27038

Access Diagnostics menu via HMI: Diagnostics > Measured Values > Axis. Identify which axis parameter %2 is violating limits in drive parameter %3. Cross-reference the actual value against the configured NCK MD in Diagnostics > Machine Data.

Compare SINAMICS parameter values (accessible via STARTER or HMI ServoDrive menu) with corresponding NCK MD entries. For example, if velocity feedback (SINAMICS r0047) exceeds MD18212 (max rapid traverse rate), increase MD18212 or reduce the drive's maximum output via p0640 (max motor speed) in SINAMICS.

Do not arbitrarily increase MD limits without engineering review; this may cause safety violations.

Verify SINAMICS commissioning parameter p1000 (rated motor speed) and p0640 (max motor frequency) are consistent with NCK axis capability MDs. If SINAMICS is configured for higher speed than the mechanical axis can handle, reduce p0640 or recalibrate drive scalars.

Reload the NCK MD configuration: Power off the 840D, verify MD settings in NCK configuration file, and power cycle to force re-validation of drive feedback against updated limits.

Ensure backup of current MD configuration before making changes.

In SINAMICS STARTER, navigate to Objects > Axis > Actual Values and note the scaling of feedback parameters. Compare p0108 (position feedback scaling factor) and p0109 (velocity scaling) with NCK MD settings for the same axis (typically MD18100 for reference feed rate).

Verify encoder resolution matches between drive and NCK: SINAMICS p0109 should correspond to increments per mm (or unit). Check NCK Diagnostics > Axis Data > Encoder to confirm matching resolution. Recalibrate scaling if mismatch detected.

Re-commission the axis in SINAMICS STARTER: Run the commissioning wizard (Wizards > Servo Drive Commissioning) to auto-detect and set correct scaling parameters. Save the result and transfer to 840D via HMI or NC Program.

Commissioning will overwrite current SINAMICS parameters; back up configuration first.

After commissioning, perform a fresh NCK validation: Power cycle the 840D and monitor alarm log. If 27038 persists, check NCK MD for axis velocity gain (typically MD18210-18212 range) against newly commissioned SINAMICS limits.

Inspect all encoder/resolver connectors on the motor and SINAMICS power module for loose contacts or visible damage. Reseat connectors and verify locking mechanisms are engaged. Check for cable abrasion or moisture ingress near connector housings.

Power off the drive before inspecting connectors.

In SINAMICS STARTER, navigate to Diagnostics > Parameters > Actual Values and monitor r0047 (actual velocity) and encoder position feedback (r2032 or equivalent) while the drive is powered but axis idle. Watch for jitter, sudden jumps, or out-of-range spikes that would violate NCK MD thresholds.