PLC Alarm Code 4002

[ind_dsnr]

Hello all,

I've recently purchased a knee mill with a Siemens Sinumerik 810M controller. I've read every relevant post in this forum and could not find anything relating to the problem that I'm having with the controller. The machine was not under power when I inspected it before the sale, so I had no idea whether it was working or not. That fact that I couldn't verify that the controller was fully functional reflected in the low, low price that I paid for the machine. I figured that if all was lost with the Sinumerik controller I could always upgrade to a modern control system. I really like the functions of the controller and would prefer to keep it if there is any way that these issues can be resolved.

The seller of the machine told me that the mill worked fine until the x-axis stopped moving. He had a tech come out to diagnose it. The tech told him that the x-axis servo needed to be rebuilt or replaced. I have a superficial understanding of how servos work but I found that the flexible coupling between the motor shaft and the encoder was broken. I was able to repair the coupler and reassemble/ reinstall the motor. I'm pretty sure that the lack of a feedback signal would cause a fault in the controller. Perhaps this is related to the PLC alarm code that I am getting, perhaps it is not. I'm not sure how long the machine sat without being under power. From what I've read in this forum, a dead onboard battery would cause the machine to lose its parameters. Maybe this alarm code is related to that, but again, I'm not sure.

I was able to find the description of the 4002 PLC alarm code in a Siemens' document on their website, but the explanation is somewhat cryptic to me as I am not a programmer. If I need to alter the parameters listed below, do I need to do this through an external computer with an editing program, or can I make these changed directly through the user interface? I would greatly appreciate any suggestions on addressing this problem. Below is the exact text from the document relating to this code. I've also attached the document that this came from.

4002 Explanation:
Channel %1 machine data %2[%3] contains an axis not defined in the
channel
%1 = channel number
%2 = string: MD identifier
%3 = index: MD array index
Only axes activated in the channel via MD 20070 AXCONF_MACHAX_USED
[kx]=m
may be declared geometry axes via
MD 20050 AXCONF_GEOAX_ASSIGN_TAB [gx]=k.
gx ... Geometry axis index k ... Channel axis no.
kx ... Channel axis index m ... Machine axis no.
k...Channel axis no.
m...machine axis no

Assignment of the geometry axes to the channel axes:

MD 20050
AXCONF_GEOAX_ASSIGN_TAB
(contains channel axis no. k)
Geometry Axis Index: 0 1 2
1. Channel: 1 2 3

MD 20070
AXCONF_MACHAX_USED
(contains machine axis no. m)
Channel Axis Index: 0 1 2 3 4
1. Channel: 1 2 3 4 5

Reaction:
Alarm display.
Interface signals are set.
NC not ready.
NC Start inhibited.
NC Stop at alarm.

Remedy:
Please inform the authorized personnel/customer service.
Check MD 20050 AXCONF_GEOAX_ASSIGN TAB and
MD 20070 AXCONF_MACHAX_USED and correct them if necessary.

The basis is the MD array MD 20070 AXCONF_MACHAX_USED in which the
machine axis number to be controlled by this channel is entered channels pecifically.
The resulting "channel axes" are assigned a name by MD 20080
AXCONF_CHANAX_NAME_TAB and assigned to a geometry axis via MD
20050 AXCONF_GEOAX_ASSIGN_TAB by entering the relevant channel axis
in this MD array for each geometry axis.

Program Condition by: Power ON

[gridley51]

You say you have an 810M control yet the manual you link to is for an 802D.
What control do you have?
If it`s a 810,is it a GA1,GA2 or GA3?

[ind_dsnr]

I posted the wrong manual. Here is the correct one, I think. It is for model 801M-GA3. I looked on the back side of the operator interface and it is a definitely a model 810M, but i couldn't find any designation as to whether it is a GA1, 2, or 3. I'm not sure where else to look.

The 4002 alarm seems to have disappeared and been replaced with a 1320 alarm. On page 369 of this manual, a 132* alarm specifies a "control loop hardware" issue. With the zero in the "*" field referring the 1st axis in the alarm code (see pg. 354).

I removed the battery to test it and it was as dead as a door nail. This brings up the question, "how do I go about restoring the machine parameters?" After extensively searching the web and Sinumerik-related forums, it seems as if I am dead in the water if I cannot locate the data to restore the controller. Where do I go from here?

[gridley51]

Did you have the power on when you removed the battery?

Reloading the 810 software is not a big issue.It can be done with PCIN or a similar programme and we can walk you through that.
The major problem is the plc programme.If you have lost that,you need the machine manufacturer or someone with the same machine.
What make of machine is it,as 810`s are scarce on knee mills.
What type of axis drive/motors does it have?