Skip to content
  • There are no suggestions because the search field is empty.

28 Troubleshooting (Clone)

Siemens SINUMERIK 828D

28.1 Siemens - Removing and Add the 4th axis unit

28.1.1 Foreword

Machines equipped with the 4th axis units have been built such that the user can remove and re-install the 4th axis as needed without manipulating multiple machine parameters

An Easy Extend function is available to make this process easy.

28.1.2 User level

The instructions herein require a user to have a good understanding of the operation of a CNC Milling machine.

In order for the user to be able to complete the steps, the physical controller key must be switched to “Setup” or “I”

28.1.3 Procedure

The 4th axis units are heavy!

Use suitable lifting equipment and observe safe lifting pratices 

Correctly rated lifting eyes are provided with the 4th axis units for this purpose

28.1.4 Removing the 4th axis:

1

Press the Menu Select key on the controller to allow selection of the advance menus

2

Press the Setup Page soft key on the bottom row of the screen

3

Press the Password soft key on the vertical row on the right hand side of the screen

4

 

Type in the system Password: SUNRISE

5

Press the OK button to accept the password. If the password has been typed correctly you will receive an acknowledgement

6

Press the OFFSETS button on the Controller

7

Scroll the bottom row of softkeys to the Right pressing the menu advance button

8

Enter the Easy Extend Menu using the softkey on the bottom of the screen

9

 

Highlight the “add/remove A axis, Estop required” option on the screen

10

Press the enable function softkey

11

 

When prompted, type in the passcode: 123456

12

Press the Emergency Stop Button

13

Press the activate softkey to enable the ATC adjusting mode.

The Process or removing the 4th axis will take approximately 1-2minutes

14

When the process is complete, switch off the power to the machine using the Isolator on the electrical cabinet

15

 

The 4th axis can now be safely removed from the machine by disconnecting the air or oil hoses and electrical connectors

28.1.5 Re-Installing the 4th axis:

1

Press the Menu Select key on the controller to allow selection of the advance menus

2

Press the Setup Page soft key on the bottom row of the screen

3

Press the Password soft key on the vertical row on the right hand side of the screen

4

 

Type in the system Password: SUNRISE

5

Press the OK button to accept the password. If the password has been typed correctly you will receive an acknowledgement

6

Press the OFFSETS button on the Controller

7

Scroll the bottom row of softkeys to the Right pressing the menu advance button

8

Enter the Easy Extend Menu using the softkey on the bottom of the screen

9

 

Highlight the “add/remove A axis, Estop required” option on the screen

10

Press the enable function softkey

11

 

When prompted, type in the passcode: 123456

12

Press the Emergency Stop Button

13

Press the activate softkey to enable the ATC adjusting mode.

The Process or removing the 4th axis will take approximately 1-2minutes

14

When the process is complete, switch off the power to the machine using the Isolator on the electrical cabinet

15

 

The 4th axis can now be safely installed in the machine by reconnecting the air or oil hoses and electrical connectors

28.2 Siemens - Re-Referencing or resetting the ARM TYPE Tool Changer

28.2.1 Foreword

There will potentially be instances in the operation of the SYIL CNC Machines that will require the user to manipulate the components of the Automatic Tool Changer in order to reset it or re-reference it.

Examples include when a user presses the Emergency Stop button during a tool change or if through use the physical carousel pocket numbers do not match the ones indicated within the controller.

For further understanding of the general operation of your Automatic Tool Changer, refer to the dedicated manual provided with your machine

28.2.2  User level

The instructions herein require a user to have a good understanding of the operation of a CNC Milling machine.

In order for the user to be able to complete the steps, the physical controller key must be switched to “Setup” or “I”

28.2.3 Procedure

If the ATC ARM has stopped with a tool gripped or mid swing, Do not proceed until you have spoken to a SYIL Engineer

28.2.4 Empty the magazine-Recommended:

1

 

Remove the tool within the spindle

2

 

Open the right hand side of the machine

3

 

Using the sheet metal tool supplied with the machine, remove the tools within the magazine

4

On the controller, press enter the Offset screen

5

Virtually unload the tools on the controller so that the tool data is not lost

28.2.5 Enable the Tool Adjust Mode:

1

Press the Menu Select key on the controller to allow selection of the advance menus

2

Press the Setup Page soft key on the bottom row of the screen

3

Press the Password soft key on the vertical row on the right hand side of the screen

4

 

Type in the system Password: SUNRISE

5

Press the OK button to accept the password. If the password has been typed correctly you will receive an acknowledgement

6

Press the OFFSETS button on the Controller

7

Scroll the bottom row of softkeys to the Right pressing the menu advance button

8

Enter the Easy Extend Menu using the softkey on the bottom of the screen

9

 

Highlight the “Tool adjust mode” option on the screen

10

Press the enable function softkey

11

 

When prompted, type in the passcode: 123456

12

Press the activate softkey to enable the ATC adjusting mode 

28.2.6 Recovering from an E-stop during a tool change

1

 

Remove the tool within the spindle

2

 

Open the right hand side of the machine

3

 

Using the sheet metal tool supplied with the machine, remove the tools within the magazine

4

Enter Jog Mode

 

Press the MAG EN to allow magazine manipulation button on the MCP keyboard and check that the LED stays on

5

If the tool pocket has stuck in the down position, press the Pocket UP/DOWN button to lift it to safe position

6

ONLY IF IT IS SAFE!

Press the ATC CW button to reset the ATC ARM

28.2.7 Check the rotation direction of the Tool Magazine

1

 

Ensure the safety door of the machine is closed and locked

2

Press the Ref Point button on the MCP keyboard

3

Press the MAG EN to allow magazine manipulation button on the MCP keyboard and check that the LED stays on

4

MAG CCW

Press the MAG CCW button and check that the magazine has advance in the Counter Clockwise direction

5

MAG CW

Press the MAG CW button and check that the magazine has advance in the Clockwise direction

6

MAG REF

Press the MAG REF button and check that the magazine has advanced and the Tool Pocket 1 is in the Standby Location

7

 

The Tool changer is now referenced

28.2.8 Reload tools as required

1

   On the controller, press enter the Offset screen

2

   Select the desired tool from the tool list

3

  Load the selected tool to the tool Pocket Location of your choice

4

   Press the OK softkey to store the tool in a Pocket or Spindle for loading into     the spindle

28.2.9 Reboot the controller

Press the Illuminated Red switch to Power down the controller. Restart pressing the green illuminated ON button.

The Procedure is now complete

SYNTEC 22MA

28.3 SYNTEC - how to set ORI positon

  1. Set the right position by your hand



  2. press “setting”---diga(Password:520)， NO28 is the spindle current position



  3. press “setting”---Param(Password:520)---Goto Param, looking for 1771, input the right number which show in NO28

28.4 SYNTEC - How to load Macro

Copy macro file to usb, and insert usb to controller, press setting—sys.admin(psw:520)--macro manager—import, choose macro file.

28.5 SYNTEC - How to load plc and alarm

Copy cnc.lad, alarmPLC_CHS.xml, alarmPLC_COM.xml, ParamExt_chs.xml, ParamExt_com.xml to usb, and insert usb to controller, press setting—sys.admin(psw:520)--sys.data manager—import, choose them and press next—press ok, controller will load them when it tell you completed, restart machine, upgrade finish.

28.6 SYNTEC - how to find original z home point

  1. Move z axis to the tool change position



  2. Press setting—param---goto param---2803, password= 520.



  3. Move z up 91mm(-91000=-91), for example, current z coordinate it -102.3, move to -102.3+91=-11.3, that’s the original z home point，set z home again in this place.

28.7 SYNTEC 220ma - how to set ORI positon

  1. find the right position by your hand



  2. press “→”---diga(Password:520)， NO28 is the spindle current position



  3. press “→”---Param(Password:520)---Goto Param, looking for 1771, input the right number which show in NO28

28.8 SYNTEC 220ma - how to set zero point

  1. Move the axis to zero point
  2. press “→”----Param(Password:520)---Serial Turning---normal axis---set ABS home（and switch to home mode）---set machine home.( when you lost machine zero point, you may get limit alarm, please modify 2401~2410.)




28.9 SYNTEC 220ma - 5 how to do tool measure

  1. press “→”--Param(Password:520)--Goto Param, input 3430 it’s standard tool length for calibrication.



  2.  press offset/setting—tool tip measure 


    Mode: choose 4, in 5 axis mode, the measure result is positive tool length,

    Tool NO. T: choose the tool number which you want to measure

    Use Reference: choose 1, Ref coord. X, Ref coord. Y will enable

    Ref coord. X: the center of X coordinate.

    Ref coord. Y: the center of Y coordinate.

    Ref coord. Z: the fast moving coordinate.

    Min Z.Mach.H: the lowest point when do tool measure

    Safe Z After Measure: Z back point when tool measure finished.

    Gauge Z Mach.coord: it’s calibration by Gauge Z coord. Teach

    Gauge Z Mach.coord teach(F7):

    Install your standard tool on the spindle, then switch to AUTO mode, press it, system will let you input password, it’s 520, then it will begin do tool length calibration, and save the result on the Gauge Z Mach.coord, when you do it first time you can enable MPG SAM function, it can protect your tool setter.

  3. After Gauge Z Mach.coord teach, press start(F1), it will begin to do tool measure, and sav e the result into tool list,press reset(f2) will stop tool measure, when you do it first time you can enable MPG SAM function, it can protect your tool setter.

28.10 SYNTEC - how to install 4th (22ma)

  1. Connect motor on driver and Turn on the breaker of 4th driver(C6)
  2. Turn on machine , and press “setting”--Param(Password:520)--Goto Param
  3. Goto parameter24, change from 0 to 2000, 4th will enable




  4. change 3445 from 0 to 1, change 3446 from 0 to 1, 4th function will enable.



  5. Restart machine, you get alarm as follow, don’t worry, cut off the main power of machine, then give power again, alarm will disappear.



  6. After machine restart, you need to reset home point of 4th



  7. Move 4 axis to zero point
  8. press “setting”----Param(Password:520)---Serial Turning---normal axis---set ABS home（and switch to home mode）---set machine home(switch to home mode ,loose estop switch and choose A), when it show set, home setting completed

28.11 SYNTEC - how to install 5th (10K-arm)

  1. Make sure all wiring of 4th &5th have been connect well, then Press “setting”--Param(Password:520)--Goto Param
  2. Goto parameter24, change it from 0 to 2000 , 4th will enable
    Goto parameter25, change it from 0 to 3000 , 5th will enable



  3. Press “→”—Param-- “→”—5 Axis Param, change 30001 from 0 to 2



  4. change 3448 from 0 to 1, system will enable third limit(it’s for 5axis kits)

    change 3449 from 0 to 1, the 4th&5th function (brake, alarm and so on) will enable

    change 3444 from 0 to 1, system will enable temperature alarm of 4th &5th



  5. After that, restart system, 4 and 5 axis will work.

    PS: please check 3034,3035, 3036, these numbers are original 5th kits center, if you remove 5th or move 5th , even X,Y,Z home point changed , you should input the right value in them, otherwise 5th may hit machine when running program.

28.12 SYNTEC - how to install U axis (10k-arm)

  1. Connect motor on driver and Turn on the breaker of 4th driver(C6)



  2. Turn on machine , and press “setting”--Param(Password:520)--Goto Param
  3. Goto parameter27, change from 0 to 4000, U axis will enable



    change 3449 from 0 to 3, 4th function will enable



  4. Restart machine, you get alarm as follow, don’t worry, cut off the main power of machine, then give power again, alarm will disappear.



  5. After machine restart, you need to reset home point of U axis



  6. Move U axis to zero point
  7. press “setting”----Param(Password:520)---Serial Turning---normal axis---set ABS home（and switch to home mode）---set machine home(switch to home mode ,loose estop switch and choose U), when it show set, home setting completed

28.13 SYNTEC - how to remove 4th (22ma)

  1. Press “setting”--Param(Password:520)--Goto Param
  2. Goto parameter24, change from 2000 to 0, 4th will disable



  3. change 3445 from 1 to 0, 3446 from 1 to 0the home point and brake of 4th will disable



  4. Until now, you can remove 4th from machine, after remove 4th , remember to cut off the breaker of 4th driver(C6)

28.14 SYNTEC - how to remove 5th (10k-arm)

  1. Press “setting”--Param(Password:520)--Goto Param
  2. Goto parameter24, change it from 2000 to 0, 4th will disable
  3. Goto parameter25, change it from 3000 to 0, 5th will disable



  4. Press “→”—Param-- “→”—5 Axis Param, change 30001 from 2 to 0


  5. change 3444 from 1 to 0, system will disable temperature alarm of 4th &5th
  6. change 3448 from 1 to 0, system will disable third limit(it’s for 5axis kits)
  7. change 3449 from 1 to 0, the 4th&5th (brake, alarm and so on) will disable



  8. Until now, you can remove 5th from machine ,and remove the power of 4th&5th driver



  9. In 3034,3035, 3036, this number is original the 5th center, if you remove 5th or move 5th ,even X,Y,Z home point changed , you should input the right value in it, or 5th may hit machine when running program.

28.15 SYNTEC - how to remove U axis (10k-arm)

  1. Press “setting”--Param(Password:520)--Goto Param
  2. Goto parameter27, change from 4000 to 0, U axis will disable



  3. change 3449 from 3 to 0, U axis brake function will be disable.



  4. Until now, you can remove U axis from machine, after remove U axis, remember to cut off the breaker of U axis driver(C6)
LNC

28.16 LNC - how to add 4th

  1. Install 4th completed, and finish all wiring, in normal, we have leave terminal in the machine（which on the back of controller）, CLP is brake clamp signal, and UCLP is brake unclamp signal, COM is the common wire which connect to 24v, if no terminal, you can connect the wire to IO board directly



  2. Press maintain key on the panel which on the right top, the user =5, password= 2222, then press input



  3. Press F6(PARAM)---F3(AXIS BASE)---change HW.PORT of (4) from 0 to 104, HW.PORT of (7) from 0 to 105.



  4. Restart machine, system will find 4th driver, and check A axis setting in param-E.gear.set—servo.ax



  5. Press F6(PARAM)---F5(HW.MAP)---SIG.IN:

    46-20108: define unclamp signal

    49-20109: define clamp signal

    59-20079: define key for open 4th brake(F5)

    F6(PARAM)---F5(HW.MAP)---SIG.OUT:

    07-50013: define 4th brake output

    make sure they have been set, or the 4th can’t work ,if you can’t find them , you can disable easy mode(make F8 EASY MODE become white),then you will see more parameters



  6. In normal, our machine have brake, please make sure follow parameter is set:

    Press F1(U.PARAM):

    8063: 4th brake delay time(0.1s)

    Press F1(U.PARAM)—F6(SW.SET):

    8013.0=1: enable brake function of 4th

    8013.2=1: check both clamp and unclamp signals.

    Press F1(U.PARAM)—F5(M code SET):

    8052=11: use m11 unclamp 4th

    8053=10: use m10 clamp 4th


  7. Until now, I think your 4th can work:

    in MPG mode, switch to 4th, and brake will auto open, you can move 4th directly

    in JOG mode, you need to press F5 to open 4th brake, then you can move 4th by 4+ and 4-

    in MDI and MEM mode, you should write G-code as above:

    M11

    G0A90

    M10

    M30

28.17 LNC - how to remove 4th

  1. Press maintain key on the panel which on the right top, the user =5 ,password= 2222, then press input



  2. Press F6(PARAM)---F3(AXIS BASE)---change HW.PORT of (4) from 104 to 0, after that system will ignore any alarm from 4th driver



  3. Cut off the power of machine, and remover the 4th motor from machine now.  

28.18 LNC - how to find original z home point

  1. Move z axis to the tool change position



  2. Press maintain key on the panel which on the right top, the user =5 ,password= 2222, then press input



  3. Press offset key on the panel, then choose mg.set---CHG.tool,setting, record 8096(as picture, -86986 means -86.986mm).

  4. Move z up 86.986, for example, current z coordinate it -102.3, move to -102.3+86.986=-15.314, that’s the original z home point.

28.19 LNC - how to let ATC push@back

  1. Press maintain key on the panel which on the right top, the user =5 ,password= 2222, then press input



  2. Press offset—F5(MAG.SET)—F3(MAG.SET),press ORI first, then press F7(MAG.PUSH), ATC will go out.



  3. Press offset—F5(MAG.SET)—F3(MAG.SET), press F8(MAG.P/B), ATC will go back

28.20 LNC - how to make ghost file of CF-card

  1. Insert CF-card to your PC, system will prompt to format disk, click cancel, otherwise you will lost all data, then run CFMaker2.exe(need administrator privileges, and only work well in win7)

  2. This is the software screen：

    备份CF/SD means make a img file which is the CF card image

    备份CF/SD->IMG: press this button, it will start to make img file,

    设定路径: set the save path of img file

  3. Wait for the progress to 100%, it will tell you make successful.

28.21 LNC - how to restore ghost file of CF-card

  1. Insert CF-card to your PC, system will prompt to format disk, click cancel, otherwise you will lost all data, then run CFMaker2.exe(need administrator privileges, and only work well in win7)



  2. This is the software screen：

    还原CF/SD means restore a img file to CF card

    还原IMG->CF/SD: press this button, it will start to restore img file,

    设定路径: set the save path of img file

  3. Wait for the progress to 100%, it will tell you make successful.

28.22 LNC - how to set G5X offset

  1. Move your tool to the surface of the workpiece



  2. Press offset---coord---TEACH IN--- set all(you can choose set X, set y and set Z if you want to set single axis ),the axis will save to g59 if blue block is on g59



  3. Switch to INS mode, if the tool length is 100mm, input -100 to the blank place, z axis will become -366.906 , that’s the coordinate which spindle nose on the face of workpiece, after that, remember to set back to ABS mode（press F7 ABS mode）.

28.23 LNC - how to set OP30

  1. Press maintain key on the panel which on the right top, the user =5, password= 2222, then press input



  2. In maintain interface, press PARAM(F6)---turn page—ADV.PARAM(F8)---MAC.PARAM(F6), set 160142 to 1 and 160144 to 62, or the probe won’t work


  3. In maintain interface, press F5(H.W)---F1(SIG.IN), set 62 as 20001, reverse is on, system will receive probe signal.



  4. press F5(H.W)---F2(SIG.OUT), set 49 as 50014(5800 machine is 50013), system will active probe when system read m10100, m10101 and reset will cancel the output



  5. the macro need password, @850=801224, @851=9999, you need set them before your run op30.

28.24 LNC - how to set ORI positon

  1. Set the right position by your hand



  2. Find C0.26 from the VFD screen, you can press menu several time until you find C0.00, then press ↑ until get c0.26, press enter about 2~3s, it will get into c0.26, the number which show on screen is the feedback from the spindle encoder.



  3. Press maintain key on the panel which on the right top, the user =5 ,password= 2222, then press input



  4. Press F1(U.param), and find 8145, , the Calculation formula is C0.26/65536x360x1000, for example ,18328 is read from c0.26,so 8145=18328/65536x360x1000=100679, input this number to 8145, then press ORI to see if the position is right

28.25 LNC - how to set tool change positon

  1. Move z axis to the tool change position



  2.  Press F1(U.param)---F6(SW.SET)---8000.2=1, then return to the maintain interface 



  3. Move the axis to zero point, Press F6(PARAM)---“→”---F2(comm.servo)---F7(ABS.HOME.SET), press estop buttom, and set axis home , for example, you want to set Y zero point, and you can press “set Y” ,then waiting until “set y” is green, and the coordinate of y also become 0.(the picture is 3 axis zero point)

28.26 LNC - how to set zero point

  1. Press maintain key on the panel which on the right top, the user =5 ,password= 2222, then press input



  2. Press F1(U.param)---F6(SW.SET)---8000.2=1, then return to the maintain interface



  3. Move the axis to zero point, Press F6(PARAM)---“→”---F2(comm.servo)---F7(ABS.HOME.SET), press estop buttom, and set axis home , for example, you want to set Y zero point, and you can press “set Y” ,then waiting until “set y” is green, and the coordinate of y also become 0.(the picture is 3 axis zero point)



28.27 LNC - how to add macro

  1. Press maintain key on the panel which on the right top, the user =5 ,password= 2222, then press input



  2. Press prog---turn page---F1MAKER MAC, press F2 file MGT, you can see macro list, press IMP\EXP, that’s for macro output or input，choose the one you want to transfer, then press TRFR, then system will complete the transfer.



28.28 LNC - how to edit PLC

  1. Press maintain key on the panel which on the right top, the user =5 ,password= 2222, then press input



  2. Press F7(backup)---choose Output to usb---select 10 ladder---F5 TRFR---you will see folder choose screen, press “input”, waiting until system show TRFR completed---now you will see machine folder in your USB device



  3. Open QPLC Programmer---click open and choose the machine folder---and you will see the plc, you can change it, when finish change, the save icon will become red, click it, wait until it become blue again(system will compile and save PLC, it may take some time)



  4. After step3, you need to copy the PLC file back to system, in maintain interface, press F7(backup)---choose from usb---you will see folder choose screen, press “input”---select 10 ladder---F5 TRFR---waiting until system show TRFR completed.


  5. Press DGNS---F3---LAD---F4 RELOAD, system will accept the new PLC.

28.29 LNC - how to solve abs alarm

  1. Press maintain key on the panel which on the right top, the user =5 ,password= 2222, then press input



  2. Press F1(U.param)---F6(SW.SET)---8000.4=1, then return to the maintain interface



  3. Press F6(PARAM)---“→”---F2(comm.servo)---F8(ABS.RESET)---F3(resety), then the ABS alarm will disappear(F1 is reset all ,f2 is reset x axis, f3 is reset y axis, f4 is reset z axis)，after that ,restart machine