Siemens SINUMERIK 808D, Service Manual

Page 1: ...presenting the highest degree of danger will be used A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage Qualified Personnel The product system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation in particular its warning notices and safety...

Page 2: ...enance personnel Function Manual Mechanical and electrical designers technical professionals Parameter Manual Mechanical and electrical designers technical professionals Service Manual Mechanical and electrical designers technical profession als commissioning engineers and service and maintenance personnel Readme file Third party software Licensing terms and copyright information My Documentation ...

Page 3: ...le encoder alarm 17 3 8 Handwheel fault 17 3 9 Feed axis fault 18 3 10 Axis moving direction fault 18 3 11 Positioning error 19 3 12 Tool change fault 19 3 13 Overload 20 3 14 System crash during startup 20 3 15 Hardware limit fault 20 3 16 Reference point approach fault 21 3 17 Drive alarm 22 3 18 Option activation failure after PPU replacement 23 3 19 CNC lock alarms 28 3 20 OEM PIN forgotten fo...

Page 4: ...cal devices when you are qualified for this job Always observe the country specific safety rules Generally six steps apply when establishing safety 1 Prepare for shutdown and notify all those who will be affected by the procedure 2 Disconnect the machine from the supply Switch off the machine Wait until the discharge time specified on the warning labels has elapsed Check that it really is in a no ...

Page 5: ...he applicable regulations WARNING Danger to life due to electric shock when opening plug connections in operation When opening plug connections in operation arcs can result in severe injury or death Only open plug connections when the equipment is in a no voltage state unless it has been explicitly stated that they can be opened in operation WARNING Danger to life through electric shock due to the...

Page 6: ...ts WARNING Danger to life due to the motor catching fire in the event of insulation overload There is higher stress on the motor insulation through a ground fault in an IT system If the insulation fails it is possible that death or severe injury can occur as a result of smoke and fire Use a monitoring device that signals an insulation fault Correct the fault as quickly as possible so the motor ins...

Page 7: ...out Touching moving motor parts or drive output elements and loose motor parts that are flung out e g feather keys in operation can result in severe injury or death Remove any loose parts or secure them so that they cannot be flung out Do not touch any moving parts Safeguard all moving parts using the appropriate safety guards WARNING Danger to life due to fire if overheating occurs because of ins...

Page 8: ...nsible for preventing unauthorized access to its plants systems machines and networks Systems machines and components should only be connected to the enterprise network or the internet if and to the extent necessary and with appropriate security measures e g use of firewalls and network segmentation in place Additionally Siemens guidance on appropriate security measures should be taken into accoun...

Page 9: ...vironmental conditions outside the specification External influences damage 3 Hazardous shock voltages caused by for example Component failure Influence during electrostatic charging Induction of voltages in moving motors Operation and or environmental conditions outside the specification Condensation conductive contamination External influences damage 4 Electrical magnetic and electromagnetic fie...

Page 10: ...In this manual the following four types of service cases are described Service cases of the hardware software faults Page 11 Service cases of the PLC alarms Page 31 Service cases of the NC program alarms Page 45 General NC program alarms Page 47 Notes ...

Page 11: ... 18 Case 10 Axis moving direction fault Page 18 Case 11 Positioning error Page 19 Case 12 Tool change fault Page 19 Case 13 Overload Page 20 Case 14 System crash during startup Page 20 Case 15 Hardware limit fault Page 20 Case 16 Reference point approach fault Page 21 Case 17 Drive alarm Page 22 Case 18 Option activation failure after PPU replacement Page 23 Case 19 CNC lock alarms Page 28 Case 20...

Page 12: ... back of the PPU for the following Whether the connection is loose Whether the 24 V terminal matches the interface Whether the 24 VDC power supply is available by measuring with a multimeter 2 Replacement and maintenance are necessary if the fault still exists after the above operations because probably the PPU is damaged 3 2 PPU HMI fault Fault description The HMI screen or the keys on the PPU ar...

Page 13: ...k whether the PPU interface X30 or the MCP interface X10 is damaged or subject to bad contact You may verify this by using a new cable 3 Check the PLC programs since a PLC program fault can also cause the flashing of all the status LEDs on the MCP 4 Replacement and maintenance are necessary if the fault still exists after the above operations because probably the PPU or MCP is damaged 3 4 MCP key ...

Page 14: ...ce is available on the PPU160 2 only Fault description Data transmission is not possible via the RS232 interface Diagnostic steps 1 Check the RS232 communication settings on the PPU for the following Whether the communication is activated Whether the communication parameters match the PC terminal Whether the X2 interface on the PPU is loose Whether the cable of RS232 is damaged Whether the RS232 i...

Page 15: ...th an encoder 0 for the spindle without an encoder 2 If you use an analog spindle check the spindle interface X54 on the back of the PPU for the following Whether the interface is loose or damaged Whether there is voltage output by measuring pins 1 and 9 of X54 with a multimeter after starting the spindle 3 Check whether the connection cables of the PPU spindle drive and encoder are in good condit...

Page 16: ...ve diagnostic steps for case 1 to check the spindle if the fault still exists Case 3 1 Check whether there is interference between the connection cables Make sure you route the power cables and signal cables separately 2 If you use an analog spindle check the interface X54 on the back of the PPU for the following Whether the interface is loose or damaged Whether the connections have bad contact 3 ...

Page 17: ...whether the spindle encoder is damaged Replace the encoder with a new one and test it again 5 Replacement and maintenance are necessary if the fault still exists after the above inspection because probably the PPU is damaged 3 8 Handwheel fault Fault description The handwheel is not available or cannot be assigned to an axis successfully Diagnostic steps 1 Check whether the operating sequence is c...

Page 18: ...PPU screen it must be deactivated 2 Check whether the mechanical coupling is loose 3 Check whether the connections between the control system and the drives are in good condition and whether the terminals on the drives are damaged 4 Replacement and maintenance are necessary if the fault still exists after the above inspection because probably the PPU is damaged Case 2 1 Check whether the settings ...

Page 19: ...me position Diagnostic steps Case 1 1 Check whether the phase sequence of the connection of the machine power supply turret motor is correct 2 Check the interface of turret rotation signal output turret in position signal input on the back of the PPU Whether it is damaged Whether the wires are loose Whether the terminals 1 and 10 are connected respectively to 24 V and 0 V Whether the connection is...

Page 20: ...he fault is resolved 2 Power off the control system and check whether the CF card is insert ed correctly or has a faulty contact and then power on again to check whether the fault is resolved 3 Replacement and maintenance are necessary if the fault still exists after the above inspection because probably the PPU is damaged 3 15 Hardware limit fault Fault description Case 1 The hardware limit switc...

Page 21: ...itch Case 7 Press the desired axis traversing key the Jog operation and automatic program execution run normally but the system does not respond when approaching the reference point Case 8 When approaching the reference point the position of the axis is out by the pitch of leadscrew Diagnostic steps Case 1 1 Check if there is an alarm on the PPU screen and continue operation after eliminating the ...

Page 22: ...INAMICS V60 drive and F30001 F30002 F31117 for the SINAMICS V70 drive Diagnostic steps A05 A06 F30001 IGBT or internal chip overcurrent It may appear when the main power supply is connected during motor operation 1 Check the U V W and PE connections on the drive for the following Whether connections between different phases are short circuited Whether a U V or W phase is disconnected Whether the g...

Page 23: ...le shielding is poor Whether the shielded ground cable is connected correctly 2 Power on again and observe whether the fault still exists after verification 3 If the fault still exists after the above operation check the connection of the encoder interface 4 Replacement and maintenance are necessary if the fault still exists after the above inspection because probably the motor encoder is damaged ...

Page 24: ... instructions in the Web License Manager to assign the licenses of your purchased options to the new PPU A license key is generated after the licenses are assigned success fully 6 Enter the license key generated by the Web License Manager in the following dialog box 7 Press this softkey to confirm your entry 8 Then you can press this softkey to check the licensing status in the following window fo...

Page 25: ...e for activating the CNC lock function 1 Start Access MyMachine on your computer 2 Select the following menu command 3 Click this button in the displayed dialog box to proceed to the next step 4 Enter the data required in the dialog box for example The software version 4 7 SP4 must be selected for the SINUMERIK 808D SINUMERIK 808D ADVANCED control system Serial number of the new CF card which can ...

Page 26: ...the screen displays as follows which indicates the CNC lock option is licensed and set properly 9 Press this softkey to open the file opening dialog box 10 Select the target directory and press this key to enter it 11 Find the desired activation file and press this softkey to import If no error occurs when importing the activation file the CNC lock function is active in the control system You can ...

Page 27: ...ollowing steps to create and import the deactivation file 1 Start Access MyMachine on your computer 2 Select the following menu command 3 Click this button in the displayed dialog box to proceed to the next step 4 Enter the following data in the dialog box Serial number of the new CF card Serial number of the new hardware PPU The original assigned OEM PIN For example 5 Click this button to save th...

Page 28: ...replacement Page 23 Alarm 8063 The alarm is a reminder of the lock date indicating the remaining days before the NC start is locked Contact the machine manufacturer or dealer to extend deactivate the CNC lock function Alarm 8064 If the lock date is reached alarm 8064 is issued and the NC start disabled Contact the machine manufacturer or dealer to deactivate the CNC lock function Alarm 8065 If a d...

Page 29: ...d provide the following information to unlock the machine License certificate CoL for the option of the CNC lock function Serial number of the CF card Serial number of the hardware PPU Software version of the CNC software Note The software version of the CNC software can be found on the PPU HMI through the following operations After receiving the activation file from the Hotline the machine manufa...

Page 30: ...Service Manual 30 01 2017 Notes ...

Page 31: ...e 38 Case 6 Alarm 700034 Page 38 Case 7 Alarm 700035 Page 39 Case 8 Alarm 700036 Page 39 Case 9 Alarm 700059 Page 40 Specific turning alarms Case 1 Alarm 700013 Page 40 Case 2 Alarm 700017 Page 41 Case 3 Alarm 700022 Page 41 Case 4 Alarm 700023 Page 42 Case 5 Alarm 700024 Page 42 Case 6 Alarm 700025 Page 42 Case 7 Alarm 700026 Page 43 Case 8 Alarm 700028 Page 43 Note PLC interface signal addresses...

Page 32: ...signing the handwheel 4 1 2 Alarm 700012 Name of alarm It is not a fault but a reminder that the spindle is braking PLC information PLC address DB1600 DBX1 4 Subroutine SPINDLE SBR 42 Remedy Wait for the end of spindle braking and then the alarm will disappear 4 1 3 Alarm 700014 Alarm description The spindle gear change time is beyond the time limit PLC information PLC address DB1600 DBX1 6 Subrou...

Page 33: ...ls of the interface on the back of the PPU are damaged loose Check whether the spindle gearbox has mechanical problems 4 1 5 Alarm 700016 Alarm description The drive is not ready for operation Note This alarm always appears along with the alarm of emergency stop PLC information PLC address DB1600 DBX2 0 Subroutine EMG_STOP SBR 33 Remedy Check whether there is an emergency stop alarm on the control...

Page 34: ...Alarm description This alarm appears because the lubricating oil level in the oil box is lower than the minimum set value It may cause mechanical damage if no remedies are taken in time PLC information PLC address DB1600 DBX2 5 Subroutine LUBRICAT SBR 45 Remedy Check whether the lubricating oil level is too low and add lubricating oil in time Check the relevant interfaces on the back of the PPU fo...

Page 35: ...ontrol system You need to execute the service plan immediately PLC information PLC address DB1600 DBX3 6 Subroutine PI_SERVICE SBR 46 Remedy 1 Select the system data operating area 2 Press this key on the PPU to access the extended softkeys 3 Enter the main screen of service planning 4 Press this softkey on the PPU after executing the relevant service plan to cancel the alarm 4 1 10 Alarm 700060 A...

Page 36: ...Remedy Check whether the coolant level is too low and add coolant in time Check the interface X102 on the back of the PPU for the following Whether the connection of pin 6 is loose broken Whether pin 10 is connected properly to 0 V 4 2 2 Alarm 700020 Alarm description The motor of the lubricating system is overloaded The lubricant function cannot be used normally and the control system issues an a...

Page 37: ...Press the following key on the MCP to cancel the alarm after the magazine has returned to the correct position 4 2 4 Alarm 700032 Alarm description The system detects that the magazine is in the spindle position and the original position at the same time The tool change action stops in this case PLC information PLC address DB1600 DBX4 0 Subroutine DISK_MGZ_M SBR 60 Remedy Check the interface X101 ...

Page 38: ...indle is executing the tool release command The emergency stop state is activated 4 2 6 Alarm 700034 Alarm description This alarm appears because the spindle tool number is different from that in the program The program cannot be executed in this case PLC information PLC address DB1600 DBX4 2 Subroutine DISK_MGZ_M SBR 60 Remedy Check whether the number of the tool to be activated in the current pr...

Page 39: ...icient Check whether the spindle tool release switch works normally Note Press the following key on the MCP to cancel the alarm after eliminating the faults 4 2 8 Alarm 700036 Alarm description The tool clamping time exceeds the monitoring time which results in the failure of spindle tool clamping PLC information PLC address DB1600 DBX4 4 Subroutine DISK_MGZ_M SBR 60 Remedy Check the interface X10...

Page 40: ... key is activated Check the interface X102 on the back of the PPU for the following Whether the connection of pin 7 is loose broken Whether pin 10 is connected to 0 V properly Check whether the door closed limit switch works normally Note Press the following key on the MCP to cancel the alarm after eliminating the faults 4 3 Specific turning alarms 4 3 1 Alarm 700013 Alarm description The chuck is...

Page 41: ...broutine MAIN OB1 Remedy Press this key on the PPU to cancel the alarm and the program will continue You can also press this key on the MCP to cancel the alarm Note The program execution is also reset in this case 4 3 3 Alarm 700022 Alarm description This alarm appears because the turret motor is overloaded and the turret function cannot be used normally In this case all operations are not availab...

Page 42: ...o 4 or 6 on the control system PLC information PLC address DB1600 DBX3 0 Subroutine MAIN OB1 Remedy Check whether the setting of MD14510 20 max tool number is correct 4 3 6 Alarm 700025 Alarm description No position signals can be detected from the turret PLC information PLC address DB1600 DBX3 1 Subroutine MAIN OB1 Remedy Check the turret encoder to see whether the turret signal interface is dama...

Page 43: ...inals are damaged loose Whether pin 10 is connected to 0 V properly Check whether the setting of MD14510 22 is correct the value can be increased appropriately 4 3 8 Alarm 700028 Alarm description The control system does not detect the tool clamp signal PLC information PLC address DB1600 DBX3 4 Subroutine Turret3_CODE_T SBR 53 Remedy Check the tool clamp signal in the following ways Check whether ...

Page 44: ...Service Manual 44 01 2017 Notes ...

Page 45: ...ase 2 Run the program in the AUTO mode M11 is deactivated so that the chuck cannot be released Remedy Case 1 In the PLC program an interlock exists so the program running is prohibited when the chuck is released You need to modify the PLC subroutine In most cases with the chuck released the spindle is not allowed to run in CW or CCW direction when in the positioning or oscillating mode Case 2 A dw...

Page 46: ...cannot be reset to zero after the control system is switched back to Siemens mode Remedy 1 Select the machining operating area 2 Switch to MDA mode 3 Enter the following program in the block editor G291 G50 3 X0 Z0 4 Press this key on the MCP and the zero offset activated previously in ISO mode is reset to zero Notes ...

Page 47: ...Service Manual 01 2017 47 6 General NC program alarms For more information about the general NC program alarms refer to the SINUMERIK 808D SINUMERIK 808D ADVANCED Diagnostics Manual Notes ...

Page 48: ...olate the rights of the owner Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described Since variance cannot be precluded entirely we cannot guarantee full consistency However the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions Siemens AG Division ...