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808D
Programming Manual
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siemens 808D Training manual

s
Training manual
Sinumerik 808D Service Guide
Version 2013-01
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Service guide 808D
List
s
For
For
For
Service case of
hardware fault
Service case of
PLC alarm
Service case of
NC program
alarm
Go to page 7
Go to page 23
Please refer to the
alarm handbook
End
Service guide
s
Service guide 808D turning and milling
Service case
of hardware
fault
s
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
Case 1
Case 2
Case 3
Case 4
Case 5
Case 6
cannot log
into the system
Battery
alarm
MCP is not
available
MCP
button
press fault
RS232 transmis­sion fault
Spindle
fault
Go to page 7
Go to page 7
Go to page 8
Go to page 9
Go to page 10
Go to page 11
Case 7
Case 8
Case 9
Case 10
Case 11
Case 12
Case 13
Spindle
encoder
alarm
Handwheel
fault
Feed axis
fault
Change of
direction
is not
possible
Position­ing error
Tool
change is
not
possible
Startup process crashes
Go to page 12
Go to page 12
Go to page 13
Go to page 14
Go to page 14
Go to page 15
Go to page 15
808D turning and milling Page 5 Service guide
Service case
of hardware
fault
s
Case 14
Case 15
Case 16
Case 17
Case 18
Hardware
limit switch
fault
Startup
can’t go to
REF. point
PPU/HMI
fault
Drive alarm
Overload
End
Go to page 16
Go to page 16
Go to page 18
Go to page 18
Go to page 20
Service guide Page 6 808D turning and milling
Service case
of hardware
fault
Startup
cannot log
into the system
s
Battery
alarm
Fault description: Cannot log into the system after power on; normally black screen, no display at all.
Diagnostic steps
Check the power indicator light on the PPU panel: If the indicator light is on: Power off and check whether
the CF card is inserted cor­rectly, then power on and restart, observe whether the fault is eliminated.
Replacement and maintenance are necessary if the fault still exists after the above inspection, because it is probable that the PPU is damaged.
808D turning and milling Page 7 Service guide
If the indicator light is off:
Check the X1 power plug interface on the back of the PPU
1. Whether the connection is loose.
2. Whether the 24 V terminal matches the interface.
3. Whether 24 VDC is available by meas­uring with a multi- meter.
Fault description: The system issues a battery alarm. tput.
Diagnostic steps
Replace the battery when the system
issues the alarm “2100”.
Remove the battery and replace it ,in the power-on state.
Note Battery: Lithium 3V DC 950mAH Life time: 3 years Order number: 6FC5247-0AA18-0AA0.
Battery alarm number 002100: This alarm indicates that the battery power of the system is low. In this case, replace the battery within six weeks, otherwise it may cause data loss.
Battery alarm number 002101: This alarm indicates that the battery power of the system will soon be used up. In this case, replace the bat­tery immediately, otherwise it may cause data loss.
Service case
of hardware
fault
s
MCP is not
available
Fault description:
1. MCP does not respond after power on, all the indicator lights are off and all the operations are not available.
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.
Diagnostic steps
Check the connections between the MCP and the PPU
1. Whether the connections are disconnected.
2. Whether the connections are damaged or have a faulty contact. (Check whether the fault is resolved by replacement with a new wire.)
Check whether the interface of X30 on the back of the PPU is damaged or there is a faulty con-
tact.(Check whether the fault is resolved by replacement with a
new wire.)
A PLC program fault can also cause flashing of all the MCP indicator lights. In this case, check whether there is problem in the PLC program.
Replacement and maintenance are necessary if the fault still exists after the above inspection, because it is probable that the PPU or MCP is damaged.
Check whether the interface of X10 on the back of theMCP is damaged or there is a faulty con-
tact.(Check whether the fault is resolved by replacement with a
new wire.)
Service guide Page 8 808D turning and milling
Service case
of hardware
fault
s
MCP
button
press fault
Fault description: Some buttons on the MCP do not respond.
(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
the buttons changes
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.
If the PLC status bit correspond­ing to the buttons does not change
Replacement and maintenance are necessary because the MCP buttons are damaged.
Note: The steps for entering the PLC status monitoring interface on the PPU:
1. Press the “Machine” button on the PPU.
2. Press the “Shift+ Alarm” buttons at the
same time.
3. Press the “PLC” softkey on the PPU.
4. Press the “PLC status” softkey on the
PPU.
Example of PLC status monitoring
Address of the “Reset” button:
DB1000.DBX3.5
Address of the “Cycle start”
button: DB1000.DBX3.3
+
808D turning and milling Page 9 Service guide
Service case
of hardware
fault
s
RS232 transmis­sion fault
Fault description: Data communication is not possible via RS232.
Diagnostic steps
Check the RS232 communication settings on the PPU
1. Whether the communication is activated.
2. Whether the communication parameters match the PC termi­nal.
3. Whether the X2 interface on the PPU panel is loose.
4. Whether the cable of RS232 is damaged.
5. Whether the RS232 interface of the PC terminal is damaged.
Replacement and maintenance are necessary if the fault still exists after the above inspection, because it is probable that the PPU is damaged.
Note: When you use WINPCIN, please make sure that STEP 7 is closed otherwise this may cause a communication fault.
Note: The steps for entering the RS232 communication interface on the PPU:
a. Using RS232 to establish the PLC programming tool connection
1. Press the “Machine” button on the PPU.
2. Press the “Shift+ Alarm” buttons at the same time
3. Press the “PLC” button on the PPU.
4. Press the “STEP 7 connect” softkey on the PPU.
5. Press the "Connect. ON" softkey on the PPU after setting up the communications data.
b. Using RS232 to establish the WINPCIN connection
1. Press the “Program management “ button on
the PPU.
2. Press the “RS232” softkey on the PPU.
3. Press the “Setup” softkey on the PPU.
4. Adjust the "Communications settings" parameters until they are exactly the same as the configuration parameters in the com­puter communication software.
Please make sure that STEP7 is closed (OFF) before using
WINPCIN !
+
Service guide Page 10 808D turning and milling
Service case
of hardware
fault
s
Spindle
fault
Fault description:
1. The spindle cannot move, the PPU screen shows the waiting for spindle signal and the screen has no alarm prompt.
2. The screen has spindle values, but the actual spindle cannot move and the screen has no alarm prompt.
3. The spindle angle of rotation is not steady (varies during rotation).
Diagnostic steps
Case1
Check the settings of machine data MD30200 (spindle is set to 1 if it has an encoder, otherwise 0).
Check the spindle interface of X54 on the back of the PPU
1. Whether the interface is loose or damaged.
2. Measure pins 1 and 9 of X54 with a multi-meter after starting the spindle, then observe if there is voltage output.
Check whether the connection cable between the PPU, spindle and encoder is good.
Check whether the settings of machine data MD30130/MD30240/MD30134/
MD32250/MD32260/MD35150 are correct.
1. MD30130 = 1 / MD30240 = 2
2. MD30134 - spindle output polarity (set between 0 ~ 2 ) 0-dual polarity, 1/2-single polarity (depends on the actual situation)
3. MD32250 = 100 / MD32260, it is consistent with actual motor rated speed.
808D turning and milling Page 11 Service guide
If the fault is：The spindle cannot move, the PPU screen shows the waiting for spindle signal.
Check whether the spindle converter shows a fault or not. Replacement and maintenance are necessary if the fault still exists after
the above inspection, because it is probable that the PPU is damaged.
Case2
Case3
If the fault is：The screen has spindle values, but the actual spindle cannot move.
Please check whether the PPU is in the program test state.
1. Whether the indicator light of the "Program test" key on MCP is on or not (it should not be on).
2. Whether the "PRT" indicator on the PPU screen is activated or not (it should not be acti-
Use the diagnostic steps of "Case1" mentioned above to check the spindle if the fault still exists.
If the fault is：The spindle angle of rotation is not steady (varies during rotation)
Check whether there is an interference between the connections (it is better to separate thicker and thinner wires).
Check the interface of X54 on the back of the PPU
1.Whether the interface is loose.
2.Whether the connections have a faulty contact. Please check whether the connection of the spindle converter is
loose or whether the converter is damaged.
Service case
of hardware
fault
s
Spindle
encoder
alarm
Fault description: The spindle cannot move, and the
025000 alarm appears on the screen at the same time.
Diagnostic steps
Check the spindle encoder interface on the back of the PPU.
Check whether the connection of the PPU spindle encoder is damaged or the connection is correct.
Check whether the settings of machine data MD30200/MD30240 in the PPU are correct.
1. MD30200: Spindle is set to 1 if it has an encoder, otherwise 0.
2. MD30240=2
Check whether the spindle encoder is damaged, replace it with a new encoder and test it again.
Replacement and maintenance are necessary if the fault still exists after the above inspection, because it is probable that the PPU is damaged.
Handwheel
fault
Fault description: Handwheel is not available / axis is not selected.
Diagnostic steps
Check whether the process is correct, and confirm whether the feed axis has been selected for operation in the "Handwheel" state.
Use the PLC input/output for monitoring the axis inspec­tion with the selected key.
Check whether the connections on the handwheel are correct, and ob­serve if there are short-circuits to adjacent connections.
Check the X10 interface on the front of the PPU.
1. Whether the connection is loose.
2. Whether the connection is damaged.
3. Check the X10 interface (terminal 5/6) and observe if there is 5 V output.
X10
Check whether the handwheel is damaged.
HANDWHEEL
Replacement and maintenance are necessary if the fault still exists after the above inspection, because it is probable that the PPU is damaged.
Service guide Page 12 808D turning and milling
Service case
of hardware
fault
s
Feed axis
fault
Fault description: The system has completed the state of returning to the reference point
1. The screen can display feed axis data, but the actual machine cannot move
2. The actual direction of motion is opposite to the operational direction of the machine / is opposite to the direction of screen display.
Diagnostic steps Case1
Please check whether the PPU is in the program test state.
1. Whether the indicator light of the "Program test" button on the MCP is on (it should not be on).
2. Whether the "PRT" indicator on the PPU screen is activated (it should not be activated).
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. Replacement and maintenance are necessary if the fault still exists after
the above inspection, because it is probable that the PPU is damaged.
If the fault is：The screen can display feed axis data, but the actual machine cannot move.
Case2
Check whether the connections of the direction keys on the V60 drive are correct. Check whether the wiring of terminal + DIR / - DIR is correct depending on the actual situation.
Check whether the settings of machine data MD32100 / MD32110 are correct.
MD32100：Axis reverse key (The implied value = 1. It is permitted to change to -1 according to the actual situation.)
MD32110：Encoder position feedback polarity key (The implied value = 1. It is permitted to change to -1 according to the actual situation.)
If the fault is: The actual direction of motion is opposite to the operational direction of the machine / is opposite to the direction
of screen display.
808D turning and milling Page 13 Service guide
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