Siemens Sinumerik 840C, SIMODRIVE 611-D, Sinumerik 840CE Diagnostics Manual

SINUMERIK 840C SIMODRIVE 611-D

Diagnostics Guide 09.2001 Edition

User Documentation

Valid for

09.2001 Edition

SINUMERIK 840C SIMODRIVE 611–D

Diagnostics Guide

Alarms 1

Diagnostics on the PLC 2

Error Display on CPU 3

Errors with Function Macros 4

Parameterization Errors

Spindle/Axis 5

Control Drive

SINUMERIK 840C/CE (Standard/Export version)

SIMODRIVE 611–D

Software Version Software Version

1.x

2.x

3.x 1.x

4.x 2.x

5.x 3.x

6.x 4.x

6.4 5.x

SINUMERIK documentation

Printing history

Brief details of this edition and previous editions are listed below. The status of each edition is shown by the code in the “Remarks” column.

Status code in the “Remarks” column:

A New documentation.. . . .

B Unrevised reprint with new Order No.. . . .

C Revised edition with new status. . . . .

If factual changes have been made on the page since the last edition, this is indicated by a new edition coding in the header on that page.

Edition Order No. Remarks

09.95 6FC5198–5AB40–0BP0 A

04.96 6FC5198–5AB40–0BP1 C

08.96 6FC5198–5AB40–0BP2 C

07.97 6FC5198–6AB40–0BP0 C

01.99 6FC5198–6AB40–0BP1 C

09.01 6FC5198–6AB40–0BP2 C

This manual is included in the documentation on CD–ROM (DOCONCD) Edition Order No. Remarks

11.01 6FC5 198–6CA00–0BG2 C

Trademarks

SIMATIC

, SIMA TIC HMIR, SIMA TIC NETR, SIROTECR, SINUMERIKR and SIMODRIVER are trademarks of Siemens AG. All other product and system names are registered trademarks of their respective companies and must be treated accordingly.

For further informationvisit our Internet address: http://www.ad.siemens.de/sinumerik

This publication was produced with Interleaf V 7 The reproduction, transmission or use of this document or its

contents is not permitted wihout express written authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved.



Other functions not decribed in this documentation might be executable in the control. This does not, however, represent an obligation to supply such functions with a new control or when servicing.

We have checked that the contents of this document correspond to the hardware and software described. Nonetheless, differences might exist and therefore we cannot guarantee that they are completely identical. The information contained in this document is, however, reviewed regularly and any necessary changes will be included in the next edition. We welcome suggestions for improvement.

Subject to change without prior notice.

Siemens–AktiengesellschaftOrder No. 6FC 5198–6AB40–0BP2

Printed in the Federal Republic of Germany

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Preliminary notes

This Guide serves as a reference work. It allows the machine tool user:

S to assess irregularities during operation at the machine correctly S to obtain information about the response of the system to the irregularity S to make use of the options for continuing operation after the irregularity

Scope This description lists the diagnostics options of the PLC and the alarms of the

MMC, NCK, servo and drive (SIMODRIVE 611–D) areas.

Sequence In the Diagnostics Guide the alarms are sorted in ascending order of alarm num-

bers. The numbers are not necessarily contiguous.

Safety

Danger

Please assess the condition of your plant carefully against the description of the alarm that has occurred. Eliminate the cause of the alarm and acknowledge it as described. If alarms are ignored, danger to the machine, workpiece, stored settings, and in certain cases, to your health, could result.

Warning

This warning notice means that loss of life, severe personal injury or substantial material damage can result if the appropriate precautions are not taken.

Caution

This warning notice (with warning triangle) means that a minor personal injury can result if the appropriate precautions are not taken.

Caution

This warning notice (without warning triangle) means that a material damage can result if the appropriate precautions are not taken.

Notice

This warning notice means that an undesired event or an undesired state can result if the appropriate notices are not observed.

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Contents

1 Alarms 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Alarm groups 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Alarm numbers/cancellation of alarms 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Display of the alarms in the alarm line 1–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 Display of the alarms as dialog box 1–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 Priority of alarms 1–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.1 Alarm description 1–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 Dialog text 1–223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.1 Notes for the operator 1–223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.2 Listing of dialog texts 1–223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Diagnostics on the PLC 2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Error numbers (ACCU 3 high byte, DB 1 DW 160) 2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Additional error information (ACCU 3 low byte, DB 1 DW 161–163) 2–7. . . . . . . . . . . . . .

3 Error Display on CPU 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Errors with Function Macros 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Parameterization Errors Spindle/Axis 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 Alarms

1.1 Alarm groups

NC alarms The alarms are divided into alarm groups.

S General alarms S Computer link alarms S Axis-specific alarms S Spindle-specific alarms S Channel-specific alarms

At POWER ON RESET (switching on control), all NC alarms are cancelled.

The CANCEL alarms can be deleted in the associated operating area only .

PLC alarms

The PLC alarms are assigned error numbers 6000 to 9999. The alarm text, alarm action and deletion conditions are configured by the machine manufacturer.

MMC alarms

MMC alarms do not interrupt an active NC program. The alarms are acknowledged automatically provided the correct sequence of operations is adhered to or via softkeys.

1 Alarms

9.1.1 Alarmgruppen

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1.2 Alarm numbers/cancellation of alarms

Alarm number

Kind of alarm

1 General alarms 2 to 15 General alarms 16 to 36 Computer link alarms 43 to 1 10 General alarms 1000 to 121 1

1240 to 1251

Axis-specific alarms

1280 to 1371 Axis-specific alarms 1440 to 1971 Axis-specific alarms 2000 to 2193 General alarms 2250 to 2263 Spindle-specific alarms 2270 to 2273 Spindle-specific alarms 2280 to 2283 Spindle-specific alarms 3000 to 3220 General alarms 4000 to 4299 5000 to 5299

Cycle alarms

6000 to 9999 PLC error messages or PLC operational messages 10000 to 12031 Axis-specific alarms 20000 to 20309 Spindle-specific alarms 100000 to 169999 MMC alarms 200000 to 209999 PLC dialogs 210000 to 219999 Free area 300000 to 399999 611D alarms

1 Alarms

1.2 Alarm numbers/cancellation of alarms

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Key

Effect of cancelling alarms

Acknowledgement

An active NC program is not aborted but only stopped. After eliminating the error, it is possible to continue execution of the NC program from the point at which it was stopped.

Reset

Execution of an active NC program is aborted. After eliminating the error, the NC program must be restarted.

POWER ON Execution of the active NC program is aborted. After eliminating the error, the

NC program must be restarted and the reference points must be reapproached. Caution! On switching off the control, the contents of the NCK part program memory are lost.

POWER ON means switching off the control and switching it on again. Please note the information provided by the machine tool manufacturer.

1 Alarms

1.2 Alarm numbers/cancellation of alarms

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1.3 Display of the alarms in the alarm line

Messages from the monitoring system are displayed in the alarm line. Existing comments are overwritten by alarm texts. The alarm line is the second display line from the top.

Machine Parameter Programm. Services Diagnosis

AUTOMATIC

Program stop

M. grp.: 1 Channel: 1

POWER ON

Actual values

Distances to go

Program pointer %1234

N1234

L1234 N1234P12

X 10.789 Y 5.231 Z 210.643

100.000

10.000

200.000

Alarm line

Delete error condition

There are three types of display representation for alarm messages: Types A, B and C.

Example of display Alarm display in sequence order representation Type A:

Machine Parameter Programm. Services Diagnosis

10243 ORD 5 X Illegal pulse multiplication

max. 6 characters for alarm number

max. 5 characters for ordinal number The ordinal number shows the order in which the alarms have occurred.

max. 40 characters for explanatory text (for single-line alarm) max. 100 characters (for two-line alarm)

1 Alarms

1.3 Display of the alarms in the alarm line

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Example of display Alarm display in block number order representation Type B:

Machine Parameter Programm. Services Diagnosis

3000 1 N0045 General programming error

max. 5 characters for alarm number

max. 5 characters for block number E.g.: the error has occurred in block N0045.

max. 38 characters for explanatory text (for single-line alarm)

1 character for channel number

Example of display representation Type C:

Machine Parameter Programm. Services Diagnosis

6000 Hydraulic oil min.

max. 4 characters for alarm number

max. 47 characters for explanatory text (for single-line alarm)

1 Alarms

1.3 Display of t h e a l a r m s i n t h e a l a r m line

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1.4 Display of the alarms as dialog box

The machine tool manufacturer can configure whether the alarm messages are displayed in the alarm line or in a dialog box. MMC messages are displayed as a dialog box.

There are 3 types of dialog box:

Dialog box with The dialog must be acknowledged from a configured application. empty softkey bar

Fig. 1.1 Example 1 dialog box

1 Alarms

1.4 Display of the alarms as dialog box

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Dialog box with OK The dialog box can be acknowledged with the OK key. softkey

Fig. 1.2 Example 2 dialog box

Dialog box with The dialog box can either be acknowledged with the OK key or it can be OK softkey and with the HIDE softkey without being acknowledged.

HIDE softkey

Fig. 1.3 Example 3 dialog box

1 Alarms

1.4 Display of the alarms as dialog box

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1.5 Priority of alarms

Only one alarm can be displayed in the alarm line and the following priorities apply:

Priority

range

Alarm type

0 – 100 Power on 101 – 200 Reset 201 – 300 Cancel 301 – 500 Message 301 – 500 PLC alarm

1000 Diagnosis

Within the alarm groups, the priority is in accordance with the alarm number or priority range, i.e. the lowest alarm number/priority range has the highest priority . The alarm priorities can be configured by the machine tool manufacturer.

An arrow on the right in the alarm line indicates that further alarms exist. These alarms are displayed if you select the alarm overview display in the DIAGNOSIS area.

1.5.1 Alarm description

The alarms are described in a uniform style. The column alarm heading boxes show the alarm number, alarm text and the means of cancellation.

Alarm number Alarm text Means of

cancel.

Scan: Specifies in which state the alarm occurs.

Effect:

Specifies the sphere of influence of processing.

Explanation:

States the reasons for the alarm.

Remedy:

Instructions for eliminating the alarm state.

1 Alarms

1.5.1 Alarm description

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1 Battery: Data loss at power off! Acknowledgement key

POWER ON Cyclic

Data is not battery-backed after power off. During operation: Do not interrupt the production process. Data will be lost if the control is switched off. Run-up: Data has been lost. Obligatory re-installation is activated.

Backup battery is empty. Replace the battery when the control is switched on

If data has been lost the whole NCK/PLC unit must be re-installed.

2 Overtemperature Acknowledgement key

POWER ON Cyclic

The second temperature monitoring threshold has been triggered because the ambient temperature is too high. NC program is not interrupted.

Safe functioning of the hardware can no longer be guaranteed, serious damage to hardware may result. Processing is not interrupted directly. A contact is opened on the CSB which the NC user must use to take the appropriate measures.

A low temperature level will eliminate the error. Switch off control (hardware damage possible).

3 Fan failure Acknowledgement key

POWER ON Cyclic

Fan monitoring is triggered because of incorrect fan functioning. Safe functioning of the hardware can no longer be guaranteed, serious damage to hardware may result.

Processing is not interrupted directly. A contact is opened on the CSB which the NC user must use to take the appropriate measures.

Eliminate the fan fault, e.g. by replacing the fan. Switch off control (hardware damage possible).

4 System of units not allowed POWER ON

S POWER ON S After modification of NC machine data

S Interlocking of NC READY S Interlocking of NC START S Interlocking of Mode Group Ready S Machining stops

An illegal combination of machine data MD 18000 display resolution and MD 5002 input resolution has been selected. Both data must use the same system of units

For rotary axes with a position control resolution smaller than = 0.5  10–4 degrees, the function bit “High-resolution rotary axis” must be set.

Check and correct machine data combinations. Then cancel the alarm with POWER ON.

5 Power failure protection / data loss Acknowledgement key

POWER ON The power failure protection integrated in the software could not be executed correctly because of a hardware

fault. Data loss in the NCK unit.

Obligatory re-installation is activated. The whole NCK unit must be re-installed.

Eliminate hardware fault.

Scan Effect

Explanation Remedy

Scan Effect Explanation

Remedy

Scan Effect

Explanation

Remedy

Scan

Effect

Exlanation

Remedy

Scan Effect

Explanation Remedy

1 Alarms

1.5.1 Alarm description

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6 Start-up due to system error Acknowledgement key

POWER ON Start-up of the control shows that a fatal error was present before reset/power off (e.g. obligatory re-installation is

activated. Alarm 5 can be set in conjunction with alarm 6. EPROM error, DRAM error, processor exceptions). Re-installation is necessary as data loss or corruption is to be expected (no data consistency). The NCK unit must be completely re-installed.

Cause of error can be eliminated as follows: a) Replace hardware b) Report the software error leading to the processor exception to the manufacturer of the control.

7 15 V undervoltage Acknowledgement key

POWER ON Cyclic

Activates 15V voltage monitoring Safe operation of the NC is no longer possible so NC Ready is cancelled. Eliminate hardware fault

8 Wrong axis/spindle assignment POWER ON

S After modification of machine data S On POWER ON

S Interlocking of NC START S Removal of Mode Group Ready S NC Ready relay drops out S Machining stops

The NC machine data for axis assignment MD200* or spindle assignment MD400* have been input incorrectly or transposed. If error in MD 461* C axis definition:

S C axis must not be fictitious (MD 564*, bit 6) S C axis must be defined (MD 564*, bit 7) S Mode group numbers of C axis and spindle must be same

(MD 360*, MD 453*)

Check and correct machine data for axis and spindle assignment. Cancel alarm with POWER ON.

9 Not enough memory for UMS POWER ON

S At POWER ON in normal mode, not in start-up mode

None The RAM area reserved on the NC is too small for the UMS address lists for the modified system area. Describe fewer elements (displays/texts) in modified system area (merge). Applies up to SW 2 only

9 Overflow in altered system area POWER ON

When powering up the control The UMS does not function In the UMS, an altered system area has been configured that exceeds the memory area. Configure UMS properly Applies as from SW 4

Scan Effect

Explanation Remedy

Scan Effect

Explanation Remedy

Scan Effect

Explanation

Remedy

Scan Effect Explanation Remedy Note

1 Alarms

1.5.1 Alarm description

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10 UMS error POWER ON

S At POWER ON S Interlocking of NC START

The UMS loaded in NCK has a faulty internal structure. Reinstall UMS on hard disk. Applies up to SW 2 only

10 Startup after software upgrade POWER ON

S At POWER ON S The NCK–internal static memory has been deleted.

There are two causes for the alarm:

– A new NCK software version has been loaded (only when booting for the first time after software upgrade) – The NCK–internal static RAM has failed (e.g. because of an empty back–up battery); alarm 5 is then dis-

played additionally. The complete NCK unit must be started up again. Applies as from SW 6

11 Undervoltage on secondary side Cancel

POWER ON Cyclic

Short circuit on secondary side or overloading of 5V voltage Caution: The error may have been signalled during initial start-up without the error being present (hardware wiring).

When the error occurs the shutdown routine is activated to achieve a safe state. Restart: Data loss has occurred, obligatory re-installation is activated

Eliminate the hardware error Re-install

20 Cam activation wrong POWER ON

POWER ON

S Interlocking of NC start S Interlocking of Mode Group Ready

Software cams can only be used for linear axes. Correct the PLC user program

26 Part program block >120 char. V.24 POWER ON

S On reading data into the NC via the computer link S Computer link transmission interrupted

S Last block declared invalid

The part program block that has been read in contains more than 120 characters. Only the characters actually stored are counted (no spaces, no CR, etc.)

Divide the block into two or more blocks. The number of the faulty block is displayed. Applies up to SW 2 only

Scan Effect Explanation Remedy Note

Scan Effect Explanation

Remedy Note

Scan Effect

Explanation

Remedy

Scan Effect

Explanation Remedy

Scan Effect

Explanation Remedy

Note

1 Alarms

1.5.1 Alarm description

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27 Data input disabled V.24 POWER ON

S On reading data into the NC via the computer link

No data has been read in

S The “Cycle lock” interface signal (DB 48 D0.11) is present S An attempt has been made to read in NC machine data in normal mode S An attempt has been made to transfer UMS data to the NC although the UMS was not enabled or not plugged

in.

S Reset DB 48 DW 0 bit 11 via PLC STATUS S Enter new NC machine data

Applies up to SW 2 only

29 Block >254 characters V.24 POWER ON

S On reading tool data into the NC via the computer link S Computer link transmission interrupted

S Last block declared invalid

The block read in has more than 254 characters (counting all characters read in, including blanks, CR, LF, etc.) Divide the block into two or more blocks. The number of the faulty block is displayed. Applies up to SW 2 only

30 Part program memory overflow V.24 POWER ON

S While reading programs in via the computer link of the NC S Computer link transmission interrupted

S Last block declared invalid

The maximum memory space for part programs is already assigned

S Delete old programs to release memory for the reading in of new programs. The number of the faulty block is

displayed.

Applies up to SW 2 only

31 No more part program input V.24 POWER ON

S On reading in via computer link

No data has been read in The part program memory available has been used up.

S Read and delete old part programs no longer required in order to provide more memory.

Applies up to SW 2 only

32 Data format error V.24 POWER ON

S On reading data into the NC via the computer link S Computer link transmission interrupted

S Last block declared invalid S The number of decades used after an address is not permissible

S The decimal point occurs in the wrong place S Part programs or subroutines are not defined or concluded correctly (check header)

Check the program to be read in. The number of the faulty block is displayed. Applies up to SW 2 only

Scan Effect Explanation

Remedy

Note

Scan Effect

Explanation Remedy Note

Scan Effect

Explanation Remedy

Note

Scan Effect Explanation Remedy Note

Scan Effect

Explanation

Remedy Note

1 Alarms

1.5.1 Alarm description

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33 Programs different V.24 POWER ON

S On reading part programs into the NC memory via the computer link of the NC

No data is read in/stored If a new program is to be read in with the same program number as one already stored in the NC, the program to

be read in is compared. If they are different, an NC alarm occurs. The point of disagreement is shown in the data input display. The new program is not stored.

Delete the old program or rename it in the NC so that the new program can be read in. Applies up to SW 2 only

43 PLC–CPU not ready for operation POWER ON

S Cyclic or on Restart S Interlocking of NC START

S Interlocking of Mode Group Ready S Interlocking of NC Ready relay S Processing is terminated

S Hardware or software error in PLC or general data interface link S PLC machine data error or not in agreement with user program S Error in the PLC user program S Selection of error fine coding

S Remove cause of error S Check detailed error coding in PLC service menu S Read out ISTACK S Ascertain cause of error using the error list in the installation lists

45 Cam signal output wrong POWER ON

POWER ON

S Interlocking of NC START S Interlocking of Mode Group Ready

Incorrect values in NC MD 310, 311 Interface output via MIXED I/O selected without the corresponding hardware

Slot in the MIXED I/O before switching on the control.

46 Invalid TO parameter number POWER ON

S After altering machine data and then formatting user memory or when powering up if MD 13 (as from SW 4

MD 60006) is not correct.

Function not usable

S Interlocking of NC START

On installation, a value greater than 32 or less than 10 has been specified for machine data 13, “Number of TO parameters”.

“Extended tool parameter for type 50..59” deselected: 10 – 32 “Extended tool parameter for type 50..59” selected: 10 – 32

S Correct machine data S Format user memory or, in General Reset mode, format the area for the TO data

Scan Effect Explanation

Remedy Note

Scan Effect

Explanation

Remedy

Scan Effect

Explanation Remedy

Scan Effect

Explanation

Remedy

1 Alarms

1.5.1 Alarm description

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47 Wrong TO assignment lists POWER ON

S At POWER ON after modifying machine data S Interlocking of NC START S Value of machine data 210, “Number of TO areas”, is greater than 4

S TO start numbers in NC MD211 to 214 have not been entered in ascending order S Input value in channel-specific NC MD 1040 to 1043 is greater than the number of TO areas under MD 210 or

is specified as 0 in the TO area

S Correct machine data S Where appropriate format user memory if machine data were input correctly or format the TO data in General

Reset mode

S POWER ON

48 Data link to PLC not ready POWER ON

S Interlocking of NC S TART S Interlocking of NC Ready relay S Interlocking of Mode Group Ready S Machining stops

During the start-up synchronization or data exchange between interface-CPU (IFC) and PLC CPU an error was established, leading to the alarm. Data exchange between NC and PLC is still possible but the link to the programmer via the interface is not possible.

Error fine coding can give information on further error sources; in addition, check whether alarm 43 is present. Applies up to SW 2 only

49 NC in general reset POWER ON

POWER ON None The software has recognized that the control is in general reset mode. Leave general reset mode

50 Flex. memory incorrectly configured POWER ON 50 Insufficient memory for block buffer POWER ON

On pressing NC Start Interlocking of machining

Interlocking of “NC Start”

1. The channel-specific machine data 6100* that defines the number of block buffers in a channel is not in the

permissible range.

2. No memory has been made available (MD 60014) for loading of drive software (MD 60003 or 60004). Check and correct the values of the machine data. Alarm Insufficient memory for block buffer (with SW 4 and higher)

Alarm Flex. memory incorrectly configured (with SW 5.4 and higher)

57 Drive link failure POWER ON

Cyclic Interlocking of NC Ready, NC Start, Mode Group Ready, NC Stop Internal software error or ring programming for GI or gantry axes.

S Eliminate ring programming for GI or gantry axes S Notify service

Scan Effect Explanation

Remedy

Effect

Explanation

Remedy Note

Scan Effect Explanation Remedy

Scan Effect

Explanation

Remedy Note

Scan Effect Explanation Remedy

1 Alarms

1.5.1 Alarm description

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60 Internal software error POWER ON

Cyclic Computer stops, machining stops, interlocking of NC Start The software has recognized an internal error but cannot rectify it. Notify service.

67 1st computer link not ready for operation POWER ON

Cyclic or after POWER ON Message frame transfer between host computer and NC is not possible Host computer and NC are not synchronized owing to an incorrect input or a fault in the interface module. This

means that message frame transfer is not possible.

S Check programming of interface module S Check machine data settings for computer link S Check whether host computer is ready or connected

68 2nd computer link not ready for operation POWER ON

means that message frame transfer is not possible.

S Check programming of interface module S Check machine data settings for computer link S Check whether host computer is ready or connected

70 Define at least one channel POWER ON

S At POWER ON S Interlocking of NC START

S Interlocking of Mode Group Ready S Interlocking of NC Ready relay S Machining not possible

At start-up, an incorrect assignment of machine data was made. The NC will not work without channel assignment.

Check and correct machine data for channel assignment

S POWER ON

71 Too many real axes POWER ON

S At POWER ON S Interlocking of NC START

S Interlocking of Mode Group Ready S Interlocking of NC Ready relay S Machining stops S Surplus axes are not shown on the service display

More real axes than are permitted were defined in axis-specific machine data bits 564* at the time of start-up The machine data MD 60013 (memory for real axes) is not within the permissible range or has been set too small.

Correct axis-specific machine data bits 564*. Correct MD 60013.

Scan Effect Explanation Remedy

Scan Effect Explanation

Remedy

Scan Effect Explanation

Remedy

Scan Effect

Explanation Remedy

Scan Effect

Explanation Remedy

1 Alarms

1.5.1 Alarm description

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72 Too many fictitious axes POWER ON

S At POWER ON or warm restart S Interlocking of NC START

S Interlocking of Mode Group Ready S Interlocking of NC Ready relay S Machining stops

More fictitious axes than are permitted were defined in axis-specific machine data bits 564* during installation. Correct axis-specific machine data bits 564*.

73 Axis preset in wrong mode group POWER ON

S At POWER ON or warm restart S Interlocking of NC START

S Interlocking of Mode Group Ready S Interlocking of NC Ready relay S Machining not possible

At start-up, an incorrect assignment of NC machine data was made or the assignment of axis selector switch with 2 machine control panels is incorrect or a wrong axis is set in the program.

Check and correct NC machine data “Axis valid in mode group”.

S Correct program S POWER ON

74 Too many drives POWER ON

S At POWER ON or warm restart S Interlocking of NC START

S Interlocking of Mode Group Ready S Interlocking of NC Ready relay S Machining stops S Surplus axes do not appear in the service display

The total number of spindles and real axes defined during installation is greater than permitted. Correct axis-specific machine data bits 564* and spindle-specific machine data bits 521*.

75 Max. number of meas. circuits exceeded POWER ON

S At POWER ON or warm restart S Interlocking of NC START

S Interlocking of Mode Group Ready S Interlocking of NC Ready relay S Machining stops S Surplus axes do not appear in the service display

Output of alarm if too many axes and spindles are defined. Reduce the number of axes (MD 564*) and spindles (MD 512*). Axes/spindles that are not assigned to a measuring circuit are included in the number of measuring circuits.

77 Mode group no. of axis invalid POWER ON

S At POWER ON S Interlocking of NC START

S Interlocking of Mode Group Ready S Interlocking of NC Ready relay S Interlocking of machining

Check and correct machine data for axis assignment and spindle assignment.

S Check and correct machine data for “Axis valid in mode group” S Perform POWER ON

Scan Effect

Explanation Remedy

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Explanation Remedy Note

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Explanation Remedy

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78 Mode group no. of spindle invalid POWER ON

S At POWER ON S Interlocking of NC START

S Interlocking of Mode Group Ready S Interlocking of NC Ready relay S Interlocking of machining

Check and correct machine data for axis assignment and spindle assignment.

S Check and correct machine data for “Mode group of spindle” S Perform POWER ON

79 Mode group no. of channel invalid POWER ON

S At POWER ON S Interlocking of NC START

S Interlocking of Mode Group Ready S Interlocking of NC Ready relay S Interlocking of machining

An incorrect assignment (e.g. channel gap) has been made in the channel-specific machine data for “Channel valid in mode group”.

S Check machine data S Perform POWER ON

80 Error in C axis definition POWER ON

S At POWER ON and warm restart S Interlocking of NC START

S Interlocking of Mode Group Ready S Interlocking of NC Ready relay S Machining stops S If C axes and spindles are incorrectly assigned, the spindle does not appear in the service display.

The C axes assigned to the spindles were either defined as non-existent or fictitious during installation, or the spindle and assigned C axis mode groups are not identical.

Check and correct axis-specific machine data bits 564*, axis-specific machine data 360* and spindle-specific machine data 453* and 461*.

84 Coupled motion grouping defined wrong POWER ON

S At POWER ON S At warm restart

S Interlocking of NC START S Interlocking of Mode Group Ready S Interlocking of machining

An illegal coupled axis grouping has been set for the assignment of coupled axes in machine data, e.g.:

S The axes do not belong to the same mode group S The axes have different position control resolutions S The axes are of different types (linear axis/rotary axis) S The axes are declared as being not present S The axes are fictitious S The leading axis is defined as a coupled axis

Correct machine data using the “Coupled motion” function and perform a warm restart (see Start-up Guide).

Scan Effect

Explanation Remedy

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85 Coupled-motion combination wrong POWER ON

S POWER ON S Warm restart

S Interlocking of NC START S Interlocking of Mode Group Ready S Interlocking of machining

An undefined combination has been input in NC machine data for the coupled axis combination. Correct machine data and perform a warm restart (see Start-up Guide).

87 Illegal software limit switch POWER ON

S After altering machine data S Interlocking of NC START

S Interlocking of Mode Group Ready S Interlocking of machining

An excessively large value has been entered in the NC machine data for the software limit switch. The maximum traversing range of the individual axes results from the axis-specific position control resolution set and the input resolution. With alarm 87, the control has automatically entered the maximum permissible value in the appropriate NC machine data.

Check machine data for software limit switch and where appropriate correct. Applies up to SW 2 only

88 Interpolation greater than 3D POWER ON

S When executing part programs in AUTOMATIC or MDA S Interlocking of NC START

S Interlocking of machining

More than 3 axes have been programmed in one block in the part program block of the NC, or the “5D” function is not active.

S Modify part program S Do not execute more than 2 programs at once

89 More than two 3D interpolations POWER ON

S When executing part program blocks in AUTOMATIC or MDA S Interlocking of NC START

S Machining stops

More than 3 axes have been programmed in more than 2 channels in the NC in one program block in each case.

S Modify program S Do not execute more than 2 programs at once

90 Customer UMS invalid POWER ON

S At POWER ON when UMS bit is set

Interlocking of NC START until alarm is acknowledged. Standard UMS is loaded.

Customer UMS faulty or >512 KB. Check customer UMS. Applies up to SW 2 only

91 ID no. in UMS header faulty POWER ON

S At POWER ON and with activated UMS data

Interlocking of NC START until alarm is acknowledged. The programmed ID number in the UMS header, which is evaluated by the system software, is incorrect or has

been read incorrectly because the UMS submodules were plugged in incorrectly. Check WS 800A software version. Applies up to SW 3 only

Scan Effect

Explanation Remedy

Scan Effect

Explanation

Remedy Note

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91 UMS invalid POWER ON

At POWER ON and activated UMS data Interlocking of NC START until alarm is acknowledged. The configured identifying number in the UMS header, evaluated by the system software, is incorrect or no UMS

has been loaded because the memory reserved for this (MD 60000) is smaller than the UMS to be loaded. Check MD 60000 or install the correct UMS. Applies as from SW 4

93 Wrong UMS selector POWER ON

S At POWER ON and with activated UMS data S Interlocking of NC START until alarm is acknowledged.

The address lists preset by the NC workstation do not contain the set selectors required for error-free processing of a UMS.

Check the system software of the NC workstation, or have it checked.

94 Wrong UMS identifier POWER ON

S At POWER ON and with activated UMS data S Interlocking of NC START until alarm is acknowledged.

An incorrect identifier is programmed in the UMS. Check UMS and NC workstation software.

95 Wrong number in GSB POWER ON

S At POWER ON and with activated UMS data S Interlocking of NC START until alarm is acknowledged.

Numbers have been used in the modified system area (GSB) which are outside the reserved areas. Check the numbers used in the modified system area.

96 Language in UMS not available Acknowledgement key

At UMS analysis (POWER ON of control not during start-up) UMS is connected in its basic language Two-language UMS does not contain the language activated in the control Put correct UMS in control Applies up to SW 1 only

101 Prewarning replace battery Acknowledgement key

POWER ON Cyclic

Battery monitoring is activated if battery voltage falls below the advance warning voltage threshold. The working process is not interrupted

User is advised to replace the backup battery to avoid the risk of data loss – see alarm 1. Replace battery when control is switched on

Scan Effect Explanation

Remedy Note

Scan Effect Explanation

Remedy

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Scan Effect Explanation Remedy Note

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102 Prewarning overtemperature Acknowledgement key

POWER ON Cyclic

The first temperature monitoring threshold on the CBS module is activated because the ambient temperature is too high

User is given advance warning. The working process is not interrupted.

A lower temperature level is required to eliminate the fault

103 Initializing error NCK FB POWER ON

When powering up the control Interlocking of NC START

Follow–up mode Removal of Mode Group Ready

The initialization routine of the NCK FB has returned a value which is not equal to zero. The return value is output in the alarm as block number N.

Check the NCK FB. The alarm is initiated when powering up the control. No program can be started. Acknowledge alarm by

POWER ON.

S Alarm 103 is output only if appropriately configured by the machine manufacturer. An error has occurred in the

safety NCK–FB. For more information and remedy, refer to the manufacturer’s documentation.Applies as from SW 5.4.

S Applies as from SW 5.4.

104 Error in machine data

When powering up the control After a warm start After changing a machine data

Interlocking of NC START Follow–up mode Removal of Mode Group Ready

A machine data contains an implausible value. The machine data error is output in the alarm as block number N. Evaluate the block number and correct the corresponding machine data. The alarm is initiated when powering up the control. No program can be started. Acknowledge alarm by

POWER ON. Applies as from SW 5.4

105 Error in NCK FB

During cyclic operation of control Interlocking of NC START

Follow–up mode Removal of Mode Group Ready Interruption of machining

The cyclic routines of the NCK FB have returned a value which is not equal to zero. Evaluate the block number and check the NCK FB. No program can be started. Acknowledge alarm by POWER ON.

S Alarm 105 is output only if appropriately configured by the machine manufacturer. An error has occured in the

safety NCK–FB. For more information and remedy, refer to the manufacturer’s documentation.

S Applies as from SW 5.4

Scan Effect Explanation Remedy

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Explanation Remedy

Continuation: Note

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Effect

Explanation Remedy Continuation

Note

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110 Checksum error safe monitorings POWER ON

When powering up the control Interlocking of NC START The MDs for the safety system are protected by a checksum after acceptance of the control. The alarm indicates

that the current checksum no longer matches the stored checksum, i.e. either an MD value has been changed without authorization or a data is defective.

Check the MDs. Inspect the safety functions again. Have the checksum calculated again. The alarm is initiated when powering up the control. No program can be started. Alarm acknowledgement only

possible by POWER ON. Applies as from SW 5.4

111 Error in collision monitoring data POWER ON

At POWER ON Block number (4–digit) Nxxss:

3rd and 4th digit: Number of protection zone 00–09 = Protection zone 1–20 1st and 2nd digit: Error identifier (see explanation)

Nibble 3,4=Error identifier: 01=Motion axis does not exist 02=Motion axes not in same mode group 03=Error in monitoring relation 04=Protection zone dimensions not available (all dimensions=0) 05=Negative protection zone dimension 06=Protection zones not defined in same plane

Machining standstill; interlocking of machining (NC Start); BAG–BB=0; NC–Ready=0

Error identifiers 01=Motion axis does not exist

A non–existing axis has been specified in the machine data 3800*, 3802*, 3804*. 02=Motion axes not in same mode group

Axes that are not in same mode group have been specified In the machine data 3800*, 3802*, 3804*. 03=Error in monitoring reference

The mutual deselection of the protection zone monitoring in the MD bits 38803+s*3 has not been executed correctly. Deselection of monitoring of protection zone 2 in the machine data of protection zone 1 causes the deselection of monitoring of protection zone 1 in the machine data of protection zone 2, i.e. deselection must always be carried out mutually.

04=Protection zone dimensions not available The protection zone dimensions specified in the machine data 3812*, 3814*, 3816* are all=0.

05=Negative protection zone dimension At least one of the protection zone dimensions specified in the machine data 3812*, 3814*, 3816* is negative. But only positive dimensions are allowed.

06=Protection zones not defined in same plane The protection zone specified is 2–dimensional. It is related to another 2–dimensional protection zone, which is defined in another plane. But 2–dimensional protection zones that are in a monitoring relation must lie in the same plane.

1st possibility: The plane of the protection zone defined in the machine data 3812*, 3814*, 3816* is not identical with the planes of the other protection zones to be monitored.

2nd possibility: The protection zone should not monitor the protection zones in other planes, i.e. the protection zone relation must be corrected in the machine data bits 38803 – 38815 (monitoring relation).

Correct machine data and execute POWER ON. Applies as from SW 6

Scan Effect Explanation

Remedy Continuation

Note

Scan Parameters:

Effect

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100* Leadscr. err. comp.-illegal grid spacg. POWER ON

S After POWER ON S Interlocking of NC START

S Interlocking of Mode Group Ready

Leadscrew error compensation with rotary axes in NC machine data “Distance between 2 values” has been entered for the appropriate axis with a value which cannot be divided into 360 degrees to give an integer, i.e. grid spacing is not equal; e.g.

S Correct: NC–MD= 10 (rotary axis) S Results in: 360/10 = 36 grid points S Incorrect: NC–MD= 1 1 S Would give: 360/11 = 32,7 grid points

The compensation value chosen is too large compared with the distance between two leadscrew error compensation points (valid for rotary and linear axes).

Modify NC machine data “Distance between 2 values” – check NC MD 324* and 328*.

S The compensation value in NC MD 328* must be less than NC MD 324*.

104* Speed setpoint value warning limit responded Reset key

S Cyclic S Interlocking of NC S TART

For analog measuring circuit: The DAC set value entered is higher than in NC machine data 268* “Maximum setpoint speed (DAC)”. It is not possible to increase the set value further.

S Traverse more slowly S Check actual values (encoder) S Check NC machine data “Maximum setpoint speed (DAC)” S Check the drive actuator

112* Zero-speed control Reset key

S When accelerating S When stopped S When clamping S When decelerating (delay)

S Interlocking of NC START S Interlocking of Mode group READY S Setpoint 0 S The control enable is removed after the time stored in NC machine data “Control enable cutout delay” has

elapsed

S Follow-up operation S The following error could not be cleared faster than the time entered in NC machine data “Control enable

cutout delay” during positioning

S On clamping, the limit defined in NC machine data “Zero speed monitoring” was exceeded S A mechanically clamped axis has been pushed out of position S Fault in the control device (actuator), at the tacho, at the motor, in the CNC measuring circuit hardware or

at/on the pulse encoder

S Incorrect specification on assigning the set value output S At start-up: wrong position control direction

S NC machine data “Zero speed monitoring” must be greater than “Coarse exact positioning limit” S NC machine data “Control enable cutout delay” must be large enough for the following error to be removed

within this time (only applies if NC machine data “Zero speed monitoring delay” = 0)

S NC machine data “Zero speed monitoring delay” must be large enough for the following error of the individual

axis to be removed within the time entered

S Check actual values (encoder) and position control direction

Scan Effect

Explanation

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Scan Effect Explanation

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Scan

Effect

Explanation

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1 Alarms

1.5.1 Alarm description

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Siemens Sinumerik 840C, SIMODRIVE 611-D, Sinumerik 840CE Diagnostics Manual

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