Siemens SINUMERIK 840D Diagnostics Manual

SINUMERIK 840DE powerline (export version) SINUMERIK 840Di SINUMERIK 840DiE (export version) SINUMERIK 810D powerline SINUMERIK 810DE powerline (export version) Drive SIMODRIVE 611 digital Alarms 1 Abbreviations / 2 References

http://www.siemens.com/motioncontrol This publication was created using FrameMaker V7.0.  Siemens AG, 1995-2004. All rights reserved Other functions not described in this documentation might be execut- able in the control. This does not, however, represent an obligation to supply such functions with a new control or when servicing. We have checked the contents of this manual for agreement with the hardware and software described. Since deviations cannot be pre- cluded entirely, we cannot guarantee full agreement.However, the data in this manual is reviewed regularly and any necessary correc- tions will be included in subsequent editions.Suggestions for improve- ment are welcomed. Technical data subject to change. Order No. 6FC5298-7AA20-0BP1 Siemens Aktiengesellschaft Printed in Germany SINUMERIK® Documentation Printing history Brief details of this edition and previous editions are listed below. The status of each edition is shown by the code in the "Remarks" column. Status code in the "Remarks" column: A .... New documentation B .... Unrevised reprint with new order number C .... Revised edition with new status If factual changes have been made on the page since the last edition, this is indicated by a new edition code in the header on that page. Edition Order No. Remarks 02.95 6FC5298-2AA20-0BP0 A 04.95 6FC5298-2AA20-0BP1 C 09.95 6FC5298-3AA01-0BP0 Description of differences 03.96 6FC5298-3AA20-0BP0 C 08.97 6FC5298-4AA20-0BP0 C 12.97 6FC5298-4AA20-0BP1 C 12.98 6FC5298-5AA20-0BP0 C 08.99 6FC5298-5AA20-0BP1 C 04.00 6FC5298-5AA20-0BP2 C 10.00 6FC5298-6AA20-0BP0 C 09.01 6FC5298-6AA20-0BP1 C 02.02 6FC5298-6AA20-0BP2 C 11.02 6FC5298-6AA20-0BP3 C 03.04 6FC5298-7AA20-0BP0 C 10.04 6FC5298-7AA20-0BP1 C Trademarks SIMATIC®, SIMATIC HMI®, SIMATIC NET®, SIROTEC®, SINUMERIK®, and SIMODRIVE® are Siemens trademarks. Other product names used in this documentation may be trademarks, which, if used by third parties, could infringe the rights of their owners.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 Preface Preface Structure of the documentation The SINUMERIK documentation is organized in 3 parts: • General documentation • User documentation • Manufacturer/service documentation This manual is intended as a work of reference. It allows the operator at the machine tool: - To correctly assess special situations when operating the machine. - To ascertain the reaction of the system to the special situation. - To utilize the possibilities for continued operation following the special situation. - To follow references to other documentation containing further details. Scope The manual deals with alarms from the NCK (NC kernel), the PLC and the SIMODRIVE 611D drive. Further alarms can occur in connection with MMC (Man Machine Communication). These alarms are displayed on the operator panel in the form of self-explanatory text. They are subsequently recorded as MMC messages. For special situations related to the integrated PLC, please refer to the SIMATIC S7-300 system references. Please contact your local SIEMENS office for more detailed information about documen- tation for SINUMERIK 840D/810Di/810D and publications, which apply to all SINUMERIK controls. Audience This documentation is intended for manufacturers of machine tools with SINUMERIK 840D/840Di/810D and SIMODRIVE 611D.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Hotline If you have any questions, please contact our hotline: A&D Technical Support Phone: +49 (0) 180 50 50 222 Fax: +49 (0) 180 50 50 223 E-mail: www.siemens.com/automation/support-request If you have any questions about the documentation (suggestions, corrections), please fax or e-mail us at the following addresses: Fax: +49 (0) 9131 98 21 76 E-mail: [email protected] Fax form: See the reply form at the end of the document. Website address http://www.siemens.com/motioncontrol SINUMERIK 840D powerline Since September 2001, the • SINUMERIK 840D powerline and • SINUMERIK 840DE powerline have been available with improved performance. The following hardware description con- tains a list of the available powerline modules: References: /PHD/SINUMERIK 840D Configuration Manual SINUMERIK 810D powerline Since December 2001, the • SINUMERIK 810D powerline and • SINUMERIK 810DE powerline have been available with improved performance. The following hardware description con- tains a list of the available powerline modules: References: /PHC/SINUMERIK 810D Configuration Manual ! Important This document is valid for: • SINUMERIK 840D powerline software version 7 • SINUMERIK 810D powerline software version 7 • SINUMERIK 840Di controller software version 3

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 Preface Export version The following functions are not available in the export version: Sorting The alarms are sorted by ascending alarm number in each section. There are gaps in the sequence. Structure of alarm description Each alarm consists of an alarm number and alarm text. There are four description cate- gories: • Explanation • Reaction • Remedy • Program continuation For a more detailed explanation of the "Reaction" category, please refer to the Section: "System reactions on alarms" For a more detailed explanation of the "Program continuation" category, please refer to the section: "Clear criteria for alarms" NCK alarms Table 1_1 Alarm number ranges Function 810E 840DE Five axis machining package - - Handling transformation package (five axes) - - Multiple-axes interpolation (> 4 axes) - - Helical interpolation 2D+6 - - Synchronized actions, stage 2 - O1) Measurements, stage 2 - O1) Adaptive control - O1) Continuous dressing - O1) Utilization of compile cycles (OEM) - - Multidimensional sag compensation - O1) 000 000 - 009 999 General alarms 010 000 - 019 999 Channel alarms 020 000 - 029 999 Axis/spindle alarms 030 000 - 099 999 Functional alarms 060 000 - 064 999 Cycle alarms SIEMENS 065 000 - 069 999 Cycle alarms user 070 000 - 079 999 Compile cycles, manufacturer and OEM

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition HMI alarms/messages Table 1_2 Alarm number ranges, continued 611D alarms Table 1_3 Alarm number ranges, continued PLC alarms/messages Table 1_4 Alarm number ranges, continued 1) More information is available via the diagnostic function (diagnostic buffer) in SIMATIC STEP 7. 2) The PLC alarms in the range 500000 - 899999 are configured and described by the machine manufacturer. 100000 - 100999 Basic system 101000 - 101999 Diagnostics 102000 - 102999 Services 103000 - 103999 Machine 104000 - 104999 Parameters 105000 - 105999 Programming 106000 - 106999 Reserve 107000 - 107999 OEM 109000 - 109999 Distributed systems (M to N) 110000 - 110999 HMI Embedded messages 111000 - 111999 ManualTurn, ShopMill, ShopTurn 120000 - 120999 HMI Advanced messages 300000 - 399999 Drive 400000 - 499999 General alarms 500000 - 599999 Channel alarms2) 600000 - 699999 Axis/spindle alarms2) 700000 - 799999 User area2) 800000 - 899999 Sequencers/graphs2) (810001 - 810009 System error messages from PLC1) )

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 Preface Action list The actions described in the alarm texts ("Action %---") are explained in detail in the table in the "Action list" section. Finding information For better orientation, you are provided with a table of contents as well as the appendices: • Abbreviations • References Safety Explanation of symbols Danger and warning concept The following warning notices with varying degrees of significance are used in the docu- ment: Danger Please use the description of the alarms that have occurred to check the situation in the system very carefully. Eliminate the causes for the occurrence of the alarms and acknowledge in the manner indicated. Failure to observe this warning will place your machine, workpiece, stored settings and possibly even your own safety at risk. ! Important This notice indicates important facts that must be taken into consideration. Danger Indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury or in substantial property damage. Warning Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury or in substantial property damage. Caution Used with the safety alert symbol to indicate a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury or in property damage.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Caution Used without the safety alert symbol to indicate a potentially hazardous situation, which, if not avoided, may result in property damage. Notice Indicates a potential situation, which, if not avoided, may result in an undesirable result or state.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 Contents Contents Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-XI Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 1.1 Overview of system error alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 1.2 Overview of alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 1.3 List of action numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-665 1.4 Error codes of alarm 300500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-678 1.5 System reactions on alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-689 1.6 Cancel criteria for alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-691 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-693 A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-693 B References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-698 1) More detailed information is available via the diagnostic function (diagnostic buffer) in SIMATIC STEP 7.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms 1 Alarms 1.1 Overview of system error alarms System errors The following alarms are system errors: 1000 1005 1013 1017 1001 1010 1014 1018 1002 1011 1015 1019 1003 1012 1016 1160 These system error alarms are not described in detail. If such a system error occurs, please note - The alarm number - The alarm text and - The internal system error number and send these details to SIEMENS AG, A&D MC, System Support Hotline Phone: 0180 50 50 222 (Germany) Fax: 09131 98 2176 Phone: +49 (0)180 50 50 222 (International) Fax: +49 (0)9131 98 21 76 1.2 Overview of alarms

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 0 No (more) alarm(s) present Definitions: If the communication (variable service) requests more alarms than currently available in the alarm list, this alarm is communicated as end-of-program function. Reactions: - No alarm reaction. Remedy: -- Program Continuation: Internal 1000 System error %1 Parameters: %1 = System error number Definitions: With this alarm, internal alarm states are displayed that, in conjunction with the trans- ferred error number, provide information on the cause and location of the error. Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Make a note of the error text and contact Siemens A&D MC, Hotline • Tel 0180 / 5050 - 222 (Germany) • Fax 0180 / 5050 - 223 • Tel +49-180 / 5050 - 222 (International) • Fax +49-180 / 5050 - 223 • Email [email protected] Program Continuation: Switch control OFF - ON. 1001 System error %1 Parameters: %1 = System error number Definitions: With this alarm, internal alarm states are displayed that, in conjunction with the trans- ferred error number, provide information on the cause and location of the error. Reactions: - Mode group not ready. - Channel not ready. - Interface signals are set. - Alarm display. Remedy: Make a note of the error text and contact Siemens AG A&D MC, Hotline (tel./fax: see alarm 1000) Program Continuation: Clear alarm with the RESET key in all channels of this mode group. Restart part program. 1002 System error %1 Parameters: %1 = System error number Definitions: With this alarm, internal alarm states are displayed that, in conjunction with the trans- ferred error number, provide information on the cause and location of the error. Reactions: - Alarm display. Remedy: Make a note of the error text and contact Siemens AG A&D MC, Hotline (tel./fax: see alarm 1000) Program Continuation: Clear alarm with the Delete key or NC START.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms 1003 Alarm pointer for this self-clearing alarm %1 is zero Parameters: %1 = Incorrect alarm number Definitions: The address (zero pointer) used by the compile cycle manufacturer or by the operating system for self-clearing alarms is not allowed in the system. Reactions: - Alarm display. Remedy: Make a note of the error text and contact Siemens AG A&D MC, Hotline (tel./fax: see alarm 1000) Check setCCAlarm/setAlarm (...) call. Program Continuation: Clear alarm with the Delete key or NC START. 1004 Alarm reaction to NCK alarm incorrectly configured Parameters: %1 = Incorrect alarm number Definitions: The alarm reaction configured by the operating system or the compile cycles manufac- turer is incorrect. Reactions: - NC not ready. - Channel not ready. - Interface signals are set. - Alarm display. Remedy: Make a note of the error text and contact Siemens AG A&D MC, Hotline (tel./fax: see alarm 1000) Change alarm reaction Program Continuation: Switch control OFF - ON. 1005 Operating system error %1 parameter %2 %3 %4 Parameters: %1 = Operating system error number %2 = Operating system error parameter 1 %3 = Operating system error parameter 2 %4 = Operating system error parameter 3 Definitions: This alarm indicates that the operating system has detected a serious error. Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Make a note of the error text and contact Siemens AG A&D MC, Hotline (tel./fax: see alarm 1000) Program Continuation: Switch control OFF - ON. 1010 Channel %1 system error %2 action %3 Parameters: %1 = Channel number %2 = System error number %3 = Action number/action name Definitions: With this alarm, internal alarm states are displayed that, in conjunction with the trans- ferred error number, provide information on the cause and location of the error.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Reactions: - NC not ready. - Interpreter stop - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Make a note of the error text and contact Siemens AG A&D MC, Hotline (tel./fax: see alarm 1000) Program Continuation: Switch control OFF - ON. 1011 Channel %1 %3 %4 system error %2 Parameters: %1 = Channel number %2 = System error number %3 = Optional parameter: Block number, label %4 = Optional parameter: Action number, .... Definitions: With this alarm, internal alarm states are displayed that, in conjunction with the trans- ferred error number, provide information on the cause and location of the error. Reactions: - Interpreter stop - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: Make a note of the error text and contact Siemens AG A&D MC, Hotline (tel./fax: see alarm 1000) Program Continuation: Clear alarm with the RESET key. Restart part program. 1012 Channel %1 system error %2 %3 %4 Parameters: %1 = Channel number %2 = System error number %3 = Parameter1 %4 = Parameter2 Definitions: With this alarm, internal alarm states are displayed that, in conjunction with the trans- ferred error number, provide information on the cause and location of the error. Reactions: - Alarm display. Remedy: Make a note of the error text and contact Siemens AG A&D MC, Hotline (tel./fax: see alarm 1000) Program Continuation: Clear alarm with the Delete key or NC START. 1013 Channel %1 system error %2 Parameters: %1 = Channel number %2 = System error number Definitions: With this alarm, internal alarm states are displayed that, in conjunction with the trans- ferred error number, provide information on the cause and location of the error. Reactions: - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Remedy: Make a note of the error text and contact Siemens AG A&D MC, Hotline (tel./fax: see alarm 1000) Program Continuation: Clear alarm with the RESET key. Restart part program. 1014 Channel %1 system error %2 Parameters: %1 = Channel number %2 = System error number Definitions: With this alarm, internal alarm states are displayed that, in conjunction with the trans- ferred error number, provide information on the cause and location of the error. Reactions: - Mode group not ready. - Local alarm reaction. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Make a note of the error text and contact Siemens AG A&D MC, Hotline (tel./fax: see alarm 1000) Program Continuation: Clear alarm with the RESET key in all channels of this mode group. Restart part program. 1015 Channel %1 axis %2 system error %3 Parameters: %1 = Channel number %2 = Axis number %3 = System error number Definitions: With this alarm, internal alarm states are displayed that, in conjunction with the trans- ferred error number, provide information on the cause and location of the error. Especially with parameter %3 (system error number) = 840001 = Problem with tool management, the identification for the axis is not contained in parameter %2, but instead, further infor- mation for the diagnostics (= Status of the data management/magazine no./location no./T no.) Reactions: - Local alarm reaction. - Channel not ready. - Interface signals are set. - Alarm display. Remedy: Make a note of the error text and contact Siemens AG A&D MC, Hotline (tel./fax: see alarm 1000) Program Continuation: Clear alarm with the RESET key. Restart part program. 1016 Channel %1 axis %2 system error %3 Parameters: %1 = Channel number %2 = Axis number %3 = System error number Definitions: With this alarm, internal alarm states are displayed that, in conjunction with the trans- ferred error number, provide information on the cause and location of the error. Reactions: - Mode group not ready. - Local alarm reaction. - Channel not ready. - Interface signals are set. - Alarm display.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Remedy: Make a note of the error text and contact Siemens AG A&D MC, Hotline (tel./fax: see alarm 1000) Program Continuation: Clear alarm with the RESET key in all channels of this mode group. Restart part program. 1017 Channel %1 axis %2 system error %3 Parameters: %1 = Channel number %2 = Axis number %3 = System error number Definitions: With this alarm, internal alarm states are displayed that, in conjunction with the trans- ferred error number, provide information on the cause and location of the error. Reactions: - Alarm display. Remedy: Make a note of the error text and contact Siemens AG A&D MC, Hotline (tel./fax: see alarm 1000) Program Continuation: Clear alarm with the Delete key or NC START. 1018 Floating point arithmetic error in channel %1 task %2 station %3 FPU state %4 Parameters: %1 = Channel number %2 = Task ID %3 = Station priority %4 = FPU status Definitions: The floating point unit of the processor has found a computational error. Reactions: - NC not ready. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. - Alarm reaction delay is canceled. Remedy: Make a note of the error text and contact Siemens AG A&D MC, Hotline (tel./fax: see alarm 1000) Program Continuation: Clear alarm with the RESET key in all channels of this mode group. Restart part program. 1019 Floating point arithmetic error at address %3 in channel %1 task %2 FPU state %4 Parameters: %1 = Channel number %2 = Task ID %3 = Code address of operation that triggered the error %4 = FPU status Definitions: The floating point unit of the processor has triggered an exception on account of a compu- tational error. Reactions: - NC not ready. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. - Alarm reaction delay is canceled. Remedy: Make a note of the error text and contact Siemens AG A&D MC, Hotline (tel./fax: see alarm 1000) Program Continuation: Clear alarm with the RESET key in all channels of this mode group. Restart part program.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms 1030 System error in link module error code %1 error type %2 Parameters: %1 = Hex-Zahl Link-Error %2 = Hex-Zahl Link-Error-Type Definitions: This alarm is not a user error. An internal error has occurred in the software of the link module. Two parameters are output with this error for debugging purposes. They provide information about the cause and location of the error. Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Make a note of the error text and contact Siemens AG A&D MC, Hotline (tel./fax: see alarm 1000) Program Continuation: Switch control OFF - ON. 1031 Link module generated an unspecified error %1 NCU %2 %3 %4 Parameters: %1 = Hex-Zahl unspecified status in stateOfLinkModules %2 = NCU number %3 = Command from link module to NCK %4 = Status of own link Definitions: This alarm is not a user error. • 1. If NCU== 0 -> A parameter not equal to zero was not found • 2. If NCU not equal to zero -> An error which the NC was not able to interpret in the con- nection to this NCU. The error is output as a number. It is possible that the NCU link mod- ule is running a newer software version than the NC. The other parameters are used for error localization in the NC/LINK-MODUL software. Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Make a note of the error text and contact Siemens AG A&D MC, Hotline (tel./fax: see alarm 1000) Program Continuation: Switch control OFF - ON. 1100 No valid firmware Definitions: No memory card or memory card without valid firmware (license) inserted. Reactions: - Alarm display. Remedy: Make a note of the error text and contact Siemens AG A&D MC, Hotline (tel./fax: see alarm 1000) Program Continuation: Switch control OFF - ON.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 1160 Assertion failed in %1: %2 Parameters: %1 = String (path with program name) %2 = String (line number) Definitions: This alarm is purely a development alarm and will not appear in a delivered software ver- sion. For an OEM customer, this alarm could indicate that an alarm has occurred in the system softwaren. Handling of the 'assertion' allows error conditions leading to this alarm to be defined in the system software during the development phase. After the develop- ment phase, this alarm output is no longer active. Reactions: - NC not ready. - The NC switches to follow-up mode. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. - Alarm reaction delay is canceled. Remedy: Check the cause of the error in the specified software component at the specified line number. Program Continuation: Clear alarm with the RESET key in all channels. Restart part program. 2000 PLC sign-of-life monitoring Definitions: The PLC must give a sign of life within a defined period of time (machine data 10100 PLC_CYCLIC_TIMEOUT). If this does not occur, the alarm is triggered. The sign of life is a counter reading on the internal NC/PLC interface which the PLC causes to count up with the 10 ms time alarm. The NCK also tests cyclically whether the counter reading has changed. Reactions: - NC not ready. - Local alarm reaction. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Check monitoring time frame in NCK-MD 10100 PLC_CYCLIC_TIMEOUT (reference value: 100 ms). Establish the cause of the error in the PLC and eliminate it (analysis of the ISTACK. If monitoring has responded with a loop in the user program rather than with a PLC Stop, there is no ISTACK entry). Program Continuation: Switch control OFF - ON. 2001 PLC has not started up Definitions: The PLC must give a sign of life within a period of time defined in MD 10120 PLC_RUNNINGUP_TIMEOUT (Default setting: 1 sec.). Reactions: - NC not ready. - Local alarm reaction. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Remedy: • Please inform the authorized personnel/service department. The monitoring time in MD 10120 PLC_RUNNINGUP_TIMEOUT must be checked and adapted to the first OB1 cycle. • Establish the cause of error in the PLC (loop or stop in the user program) and eliminate. Program Continuation: Switch control OFF - ON. 2100 NCK battery warning threshold reached Definitions: The undervoltage monitor of the NCK battery has reached the prewarning threshold. This is at 2.7-2.9 V (nominal voltage of the battery is 3.0-3.1 V at 950 mAh). Reactions: - Alarm display. Remedy: Please inform the authorized personnel/service department. The battery must be replaced within the next 6 weeks. After this period, the voltage can drop below the alarm limit of 2.4-2.6 V if the RAMs to be buffered take up a lot of current. Program Continuation: Clear alarm with the Delete key or NC START. 2101 NCK battery alarm Definitions: The undervoltage monitoring (2.4 - 2.6 V) of the NCK battery has responded during cyclic operation. Reactions: - Alarm display. Remedy: If the NCK battery is replaced without interrupting the power supply, no data will be lost. This means that production can continue without taking any further steps. (A buffer capac- itor on the NCK holds the supply voltage for at least 30 minutes and the battery can be replaced within this time even when the control is switched off). Program Continuation: Clear alarm with the Delete key or NC START. 2102 NCK battery alarm Definitions: The undervoltage monitoring (2.4 - 2.6 V) of the NCK battery was detected during system power-up. Reactions: - NC not ready. - The NC switches to follow-up mode. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Pull out the battery/fan unit from the NC module and replace the battery (type: lithium battery with lead, size 1/2 AA, 850 mAh, min. 3.2 V). The system must then be reinitialized because it must be assumed that data has been lost in the buffered RAM during the last power-off phase as a result of insufficient supply voltage (refer to Section 2.2 in the Installation and Start-up Guide for the procedure). The following data might have been corrupted or entirely lost: • NC machine data • Drive machine data • Option data • Setting data • User variable • Global subroutines • Cycles and macros, as well as • PLC machine data

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition • PLC basic program • PLC user program, and all • PLC user data User data in the NCK and PLC (e.g. tool and workpiece data) that have been altered by the manufacturing process since the last data backup must be updated manually to match the present machine status! Program Continuation: Switch control OFF - ON. 2110 NCK temperature alarm Definitions: The temperature sensor has reached the response threshold of 60 degrees C +/- 2.5 degrees C. Reactions: - Alarm display. Remedy: In order to reset the sensor, the temperature must be reduced by 7 degrees C. Program Continuation: Clear alarm with the Delete key or NC START. 2120 NCK fan alarm Definitions: The fan consists of a 26 V DC motor with electronic commutator (rated speed: approx. 8700 rpm). The commutator signal is used for speed monitoring, response speed: < 7500 rpm. Reactions: - Alarm display. Remedy: Please inform the authorized personnel/service department. The unit with the fan and NCK battery must be replaced. Program Continuation: Clear alarm with the Delete key or NC START. 2130 5V/24V encoder or 15V D/A converter undervoltage Definitions: A failure has occurred in the power supply (FM357-2) to the encoder (5V/24V) or D/A con- verter (+/-15V). Reactions: - NC not ready. - The NC switches to follow-up mode. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Axes of this channel must be re-referenced. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Check the encoder and cable for short-circuits (the fault should not occur when you remove the cable). Check the power feeder line. Program Continuation: Switch control OFF - ON. 2140 The actual service switch position forces a SRAM to be cleared at the next Power On (general reset active) Definitions: The initialization switch is currently set to overall reset. This means that the module's SRAM is deleted with the next module reset. The NC data memory is cleared during this operation. Reactions: - NC not ready. - Interface signals are set. - Alarm display.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Remedy: Reset initialization switch to zero. Program Continuation: Alarm display showing cause of alarm disappears. No further operator action necessary. 2190 Hardware plug-in module for communication with the digitizer missing Definitions: MD $MN_ASSIGN_DIGITIZE_TO_CHAN was used to activate the digitizing function by assigning it to a channel. The function requires a hardware module (RS422 board plugged into the NCU) for communication with the digitizing unit. This module was not found when booting. Reactions: - Interface signals are set. - Alarm display. Remedy: Please inform the authorized personnel/service department. Plug in communications module or cancel channel assignment. Program Continuation: Switch control OFF - ON. 2192 No NCU link module exists, MD %1 reset Parameters: %1 = String: MD identifier Definitions: An attempt was made to activate the NCU link functionality but the hardware is not avail- able. The MD was reset. Only occurs with the NCU link system Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Install the hardware module and activate the function again (MD). Program Continuation: Switch control OFF - ON. 2193 'Safety Integrated' is not available for link axis %1. Parameters: %1 = Machine axis index Definitions: The "Safety Integrated" function is not available for a link axis. Only occurs with the NCU link system Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Use "Safety Integrated" function for local axes only. Program Continuation: Switch control OFF - ON. 2194 Link axis active and $MN_SERVO_FIFO_SIZE != 3 Definitions: At least one axis is to be distributed via NCU link, then the machine data $MN_MM_SERVO_FIFO_SIZE must be 3. Occurs only with an NCU link system. Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Remedy: Set $MN_SERVO_FIFO_SIZE to 3. Program Continuation: Switch control OFF - ON. 2195 Channel %1 axis %2 high-speed punching/nibbling not possible via link Parameters: %1 = Channel number %2 = Axis name, spindle number Definitions: An attempt was made to activate high-speed nibbling or punching for an axis programmed on a different NCU than the drive. Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. - Channel not ready. Remedy: High-speed nibbling and punching is only supported on one NCU. Program Continuation: Clear alarm with the RESET key in all channels of this mode group. Restart part program. 2196 Link axis active and $MN_MM_SERVO_FIFO_SIZE != %1 Parameters: %1 = required value in MD $MN_MM_SERVO_FIFO_SIZE Definitions: Occurs only with an NCU link system. • Possible causes of the fault: • At least one axis is to be distributed via NCU link, then the machine data $MN_MM_SERVO_FIFO_SIZE must be 3 or 4. • The IPO cycle of this NCU is faster than the link communication cycle, then the machine data $MN_MM_SERVO_FIFO_SIZE must be set to the value proposed in the alarm. Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: The machine data $MN_MM_SERVO_FIFO_SIZE must be set to the value proposed in the alarm. Program Continuation: Switch control OFF - ON. 2200 Channel %1 fast punching/nibbling not possible in several channels Parameters: %1 = Channel number Definitions: An attempt was made to activate fast nibbling or punching in a channel while it has already been active in another channel. Fast punching and nibbling is only possible simul- taneously in the same channel. Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Fast nibbling and punching simultaneously in one channel only. Program Continuation: Clear alarm with the RESET key. Restart part program.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms 2900 Reboot is delayed Definitions: This alarm indicates a delayed reboot. This alarm only occurs when reboot was carried out by the MMC via PI - "_N_IBN_SS" and MD 11410 $MN_REBOOT_DELAY_TIME was set greater than zero. The alarm can be suppressed with $MN_SUPPRESS_ALARM_MASK BIT 20. Reactions: - NC not ready. - The NC switches to follow-up mode. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. - Alarm reaction delay is canceled. Remedy: See $MN_REBOOT_DELAY_TIME and $MN_SUPPRESS_ALARM_MASK. Program Continuation: Switch control OFF - ON. 3000 Emergency stop Definitions: The EMERGENCY STOP request is applied to the NCK/PLC interface (DB 10, DBX 56.1). Reactions: - NC not ready. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. - Alarm reaction delay is canceled. Remedy: Please inform the authorized personnel/service department. Rectify the cause of EMER- GENCY STOP and acknowledge EMERGENCY STOP via the PLC/NCK interface (DB 10, DBX 56, Bit 2). Program Continuation: Clear alarm with the RESET key in all channels of this mode group. Restart part program. 3001 Internal emergency stop Definitions: This alarm is not displayed. Reactions: - NC not ready. - Local alarm reaction. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - NC Stop on alarm. Remedy: No remedy required Program Continuation: Clear alarm with the RESET key in all channels of this mode group. Restart part program. 4000 Channel %1 machine data %2[%3] has gap in axis assignment Parameters: %1 = Channel number %2 = String: MD identifier Definitions: The assignment of a machine axis to a channel by the machine data 20070 AXCONF_MACHAX_USED must be contiguous. At system power-up (Power On) gaps are detected and displayed as an alarm.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Reactions: - NC not ready. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. The entries for the indices for the machine axes used in the channels must be contiguous in table $MC_AXCONF_MACHAX_USED. Channel axis gaps must be enabled via $MN_ENABLE_CHAN_AX_GAP. Program Continuation: Switch control OFF - ON. 4001 Channel %1 axis %2 defined for more than one channel via machine data %3 Parameters: %1 = Channel number %2 = Index: Machine axis number %3 = String: MD identifier Definitions: In the channel-specific MD: 20070 AXCONF_MACHAX_USED [CHn, AXm]=x (n .. chan- nel number, m ... channel axis number, x ... machine axis number), several channels were assigned to a machine axis without having a master channel defined for this axis. There is usually not much point in assigning a machine axis to several channels. In exceptional cases, multiple assignment can be performed if a master channel is defined for this axis. The channel assignment can be performed in accordance with the machining requirements in the NC part program by means of a keyword (yet to be defined in later product versions). Reactions: - NC not ready. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. In the axis-specific MD 30550 AXCONF_ASSIGN_MASTER_CHAN [AXm]=n (m ... machine axis number, n ... channel number), a master axis was set for the axes that are supposed to be alternately assigned by the NC program to one or the other channel. Program Continuation: Switch control OFF - ON. 4002 Channel %1 machine data %2[%3] assigns an axis not defined in channel Parameters: %1 = Channel number %2 = String: MD identifier %3 = Index: MD array Definitions: Only axes that have been activated in the channel by means of the channel-specific machine data 20070 AXCONF_MACHAX_USED [kx]=m may be declared as geometry axes or transformation axes by means of the MD 20050 AXCONF_GEOAX_ASSIGN_TAB [gx]=k. This also applies to $MC_FGROUP_DEFAULT_AXES (gx: Geometry axis index, kx: Channel axis index, k: Channel axis no., m: Machine axis no.). Assignment of geometry axes to channel axes AXCONF_GEOAX_ASSIGN_TAB (includes channel axis no. k): • Geometry axis index: 0, 1. 0, 2nd channel: 1, 2. 0, 2nd channel: 1 • Geometry axis index: 1, 1. 0, 2nd channel: 2, 2. 0, 2nd channel: 0 • Geometry axis index: 2, 1. 0, 2nd channel: 3, 2. 0, 2nd channel: 3

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms AXCONF_MACHAX_USED (includes machine axis no. m): • Channel axis index: 0, 1. 0, 2nd channel: 1, 2. 0, 2nd channel: 4 • Channel axis index: 1, 1. 0, 2nd channel: 2, 2. 0, 2nd channel: 5 • Channel axis index: 2, 1. 0, 2nd channel: 3, 2. 0, 2nd channel: 6 • Channel axis index: 3, 1. 0, 2nd channel: 7, 2. 0, 2nd channel: 0 • Channel axis index: 4, 1. 0, 2nd channel: 8, 2. 0, 2nd channel: 0 • Channel axis index: 5, 1. 0, 2nd channel: 0, 2. 0, 2nd channel: 0 • Channel axis index: 6, 1. 0, 2nd channel: 0, 2. 0, 2nd channel: 0 • Channel axis index: 7, 1. 0, 2nd channel: 0, 2. 0, 2nd channel: 0 Reactions: - NC not ready. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Check and correct either • $MC_GEOAX_ASSIGN_TAB • $MC_TRAFO_AXES_IN_X • $MC_TRAFO_GEOAX_ASSIGN_TAB_X • $MC_FGROUP_DEFAULT_AXES • and/or $MC_AXCONF_MACHAX_USED. Program Continuation: Switch control OFF - ON. 4003 Axis %1 incorrect assignment of master channel in machine data %2 Parameters: %1 = Axis %2 = String: MD identifier Definitions: For some applications, it is useful to operate an axis in several channels (C axis or spindle on single spindle or double carriage machines). The machine axes which are defined in several channels by means of the MD 20070 AXCONF_MACHAX_USED, must be assigned to a master channel with the axis-specific machine data 30550 AXCONF_ASSIGN_MASTER_CHAN. For axes that are activated in only one channel, the number of this channel or zero must be entered as master channel. Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Modify MD 20070: AXCONF_MACHAX_USED and/or MD 30550: AXCONF_ASSIGN_MASTER_CHAN. Program Continuation: Switch control OFF - ON. 4004 Channel %1 machine data %2 axis %3 defined repeatedly as geometry axis Parameters: %1 = Channel number %2 = String: MD identifier %3 = Axis index Definitions: An axis may only be defined once as a geometry axis.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Correct $MC_GEOAX_ASSIGN_TAB. Program Continuation: Switch control OFF - ON. 4005 Maximum number of axes in channel %1 exceeded. Limit %2 Parameters: %1 = Channel number %2 = Upper limit for the number of axes in the channel Definitions: Machine data $MC_AXCONF_MACHAX_USED defines which machine axes can be used in this channel. This simultaneously defines the number of active axes in the chan- nel. This upper limit has been exceeded. Note: The channel axis gaps may cause certain indices of AXCONF_MACHAX_USED to remain unused and therefore do n_o_t count as active channel axes. Example: • CHANDATA(2) • $MC_AXCONF_MACHAX_USED[0] = 7 • $MC_AXCONF_MACHAX_USED[1] = 8 • $MC_AXCONF_MACHAX_USED[2] = 0 • $MC_AXCONF_MACHAX_USED[3] = 3 • $MC_AXCONF_MACHAX_USED[4] = 2 • $MC_AXCONF_MACHAX_USED[5] = 0 • $MC_AXCONF_MACHAX_USED[6] = 1 • $MC_AXCONF_MACHAX_USED[7] = 0 This channel uses the five machine axes 1, 2, 3, 8, 7, i.e. it has 5 active channel axes. Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Modify $MC_AXCONF_MACHAX_USED. Program Continuation: Switch control OFF - ON. 4007 Axis %1 incorrect assignment of master NCU in machine data %2 Parameters: %1 = Axis %2 = String: MD identifier Definitions: Machine axes which can be activated on several NCKs through $MN_AXCONF_LOGIC_MACHAX_TAB must be assigned to a master NCU in $MA_AXCONF_ASSIGN_MASTER_NCU. For axes that are activated on only one NCU, the number of this NCU or zero must be entered as master NCU. An assignment can only be made with MA_AXCONF_ASSIGN_MASTER_NCU if the machine axis is also addressed via a channel ($MC_AXCONF_MACHAX_USED+$MN_AXCONF_LOGIC_MACHAX_TAB).

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Correct $MA_AXCONF_ASSIGN_MASTER_NCU and/or $MN_AXCONF_LOGIC_MACHAX_TAB. Program Continuation: Switch control OFF - ON. 4010 Invalid identifier used in machine data %1[%2] Parameters: %1 = String: MD identifier %2 = Index: MD array Definitions: When determining a name in the NCK tables (arrays) for: machine axes, Euler angles, direction vectors, interpolation parameters and intermediate point coordinates, one of the following syntax rules for the identifier to be entered has been violated: • The identifier must be an NC address letter (A, B, C, I, J, K, U, V, W, X, Y, Z), possibly with a numerical extension (840D: 1-99, FM-NC: 1-9) • The identifier must begin with 2 arbitrary capital letters but not with $ (reserved for sys- tem variable). • The identifier must not be a keyword of the NC language (e.g. POSA). Reactions: - NC not ready. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Enter the identifier for user- defined names with correct syntax in the displayed MD. • Machine axes: AXCONF_MACHAX_NAME_TAB • Euler angles: EULER_ANGLE_NAME_TAB • Normal vectors: NORMAL_VECTOR_NAME_TAB • Direction vectors: 10640 DIR_VECTOR_NAME_TAB • Interpolation parameters: 10650 IPO_PARAM_NAME_TAB • Intermediate point coordinates: 10660 INTERMEDIATE_POINT_NAME_TAB Program Continuation: Switch control OFF - ON. 4011 Channel %1 invalid identifier used in machine data %2[%3] Parameters: %1 = Channel number %2 = String: MD identifier %3 = Index: MD array Definitions: When defining names in the channel-specific tables for geometry axes and channel axes, one of the following syntax rules for the identifier to be entered has been violated: • The identifier must be an NC address letter (A, B, C, I, J, K, U, V, W, X, Y, Z), possibly with a numerical extension (840D: 1-99, FM-NC: 1-9). • The identifier must begin with 2 arbitrary capital letters but not with $ (reserved for sys- tem variable). • The identifier must not be a keyword of the NC language (e.g. POSA).

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Reactions: - NC not ready. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Enter the identifier for user- defined names with correct syntax in the displayed MD • Geometry axes: 20060 AXCONF_GEOAX_NAME_TAB • Channel axes: 10000 AXCONF_MACHAX_NAME_TAB Program Continuation: Switch control OFF - ON. 4012 Invalid identifier used in machine data %1[%2] Parameters: %1 = String: MD identifier %2 = Index: MD array Definitions: The selected identifier is invalid. Valid identifiers are: • AX1 - AXn: Machine axis identifiers • N1AX1 - NnAXm: Link axis identifiers (NCU + machine axis), only occurs with 'NCU link' expansion level! • C1S1 - CnSm: Container axis identifiers (container + container location). Only occurs with 'axis container' expansion level! Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Use the correct identifier. Program Continuation: Switch control OFF - ON. 4013 Invalid NCU link configuration by machine data %1 = %2 , on NCU_1 = %3 Parameters: %1 = String: MD identifier %2 = Index: MD array %3 = MD value of master NCU Definitions: The link module configuration detected on the local NCU is different from the master NCU of the NCU cluster. The link module configuration defines the system clock time, the com- munication baudrate and the maximum number of message transfer retries. The following machine data are used for this purpose: • SYSCLOCK_SAMPL_TIME_RATIO, • IPO_SYSCLOCK_TIME_RATIO, • LINK_RETRY_CTR, • LINK_BAUDRATE_SWITCH, • SYSCLOCK_CYCLE_TIME The values of these machine data must be the same on all NCUs. Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Remedy: The machine data required for the link module configuration must be the same on all NCUs in the cluster. Program Continuation: Switch control OFF - ON. 4014 Axis %1 defined several times in %2 Parameters: %1 = String: MD identifier %2 = String: Check and, if necessary, correct the following machine data with reference to the data sheet: Definitions: An axis was assigned several times. The axis can be a: • Machine axis • Link axis • Axis in a container location Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Define a correct, unique axis assignment. Program Continuation: Switch control OFF - ON. 4016 Axis %1 already used by NCU %2 Parameters: %1 = Machine axis index %2 = NCU number Definitions: An attempt was made to apply setpoints to one axis from several NCUs. Only occurs with the NCU link system Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Define a correct, unique axis assignment. Program Continuation: Switch control OFF - ON. 4017 Axis container %1, location %2 already used by NCU %3 Parameters: %1 = Axis container number %2 = Axis container location %3 = NCU number Definitions: A multiple reference to the axis container location has been made via the logical axis table (machine data: MN_AXCONF_LOGIC_MACHAX_TAB). With the NCU link, the multiple reference may also have been made by another NCU in the NCU group. Example: Container1 location1 was referenced twice incorrectly • MN_AXCONF_LOGIC_MACHAX_TAB[0] = CT1_SL1 • MN_AXCONF_LOGIC_MACHAX_TAB[6] = CT1_SL1

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Correct and complete the container location assignments. Check the machine data for the logical axis assignment table (MN_AXCONF_LOGIC_MACHAX_TAB) Program Continuation: Switch control OFF - ON. 4018 Axis container %1, location %2 not used by any channel Parameters: %1 = Axis container number %2 = Axis container location Definitions: The container location is not referenced by any channel. Reactions: - NC not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Correct and complete the container location assignments. Check machine data MC_AXCONF_MACHAX_USED and MN_AXCONF_LOGIC_MACHAX_TAB. Program Continuation: Switch control OFF - ON. 4019 Axis container %1 advance not allowed with current status of NCU %2 Parameters: %1 = NCU number %2 = Axis container number Definitions: This error only occurs with direct advancing of the container. With direct container advancing, only one channel is allowed to activate the NC language command for advancing the container. In order to ensure this, the other channels must have the reset status and the axes must be stationary. With NCU link, the above condition applies to all channels of the NCU group. Error parameters: • 1 : NC Ready missing • 16: At least one other channel is active • 35: AXCT axis is active following axis/spindle • 36: AXCT axis is active leading axis • 39: Axis/spindle disable active • 40: Overlaid motion active for AXCT axis • 41: Axis replacement active for AXCT axis • 42: Interpolator active for one axis container axis • 46: Rotating spindle with different Ipo cycle of NCUs • 47: New-Config active Reactions: - Interpreter stop - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: The program must be canceled with Reset and the zero offset deselected before activat- ing the axis container switch. Program Continuation: Clear alarm with the RESET key. Restart part program.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms 4020 Identifier %1 used several times in machine data %2 Parameters: %1 = String: Name of identifier %2 = String: MD identifier Definitions: When determining a name in the NCK tables (arrays) for: machine axes, Euler angles, direction vectors, interpolation parameters and intermediate point coordinates, an identi- fier has been used that is already in the control. Reactions: - NC not ready. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Select for the identifier to be entered a character string that is not yet used in the system (max. 32 characters). Program Continuation: Clear alarm with the RESET key in all channels of this mode group. Restart part program. 4021 Channel %1 identifier %2 used several times in machine data %3 Parameters: %1 = Channel number %2 = String: Name of identifier %3 = String: MD identifier Definitions: To determine the name in the channel-specific tables for geometry axes and channel axes an identifier already existing in the control has been used. Reactions: - NC not ready. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Select for the identifier to be entered a character string that is not yet used in the system (max. 32 characters). Program Continuation: Switch control OFF - ON. 4022 Axis container %3 switch not allowed: ext. zero offset active channel %1 axis %2 Parameters: %1 = Channel %2 = Axis/spindle %3 = Axis container number Definitions: The axis container switch enable cannot be given because an external zero offset is active. Reactions: - Interpreter stop - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: The program must be aborted with the RESET key and the external zero point offset deselected before the container is advanced. Program Continuation: Clear alarm with the RESET key. Restart part program.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 4023 Axis container %1 switch not allowed, axis container %2 switch active Parameters: %1 = Axis container %2 = Axis container Definitions: Only one axis container can be rotated at a time. Reactions: - Interpreter stop - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Program must be canceled with Reset and the program sequences (NCUs, channels) must be synchronized such that only one axis container switch is active at a time. Program Continuation: Clear alarm with the RESET key. Restart part program. 4024 Invalid axis configuration due to missing axis container machine data Parameters: %1 = NCU number %2 = Axis container number Definitions: The axis configuration could not be generated due to missing axis container machine data. This error can only occur as a result of a communication error. The communication failure will be indicated separately by further alarms. Reactions: - NC not ready. - Interpreter stop - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Correct the link communication problems (refer to the other alarm messages). Program Continuation: Switch control OFF - ON. 4025 Axis container %3 switch not allowed: master/slave active channel %1 axis %2 Parameters: %1 = Channel %2 = Axis/spindle %3 = Axis container number Definitions: It is not possible to enable axis container switch as a master/slave link is active. Reactions: - Interpreter stop - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Abort program with the RESET key. If required, disconnect the master - slave coupling. Program Continuation: Clear alarm with the RESET key. Restart part program. 4026 Machine data %1[%2], link axis NC%3_AX%4 not used by any channel Parameters: %1 = String: MD identifier %2 = Index: MD array %3 = NCU number %4 = Machine axis number Definitions: The link axis is not referenced by any channel.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Reactions: - NC not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Correct and complete the logical axis assignments. Check machine data MC_AXCONF_MACHAX_USED and MN_AXCONF_LOGIC_MACHAX_TAB. Program Continuation: Switch control OFF - ON. 4027 Caution: MD %1 was also changed for the other axes of axis container %2 Parameters: %1 = String: MD identifier %2 = Axis container number Definitions: Message to the user indicating that the machine data change for the axis was also per- formed for all other axes in the same container. Reactions: - Alarm display. Remedy: None Program Continuation: Clear alarm with the Delete key or NC START. 4028 Attention! The axial MDs of the axes of the axis containers were matched. Definitions: Note for the user, that the machine data of the axis were matched in the axis containers. Reactions: - Alarm display. Remedy: None Program Continuation: Clear alarm with the RESET key. Restart part program 4029 Caution: the axial MDs in axis container %1 will be matched on the next power-up Parameters: %1 = Axis container number Definitions: Message to the user indicating that the machine data of the axes in the axis container will be matched on the next power-up. An axis container allows axes to be exchanged between channels and NCUs. To ensure that no conflicts arise, the axes within the same axis container must have a similar behavior. The first axis in the axis container determines which machine data have to be the same for the other axis in the axis container. Reactions: - Alarm display. Remedy: None Program Continuation: Clear alarm with the Delete key or NC START. 4030 Channel %1 axis identifier missing in machine data %2[%3] Parameters: %1 = Channel number %2 = String: MD identifier %3 = Index: MD array Definitions: An axis identifier is expected for the displayed MD in accordance with the axis configura- tion in the MD 20070 AXCONF_MACHAX_USED and 20050 AXCONF_GEOAX_ASSIGN_TAB. Reactions: - NC not ready. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Remedy: Please inform the authorized personnel/service department. Check axis configuration and enter the missing identifier into the MD or, should the axis not exist, specify for this chan- nel axis the machine axis 0 in the channel-specific MD 20070 AXCONF_MACHAX_USED. If this concerns a geometry axis that is not to be used (this applies only for 2-axis machining, e.g. on lathes), then channel axis 0 must be entered additionally in the channel-specific MD 20050 AXCONF_GEOAX_ASSIGN_TAB. Program Continuation: Switch control OFF - ON. 4031 Channel %1 link axis %2 defined for more than one channel in machine data %3 Parameters: %1 = Channel number %2 = Index: Axis number for logical axis assignment %3 = String: MD identifier Definitions: Occurs only with an NCU link system. The specified axis was defined several times or in several channels in machine data $MC_AXCONF_MACHAX_USED. If an axis is to be defined in several channels, a master channel must be assigned to the axis with the axial machine data $MA_AXCONF_ASSIGN_MASTER_CHAN. This error can only occur with an NCU link axis. The cause of a definition error can also be an NCU link communication failure. The link communication failure must be indicated separately by further alarms. Reactions: - NC not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Correct the machine data $MC_AXCONF_MACHAX_USED or assign a master channel. In the event of a link communication failure, these error causes have to be remedied first. Program Continuation: Switch control OFF - ON. 4032 Channel %1 wrong identifier for facing axis in %2 Parameters: %1 = Channel number %2 = String: MD identifier Definitions: According to the axis configuration in $MC_GCODE_RESET_VALUES or $MC_DIAMETER_AX_DEF, a facing axis identifier is expected at the specified location. Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Add the correct identifier. Program Continuation: Switch control OFF - ON. 4033 Caution: NCU link communication still not connected. Definitions: The NCU link communication could not be established due to other active alarms. This is the case, for example, if during boot-up the system detects and modifies incorrect cycle times (see alarm 4110). Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Remedy: Analyze and fix the other alarms and start the control again. Program Continuation: Switch control OFF - ON. 4034 Local link axis %1 is not allowed for different interpolation cycle time = %2/%3 Parameters: %1 = Axis name %2 = Local interpolation cycle %3 = Max. interpolation cycle Definitions: Local link axes are only permissible on an NCU if the interpolation cycle set corresponds to the slowest interpolation cycle of the interconnected NCU systems. Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Remove local link axis (see MN_AXCONF_MACHAX_NAME_TAB and MN_AXCT_AXCONF_ASSIGN_TAB1) or adapt the interpolation cycle (MN_IPO_SYSCLOCK_TIME_RATIO). Program Continuation: Switch control OFF - ON. 4035 Interpolation cycle from NCU%1 = %2 does not match NCU%3 = %4 Parameters: %1 = NCU_number1 %2 = MD value of NCU_number1 %3 = NCU_number2 (with slowest IPO cycle) %4 = MD value of NCU_number2 Definitions: Occurs only with an NCU link system. The interpolation cycles of the NCUs specified in the alarm do not match one another. The slowest IPO cycle in interconnected NCU sys- tems must be an integral multiple of all configured IPO cycles. Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Set a suitable value in MN_IPO_SYSCLOCK_TIME_RATIO for all interconnected NCUs. Program Continuation: Switch control OFF - ON. 4036 Wrong NCU link configuration by MD %1 Parameters: %1 = String: MD identifier Definitions: Occurs only with an NCU link system. Different interpolation and position control cycles have been set in the NCUs of the LINK group. This is only allowed if the function FAST- IPO-LINK in MD $MN_MM_NCU_LINK_MASK has been activated. Caution: For diagnostic purposes, two additional alarm parameters are output together with this alarm. • 1. parameter: Position control or IPO cycle time of this NCU • 2. parameter: Position control or IPO cycle time of another NCU

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: • Activate FAST-IPO-LINK function in MN_MM_NCU_LINK_MASK • Or do not set different position control or IPO cycles on the NCUs (see MN_IPO_SYSCLOCK_TIME_RATIO and MN_POSCTRL_SYSCLOCK_TIME_RATIO). Program Continuation: Switch control OFF - ON. 4040 Channel %1 axis identifier %2 not consistent with machine data %3 Parameters: %1 = Channel number %2 = String: Axis identifier %3 = String: MD identifier %4 = There are not enough channel axes entered in the MD displayed Definitions: The use of the specified axis identifier in the displayed MD is not consistent the channel's axis configuration stated in the MD 20070 AXCONF_MACHAX_USED and MD 20050 AXCONF_GEOAX_ASSIGN_TAB. Only with active "OEM transformation" compile cycle: There are not enough channel axes entered in the MD displayed. Reactions: - NC not ready. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Check and correct the identi- fier used in the MDs 10000 AXCONF_MACHAX_NAME_TAB, 20080 AXCONF_CHANAX_NAME_TAB and/or 20050 AXCONF_GEOAX_NAME_TAB. Only with active "OEM transformation" compile cycle: In addition to the specified MD, check and correct MD 24110 TRAFO_AXES_IN_1[n] of the activated OEM transforma- tion according to the function description. Program Continuation: Switch control OFF - ON. 4045 Channel %1 conflict between machine data %2 and machine data %3 Parameters: %1 = Channel number %2 = String: MD identifier %3 = String: MD identifier Definitions: Using the specified machine data %2 leads to a conflict with machine data %3. Reactions: - NC not ready. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Correct the specified machine data. Program Continuation: Switch control OFF - ON.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms 4050 NC code identifier %1 cannot be reconfigured to %2 Parameters: %1 = String: Old identifier %2 = String: New identifier Definitions: Renaming of an NC code was not possible for one of the following reasons: • The old identifier does not exist • The new identifier is within another type range. NC codes/keywords can be reconfigured as long as you stay within the type range. Type 1: "true" G codes: G02, G17, G33, G64, ... Type 2: named G codes: ASPLINE, BRISK, TRANS, ... Type 3: addresses which can be set: X, Y, A1, A2, I, J, K, ALF, MEAS, ... Reactions: - NC not ready. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Correct machine data 10712: NC_USER_CODE_CONF_NAME_TAB (protection level 1). The list must be built up as follows: Even address: Identifier to be modified Following odd address: New identifier e.g.: NC_USER_CODE_CONF_NAME_TAB [10] = "ROT", NC_USER_CODE_CONF_NAME_TAB [11] = " " clears the ROT function from the control Program Continuation: Switch control OFF - ON. 4060 Standard machine data loaded Definitions: The standard MD were loaded because • a cold start was requested or • the MD buffer voltage failed or • an initialization was requested for loading the standard machine data (MD 11200 INIT_MD). Reactions: - Alarm display. Remedy: Please inform the authorized personnel/service department. After automatically loading the standard MDs, the individual MDs must be entered or loaded in the relevant system. Program Continuation: Clear alarm with the RESET key. Restart part program. 4062 Backup data loaded Definitions: The user data saved in the flash memory are loaded to the SRAM. Reactions: - Alarm display. Remedy: Please inform the authorized personnel/service department. Load specific machine data again. Program Continuation: Clear alarm with the RESET key. Restart part program. 4065 Buffered memory was restored from backup medium (potential loss of data!) Definitions: Only occurs with PC-NC. A possible data integrity error was detected in the buffered memory during power-up. The buffered memory was initialized with the last backup copy. Changes in the buffered memory, which have been made since the last backup copy update, have been lost. Backup copies of the buffered memory are updated (on the hard disk) every time the control is shut down normally.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition !! Only for 802D: The reason for this procedure is that the backup time is exceeded. Make sure that the required operating time of the control corresponds to the specifications in your Installation & Start-up Guide. The current backup copy of the buffered memory has been created by the last internal data backup via the "Save data" softkey on the HMI. Reactions: - NC not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: Start the control again. Program Continuation: Switch control OFF - ON. 4066 Buffered memory of FFS restored from backup medium (potential loss of data!) Definitions: For PC-NC: A possible data integrity error was detected in the FFS memory during power-up. The FFS memory was initialized with the last backup copy. Changes in the FFS memory, which have been made since the last backup copy update, have been lost. !! Only for PC-NC: Backup copies of the buffered memory are updated (on the hard disk) every time the control is shut down normally. Reactions: - NC not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: Start the control again. Program Continuation: Switch control OFF - ON. 4070 Normalizing machine data has been altered Definitions: The control uses internal physical units (mm, degrees, s, for paths, velocities, accelera- tion, etc.). During programming or data storage, some of these values are input and out- put using different units (rev./min., m/s2, etc.). The conversion is carried out with the scaling factors that can be entered (system-specific MD array 10230 SCALING_FACTORS USER_DEF[n] (n ... index number 0 - 10), when the corresponding masking bit is set to "1". If the masking bit is set to "0" then scaling takes place with the internal standard factors. The following machine data influence the scaling of other MDs: • 10220: SCALING_USER_DEF_MASK • 10230: SCALING_FACTORS_USER_DEF • 10240: SCALING_SYSTEM_IS_METRIC • 10250: SCALING_VALUE_INCH • 30300: IS_ROT_AX If these data are modified, the NCK must be powered up again. Only then will the input of dependent data be performed correctly. Reactions: - Alarm display. Remedy: Please inform the authorized personnel/service department. If the alarm has been dis- played after downloading an MD file which is consistent within itself, then the download operation must be repeated with a new NCK power-up. (The file contains scaling-depen- dent machine data in front of the scaling factors). Program Continuation: Clear alarm with the Delete key or NC START. 4071 Check absolute encoder position Definitions: A machine date has been changed influencing the value of an absolute encoder position. Please check the position values.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Reactions: - Alarm display. Remedy: Please inform the authorized personnel/service department. Program Continuation: Clear alarm with the Delete key or NC START. 4073 Compile cycle functions define machine data number %1 several times Parameters: %1 = Machine data number Definitions: Can only occur when installing compile cycle functions. Two different compile cycle appli- cations use the same machine data number. The machine data which was defined twice is shifted into the free number range above 64000. Reactions: - Alarm display. Remedy: The error has no effect on the usability of the machine data and the function of the com- pile cycle application. To ensure that the compile cycle machine data documentation is correct, you must contact the supplier of the compile cycle. Only the supplier can remedy the error by changing the software. Program Continuation: Switch control OFF - ON. 4075 Machine data %1 (and maybe others) not altered due to missing permission level %2 Parameters: %1 = String: MD identifier %2 = Write protection level of the MD Definitions: On executing a TOA file or when writing data from the part program, an attempt has been made to write an item of data with a higher protection level than the access authorization currently set in the control. The item of data in question has not been written and program execution is continued. This alarm is set only when access violation is detected for the first time. Reactions: - Alarm display. Remedy: Please inform the authorized personnel/service department. Set the required access level by means of keyswitch or password entry or delete the machine data concerned from the MD file/part program. Program Continuation: Clear alarm with the Delete key or NC START. 4076 %1 Machine data could not be altered with permission level %2 Parameters: %1 = Number of MDs %2 = Preset access authorization Definitions: On executing a TOA file or when writing data from the part program an attempt has been made to write data with a higher protection level than the access authorization currently set in the control. The data in question have not been written and program execution is continued without hindrance. This alarm is issued on acknowledging the alarm EXBSAL_MD_PERMISSION_DENIED. It can be cleared only with Power On. Reactions: - NC Start disable in this channel. - Alarm display. Remedy: Please inform the authorized personnel/service department. Set the required access level by means of keyswitch or password entry or delete the machine data concerned from the MD file/part program. Program Continuation: Switch control OFF - ON. 4077 New value %1 of MD %2 not set. Requested %3 bytes too much %4 memory. Parameters: %1 = New value of machine data %2 = Machine data number %3 = Number of bytes requested that exceeded availability %4 = Type of memory

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Definitions: An attempt was made to enter a new value in the specified memory configuration machine data. It was not possible to modify the value, since this would clear the contents of the user memory. This is because the memory requested exceeded the available capacity. The third parameter specifies the number of bytes by which the maximum user memory was exceeded. The fourth parameter specifies the type of memory whose limit was exceeded. • "D" stands for dynamic or non-buffered user memory (this is where the LUD variables are stored and the interpolation buffer size is entered, for example). The capacity of this memory type is defined by the current memory expansion and the value in MD MM_USER_MEM_DYNAMIC (18210). • "S" stands for static or buffered user memory (this is where part programs, offset data, R parameters, tool data, etc. are stored). This memory type is defined by the current mem- ory expansion and the value in MD MM_USER_MEM_BUFFERED (18230). Reactions: - Alarm display. Remedy: If the modification was unintentional, ignore the error message and continue. The alarm has no negative effects. The remedy depends on the access rights and the current mem- ory expansion of the NCK. • The intended change is not possible -> try again with a smaller value. Observe the change in the number of bytes. • Buy more memory? This option depends on the model in use. • The NCK user memory setting may be smaller than possible. The MDs can be changed with appropriate access rights. Program Continuation: Clear alarm with the Delete key or NC START. 4080 Incorrect configuration of indexing axis in MD %1 Parameters: %1 = String: MD identifier Definitions: The assignment of a position table to an indexing axis or the contents of a position table contains an error, or the length of a position table has been parameterized with 0. Reactions: - NC not ready. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. 3 MD identifiers are output, depending on the type of error. 1. $MA_INDEX_AX_ASSIGN_TAB (axis-specific MD 30500: The error is due to multiple assignment of a position table (NCK MD 10910/10930 INDEX_AX_POS_TAB_n) to axes with different types (linear/rotary axis). 2. $MN_INDEX_AX_POS_TAB_n (NCK MD 10910/10930): The contents of the displayed table n contain an error. • The entered positions must be arranged in increasing size. • A particular position must not be set more than once. • If the table is assigned to one or several modulo axes, then the contents must be within the 0 to < 360 degree range. 3. $MN_INDEX_AX_LENGTH_POS_TAB_n (NCK MD 10900/10920): The length of the displayed position table n was specified with 0. Program Continuation: Clear alarm with the RESET key. Restart part program 4090 Too many errors during power-up Definitions: More than errors occurred during control power-up.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Reactions: - NC Start disable in this channel. - Alarm display. Remedy: Set the machine data correctly. Program Continuation: Switch control OFF - ON. 4100 System cycle time/scan time divider corrected for digital drive Definitions: The machine data 10050 SYSCLOCK_CYCLE_TIME (system clock cycle time) and/or MD 10080 SYSCLOCK_SAMPL_TIME_RATIO (dividing factor of the position control cycle for actual value acquisition) have been corrected. If this requirement cannot be sat- isfied with the entered values (e.g. because the system clock cycle time is not a multiple of 31.25 ms), then the system clock cycle time is automatically expanded until the drive clock cycle time lies within the 31.25 ms grid. The modifications were so made that, due to the selection of the system clock cycle time in MD 10050 SYSCLOCK_CYCLE_TIME, the programmable hardware divider 1 was readjusted in such a way that the selected time and the basic drive cycle result in a 31.25 ms grid. If this requirement is unfeasible (e.g. because the system clock cycle is not a multiple of 31.25 ms), the system clock cycle is automatically increased until the basic drive cycle is in a 31.25 ms grid. The new value of the SYSCLOCK_CYCLE_TIME can be obtained from the MD 10050. The position control cycle can be set with the following gradations: • up to 4 ms: 125 µs step • up to 8 ms: 250 µs step • up to 16 ms: 0.5 ms step • up to 32 ms: 1 ms step Reactions: - Alarm display. Remedy: No remedial measures are required. The alarm display can be canceled with Reset. Program Continuation: Clear alarm with the Delete key or NC START. 4101 Position control cycle for digital drive reduced to %1 ms Parameters: %1 = String (time in ms) Definitions: The position control clock divisor in the NCK MD 10060 POSCTRL_SYSCLOCK_TIME_RATIO was set such that a position control cycle time of more than 16 ms resulted. The boundary value for the drive actuator 611D is however 16 ms. Reactions: - Alarm display. Remedy: No remedial measures are required. The alarm display is canceled with Reset. Program Continuation: Switch control OFF - ON. 4102 Default values for drive cycle times differ Definitions: External control modules of the 611D bus and the controls within the CCU3 module have different default values for the current and speed control cycle times. Reactions: - Interpreter stop - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: External control modules of the 611D bus and the controls within the CCU3 module have different default values for the current and speed control cycle times. Check the specified values and modify accordingly (see MD_CURRCTRL_CYCLE_TIME and MD_SPEEDCTRL_CYCLE_TIME). Program Continuation: Switch control OFF - ON.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 4110 IPO factor increased to %1 Parameters: %1 = String (new IPO cycle time) Definitions: The IPO cycle divisor was set to a value which was not an integral multiple of the position control cycle divisor. The divisor (MD 10070 IPO_SYSCLOCK_TIME_RATIO) was increased. IPO_SYSCLOCK_TIME_RATIO has been modified on systems with PROFI- BUS DP because of the modified DP cycle in SDB1000 (MD 10050 SYSCLOCK_CYCLE_TIME). Reactions: - Alarm display. Remedy: Machine data 10070 IPO_SYSCLOCK_TIME_RATIO has been modified. Program Continuation: Clear alarm with the RESET key. Restart part program. 4111 PLC cycle increased to %1 ms Parameters: %1 = String (new PLC cycle time) Definitions: The PLC cycle divisor was set to a value which was not an integral multiple of the IPO cycle divisor. The divisor (MD 10074 PLC_IPO_TIME_RATIO) has been increased. MD 10074 PLC_IPO_TIME_RATIO has been modified on systems with PROFIBUS DP because of the modified DP cycle in SDB1000 (MD 10050 SYSCLOCK_CYCLE_TIME). Reactions: - Alarm display. Remedy: Machine data 10074 PLC_IPO_TIME_RATIO has been modified. Program Continuation: Clear alarm with the RESET key. Restart part program. 4112 Servo cycle changed to %1 ms Parameters: %1 = String (new servo cycle time) Definitions: MD 10060 POSCTRL_SYSCLOCK_TIME_RATIO has been modified on systems with PROFIBUS DP because of the modified DP cycle in SDB1000 (10050 SYSCLOCK_CYCLE_TIME). Reactions: - Alarm display. Remedy: Machine data 10060 POSCTRL_SYSCLOCK_TIME_RATIO RATIO has been modified. Program Continuation: Clear alarm with the RESET key. Restart part program. 4113 Sysclock cycle changed to %1 ms Parameters: %1 = String (new PLC cycle time) Definitions: MD 10050 SYSCLOCK_CYCLE_TIME has been modified on systems with PROFIBUS DP because of the modified DP cycle in SDB1000. Reactions: - Alarm display. Remedy: Machine data 10050 SYSCLOCK_CYCLE_TIME has been modified. Program Continuation: Clear alarm with the RESET key. Restart part program. 4114 Error in DP cycle of SDB1000 Parameters: %1 = String (new PLC cycle time) Definitions: The DP cycle in SDB1000 contains an error and cannot be set. The default value of $MN_SYSCLOCK_CYCLE_TIME is set. Reactions: - Alarm display. Remedy: Correct SDB1000 Program Continuation: Switch control OFF - ON.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms 4115 Time ratio communication to Ipo changed to %1 Parameters: %1 = String (new PLC cycle time) Definitions: The value of the machine data 10072 has been adapted. This can only occur, if the value of the machine data is smaller than one and the time thus calculated is no multiple of the position control cycle. Reactions: - Alarm display. Remedy: The machine data $MN_COM_IPO_TIME_RATIO has been adapted. Please check to ensure that the calculated value is correct. Program Continuation: Clear alarm with the RESET key. Restart part program. 4150 Channel %1 invalid M function subprogram call configured Parameters: %1 = Channel number Definitions: The machine data $MN_M_NO_FCT_CYCLE[n] or $MN_M_NO_FCT_CYCLE_PAR con- tains invalid configuration data: An M function, which is used by the system and can not be replaced by a subprogram call has been specified in the machine data $MN_M_NO_FCT_CYCLE[n] for the configuration of the subprogram call via M function: • M0 to M5, • M17, M30, • M19, M40 to M45, • M function for selecting spindle/axis mode according to $MC_SPIND_RIGID_TAPPING_M_NR (default: M70), • M functions for nibbling/punching as configured in $MC_NIBBLE_PUNCH_CODE if acti- vated by $MC_PUNCHNIB_ACTIVATION. • Also M96 to M99 for applied external language ($MN_MM_EXTERN_LANGUAGE). The machine data $MN_M_NO_FCT_CYCLE_PAR contains an invalid array index of $MN_M_NO_FCT_CYCLE[n]. Currently, the values 0 to 9 are permissible. The affected machine data is reset to the default value -1. This deactivates the function. Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Configure an M function in the machine data $MN_M_NO_FCT_CYCLE[n] that is not assigned by the system, or configure a permissible array index in the machine data $MN_M_NO_FCT_CYCLE_PAR. Program Continuation: Switch control OFF - ON. 4152 Illegal configuration of the 'Block display with absolute values' function Definitions: The "Block display with absolute values" function has been illegally parameterized: • An illegal block length has been set with $MC_MM_ABSBLOCK: While ramping up, the machine data will be checked for the following value range: 0, 1, 128 to 512 • An invalid display range has been set with $MC_MM_ABSBLOCK_BUFFER_CONF[]. While ramping up, the machine data will be checked for the following upper and lower lim- its: • 0 <= $MC_MM_ABSBLOCK_BUFFER_CONF[0] <= 8 • 0 <= $MC_MM_ABSBLOCK_BUFFER_CONF[1] <= ($MC_MM_IPO_BUFFER_SIZE + $MC_MM_NUM_BLOCKS_IN_PREP). Alarm 4152 is issued if the limits are violated.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Configure block length/display range within the permissible limits. Program Continuation: Switch control OFF - ON. 4160 Channel %1 invalid M function number configured for spindle switchover Parameters: %1 = Channel number Definitions: An M function was specified in machine data $MC_SPIND_RIGID_TAPPING_M_NR in order to configure the M function number for spindle switchover. The M function number is assigned by the system and cannot be used for the switchover (M1 to M5, M17, M30, M40 to M45). Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: (M1 to M5, M17, M30, M40 to M45). Configure an M function which is not used by the sys- tem (M1 to M5, M17, M30, M40 to M45) in machine data $MC_SPIND_RIGID_TAPPING_M_NR. Program Continuation: Switch control OFF - ON. 4170 Invalid M function number for channel synchronisation assigned Definitions: An M number between 0 and 99 has been specified In machine data $MN_EXTERN_CHAN_SYNC_M_NR_MIN or $MN_EXTERN_CHAN_SYNC_M_NR_MAX for the configuration of the M number range for channel synchronization in ISO2/3 mode or the machine data $MN_EXTERN_CHAN_SYNC_M_NR_MAX is smaller than $MN_EXTERN_CHAN_SYNC_M_NR_MIN. Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Check machine data $MN_EXTERN_CHAN_SYNC_M_NR_MIN and $MN_EXTERN_CHAN_SYNC_M_NR_MAX. Program Continuation: Switch control OFF - ON. 4180 Invalid M function number assigned to enable ASUP Definitions: An invalid M function number has been assigned for activation of ASUP. An illegal M number has been assigned in machine data $MN_EXTERN_M_NO_SET_INT or $MN_EXTERN_M_NO_DISABLE_INT for the configuration of the M number range for activation/deactivation of the interrupt program.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Check machine data $MN_EXTERN_ M_NO_SET_INT and $MN_EXTERN_M_NO_DISABLE_INT. Program Continuation: Switch control OFF - ON. 4181 Channel %1 invalid assignment of an M auxiliary function number Parameters: %1 = Channel number Definitions: In machine data $MC_AUXFU_ASSOC_M0_VALUE or $MC_AUXFU_ASSOC_M1_VALUE, a number has been specified for the configuration of a new predefined M function which is occupied by the system, and cannot be used for an assignment. (M0 to M5, M17, M30, M40 to M45). Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Configure an M function in machine data $MC_AUXFU_ASSOC_M0_VALUE or $MC_AUXFU_ASSOC_M1_VALUE which is not occupied by the system (M1 to M5, M17, M30, M40 to M45). Program Continuation: Switch control OFF - ON. 4182 Channel %1 invalid M auxiliary function number in %2%3, MD reset Parameters: %1 = Channel number %2 = MD identifier %3 = If required, MD index Definitions: In the specified machine data, a number has been specified for the configuration of an M function which is occupied by the system, and cannot be used for an assignment. (M0 to M5, M17, M30, M40 to M45 and also M98, M99 with applied ISO dialect). The value set by the user has been reset to the default value by the system. Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Configure an M function in the specified machine data which is not occupied by the sys- tem (M0 to M5, M17, M30, M40 to M45 and also M98, M99 with applied ISO dialect). Program Continuation: Clear alarm with the RESET key. Restart part program 4183 Channel %1 M auxiliary function number %2 used several times (%3 and %4) Parameters: %1 = Channel number %2 = M auxiliary function number %3 = MD identifier %4 = MD identifier

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Definitions: In the specified machine data, a number has been used several times for the configura- tion of an M function. Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Check the specified machine data and create a unique assignment of M auxiliary function numbers. Program Continuation: Switch control OFF - ON. 4184 Channel %1 illegally predefined auxiliary function in %2%3, MD reset Parameters: %1 = Channel number %2 = MD identifier %3 = If required, MD index Definitions: In the specified machine data, a predefined auxiliary function has been illegally config- ured. The value set by the user has been reset to the default value by the system. Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Configure a valid value in the specified machine data. Program Continuation: Clear alarm with the RESET key. Restart part program. 4185 Channel %1 illegal auxiliary function configured %2 %3 %4 Parameters: %1 = Channel number %2 = Type of auxiliary function %3 = Extension %4 = Auxiliary function value Definitions: An auxiliary function has been illegally configured. Predefined auxiliary functions cannot be reconfigured by user-defined auxiliary functions. Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Reconfigure the auxiliary function. Program Continuation: Clear alarm with the RESET key. Restart part program. 4200 Channel %1 geometry axis %2 must not be declared a rotary axis Parameters: %1 = Channel number %2 = Axis name Definitions: The geometry axes represent a Cartesian coordinate system and therefore the declara- tion of a geometry axis as rotary axis leads to a definition conflict.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Reactions: - NC not ready. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Remove rotary axis declara- tion for this machine axis. For this purpose, the geometry axis index for the displayed geometry axis must be deter- mined by means of the channel-specific MD array 20060 AXCONF_GEOAX_NAME_TAB. The channel axis number is stored with the same index in the channel-specific MD array 20050 AXCONF_GEOAX_ASSIGN_TAB. The channel axis number minus 1 provides the channel axis index under which the machine axis num- ber is found in the channel-specific MD array 20070 AXCONF_MACHAX_USED. Program Continuation: Switch control OFF - ON. 4210 Channel %1 spindle %2 declaration as rotary axis missing Parameters: %1 = Channel number %2 = Axis name, spindle number Definitions: If a machine axis is to be operated as a spindle, this machine axis must be declared as a rotary axis. Reactions: - NC not ready. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Set rotary axis declaration for this machine axis in the axis-specific MD 30300 IS_ROT_AX. Program Continuation: Switch control OFF - ON. 4215 Channel %1 spindle %2 declaration as modulo axis missing Parameters: %1 = Channel number %2 = Axis name, spindle number Definitions: The spindle functionality requires a modulo axis (positions in [deg],.). Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Set MD "ROT_IS_MODULO". Program Continuation: Switch control OFF - ON. 4220 Channel %1 spindle %2 declared repeatedly Parameters: %1 = Channel number %2 = Axis name, spindle number Definitions: The spindle number exists more than once in the channel.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Reactions: - NC not ready. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. The spindle number is stored in the axis-specific MD array 35000 SPIND_ASSIGN_TO_MACHAX. The channel to which this machine axis/spindle is assigned is listed in the machine axis index. (The machine axis number is given in the channel-specific MD array 20070 AXCONF_MACHAX_USED). Program Continuation: Switch control OFF - ON. 4225 Channel %1 axis %2 declaration as rotary axis missing Parameters: %1 = Channel number %2 = Axis name, axis number Definitions: The modulo functionality requires a rotary axis (positions in [deg],.). Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Set MD "IS_ROT_AX". Program Continuation: Switch control OFF - ON. 4230 Channel %1 data alteration from external not possible in current channel state Parameters: %1 = Channel number Definitions: It is not allowed to enter this data while the part program is being executed (e.g. setting data for working area limitation or for dry run feedrate). Reactions: - Alarm display. Remedy: The data to be entered must be altered before starting the part program. Program Continuation: Clear alarm with the Delete key or NC START. 4240 Runtime overflow for IPO cycle or position controller cycle, IP %1 Parameters: %1 = Program location Definitions: The settings for the interpolation and position control cycle were modified before the last power-up such that too little computing time is now available for the requisite cyclic task. The alarm occurs immediately after power-up if too little runtime is available even when the axes are stationary and the NC program has not started. However, task overflow can occur only when computation-intensive NC functions are called during program execu- tion. Reactions: - NC not ready. - The NC switches to follow-up mode. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. - Alarm reaction delay is canceled.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Remedy: Please inform the authorized personnel/service department. Take greater care when opti- mizing the clock times NCK MD 10050 SYSCLOCK_CYCLE_TIME, MD 10060 POSCTRL_SYSCLOCK_TIME_RATIO and/or MD 10070 IPO_SYSCLOCK_TIME_RATIO. The test should be performed with an NC program that represents the worst case. For safety, a margin of 15 to 25% should be added to the times determined in this way. Program Continuation: Switch control OFF - ON. 4250 FastPlcCom functionality not available Definitions: This alarm indicates that the PLC provides the None FastPlcCom functionality during start-up although this functionality is requested by the NCK. Reactions: - Alarm display. Remedy: Retrofit the PLC with the FastPlcCom functionality or deactivate the FastPlcCom function- ality by means of NCK machine data. Program Continuation: Clear alarm with the RESET key. Restart part program. 4252 PLCIO read error: %1 Parameters: %1 = PLCIO error code Definitions: This alarm indicates that errors occurred when reading the PLCIO with the FastPlcCom functionality. Reactions: - Alarm display. Remedy: Check machine data MD 10394/10395 or check the PLC hardware configuration. Program Continuation: Clear alarm with the RESET key. Restart part program. 4254 PLCIO write error: %1 Parameters: %1 = PLCIO error code Definitions: This alarm indicates that errors occurred when writing on the PLCIO with the FastPlcCom functionality. Reactions: - Alarm display. Remedy: Check machine data MD 10396/103947 or check the PLC hardware configuration. Program Continuation: Clear alarm with the RESET key. Restart part program. 4260 Machine data %1 illegal Parameters: %1 = String: MD identifier Definitions: Selected cam pair not activated by MD $MN_SW_ASSIGN_TAB or several cam pairs selected. Reactions: - Mode group not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Activate the cam pair or select only one cam pair. Program Continuation: Switch control OFF - ON. 4270 Machine data %1 assigns not activated NCK input/output byte %2 Parameters: %1 = String: MD identifier %2 = Index Definitions: The specified machine data assigns a digital input/output byte or an analog input/output signal the processing of which has not been activated to an NC function.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Correct machine data. Acti- vate required inputs/outputs via MDs: • $MN_FASTIO_DIG_NUM_INPUTS • $MN_FASTIO_DIG_NUM_OUTPUTS • $MN_FASTIO_ANA_NUM_INPUTS • $MN_FASTIO_ANA_NUM_OUTPUTS Activation of fast inputs/outputs does not require the corresponding hardware configura- tion to be available at the control. All functions using fast inputs/outputs can also be made use of by the PLC specification/modification defined in the VDI interface, if the response time requirements are reduced accordingly. Activated inputs/outputs increase the computation time requirement of the interpolation cycle because the PLC manipulation signals are handled cyclically. Note: Deactivate any inputs/outputs not in use. Program Continuation: Switch control OFF - ON. 4275 Machine data %1 and %2 both assign the same NCK output byte no. %3 several times Parameters: %1 = String: MD identifier %2 = String: MD identifier %3 = No. of output Definitions: The specified machine data assign two NC functions to the same digital/analog output. Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Correct machine data. Program Continuation: Switch control OFF - ON. 4280 Assignment of NCK input/output byte via MD %1[%2] does not match hardware configuration Parameters: %1 = String: MD identifier %2 = Index: MD array Definitions: When booting, the required input/output module was not found at the slot specified in the MD. Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Remedy: Please inform the authorized personnel/service department. Check hardware and correct the MD if necessary. Note: Monitoring of the hardware configuration is performed inde- pendently of the number of activated inputs/outputs (MD 10300 - 10360 FASTIO_ANA(DIG)_NUM_INPUTS(OUTPUTS)) Program Continuation: Switch control OFF - ON. 4282 Hardware of external NCK outputs assigned repeatedly Definitions: Several outputs have been configured on the same hardware byte. Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Alter MD 10364 HW_ASSIGN_DIG_FASTOUT or MD 10364 HW_ASSIGN_ANA_FASTOUT. Program Continuation: Switch control OFF - ON. 4285 Error on terminal block %1, error code %2 Parameters: %1 = Number of terminal block (1 ... 4) %2 = Error code Definitions: An error occurred on terminal block no. %1 (sign-of-life failure, I/O module removed in current operation, etc.). All possible errors which can lead to this alarm are not yet known (and will be completed later). Further information together with a description of the error code and its meaning will be provided at a later date. Error code 1: Sign-of-life failure from terminal block Error code 10: Sign-of-life failure NC Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Check hardware. Program Continuation: Switch control OFF - ON. 4290 Sign of life monitoring: local P-bus not alive Definitions: The COM computer must alter the sign-of-life on the local P-bus in each SERVO cycle. Monitoring for alteration takes place in the IPO cycle. If the sign of life has not altered, this alarm is triggered. Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Check hardware. Program Continuation: Switch control OFF - ON.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 4291 Failure of module in local P-bus slot %1, error codes: %2 %3 %4 Parameters: %1 = Slot number %2 = Error code %3 = Error code %4 = Error code Definitions: The module on the specified slot has signaled a diagnostics alarm. The error code reported corresponds to the AS300 documentation. Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Check hardware. Program Continuation: Switch control OFF - ON. 4300 Declaration in MD %1 is not allowed for geometry axis/spindle %2. Parameters: %1 = String: MD identifier %2 = Axis name, spindle number Definitions: Geometry axes and spindles cannot be operated as concurrent positioning axes. Reactions: - NC not ready. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Reset MD 30450 IS_CONCURRENT_POS_AX for the axis concerned. Program Continuation: Switch control OFF - ON. 4310 Declaration in MD %1 index %2 is not allowed. Parameters: %1 = String: MD identifier %2 = Index: MD array Definitions: The machine data values must be written in the array in ascending order. Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Correct the MD. Program Continuation: Clear alarm with the RESET key in all channels of this mode group. Restart part program. 4320 Axis %1 function %2 %3 and %4 not allowed Parameters: %1 = String: Axis identifier %2 = String: MD identifier %3 = String: Bit %4 = String: MD identifier

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Definitions: The functions declared by the specified machine data cannot simultaneously be active for one axis. Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Deactivate one of the functions. Program Continuation: Switch control OFF - ON. 4334 Channel %1 The amount of fine correction in parameter %2 of the orientable tool- holder %3 is too large Parameters: %1 = Channel number %2 = Invalid parameter of the orientable toolholder %3 = Number of the orientable toolholder Definitions: The maximum permissible value of the fine correction in an orientable toolholder is limited by the machine data $MC_TOCARR_FINE_LIM_LIN for linear variables, and by the machine data $MC_TOCARR_FINE_LIM_ROT for rotary variables. The alarm can only occur if the setting data $SC_TOCARR_FINE_CORRECTION is not equal to zero. Reactions: - Correction block is reorganized. - Interface signals are set. - Alarm display. - NC Stop on alarm at block end. Remedy: Enter a valid fine correction value. Program Continuation: Clear alarm with the RESET key. Restart part program. 4336 Channel %1 orientable toolholder no. %2 for orientation transformation %3 does not exist Parameters: %1 = Channel number %2 = Number of the orientable toolholder %3 = Number of the orientation transformation that is to be parameterized with the orient- able toolholder Definitions: The orientable toolholder, with whose data the orientation transformation is to be parame- terized (see machine data $MC_TRAFO5_TCARR_NO_1/2), does not exist. Reactions: - Correction block is reorganized. - Interface signals are set. - Alarm display. - NC Stop on alarm at block end. Remedy: Enter a valid tool-carrier number. Program Continuation: Clear alarm with the RESET key. Restart part program. 4338 Channel %1 invalid transformation type '%2' in toolholder %3 for orientation trans- former %4 Parameters: %1 = Channel number %2 = Transformer type %3 = Number of the orientable toolholder %4 = Number of the orientation transformation that is to be parameterized with the orient- able toolholder

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Definitions: The parameters of the orientation transformation are taken over from the data of an ori- entable toolholder. This orientable toolholder contains an invalid transformation type. (Types T, P and M are permissible). Reactions: - Correction block is reorganized. - Interface signals are set. - Alarm display. - NC Stop on alarm at block end. Remedy: Enter a valid transformation type. Program Continuation: Clear alarm with the RESET key. Restart part program. 4340 Channel %1 block %2 invalid transformation type in transformation no. %3 Parameters: %1 = Channel number %2 = Block number, label %3 = Transformation number Definitions: An invalid, i.e. undefined, number was entered in one of the machine data TRAFO_TYPE_1 ... TRAFO_TYPE_8. This alarm also occurs if a certain type of transfor- mation is only impossible on the type of control used (e.g. 5-axis transformation on a SINUMERIK 802D). Reactions: - Correction block is reorganized. - Interface signals are set. - Alarm display. - NC Stop on alarm at block end. Remedy: Enter a valid transformation type. Program Continuation: Clear alarm with the RESET key. Restart part program. 4341 Channel %1 block %2 no data set available for transformation no. %3 Parameters: %1 = Channel number %2 = Block number, label %3 = Transformation number Definitions: Only a limited number of machine data sets (usually 2) is available for each related group of transformations (e.g. orientation transformations, Transmit, Tracyl, etc.). This alarm is output if an attempt is made to set more transformations from a group. Example: Two orientation transformations are allowed. The machine data contains e.g.: TRAFO_TYPE_1 = 16 ; 1st orientation transformation TRAFO_TYPE_2 = 33 ; 2nd orientation transformation TRAFO_TYPE_3 = 256 ; 1st transmit transformation TRAFO_TYPE_4 = 20 ; 3rd orientation transformation ==> This entry triggers alarm Reactions: - Correction block is reorganized. - Interface signals are set. - Alarm display. - NC Stop on alarm at block end. Remedy: Enter valid machine data. Program Continuation: Clear alarm with the RESET key. Restart part program. 4342 Channel %1 invalid machine data for general 5-axis transformation error no. %2 Parameters: %1 = Channel number %2 = Error type

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Definitions: The machine data which describe the axis directions and the base orientation or the input axes for the general five-axis transformation are invalid. The error parameter displayed specifies the cause of the alarm: • 1: The first axis (TRAFO5_AXIS1_*) is not defined (all three entries of the vector are 0) • 2: The second axis (TRAFO5_AXIS2_*) is not defined (all three entries of the vector are 0) • 3: The basic orientation (TRAFO5_BASE_ORIENT_*) is not defined (all three entries of the vector are 0) • 4: The first and second axis are (virtually) parallel • 5: On TRAFO_TYPE = 56 (rotatable tool and workpiece) there is no four-axis transfor- mation, i.e. two rotary axes must always be available. (See MD TRAFO_AXES_IN_X) • 6: The third axis (TRAFO5_AXIS3_*) is not defined (all three entries of the vector are 0) (six-axis transformation) • 7: The normal tool vector (TRAFO6_BASE_ORIENT_NORMAL_*) is not defined (all three entries of the vector are 0) (six-axis transformation) • 8: The basic tool orientation (TRAFO5_BASE_ORIENT_*) and the normal tool vector (TRAFO6_BASE_ORIENT_NORMAL_*) are (virtually) parallel (six-axis transformation) Reactions: - Correction block is reorganized. - Interface signals are set. - Alarm display. - NC Stop on alarm at block end. Remedy: Set valid machine data. Program Continuation: Clear alarm with the RESET key. Restart part program. 4343 Channel %1 attempt made to change the machine data of an active transformation. Parameters: %1 = Channel number Definitions: An attempt was made to change the machine data of an active transformation and to acti- vate the machine data with RESET or NEWCONFIG. Reactions: - Interpreter stop - Interface signals are set. - Alarm display. - NC Stop on alarm at block end. Remedy: Set valid machine data. Program Continuation: Clear alarm with the RESET key. Restart part program. 4345 Channel %1 invalid configuration in chained transformation no. %2 Parameters: %1 = Channel number %2 = Transformation number Definitions: A chained transformation is incorrectly configured (machine data $MC_TRACON_CHAIN_1 or $MC_TRACON_CHAIN_2). The following causes for the error are possible: • The list of transformations to be chained starts with a 0 (at least one entry not equal to zero is required). • The list of transformations to be chained contains the number of a transformation which does not exist. • The number of a transformation in the list is greater than or equal to the number of the chained transformation. Example: The cascaded transformation is the fourth transforma- tion in the system, i.e. $MC_TRAFO_TYPE_4 = 8192. In this case, only values 1, 2 or 3 may be entered in the associated list (e.g. $MC_TRACON_CHAIN_1[...]).

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition • The chaining setting is invalid. The following restrictions currently apply. A maximum of two transformations can be chained. The first transformation must be an orientation trans- formation, transmit, peripheral curve transformation or inclined axis. The second transfor- mation must be the inclined axis transformation. Reactions: - Correction block is reorganized. - Interface signals are set. - Alarm display. - NC Stop on alarm at block end. Remedy: Set a valid transformation chain. Program Continuation: Clear alarm with the RESET key. Restart part program. 4346 Channel %1 invalid geoaxis assignment in machine data %2[%3] Parameters: %1 = Channel number %2 = Name of machine data %3 = Transformation number Definitions: Machine data TRAFO_GEOAX_ASSIGN_TAB_X contains an invalid entry. The following causes for the error are possible: • The entry references a channel axis which does not exist. • The entry is zero (no axis) but the transformation needs the relevant axis as a geometry axis. Reactions: - Correction block is reorganized. - Interface signals are set. - Alarm display. - NC Stop on alarm at block end. Remedy: Correct the entry in TRAFO_GEOAX_ASSIGN_TAB_X or TRAFO_AXES_IN_X. Program Continuation: Clear alarm with the RESET key. Restart part program. 4347 Channel %1 invalid channel axis assignment in machine data %2[%3] Parameters: %1 = Channel number %2 = Name of machine data %3 = Transformation number Definitions: Machine data TRAFO_AXIS_IN_X contains an invalid entry. The following causes for the error are possible: • The entry references a channel axis which does not exist. • The entry is zero (no axis) but the transformation needs the relevant axis as a channel axis. Reactions: - Correction block is reorganized. - Interface signals are set. - Alarm display. - NC Stop on alarm at block end. Remedy: Correct the entry in TRAFO_AXES_IN_X. Program Continuation: Clear alarm with the RESET key. Restart part program. 4350 Channel %1 axis identifier %2 machine data %3 not consistent with machine data %4 Parameters: %1 = Channel number %2 = String: Axis identifier %3 = String: MD identifier %4 = String: MD identifier

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Definitions: MD 32410 JOG_AND_POS_JERK_ENABLE (jerk limitation) and MD 35240 ACCEL_TYPE_DRIVE (acceleration reduction) have been defined as the initial setting for an axis. However, the two functions cannot be activated at the same time for one axis. Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Resetting of 32410 JOG_AND_POS_JERK_ENABLE or 35240 ACCEL_TYPE_DRIVE. Program Continuation: Switch control OFF - ON. 4400 MD alteration will cause reorganisation of buffered memory (loss of data!) Definitions: A machine data has been altered that configures the buffered memory. If the NCK powers up with the altered data, this will lead to reorganization of the buffered memory and thus to the loss of all buffered user data (part programs, tool data, GUD, leadscrew error com- pensation, ...) Reactions: - Alarm display. Remedy: Please inform the authorized personnel/service department. If the control includes user data that has not yet been saved, then a data backup must be performed before the next NCK power-up. By manually resetting the altered MD to the value it had before the last power-up, reorganization of the memory can be avoided. Program Continuation: Alarm display showing cause of alarm disappears. No further operator action necessary. 4402 %1 causes a machine data reset Parameters: %1 = Machine data Definitions: If this machine data is set, the current machine data values are overwritten by the default values at the next ramp-up. Under certain circumstances, this may cause data loss (even in the buffered memory). Reactions: - Alarm display. Remedy: Please inform the authorized personnel/service department. If the control includes user data that has not yet been saved, then a data backup must be performed before the next NCK power-up. By manually resetting the altered MD to the value it had before the last power-up, reorganization of the memory can be avoided. Program Continuation: Alarm display showing cause of alarm disappears. No further operator action necessary. 4502 Channel %1 anachronism %2(%3) -> %4 Parameters: %1 = Channel number %2 = String: MD identifier %3 = String: MD identifier %4 = String: MD identifier Definitions: Previously, in $MC_RESET_MODE_MASK Bit4 and Bit5, the reset behavior of the 6th or 8th G group was determined. This setting is now made in $MC_GCODE_RESET_MODE. In order to ensure compatible handling of "old" data backups, the "old" values are taken from $MC_RESET_MODE_MASK and entered in $MC_GCODE_RESET_MODE. Reactions: - Alarm display. Remedy: -- Program Continuation: Clear alarm with the Delete key or NC START.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 4503 In TO unit, %1 H number %2 assigned more than once. H number linked again. Parameters: %1 = TO unit %2 = H number Definitions: This error can only occur when MD $MN_MM_EXTERN_CNC_SYSTEM= 1 or 2. The Power ON effective machine data bit 10890, $MN_EXTERN_TOOLPROG_MODE, bit 3 has been reset. On reconstructing data handling after Power ON, it has been found that different edges of the same TO unit have the same H number. They had been linked pre- viously. They are linked again and MD bit $MN_EXTERN_TOOLPROG_MODE, bit 3 is set again. Reactions: - Alarm display. Remedy: H numbers must be assigned only once in a TO unit. Then, machine data bit 10890, $MN_EXTERN_TOOLPROG_MODE, bit 3 can be set = 0 and a restart can be per- formed. Program Continuation: Clear alarm with the Delete key or NC START. 5000 Communication job not executable %1 Parameters: %1 = Reference to which resources are no longer available. Definitions: The communication job (data exchange between NCK and MMC, e.g.: loading an NC part program) cannot be executed because there is insufficient memory space. Cause: Too many communication jobs in parallel. Reactions: - Alarm display. Remedy: • Reduce the number of communication jobs taking place at the same time or increase $MN_MM_NUM_MMC_UNITS • Restart communication job. Please inform the authorized personnel/service department. No remedial measures are possible - the operation triggering the alarm message has to be repeated. Clear the alarm display with Cancel. Program Continuation: Clear alarm with the Delete key or NC START. 6000 Memory reorganized using standard machine data Definitions: The memory management was not able to allocate the NC user memory with the values in the machine data. Because the total memory available is provided as dynamic and static memory for the NC user (e.g. for macro definitions, user variables, number of tool offsets, number of directories and files etc.) and therefore its size is not adequate. Reactions: - NC not ready. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Redefine the NC memory structure! A specific machine data for NC user memory allocation cannot be given as the cause of the alarm. Therefore, the MD initiating the alarm must be determined on the basis of the default values in the machine data by changing the user-specific memory structure step by step. Usually, not just one machine data has been chosen too large and therefore it is advisable to reduce the memory area by a certain proportion in several MDs. Program Continuation: Clear alarm with the RESET key in all channels of this mode group. Restart part program.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms 6010 Channel %1 data block %2 not or not completely created, error code %3 Parameters: %1 = Channel number %2 = String (block name) %3 = Internal error code Definitions: Data management has detected an error in power-up. The specified data block may not have been created. The error number specifies the type of error. If the error number >100000, then there is a fatal system error. Otherwise, the user memory area was made too small. In this case the (user) error codes have the following meaning: • Error number 1: No memory space available • Error number 2: Maximum possible number of symbols exceeded • Error number 3: Index 1 outside of valid value range • Error number 4: Name in channel already exists • Error number 5: Name in NCK already exists If the alarm occurs after cycle programs, macro definitions or definitions for global user data (GUD) have been introduced, the machine data for the NC user memory configura- tion have been incorrectly configured. In all other cases, changes to machine data that are already correct lead to errors in the user memory configuration. The following block names (2nd parameter) are known in the NCK (all system and user data blocks; in general, only problems in the user data blocks can be remedied by user intervention: • _N_NC_OPT - System internal: option data, NCK global • _N_NC_SEA - System internal: setting data, NCK global • _N_NC_TEA - System internal: machine data, NCK global • _N_NC_CEC - System internal: 'cross error compensation' • _N_NC_PRO - System internal: protection zones, NCK global • _N_NC_GD1 - User: 1. GUD block defined by _N_SGUD_DEF, NCK global • _N_NC_GD2 - User: 2. GUD block defined by _N_MGUD_DEF, NCK global • _N_NC_GD3 - User: 3. GUD block defined by _N_UGUD_DEF, NCK global • _N_NC_GD4 - User: 4. GUD block defined by _N_GUD4_DEF, NCK global • _N_NC_GD5 - User: 5. GUD block defined by _N_GUD5_DEF, NCK global • _N_NC_GD6 - User: 6. GUD block defined by _N_GUD6_DEF, NCK global • _N_NC_GD7 - User: 7. GUD block defined by _N_GUD7_DEF, NCK global • _N_NC_GD8 - User: 8. GUD block defined by _N_GUD8_DEF, NCK global • _N_NC_GD9 - User: 9. GUD block defined by _N_GUD9_DEF, NCK global • _N_NC_MAC - User: Macro definitions • _N_NC_FUN - User: Cycle programs • _N_CHc_OPT - System internal: option data, channel-specific • _N_CHc_SEA - System internal: setting data, channel-specific • _N_CHc_TEA - System internal: machine data, channel-specific • _N_CHc_PRO - System internal: protection zones, channel-specific • _N_CHc_UFR - System internal: frames, channel-specific • _N_CHc_RPA - System internal: arithmetic parameter, channel-specific • _N_CHc_GD1 - User: 1. GUD block defined by _N_SGUD_DEF, channel-specific • _N_CHc_GD2 - User: 2. GUD block defined by _N_MGUD_DEF, channel-specific • _N_CHc_GD3 - User: 3. GUD block defined by _N_UGUD_DEF, channel-specific • _N_CHc_GD4 - User: 4. GUD block defined by _N_GUD4_DEF, channel-specific • _N_CHc_GD5 - User: 5. GUD block defined by _N_GUD5_DEF, channel-specific • _N_CHc_GD6 - User: 6. GUD block defined by _N_GUD6_DEF, channel-specific • _N_CHc_GD7 - User: 7. GUD block defined by _N_GUD7_DEF, channel-specific • _N_CHc_GD8 - User: 8. GUD block defined by _N_GUD8_DEF, channel-specific • _N_CHc_GD9 - User: 9. GUD block defined by _N_GUD9_DEF, channel-specific

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition • _N_AXa_OPT - System internal: option data, axial • _N_AXa_SEA - System internal: setting data, axial • _N_AXa_TEA - System internal: machine data, axial • _N_AXa_EEC - System internal: leadscrew error compensation data, axial • _N_AXa_QEC - System internal: quadrant error compensation data, axial • _N_TOt_TOC - System internal: toolholder data, TOA-specific • _N_TOt_TOA - System internal: tool data, TOA-specific • _N_TOt_TMA - System internal: magazine data, TOA-specific c = Channel number a = Machine axis number t = TOA unit number There are further internal system data blocks with identifier. Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Correct the machine data or undo the changes made. Please inform the authorized personnel/service department. There are two determining machine data for cycle programs: • $MN_MM_NUM_MAX_FUNC_NAMES = max. number of all cycle programs, error num- ber = 2 shows that this value is too small. • $MN_MM_NUM_MAX_FUNC_PARAM = max. number of all parameters defined in the cycle programs, error number = 2 shows that this value is too small (If these MDs are modified, the memory backup is retained) The following applies to macro definitions: $MN_MM_NUM_USER_MACROS = max. number of all macro definitions, error number = 2 shows that this value is too small. (If these MDs are modified, the memory backup is retained) The following applies to GUD variables: • $MN_MM_NUM_GUD_MODULES = max. number of GUD data blocks per area (NCK/ channel) (if GD1, GD2, GD3, GD9 are to be defined, then the value must be = 9 and not e.g. = 4). • $MN_MM_NUM_GUD_NAMES_NCK = max. number of all NCK global GUD variables, error number = 2 shows that this value is too small. • $MN_MM_NUM_GUD_NAMES_CHAN = max. number of all channel-specific GUD vari- ables in the channel, error number = 2 shows that this value is too small. • $MN_MM_GUD_VALUES_MEM = total value memory of all GUD variables together, error number = 1 shows that this value is too small. Program Continuation: Switch control OFF - ON. 6020 Machine data have been altered - now memory is reorganized Definitions: Machine data have been changed that define the NC user memory allocation. Data man- agement has restructured the memory in accordance with the altered machine data. Reactions: - Alarm display. Remedy: No remedial measures are required. Any user data that are required must be input again. Program Continuation: Clear alarm with the RESET key. Restart part program.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms 6030 Limit of user memory has been adapted Definitions: Data management checks during power-up the actually available physical user memory (DRAM, DPRAM and SRAM) with the values in the system-specific machine data 18210 MM_USER_MEM_DYNAMIC, MD 18220 MM_USER_MEM_DPR und MD 18230 MM_- USERMEM_BUFFERED. Reactions: - Alarm display. Remedy: No remedial measures are required. The new maximum permissible value can be read from the reduced machine data. Program Continuation: Clear alarm with the RESET key. Restart part program. 6035 Instead of %1 KB the system has only %2 KB of free user memory of type '%3' Parameters: %1 = Free memory capacity in KB defined for the control model %2 = Actual maximum capacity of free memory in KB %3 = Type of memory, "D"=non-battery-backed, "S"=battery-backed Definitions: The alarm can only occur after a 'cold start' (=NCK start-up with standard machine data). The alarm is only a notice. There is no interference with any NCK functions. It shows that the NCK has less free user memory available than specified by Siemens for this control variant. The value of the actually available free user memory can also be taken from the machine data $MN_INFO_FREE_MEM_DYNAMIC, $MN_INFO_FREE_MEM_STATIC. Siemens supplies NCK with default settings that, depending on the model, have certain (free) memory space available for the specific settings of the actual applications. The orig- inal factory setting of NCK systems is thus that the alarm does not occur with a cold start. Reactions: - Alarm display. Remedy: Reasons for the message: • The NCK contains compile cycle software, that uses so much memory space that the hardware cannot provide the required memory. • The NCK runs on hardware that is not intended for this NCK release (i.e. that has not enough memory capacity). • If the application runs properly with the remaining free user memory (i.e. can be started up without any errors), the message can simply be ignored. • If the actual application cannot be configured because there is not enough memory capacity available, either the existing compile cycle must be reduced or, if possible, the system must be upgraded with additional memory space. Program Continuation: Clear alarm with the RESET key. Restart part program. 6100 Error while creating %1, error number %2 %3 Parameters: %1 = Symbolname %2 = Error code %3 = If required, internal error identifier Definitions: An error was detected while creating a compile cycle machine data. The error number specifies the type of error. • Error number 1: Insufficient memory available • Error number 2: Symbol in the NCK already exists • Error number 3: Maximum possible number of symbols exceeded • Error number 4: Invalid name prefix • Error number 5: Illegal array size Note: Other errors of this type could have occurred, but have not been displayed.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: • Error number 1: The memory reserved by machine data 12328 $MN_MM_CC_MD_MEM_SIZE has to be increased. If the error occurs while loading an archive, then the machine data must be increased "manually". To do this, either Edit the archive with 'arcedit' or Overwrite the MD in the MD picture and prevent the deletion of the machine data when writing the archive (MMC: Set Ask_for_CFG_RESET.INI = 1 in 'dino.ini'). Also refer to: Upgrade instructions P6.x. • Error number 2: Error in the combination or while reloading compile cycles: Do not acti- vate compile cycle. • Error number 3: Error in the combination or while reloading compile cycles: Do not acti- vate compile cycle. • Error number 4: Error in the compile cycle: Do not activate compile cycle. • Error number 5: Error in the compile cycle: Do not activate compile cycle. Program Continuation: Switch control OFF - ON. 6401 Channel %1 tool change not possible: Empty location for tool %2 Duplo no. %3 on magazine %4 not available. Parameters: %1 = Channel ID %2 = String (identifier) %3 = Duplo number %4 = Magazine number Definitions: The tool cannot be moved into the selected tool magazine. There is no appropriate loca- tion for this tool. A suitable location is mainly determined by the status. The status must indicate that this location is free, not disabled, not reserved and not co-occupied by a tool that is too large. Furthermore, it is important that the type of tool matches the type of any magazine location that may be free. (If, for example, all magazine locations are of the 'B' type and these are all free and the tool is of type 'A', then this tool cannot be put into this magazine). Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: • Check whether the magazine data have been defined correctly. • Check whether there is still room in the magazine to add another tool; there may not be due to operating procedures. • Check whether a location type hierarchy is defined and whether it, for example, does not allow insertion of a type 'A' tool in a free location with type 'B'. Program Continuation: Clear alarm with the RESET key. Restart part program. 6402 Channel %1 tool change not possible. Magazine no. %2 not available Parameters: %1 = Channel ID %2 = Magazine number Definitions: The desired tool change is not possible. The magazine with the specified number is not available.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: • Check whether the magazine data have been defined correctly. • Check whether the magazine is connected to the desired tool holder/spindle via a dis- tance relation. • The user PLC program may have sent wrong data to the NCK. Program Continuation: Clear alarm with the RESET key. Restart part program. 6403 Channel %1 tool change not possible. Magazine location number %2 on magazine %3 not available. Parameters: %1 = Channel ID %2 = Magazine number %3 = Magazine location number Definitions: The desired tool change is not possible. The specified magazine location is not contained in the specified magazine. Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Check whether the magazine data have been defined correctly. The user PLC program may have delivered incorrect data to the NCK. Program Continuation: Clear alarm with the RESET key. Restart part program. 6404 Channel %1 tool change not possible. Tool %2 not available or not usable Parameters: %1 = Channel ID %2 = String (identifier) Definitions: The desired tool change is not possible. The specified tool does not exist or cannot be inserted. Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: • Check whether the part program is written correctly. • Check whether the tool data are correctly defined. • Check whether there is a replacement tool which can be used for the specified tool. Program Continuation: Clear alarm with the RESET key. Restart part program. 6405 Channel %1 command %2 has invalid PLC acknowledge parameter %3 - identifier %4 Parameters: %1 = Channel ID %2 = Command no. %3 = PLC acknowledge parameter %4 = Error code Definitions: The specified command has been answered by PLC with an invalid acknowledgement in the current combination. The following assignments are defined for "command no.": 1 Move tool, load or unload magazine 2 Prepare tool change

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 3 Execute tool change 4 Prepare tool change and execute with T command 5 Prepare tool change and execute with M command 7 Terminate canceled tool command 8 Check tool movement with reservation 9 Check tool movement 0 Transport acknowledgement Parameters 2 and 3 designate the PLC command and the status number of the acknowl- edgement. Example: Parameter 4 of the alarm message is 10. It is not defined whether a buffer loca- tion for asynchronous tool motion must be reserved. In the example, the parameter is ignored by the NCK. Further possible causes for the alarm: The tool change defined by the command is not possible. The magazine location specified in the invalid parameter does not exist in the magazine. The 3rd parameter - error identification - gives a more detailed description of the alarm. Meanings: • 0 = not defined • 1 = status not allowed or undefined status received by PLC • 2 = source and/or target magazine no./location no. unknown • 3 = not defined • 4 = target magazine no. and/or location no. in tool motion command not end target • 5 = not defined • 6 = source and/or target magazine no./location no. unknown during tool change • 7 = PLC comm. with inconsistent data: either inconsistent magazine addresses in VDI or NCK command unequal to PLC acknowledgement or both • 8 = PLC comm. with inconsistent data: while rejecting a tool, the tool to be rejected was unloaded asynchronously. NCK cannot perform a new selection. • 9 = PLC comm. with inconsistent data: the command acknowledgement data wants to move a tool to a location that is occupied by another tool. • 10 = it is not defined whether a buffer location for asynchronous tool motion must be reserved. Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Please inform the authorized personnel/service department. Erroneous PLC communica- tion: Correct the PLC program. Program Continuation: Clear alarm with the RESET key. Restart part program. 6406 Channel %1 PLC acknowledge for command %2 is missing Parameters: %1 = Channel ID %2 = Command no. Definitions: There is still no acknowledgement from the PLC for the tool change. The NCK cannot continue processing until it receives this acknowledgement for the specified command number. Possible command number values are described for alarm 6405. Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Remedy: Please inform the authorized personnel/service department. • Erroneous PLC communication: Correct the PLC program. • It is possible to release NCK with the PLC command 7 from the wait condition. This aborts the waiting command. Program Continuation: Clear alarm with the RESET key. Restart part program. 6407 Channel %1 tool %2 cannot be placed in magazine %3 on location %4. Invalid defi- nition of magazine! Parameters: %1 = Channel ID %2 = String (identifier) %3 = Magazine number %4 = Magazine location number Definitions: A tool change request or a verification request was issued to put the tool in a location which does not satisfy the prerequisites for filling. The following causes for the error are possible: • Location is blocked or not free! • Tool type does not match the location type! • Tool possibly too large, adjacent locations are not free! Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: • Check whether the magazine data are correctly defined (especially the location type). • Check whether the tool data are correctly defined (especially the location type). Program Continuation: Clear alarm with the RESET key. Restart part program. 6410 TO unit %1 tool %2 / Duplo no. %3 has reached its prewarning limit with D = %4 Parameters: %1 = TO unit %2 = Tool identifier (name) %3 = Duplo number %4 = D number Definitions: Tool monitoring: This message informs that the specified D offset has reached its pre- warning limit for a time-, quantity- or wear-monitored tool. If possible, the D number is dis- played; if not, value 0 is assigned to the 4th parameter. If the function additive offset is being used, additive offset monitoring may be active instead of tool wear monitoring. The actual type of tool monitoring is a tool property (see $TC TP9). If replacement tools are not being used, the duplo number specified has no meaning. The alarm is triggered through the MMC or PLC (=OPI interface). The channel context is not defined. The TO unit was specified for this reason (see $MC_MM_LINK_TOA_UNIT). Reactions: - Interface signals are set. - Alarm display. Remedy: For information only. The user must decide what to do. Program Continuation: Clear alarm with the Delete key or NC START. 6411 Channel %1 tool %2 / Duplo no. %3 has reached its prewarning limit with D = %4 Parameters: %1 = Channel number %2 = Tool identifier (name) %3 = Duplo number %4 = D number

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Definitions: Tool monitoring: This message informs that the specified D offset has reached its pre- warning limit for a time-, quantity- or wear-monitored tool. If possible, the D number is dis- played; if not, value 0 is assigned to the 4th parameter. If the function additive offset is being used, additive offset monitoring may be active instead of tool wear monitoring. The actual type of tool monitoring is a tool property (see $TC TP9). If replacement tools are not being used, the duplo number specified has no meaning. The alarm originates during NC program execution. Reactions: - Interface signals are set. - Alarm display. Remedy: For information only. The user must decide what to do. Program Continuation: Clear alarm with the Delete key or NC START. 6412 TO unit %1 tool %2 / Duplo no. %3 has reached its monitoring limit with D = %4 Parameters: %1 = TO unit %2 = Tool identifier (name) %3 = Duplo number %4 = D number Definitions: Tool monitoring: This message informs that the specified D offset has reached its pre- warning limit for a time-, quantity- or wear-monitored tool. If possible, the D number is dis- played; if not, value 0 is assigned to the 4th parameter. If the function additive offset is being used, additive offset monitoring may be active instead of tool wear monitoring. The actual type of tool monitoring is a tool property (see $TC TP9). If replacement tools are not being used, the duplo number specified has no meaning. The alarm is triggered through the MMC or PLC (=OPI interface). The channel context is not defined. The TO unit was specified for this reason (see $MC_MM_LINK_TOA_UNIT). Reactions: - Interface signals are set. - Alarm display. Remedy: For information only. The user must decide what to do. Program Continuation: Clear alarm with the Delete key or NC START. 6413 Channel %1 tool %2 / Duplo no. %3 has reached its monitoring limit with D = %4 Parameters: %1 = TO unit %2 = Tool identifier (name) %3 = Duplo number %4 = D number Definitions: Tool monitoring: This message informs that the specified D offset has reached its pre- warning limit for a time-, quantity- or wear-monitored tool. If possible, the D number is dis- played; if not, value 0 is assigned to the 4th parameter. If the function additive offset is being used, additive offset monitoring may be active instead of tool wear monitoring. The actual type of tool monitoring is a tool property (see $TC TP9). If replacement tools are not being used, the duplo number specified has no meaning. The alarm originates during NC program execution. Reactions: - Interface signals are set. - Alarm display. Remedy: For information only. The user must decide what to do. Program Continuation: Clear alarm with the Delete key or NC START.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms 6415 TO unit %1 tool %2 with tool edge no. %3 has reached tool monitor warning limit Parameters: %1 = TO unit %2 = Tool identifier %3 = Cutting edge number Definitions: This message informs that at least one cutting edge of the time or quantity monitored tool has reached its monitoring limit. The alarm was triggered through the OPI interface (MMC, PLC). The channel context is not defined. The TO unit was specified for this rea- son. Reactions: - Interface signals are set. - Alarm display. Remedy: For information only. The user must decide what to do. Program Continuation: Clear alarm with the Delete key or NC START. 6416 Channel %1 tool %2 with tool edge no. %3 has reached tool monitor warning limit Parameters: %1 = Channel number %2 = Tool identifier %3 = Cutting edge number Definitions: This message informs that at least one cutting edge of the time or quantity monitored tool has reached its monitoring limit. The limit was detected in the channel context. The alarm originated during NC program execution. Reactions: - Interface signals are set. - Alarm display. Remedy: For information only. The user must decide what to do. Program Continuation: Clear alarm with the Delete key or NC START. 6417 TO unit %1 tool %2 with tool edge no. %3 has reached tool monitoring limit Parameters: %1 = TO unit %2 = Tool identifier %3 = Cutting edge number Definitions: This message informs that at least one cutting edge of the time or quantity monitored tool has reached its monitoring limit. The alarm was triggered through the OPI interface (MMC, PLC). The channel context is not defined. The TO unit was specified for this rea- son. Reactions: - Interface signals are set. - Alarm display. Remedy: For information only. The user must decide what to do. Program Continuation: Clear alarm with the Delete key or NC START. 6418 Channel %1 tool %2 with tool edge no. %3 has reached tool monitoring limit Parameters: %1 = Channel number %2 = Tool identifier %3 = Tool number Definitions: This message informs that at least one cutting edge of the time or quantity monitored tool has reached its monitoring limit. The limit was detected in the channel context. The alarm originated during NC-program execution. Reactions: - Interface signals are set. - Alarm display. Remedy: For information only. The user must decide what to do. Program Continuation: Clear alarm with the Delete key or NC START.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 6421 Channel %1 tool move not possible. Empty location for tool %2 Duplo no. %3 on magazine %4 not available Parameters: %1 = Channel ID %2 = String (identifier) %3 = Duplo number %4 = Magazine number Definitions: The desired tool motion command - triggered from the MMC or PLC - is not possible. The tool cannot be moved into the specified tool magazine. There is no appropriate location for this tool. Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: • Check whether the magazine data have been defined correctly (e.g. the magazine must not be disabled). • Check whether the tool data are correctly defined (for example, the tool location type must match the location types allowed in the magazine). • Check whether there is still room in the magazine to add another tool; there may not be due to operating procedures. • Check whether a location type hierarchy is defined and whether it, for example, does not allow insertion of a type 'A' tool in a free location with type 'B'. Program Continuation: Clear alarm with the Delete key or NC START. 6422 Channel %1 tool move not possible. Magazine no. %2 not available. Parameters: %1 = Channel ID %2 = Magazine number Definitions: The desired tool motion command - triggered from the MMC or PLC - is not possible. The magazine with the specified number is not available. Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: • Check whether the magazine data have been defined correctly. • If the PLC issued the command for motion: check whether the PLC program is correct. • If the MMC issued the command for motion: check whether the MMC command was assigned correct parameters. Program Continuation: Clear alarm with the Delete key or NC START. 6423 Channel %1 tool move not possible. Location %2 on magazine %3 not available. Parameters: %1 = Channel ID %2 = Magazine location number %3 = Magazine number Definitions: The desired tool motion command - triggered from the MMC or PLC - is not possible. The specified magazine location is not contained in the specified magazine. Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: Check whether the magazine data have been defined correctly. Program Continuation: Clear alarm with the Delete key or NC START.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms 6424 Channel %1 tool move not possible. Tool %2 not available/not usable. Parameters: %1 = Channel ID %2 = String (identifier) Definitions: The desired tool motion command - triggered from the MMC or PLC - is not possible. The status of the named tool does not allow movement of the tool. The named tool is not defined or not permitted for the command. Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: • Check whether the tool status 'is being changed' ('H20') is set. If yes, then the appropri- ate tool change command must first be completed by the PLC. Then the tool should be able to be moved. • Check whether the tool data are correctly defined. Has the correct T number been spec- ified? • Check whether the move command has been correctly parameterized. Is the desired tool at the source location? Is the target location suitable for taking the tool? • Check whether the tool has already been loaded (if the alarm occurs while loading the tool). Program Continuation: Clear alarm with the Delete key or NC START. 6425 Channel %1 tool %2 cannot be placed in magazine %3 on location %4. Invalid defi- nition of magazine. Parameters: %1 = Channel ID %2 = String (identifier) %3 = Magazine number %4 = Magazine location number Definitions: The desired tool motion command - triggered from the MMC or PLC - is not possible. A movement request was issued to put the tool in a location which does not satisfy the pre- requisites for filling. The following causes for the error are possible: • Location is blocked or not free! • Tool type does not match the location type! • Tool possibly too large, adjacent locations are not free! • If a tool is to be loaded or unloaded, the load/unload position must be of 'load location' type. • If a tool is to be loaded or unloaded, is the magazine in question linked to the load/ unload location? See $TC_MDP1, $TC_MDP2. Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: • Check whether the magazine data have been defined correctly. • Check whether there is still room in the magazine to add another tool; there may not be due to operating procedures. • Check whether a location type hierarchy is defined and whether it, for example, does not allow insertion of a type 'A' tool in a free location with type 'B'. • Check whether the magazine in question is linked to the load/unload location or whether a distance has been defined. • Check whether the load/unload position is of 'load location' type. See also $TC_MPP1. Program Continuation: Clear alarm with the Delete key or NC START.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 6430 Workpiece counter: overflow in table of monitored cutting edges. Definitions: No more cutting edges can be entered in the piece counter table. As many cutting edges can be noted for the workpiece counter as are possible in total in the NCK. This means that if for each tool each cutting edge in each TO unit is used precisely once for a work- piece then the limit is reached. If several workpieces are made on several toolholders/spindles simultaneously, it is possi- ble to note 18100 MM_NUM_CUTTING_EDGES_IN_TOA cutting edges for the work- piece counter for all of the workpieces. If this alarm occurs, it means that cutting edges used subsequently are no longer quantity monitored until the table has been emptied again, e.g. by means of the NC language com- mand SETPIECE or by the relevant job from MMC, PLC (PI service). Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: • Was decrementing of the piece counter forgotten? Then program SETPIECE in the part program, or add the correct command in the PLC program. • If the part program/PLC program is correct, then more memory should be set for tool cut- ting edges via the machine data $MN_MM_NUM_CUTTING_EDGES_IN_TOA (can only be performed with the necessary access rights!). Program Continuation: Clear alarm with the Delete key or NC START. 6431 Channel %1 block %2 Function not allowed. Tool management/monitoring is not active. Parameters: %1 = Channel ID %2 = Block number, label Definitions: Occurs when a data management function is called which is not available because Tool- Man is deactivated. For example, the language commands GETT, SETPIECE, GET- SELT, NEWT, DELT. Reactions: - Correction block is reorganized. - Interface signals are set. - Alarm display. Remedy: • Please inform the authorized personnel/service department. • Make sure of how the NC is supposed to be configured! Is tool management or tool monitoring needed but not activated? • Are you using a part program that is meant for a numerical control with tool manage- ment/tool monitoring? It is not possible to start this program on the numerical control with- out tool management/tool monitoring. Either run the part program on the appropriate NC control or edit the part program. • Activate tool management/tool monitoring by setting the appropriate machine data. See $MN_MM_TOOL_MANAGEMENT_MASK, $MC_TOOL_MANAGEMENT_MASK • Check whether the required option is set accordingly. Program Continuation: Clear alarm with NC START or RESET key and continue the program. 6432 Function not executable. No tool assigned to tool holder/spindle Parameters: %1 = Channel ID Definitions: When an attempt is made to perform an operation that requires a tool to be located on the spindle. This can be the quantity monitoring function, for example. Reactions: - Interface signals are set. - Alarm display. Remedy: Select another function, another toolholder/spindle, position tool on toolholder/spindle. Program Continuation: Clear alarm with the Delete key or NC START.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms 6433 Channel %1 block %2 %3 not available with tool management Parameters: %1 = Channel number %2 = Block number, label %3 = Source symbol Definitions: The symbol variable specified in %3 is not available with active tool management. The function GELSELT should be used with $P_TOOLP. Reactions: - Interpreter stop - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: Modify program. If $P_TOOLP has been programmed, the GETSELT function should be used instead. Program Continuation: Clear alarm with the RESET key. Restart part program. 6434 Channel %1 block %2 NC command SETMTH not allowed because tool holder func- tion not active Parameters: %1 = Channel number %2 = Block number, label Definitions: No master toolholder has been defined for the initial state ($MC_TOOL_MANAGEMENT_TOOLHOLDER = 0), therefore no toolholder is available. The NC command SETMTH has neither been defined. In this setting, the tool change is carried out referring to the master spindle. The master spindle is set with SETMS. Reactions: - Correction block is reorganized. - Local alarm reaction. - Interface signals are set. - Alarm display. Remedy: Correct the NC program (delete or replace SETMHT) or enable toolholder function via machine data. Program Continuation: Clear alarm with NC START or RESET key and continue the program. 6441 Writing of $P_USEKT not allowed. Definitions: An attempt was made to write the value of $P_USEKT. This is not possible since pro- gramming T= 'location number' with automatic setting of $P_USEKT is active. Reactions: - Interpreter stop - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: • Make sure of how the NC is supposed to be configured! (see bit16 and bit22 in $MC_TOOL_MANAGEMENT_MASK) • Tool change with "Reject tool" is configured. If you now try to start this program on NC control with T='location number' with automatic setting of $P_USEKT this will not be pos- sible. • Either run the part program on the appropriate NC control or edit the part program. Program Continuation: Clear alarm with the Delete key or NC START. 6442 Channel %1 function not executable. No tool assigned to desired magazine/maga- zine location %2. Parameters: %1 = Channel ID %2 = Magazine/magazine location no.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Definitions: PLC logic is presumably incorrect. Tool change with reject tool is configured. Preparatory command is pending. Selected tool is (e.g. from PLC) unloaded from its location. PLC acknowledges preparatory command with 'Repeat tool selection' (e.g. status =7). NCK cannot find the tool at the magazine location specified in the PLC command. Or: Illegal operator intervention in an active tool selection (unloading of the tool to be selected) has occurred. Therefore the PLC acknowledgement fails. Reactions: - Interface signals are set. - Alarm display. Remedy: PLC programmer must note the following: • Ensure that the tool is not removed from the specified magazine location (e.g. incorrect PLC program). • Do not remove the tool from the programmed tool change before the final acknowledge- ment of the command (= unload). !! It is however permissible to change the location of the tool to be loaded. The NCK can deal with this situation. This alarm supplements Alarm 6405, if it contains the identifier 8. Therefore, the diagnos- tics should be easier. Program Continuation: Clear alarm with the Delete key or NC START. 6450 Channel %1 block %2 tool change not possible. Invalid magazine location no. %3 in buffer magazine Parameters: %1 = Channel ID %2 = Block number, label %3 = Magazine location number Definitions: The desired tool change is not possible. The specified magazine location is either tool- holder/spindle or empty. Only the numbers of the buffer that are not toolholder/spindle may be programmed with the NC command TCI, i.e. the location number of a gripper is allowed. Reactions: - Correction block is reorganized. - Interface signals are set. - Alarm display. Remedy: • Check whether the magazine data ($TC_MPP1) have been defined correctly. • Check whether the alarm-causing program command _ e.g. TCI _ has been pro- grammed correctly. Program Continuation: Clear alarm with NC START or RESET key and continue the program. 6451 Channel %1 block %2 tool change not possible. No buffer magazine defined. Parameters: %1 = Channel ID %2 = Block number, label Definitions: The desired tool change is not possible. No buffer magazine defined. Reactions: - Correction block is reorganized. - Interface signals are set. - Alarm display. Remedy: Check whether the magazine data have been defined correctly. Program Continuation: Clear alarm with NC START or RESET key and continue the program. 6452 Channel %1 block %2 tool change not possible. Tool holder/spindle number = %3 not defined. Parameters: %1 = Channel ID %2 = Block number, label %3 = Tool holder/spindle number

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Definitions: The desired tool change is not possible. The toolholder/spindle number has not been defined. Reactions: - Correction block is reorganized. - Interface signals are set. - Alarm display. Remedy: Check whether the toolholder number/spindle number and the magazine data have been defined correctly. (See system variables $TC_MPP1, $TC_MPP5 of the buffer magazine) Program Continuation: Clear alarm with NC START or RESET key and continue the program. 6453 Channel %1 block %2 tool change not possible. No assignment between tool- holder/spindle no. = %3 and buffer magazine location %4 Parameters: %1 = Channel ID %2 = Block number, label %3 = Spindle no. %4 = Location no. Definitions: The desired tool change is not possible. No relation has been defined between the tool- holder/spindle number and the buffer magazine location (Location No.) Reactions: - Correction block is reorganized. - Interface signals are set. - Alarm display. Remedy: • Check whether the magazine data ($TC_MLSR) have been defined correctly. • Check whether the alarm-causing program command _ e.g. TCI _ has been pro- grammed correctly. Program Continuation: Clear alarm with NC START or RESET key and continue the program. 6454 Channel %1 block %2 tool change not possible. No distance relation available. Parameters: %1 = Channel ID %2 = Block number, label Definitions: The desired tool change is not possible. Neither the spindle nor the buffer magazine loca- tion have a distance relation. Reactions: - Correction block is reorganized. - Interface signals are set. - Alarm display. Remedy: • Check whether the magazine data ($TC_MDP2) have been defined correctly. • Check whether the alarm-causing program command _ e.g. TCI _ has been pro- grammed correctly. Program Continuation: Clear alarm with NC START or RESET key and continue the program. 6455 Channel %1 block %2 tool change not possible. Magazine location no. %3 not avail- able in magazine %4 Parameters: %1 = Channel ID %2 = Block number, label %3 = Magazine location number %4 = Magazine number Definitions: The desired tool change is not possible. The indicated magazine location is not available in the indicated magazine. Reactions: - Correction block is reorganized. - Interface signals are set. - Alarm display.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Remedy: • Check whether the causing program command - e.g. TCI - has been parameterized cor- rectly. • Check whether magazine data have been defined correctly. ($TC_MAP6 and $TC_MAP7 of the intermediate location magazine) Program Continuation: Clear alarm with NC START or RESET key and continue the program. 6500 NC memory full Definitions: The NCK file system is full. The available buffered memory does not suffice. Note: At initial start-up, files of the NC file system may be affected such as drive data, MMC files, FIFO files, NC programs... Reactions: - Alarm display. Remedy: Adjust the size of the buffered memory ($MN_MM_USER_MEM_BUFFERED) or increase the space available in the buffered memory, e.g. by unloading part programs that are no longer being used. Or decrease the size of the ring buffer (see $MC_RESU_RING_BUFFER_SIZE). Program Continuation: Clear alarm with the Delete key or NC START. 6510 Too many part programs in the NC memory Definitions: The number of files in the file system (part of the NC memory) of the NC has reached the maximum number possible. Note: During initial start-up, this can concern files from the NC file system, e.g. drive data, MMC files, FIFO files, NC programs, ... Reactions: - Alarm display. Remedy: Please inform the authorized personnel/service department. • Delete or unload files (e.g. part programs), or • Increase $MM_NUM_FILES_IN_FILESYSTEM. Program Continuation: Clear alarm with the Delete key or NC START. 6520 The value of the machine data %1%2 is too low Parameters: %1 = String: MD identifier %2 = If required, index: MD array Definitions: The machine data $MN_MM_PROTOC_NUM_FILES specifies the number of protocol files for the protocol users. However, more types are used than configured. Reactions: - Alarm display. Remedy: Increase machine data $MN_MM_PROTOC_NUM_FILES. Program Continuation: Clear alarm with the Delete key or NC START. 6530 Too many files in directory Definitions: The number of files in one directory of the NCK has reached the maximum limit. Reactions: - Alarm display. Remedy: Please inform the authorized personnel/service department. • Delete or unload files (e.g. part programs) in the respective directory, or • Increase $MM_NUM_FILES_PER_DIR. Program Continuation: Clear alarm with the Delete key or NC START. 6540 Too many directories in the NC memory Definitions: The number of directories in the file system of the NCK has reached the maximum limit. Reactions: - Alarm display.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Remedy: • Delete or unload directory (e.g. workpiece), or • Increase $MM_NUM_DIR_IN_FILESYSTEM. Program Continuation: Clear alarm with the Delete key or NC START. 6550 Too many subdirectories Definitions: The number of subdirectories in a directory of the NCK has reached the maximum limit. Reactions: - Alarm display. Remedy: Please inform the authorized personnel/service department. • Delete or empty subdirectories in the respective directory, or • Increase $MM_NUM_SUBDIR_PER_DIR. Program Continuation: Clear alarm with the Delete key or NC START. 6560 Data format not allowed Definitions: An attempt was made to write impermissible data in an NCK file. This error can occur in particular when the attempt was made to load binary data in the NCK as ASCII file. The error can also occur during preprocessing of cycles (see $MN_PREPROCESSING_LEVEL) if the NC block is very long. In this case, subdivide the NC block. Reactions: - Alarm display. Remedy: Specify that the file concerned is a binary file (e.g. extension: .BIN). Program Continuation: Clear alarm with the Delete key or NC START. 6570 NC memory full Definitions: The NC card file system of the NCK is full. The task cannot be executed. Too many sys- tem files were created in the DRAM. Reactions: - Alarm display. Remedy: Start fewer "execute from external" processes. Program Continuation: Clear alarm with the Delete key or NC START. 6580 NC memory full Definitions: The NC card file system of the NCK is full. The task cannot be executed. To many files have been loaded Reactions: - Alarm display. Remedy: Delete or empty files (e.g. part programs). Program Continuation: Clear alarm with the Delete key or NC START. 6600 NC card memory is full Definitions: The NC card file system of the NCK is full. No more data can be stored on the NC card. Reactions: - Alarm display. Remedy: Delete the data on the PCMCIA card. Program Continuation: Clear alarm with the Delete key or NC START. 6610 Too many files open on NC card Definitions: Too many files are being accessed simultaneously on the NC card. Reactions: - Alarm display. Remedy: Repeat the action later. Program Continuation: Clear alarm with the Delete key or NC START.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 6620 NC card has incorrect format Definitions: The NC card cannot be accessed because the format is incorrect. Reactions: - Alarm display. Remedy: Replace the NC card. Program Continuation: Clear alarm with the Delete key or NC START. 6630 NC card hardware is defective Definitions: The NC card cannot be accessed because the card is defective. Reactions: - Alarm display. Remedy: Replace the PCMCIA card. Program Continuation: Clear alarm with the Delete key or NC START. 6640 NC card is not inserted Definitions: The NC card cannot be accessed because the card is not plugged in. Reactions: - Alarm display. Remedy: Plug in the NC card. Program Continuation: Clear alarm with the Delete key or NC START. 6650 Write protection of NC card is active Definitions: The NC card cannot be accessed because the write protection is active. Reactions: - Alarm display. Remedy: Deactivate the write protection. Program Continuation: Clear alarm with the Delete key or NC START. 6660 'Flash File System' option is not set Definitions: The NC card cannot be accessed because the option is not enabled. Reactions: - Alarm display. Remedy: Buy option. Program Continuation: Clear alarm with the Delete key or NC START. 6670 NC card read active Definitions: The alarm is active while the contents of the NC card are being read out. The FFS cannot be accessed during this period. Reactions: - Alarm display. Remedy: Wait until the read-out procedure is terminated. Program Continuation: Alarm display showing cause of alarm disappears. No further operator action necessary. 6671 NC card write active Definitions: The alarm is active while the contents of the NC card are being written. The FFS cannot be accessed during this period. If the power is switched off while the alarm is active, the contents of the PCMCIA card are destroyed! Reactions: - Alarm display. Remedy: Wait until the write procedure is terminated. Program Continuation: Alarm display showing cause of alarm disappears. No further operator action necessary.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms 6690 Cycles from NC card cannot be copied to the passive file system. Definitions: There is not enough space in the file system that the directories specified in the $PCMCIA_FUNKTION_MASK can be copied from the NC card to the passive file system. Reactions: - Alarm display. Remedy: Delete data in the file system. Program Continuation: Clear alarm with the Delete key or NC START. 6691 Cycles from the passive file system cannot be saved on the NC card Definitions: There is not enough space on the NC card that the directories specified in the $PCMCIA_FUNKTION_MASK can be saved. It is possible that cycles are lost during the next booting. Reactions: - Alarm display. Remedy: Delete data on the NC card or delete cycles not required. Program Continuation: Clear alarm with the Delete key or NC START. 6692 Cycle %1 lost Parameters: %1 = Name of cycle Definitions: A cycle has been changed and due to a power failure, the backup on the PC card could not be terminated properly. The cycle is lost. Reactions: - NC not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: Import the cycle again. Program Continuation: Switch control OFF - ON. 6693 File %1 lost Parameters: %1 = Name of file Definitions: Due to a power failure, a file change could not be terminated properly. The file is lost. Reactions: - NC not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: Import the file again. Program Continuation: Switch control OFF - ON. 6698 Unknown NC card (%1/%2). Writing not possible. Parameters: %1 = actManufactorCode (manufacturer code read by the card) %2 = actDeviceCode (memory code read by the card) Definitions: The NC card cannot be accessed because a valid write algorithm is not available for the flash memory. Reactions: - Alarm display. Remedy: Use a compatible NC card or enter the new manufacturer code/device code in MD $MN_PERMISSIVE_FLASH_TAB after consultation with SIEMENS. Program Continuation: Clear alarm with the Delete key or NC START.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 6700 Channel %1 value of the machine data %2%3 is too low Parameters: %1 = Channel number %2 = MD identifier %3 = If required, field index Definitions: The machine data $MC_MM_PROTOC_NUM_ETP_STD_TYP specifies the number of default event types for the protocol users. However, more types are used than configured. Reactions: - Alarm display. Remedy: Increase machine data $MC_MM_PROTOC_NUM_ETP_STD_TYP. Program Continuation: Clear alarm with the Delete key or NC START. 7000 Too many compile cycle alarms defined Definitions: Too many alarms are defined for the compile cycles. On powering up, the quantity was exceeded when defining a new CC alarm. Reactions: - Alarm display. Remedy: Apart from reducing the number of CC alarms, no remedial measures are possible at the present time. (contact SIEMENS AG, System Support for A&D MC products, Hotline (Tel.: see alarm 1000) Program Continuation: Clear alarm with the Delete key or NC START. 7010 Range of MMC alarm numbers for compile cycles exceeded Definitions: A fixed quantity of alarm numbers (100) is reserved for the compile cycles. This has been exceeded when defining a new CC alarm. (The valid range is between 0 and 4999). Reactions: - Alarm display. Remedy: Define the CC alarm numbers in the valid range from 0 to 4999. Program Continuation: Clear alarm with the Delete key or NC START. 7020 Compile cycle alarm number has not been defined Definitions: The alarm ID used by the manufacturer is not known to the system. This was not allo- cated when the alarms were generated. Reactions: - Alarm display. Remedy: The alarm can have 2 possible causes: • The alarm number has not been defined. A definition must still be made. • The call parameter used is not the same as the one transferred by the NCK. Program Continuation: Clear alarm with the Delete key or NC START. 7100 Compile cycles VDI area: %1 byte for inputs and %2 byte for outputs. Maximum %3 bytes available. Parameters: %1 = String (machine data) %2 = String (machine data) %3 = Max. length for interface Definitions: The sum of the input and output bytes at the VDI user interface for the compile cycles exceeds the maximum quantity of 400 bytes. Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Remedy: Please inform the authorized personnel/service department. Set the machine data for dividing up the VDI user interface of the compile cycles (DB 9) into input and output bytes in accordance with the functions in the compile cycles. The maximum quantity of 400 bytes must not be exceeded. There are no restrictions concerning the division into input and output bytes. Program Continuation: Switch control OFF - ON. 7200 Problem with externally linked compile cycle %1 %2 Parameters: %1 = Internal number %2 = could be Definitions: Problem with externally linked compile cycles. Reactions: - Alarm display. Remedy: See function description of the compile cycle! Program Continuation: Clear alarm with the Delete key or NC START. 7201 Assertion error in %1 line %2 Parameters: %1 = String (path with program name) %2 = String (line number) Definitions: This alarm is purely a development alarm. It only occurs with externally linked compile cycles. Reactions: - NC not ready. - The NC switches to follow-up mode. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. - Alarm reaction delay is canceled. Remedy: Consultation with CC developer Program Continuation: Clear alarm with the RESET key in all channels. Restart part program. 7202 Missing option bit for %1: %2 Parameters: %1 = (string) name of the specific .elf file %2 = (int) required option bit (hex) Definitions: Alarm for SIEMENS compile cycles. This alarm appears when the option bit required for a SIEMENS compile cycle is not set. Reactions: - NC not ready. - Channel not ready. - Interface signals are set. - Alarm display. - Alarm reaction delay is canceled. Remedy: Set the required option bit or delete the .elf file from the Flash File System. Program Continuation: Clear alarm with the RESET key in all channels. Restart part program. 7205 Incompatible OEM transformation channel %1 version NCK %2 CC %3 Parameters: %1 = (int) channel number %2 = Transformer interface version NCK %3 = Transformer interface version OEM

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Definitions: The interface for OEM transformations has changed incompatibly in the system. Reactions: - NC not ready. - Channel not ready. - Interface signals are set. - Alarm display. - Alarm reaction delay is canceled. Remedy: Load the new compile cycle version Program Continuation: Clear alarm with the RESET key in all channels. Restart part program. 7500 Block %1 invalid protection level for command %2 (protection level act.: %3 prog.: %4) Parameters: %1 = Block number %2 = Programmed command %3 = Current protection level of the command %4 = Programmed protection level of the command Definitions: On assigning a protection level for a parts program command via REDEF command • an impermissible parts program command has been programmed • a protection level has been programmed that is logically smaller (larger in value) than the protection level currently applicable for this command. • the relevant definition file has not been protected sufficiently against write access. The write protection of the file must be at least as high as the highest protection level that has been assigned to a parts program command in this definition file. Reactions: - Alarm display. Remedy: Modify definition files /_N_DEF_DIR/_N_MACCESS_DEF or /_N_DEF_DIR/_N_UAC- CESS_ DEF. Please see the Siemens Programming Guide or the OEM documentation for the language commands permissible for the relevant system configurations. Program Continuation: Clear alarm with the RESET key. Restart part program 8000 Channel %1 option 'user interrupt programs' not set Parameters: %1 = Channel number Definitions: The input signals of NCK inputs are required in order to activate the interrupt routines and rapid lift from contour. This function is not included in the basic version and must be retro- fitted when needed. Reactions: - Interpreter stop - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: Please inform the authorized personnel/service department. Do not use rapid interrupt inputs or contact the machine manufacturer with a view to retrofitting this option! Program Continuation: Clear alarm with the RESET key. Restart part program 8010 Option 'activation of more than %1 axes' not set Parameters: %1 = Number of axes Definitions: More machine axes have been defined through the channel-specific MD 20070 AXCONF_MACHAX_USED than are allowed in the system. Reactions: - NC not ready. - Mode group not ready, also effective for single axes - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Remedy: Please inform the authorized personnel/service department. The sum of all axes that have been configured through the channel-specific MD 20070 AXCONF_MACHAX_USED, must not exceed the maximum number of axes (dependent on configuration -> option, basic version: 4 axes). Program Continuation: Switch control OFF - ON. 8020 Option 'activation of more than %1 channels' not set Parameters: %1 = Number of channels Definitions: A 2nd channel has been indicated but the corresponding option does not exist. Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: In the system-specific MD 10010 ASSIGN_CHAN_TO_MODE_GROUP, reduce the num- ber of channels to 1 or retrofit the option for a 2nd channel. Program Continuation: Switch control OFF - ON. 8021 Option 'activation of more than %1 mode groups' not set Parameters: %1 = Number of mode groups Definitions: The option for the number of mode groups is not compatible with the activated mode group. Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: Add option for more mode groups. Activate fewer mode groups. Program Continuation: Switch control OFF - ON. 8022 Option 'activation of more than %1KB SRAM' not set Parameters: %1 = Memory size Definitions: The option for memory extension does not correspond to the active SRAM. Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: Please inform the authorized personnel/service department. • Buy option • Activate less SRAM Program Continuation: Switch control OFF - ON. 8023 Option 'Activation of more than %1 KB PLC user memory' not set Parameters: %1 = Memory size Definitions: The option for the memory configuration does not correspond to the PLC user memory used. Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: Please inform the authorized personnel/service department. • Purchase option • Use less PLC user memory Program Continuation: Switch control OFF - ON.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 8030 Channel %1 block %2 option 'interpolation of more than 4 axes' not set Parameters: %1 = Channel number %2 = Block number, label Definitions: The option for the number of interpolating axes does not correspond to the number of axes programmed in the interpolation group. Reactions: - Interpreter stop - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: Option: "Interpolation of more than 4 axes" (the number of axes that is then allowed can be set in this option) or specify in the part program as many (or fewer, as required) axes corresponding to the configuration of the control. Program Continuation: Clear alarm with the RESET key. Restart part program. 8032 Option 'activation of more than %1 link axes' not set Parameters: %1 = Number of axes Definitions: The option for the number of link axes does not match the number of axes programmed in MD $MN_AXCONF_LOGIC_MACHAX_TAB. Reactions: - Interpreter stop - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: • Buy option • Configure fewer link axes Program Continuation: Clear alarm with the RESET key. Restart part program. 8034 Option 'activation of axis containers' not set Definitions: The option for activating the axis container function in MD $MN_AXCONF_LOGIC_MACHAX_TAB is not enabled. Reactions: - Interpreter stop - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: • Buy option • Do not configure any containers Program Continuation: Clear alarm with the RESET key. Restart part program. 8036 Option: it is not allowed to set different IPO cycles or position control cycles with NCU link. Definitions: The option for activating the FAST_IPO_LINK has not been set. For NCU link, all Ipo or position control cycles must then be equal (see FAST-IPO-LINK description). Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Remedy: • Buy option • Do not activate different Ipo or position control cycles (see MN_IPO_SYSCLOCK_TIME_RATIO and MN_POSCTRL_SYSCLOCK_TIME_RATIO). Program Continuation: Switch control OFF - ON. 8037 Option 'APC activation' not set Definitions: Function 'Advanced Positioning Control' (APC) has been activated in the drive, although the corresponding option was not set. Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: • Buy option • Deactivate function 'Advanced Positioning Control' (APC) in the drive Program Continuation: Switch control OFF - ON. 8038 Option 'activation of more than %1 lead link axes' not set Parameters: %1 = Number of axes Definitions: The option for the number of lead link axes does not match the number of configured axes in the MD $MA_AXCONF_ASSIGN_MASTER_NCU. Reactions: - Interpreter stop - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: • Buy option • Configure fewer lead link axes Program Continuation: Clear alarm with the RESET key. Restart part program. 8040 Machine data %1 reset, corresponding option is not set Parameters: %1 = String: MD identifier Definitions: A machine data has been set that is locked by an option. Reactions: - Alarm display. Remedy: Please inform the authorized personnel/service department. For retrofitting the option, please refer to your machine manufacturer or to a sales representative of SIEMENS AG, A&D MC. Program Continuation: Clear alarm with the Delete key or NC START. 8041 Axis %1: MD %2 reset, corresponding option not sufficient Parameters: %1 = Axis number %2 = String: MD identifier Definitions: All of the axes selected in the machine data of the assigned option are used. Safety func- tions have been selected for too many axes in the axial machine data. The alarm can be reprogrammed in the MD ALARM_REACTION_CHAN_NOREADY (channel not ready).

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. - Channel not ready. Remedy: -- Program Continuation: Switch control OFF - ON. 8044 Option for IPO cycle time %1 ms not set Parameters: %1 = Impermissible IPO cycle time Definitions: The option for activation of an IPO cycle time of %1 ms has not been set. Option - Permiss. IPO cycle time: • Option-free >= 8ms • 1. step >= 6ms • 2. step >= 4ms • 3. step >= 2ms • 4. step <2ms Reactions: - Interpreter stop - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: • Buy option • Increase IPO cycle time (e.g. via MD IPO_SYSCLOCK_TIME_RATIO) Program Continuation: Switch control OFF - ON. 8045 Option for selected cycle settings not set Definitions: The option for the 810D Powerline for activation of the same current/speed/position con- troller/IPO cycle time grid as with the 840D is not set. Without the option, only the set val- ues of the 810D Standard are permitted. Reactions: - Interpreter stop - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: • Buy option • Set (current/speed controller) cycle times to 810D default values. Program Continuation: Switch control OFF - ON. 8080 %1 options are activated without setting the license key Parameters: %1 = Number of non-licensed options Definitions: An option was activated but no license key set to prove the purchase of the option. Reactions: - Alarm display. Remedy: Generate and enter license key via Internet. Program Continuation: Clear alarm with the Delete key or NC START. 8081 %1 options are activated that are not licensed by the license key Parameters: %1 = Number of non-licensed options

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Definitions: Options were activated, that are not licensed by the license key entered. Reactions: - Alarm display. Remedy: Generate and enter license key via Internet. Program Continuation: Clear alarm with the Delete key or NC START. 8082 The license key was entered three times, Power On required before next try. Definitions: The license can be entered three times max (correctly or incorrectly). Reactions: - Alarm display. Remedy: Execute NCK Power On and enter the license key (correctly). Program Continuation: Clear alarm with the Delete key or NC START. 8088 'Selection of non-grinding-specific tools' option not possible Definitions: The system version of the software only allows selection of grinding specific tools (i.e. tools of type 4xx). Reactions: - Interpreter stop - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: Select a tool of type 4xx (grinding tool) or install a standard version of the system software Program Continuation: Clear alarm with the RESET key. Restart part program. 8098 Invalid combination of options (%1) Parameters: %1 = Bit mask of options Definitions: The following restrictions apply to this module for the combination of options: The option "Two-channel" and the options "External language", "Nibbling", "Neural quad- rant error compensation" and "Measurement level 2" exclude one another! Bit0 (LSB): Nibbling Bit1 : External language Bit2 : Neural quadrant error compensation Bit3 : Measurement level 2 Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Set the options accordingly. Program Continuation: Switch control OFF - ON. 8100 Channel %1 block %2: function not possible Parameters: %1 = Channel number %2 = Block number, label

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Definitions: • Impossible due to embargo regulations: • 1. Synchronous actions: Writing of feed, override and axial offsets ($AA_VC, $AC_VC, $AA_OVR, $AA_VC and $AA_OFF) from synchronous actions as well as Continuous Dressing can be programmed only once in a block. • 2. Extended measurement: 'Cyclic measurement' (MEAC) and 'Measurement from syn- chronous action' is not possible. • 3. Axis interpolation: The number of axes interpolating with one another must not exceed 4 (this also includes synchronous coupling of axes via synchronous actions "DO POS[X]=$A..." "DO FA[X]=$A..."). Reactions: - Interpreter stop - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Modify part program. Program Continuation: Clear alarm with the RESET key. Restart part program. 10200 [up to SW 3.x] Channel %1 NC start with active alarm not allowed Parameters: %1 = Channel number Definitions: An alarm is currently active, the internal reaction to which is to inhibit an NC start. Reactions: - Alarm display. Remedy: Find and eliminate the cause of the alarm. Program Continuation: Clear alarm with NC START or RESET key and continue the program. 10202 [up to SW 3.x] Channel %1 NC start not possible Parameters: %1 = Channel number Definitions: NC start is not accepted because, e.g. • REORG is still active • Delete distance-to-go is still active • The system is waiting for another channel. Reactions: - Alarm display. Remedy: Press NC Start again. Program Continuation: Clear alarm with NC START or RESET key and continue the program. 10203 Channel %1 NC start without reference point (action=%2) Parameters: %1 = Channel number %2 = Action number/action name Definitions: NC start has been activated in the MDA or AUTOMATIC mode and at least one axis that needs to be referenced has not reached its reference point. Reactions: - Interface signals are set. - Alarm display. Remedy: Please inform the authorized personnel/service department. Via the channel-specific MD 20700: REFP_NC_START_LOCK (NC Start without reference point) you can decide whether the axis must be referenced before NC Start or not. The start of referencing can be enabled channel-specific or axis-specific.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Channel-specific reference point approach: The rising edge of the interface signal "acti- vate referencing" (DB 21 - 28, DBX 1.0) starts an automatic sequence which starts the axes of the channel in the same sequence as specified in the axis-specific MD 34110 REFP_CYCLE_NR (axis sequence channel-specific referencing). 0: The axis does not participate in channel-specific referencing, but it must be referenced for NC Start, -1: The axis does not participate in channel-specific referencing, but it need not be referenced for NC Start, 1- 8: Starting sequence for the channel-specific referencing (simultaneous start at the same no.), 1 - 31: CPU type Axis-specific referencing: Press the direction key that corresponds to the approach direc- tion in the axis-specific MD 34010 REFP_CAM_MDIR_IS_MINUS (reference point approach in minus direction). Program Continuation: Clear alarm with NC START or RESET key and continue the program. 10204 [up to SW 3.x only] Channel %1 general error Parameters: %1 = Channel number Definitions: A general error has occurred in the channel. Reactions: - Alarm display. Remedy: This message indicates an internal conflict with no further consequences. Program Continuation: Clear alarm with the Delete key or NC START. 10205 [up to SW 3.x only] Channel %1 internal error in %2 Parameters: %1 = Channel number %2 = String Definitions: An internal error has occurred in the channel. Reactions: - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Press RESET. Program Continuation: Clear alarm with the RESET key. Restart part program. 10206 [up to SW 3.x only] Channel %1 general error in function generator Parameters: %1 = Channel number Definitions: An error has occurred during activation/deactivation of the function generator. Reactions: - Alarm display. Remedy: Press RESET. Program Continuation: Clear alarm with the Delete key or NC START. 10207 Channel %1 error when selecting or deselecting the digitize function Parameters: %1 = Channel number Definitions: An error has occurred on activating/deactivating the digitizing module; e.g. not in channel ready state, already activated, etc. Reactions: - Alarm display. Remedy: Press RESET. Program Continuation: Clear alarm with the Delete key or NC START. 10208 Channel %1 continue program with NC start Parameters: %1 = Channel number

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Definitions: After block search with calculation, the control is in the desired state. The program can now be started with NC Start or the state can be changed for the time being with over- store/jog. Reactions: - Interpreter stop - Alarm display. - NC Stop on alarm. Remedy: Press NC Start. Program Continuation: Clear alarm with NC START or RESET key and continue the program. 10209 Channel %1 internal NC stop after block search Parameters: %1 = Channel number Definitions: Internal alarm which initiates an NC Stop. The alarm is output if $MN_SEARCH_RUN_MODE ==1 and the last action block is activated after block search in the main run. Alarm 10208 is activated depending on the VDI signal PLC -> NCK chan- nel DBB1.6. Reactions: - Interpreter stop - NC Stop on alarm. Remedy: NC-Start Program Continuation: Clear alarm with NC START or RESET key and continue the program. 10220 [up to SW 3.x only] Channel %1 active Parameters: %1 = Channel number Definitions: The internal command "delete NC blocks prepared by preprocessor and reorganize (REORG)" has been requested for this channel. It is initiated, e.g. as a result of an over- store, but cannot be executed in a running channel. Reactions: - Alarm display. Remedy: Stop the channel (NC Stop) and repeat the action. Program Continuation: Clear alarm with the Delete key or NC START. 10221 [up to SW 3.x only] Channel %1 not stopped at end of block Parameters: %1 = Channel number Definitions: The reorganization of NC blocks starting at the current block (REORG) is only possible at the end of the block. Reactions: - Alarm display. Remedy: Stop the channel (NC Stop) and repeat the action. Program Continuation: Clear alarm with the Delete key or NC START. 10222 Channel %1 inter-channel communication not possible Parameters: %1 = Channel number Definitions: This channel has received a negative acknowledgment from the inter-channel communi- cation because the destination channel number is not known, e.g.: START(x) or WAITE(x) but channel x has not been initialized Reactions: - Alarm display. Remedy: This is an indication of possible discrepancies. The program continues if no acknowledg- ment is called for. Program Continuation: Clear alarm with the Delete key or NC START.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms 10223 Channel %1: Command %2 is already occupied Parameters: %1 = Channel number %2 = Event name Definitions: This channel has received a negative acknowledgment from the inter-channel communi- cation because this command is already active or has not yet been terminated, e.g.: INIT(x,"ncprog") but a program select request is already active for channel x. Reactions: - Alarm display. Remedy: This is an indication of possible discrepancies. The program continues if no acknowledg- ment is called for. Program Continuation: Clear alarm with the Delete key or NC START. 10224 [up to SW 3.x only] Channel %1: command denied Parameters: %1 = Channel number Definitions: The channel has received a command that cannot be executed, e.g.: activation of a pro- gram test in automatic mode is only possible in the reset state. Reactions: - Alarm display. Remedy: Press RESET and activate the command again. Program Continuation: Clear alarm with the Delete key or NC START. 10225 Channel %1: command denied Parameters: %1 = Channel number Definitions: The channel has received a command. The command cannot be executed. Reactions: - Alarm display. Remedy: Press RESET. Program Continuation: Clear alarm with the Delete key or NC START. 10226 [up to SW 3.x only] Channel %1: reset aborted Parameters: %1 = Channel number Definitions: An error occurred during the reset, with the result that the sequence could not be contin- ued. Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Alarm display. Remedy: Press RESET again. Program Continuation: Clear alarm with the RESET key in all channels of this mode group. Restart part program. 10227 [up to SW 3.x only] Channel %1: command aborted Parameters: %1 = Channel number Definitions: An error occurred while a command was active, with the result that the sequence could not be continued. Reactions: - Alarm display. Remedy: Activate the command again. Program Continuation: Clear alarm with the Delete key or NC START.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10230 [up to SW 3.x only] Mode group %2 channel %1 program interruption does not per- mit mode change Parameters: %1 = Channel number %2 = Mode group number Definitions: While in the "program interrupted" status (interface signal DB 21 - 28, DBX 35.3) - trig- gered by an NC Stop followed by a mode change to JOG - it is only possible to change back to the previous mode (AUTOMATIC or MDA). Reactions: - Alarm display. Remedy: You can change the mode via the "program aborted" status (interface signal DB 21 - 28, DBX 35.4) - triggered by a "reset". Program Continuation: Clear alarm with the Delete key or NC START. 10231 [up to SW 3.x only] Mode group %2 channel %1 program stop does not permit mode change Parameters: %1 = Channel number %2 = Mode group number Definitions: While in the "program stopped" status (interface signal DB 21 - 28, DBX 35.2, triggered by an NC Stop), it is only possible to change back to continuous program operation (by means of an NC Start). Reactions: - Alarm display. Remedy: You can change the mode via the "program aborted" status (interface signal DB 21 - 28, DBX 35.4) - triggered by a "reset". Program Continuation: Clear alarm with the Delete key or NC START. 10232 [up to SW 3.x only] Mode group %2 channel %1 does not permit mode change Parameters: %1 = Channel number %2 = Mode group number Definitions: The change to the desired mode is not permitted. You can only perform the mode change in the "reset" state. Reactions: - Alarm display. Remedy: You can change the mode by pressing the Reset key and repeating the mode change. Program Continuation: Clear alarm with the Delete key or NC START. 10240 [up to SW 3.x only] Mode group %2 channel %1 mode change not possible Parameters: %1 = Channel number %2 = Mode group number Definitions: The mode change would cause the "reorganization" of the preprocessor buffer. This is not possible at present, because a complex geometry section is being processed. Reactions: - Alarm display. Remedy: You can change the mode by pressing the Reset key and repeating the mode change. Program Continuation: Clear alarm with the Delete key or NC START. 10241 [up to SW 3.x only] Mode group %2 mode change in active channel %1 not possible Parameters: %1 = Channel number %2 = Mode group number Definitions: The channel is not in the stopped state. Reorganization is therefore impossible. Reactions: - Alarm display. Remedy: Press NC Stop and perform the action again. Program Continuation: Clear alarm with the Delete key or NC START.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms 10242 [up to SW 3.x only] Mode group %2 mode change in channel %1 not possible at this time Parameters: %1 = Channel number %2 = Mode group number Definitions: The internal state of the indicated channel is not uniquely defined (e.g. in initialization mode or waiting for an acknowledgement from the sequence control system). Reactions: - Alarm display. Remedy: You can change the mode by pressing the Reset key and repeating the mode selection. Program Continuation: Clear alarm with the Delete key or NC START. 10243 [up to SW 3.x only] Channel %1: mode group %2 cannot change mode Parameters: %1 = Channel number %2 = Mode group number Definitions: The requested mode change cannot be executed because NC functions are still running in the other channel, e.g. part program execution. Reactions: - Alarm display. Remedy: You can change the mode by pressing the Reset key and repeating the mode selection. Program Continuation: Clear alarm with the Delete key or NC START. 10249 [up to SW 3.x only] Mode group %2 channel %1: mode change command canceled Parameters: %1 = Channel number %2 = Mode group number Definitions: An error occurred while a mode change command was active, with the result that the sequence could not be continued. Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: Press RESET and select the mode again. Program Continuation: Clear alarm with the RESET key in all channels of this mode group. Restart part program. 10250 [up to SW 3.x only] Channel %1 reorganization of block processing not possible at this time Parameters: %1 = Channel number Definitions: REORG is not possible at present. Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: -- Program Continuation: Clear alarm with the RESET key. Restart part program. 10251 [up to SW 3.x only] Channel %1 Parameters: %1 = Channel number Definitions: REORG is not possible at present.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Press RESET. Program Continuation: Clear alarm with the RESET key. Restart part program. 10252 [up to SW 3.x only] Channel %1 reorg sequence canceled Parameters: %1 = Channel number Definitions: Internal sequence error. REORG is not possible at present. Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Press RESET. Program Continuation: Clear alarm with the RESET key. Restart part program. 10253 [up to SW 3.x only] Channel %1 reorg sequence canceled Parameters: %1 = Channel number Definitions: Internal sequence error. REORG is not possible at present. Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Press RESET. Program Continuation: Clear alarm with the RESET key. Restart part program. 10254 [up to SW 3.x only] Channel %1 reorg sequence canceled Parameters: %1 = Channel number Definitions: Interpreter output negative acknowledgement for REORG. Reactions: - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Press RESET. Program Continuation: Clear alarm with the RESET key. Restart part program. 10255 [up to SW 3.x only] Channel %1 reorg sequence canceled Parameters: %1 = Channel number Definitions: Internal sequence error. REORG is not possible at present. Reactions: - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Press RESET. Program Continuation: Clear alarm with the RESET key. Restart part program.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms 10256 [up to SW 3.x only] Channel %1 reorg sequence canceled Parameters: %1 = Channel number Definitions: Internal sequence error. REORG is not possible at present - program abort. Reactions: - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Press RESET. Program Continuation: Clear alarm with the RESET key. Restart part program. 10257 [up to SW 3.x only] Channel %1 reorg sequence canceled Parameters: %1 = Channel number Definitions: Internal sequence error. REORG is not possible at present - program abort. Reactions: - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Press RESET. Program Continuation: Clear alarm with the RESET key. Restart part program. 10258 [up to SW 3.x only] Mode group %2 channel %1: ID invalid or duplicated Parameters: %1 = Channel number %2 = Mode group number Definitions: An invalid channel/mode group assignment was detected on power-up. Reactions: - Mode group not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Check machine data ASSIGN_CHAN_TO_MODE_GROUP. Program Continuation: Clear alarm with the RESET key in all channels of this mode group. Restart part program. 10259 [up to SW 3.x only] Channel %1 Parameters: %1 = Channel number Definitions: REORG is not possible at present. Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: -- Program Continuation: Switch control OFF - ON.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10260 [up to SW 3.x only] Channel %1 Parameters: %1 = Channel number Definitions: REORG is not possible at present. Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: -- Program Continuation: Switch control OFF - ON. 10261 Channel %1 communication overload for block preparation Parameters: %1 = Channel number Definitions: The internal communication between the NCK modules that evaluate the channel-specific VDI signals (START/STOP/RESET/DDTG/ASUBS/...) and the block preparation are over- loaded. The block preparation modules are not being allocated enough computing time. Reactions: - NC not ready. - Channel not ready. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: More processor time must be allocated to the block preparation modules. Machine data $MN_IPO_SYSCLOCK_TIME_RATIO or $MN_SYSCLOCK_CYCLE_TIME can be increased for this purpose. Program Continuation: Switch control OFF - ON. 10299 Channel %1 Auto-Repos function is not enabled Parameters: %1 = Channel number Definitions: The Auto-Repos function (operating mode) was selected in the channel but is not imple- mented. Reactions: - Alarm display. Remedy: This message is purely informational. Program Continuation: Clear alarm with the Delete key or NC START. 10600 Channel %1 block %2 auxiliary function during thread cutting active Parameters: %1 = Channel number %2 = Block number, label Definitions: An auxiliary function output is programmed in a thread cutting block. Reactions: - Alarm display. Remedy: Consequential errors can occur if the machining path of the thread block is too short and further blocks (thread blocks) follow in which no machining stop may occur. Possible remedial measures: • Program a longer path and/or a lower traversing rate. • Output auxiliary function in another block (program section). Program Continuation: Clear alarm with the Delete key or NC START.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms 10601 Channel %1 block %2 zero velocity at block end point during thread cutting Parameters: %1 = Channel number %2 = Block number, label Definitions: This alarm occurs only when several blocks with G33 follow in succession. The block end velocity in the specified block is zero although a further velocity block follows. The rea- sons for this can be, for instance: • G9 • Auxiliary function after motion • Auxiliary function output before the motion of the following block • Positioning axis in the block Reactions: - Interpreter stop - NC Start disable in this channel. - Interface signals are set. - Alarm display. Remedy: Please inform the authorized personnel/service department. Modify the NC part program by removing any programmed "Stop at end of block" G09. Modify general machine data 11110 AUXFU_GROUP_SPEC [n] for selecting the output time of an auxiliary function group by changing "Auxiliary function output before/after the movement" to "Auxiliary function output during the movement". Bit 5 = 1: Auxiliary function output before movement Bit 6 = 1: Auxiliary function output during movement Bit 7 = 1: Auxiliary function output after movement Program Continuation: Clear alarm with the RESET key. Restart part program. 10602 Channel %1 block %2 velocity limitation during thread cutting Parameters: %1 = Channel number %2 = Block number, label Definitions: In the displayed thread block, the axis would exceed its maximum velocity when the spin- dle override is in the maximum position. Reactions: - Local alarm reaction. - Alarm display. Remedy: If the axis velocity is not limited (faultless thread) no remedial measures are necessary. Otherwise, a lower spindle speed must be programmed for the thread block. Program Continuation: Clear alarm with the Delete key or NC START. 10604 Channel %1 block %2 thread lead increase too high Parameters: %1 = Channel number %2 = Block number, label Definitions: The thread lead increase is causing an axis overload. A spindle override of 100% is assumed during verification. Reactions: - Correction block is reorganized. - Local alarm reaction. - Interface signals are set. - Alarm display. Remedy: Reduce the spindle speed, thread lead increase or path length in the NC program. Program Continuation: Clear alarm with NC START or RESET key and continue the program.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10605 Channel %1 block %2 thread lead decrease too high Parameters: %1 = Channel number %2 = Block number, label Definitions: The thread lead decrease is causing an axis standstill in the thread block. Reactions: - Correction block is reorganized. - Local alarm reaction. - Interface signals are set. - Alarm display. Remedy: Reduce the thread lead decrease or path length in the NC program. Program Continuation: Clear alarm with NC START or RESET key and continue the program. 10607 Channel %1 block %2 thread with frame not executable Parameters: %1 = Channel number %2 = Block number, label Definitions: The current frame is corrupting the reference between the thread length and the thread lead. Reactions: - Local alarm reaction. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm at block end. Remedy: • Perform thread cutting with G33, G34, G35 without a frame. • Use G63 or G331/G332. Program Continuation: Clear alarm with the RESET key. Restart part program. 10610 Channel %1 axis %2 not stopped Parameters: %1 = Channel number %2 = Block number, label Definitions: An axis/spindle has been positioned over several NC blocks using the POSA/SPOSA instruction. The programmed target position had not yet been reached ("exact stop fine" window) when the axis/spindle was reprogrammed. Example: N100 POSA[U]=100 : N125 X... Y... U... ; e.g.: U axis still travels from N100! Reactions: - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm. Remedy: Check and correct the part program (analyze whether motion beyond block boundaries is appropriate here). Prevent block change by means of the keyword WAITP for axes or WAITS for spindles until the positioning axes or positioning spindles have also reached their target position. Example for axes: N100 POSA[U]=100 : N125 WAITP[U] N130 X... Y... U...

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10.04 1 Alarms Example for spindles: N100 SPOSA[2]=77 : N125 WAITS(2) N130 M6 Program Continuation: Clear alarm with the RESET key. Restart part program. 10620 Channel %1 block %3 axis %2 at software limit switch %4 Parameters: %1 = Channel number %2 = Axis name, spindle number %3 = Block number, label %4 = String Definitions: During the traversing motion, the system detected that the software limit switch would be crossed in the direction indicated. During block preparation, it was not yet possible to detect that the traversing range would be exceeded: Either there has been a motion over- lay by the handwheel or a coordinate transformation is active. Reactions: - Local alarm reaction. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm at block end. Remedy: Depending on the reason for this alarm being triggered, the following remedial measures should be undertaken: • Handwheel override: Cancel the motion overlay and avoid this or keep it smaller when the program is repeated. • Transformation: Check the preset/programmed zero offsets (current frame). If the values are correct, the tool holder (fixture) must be moved in order to avoid triggering the same alarm when the program is repeated, which would again cause the program to be aborted. Program Continuation: Clear alarm with the RESET key. Restart part program 10621 Channel %1 axis %2 rests on software limit switch %3 Parameters: %1 = Channel number %2 = Axis name, spindle number %3 = String Definitions: The specified axis is already stationary at the displayed software limit. Reactions: - Alarm display. Remedy: Please inform the authorized personnel/service department. Machine data 36110 POS_LIMIT_PLUS/36130 POS_LIMIT_PLUS2 and 36100 POS_LIMIT_MINUS/36120 POS_LIMIT_MINUS2 must be checked for the software limit switches. Shut down in JOG mode from the software limit switch. Please inform the authorized personnel/service department. Machine data: Check the axis-specific interface signals: "2nd software limit switch plus" (DB 31 - 61, DBX 12.3) or "2nd software limit switch minus" (DB 31 - 61, DBX 12.2) check whether the 2nd software limit switch is selected. Program Continuation: Alarm display showing cause of alarm disappears. No further operator action necessary.

SINUMERIK 840D/840Di/810D Diagnostics Guide (DA), 10.04 Edition 10630 Channel %1 block %2 axis %3 at working area limit %4 Parameters: %1 = Channel number %2 = Block number, label %3 = Axis, spindle number %4 = String ( + or - ) Definitions: The specified axis violates the working area limitation. This is recognized only in the main run either because the minimum axis values could not be measured before the transfor- mation or because there is a motion overlay. Reactions: - Local alarm reaction. - NC Start disable in this channel. - Interface signals are set. - Alarm display. - NC Stop on alarm at block end. Remedy: Program other motion or do not perform overlaid motion. Program Continuation: Clear alarm with the RESET key. Restart part program. 10631 Channel %1 axis %2 rests at working area limit %3 Parameters: %1 = Channel number %2 = Axis, spindle %3 = String ( + or - ) Definitions: The specified axis reaches the working area limitation in JOG mode. Reactions: - Alarm display. Remedy: Setting data: Check 43420 WORKAREA_LIMIT_PLUS and 43430 WORKAREA_LIMIT_MINUS for the working area limitation. Program Continuation: Alarm display showing cause of alarm disappears. No further operator action necessary. 10640 [up to SW 3.x only] Channel %1 block %3 spindle %2 cannot stop during gear change Parameters: %1 = Channel number %2 = Spindle number %3 = Block number, label Definitions: The spindle is in the oscillating mode for a gear change and is waiting for the PLC acknowledgement stating that the gear change has taken place (interface signal: Gear has changed DB 31 - 48, DBX 16.3). During this phase spindle stop is not possible, initi- ated by Reset (DB 21 - 28, DBX 7.7) or NC Stop axes plus spindle (DB 21 - 28, DBX 7.4). Reactions: - Alarm display. Remedy: No remedial measures are necessary. The spindle-specific interface signal Spindle reset (DB 31 - 48, DBX 2.2) cancels the oscillation mode. Program Continuation: Alarm display showing cause of alarm disappears. No further operator action necessary. 10650 Channel %1 axis %2 incorrect gantry machine data, error code %3 Parameters: %1 = Channel number %2 = Axis %3 = Error no. Definitions: An incorrect value was entered in the gantry-specific axial machine data. Further informa- tion can be derived from the error number. • Error no. = 1 => either an incorrect gantry unit has been entered or the designation of the following axis is incorrect. • Error no. = 2 => master axis has been specified more than once.