLC
DB1600.DBX2.6
PLCPLC
DB1600.DBX2.6
MAINOB1
MAINOB1
PLC DB1600.DBX4.1
Name
of subprogram: MAIN(OB1)
DB1600.DBX2.7
PLC PLC
DB1600.DBX2.7

MAINOB1
PLC
DB1600.DBX4.1
MAINOB1
PLC
DB1600.DBX4.2
Name
of
subprogram:
MAIN(OB1)
DISK_MGZ_MSBR
60 60
DISK_MGZ_MSBR
DISK_MGZ_MSBR 60
Alarm comment
Alarm
comment
PL
,,,
Fault,
the turret motor is overloaded, the function cannot be used normally,
,,,
,
,
Fault,
because
the program is incorrect.
the
system issues the alarm; the result is that all operations are
,
not
available.
,
,
Check
whether the motor overload protection switch
,
,
Check
the content of the machining program, then set the program tool
PPU
Check
PPUterminal
X102
X102
onX102
the back of the PPU
1.1.
Whether
the connections
of pin 2 are
2
/
1.
2
/
loose/disconnected.
2.
10
0V
2.
10
0V
normally with 0 V.
2. Whether pin 10 is connected
Processing
method
Processing method
number according to actual situation.
Is operable.
page 38
Service guide
Service case
of PLC alarm
700024
700025
PLC
Name of alarm
Name of alarm
PLC
Max. tool number setting error
No position signals from turret
PLC DB1600.DBX3.1
MAINOB1
PLC information
PLC DB1600.DBX3.0
MAINOB1
PLC information


,
Alarm comment
4 6
,
Alarm comment
Fault, the setting of the max. tool number in the system is not correct.
The correct setting number is4 or 6
Processing method
MD14510[20] ()
Fault, no position signals can be detected from the turret.

Processing method
Check whether the settings of parameters MD14510[20] (max. tool number)

Check the tool code wheel
1.
are correct.
1.Whether the tool signal point is damaged.
2.
2.Whether the tool itself is faulty.
808D turning
and milling
PPU I/O
Check the corresponding
terminals of the
1.
/
I/O interface on the back of the PPU
2.
/
1. Whether the
connections are disconnected/loose.
the terminals
are damaged/loose?
2. Whether
3.
M
0V
3. Whether the point of mon. terminal is connected normally

to 0 V.
39
page
Service
guide
Service case
of PLC alarm
700026
700028
,
Not
able to find expected tool in
monitor
time
,
Tool is,
not locked
PLC
PLC
PLC
PLC
DISK_MGZ_MSBR 60
DISK_MGZ_MSBR
60 60
DISK_MGZ_MSBR
Fault,
the alarm appears because no tool position is detected in the time
Fault,
the tool-locked signal is not in the system and therefore the tool is
limit.
not locked tightly.

,
Check the tool code wheel

the tool signal point is damaged.
1.Whether
2.Whether the tool itself is faulty.
Check
the tool-locked signal
Name of alarm:
PLC information

PLC DB1600.DBX4.1
Name
of subprogram: MAIN(OB1)
Alarm comment
,
Processing method
Check the corresponding terminals of

the I/O interface on the back of the PPU
1. Whether the connections are disconnected/loose.
2. Whether the terminals are damaged/loose.
3. Whether the point of the mon. terminal are connected
normally
to 0 V.
Check whether the settings of MD14510[22] are correct (the
value
can be increased
appropriately).
Service guide
Name of alarm:
PLC information

PLC
PLC
DB1600.DBX4.2
NameDB1600.DBX4.1
of subprogram:
Turret3_CODE_T(SBR 53)
Alarm comment
Processing method
PL
1.Whether the relevant input terminals on the back of the PPU are loose/
,
damaged.
2.Whether the connections of relevant input terminals on the back of the
PPU are
damaged/disconnected.
3. Use the PLC monitoring to detect whether the corresponding input point
of this signal has input signals.
page 40
Notes
page 41
Service guide
Notes
Service guide
page 42
Notes
page 43
Service guide
Notes
Service guide
page 44
Everything ever wanted to know about SINUMERIK 808D:

www.siemens.com.cn/808D
Everything about shopfloor manufacturing:
www.siemens.com/cnc4you
Everything about the SINUMERIK Manufacturing Excellence portfolio of services:
www.siemens.com/sinumerik/manufacturing-excellence
Information about CNC training:
www.siemens.com/sinumerik/training
Siemens AG
Industry Sector
Motion Control Systems
P.O.Box 3180
91050 ERLANGEN
GERMANY
Subject to change without prior notice

Order No.:
Dispostelle 06311
W/35557 WERK.52.2.01 WS 11113.0
Printed in Germany
Siemens AG 2012
The information provided in this brochure contains merely general

descriptions or characteristics of performance which in actual case of
use do not always apply as described or which may change as a result
of further development of the products. An obligation to provide the
respective characteristics shall only exist if expressly agreed in the
terms of contract.
All product designations may be trademarks or product names of
Siemens AG or supplier companies whose use by third parties for
their own purposes could violate the rights of the owners.

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Training handbook

SINUMERIK 808D Service

Please refer to the

808D turning and milling

808D turning and milling

808D turning and milling

The system issues a battery alarm.

Replace the battery when the system

If the indicator light is off:

power of the system will soon be used up. In this

808D turning and milling

Check whether the interface of

(Check whether the fault is

resolved by replacement with a

are off and all the operations are

808D turning and

(Common buttons with faults: "Cycle

Check the state of the PLC input/output.

this case, make further observation

to see if there are other

808D turning and milling

Note: The steps for entering the RS232

a. Using RS232 to establish the PLC programming tool connection

Data communication is not possible via RS232.

5. Press theConnect. ONsoftkey on the PPU

3. Whether the X2 interface on the PPU panel is loose.

b. Using RS232 to establish the WINPCIN connection

4. Whether the cable of RS232 is damaged.

5. Whether the RS232 interface of the PC terminal is damaged.

closed otherwise this may cause a communication fault.

Please make sure that STEP7 is

808D turning and milling

should not be on).

2. MD30134 - spindle output polarity (set between 0 ~ 2 )

808D turning and milling

screen at the same time.

Check whether the spindle encoder is damaged, replace it with a new

Check whether the handwheel is damaged.

above inspection, because it is probable that the PPU is damaged.

808D turning and milling

If the fault is: The actual direction of motion is opposite to the

Check whether the settings of machine data MD32100 / MD32110 are

2. Whether the "PRT" indicator on the PPU

The operating position of the machine coordinate system is not accurate.

Check whether the settings of machine parameters MD31030/MD31050/

808D turning and milling

tool rotation signal output/

input points interface of the tool signal in place

contact, then power

Check whether the wires between the tool signal input /

ensure that there is an appropriate

Check whether the signal code wheel of the machine is damaged.

808D turning and milling

1. Hardware limit switch alarm appears on the PPU.

The hardware limit switches on the machine must be checked if these

If the fault isThe machine has crossed the hardware limit

Check whether the hardware limit switch connection is short-circuited

The machine data is lost if the alarm numbers 004060/004062/004065

808D turning and milling

Check whether the PPU is in the program test

Check whether the settings of machine data MD34060 are correct.

Check whether the machine deceleration switches and their related

Check whether the settings of machine data MD30130/MD30240/