Sinumerik 810 Manual: Locating English Documentation for 810M, 810G, GA1 and GA2 Variants

The Siemens Sinumerik 810 is a compact CNC control that was widely deployed on machine tools during the late 1980s and 1990s, including grinders, milling machines, lathes, and special-purpose machines built by original equipment manufacturers such as MEWAG. Although the platform is now considered legacy, a large installed base remains in service worldwide, and field engineers are regularly asked to recover, replace, or migrate documentation in languages other than the original. This reference consolidates the practical knowledge required to identify the exact Sinumerik 810 variant in front of you, locate the correct Siemens-issued English manual, and apply the right commissioning, programming, and service procedures.

The information below is written for the maintenance engineer, CNC retrofit specialist, or service technician who has been handed a machine with no English documentation and a Sinumerik 810 badge on the front panel. Use the identification procedure in §2 and §3 first; everything else depends on knowing the correct system variant (810M, 810T, 810G, 810N) and the system software generation (GA1, GA2, GA3) before you request any documentation or order spare parts.

1. Sinumerik 810 Control Family Overview

The Sinumerik 810 is a member of the lower-mid-range Sinumerik line that bridged the older Sinumerik 3/8 systems and the later Sinumerik 820/840 family. Its distinguishing characteristics:

• Compact panel-mount or standalone enclosure with integrated operator keyboard and 9-inch or 12-inch monochrome CRT.
• Built-in integrated PLC (the 810 variants with the "S5" designation or PLC option board use a SIMATIC S5-100U-compatible logic interpreter).
• Up to 4 axis/spindle channels, depending on the variant and software generation.
• Support for DIN/ISO (G-code) programming and Siemens conversational programming in parallel.
• Battery-backed CMOS RAM or EPROM sub-modules for part-program and PLC storage, depending on hardware revision.

The 810 was offered in several machine-type variants. Each variant ships with different default axis configurations, canned cycles, and post-processors. Siemens identifies these on the ID plate and on the splash screen that appears at power-up.

2. Hardware Variant Identification (810M, 810T, 810G, 810N)

The letter suffix on the model designation defines the machine type the control was configured for at the factory:

On MEWAG machines, the most common fitment is the 810G (grinder) because MEWAG is well-known for their surface and cylindrical grinders. However, MEWAG also produced drilling and special-purpose machines, so do not assume the variant from the OEM name alone.

The variant is reported by the control in three ways:

1. On the ID plate riveted to the chassis (see §3).
2. In the power-up splash banner on the CRT: e.g., "SINUMERIK 810M GA2".
3. Through the softkey path DIAGNOSIS > SYSTEM DATA > IDENTIFICATION on later GA levels.

3. Reading the ID Plate

The ID plate is the authoritative source for variant, software generation, and order number. On most 810 chassis, it is located:

• On the rear of the operator panel (flap up), or
• Inside the main electronics cabinet on the side of the NC module, or
• On the backplane of the central controller unit.

The plate typically carries the following fields, top to bottom:

1. Siemens AG manufacturer line.
2. Model designation (e.g., 6FC3111-0AA or 6FC3981-1... for the operator panel front).
3. Variant (810M, 810T, 810G, 810N) printed in plain text.
4. System software generation: GA1, GA2, or GA3 (and occasionally an OEM-specific suffix).
5. Software version / build number (e.g., SW x.y).
6. Serial number (six- or seven-digit, used for spare-part ordering).
7. Date of manufacture (month/year, useful for battery-replacement scheduling).
8. MLFB / Order No. – the full 6FC... Siemens article number required when ordering any replacement module.

4. System Software Generation: GA1 vs GA2

Siemens revised the 810 firmware several times during its production life. The major releases are referred to as system software generations or GA levels (from the German Geräteausführung, hardware/software release).

Mixing software generations across the NC, PLC, and operator-panel sub-modules is a common cause of "Clear PLC" boot loops and unexplained alarm storms. Always verify that all sub-modules are at the same GA level. Siemens published compatibility matrices in the service manual for each generation; consult the relevant manual before substituting modules.

5. Locating Official Siemens Documentation

Once you have the variant and the GA level, request the correct manual set from one of the following sources, in order of preference:

1. Siemens Industry Online Support – the current consolidated portal. The legacy entry point for the 810 documentation set is the product support page reachable from the Siemens support site, including the historical entry: Siemens Automation Support – Sinumerik 810 documentation entry.
2. Siemens DOC ON WEB – the historical CD-based documentation system that has been mirrored online. Many legacy 810 manuals are still available via this portal: Siemens DOC ON WEB.
3. Siemens regional spare-parts / retrofit desk – for machines under a service contract, the local Siemens office can supply paper copies of the operator's manual and the programming manual on request.
4. OEM (e.g., MEWAG) documentation – the machine builder typically issued an addendum covering machine-specific options, safety circuits, and I/O mapping. This is not in the Siemens manual and must be obtained from the OEM.

The full documentation set for a Sinumerik 810 includes, at minimum:

• Operator's Manual (varies by variant and GA level).
• Programming Manual – DIN/ISO and Siemens conversational.
• Setup / Commissioning Manual – including machine data descriptions.
• PLC Programming Manual – for the integrated PLC (S5-100U-compatible).
• Diagnostics Manual – alarm list, I/O status, trace.
• Service Manual – board-level, intended for Siemens-trained technicians.

6. Operator Interface and Key Layout

The 810 operator panel is divided into three zones:

1. Machine Control Panel (MCP) on the left – mode selector, feed/spindle override, jog keys, NC-Start/NC-Stop, emergency stop.
2. Alpha-numeric keyboard in the centre – QWERTY layout, softkeys below the CRT, plus the dedicated cursor block and the channel/area select keys.
3. CRT display – 9" or 12" monochrome, eight softkey labels along the bottom edge.

The mode selector is the first place to look for operator confusion. The 810 uses the same five-mode structure as the broader Sinumerik family:

• JOG – manual incremental jogging.
• REF – reference-point approach (mandatory after power-up on absolute encoders).
• INC – incremental handwheel mode.
• MDI – Manual Data Input, single-block execution.
• AUTO – automatic program execution.

7. Programming Reference (DIN/ISO and Siemens Modes)

Sinumerik 810 supports two programming modes in parallel, switchable per program block:

• Siemens conversational – a step-by-step, menu-driven parameter entry used by operators with little G-code background. Best for simple turned or milled parts and for first-time setup of a workpiece.
• DIN/ISO – standard G-code (G0, G1, G2/G3, G17/G18/G19, G41/G42, G90/G91, etc.) with M-functions for spindle, coolant, and tool change. This is the mode used for complex contour programs and for any program generated by a CAM post-processor.

Both modes coexist in the same part-program file; the control distinguishes them by an opening identifier. An operator moving from a Sinumerik 810 to a modern Sinumerik 840D sl or 828D will find the G-code semantics broadly compatible, with a small set of differences in canned-cycle call syntax and in the way tool offsets are addressed.

7.1 Sample DIN/ISO Program Skeleton

%_N_TEST_MPF
;$PATH=/_N_MPF_DIR
;Test program - face and turn a Ø40 mm bar
N10 G0 G95 G97 X42 Z2       ; start position, feed-per-rev, constant RPM
N20 T1 D1 M6                 ; tool 1, offset 1, tool change
N30 S1500 M3                 ; spindle CW at 1500 rpm
N40 G0 X40 Z0.5              ; approach
N50 G1 Z-30 F0.2             ; rough plunge
N60 G0 X42                   ; retract
N70 G0 Z2                    ; return
N80 M5                       ; spindle stop
N90 M30                      ; end of program

The exact address layout and the canned-cycle call syntax differ between GA1, GA2, and GA3, so a program written for one generation may not run on another without conversion. The Setup Manual for your specific GA level contains the binding reference.

8. Integrated PLC Interface

The 810's integrated PLC is one of the control's most service-relevant subsystems. The PLC is responsible for:

• Reading the machine's hard-wired inputs (limit switches, reference markers, push-buttons, guards).
• Driving the machine's hard-wired outputs (contactors, solenoids, indicator lamps, axis enables).
• Interfacing the NC to the operator panel and to the MCP.
• Generating user-defined alarms (the 6000-6999 range on most 810 variants) and operator messages.

The PLC program is stored in a sub-module (UV-EPROM or battery-backed RAM, depending on the GA level) and can be edited with Siemens PG 675/PG 685/PG 720 programmers or with a PC running the appropriate STEP 5-compatible software and a serial programming cable. Always back up the PLC program to UV-EPROM or to a file before any intervention – a corrupted PLC program will lock the machine out with PLC Stop on the splash banner and will not clear on its own.

9. MEWAG Machine-Specific Considerations

MEWAG is a Swiss manufacturer of grinding machines. The 810-equipped MEWAG machines are predominantly surface and cylindrical grinders. Field engineers should be aware of the following when working on a MEWAG installation:

1. The MEWAG machine documentation (circuit diagrams, hydraulic schematic, safety circuit) is not in the Siemens manual. It must be obtained from MEWAG directly, or recovered from the machine's documentation cabinet.
2. MEWAG often integrated a separate in-process gauging station (Marposs or similar) that communicates with the 810 through the PLC, not through a high-speed serial interface. The PLC alarm list will include dedicated alarms (e.g., 6120 series) for gauging faults.
3. Dressing cycles on MEWAG grinders are implemented as Siemens conversational cycles with a MEWAG-specific parameter set. The cycle names differ from the standard 810G canned cycles – consult the MEWAG-supplied programming sheet, not the Siemens manual.
4. The 810 used on MEWAG machines is frequently mounted inside the machine column, not in a standalone cabinet. The ID plate may be hidden behind an enclosure panel that requires a key to open.
5. Battery replacement on the CMOS RAM is a 2- to 3-year interval; loss of battery backup will wipe both the PLC and the part-program memory. Schedule replacement proactively.

10. Backup, Restore, and Data Transfer

Use the following procedure to back up a working 810 to a serial-connected PC running a Siemens-compatible transfer utility (e.g., PCIN or any terminal emulator set to the parameters below):

1. Connect the PC to the 810's RS-232 service port (X2 or V.24 on the rear of the operator panel).
2. Set the serial parameters: 9600 baud, 8 data bits, even parity, 1 stop bit, XON/XOFF (or hardware handshake, depending on the GA level – see the Setup Manual).
3. On the 810, enter SYSTEM > DATA TRANSFER > READ OUT and select the area to dump: NC programs, Tool offsets, Zero offsets, Setting data, PLC program, or All.
4. Capture the resulting ASCII stream to a text file on the PC. Treat the file as the master backup and store at least two copies offsite.
5. To restore, reverse the procedure: DATA TRANSFER > READ IN on the 810, with the PC sending the file from disk.

11. Field Service Diagnostics

The 810 has a built-in diagnostic screen accessed by DIAGNOSIS > ALARM or by pressing the ALARM CANCEL key twice. The alarm number identifies the fault class:

The SERVICE display in the same area shows axis position-lag, following-error, and drive-load values, which are the first parameters to capture when investigating a drive or mechanical problem.

12. Migration and Modernization Path

Machines still running Sinumerik 810 face an increasing spare-parts and documentation problem as the original electronics reach end-of-life. Two practical migration paths are common:

1. Like-for-like repair – continue with the original 810, using tested-refurbished sub-modules and the documentation set described in §5. This is appropriate when the machine is still in production, the mechanical axes are healthy, and the operator is familiar with the existing HMI.
2. Sinumerik 810D/840D retrofit – a complete digital control replacement. The 810D/840D shares much of the G-code and PLC semantics with the 810, reducing conversion effort. For a MEWAG grinder, the OEM-end mechanical interface (encoders, drives, I/O) is the dominant retrofit cost, not the CNC itself.

For owners who only need the original 810 to keep working for another 5 to 10 years, the most cost-effective single action is to document the ID plate, back up the NC, PLC, and setting data, and order two copies of the operator's manual in English – one for the machine, one for the service desk. Without that documentation, the next service event is at high risk of becoming a half-day reverse-engineering exercise.

13. Verification Checklist

Use the following checklist before signing off any service intervention on a Sinumerik 810:

1. ID plate photographed and recorded (variant, GA level, MLFB, serial).
2. Battery voltage measured; replacement date noted.
3. All sub-modules confirmed to be at the same GA level.
4. NC programs, tool offsets, zero offsets, setting data, and PLC program backed up to a PC file and to UV-EPROM (where the option exists).
5. Reference-point approach performed in all axes; position values agree with the machine's mechanical zero.
6. JOG mode checked in both directions on every axis; feed-override and rapid-override both functional.
7. MDI mode tested with a known-good short program.
8. AUTO mode tested with a known-good short program; NC-Start, NC-Stop, and single-block all functional.
9. Alarm list clear.
10. Operator's manual (English) located and placed in the documentation cabinet.