231-8003

Check axis movement manually

Use MOD function and select Manual Operation mode. Test each axis for smooth movement and unusual resistance.

Ensure machine is in safe position before manual movement

Monitor current consumption

Access Machine Parameters menu, navigate to CfgAxisList and check MP1020 (maximum drive current) settings against actual values in the diagnostic display.

Compare current readings between axes - significant differences indicate mechanical issues

Inspect mechanical components

Check ball screws, linear guides, and coupling connections for wear, contamination, or binding conditions.

Lock out machine power before mechanical inspection

Verify lubrication system

Check automatic lubrication system operation and manual lubrication points per machine maintenance schedule.

Cold machines often show higher friction - allow warm-up cycle before diagnosis

Review acceleration parameters

Check MP1110 (maximum acceleration) and MP1111 (maximum deceleration) values in CfgAxisList. Reduce values by 20% for testing.

High-speed spindles often cause regenerative issues during rapid stop cycles

Examine cutting parameters

Review active NC program for excessive feed rates or rapid direction changes that cause high regenerative loads.

Test with reduced feed override (50-75%) to isolate regenerative issues

Check brake resistor operation

Verify brake resistor connections and resistance values match specifications in the CC module documentation.

Brake resistors often fail open circuit - measure resistance when power is off

Monitor DC-link voltage

Use TNCdiag diagnostic software to monitor real-time DC-link voltage during problem operations.

Voltage spikes above 400V typically indicate regenerative overload conditions

Check module temperature

Monitor CC%2 module temperature using built-in diagnostics. Access via MOD > Diagnosis > Drive Diagnosis menu.

Temperatures above 70°C indicate potential internal component issues

Verify cooling system

Check cooling fan operation, air filter cleanliness, and heat sink condition on the CC%2 module.

Clean filters only with compressed air - avoid solvents on electronic components

Test with reduced load

Run axis movements at 25% feed override to determine if alarm persists under light load conditions.

Intermittent alarms under light load often indicate semiconductor degradation

Review module error history

Check PLC error log and drive diagnostic history for recurring thermal or overcurrent events on CC%2.

Pattern of increasing frequency indicates progressive component failure

Monitor input voltage

Use multimeter to check incoming AC voltage stability at the main power connection. Verify voltage remains within ±10% of nominal.

Only qualified electricians should work on main power connections

Check DC-link capacitors

Review power supply module diagnostics for DC-link capacitor health indicators and ripple voltage measurements.

Capacitor degradation shows as increased ripple voltage and reduced hold-up time

Verify grounding system

Check electrical cabinet grounding connections and measure ground resistance between cabinet and building ground.

Poor grounding causes voltage instability and increased electromagnetic interference

Test power supply regulation

Monitor DC-link voltage stability during varying load conditions using TNCdiag oscilloscope function.

Voltage variations greater than 5% indicate power supply regulation issues