Alarm Sinumerik 808 d

www.siemens.com.cn/808D

西门子建筑电气SINUMERIK 808D Service guide

Training handbook

Version: 05.2012

808D turning and milling Service guide

List

For

Please refer to thealarm handbook

Go to page 23

Go to page 5Service case ofhardware fault

Service case ofPLC alarm

Service case ofNC program

alarm

For

For

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page 5808D turning and milling Service guide

Service caseof hardware

fault

For normal hardware faults, we provide the basic service diagnostic stepsand detecting procedures which are only for Siemens service engineers,OEM service engineers and Siemens authorized service engineers.

Case 1

Case 7

Case 8

Case 9

Case 10

Case 11

Case 12

Case 13

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Startup cannotlog into

the system

Spindleencoder

alarm

Handwheelfault

Feed axisfault

Change ofdirection

is notpossible

Positioningerror

Tool changeis not possible

Startupprocesscrashes

Batteryalarm

MCP is notavailable

MCPbutton

press fault

RS232transmission

fault

Spindlefault

Case 2

Case 3

Case 4

Case 5

Case 6

Service guide 808D turning and millingpage 6

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Case 15

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Case 18

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Hardwarelimit switch

fault

Startup cannot return to

the referencepoint

PPU/HMIfault

Drivealarm

Overload

End


fault


车削与铣削车削与铣削车削与铣削车削与铣削第第第第页页页页服务指南服务指南服务指南服务指南

硬件故障硬件故障硬件故障硬件故障服务案例服务案例服务案例服务案例

故障现象描述故障现象描述故障现象描述故障现象描述：

上电后无法进入系统，常见现象为出现黑屏无任何显示。

诊断步骤

检查面板上的“电源”指示灯是否点亮

开机不能开机不能开机不能开机不能

进入系统进入系统进入系统进入系统

如果指示灯亮

断电检查卡是否插

紧,重新上电开机,观察

故障是否解除。

如果指示灯不亮

检查 PPU 后侧 X1 电源插头接口

1. 接线是否松动

2. 24v 端子是否与接口相符

3. 用万用表测量是否有 DC24V


系统出现电池报警

诊断步骤

电池报警电池报警电池报警电池报警

系统出现电池报警时,说明系统电池电

量不足,需要更换电池。

请在系统上电状态下将电池拔出,进行

电池更换！

如果上述检查之后故障仍然存在,则很可能是系统主板 () 损坏,需要

进行更换或维修

电池报警号为 002100：此报警表明系统电池电量已经不足，应在出现该

报警的 6 周之内更换电池，否则可能会导致数据丢失。

电池报警号为 002101：此报警表明系统电池电量即将用尽，需立即更换

电池，否则可能会导致数据丢失。




上电后无法进入系统，常见现象为出现黑屏无任何显示。

诊断步骤

检查面板上的“电源”指示灯是否点亮

开机不能开机不能开机不能开机不能

进入系统进入系统进入系统进入系统

如果指示灯亮

断电检查卡是否插

紧,重新上电开机,观察

故障是否解除。

如果指示灯不亮

检查 PPU 后侧 X1 电源插头接口

1. 接线是否松动

2. 24v 端子是否与接口相符

3. 用万用表测量是否有 DC24V


系统出现电池报警

诊断步骤

电池报警电池报警电池报警电池报警

系统出现电池报警时,说明系统电池电

量不足,需要更换电池。

请在系统上电状态下将电池拔出,进行

电池更换！

如果上述检查之后故障仍然存在,则很可能是系统主板 () 损坏,需要


电池报警号为 002100：此报警表明系统电池电量已经不足，应在出现该

报警的 6 周之内更换电池，否则可能会导致数据丢失。

电池报警号为 002101：此报警表明系统电池电量即将用尽，需立即更换

电池，否则可能会导致数据丢失。

Startup cannot

log into thesystem

Batteryalarm

Fault description:

Cannot log into the system after power on; normally black screen, nodisplay at all.

Fault description:

The system issues a battery alarm.

Check the power indicator light on the PPU panel:

Replacement and maintenance are necessary if the fault still exists afterthe above inspection, because it is probable that the PPU is damaged.

Battery alarm number 002100: This alarm indicates that the batterypower of the system is low. In this case, replace the battery within sixweeks, otherwise it may cause data loss.

Battery alarm number 002101: This alarm indicates that the batterypower of the system will soon be used up. In this case, replace the batteryimmediately, otherwise it may cause data loss.

If the indicator light is off:

Check the X1 power plug interface on the back of the PPU1. Whether the connection is loose.2. Whether the 24 V terminal matchesthe interface.3. Whether 24 VDC is available by measuring with a multi- meter.

If the indicator light is on:

Power off and check whetherthe CF card is inserted correctly,then power on andrestart, observe whether thefault is eliminated.


fault

Diagnostic stepsDiagnostic steps

Replace the battery when the systemissues the alarm “shortage of electricity”.

Remove the battery and replace it inthe power-on state.


服务指南服务指南服务指南服务指南第第第第页页页页车削与铣削车削与铣削车削与铣削车削与铣削



1. 上电后 MCP 无任何反应,

所有指示灯均未点亮,所有操

作均无法进行。

2. 上电后 MCP 全部指示灯

都在不停闪动。

注注注注：：：：此时此时此时此时上可能出现的报警号为上可能出现的报警号为上可能出现的报警号为上可能出现的报警号为

面板不可用面板不可用面板不可用面板不可用

诊断步骤

检查 MCP 与 PPU 之间的连线

1.连线是否断开

2.连接线本身是否损坏或接触不良

（另换一条完好的连接线连接，查看故障是否解决）

检查 PPU 后侧 X30 接口是否损坏

或接触不良（另换一条完好的连接

线连接，查看故障是否解决）

检查 MCP后侧 X10 接口是否损坏



如果上述检查之后故障仍然存在,则很可能是系统 PPU 或 MCP 损坏,需

要进行更换或维修

PLC 编程错误也会导致 MCP 全部指示灯不停闪动,此时应确认 PLC 编写

是否存在问题。




1. 上电后 MCP 无任何反应,

所有指示灯均未点亮,所有操

作均无法进行。

2. 上电后 MCP 全部指示灯

都在不停闪动。

注注注注：：：：此时此时此时此时上可能出现的报警号为上可能出现的报警号为上可能出现的报警号为上可能出现的报警号为

面板不可用面板不可用面板不可用面板不可用

诊断步骤

检查 MCP 与 PPU 之间的连线

1.连线是否断开

2.连接线本身是否损坏或接触不良

（另换一条完好的连接线连接，查看故障是否解决）

检查 PPU 后侧 X30 接口是否损坏



检查 MCP后侧 X10 接口是否损坏



如果上述检查之后故障仍然存在,则很可能是系统 PPU 或 MCP 损坏,需

要进行更换或维修

PLC 编程错误也会导致 MCP 全部指示灯不停闪动,此时应确认 PLC 编写

是否存在问题。

MCP is notavailable

Fault description:

1. MCP does not respond afterpower on, all the indicator lightsare off and all the operations arenot available.

2. All the indicator lights of MCPare 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 PPU1. 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.)

A PLC program fault can also cause flashing of all the MCP indicatorlights. In this case, check whether there is problem in the PLC program.

Replacement and maintenance are necessary if the fault still exists afterthe above inspection, because it is probable that the PPU or MCP is damaged.

Check whether the interface ofX30 on the back of the PPU isdamaged or there is a faulty contact.(Check whether the fault isresolved by replacement with anew wire.)

Check whether the interface ofX10 on the back of theMCP isdamaged or there is a faulty contact.(Check whether the fault isresolved by replacement with anew wire.)


fault


MCPbutton

press fault

Diagnostic steps

Fault description:

Some buttons on the MCP do not respond.(Common buttons with faults: "Cycle start" button and "Reset" button.)



检测输入输出状态

““““复位复位复位复位””””键地址键地址键地址键地址 ““““循环启动循环启动循环启动循环启动””””键地址键地址键地址键地址


MCP 上个别按键没有反应

(常见故障按键：“循环启动”键 /“复位”键)

按键故障按键故障按键故障按键故障

诊断步骤

若按键对应的状态位有变化

按键正常,需要进一步观察系

统是否存在其他报警或程序

其他位置的编写是否正确。

若按键对应的状态位无变化

按键损坏,需进行更换或维修

PLC 状态监控举例

附注附注附注附注：：：：在在在在上进入上进入上进入上进入状态监控界面的操作步骤状态监控界面的操作步骤状态监控界面的操作步骤状态监控界面的操作步骤

+ 2.同时按 PPU 上的“上档 + 诊断”键

3.按 PPU 上的“PLC”键

4.按 PPU 上的“PLC 状态”键

1.按 PPU 上的“加工操作”键

Note: The steps for entering the PLC status monitoring interface onthe 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 soft key of“state of PLC”on PPU.

Check the state of the PLC input/output.

If the PLC status bit corresponding tothe buttons changes

MCP buttons function correctly. Inthis case, make further observationto see if there are otheralarms or whether the PLC programis correct in a different position.

If the PLC status bit correspondingto the buttons does notchange

Replacement and maintenanceare necessary because the MCPbuttons are damaged.

Example of PLCstatus monitoring

Address of the “Reset” button:DB1000.DBX3.5Address of the “Cycle start”button: DB1000.DBX3.3


fault





使用 RS232 无法进行数据通信传输。

诊断步骤

检查 PPU 面板上 X2 接口是否松动

传输故障传输故障传输故障传输故障

如果上述检查之后故障仍然存在,则很可能是系统主板 (PPU) 损坏,需要


检查所使用的 RS232 电缆是否损坏

检查 PPU 中的 RS232 通讯设置

1.通讯是否激活

2.通讯参数设置是否与 PC 端匹配

检查所使用 PC 端的 RS232 接口是否损坏

附注附注附注附注：：：：在在在在上进入上进入上进入上进入通讯界面的操作步骤通讯界面的操作步骤通讯界面的操作步骤通讯界面的操作步骤

....使用使用使用使用进行进行进行进行连接时连接时连接时连接时


3.按 PPU 上的“PLC”键

4.按 PPU 上的“STEP7 连接”键

1.按 PPU 上的“加工操作”键

5.合理设置通讯数据后,按 PPU 上的

“STEP7 连接”键

....使用使用使用使用进行进行进行进行连接时连接时连接时连接时

1.按 PPU 上的 “程序管理”

2.按 PPU 上的 “RS232” 软键

3.按 PPU 上的 “设置” 软键

4.调整 “通讯设置” 中的参数，与电脑上

通信软件的参数配置完全相同即可

注注注注：：：：使用使用使用使用时必须确保时必须确保时必须确保时必须确保已关闭已关闭已关闭已关闭,,,,否则会出现通讯故障否则会出现通讯故障否则会出现通讯故障否则会出现通讯故障

使用使用使用使用时请先确保系统中时请先确保系统中时请先确保系统中时请先确保系统中

的的的的处于关闭处于关闭处于关闭处于关闭(((())))状态状态状态状态!!!!

RS232transmission

fault

Fault description:

Data communication is not possible via RS232.

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.


Note: When you use WINPCIN, please make sure that STEP 7 isclosed otherwise this may cause a communication fault.

Note: The steps for entering the RS232communication 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 PPUafter 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 sameas the configuration parameters in the computer communication software.

Please make sure that STEP7 isclosed (OFF) before usingWINPCIN !

Diagnostic steps


fault




检查机床数据 MD30200 设置（主轴有编码器设为 , 无编码器设为）

检查连接线之间是否存在干扰(强弱电连接线最好分开)

若故障为：主轴无法转动 / PPU 屏幕提示“等待主轴”


1.主轴无法转动 / PPU 屏幕提示等待主轴,且屏幕中无报警提示。

2.屏幕有主轴数值,实际主轴不动,且屏幕中无报警提示。

3.主轴转度不稳定(时快时慢)

诊断步骤

检查 PPU 后侧主轴接口 X54 1.接口是否松动或损坏

2.启动主轴后用万用表测量 X54 的引脚 1 和 9,观察是否有电压输出

检查主轴与变频器的连接电缆是否完好



若故障为：屏幕有主轴转速数值,实际主轴不动

检查机床数据 MD30130 / MD30240 / MD30134 / MD32250 / MD32260 / MD35150 的设置是否正确 1.MD30130=1 / MD30240=2 2.MD30134 → 主轴输出极性(可在 0～2 之间设置)

0 →双极性,1 / 2 → 单极性(由实际情况确定)

3.MD32250=100 / MD32260与实际电机额定转速保持一致

情况1

检查所使用的主轴变频器是否出现故障

情况2

若故障为：主轴转度不稳定(时快时慢) 情况3

检查 PPU 后侧 X54 接口

1.接线是否松动

2.是否接触不良

检查主轴变频器连接线是否松动 / 变频器是否故障

主轴故障主轴故障主轴故障主轴故障

检查 PPU 上是否处于程序测试状态

1.MCP 上的“程序测试”按键指示灯是

否点亮（不可点亮） 2.PPU 屏幕上“PRT”指示符是否激活

（不可激活）

如故障仍存在,可根据“情况”中提及的检查步骤顺次进行检查



检查机床数据 MD30200 设置（主轴有编码器设为 , 无编码器设为）

检查连接线之间是否存在干扰(强弱电连接线最好分开)

若故障为：主轴无法转动 / PPU 屏幕提示“等待主轴”


1.主轴无法转动 / PPU 屏幕提示等待主轴,且屏幕中无报警提示。

2.屏幕有主轴数值,实际主轴不动,且屏幕中无报警提示。

3.主轴转度不稳定(时快时慢)

诊断步骤

检查 PPU 后侧主轴接口 X54 1.接口是否松动或损坏

2.启动主轴后用万用表测量 X54 的引脚 1 和 9,观察是否有电压输出

检查主轴与变频器的连接电缆是否完好



若故障为：屏幕有主轴转速数值,实际主轴不动

检查机床数据 MD30130 / MD30240 / MD30134 / MD32250 / MD32260 / MD35150 的设置是否正确 1.MD30130=1 / MD30240=2 2.MD30134 → 主轴输出极性(可在 0～2 之间设置)

0 →双极性,1 / 2 → 单极性(由实际情况确定)

3.MD32250=100 / MD32260与实际电机额定转速保持一致

情况1

检查所使用的主轴变频器是否出现故障

情况2

若故障为：主轴转度不稳定(时快时慢) 情况3

检查 PPU 后侧 X54 接口


2.是否接触不良

检查主轴变频器连接线是否松动 / 变频器是否故障

主轴故障主轴故障主轴故障主轴故障




（不可激活）

如故障仍存在,可根据“情况”中提及的检查步骤顺次进行检查

Spindlefault

Fault description:

1. The spindle cannot move, the PPU screen shows the waiting for spindlesignal and the screen has no alarm prompt.2. The screen has spindle values, but the actual spindle cannot move andthe screen has no alarm prompt.3. The spindle angle of rotation is not steady (varies during rotation).

If the fault is：The spindle cannot move, the PPU screen showsthe waiting for spindle signal.

If the fault is：The screen has spindle values, but the actualspindle cannot move.

If the fault is：The spindle angle of rotation is not steady (variesduring rotation)

Check whether there is an interference between the connections (it isbetter to separate thicker and thinner wires).

Check the interface of X54 on the back of the PPU1.Whether the interface is loose.2.Whether the connections have a faulty contact.

Please check whether the connection of the spindle converter isloose or whether the converter is damaged.

Please check whether the PPU is in the programtest state.1. Whether the indicator light of the“Program test”key on MCP is on or not (itshould not be on).2. Whether the“PRT”indicator on the PPUscreen is activated or not (it should not be acti-

Use the diagnostic steps of“Case1”mentionedabove to check the spindle if the fault still exists.

Check the settings of machine data MD30200 (spindle is set to 1 if it has anencoder, otherwise 0).

Check the spindle interface of X54 on the back of the PPU1. Whether the interface is loose or damaged.2. Measure pins 1 and 9 of X54 with a multi-meter afterstarting 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 = 22. 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 ratedspeed.

Check whether the spindle converter shows a fault or not.


Diagnostic steps

Case1

Case2

Case3


fault




手轮故障手轮故障手轮故障手轮故障


手轮不可用 / 轴选无效。

诊断步骤

检查 PPU 面板上 X10 接口

1.连接线是否松动

2.接口本身是否损坏

3.检查 X10 接口（端子 5 / 6）是否有 5V 电压输出



检查手轮上的连线是否正确,相邻连线是否出现短接等问题

检查操作过程是否正确,确认是否已在

“手轮”状态下选中要操作的进给轴。

检查所使用的手轮是否损坏


主轴无法转动,

同时屏幕上方 025000 报警

诊断步骤

主轴主轴主轴主轴

编码器报警编码器报警编码器报警编码器报警

检查 PPU 后侧主轴编码器接口

X60 是否松动或损坏。

检查 PPU 中的参数 MD30200 / MD30240 设置是否正确

1.MD30200：主轴有编码器时设为 1, 主轴无编码器时设为 0 2.MD30240=2

检查主轴编码器连接线是否损坏接线是否出错

检查主轴编码器是否损坏,更换一个完好的编码器后重新检测



使用 PLC 监控检测轴选键的 PLC 输入 / 输出状态






诊断步骤












主轴无法转动,


诊断步骤

















诊断步骤












主轴无法转动,


诊断步骤

















诊断步骤












主轴无法转动,


诊断步骤












Spindleencoder

alarm

Handwheelfault

Fault description:

The spindle cannot move, and the 025000 alarm appears on thescreen at the same time.

Fault description:

Handwheel is not available / axis is not selected.

Check the spindle encoder interface on the back of the PPU.

Check whether the connection of the PPU spindleencoder is damaged or the connection is correct.

Check whether the settings of machine data MD30200 / MD30240 in thePPU 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.

Check whether the process is correct, and confirmwhether the feed axis has been selected for operation in the“Handwheel”state.

Use the PLC input/output for monitoring the axis inspectionwith the selected key.

Check whether the connections on the handwheel are correct, and observeif 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) andobserve if there is 5 V output.

Check whether the handwheel is damaged.


Diagnostic steps

Diagnostic steps


fault


If the fault is：The screen can display feed axis data, but the actual machine cannot move.



若故障为：机床实际移动方向与操作方向相反 / 机床实际移动方向

与屏幕显示方向相反

情况2

检查 V60 驱动器上的方向键连接线是否正确

端子 DR / DR 的接线与实际相比是否接反

检查机床数据 MD32100 / MD32110 设置是否正确

MD32100：轴反向键(默认值 =1,根据需要可调整为 1) MD32110：编码器位置反馈极性键(默认值 =1,根据需要可调整为 1)


系统已完成回参考点状态

1.屏幕上有进给轴移动数值显示,但实际机械不动

2.机床实际移动方向与操作方向相反 / 机床实际移动方向与屏幕显示方向相反

进给轴故障进给轴故障进给轴故障进给轴故障

诊断步骤

如使用第三方驱动器,检查驱动器上是否存在报警



检查机械上的联轴器是否松动




（不可激活）

若故障为：屏幕上有进给轴移动数值显示,但实际机械不动情况1

检查轴信号与驱动器连接是否良好：V60 驱动器上的端子是否插紧 / 损坏

Feed axisfault

Please check whether the PPU is in the programtest state.1. Whether the indicator light of the"Program test" button on the MCP is on (itshould not be on).2. Whether the "PRT" indicator on the PPUscreen 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.

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 arecorrect.MD32100：Axis reverse key (The implied value = 1. It is permitted tochange 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.)

Diagnostic steps

Fault description:

The system has completed the state of returning to the reference point1. The screen can display feed axis data, but the actual machine cannot move2. The actual direction of motion is opposite to the operational direction ofthe machine / is opposite to the direction of screen display.

Case1

Case2 If the fault is: The actual direction of motion is opposite to theoperational direction of the machine / is opposite to the directionof screen display.


fault


Change ofdirection

is notpossible

Positioningerror

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.

Fault description:

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 betweenthe system and the drive.

Check whether the settings of machine parameters MD31030/MD31050/MD31060/MD31020/MD31400 are consistent with the actual mechanicalparameters.1. MD31030 → leadscrew pitch value storage2. MD31050/MD31060 → shaft deceleration rate3. MD31020 = MD31400 → encoder line number (set to 10000 whenusing the V60 drive)Note: Check whether there is play on the drive encoder.

Check the drive parameters. Do not set up the deceleration rate parametersin 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 leadscrewpitch and the backlash.


fault


Check whether the connected sequence of machine source / tool motor is correct.

Check the tool rotation signal output on the back of the PPU /input points interface of the tool signal in place1. Whether it is damaged.2. Whether the wire is loose.3. Terminal no. 1/10 is connected to 24 V / 0 V.4. Whether the connection is correct or different in the settingsof PLC program.

Check whether the wires between the tool signal input /output point on the back of the PPU and the connectionsbetween the tools are loose or damaged.

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

Replacement and maintenance are necessary if the fault still exists afterthe above inspection, because it is probably the fault of the PPU.



不能换刀不能换刀不能换刀不能换刀


机床无法进行换刀 / 机床换刀错误 / 刀架不停转动

诊断步骤

检查机床电源刀架电机的连接相序是否正确

如果上述检查之后故障仍然存在,则很可能是系统主板 () 故障,需要


检查 PPU 后侧刀架转动信号输出点 / 刀架到位信号输入点接口

1.是否损坏


3.端子 1 / 10 号口与 24V / 0V 连接 4.接点是否接错或与 PLC 程序中设置不符

检查机床刀架信号码盘是否损坏

检查后侧刀架信号输入输出点与刀架之间的连接线是否松动或损坏

使用到的接口使用到的接口使用到的接口使用到的接口


开机时,系统加载过程中出现死机(常见为加载至 40% 时死机)

诊断步骤

断电,检查卡是否插紧或接触

不良,然后重新上电观察故障是否

排除

启动过程启动过程启动过程启动过程

死机死机死机死机



断电重启,观察故障是否解决

断电,在上电开机的过程中按 PPU 上的“选择”键进入菜单选择“缺

省值启动”

注注注注：：：：此步骤会丢失所有机床数据此步骤会丢失所有机床数据此步骤会丢失所有机床数据此步骤会丢失所有机床数据,,,,请确请确请确请确

保操作前已有相关备份保操作前已有相关备份保操作前已有相关备份保操作前已有相关备份！！！！






诊断步骤





1.是否损坏








诊断步骤



排除







省值启动”








诊断步骤





1.是否损坏








诊断步骤



排除







省值启动”



Diagnostic stepsDiagnostic steps

Power off and restart. Check whether the fault is resolved.

Power off and check whether theCF card is inserted correctly orhas a faulty contact, then poweron again to check whether thefault is resolved.

Power off and press the“Selection”button on the PPU during power-upto open the menu, then select“Startup with default data”.

Note: All machine data is lostduring this operation. Pleaseensure that there is an appropriatebackup.


Startup processcrashes

Fault description:

Machine cannot change tools / tool change error / tools keep rotating.

Fault description:

The system loading process crashes during startup (usually it freezeswhen loading at 40%).

Connectedinterface


fault

Tool changeis not possible


Hardware limitswitch fault

Startup cannotreturn to the

reference point

Fault description:

1. Hardware limit switch alarm appears on the PPU.2. The machine has crossed the hardware limit switch, but can still move, noalarm.

If the fault is: Hardwarelimit switch alarm appearson the PPU.

If the fault is：Press the axis + (or axis-) key, the screen coordinatesdo not change and the machine does not move.

If the fault is：The machine has crossed the hardware limitswitch, but can still move, no alarm.

Fault description:

1. Press the axis + (or axis-) key, the screen coordinates do not change andthe machine does not move.2. Press the axis + (or axis-) key, screen coordinates change but the machinedoes not move.3. Press the axis + (or axis-) key, the machine can move until the hardwarelimit switch alarm appears.4. Press the axis + (or axis-) key, the machine is always moving in the oppositedirection.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 exitingthe slowdown switch.7. Press the axis + (or axis-) key, the start point and automatic processingprogram are running normally, but the system does not respond when returningto the reference point.

Diagnostic steps

Diagnostic steps

Case1

Case1

Case2


fault

Press the "Reset" button on the PPU and press the direction key controllingthe feed shaft movement on the PPU at the same time to make thefeed axis move in the opposite direction and break away from the hardwarelimit switch. The alarm can then be cleared.

The hardware limit switches on the machine must be checked if thesemethods 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.

Check if there is an alarm number on the PPU screen, continue operationafter eliminating the alarm via the“Reset”key.

The machine data is lost if the alarm numbers 004060/004062/004065appear; in this case, it is necessary to back up the data and restart afterpower-off to check whether the fault has been eliminated.

Check whether the hardware limit switch connection is short-circuitedwith the high level.

Check whether the hardware limit switches are damaged.


Case3

Case2 If the fault is：Press the axis + (or axis-) key, screen coordinateschange but the machine does not move.

If the fault is：Press the axis + (or axis-) key, the machine canmove until the hardware limit switch alarm appears.

If the fault is：Press the axis + (or axis-) key, the machine is alwaysmoving in the opposite direction.

Case4


fault

Check whether the PPU is in the program teststate.1. Whether the indicator light of the"Program test" key on MCP is on (it should notbe on).2. Whether the "PRT" indicator on the PPUscreen is activated (it should not be activated).

Check whether the machine deceleration switches and their related connections are broken.

Check whether the machine deceleration switches can bounce.

Check whether the machine deceleration switches and their related connectionsare broken.

Case5 If the fault is：Press the axis + (or axis-) key, the machine movesonly a short distance.

If the fault is：Press the axis + (or axis-) key, the machine alarm20002 appears after exiting the slowdown switch.

If the fault is：Press the axis + (or axis-) key, the start point andautomatic processing program are running normally, but thesystem does not respond when returning to the reference point.

Case6

Case7

Check whether the settings of machine data MD34000 are correct (themachine deceleration switches are not available when 34000=0).

Check whether the machine approaching switch and its related connectionsare damaged.

Check whether the settings of machine data MD34060 are correct.

Check whether the encoder corresponding to the feed axis and its relatedconnections are damaged.

Check whether the settings of machine data MD30200 are correct (itcannot return to the reference point when 30200=0).

Check whether the settings of machine data MD30130/MD30240/MD30350 are correct.1. Feed axis MD30130=2 / MD30240=32. MD30350=0


PPU/HMIfault

Drivealarm

Fault description:

PPU button is defect / HMI screen is defect

Fault description:

The system issues a drive-related alarm.The V60 drive also issues an alarm, the common alarm numbers are A05/A06/A07/A08/A09

This section discusses only the SiemensSINAMICS V60 drive

A05 alarm

Check whether it is in the crashed state. If so, power off and on, thencheck 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 PPU is damaged.

IGBT overcurrent → appears when power is obtained fromthe line supply / appears during motor operation.

Check the U, V, W, PE connections on the drive1. 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 themotor 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 afterthe above operation, because it is probable that the drive is damaged.


fault

Diagnostic steps

Diagnostic steps


故障故障故障故障服务案例服务案例服务案例服务案例

报警名称报警名称报警名称报警名称：

手持单元激活。


主轴制动中。

报警解说

PLC 信息

PLC 地址：DB1600.DBX1.2 子程序段名称：MINI_HHU（SBR 41）

非故障,此报警作为提示信息,提示“手轮”已激活

(报警出现条件：手轮功能激活且手轮上已经进行轴选择操作)

报警解说

PLC 信息

PLC 地址：DB1600.DBX1.4 子程序段名称：SPINDLE（SBR 42）

非故障,此报警作为提示信息,提示主轴正在进行刹车

等待主轴刹车结束,该报警会消失

不需进行特别处理,当取消手轮功能取消手轮轴选之后该报警自动消失。

处理方法


处理方法


A06 alarm

A07 alarm



如果上述操作之后故障仍然存在,则很可能是驱动器损坏,需要进行更换或

维修。

检查驱动器、、、之间的连接线

不同相位之间的连线是否短接

检查、、是否有一相断开

线路接地是否错误或接地不良

连接线本身是否损坏

核查后重新上电观察故障是否还存在。

如果上述操作后故障仍在,则需要检查电机的绝缘是否损坏,必要时可更换

电机,重新上电后观察故障是否存在。

内部芯片过电流 → 接通主电源时出现 / 电机运行过程中出现 A06 报警

如果上述操作之后故障仍然存在,则很可能是驱动器内部模块损坏,

需要进行更换或维修。

检查驱动器、、、之间的连接线

不同相位之间的连线是否短接


接地短路 → 接通主电源时出现 / 电机运行过程中出现 A07 报警

如果上述操作之后故障仍然存在,则很可能是电机内部的编码器损坏,需要

进行更换或维修。

检查驱动器与电机之间的信号电缆(从驱动器到电机的编码器)

是否存在电缆内部线路接触不良

是否存在电缆屏蔽不良

屏蔽地线是否接好


如果上述操作后故障仍在,则需要检查编码器的接口电路是否出现故障

编码器 U / V / W 错误 A08 报警

如果上述操作之后故障仍然存在,则很可能是电机内部的编码器损坏,需要

进行更换或维修。

检查驱动器与电机之间的信号电缆(从驱动器到电机的编码器)

编码器电缆连接是否正确是否存在电缆内部线路接触不良

是否存在电缆屏蔽不良

屏蔽地线是否接好


如果上述操作后故障仍在,则需要检查编码器的接口电路是否出现故障

编码器 TTL 脉冲错误 A09 报警

Internal chip overcurrent → appears when power is obtainedfrom the line supply / appears during motor operation.

The ground circuit is short-circuited → appears whenpower is obtained from the line supply / appears duringmotor operation.

Check the U, V, W, PE connections on the drive1. Whether connections between different phasesare 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.

Power on again and observe whether the fault still exists after verification.

Check the U, V, W, PE connections on the drive1. Whether connections among different phases are short-circuited.Power on again and observe whether the fault still exists after verification.

Replacement and maintenance are necessary if the fault still exists afterthe above operation, because it is probable that the IGBT module in thedrive is damaged.

If the fault still exists after the above operation, check the insulation of themotor 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 afterthe above operation, because it is probable that the drive is damaged.

A08 alarm

A09 alarm

The encoder U/V/W connections are incorrect.

The encoder TTL has pulse faults.

Check the signal cable between the motor and the drive (the encoderfrom 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.

Check the signal cable between the motor and the drive (the encoderfrom 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.Power on again and observe whether the fault still exists after verification.

The interface circuit of the encoder must be checked if the fault still exists after the above operation.

Replacement and maintenance are necessary if the fault still exists afterthe above operation, because it is probable that the encoder in the driveis damaged.

The interface circuit of the encoder must be checked if the fault still existsafter the above operation.

Replacement and maintenance are necessary if the fault still exists afterthe above operation, because it is probable that the encoder on the driveis damaged.


fault


Overload

Fault description:

The machine cannot move or moves difficultly because of overload (thedrive may issue an overload alarm).

Diagnostic steps

Check whether the guide lubrication is sufficient1. Whether the tubing/nozzle is unimpeded.2. Whether the setting of the lubrication interval time is sufficient (theinterval 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 coupling1. Whether the connection is too tight.2. Whether the connection is concentric.


fault


Notes


Notes


Service caseof PLC alarm

We provide guidance in analyzing and diagnosing alarms caused by thestandard PLC in the 808D which are only for Siemens service engineers,OEM service engineers and Siemens authorized service engineers.

Turning/millinggeneral alarms

Case 1

Case 2

Case 3

Case 4 700015

700014

700018

700021

700027

700029

700030

700060

End

700012

700010

700016Case 5

Go to page 26

Go to page 26

Go to page 27

Go to page 27

Go to page 28

Case 6

Case 7

Case 8

Case 9

Case 10

Case 11

Go to page 28

Go to page 29

Go to page 29

Go to page 30

Go to page 30

Go to page 31



Specific millingalarms

Case 1

Case 7

Case 2

Case 8

Case 3

Case 9

Case 4 700032

700031

700059

End

700020

700036700019

700035

700033Case 5

Go to page 32

Go to page 35

Go to page 32

Go to page 35

Go to page 33

Go to page 36

Go to page 33

Go to page 34

700034Case 6 Go to page 34


Specific turningalarms


Case 2

Case 3

Case 4

Case 5 700024

700023

700026

700028

700022

700017

700025Case 6

Go to page 37

Case 1 700013 Go to page 37

Go to page 38

Go to page 38

Go to page 39

Go to page 39

Case 7

Case 8

Go to page 40

Go to page 40

End


700010 700012






主轴制动中。

报警解说

PLC 信息




报警解说

PLC 信息





处理方法


处理方法






主轴制动中。

报警解说

PLC 信息




报警解说

PLC 信息





处理方法


处理方法

Name of alarm:

HHU is active

Address of PLC: DB1600.DBX1.2Name of subprogram: MINI_HHU(SBR 41)

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 beenactivated and the axis selection operation is already in progress.)

No special action is required; the alarm will disappear after cancellationof the handwheel function / cancellation of the handwheel selection.

PLC information

Alarm comment

Processing method

Address of PLC: DB1600.DBX1.4Name of subprogram: SPINDLE(SBR 42)

It is not a fault, the alarm acts as a reminder and points out that the spindleis braking.

Please wait for the end of spindle braking, the alarm will disappear.

PLC information

Alarm comment

Processing method

Name of alarm:

Spindle in braking progress



700014 700015






主轴制动中。

报警解说

PLC 信息




报警解说

PLC 信息





处理方法


处理方法

Name of alarm:

Gear-change timeout

Address of PLC: DB1600.DBX1.6Name of subprogram: GearChg1_Auto(SBR 49)

Fault, the spindle shift time is beyond the permitted limit.

Check whether the gear-change monitoring time of MD14510[x] is set toolow.

Check whether the spindle gearbox has mechanical problems.

PLC information

Alarm comment

Processing method






主轴制动中。

报警解说

PLC 信息




报警解说

PLC 信息





处理方法


处理方法

Name of alarm:

Gear level position error

Address of PLC: DB1600.DBX1.7Name of subprogram: GearChg1_Auto(SBR 49)

Fault, the control cannot accept the gear level signal / the control acceptsthe wrong gear level signal.

Check the related parts of the gear level signal1.Use PLC monitoring to detect if there is an input signal at the gear levelsignal’s relevant input points.2.Check whether the input terminals of the interface on the back of thePPU are damaged/loose or the wiring is damaged.

Check whether the spindle gearbox has mechanical problems.

PLC information

Alarm comment

Processing method





检查 PPU 后侧端子 X102 1.引脚 7 接线是否松动 / 断线。

2.确认引脚 10 是否与 0V 正常连接


驱动器未就绪。


冷却电机过载。

报警解说

PLC 信息

PLC 地址：DB1600.DBX2.0 子程序段名称：EMG_STOP（SBR 33）

故障,运行准备过程中驱动器没有准备就绪

注注注注：：：：该报警必然伴随该报警必然伴随该报警必然伴随该报警必然伴随““““急停报警急停报警急停报警急停报警””””

报警解说

PLC 信息

PLC 地址：DB1600.DBX2.2 子程序段名称：COOLING（SBR 44）

故障,冷却液电机过载,冷却液功能无法正常使用,系统出现报警。

处理方法

检查电柜中冷却电机的过载保护开关是否动作。

处理方法

检查驱动器

1.X6 端子是否插紧 / 接线是否松动或断开 / 65 使能

与 M24 引脚是否故障 2.驱动器是否存在报警 / 未启动

3.驱动器是否损坏

检测是否由于系统存在急停报警而导致该报警发生









报警解说

PLC 信息




报警解说

PLC 信息



处理方法


处理方法

检查驱动器













报警解说

PLC 信息




报警解说

PLC 信息



处理方法


处理方法

检查驱动器





700016 700018






主轴制动中。

报警解说

PLC 信息




报警解说

PLC 信息





处理方法


处理方法

Name of alarm:

Drives not ready

Address of PLC: DB1600.DBX2.0Name of subprogram: EMG_STOP(SBR 33)

Fault, the drive is not ready for operation or preparation.Note: This alarm always appears for an "emergency stop".

Check whether an emergency stop alarm has caused this alarm.

Check the drive1. Whether the terminal of X6 is tight / wiring is loose or disconnected / 65 enable and M24 pins are faulted.2. Whether a drive alarm exists / no startup.3. Whether the drive is damaged.

PLC information

Alarm comment

Processing method

Name of alarm:

Cooling motor overload

Address of PLC: DB1600.DBX2.2Name of subprogram: COOLING(SBR 44)

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.

Check the terminal of X102 on the back of the PPU1. Whether the connection of pin 7 is loose/disconnected.2. Confirm that pin 10 is connected normally with 0 V.

PLC information

Alarm comment

Processing method






主轴制动中。

报警解说

PLC 信息




报警解说

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处理方法


处理方法



700021 700027




润滑油油位低。


旋转监控触发,

请重新返回参考点。

报警解说

PLC 信息

PLC 地址：DB1600.DBX2.5 子程序段名称：LUBRICAT（SBR 45）

故障,油箱中的润滑油低于最低设定值导致该报警产生,若不及时处理,有可

能造成机床的机械损坏。

报警解说

PLC 信息

PLC 地址：DB1600.DBX3.3 子程序段名称：AXIS_CTL（SBR 46）

故障,驱动器丢步导致(多为电机高速运行中发生)。

表现为系统运行程序终止,同时参考点丢失。

检查润滑油是否太少，并及时添加润滑油

处理方法

断电后重新上电观察故障是否排除。

处理方法

在可能范围内适当降低加工速度。

检查 PPU 后侧的相关端子

1.输入点是否损坏 / 松动

2.引脚 10 是否与 0V 正常连接

如果该故障频繁发生,有可能是驱动器出现问题,需要进行更换或维修。

检查驱动器上的 X6 端子中的 24V 24 1.连接是否正确。

2.接线是否断开 / 损坏






主轴制动中。

报警解说

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报警解说

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处理方法


处理方法

Name of alarm:

Lubricant liquid position in low level

Address of PLC: DB1600.DBX2.5Name of subprogram: LUBRICAT(SBR 45)

Fault, the lubricating oil level in the oil box is lower than the lowest setvalue and this results in the alarm; it may cause mechanical damage ifnot corrected in time.

Check whether the lubricating oil level is too low and add lubricating oil in time.

Check the relevant terminals on the back of the PPU1. Whether the input point is damaged/loose.2. Whether pin10 is connected normally with 0 V.

PLC information

Alarm comment

Processing method

Name of alarm:

Approach ref point again after rot. monitoring

Address of PLC: DB1600.DBX3.3Name of subprogram: AXIS_CTL(SBR 46)

Fault caused by a drive stage loss (this usually occurs during motor highspeed operation ).The result is that the running program is terminated and thereference points are lost.

Check the +24 V, Z-M, M24 of the X6 cable on the drive1.Whether the connection is correct.2.Whether the connection has been cut / damaged.

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.

PLC information

Alarm comment

Processing method






主轴制动中。

报警解说

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报警解说

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处理方法


处理方法



700029 700030




第一个维修任务提示信息


第一个维修任务报警。

报警解说

PLC 信息

PLC 地址：DB1600.DBX3.5 子程序段名称：PI_SERVICE（SBR 46）

非故障,此报警作为提示信息。该报警出现时表明：预先在系统中设置好的

第一个维修计划即将到来,请做好准备。

报警解说

PLC 信息



第一个维修计划已到,请马上执行相关服务计划。

核查预先设定好的服务维护计划,做好相关准备

处理方法处理方法

按 PPU 上的“任务完成”键可清除该报警

执行相关的服务维护计划后,按“服务计划”

界面下的“任务完成”软键可清除该报警。

附注附注附注附注：：：：进入进入进入进入““““服务计划服务计划服务计划服务计划””””界面的操作步骤如下界面的操作步骤如下界面的操作步骤如下界面的操作步骤如下


2.按 PPU 上的“服务计划”键







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主轴制动中。

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报警解说

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处理方法


处理方法

Name of alarm:

Reminding information for 1st service plan

Address of PLC: DB1600.DBX3.5Name of subprogram: PI_SERVICE(SBR 46)

It is not a fault, the alarm acts as a reminder. The appearance of thisalarm shows that the reminding information for the 1st service plan whichis set ahead of time is arriving.

Check the predetermined service maintenance plan and make the relevant preparations.

Press the“Task completed”softkey on the PPU to eliminate the alarm.

PLC information

Alarm comment

Processing method






主轴制动中。

报警解说

PLC 信息




报警解说

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处理方法


处理方法

Name of alarm:

Alarm for 1st service plan

Address of PLC: DB1600.DBX3.6Name of subprogram: PI_SERVICE(SBR 46)

It is not a fault, the alarm acts as a reminder. The appearance of thisalarm shows that the reminding information for the 1st service plan whichis set ahead of time has arrived, please execute the relevant service planimmediately.

Press the“Task completed”softkey on the“Serviceplan”interface after executing the relevant serviceplan to eliminate the alarm.

Note: The steps on the "Service plan" interface are as follows

1. Press the“Shift + Diagnosis”buttons at the same time.2. Press the“Service plan”softkey on the PPU.

PLC information

Alarm comment

Processing method






通道未复位,

不能改变 PRT 状态。

报警解说

PLC 信息

PLC 地址：DB1600.DBX7.4 子程序段名称：MCP_NCK（SBR 37）

故障,程序运行过程中,不可使用

“程序测试”键改变此状态,必须

先把系统置于“复位”状态。


也可以按“复位”键取消该报警

（注注注注：：：：此时所执行的程序也被复位了此时所执行的程序也被复位了此时所执行的程序也被复位了此时所执行的程序也被复位了）

按“报警清除”键可取消该报警,程序会继续执行




通道未复位,

不能改变 PRT 状态。

报警解说

PLC 信息

PLC 地址：DB1600.DBX7.4 子程序段名称：MCP_NCK（SBR 37）

故障,程序运行过程中,不可使用

“程序测试”键改变此状态,必须

先把系统置于“复位”状态。


也可以按“复位”键取消该报警

（注注注注：：：：此时所执行的程序也被复位了此时所执行的程序也被复位了此时所执行的程序也被复位了此时所执行的程序也被复位了）

按“报警清除”键可取消该报警,程序会继续执行

700060

Name of alarm:

Channel not in reset, change PRT not possible.

Address of PLC: DB1600.DBX7.4Name of subprogram: MCP_NCK(SBR 37)

Fault, the“Program test”softkey tochange this state is not availableduring the program operation so thesystem must first be switched to the“Reset”state.

Press the“Alarm cancel”button to cancel the alarm,the program will continue.

You can also press the“Reset”button to cancel the alarm.(Note: the implemented program is also reset at this time.)

PLC information

Alarm comment

Processing method






主轴制动中。

报警解说

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报警解说

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处理方法


处理方法



700019 700020






主轴制动中。

报警解说

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报警解说

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处理方法


处理方法

Name of alarm:

Coolant liquid position in low level

Address of PLC: DB1600.DBX2.3Name of subprogram: COOLING(SBR 44)

Fault, the coolant liquid position in the machine is lower than the lowestset value and this alarm is issued; it can cause mechanical damage if notcorrected in time.

Check whether the lubricating oil level is too low and add lubricating oil in time.

Check terminal X102 on the back of the PPU1. Whether the connection of pin 6 is loose/disconnected.2. Whether pin10 has been connected normally to 0 V.

PLC information

Alarm comment

Processing method






主轴制动中。

报警解说

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报警解说

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处理方法


处理方法

Name of alarm:

Lubricating motor overload

of PLC ：DB1600.DBX2.4name of subroutine：LUBRICAT（SBR 45）

Fault, lubricating motor overload, lubricating fluid function cannot be usednormally, the system issues an alarm.

Check whether the motor's lubricating overload protection switch is operable or not.

Check the relevant terminals on the back of the PPU1. Whether the input point is damaged/loose.2. Whether pin 10 is connected normally to 0 V.

PLC information

Alarm comment

Processing method





检查刀库气压是否偏低。

检查刀库推出到位和退回到位的检测开关是否故障。

注注注注：：：：当刀库回到正确位置之后当刀库回到正确位置之后当刀库回到正确位置之后当刀库回到正确位置之后，，，，按按按按““““复位复位复位复位””””键可消除报警键可消除报警键可消除报警键可消除报警


刀库不在主轴及原始位置。

报警解说

PLC 信息

PLC 地址：DB1600.DBX3.7 子程序段名称：DISK_MGZ_M（SBR 60）

故障,刀库既不在主轴位置,也不在原始位置。

此时换刀动作停止。

PLC 信息


处理方法

检查 PPU 后侧端子 X101 1.使用 PLC 状态监控检测 I1.3 / I1.4 的输入状态 2.引脚 5 和 6 接线是否松动 / 断线。



刀库在主轴位及原始位置。



报警解说

故障,系统检测到刀库同时位于主轴位置和原始位置。

此时刀库动作停止。

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处理方法



Name of alarm:

Magazine not in spindle pos. or original pos.

Name of alarm:

Magazine in spindle pos. and original pos.

700031 700032

Address of PLC: DB1600.DBX3.7Name of subprogram: DISK_MGZ_M(SBR 60)

Fault, the magazine is not in the spindle position or the original position,the changing of tool is stopped at this time.

Check terminal X101 on the back of the PPU1. Use the PLC status monitoring to detect the inputstate of I1.3 / I1.42. Whether the connections of pin 5 and pin 6 areloose/disconnected.3. Whether pin 10 is connected normally to 0 V.

Check whether the magazine air pressure is low.

Check whether the test switches of the magazine’s extrusion limit andwithdrawal limit are faulty.

Note: Press the "Reset" button to eliminate the alarm after themagazine has returned to the correct position.

PLC information

Alarm comment

Processing method


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

Check terminal X101 on the back of the PPU1. Use the PLC status monitoring to detect the input state of I1.3 / I1.42. Whether the connections of pin 5 and pin 6 are loose/disconnected.3. Whether pin 10 is connected normally to 0 V.

Check whether the test switches of the magazine’s extrusion limit and withdrawal limit are faulty.

Note: Press the "Reset" button to eliminate the alarm after themagazine has returned to the correct position.

PLC information

Alarm comment

Processing method



700033 700034



注注注注：：：：常见的不可移动刀库的状态常见的不可移动刀库的状态常见的不可移动刀库的状态常见的不可移动刀库的状态

主轴正旋转主轴正旋转主轴正旋转主轴正旋转

刀库正在执行正转刀库正在执行正转刀库正在执行正转刀库正在执行正转反转指令反转指令反转指令反转指令

主轴正在执行松刀指令主轴正在执行松刀指令主轴正在执行松刀指令主轴正在执行松刀指令

系统急停状态激活系统急停状态激活系统急停状态激活系统急停状态激活


刀库或主轴未就绪时,

启动刀库运转。

报警解说

PLC 信息


故障,刀库或者主轴未准备就绪的时候，按下了刀库移动键。

表现为刀库不可移动。

PLC 信息


处理方法


程序段搜索后,

主轴不等于编程刀号。

检查当前程序中即将激活的刀具号选择是否与当前主轴上装载的刀具一致

报警解说

故障,主轴上的刀号与程序中编程刀号不一致。

表现为出现报警,程序不可继续执行。

处理方法

确认已使用正确的“程序搜索”方法重启程序按“复位”键可取消该报警,然后继续进行操作

所有信息核对正确后,可按“复位”键取消该报警











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PLC 信息


处理方法


程序段搜索后,



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程序段搜索后,



报警解说



处理方法



Name of alarm:

Magazine turn key when magazine or sp. not ready


Fault, the“Move magazine”button is pressed when the magazine or thespindle is not ready; the result is that the magazine cannot move.

Press the“Reset”button to cancel the alarm, then continue.

Note：The magazine cannot be moved in the following cases1. The spindle is turning in the positive direction.2. The magazine is executing the forward rotation / reverse rotationcommand.3. The spindle is executing the tool-release command.4. The emergency stop state is activated.

PLC information

Alarm comment

Processing method

Name of alarm:

Block search, tool in spindle <> programmed tool


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.

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 the“Reset”button after making sure that the entire information is correct.

PLC information

Alarm comment

Processing method



Name of alarm：

Spindle not reach tool-release pos. in time


Fault, the tool-release process takes longer than the monitoring time; thisresults in the failure of the spindle tool release.

Check terminal X101 on the back of the PPU1. Use the PLC status monitoring to detect the inputstate of I1.52. Whether the connections of pin 7 are loose/disconnected?

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

Check whether the air pressure is sufficient.Check whether the spindle tool-release switch is normal.Note: Press the“Reset”button to eliminate the alarm after eliminatingthe actual fault.

700035 700036

PLC information

Alarm comment

Processing method

Name of alarm：

Spindle not reach tool-lock pos. in time


Fault, the tool-lock process takes longer than the monitoring time; thisresults in the failure of the spindle tool lock.

Check terminal X101 on the back of the PPU1. 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-lock monitoring timer (T20) in PLC is reasonable.

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 eliminatingthe actual fault.

PLC information

Alarm comment

Processing method



700059

Name of alarm:

Safety door not closed, NC start not possible.

Address of PLC: DB1600.DBX7.3Name of subprogram: AUX_MCP(SBR 20)

Fault, running the program without closing the safety door; the result isthat the program cannot be executed.

Check whether the safety door is closed (if usingthe safety door control key on the MCP, pleasecheck whether this button is activated).

If the safety door has been closed, please check the following:

Check terminal X102 on the back of the PPU1. Whether the connections of pin 7 are loose/disconnected.

Check whether the door-closed limit switch is normal.

Note: Press the“Reset”button to eliminate the alarmafter eliminating the actual fault.

PLC information

Alarm comment

Processing method











报警解说

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处理方法


程序段搜索后,



报警解说



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700013 700017



检查 MCP 上的“卡盘夹紧”指示灯是否点亮该报警产生是由于操作故障,请注意不要在程序运行主轴转动时对卡盘功

能进行操作！


卡盘放松状态,操作禁止。

报警解说

PLC 信息

PLC 地址：DB1600.DBX1.5 子程序段名称：Lock_unlock _T（SBR 56）

故障,没有锁紧卡盘,不允许循环启动以及主轴正反转操作。

PLC 信息

PLC 地址：DB1600.DBX2.1 子程序段名称：MAIN（OB1）

处理方法


主轴或程序运行时,

卡盘操作禁止。

报警解说

故障,在程序运行或主轴转动时不可以对“卡盘夹紧”键进行操作。

处理方法

检查实际机床上的工件是否在卡盘上卡紧。


2.确认引脚 10 是否与 0V 正常连接也可以按“复位”键取消该报警

（注注注注：：：：此时所执行的命令动作也被复位了此时所执行的命令动作也被复位了此时所执行的命令动作也被复位了此时所执行的命令动作也被复位了）

按“报警清除”键可取消该报警,所执行的命令动

作会继续执行。

Name of alarm：

Operation while chuck is not locked

Address of PLC: DB1600.DBX1.5Name of subprogram: Lock_ unlock _T(SBR 56)

Fault, the chuck is not locked tightly and the cycle start as well as thespindle forward/reverse operation is not permitted.

Check whether the MCP "Chuck open" indicator lightis on.

Check whether the actual machine parts are clamped in the chuck.

Check terminal X102 on the back of the PPU1. Whether the connections of pin 5 are loose/disconnected.2. Whether pin 10 is connected normally to 0 V.

PLC information

Alarm comment

Processing method

Name of alarm：

Operate chuck when sp. or part prog. is running

Address of PLC: DB1600.DBX2.1Name of subprogram: MAIN(OB1)

Fault, no“Chuck open”operation when spindle or program is running.

The fault causes the issuing of this alarm. Please notice that there is nochuck operation when the spindle / program is running.

Press the“Alarm cancel”button to cancel thealarm, the action will continue.

You can also press the“Reset”button to cancel the alarm.(Note: The action is also reset at this time.)

PLC information

Alarm comment

Processing method






刀架电机过载。

报警解说

PLC 信息


故障,刀架电机过载,刀架功能无法正常使用,系统出现报警。

表现为所有操作无法执行。

PLC 信息


处理方法


编程刀位,大于最大刀位数。

报警解说

故障,编程错误。

处理方法

核对加工程序内容,根据实际建立刀具数进行编程。



检查电柜中刀架电机的过载保护开关是否动作。




刀架电机过载。

报警解说

PLC 信息


故障,刀架电机过载,刀架功能无法正常使用,系统出现报警。

表现为所有操作无法执行。

PLC 信息


处理方法


编程刀位,大于最大刀位数。

报警解说

故障,编程错误。

处理方法

核对加工程序内容,根据实际建立刀具数进行编程。



检查电柜中刀架电机的过载保护开关是否动作。

700022 700023

Name of alarm:

Turret motor overload


Fault, the turret motor is overloaded, the function cannot be used normally,the system issues the alarm; the result is that all operations arenot available.

Check whether the motor overload protection switchIs operable.

Check terminal X102 on the back of the PPU1. Whether the connections of pin 2 are loose/disconnected.2. Whether pin 10 is connected normally with 0 V.

PLC information

Alarm comment

Processing method

Name of alarm:

Programmed tool num. > max. tool number


Fault, because the program is incorrect.

Check the content of the machining program, then set the program toolnumber according to actual situation.

PLC information

Alarm comment

Processing method











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处理方法


程序段搜索后,



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700024 700025




最大刀位数设置错误。

报警解说

PLC 信息


故障,系统中设置的最大刀位数不合适。

正确的设置数目为：4 或 6

PLC 信息


处理方法


无刀位信号。

报警解说

故障,系统任何刀位信号都无法检测到。

处理方法

检查参数 MD14510[20] (最大刀位数) 设置是否合理。

检查 PPU 后侧对应的 I/O 口端子

1.连接线是否断开 / 松动

2.端子是否损坏 / 松动

3.端子上的 M 点是否与 0V 正确连接

检查刀架码盘

1.刀架信号点是否损坏

2.刀架本身是否故障

Name of alarm：

Max. tool number setting error


Fault, the setting of the max. tool number in the system is not correct.The correct setting number is：4 or 6

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

PLC information

Alarm comment

Processing method

Name of alarm：

No position signals from turret


Fault, no position signals can be detected from the turret.

Check the tool code wheel1.Whether the tool signal point is damaged.2.Whether the tool itself is faulty.

Check the corresponding terminals of theI/O interface on the back of the PPU1. Whether the connections are disconnected/loose.2. Whether the terminals are damaged/loose?3. Whether the point of mon. terminal is connected normallyto 0 V.

PLC information

Alarm comment

Processing method



700026 700028

Name of alarm:

Not able to find expected tool in monitor time


Fault, the alarm appears because no tool position is detected in the timelimit.

Check the tool code wheel1.Whether the tool signal point is damaged.2.Whether the tool itself is faulty.

Check the corresponding terminals of the I/O interface on the back of the PPU1. Whether the connections are disconnected/loose.2. Whether the terminals are damaged/loose.3. Whether the point of the mon. terminal are connectednormally to 0 V.

Check whether the settings of MD14510[22] are correct (thevalue can be increased appropriately).

PLC information

Alarm comment

Processing method











报警解说

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程序段搜索后,



报警解说



处理方法



Name of alarm:

Tool is not locked

Address of PLC: DB1600.DBX3.4Name of subprogram: Turret3_CODE_T(SBR 53)

Fault, the tool-locked signal is not in the system and therefore the tool isnot locked tightly.

Check the tool-locked signal1.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 thePPU are damaged/disconnected.3. Use the PLC monitoring to detect whether the corresponding input pointof this signal has input signals.

PLC information

Alarm comment

Processing method











报警解说

PLC 信息




PLC 信息


处理方法


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报警解说



处理方法





Notes

Notes


Notes


Notes


Everything ever wanted to know about SINUMERIK 808D: www.siemens.com.cn/808D

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Subject to change without prior noticeOrder No.: Dispostelle 06311WÜ/35557 WERK.52.2.01 WS 11113.0Printed in Germany© Siemens AG 2012

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Documents

Alarm Sinumerik 808 d