Notes:Diagnostic programs which are not available in the CC 200/300 are identified by
an ‘ in front of the page number.
If a diagnostic program contains new or modified functions – compared with the
controls of the Type CC 200/300 –, this is indicated by a − in front of the page num-
ber.
The following diagnostic programs are intended exclusively for BOSCH service
personnel and are not described in this manual:
D2Reloading the operating program
D3Cancelling all memory
Separate manuals are available for the diagnostic programs D4 and D26:
D4Machine parameter programCC 220 M/T:P. No.: 4201
CC 320 M:P. No.: 4180
D26CNC remote diagnosisP. No.: 4184
The diagnostic programs
D8Change language
D10Library management
implemented in the CC 220/320 are no longer present as special diagnostic programs in controls of the type CC 220/320, but can now be called directly by way
of softkey. Please refer to the appropriate operating manual for operating instructions.
C – 1
Flexible Automation
Contents
CC 220 / 320
Diagnosis
C – 2
Flexible Automation
1.General
This manual refers to the software version V25 for the controls CC 220/320.
The diagnostic programs D21 to D28 are options which are subject to charge.
2.Safety instructions
Diagnostic programs permit critical changes to be made in the interaction of CNC,
machine and drives right up to complete deletion of the CNC memory.
If they are used by insufficiently trained or untrained personnel, this may thus result
in serious damage to the machine and drives, loss of software or even injury!
For this reason, diagnostic programs must be started and operated only by
correspondingly trained expert personnel.
In this context, please note our extensive range of training courses. You will find
an overview of the available seminars on the inner cover of this manual. Our training center will gladly provide you with further information.
General
CC 220 / 320
Diagnosis
MOVE
MP
In some diagnostic programs, axes have to be traversed in order to optimize CNC
servo loops and drives.
For this reason, make sure that no one enters the machine’s danger area during execution of such diagnostic programs.
The following symbols are used in this manual in order to point out certain things
which are relevant to safety:
Axis movement possible!
For this reason, make sure that there are no persons or objects in the machine’s
danger area.
Make sure that no collisions are possible in the axis traversing range.
Machine parameter record is modified! This is followed by a CNC restart. The modified machine parameters are active after this.
Is there a backup of the original machine parameters?
BOSCH will not be liable for damaging resulting from incorrectly calculated, programmed or optimized machine parameters or non–observance of limit data!
Active axis processor data is modified!
This effects the axis response.
SERVO
Data loss possible!
Data in the user RAM (part programs, tables etc.) may possibly be deleted or over-
DATA
written.
Do you possess a backup of this data?
3.Calling the diagnostic programs
1 – 1
Flexible Automation
General
The following monitor display appears after selection of group operating mode
(DIAGNOSTIC):
Diagnosis
CC 220 / 320
NoCP0
ERRORCONDITION ONSTATUS
AT LAST PROGR.
F0.0M 0T 0
DIAGNOSTIC
CONTROL
ACT
DIAGNOSTIC
MACHINE
NC0
STOP
G
90
G
94
G
14
G
15
G
80
G
153
G
39
G
65
G
146
G
994
FUNCTION
G
G
G
G
G
G
130
G
253
G
G
G
115
RESET
66
40
29
62
68
DIAGNOSTIC
12. 5 16:53PROGRAM
G
1
8
71
G
140
G
G
27
G
79
G
53
G
67
G
97
G
99
G
167
DRIVE ON
7
SERVICE
FUNCTION
The control displays all available diagnostic programs after operation of the softkey
SERVICE FUNCTION (possibly only after input of a code number; refer to the section ”Notes”):
NoCP0
NUMBERPROGRAM NAMELENGTH
D
D
D
D
D
D
D
D
D
D
D
D
D
D
MEMORY USED BY DIAG.:
MEMORY A V AILABLE:
SERVICE FUNCTION
21
22
23
24
25
27
1
2
3
4
5
6
7
9
ACT
LOGBOOK MONITOR
RELOAD OPERATING PROGRAM
CANCEL ALL MEMORY
MACHINE PARAMETER PROGRAM
INTERNAL REF. POINT OFFSET
INTERFACE DATA
COMMUNICATION STORE DISPLAY
MANAGE EEPROM
LOGIC–ANALYZER
AXIS OSCILLOSCOPE
CONTOUR DISPLAY
AXIS OPTIMIZATION
LEAD SCREW ERROR COMPENSATION
PUTTING INTO OPERATION FOR CIRCULAR COMPENSATION
DATA INDATA OUTSTARTDELETE
NC0
WAIT
DIAGNOSTIC
14.10 8:28PROGRAM
ACCESS
E
E
E
E
E
E
E
E
E
E
E
E
E
E
44384OTHERS:2658
2574398
The system asks for the number of the desired program when the softkey START
is pressed. Input of the program number is acknowledged with the ENTER key. The
CNC then starts the corresponding diagnostic program.
1 – 2
Flexible Automation
General
Notes:
‘If the softkey RESET FUNCTION and then softkey CLEAR ALL LOGIC are
pressed in group operating mode DIAGNOSTIC, it is possible to enter the
softkey level SERVICE FUNCTION only by input of a code number as from
this point in time.
When a correct code number has been entered, the softkey level SERVICE
FUNCTION is accessible without input of the code number until renewed operation of the softkey sequence DIAGNOSTIC, RESET FUNCTION, CLEAR
ALL LOGIC.
‘Some diagnostic programs create files with the group identifier ”L” or ”D” for
recording data. This reduces the memory space which is available for part
programs.
‘Data recordings can be repeated any number of times within diagnostic pro-
grams, since the previous recording is overwritten by each new recording.
All other operating modes of the control can be used during recording of data
by a diagnostic program.
Exception: CONTROL RESET and selection of a different diagnostic program cancel the currently active diagnostic program (except for D21).
Diagnosis
CC 220 / 320
1 – 3
Flexible Automation
General
CC 220 / 320
Diagnosis
1 – 4
Flexible Automation
D1 Logbook
4.Description of the diagnostic programs
D1 – Logbook
General
The diagnostic program D1 is used for management of one or more ”logbooks”. A
logbook is a file with the identifier ”D” which contains various data for reconstruction
of operating sequences, error messages or warnings etc. This file is divided into
5 ring memories which store warnings, errors, system errors, other messages and
operating steps in the order of their occurrence.
Activating/deactivating a logbook
There are two possibilities for activation of a logbook:
CC 220 / 320
Diagnosis
‘Input of a logbook file number in machine parameter P 9914. Then ACTI-
V ATE the machine parameters. The logbook is automatically initialized with
the specified file number after control start–up and is active as from this point
in time. The ring memories are created with the following sizes: R1 to R4:
512 bytes, R5: 0 byte.
‘Operation of softkey INIT in diagnostic program D1.
An already active logbook can be deactivated in diagnostic program D1 by pressing
softkey INIT, input of ”0” and acknowledgement with the ENTER key or by selection
of a different logbook (also refer to softkey LOGBOOK SELECTION). A logbook
cannot be activated again once it has been deactivated. Only deactivated logbooks
can be deleted.
User interface/softkey assignments
The following display appears if no logbook is yet active when D1 is selected:
NoCP0
ACT
LOGBOOK NOT INITIALIZED!
NC0
STOP
DIAGNOSTIC
12. 5 16:59
12. 5 16:59PROGRAM
DISPLAY
RING STORE
D1 – 5
INIT
LOGBOOK
SELECTION
LOGBOOK
PUNCHOUT
Flexible Automation
D1 Logbook
CC 220 / 320
The following monitor display is shown if a logbook is already active:
Diagnosis
NoCP0
PROGRAM
LOGBOOKD 11000 ACTIVE
RING STORE FOR WARNING
RING STORE 2 FOR ERRORS
RING STORE 3 FOR SYSTEM ERRORS
RING STORE 4 FOR OTHER MESSAGES
RING STORE 5 FOR OPERATING STEPS
TEST POINT 1 ADDRESS 0000064
TEST POINT 2 ADDRESS 00000000
Initialization of a logbook (creation of a new logbook file).
When the softkey INIT is pressed, the CNC expects input of a logbook file number
(value range 0.3000–999999999).
Input of ”0” deactivates a currently active logbook (”active” means that recordings
take place in this logbook). A logbook cannot be activated again once it has been
deactivated. Only deactivated logbooks can be deleted.
Two test points are interrogated after input of the file number. However, these are
of importance only for service purposes. Skip test point input by pressing the ENTER key twice.
The system then asks for the memory size for the individual ring stores. Reservation of approx. 500 bytes per ring store will already permit a sensible recording to
be made.
After this, the logbook is initialized and automatically activated. Any events which
occur are recorded from this point in time onwards.
The number of logbooks which can be created is limited by the available memory
space. Only one logbook can be active at any time.
In order to use the file number of a deactivated logbook again for an active logbook,
it is first necessary to delete the deactivated logbook in the softkey level SERVICE
FUNCTION and to then create a logbook again in D1 under softkey INIT.
LOGBOOK
SELECTION
Selection of any existing deactivated logbooks for display on the monitor.
D1 – 6
Flexible Automation
D1 Logbook
CC 220 / 320
Diagnosis
LOGBOOK
PUNCHOUT
The currently displayed logbook is output on an external data medium. The current
setting in group operating mode DATA I/O, softkey DATA OUT, determines via
which interface output takes place. A change in operating mode aborts active output. Output via the DNC interface is not possible.
DISPLAY
RING STORE
This softkey results in display of the contents of the individual ring stores. The store
contents are displayed in plain text with data, time and message.
Example: Ring store 1 (warnings):
NoCP0
PROGRAM
LOG11 23.0509:31WARNING: DATA PROTECTED
KEYING:DATA SK1+ SK1−0ENTR
TEST POINT:1=000000002=00000000MODE: DATA
LOG 7 16.0511:34WARNING: AXIS MOVING
KEYING:SK5+
TEST POINT:1=000000002=00000000MODE: DIAGNOSTIC
The last–pressed key is shown at the top left in the uppermost data line of the monitor (”ENTR” here in the example).
D1 – 7
Flexible Automation
D1 Logbook
The following abbreviations are used for display of the keys:
ABAR, MDI, MASC, DATA, DIAG, KORRGroup operating modes
CUP+, CDN+, CRI+, CLE+Cursor keys pressed
CUP–, CDN–, CRI–, CLE–Cursor keys released
LPE+Magnifier pressed
LPE–Magnifier released
SK1+, SK2+, SK3+, SK4+, SK5+Softkey pressed
SK1–, SK2–, SK3–, SK4–, SK5–Softkey released
ERETLevel return
DELDelete key
ENTREnter key
1 ... 0Numeric keys
: * – + =Arithmetic operation keys
+/–Sign change
.Decimal point
RESETStands for Control Reset,
CAL = System error 1
NC reset, switching on/off,
Logbook Init
??Unknown key code
CC 220 / 320
Diagnosis
SOFTKEY
MASK
The softkey mask present at the time of the entry is displayed. If the key assignment
is displayed by a number, this indicates variable softkey designations, such as occur, for example, for wool sub–tables.
D1 – 8
Flexible Automation
D5 – Internal reference point offset
D5 Internal reference point offset
CC 220 / 320
Diagnosis
The currently active axis offset values are displayed after selection of the program
D5.
These may have been generated by G92 or by ZERO SET. Zero offsets by way of
G54 – G59, G154 – G159, G254 – G259, G60 or G160 are not taken into account
here.
NoCP0
AXIS
X
Y
Z
ACT
OFFSET VALUE
767.766MM
− 715.692
124.423
NC0
WAIT
MM
MM
DIAGNOSTIC
14.10 8:32PROGRAM
D5 – 9
Flexible Automation
D5 Internal reference point offset
CC 220 / 320
Diagnosis
D5 – 10
Flexible Automation
D6 – Interface data
General
User interface/softkey assignments
D6 Interface data
CC 220 / 320
Diagnosis
Data arriving at the standard interfaces can be displayed with D6. The data is not
stored during this operation.
No check is made of the data (e.g. with respect to correct file header, program end,
ECODE etc.). Reading–in is not subject to any time monitoring function. No mes-
sage is issued if data transfer is faulty.
The following functions are offered after program selection:
DEVICE
SELECT
DEVICE
SELECT
STATUS
DFS
SEARCH
DFS–NO.
SEARCH
START
Selection of the data interface and definition of the connected peripheral device.
STATUS
The following softkey bar appears when STATUS is pressed:
SW
CONTROL
SW
CONTROL
HEXCHAR/HEXCHAR/SYMB
Activation/deactivation of the XON/XOFF protocol.
Softkey is shown inverted: software handshake active (Xon/Xoff).
Softkey is displayed normally: hardware handshake active (DTR/DSR).
HEX
Display of the incoming data in HEX format.
CHAR/HEX
Incoming data is displayed as ASCII characters. Exception: display of control characters occurs in HEX format.
CHAR/SYMB
Incoming data is shown as ASCII characters. Exception: control characters are displayed symbolically (e.g. <SP> = Space, <LF> = Line Feed).
D6 – 11
Flexible Automation
D6 Interface data
CC 220 / 320
Diagnosis
START
Start of the reading–in operation. This operation continues until the screen is full.
Half of the screen is filled again in each case by repeated operation of this key.
DFS
SEARCH
Reading–in is started by pressing the softkeys DFS SEARCH and START and is
then continued until a correct DFS identifier is found. After this, a maximum of 17
lines of the program/table are displayed. The rest of the incoming program/table
data of this file is skipped after renewed operation of DFS SEARCH and then
START. The control displays the first 17 lines of the program/table again only after
the next DFS identifier has been found.
Note: ”DFS search” is active as long as the softkey is shown inverted. The function
is executed only if the DFS identifier is correctly received.
DFS–NO.
SEARCH
The system asks for the file number for which a search is to be made after operation
of this softkey. After input of this number and subsequent operation of the softkey
START, reading–in takes place until the specified file number (DFS identifier) is
found. The incoming data is displayed only after this has occurred.
Note:”DFS search” is active as long as the softkey is displayed inverted. The
function is executed only if the DFS identifier is received correctly.
Example: Display of read–in data in the format CHAR/HEX:
The content of the communication store from the point of view of the PLC can be
displayed on the monitor of the CNC in hexadecimal format using the diagnostic
program D7. D7 is offered only if word coupling exists between the CNC and PLC.
The communication store is a 128 KByte dual port RAM area on the NC–PLC–word
module (WK3). Both the CNC and the PLC (PC 600) have read and write access
to this area.
Start address Page 0
End address Page 0
Start address Page 1
End address Page 1
User interface/softkey assignments
After D7 is started, the control always displays the communication store content
from address C000 H to C07F H (address information as hexadecimal numbers
from the point of view of the PLC):
128 data words (256 bytes) can be displayed on one screen page. The data is displayed in a table form (8 columns of 16 lines each). It is possible to see the assign-
D7 – 13
Flexible Automation
D7 Communication store display
CC 220 / 320
Diagnosis
ment between the displayed data words and their addresses in the communication
store by way of the inversely displayed bars above and on the right of the table.
The three most significant positions of an address (e.g. ”C02” of address ”C02F”)
are shown in the top, highlighted bar, while the least significant position is shown
in the bar on the right of the table (e.g. ”F” of the address ”C02F”).
The address of the top left data word is displayed in the prompt line (here in the
example: ”C000 COMMUNICATION STORE DISPLAY”).
Select the required memory area by means of the softkey PAGE 0/PAGE1. The currently displayed memory area is shown inverted on the softkey.
The individual digits of the address displayed in the prompt line can be incremented
or decremented by means of the three softkeys *000,0*00 and 00*0. The asterisk
on the softkey indicates the position which is changed.
The least significant address need not be specified, since all 16 possible addresses
are displayed underneath each other in one column.
It is possible to switch between incrementation and decrementation of the corresponding position by means of the softkey ADVANCE/BACKUP. The active condition is shown inverted.
D7 – 14
Flexible Automation
D7 Communication store display
Example:
You are on Page 0. The prompt line shows the address C000 H.
You are looking for the content of the address D123 H on Page 0.
Switch to ”Increment” (the field ADVANCE on the softkey ADVANCE/BACKUP is
then shown inverted).
Press the softkey *000 once.
Press the softkey 0*00 once.
Press the softkey 00*0 twice.
The 4th data value (from the top) in the left column now shows the content of address D123 H.
CC 220 / 320
Diagnosis
D7 – 15
Flexible Automation
D7 Communication store display
CC 220 / 320
Diagnosis
D7 – 16
Flexible Automation
D9 – EEPROM management
General
D9 EEPROM management
CC 220 / 320
Diagnosis
The MEM5 memory module (or CP/MEM4 in the case of CC220) contains a 32
KByte EEPROM area as standard (optionally 64 KBytes).
Important data should be saved in the EEPROM since the content of the EEPROM
area is not lost – in contrast to the RAM area – after a total power failure on the MEM
module or after forced backup loading.
The following files can be written into the EEPROM area and read out again using
the diagnostic program D9:
Part programs
LSEC tables
W tables
Zero offset tables
Compensation tables
Machine parameters.
For example, it is then possible to choose whether machine parameters and tables
are to be copied back from the EEPROM to the RAM when the control is put into
operation again.
User interface/softkey assignment
After D9 has been started, the monitor displays a list of all files stored in the EEPROM area.
Each entry in the list additionally contains information as to whether a file with the
same name already exists in the RAM area (column ”IN RAM”) and whether this
file also contains the same data (column ”EQUAL”).
NoCP0
LIST OF PROGRAMS TO BE SPECIFIED
No PROGRAM NAMEIN RAMEQUAL
0
1
P
2
P
3
P
4
P
ACT
3000
3001
3002
1131
NC0
WAIT
MACHINE PARAMETER
MAIN PROGRAM MOD. DIA18.08
SR SELECT MODULE
SR TEST DIAGNOSTIC CHANNEL
SR CP
22.06
02.07
22.01
DIAGNOSTIC
14.10 8:45PROGRAM
YES
YES
YES
YES
YES
NO
NO
NO
NO
NO
MEMORY USED BY PROGRAM:
MEMORY AVAILABLE::
MANAGE EEPROM
MACHINE
PARAMETER
PROGRAM
SELECTION
5409
22239
DELETECOPY
OTHERS:3224
EEPROM
PROGR.
This list can now be extended by new entries or be shortened by deleting entries.
The functions PROGRAM EEPROM and COPY (from EEPROM to RAM) refer
to the files displayed here!
If it is wished to store files in addition to the files which are already contained in the
EEPROM, it is not necessary for files which are already stored in the EEPROM to
also be present in the RAM for programming of the EEPROM.
D9 – 17
Flexible Automation
D9 EEPROM management
CC 220 / 320
Diagnosis
The following functions can be initiated by means of the softkeys:
MACHINE
PARAMETER
The currently active machine parameter record (not file L444!) is incorporated in
the list under number ”0”.
A machine parameter record stored in the EEPROM can be copied into the RAM
area again only if the softkey FROM EEPROM is selected when reloading the complete operating system (diagnostic program D2).
File L444 must be stored in the EEPROM (by means of the softkey PROGRAM
SELECTION) if it i s w i shed to permit restoration of machine parameters without reloading the complete operating system.
PROGRAM
SELECTION
PROGRAM
ALL
PROGRAMS
NEXT
GROUP
PREVIOUS
GROUP
Files can be entered in the list from the groups P, L, V, K, W after pressing PROGRAM SELECTION.
To do this, first select the desired file group with the softkeys NEXT GROUP or
PREVIOUS GROUP. The control then shows you all existing files of the selected
group.
All files of this group can be included in the list by pressing the softkey ALL PROGRAMS.
The softkey PROGRAM permits selection of a single file.
Notes:
‘When programs are entered in the list, the CNC checks whether the size of
the EEPROM area is sufficient for later programming. If not, the error mes-
sage ”MEMORY FULL” appears in the prompt line.
‘Link files cannot be included in the list.
‘The K1 table must not be stored in the EEPROM.
DELETE
DELETE LIST ENTRIES
PROGRAM
ALL
PROGRAMS
D9 – 18
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