Need Help!- int4 mk2 tnc2500c

[BANKROBBER]

hi all,
i am at my wits end with this machine.
i am getting a 'y axis drive fault' coming up on my control.
i power on and the memory check completes,then when i press power enable the fault comes up and thats it.pressing estop clears the error,but the problem remains.
i have tried 3 motors on this,swapped the x/z drives with the y drives,changed the ports of the encoder(param 110) and the analogue inputs(param 120).
i have checked the polarity and running direction of the motors/encoders also.
the drives are the small green midi-maestro units.and the enable light comes on no problem and connections 13-14 are linked in the drive(allowing the 24v pass through) what i dont get is the enable connection active(terminal 5),but according to the wiring.....if i have 24v at the axis enable terminal on the distribution board i should have an input to input 30 on the tnc.i dont see that in the diagnostic screen,but then again i dont see inputs for the other drives in the places they should be!
i am aware that this control is a custom bridgeport 360 plc....but even so,i have done all the basic simple checks to try and solve this problem.
yes,i have checked all the cables for continuity and everything checks out ok.
i did find a braking resistor cracked on the y axis,but even replacing that has made no difference.(thats when i removed the board to check for track damage etc)
i am wondering if i am getting some kind of interference or a cable is breaking down under load???

any input would be appreciated......has anyone had this kind of problem before?

[txcncman]

Start swapping components one at a time between the X and the Y axis. When the error jumps to the X axis, you have found the problem.

[gridley51]

When you say it`s a custom Bridgeport 360 plc,what do you mean?

Mark.

[BANKROBBER]

....swapping out components.
the 2500c is a 'bridgeport' version of the 360 tnc.no support from heidenhain as it was the machine builders custom setup.essentially it is a 360 and the wiring from a interact1 mk2 is the same.i think all the input/outputs are different in the plc tho.i cant make any sense as to what is correct in the machine.
i need to find someone who has the same machine and that have an original wiring diagram for the 2500c int4 mk2.
the motor started turning yesterday.i wrote a program to run the y axis along its limits.as it was running it would start to slow down,but it would make the distance.as soon as i stop the program and try to restart,it would come up with the y axis error.very frustrating!
i think the polarity/runningdirection of the encoder/voltages/and all parameters are correct.it has to be something triggering the tnc to bring this error.or something breaking down under operation.

ROB

[gridley51]

First things first.Heidenhain did not write any plc programmes for any machine tool builders.
Your Bridgeport is not unique unless someone has taken the original plc eprom from the machine and substituted their own or,have edited the original plc programme in to RAM and have been running the machine from there.This is possible as it`s only a parameter change.
If you read some of the Heidenhain manuals for the control,(they did not write manuals for the machines) you will understand more about how the plc programme is used by the machine.
If your plc programme is corrupt,a new eprom can be bought from Heidenhain by telling them the code number printed on the eprom or by reading the number of the screen.(This may not be 100% true for the 360)
An even better bet is to contact A L Machine tools in Birmingham.This is owned by an ex Bridgeport service engineer who should have the plc programme for your machine.
When calling Heidenhain support you need to know what questions to ask as Martin who is usually on the desk does not volunteer information.
Have you read the technical manual here?
http://content.heidenhain.de/doku/om...9F/N1499F.html

[BANKROBBER]

.....finally!
turns out input 29 was at fault. a local guy came in and found it.(wiring is identical to the tnc370 but without the sr1/sr2 safety relays )
changed the input to 27 and changed the signal wire to the correct pin and away it went!
now it all works fine and so do all the drives and motors that i had swapped out!!(good opertunity to test stock :O) )
i have to say.....changing stuff in the plc is not my thing but it was very interesting to found out how it all went on etc.
and of course....the humble pie was oh-so bitter!
i hate it when people come in and fix stuff in 10mins and i have lost sleep on the damn thing :O) we live and learn.....every day!

ROB