AutoGen_2671741

When I say I homed the axis I mean i turned it by hand until it lined up with its home position mark and I set it there. I wasn't able to jog it over due to the fact that the axis enable is missing.

 Are you commissioning this machine or machine was in operational & problem has occurred during operation? 

OK. So summary is, - this is working machine. You replaced motor (reason of replacement is not mentioned), alarm 25022 popped up. It is mainly for to calibrate absolute encoder. After calibration of encoder alarm 25022 disappeared but system displayed Emergancy stop -3000.

Assuming above true, please check below points.

1. Have you modified sinamics drive encoder feedback parameter of corresponding axis? i.e. original 16 bit & new replacement by 22 bit) Do you see any LED indication/fault on Sinamics CU?

2. Have you defined/calibrate the encoder at same/exact original position?

3. Have you cross checked the working limits, safe limits of machine axes defined in setting data?

4. Could you please explain the reason of replacement of motor?

5. Is your system has safety integrated features?

HTH. 

1. Not sure where to check the bit count 16 or 22. LED indication on the frot of the drive shows ready. Top LED orang and bottom is green.

2. I ran through the axis calibration steps as suggested by you earlier and it is set. Only difference is that in the past when I run through a axis cal I was able to set MD34210 to 0 and jog the axis to its home mark then change it to 1 and hit the + and set the axis. This time since none of my axis will move I had to move the motor to its home position by hand and set it. Which did clear the 25022 alarm I had.

3. I have not checked the work limits but I will verify when I get to the shop today. I'm fairly certain that the x axis(which is the one in question) is setting at 15" ish.

4. The reason I replaced the original motor was due to its encoder failing. And as far as the paramiters difined for the new motor. It appears that they are all correct. In the S120 drive at least. I checked the encoder info against the other axis and it looks as though the Starter Commisioning tool filled them in correctly. The problem is there are literally 100s of parameters. I feel that since the only alarm I'm carying now is the 3000NCK I think the parameters are set correctly in the S120 drive and that the problem likely exists elseware but that is an assumption. This is my first time modifying a 840dsl system.

5. I am not sure if the system ha safety integrated features. How would I know.

One thing I do know is that this controller is super overkill for my simple three axis cnc machine with no tool changer. I liked it at first because I though it would be easy to expand and work on being a modular design. I wanted to add a tool changer and a 4th mabe even a 5th axis but considering how much trouble it is to change a freaking encoder I'm thinking not. 

Ok.

Just one suggestion, please attach the photo snaps of operator screen/display, sinamics drive CU when alarm 3000 display. Moreover at same time check the diagnosis, to do so, press MENU SELECT key on keypad ------> Diagnosis (horizontal softkey) --------> Alarms (horizontal softkey).

This window will display other alarm if exist along with emergency alarm.

HTH.

Hello,

From the attached snaps , it is clear the below are the alarms displayed by system which are causing emergency alarm 3000. Are those snaps taken when Emergancy 3000 alarm displayed status? 

1. PLC CRASH - Why this alarm displays? If this alarm pops up then how NCU 7-segment displays 6? Please check the LED display status on NCU.

2. Alarm 25282 - Axis SP & Z1 waiting for drive. This alarm is displayed when the communication to drive fails. Please check the profibus or drive CLiQ connection of drive. (It depends how sinamics drives are connected) Most probably may be loose connection or cable problem.

In case of earlier alarm 25022, during remedial action/steps axis motion must be via system & not by manual/hand.

To summaries -

Check why PLC crash alarm pops up? Have you changed any PLC related data or modified PLC logic?

Please check the drive CLiQ or profibus connection of Sinamics drives.

HTH. 

AutoGen_2671741

Please Note that the PLC_CRASH is a result of the 3000 NCK alarm note the cause. 

 Hello,

Please refer the attached sheet. (Extracted from Siemens manual)

DB10.DBX56.1 is signal for emergency stop. It is signal to NC from PLC. So when PLC gets crash, it sends signal to NC & 3000 alarm outputs.

According to me, after change in motor with different encoder, motor identification has not been carried out correctly, moreover during diagnosis, NC or PLC data/parameter might have been changed, which has made the work more difficult.

HTH.

Ahh. I stand corrected. Knowing that the motor has been changed with one of a similar type with the exception of the encoder and the fact that I am carrying the 3000 NCK alarm. Where might I begin trouble shooting to find what is holding me up. I'm imagining that if I were a field tech I would have some sort of generic attack plan when it comes to these types of situations. A general guide of sorts. For instance if this were a combustion engine that would not start I know that all I have to do is privide fuel, air, compression and fire. I realize this situation is a bit more complex then that but I'm not necessarily looking for simple just a starting point from which to trouble shoot. The 3000 NCK alarm isn't giving me much to go on or maybe it is and I just cannot see it. Also maybe it would help if someone could tell me how they would go about changing from one motor to another and I could start over from the beginning using their technique.

OK.

Please refer attached sheets which will give detailed information as how to commission Siemens motor & encoder. In drive CLiq Technic motor is identified but encoder needs to be configure.

HTH.

To follow the instruction that you provide I need to reset my NCU & PLC to factory setting to put the system into "Commisionning". This would require that I recommision both PLC and NCU. I have been reading the commisionning manual for my hardware and it has some pre-reqs.

-STEP 7 V5.5 ***I have this downloaded as a 14 day trial***

-STEP 7 Package for NCU7x0 on PG/PC(toolbox) ***I have not been able to locate this software. Any ideas?***

-GSD file ***no idea where to find this or what it is really***

-Compact Flash Card with CNC software. ***This I Have***

-External HMI or commissioning tool on PG/PC for the commissioning of internal HMI. *** It doen't tell me what sotware it is refering to***

Hello,

I suggest you to contact your nearest Siemens service support, since these s/w are not available with you. Even if you procure encoder equivalent to one, it needs to be align/configure. For this also you may need help from Siemens motor division technical support.

So please contact your nearest Siemens service support.

OK, Fine.

But does your company will allow you to keep a CNC machine under brake down for so long time? Step 7 is costly software.

Don't you think, it will be more costlier to keep machine under-brake down?

Instead with field technician/engineer support, the machine could be put back into operation. 

Problem Solved.

After receiving my new encoder I swapped out but still alarms persist. Different alarms but still no function. The encoder was brand new so it was apparent that the issue may not be the encoder. To prove the theory I traded the "X" & "Z" encoders thinking that if it were the encoder the problem would follow it. The problem did not. The alarms remained and after setting the "Z" home ref it was good to go. Next I tested the drive cliq cable trading "X" for "Z". Still the problem remained with "X". This left only the motor SMI, the S120 Drive itself, or the small section of cable inside the motor between the encoder and the SMI. I had an extra motor so I swapped the small section of cable inside the motor. I cycled the power and the axis came alive. I set the home ref and the machine lives once again. So, summory, don't take the alarms that are generated at face value. Check all possible simple possibilities first. My assumption cost me $700 for the new encoder(which was a bargain). Plus through unfortunate tinkering I destroyed the original encoder that in hind sight was a perfectly good encoder.