Hi, I'm looking for some guidance to troubleshoot a new to me CNC machine to run. The controller is an 840Di sl with PCU 50.3-c . At first, I could not get the system to boot at all and diagnosed that the PSU may have failed since it was clicking and not getting power when turned on. I replaced with a costly new PSU, and it still would not power on. Come to figure out, this machine comes with a SITOP 1600 that's connected to an external UPS (two 12V 3.2ah batteries). These batteries were faulty and when replaced with new, system would now boot (would never figure UPS could prevent power on).

Now once booted and HMI loaded, I'm unable to progress further to get the machine to turn on the servos/drives and function. In the Alarm messages, I'm getting a 3000 Emergency Stop and cannot get it cleared (There are 6 physical emergency stops around the machine I've checked countless time to ensure they are released). Other alarms are the MNT--001 (Check the daily inspection items) and PANEL-060 (UPS Battery comes to abnormal. Change to UPS battery to new one) . For the PANEL-060 I cannot get it cleared either, I'm not sure what the logic for checking this is as the batteries are new measuring 24+ volts at the terminals and SITOP UPS1600 is showing Green status on LED 1 & 2.

Next, I try to check the Diagnostic Buffer in Simatic Manager that is located on the system. I'm seeing ~10 I/O access error requests to OB122. Not sure if this is because the machine drives/servos have not started yet because of the E-Stop. Was hoping to see something related to what is triggering the E-Stop.

It may bet worth noting that there does not seem to be a license attached to the 840Di after checking with license manager (license for the Step 7 does exist however). I have the physical license certificates but have not pursued getting it resolved through support request yet.

I'm new to this and tried to troubleshoot this far myself, but not sure which direction to head from here because not sure what issue I should focus on that is ultimately preventing the machine from starting. Could it be license issue that's throwing things off, or faulty modules somewhere that's preventing proper communication, or needing to understand the PANEL-060 alarm logic that may be throwing the emergency stop?

I've made backups of ghost system image and archives of the NC/PLC/Drives/HMI etc. I've tried reloading past archives and still experience same issue.

I'm just throwing all the information I've discovered so far and hopefully someone can help steer me in the right direction, I thank you for your time and help. Attached are some screen pictures.