Please post NCU part# is it 840D Powerline or Solutionline ?

You use same NCU to replacement? why do you need to replace. 

Did you try to insert old NCU back and reloading backup files to see what happen?

Hello,

Significance of the alarm is, difference between safe actual value in NCK & drive is greater than set in MD 36942 i.e. SAFE_POS_TOL. Since you replaced NCU card, value in NCU is zero,where as drive position value is retained due to which difference is too large, which results in triggering alarm/fault.

To overcome this problem, you need to carry out axis encoder re-evaluation i.e.  commissioning. Please refer manual SINUMERIK 840D sl/SINAMICS S120, SINUMERIK Safety Integrated & SINUMERIK 840D sl: Component replacement for Safety Integrated as of CNC software 4.7 FAQ which will help you to understand commissioning of SI component. 
If you are not fully aware with commissioning then I suggest you to contact your local Siemens support/service center or OEM.

How many & which type of encoders are configured to axes?

Which safety functions are enabled? for NC check MD36901 & for drives check CU p9501 value.

You need to carry out referencing of axes & check.

 I still not understand you. what are you doing? what is meaning "Solution Line setup" are You machine builder ? making a new machine set up. You don't answer "WHY you replaced NCU? "

PISCEAN already answered you and suggested Siemens manuals.  your original post has STEPs, 1, 2,3, ..where are those coming?

Actually I didn't do any 840D sl with SI recovery. But couple of times 840D PL SI recovery/ Replaced NCU.

I remember one step is --after reloading NCK/PLC arc. DO NOT activate "SI" right the way. to see machine can be jog? and making Reference all axis. then activate "SI" --PL "set User Agreement 

There are some OEM menus, But I did all steps quit smoothly--every time just one time

successful   

So I can only suggest you, check if you are sure the back up data are good? why you load back to old NCU also failed ? are there all same error ? @PISCEAN , do you understand why for this point 

Check if you can reference machine before set "SI"--

msmith_1988f

It is a Solution Line setup. After doing some more research the drive and nck have different values for 2 of the axis. This was after a Copy and Comfirm SI Yes the same issue occurs with the old ncu card.  

The NCK is at 0 while the drive has the correct value.

nulizhang

 @PISCEAN , do you understand why for this point 

msmith_1988f

 

Hello nulizhang,

@PISCEAN,

Thanks for response. I mean --why user load back to original NCU machine still failed. 

You know I said the back up data is most important , in 840D PL , special with "SI" function, I always suggest my customers, making good archive regularly (update). and try to make back up when machine in the good condition and reference all axis if with ATC return spindle tool (some OEM making T0 to do so) .

And I said I did couple of times for PL recovery due to NCU defective, normally one time successful.

Some OEM let operator Jog and reference  after reloading archives, then set "User agreement" recycle the power. --Can you share similar action in 840D sl regarding this step --means what time to set or copy "SI" data? 

I also remember some machine loading archine sequence also matter --maybe NC.arc 1st then PLC.arc, If not working do it reviser.

 BR