231-E200

Check brake system status in TNC diagnostics

Navigate to MOD 9906 (Service) → Diagnosis → Drive diagnosis and check brake status signals for all axes. Verify brake engagement signals are active during emergency stop.

Ensure machine is in safe state before testing brake systems

Inspect physical brake components

Visually inspect brake pads, discs, and actuators on each axis. Check for excessive wear, contamination, or mechanical damage. Verify proper brake gap adjustment per machine manual.

Look for brake dust or scoring on brake discs which indicates excessive wear

Test brake holding torque

Use machine-specific brake test procedure to verify each axis brake can hold rated torque. Check pneumatic/hydraulic pressure to brake actuators meets specification.

Follow lockout/tagout procedures when testing brake systems

Access safety parameter configuration

Enter MOD 9906 → Safety → Safety parameters. Check parameter MP7380 (SS1 timeout) and verify it matches machine specification. Typical values range from 1000-5000ms depending on machine size.

Document original values before making any changes

Review axis-specific safety parameters

Check MP7381-MP7386 for individual axis SS1 monitoring parameters. Verify deceleration ramp values in MP7390-MP7395 match actual machine brake performance.

Safety parameter changes require safety validation and may need machine builder approval

Validate with actual stop time measurement

Perform controlled emergency stop test and measure actual stop times using TNC trace function. Compare measured values to configured timeout parameters and adjust if necessary.

Use oscilloscope on encoder signals for precise stop time measurement

Check drive amplifier status and error logs

Access MOD 9906 → Diagnosis → Drive diagnosis and check for drive faults or warnings. Review drive amplifier LED status and internal error logs for each axis involved in alarm.

Drive amplifiers may log internal faults that don't immediately appear in TNC diagnostics

Verify encoder feedback integrity

Check encoder signals in TNC diagnosis screens. Verify position feedback is stable and accurate during normal operation. Test encoder cable connections and shielding integrity.

Encoder signal issues can cause unpredictable machine behavior

Test drive response to stop commands

Monitor drive enable signals and torque commands during emergency stop sequence. Verify drives are receiving and responding to SS1 stop commands within expected timeframe.

Use TNC trace function to capture drive signals during emergency stop sequence

Verify emergency stop circuit continuity

Check emergency stop button contacts and safety relay operation. Measure signal timing from E-stop activation to TNC safety input using oscilloscope or logic analyzer.

Work on safety circuits requires qualified personnel and proper safety procedures

Test safety relay response times

Verify safety relay switching times meet specification (typically <10ms). Check for contact welding, contamination, or mechanical wear in safety contactors.

Safety relays have finite switching cycles and should be replaced per maintenance schedule

Validate TNC safety input signals

Check safety input signals at TNC terminals using MOD 9906 → Diagnosis → PLC diagnosis. Verify emergency stop signals reach TNC within expected timeframe and remain stable.

Safety circuit modifications require safety validation and documentation