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Power down system safely

Execute emergency stop, wait for all axes to stop, then power down the TNC control and drive system completely.

Ensure all rotating components have stopped before opening electrical panels

Verify encoder cable connections

Check encoder feedback cables at both motor and drive ends. Verify cable routing matches the axis assignment in MP2410 AXIS_ASSIGNMENT parameters.

Use a flashlight to check for bent pins or contamination in encoder connectors

Cross-reference motor serial numbers

Compare physical motor serial numbers with those recorded in MP1010 MOTOR_TYPE and MP1020 MOTOR_SERIAL_NUMBER parameters.

Document all connections with photos before making changes

Test motor assignment

Power up system and execute small manual movements in MOD mode to verify each axis moves correctly without triggering position errors.

Access motor parameter menu

Navigate to MOD → SYSTEM → MACHINE PARAMETERS → AXES → select affected axis from alarm message.

Note the axis number and position values shown in the alarm for reference

Verify motor type parameters

Check MP1010 MOTOR_TYPE matches installed motor. Verify MP1020 MOTOR_SERIAL_NUMBER, MP1030 MOTOR_POLES, and MP1040 MOTOR_RATED_CURRENT against motor nameplate.

HEIDENHAIN motors have QR codes that can be scanned for exact parameter values

Validate encoder parameters

Confirm MP2210 ENCODER_TYPE and MP2220 ENCODER_RESOLUTION match the installed encoder specifications exactly.

Incorrect encoder parameters can cause severe position errors and potential crashes

Execute motor auto-setup

Run automatic motor identification via MOD → DIAGNOSIS → MOTOR SETUP if available, or manually input correct parameters and save configuration.

Check drive channel assignment

Verify physical motor power connections match MP2400 DRIVE_CHANNEL and MP2410 AXIS_ASSIGNMENT parameters in the TNC.

Drive channels are typically labeled U, V, W for each axis on multi-axis drives

Inspect drive module connections

Examine motor power cable connections at the drive amplifier, ensuring proper phase sequence (U-V-W) and secure connections.

Only qualified personnel should work on drive power connections with proper PPE

Verify CAN bus addressing

Check that drive module CAN addresses match those configured in MP2430 DRIVE_CAN_ADDRESS parameters.

Use HEIDENHAIN diagnostic software to scan CAN bus and verify all drives are responding

Test drive communication

Navigate to MOD → DIAGNOSIS → DRIVE STATUS to verify communication with all configured drives and check for additional error codes.

Check encoder signal quality

Navigate to MOD → DIAGNOSIS → ENCODER SIGNALS and monitor signal amplitude and quality for the affected axis encoder.

Healthy encoder signals should show consistent amplitude and minimal noise

Perform encoder cable continuity test

Use a multimeter to check continuity of all encoder cable conductors from motor to drive connection, including shield continuity.

Perform continuity tests only with power disconnected

Inspect encoder cable routing

Check for cable damage, excessive bending, or routing near high-power cables that could cause electromagnetic interference.

Encoder cables should maintain minimum 6-inch separation from motor power cables

Replace encoder cable if faulty

If cable faults are found, replace with genuine HEIDENHAIN encoder cable of correct length and type, ensuring proper strain relief.

Access FS parameter menu

Navigate to MOD → SYSTEM → FS PARAMETERS to review functional safety configuration for the affected axis.

FS parameters require special authorization codes and should only be modified by certified personnel

Verify FS motor assignment

Check that FS parameters MP7010-MP7019 (FS axis assignment) match the standard axis parameters MP2410.

Incorrect FS parameters can disable safety functions and create hazardous conditions

Synchronize FS controller

Execute FS controller synchronization procedure via MOD → DIAGNOSIS → FS SYNC to ensure proper communication between controllers.

FS synchronization may require machine to be in a specific reference position

Validate safety circuit integrity

Perform complete safety circuit test including emergency stops, door interlocks, and axis monitoring functions to ensure proper FS operation.