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Self check manual for common faults of machine tool probes: 15 types of fault phenomena+corresponding solutions
Applicable brands: Renishaw, Marpos, Blum Novotet and their compatible models
Target audience: CNC machine operators, equipment maintenance personnel, production supervisors
The malfunction of the probe does not necessarily indicate hardware failure. According to our statistical analysis of over 5100 repair orders, approximately 30% of “faults” are actually misjudgments caused by external factors (such as parameter settings, external interference, cleaning issues, etc.) – they can be resolved by simply adjusting parameters or cleaning.
This article lists the 15 most common fault phenomena and follows the principle of “self check first, send for repair” to help you quickly locate the problem.
Quick diagnosis flowchart
Is there a problem with the probe?│Does it not work at all? → ① Check the battery → ② Check the power supply → ③ Check the receiver connection│Does it occasionally not trigger? → ① Clean the measuring needle and probe → ② Check the triggering force → ③ Check for signal interference│Does the accuracy exceed the tolerance? → ① Check if the measuring needle is bent → ② Re calibrate → ③ Check the rigidity of the machine tool│Is there a communication error? → ① Check receiver antenna → ② Check channel matching → ③ Check interference source│└ – Physical damage? → Directly send for repair
1、 Power supply and startup faults
Fault 1: The probe does not turn on/has no response
Phenomenon: When the probe or power button is pressed, there is no indicator light on the probe and no signal output..
Troubleshooting steps:1.Check battery(most common reason): Measure battery voltage, Renishaw standard probe uses3.6V lithium battery, if it is lower than 3.0V, it is recommended to replace it (LTC lithium sub battery discharge curve is flat, and when 2.8V is measured, it is on the verge of a sudden drop in power failure state)2.Check the battery compartment contact piece: Check for oxidation/corrosion, clean and reinstall3.Check the startup mode: Some models require rotating the measuring needle or short pressing the startup button4.If all of the above are normal: It may be a circuit board malfunction and needs to be sent for repair
What you can do on your own: ✅ Replace the battery and clean the contact pads
Fault 2: Fast power consumption/battery not durable
Phenomenon: The newly replaced battery runs out of battery after less than a month of use.
Possible reasons:-The probe did not shut down properly (after receiving the shutdown signal, the indicator light needs to be turned off to confirm)-Poor sealing of battery compartment leads to micro leakage-There is a short circuit on the circuit board (mostly caused by the infiltration of cutting fluid)
Self inspection method:After shutting down, the side indicator light of the probe should be completely off2. Use a multimeter to measure the resistance of the battery compartment to ground (normally infinite)3. Check if the sealing ring is damaged
What you can do on your own: ✅ Check the shutdown process, clean the battery compartment, and replace the sealing ring
2、 Trigger and signal related faults
Fault 3: The probe does not trigger/triggered without signal
Phenomenon: The probe contacts the surface of the workpiece, but there is no trigger signal on the control panel..
Troubleshooting steps:1.Listen to the sound: Do you hear a mechanical “click” sound? There is sound → triggering mechanism is normal, check wireless/infrared communication2.Look at the indicator light: When triggered, the indicator light should flash or change color (different brands have different definitions), no light → It may be a fault in the triggering mechanism3.Check the probe: Check if the probe is bent/stuck, causing it to fail to trigger4.Check the receiver: Is the receiver indicator light normal?? Power off and restart the receiver
What you can do on your own: ✅ Check the probe, power off and restart, check the indicator light
Fault 4: Signal instability/occasional failure to trigger
Phenomenon: 1-2 out of 10 measurements have no trigger signal, sometimes good and sometimes bad.
Possible reasons:–Infrared probe: Insufficient battery voltage is the primary reason for the weakening of infrared signals-Radio probe: There is co frequency interference (there are other radio devices/walkie talkies nearby)-Environmental factors: Cutting fluid splashes block the infrared light path-Receiver Position: The infrared receiver is not installed properly, and there are obstacles between the probe and the receiver.
Self inspection method:1. Replace with a brand new battery and retest2. Check if there is any obstruction between the probe and the receiver3. Turn off other nearby wireless devices for testing4. Use the phone camera function to check if the infrared emission window is emitting light (infrared light is not visible to the naked eye, but can be seen by the phone camera; note: some new iPhone main cameras with IR filters may not be visible, it is recommended to use an Android phone or iPhone front camera for observation)
What you can do on your own: ✅ Replace battery, adjust receiver position, remove obstacles
Fault 5: False/false triggering
Phenomenon: The probe emits a trigger signal when it does not touch the workpiece..
Possible reasons:–Cutting fluid/chip accumulation: Form a conductive channel at the probe interface to simulate a trigger signal-Signal line virtual connection: Poor cable contact generates pulse signals-Receiver parameter incorrect: Signal filtering parameters are unreasonable-Driver board filter capacitor aging(Common contact type tool setter)
Self inspection method:1. Clean the cutting fluid and chips at the probe and its interface2. Check if the signal line plug is loose or oxidized3. Restart the receiver and re pair it
What you can do on your own: ✅ Clean, check wiring, restart
Fault 6: Short infrared communication distance
Phenomenon: The distance that used to be able to communicate normally now requires moving the probe closer..
Possible reasons:-Low battery voltage (most common)-Infrared emission window fouling: covered with oil or cutting fluid-Receiver infrared filter aging
Self inspection method:1. Replace with a brand new battery2. Clean the infrared emission window and receiver filter of the probe with anhydrous alcohol3. Check if the installation direction of the receiver is offset
What you can do on your own: ✅ Replace the battery and clean the launch window
3、 Precision related faults
Fault 7: Repetitive accuracy exceeds the tolerance
Phenomenon: Multiple measurements taken at the same location result in differences exceeding the specification value (usually 2 μ m or more)..
Troubleshooting steps:1. Test on a standard ball: Repeat the measurement 10 times at a fixed position and record the maximum difference2.Check the measuring needle: Check if the measuring needle is bent (any slight bending that cannot be seen by the naked eye needs to be detected with a dial gauge)3.Check the ruby measuring ball: Check for wear or chipping (under a magnifying glass)4.Check the triggering mechanism: Check if the triggering force is attenuated – use a standard force gauge to detect
What you can do on your own: ✅ Test and visually inspect the measuring needle on a standard ball
Fault 8: Inconsistent measurement data between X+and X –
Phenomenon: When measuring from the X+and X – directions at the same point, the data differs by more than the specified value..
Possible reasons:–Needle bending: This is the most common reason.. The slight bending of the measuring needle will result in differences in different directions-The installation surface of the probe is not perpendicular to the axis of the measuring needle-Trigger isotropic failure of the mechanism (rare)
Self inspection method:1. Check if the measuring needle is bent (rotate the measuring needle to see if the ruby ball is eccentric)2. Re calibrate and test
What you can do on your own: ✅ Rotate the measuring needle for self inspection and recalibration
Fault 9: The measuring needle breaks upon contact/frequently breaks the needle
Phenomenon: The measuring needle frequently breaks during normal use..
Possible reasons:–Feed rate too fast: The measurement speed exceeds the maximum allowable value of the probe (usually 200-500mm/min)-Approximation direction error: Not approaching along the normal direction of the workpiece surface-Cutting fluid impact: High pressure cutting fluid impacts the measuring needle, causing it to break
Self inspection method:1. Check if the measurement speed in programming is reasonable2. Check if the approaching direction is correct3. Test after reducing the feed rate
What you can do on your own: ✅ Adjust measurement parameters
Fault 10: Tool presetter “contact overload” alarm
Phenomenon: When using a contact type tool setter, the system reports “contact overload” or similar errors.
Possible reasons:–Feed speed too fast: The allowable contact speed of the tool setter is usually 50-200mm/min-The tool is not aligned with the center of the tool setter: Eccentric contact causes overload-Abnormal damping of the triggering mechanism of the tool setter
Self inspection method:1. Reduce the feed rate in the G37 command2. Ensure that the tool is aligned with the center position of the tool setter3. Manually touch the contact surface of the tool setter to feel if the resistance is normal
What you can do on your own: ✅ Reduce feed and check alignment
4、 Communication malfunction
Fault 11: Probe reports “communication timeout”/”no signal received”
Phenomenon: When the program reaches the measurement command, the system prompts a communication timeout.
Troubleshooting steps:1. Check if the receiver is powered on (the indicator light should be constantly on)2. Manually trigger the probe: check if the receiver indicator light flashes and responds3. Check if the receiver antenna is damaged4. Re pair the probe and receiver
What you can do on your own: ✅ Check the power supply, manually trigger the test, and re pair
Fault 12: System error reported after replacing the probe
Phenomenon: After replacing a probe, the CNC system prompts a communication error or abnormal measurement results.
Possible reasons:-The new probe is not paired with the original receiver-The probe model is incompatible with the receiver-The parameter settings in the macro program have not been updated
Self inspection method:1. Check if the new probe has completed the pairing process with the receiver2. Check if the probe serial number is locked in the machine parameters3. Confirm that the new probe model is consistent (or compatible) with the original probe
What you can do on your own: ✅ Re pair and check parameter settings
5、 Physical damage type fault
Fault 13: The probe can still be used after collision, but there is concern about accuracy
Phenomenon: A collision has occurred, but the probe does not appear to be damaged and the measurement can still be triggered. I want to confirm if the accuracy is affected..
Suggestion:1.Immediately stop: Even if it doesn’t look bad, collisions may cause slight deformation of the triggering mechanism.2.For repair and testing: Use a standard force gauge to test the triggering force, and use a standard ball to verify the repeatability accuracy3. Small collision (low-speed slight contact): may only affect 0.5-1 μ m, can continue to be used in situations with low requirements4.Large collision(obvious collision sound heard): Even if the appearance is normal, the interior may have been damaged
⚠️ Continuing to use the probe after collision may result in the accumulation of measurement deviation and affect the machining quality.
Fault 14: Cracks in the shell/exposed sealing ring
Phenomenon: Cracks appear on the probe housing, or the sealing ring is partially exposed from the housing..
Suggestion:–Immediately stop: Cutting fluid will seep into the interior through cracks and sealing ring gaps-Sending for repair and replacement of seals: If not dealt with in a timely manner, the infiltration of cutting fluid can cause corrosion of the circuit board-Industrial grade sealant can be used for emergency treatment of shell cracks, but it is recommended to send them for repair as soon as possible
Fault 15: Water ingress into the probe/cutting fluid inside
Phenomenon: Upon opening the probe battery compartment, traces of cutting fluid were found inside.
Suggestion:–Immediately remove the battery: prevent the short circuit from further expanding the damage-Clean with anhydrous alcohol: The battery compartment and contact pads can be cleaned with anhydrous alcohol and blown dry-Send for repair and inspection of circuit board: Cutting fluid is usually insulating, but the residue left after drying may be conductive-Do not perform power on testing: Do not install battery testing before confirming that the interior is completely dry
6、 Under what circumstances is it recommended to send it for repair directly?
Based on the troubleshooting results of the 15 types of faults mentioned above:
| judgment | take action |
| ✅ Replacing the battery/cleaning/adjusting parameters can solve the problem | Do it yourself |
| ✅ The measuring needle is bent and needs to be replaced | Change by yourself (pay attention to matching specifications) |
| ⚠️ Triggered on and off, occasionally not triggered | Suggest sending for repair and testing |
| ⚠️ The accuracy is uncertain after collision | Suggest sending for repair and calibration |
| ❌ Circuit board corrosion, non triggering, wireless communication failure | Need professional maintenance |
| ❌ Shell rupture and severe water ingress | Need professional maintenance |
7、 Do you need help?
If the above troubleshooting fails to solve your problem, please feel free to contact us for free diagnosis:
💡 Please attach a description of the fault phenomenon when sending for repair, which will help speed up the detection process.