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HEIDENHAIN Inverter Systems and Motors Service Manual

Service Manual

Inverter Systems and Motors

June 2008
1 Safety Precautions .................................................................................................................................................... 7
1.2 Meaning of the Symbols Used in this Manual.................................................................................................... 7
1.4 With Inverter Systems, Especially Remember:.................................................................................................. 9
1.5 With Motors, Especially Remember: ............................................................................................................... 10
2 How to Use this Service Manual............................................................................................................................ 11
2.1 About this Manual ............................................................................................................................................ 11
2.2 Further Service Manuals .................................................................................................................................. 12
2.3 Other Documentation....................................................................................................................................... 12
2.4 Support............................................................................................................................................................. 12
2.5 Service Training Seminars ................................................................................................................................ 12
2.6 Safety ............................................................................................................................................................... 12
3 Errors and Error Messages ..................................................................................................................................... 13
3.1 Introduction ...................................................................................................................................................... 13
3.2 Overview of Possible Errors............................................................................................................................. 14
3.3 Important Notes on the Use of HEIDENHAIN Expansion Boards in the
SIMODRIVE System ........................................................................................................................................ 17
3.4 Error Messages on the Monitor of the Control ................................................................................................ 23
4 Explanation of the LEDs.......................................................................................................................................... 25
4.1 Compact Inverters............................................................................................................................................ 25
4.2 Power supply units........................................................................................................................................... 28
4.3 Power Modules ................................................................................................................................................ 30
4.4 HEIDENHAIN Interface Cards for the SIMODRIVE System............................................................................. 31
4.4.1 Boards with Ribbon Cable Connection for the PWM Interface............................................................... 31
4.4.2 Boards with D-sub Connection for the PWM Interface........................................................................... 31
5 Procedures and Tips for Error Diagnosis............................................................................................................... 33
5.1 Introduction ...................................................................................................................................................... 33
5.2 Sequence for Finding Errors in Digital Drives ................................................................................................... 33
5.3 Sequence for Finding Errors in the Control Loop ............................................................................................. 35
5.4 Error Localization by Process of Interchange ................................................................................................... 37
5.5 Notes and Tips ................................................................................................................................................. 38
6 Troubleshooting on Motors.................................................................................................................................... 45
6.1 Safety ............................................................................................................................................................... 45
6.2 Possible Causes of Error .................................................................................................................................. 45
6.3 Visual Inspection .............................................................................................................................................. 46
6.4 Trouble Shooting on Ground Fault.................................................................................................................... 47
6.5 Inspection for Winding Short Circuit or Interruption......................................................................................... 50
6.6 Inspection of the Motor Encoder ..................................................................................................................... 53
6.7 Inspection of the Fan.......................................................................................................
6.8 Inspection of the Temperature Sensor............................................................................................................. 62
6.9 Inspection of the Motor Brakes........................................................................................................................ 64
6.10 Inspection for Unbalance.................................................................................................................................. 66
7 Error Diagnosis on the Inverter System................................................................................................................ 67
7.1 Safety ............................................................................................................................................................... 67
7.2 Possible Causes of Error .................................................................................................................................. 67
7.3 Visual Inspection .............................................................................................................................................. 68
7.4 Checking the Criteria for Water-Cooled Inverters............................................................................................. 69
7.5 Error Diagnosis on the UV, UVR Power Supply Unit ........................................................................................ 71
7.5.1 Inspection for Ground Fault..................................................................................................................... 71
7.5.2 Inspection for Short Circuit or Interruption.............................................................................................. 74
7.5.3 Checking the fuses.................................................................................................................................. 78
7.5.4 Checking the Braking Resistor Switch .................................................................................................... 79
7.5.5 Checking the LEDs.................................................................................................................................. 81
7.5.6 Checking the Voltages............................................................................................................................. 82
7.6 Error Diagnosis on the UM Power Module ...................................................................................................... 88
7.6.1 Inspection for Ground Fault..................................................................................................................... 88
7.6.2 Inspection for Short Circuit or Interruption.............................................................................................. 91
7.6.3 Checking the LEDs.................................................................................................................................. 96
................................. 61
7.6.4 Checking the Voltages............................................................................................................................. 98
7.6.5 Exchanging Power Modules or Output Stages of the Same Type........................................................ 100
7.6.6 Exchanging the PWM Interfaces........................................................................................................... 103
7.7 Error Diagnosis on the UE, UR Compact Inverter .......................................................................................... 104
7.7.1 Inspection for Ground Fault................................................................................................................... 104
7.7.2 Inspection for Short Circuit or Interruption............................................................................................ 107
7.7.3 Checking the Fuses............................................................................................................................... 113
7.7.4 Checking the Internal Braking Resistor ................................................................................................. 114
7.7.5 Checking the Braking Resistor Switch .................................................................................................. 116
7.7.6 Checking the LEDs................................................................................................................................ 119
7.7.7 Checking the Voltages........................................................................................................................... 122
7.7.8 Exchanging Output Stages of the Same Type ...................................................................................... 128
7.7.9 Exchanging the PWM Interfaces........................................................................................................... 131
7.8 Error Diagnosis on Non-HEIDENHAIN Inverter Systems .............................................................................. 132
7.8.1 Inspection for Ground Fault................................................................................................................... 132
7.8.2 Inspection for Short Circuit or Interruption............................................................................................ 132
7.8.3 Checking the Displays on the Infeed/Regenerative Module of the Non-HEIDENHAIN Manufacturer.. 133
7.8.4 Checking the LEDs on the HEIDENHAIN Expansion Boards ................................................................ 133
7.8.5 Checking the Voltages........................................................................................................................... 134
7.8.6 Exchanging the HEIDENHAIN Expansion Boards for the SIMODRIVE 611 System............................. 135
7.8.7 Exchanging Output Stages of the Same Type ...................................................................................... 136
7.8.8 Exchanging the PWM interfaces........................................................................................................... 138
8 Error Diagnosis on Accessories............................................................................................................................ 139
8.1 Safety ............................................................................................................................................................. 139
8.2 Possible Causes of Error ................................................................................................................................ 139
8.3 Visual Inspection ............................................................................................................................................ 139
8.4 Error Diagnosis on the PW Braking Resistor .................................................................................................. 140
8.4.1 Inspection for Ground Fault................................................................................................................... 140
8.4.2 Checking the Resistance Value............................................................................................................. 143
8.4.3 Checking the Fan................................................................................................................................... 144
8.4.4 Checking the Temperature Switch........................................................................................................ 144
8.5 Error Diagnosis on the UP 1x0 Braking Resistor Module ............................................................................... 145
8.5.1 Inspection for Ground Fault................................................................................................................... 145
8.5.2 Inspection for Short Circuit.................................................................................................................... 148
8.5.3 Checking the Resistance Value............................................................................................................. 150
8.5.4 Checking the Braking Resistor Switch ......................................................................................
8.5.5 Checking the Temperature Switch........................................................................................................ 154
8.6 Error Diagnosis on the SM Voltage Protection Module.................................................................................. 155
8.6.1 Inspection for Short Circuit.................................................................................................................... 155
8.6.2 Checking the Temperature Switch........................................................................................................ 158
............ 151
9 Error Diagnosis on UV Power Supply Units ....................................................................................................... 159
9.1 Safety ............................................................................................................................................................. 159
9.2 Possible Causes of Error ................................................................................................................................ 159
9.3 Error Diagnosis on UV 101 B.......................................................................................................................... 160
9.4 Error Diagnosis on the UV 102 ...................................................................................................................... 163
9.5 Error Diagnosis on UV 105, UV 105 B ............................................................................................................ 165
9.6 Error Diagnosis on UV 106 B.......................................................................................................................... 171
9.7 Error Diagnosis on the UV 111A, UV 111B .................................................................................................... 173
10 Exchanging HEIDENHAIN Components .............................................................................................................. 175
10.1 Important Notes ............................................................................................................................................. 175
10.2 Exchanging the Complete Inverter................................................................................................................. 178
10.3 Exchanging the Complete Motor ................................................................................................................... 180
10.4 Exchanging the Motor Encoder of the QAN Asynchronous Motor ................................................................ 181
10.5 Exchanging the Signal Socket of the Motor ................................................................................................... 184
10.6 Exchanging the Fan of a Spindle Motor ......................................................................................................... 186
10.7 Exchanging the Fan Guard of a Spindle Motor............................................................................................... 191
10.8 Changing Connections to the Reserve Temperature Sensor ......................................................................... 194
10.9 Exchanging Inverter Accessories ................................................................................................................... 195
10.10 Exchanging Cables and Connectors ............................................................................................................... 196
10.11 Exchanging Power Supply Units .............................................................................................
10.11.1 Exchanging the UV 101 B Power Supply Unit ....................................................................................... 197
10.11.2 Exchanging the UV 102 Power Supply Unit .......................................................................................... 197
HEIDENHAIN Service-Handbuch Umrichter-Systeme und Motoren
....................... 197
10.11.3 Exchanging the UV 105 Power Supply Unit .......................................................................................... 198
10.11.4 Exchanging the UV 105 B Power Supply Unit ....................................................................................... 199
10.11.5 Exchanging the UV 106 B Power Supply Unit ....................................................................................... 200
10.11.6 Exchanging the UV 111 A, UV 111 B Power Supply Units .................................................................... 201
11 Overview of Components..................................................................................................................................... 203
11.1 Compact Inverters.......................................................................................................................................... 203
11.1.1 Assembly............................................................................................................................................... 203
11.1.2 UE 1xx Compact Inverter ...................................................................................................................... 204
11.1.3 UE 2xx compact inverter ....................................................................................................................... 204
11.1.4 UE 2xxB Compact Inverter.................................................................................................................... 205
11.1.5 UR 2xx(D) Compact Inverter ................................................................................................................. 205
11.1.6 Toroidal Cores ....................................................................................................................................... 206
11.1.7 Ribbon Cables and Covers (Only for UE 2xxB, UR 2xx) ........................................................................ 206
11.2 Modular Inverters ........................................................................................................................................... 207
11.2.1 Assembly............................................................................................................................................... 207
11.2.2 UV 130(D) Power Supply Unit ............................................................................................................... 208
11.2.3 UV(R) 1x0(D) Power Supply Unit ........................................................................................................... 208
11.2.4 UM 1xx(B)(D) Power Modules .............................................................................................................. 209
11.2.5 Ribbon Cables and Covers .................................................................................................................... 209
11.3 Accessories for Compact Inverters and Modular Inverters............................................................................ 210
11.3.1 PW 21x, PW 110(B), PW 120 Braking Resistors................................................................................... 210
11.3.2 UP 110, UP 120 Braking Resistor Module (Optional) ............................................................................ 211
11.3.3 Line Filters............................................................................................................................................. 212
11.3.4 Three-Phase Capacitor .......................................................................................................................... 214
11.3.5 KDR 1x0(B) Commutating Reactor........................................................................................................ 215
11.3.6 ZKF 1x0 DC-Link Filter........................................................................................................................... 216
11.3.7 SM 1xx Voltage Protection Module....................................................................................................... 218
11.3.8 Adapter Module...........................................................................................................
11.3.9 Axis-Release Module............................................................................................................................. 220
11.3.10 Capacitor Module .................................................................................................................................. 221
11.4 HEIDENHAIN interface cards for the SIMODRIVE system............................................................................ 222
11.4.1 Assembly............................................................................................................................................... 222
11.4.2 Expansion Boards.................................................................................................................................. 222
11.5 Power Supply Unit.......................................................................................................................................... 223
11.5.1 UV 101 B Power Supply Unit ................................................................................................................ 223
11.5.2 UV 102 Power Supply Unit.................................................................................................................... 224
11.5.3 UV 105 Power Supply Unit.................................................................................................................... 225
11.5.4 UV 105 B Power Supply Unit ................................................................................................................ 225
11.5.5 UV 106 B Power Supply Unit ................................................................................................................ 226
11.5.6 UV 111 A, UV 111 B Power Supply Units ............................................................................................. 226
11.6 HEIDENHAIN Motors ..................................................................................................................................... 227
.......................... 219
12 Connector Designation and Layout ..................................................................................................................... 229
12.1 Important Note ............................................................................................................................................... 229
12.2 Compact Inverters.......................................................................................................................................... 229
12.2.1 Designation and Position of Connections ............................................................................................. 229
12.2.2 Pin Layout on the Compact Inverter...................................................................................................... 247
12.3 Power supply units......................................................................................................................................... 255
12.3.1 Designation and Position of Connections ............................................................................................. 255
12.3.2 Pin Layout on the Power Supply Units.................................................................................................. 267
12.4 Braking Resistors and Braking Resistor Module ............................................................................................ 271
12.4.1 Designation and Position of Connections ............................................................................................. 271
12.4.2 Pin Layout of Braking Resistor or Braking Resistor Module.................................................................. 273
12.5 Power Modules .............................................................................................................................................. 275
12.5.1 Designation and Position of Connections ............................................................................................. 275
12.5.2 Pin Layout on the Power Supply Units.................................................................................................. 295
12.6.1 Designation and Position of Connections ............................................................................................. 297
12.6.2 Pin Layout on the DC-Link Filter............................................................................................................ 298
12.7 Adapter Module.............................................................................................................................................. 299
12.7.1 Designation and Position of Connections ............................................................................................. 299
12.7.2 Pin Layout on the Adapter Module........................................................................................................ 300
12.8 HEIDENHAIN Expansion Boards for the SIMODRIVE System....................................................................... 302
12.8.1 Designation and Position of Connections ............................................................................................. 302
12.8.2 Pin Layout on the Interface Cards......................................................................................................... 304
12.9 UV 101 B Power Supply Unit ......................................................................................................................... 306
12.9.1 Designation and Position of Connections ............................................................................................. 306
12.9.2 Error Diagnosis on UV 101 B................................................................................................................. 307
12.10 UV 102 Power Supply Unit ............................................................................................................................. 309
12.10.1 Designation and Position of Connections ............................................................................................. 309
12.10.2 Pin Layout on the UV 102...................................................................................................................... 310
12.11 UV 105 Power Supply Unit ............................................................................................................................. 311
12.11.1 Designation and Position of Connections ............................................................................................. 311
12.11.2 Pin Layout on the UV 105...................................................................................................................... 312
12.12 UV 105 B Power Supply Unit ......................................................................................................................... 314
12.12.1 Designation and Position of Connections ............................................................................................. 314
12.12.2 Error Diagnosis on UV 105 B................................................................................................................. 315
12.13 UV 106 B Power Supply Unit ......................................................................................................................... 317
12.13.1 Designation and Position of Connections ............................................................................................. 317
12.13.2 Error Diagnosis on UV 106 B................................................................................................................. 318
12.14 Error Diagnosis on the UV 111A, UV 111B .................................................................................................... 319
12.14.1 Designation and Position of Connections ............................................................................................. 319
12.14.2 Pin layout on the UV 111A, UV 111B .................................................................................................... 320
13 ID Labels ................................................................................................................................................................. 323
13.1 ID Label for Inverters...................................................................................................................................... 323
13.2 Electronic ID Label for Inverters..................................................................................................................... 326
13.3 ID Label for Motors ........................................................................................................................................ 328
13.4 Electronic ID Label for Motor ......................................................................................................................... 329
13.5 ID Label for HEIDENHAIN Interface Cards..................................................................................................... 331
13.6 ID Label for Accessories ................................................................................................................................ 331
14 Measuring, Testing and Inspection Equipment.................................................................................................. 333
14.1 Important Notes ............................................................................................................................................. 333
14.2 Voltage Test Unit............................................................................................................................................ 333
14.3 Insulation Tester..........................................................................................................
14.5 Current Probe ................................................................................................................................................. 334
14.6 Test Adapter................................................................................................................................................... 335
14.7 Universal Measuring Adapter ......................................................................................................................... 339
14.8 PWM 9 Encoder Diagnostic Set ..................................................................................................................... 340
14.9 PWT 18 Test Unit ........................................................................................................................................... 342
14.10 IK 215 Adjusting and Testing Package ........................................................................................................... 343
15 Annex: Functional Principles ................................................................................................................................ 345
15.1 PWM Signals.................................................................................................................................................. 345
15.2 HEIDENHAIN Inverter Systems ..................................................................................................................... 348
15.3 HEIDENHAIN Motors..................................................................................................................................... 351
15.3.1 Introduction ........................................................................................................................................... 351
15.3.2 Asynchronous Motors........................................................................................................................... 352
15.3.3 Synchronous Motors............................................................................................................................. 353
15.3.4 Linear Motors........................................................................................................................................ 354
15.3.5 Torque Motors....................................................................................................................................... 354
................................... 334
HEIDENHAIN Service-Handbuch Umrichter-Systeme und Motoren

1 Safety Precautions

DANGER
Caution
Note

1.1 Target Group

This Service Manual has been written for specialist electricians for service, maintenance and commissioning.
Specialists who perform work on the electrical system of a machine tool and its components must have the required knowledge and competence!

1.2 Meaning of the Symbols Used in this Manual

Failure to comply with this information could result in most serious or fatal injuries, and/or in substantial material damage.
Failure to comply with this information could result in injuries and interruptions of operation, including material damage.
These boxes contain important and useful information.
June 2008 1 – 7

1.3 Please Observe:

DANGER
DANGER
DANGER
DANGER
Caution
Caution
DANGER
DANGER
Ensure that the equipment grounding conductor is continuous! Interruptions in the equipment grounding conductor may cause damage to persons or property.
Ensure that the main switch of the machine is switched off and that connected devices are not under power when you engage or disengage any connecting elements or connection clamps. Take precautions against restart! Use an appropriate voltage test unit to ensure that the unit is not under voltage! Always observe that the dc-link voltage must be reduced completely!
Use suitable tools, e.g. insulated screwdrivers and pincers!
In order to be able to judge the behavior of an NC controlled machine, service engineers need to have fundamental knowledge of controls, encoders, drives, electronics and mechanics.
Inappropriate use may cause considerable damage to persons or property.
HEIDENHAIN assumes no liability for indirect or direct damage caused to persons or property through incorrect use or operation of the machine.
Note the safety precautions on the machine (e.g. stickers, signs) and the safety precautions in the documentation of the machine manufacturer (e.g. operating instructions).
Observe the national regulations for power installations and the general instructions for safety and prevention of accidents!
Always secure vertical axes to prevent them from falling down before you perform tests on these axes!
1 – 8 HEIDENHAIN Service Manual Inverter Systems and Motors

1.4 With Inverter Systems, Especially Remember:

DANGER
DANGER
During operation several parts of the inverter systems may be live and are thus extremely dangerous.
This includes:
The primary connection with 3 phases, 400 Vac +/- 10 % (may be higher in case of an
error)
The conductor bars with 565 Vdc or 650 Vdc (may be higher in case of an error)
The motor outputs
The connecting terminals for the braking resistor
Photo: Example with UV 130 and power modules
Switch off the machine and wait at least 5 minutes; then ensure that it is not under voltage before removing the conductor bars or disconnecting the braking resistor. See label on the protective caps!
June 2008 1 – 9

1.5 With Motors, Especially Remember:

DANGER
Caution
Caution
DANGER
During operation several of the motor parts may be either live or moving and are thus extremely dangerous.
Never perform any kind of work on the motor (open of terminal box, make or break connections) while it is under power.
Temperatures of up to 145 °C may occur on the motor surfaces.
When connecting the fan, ensure that the direction of rotation is correct. The arrow symbol on the fan housing indicates the correct direction.
After mounting the motor you must verify the trouble-free functioning of the brake.
On motors that are equipped with a feather key at the shaft end, the feather key must be secured against ejection.
You will find further information on the safe and trouble-free functioning of your motor in the operating instructions that accompany each unit.
1 – 10 HEIDENHAIN Service Manual Inverter Systems and Motors

2 How to Use this Service Manual

Note

2.1 About this Manual

This service manual assists service personnel in the field in diagnosing and correcting errors on HEIDENHAIN inverter systems and HEIDENHAIN motors.
HEIDENHAIN inverter systems are available as regenerative and non-regenerative version.
HEIDENHAIN motors fall into the categories of synchronous motors for feed drives and asynchronous motors for main spindles (see brochure HEIDENHAIN Motors of June 2006).
If you need information on linear and torque motors, please contact the corresponding manufacturer.
This manual also contains information on HEIDENHAIN interface boards for the SIMODRIVE system.
HEIDENHAIN inverter systems and motors are designed for digital axes and spindles and are controlled with PWM signals (pulse width modulation).
These drives are mainly operated with HEIDENHAIN controls e.g.:
Milling controls: TNC 410 M, TNC 426 M, TNC 430 M, iTNC 530Lathe controls: MANUALplus 4110, MANUALplus M, CNC PILOT 4290
Among other things, the Service Manual contains:
Information on possible error causesDescriptions of error diagnosisInformation on corrective actionTheoretical explanation of functions and their correlations
The “Overview of Possible Errors” on page 14 includes many references to troubleshooting descriptions. You will find these descriptions in the chapters of the Service Manual sorted by topics.
It comprises the service possibilities with the current hardware at the editing date of this manual. The service possibilities of your devices may differ from those described here. The descriptions also provide information on any peculiarities regarding service of the units.
For the instructions for the field service it is assumed that ...
the machine had been working perfectly before the error occurred andonly original spare parts are used!
Udpate service This Service Manual is updated at irregular intervals.
You find the current printable version on our website -->
www.heidenhain.de
A zip file can be downloaded. This zip file can be unzipped with a password. Your receive this password during a HEIDENHAIN service training course or upon request by telephone!
Printed copies of the manual (ring binders) are only distributed to the participants of our service training courses.
June 2008 2 – 11

2.2 Further Service Manuals

Note
Caution
Note
Danger
Service Manual MANUALplus MService Manual TNC 410Service Manual TNC 426 CB/PB/M, TNC 430 CA/PA/MService Manual iTNC 530

2.3 Other Documentation

In the following documents you find further important information:
Machine documentation by the manufacturer
(circuit diagrams, wiring diagrams, machine operation manual, etc.)
User's Manuals for HEIDENHAIN controlsTNCguide (DVD) HEIDENHAIN mounting instructionsBrochures of the respective HEIDENHAIN productsPWM 9 Operating Instructions
Current HEIDENHAIN documentation can be obtained fast from our website. --> www.heidenhain.de

2.4 Support

The machine manufacturer must be contacted first for error diagnosis on your machine tool!
Support will, however, also be provided by the HEIDENHAIN service department and agencies.
You will find telephone and fax numbers, as well as e-mail addresses, on the back cover of this Service Manual, or on the HEIDENHAIN website at www.heidenhain.de.

2.5 Service Training Seminars

HEIDENHAIN Traunreut offers service training seminars in German. We recommend the HEIDENHAIN Service Training Seminars for iTNC 530 for the technician who works with this Service Manual. Please inquire at HEIDENHAIN Traunreut or go to our website at www.heidenhain.de/Services/ Training.
If required, please inquire at the HEIDENHAIN subsidiary in your country whether Service Training Seminars are offered in your language.

2.6 Safety

It is extremely important that you read the safety precautions in chapter 1! See “Safety Precautions” on page 7.
2 – 12 HEIDENHAIN Service Manual Inverter Systems and Motors

3 Errors and Error Messages

DANGER

3.1 Introduction

Errors in the drives of machine tools usually lead to an error message on the monitors of the control.
But not all error conditions of the machine generate an error message. Therefore, here you find an overview of errors with notes and tips on how to proceed.
Static and nonstatic errors
Sporadic and nonsporadic errors
Errors can also be defined in the categories of static errors (e.g., interruption in the electrical cabinet, defective unit) and nonstatic errors (e.g., loose connection, shielding problems, interferences). Naturally, static errors can be found more easily.
Check whether you can reproduce a certain error on the machine at any time (nonsporadic error). This assists you in troubleshooting. Integrated diagnosis tools in the control (e.g.,. an integrated log, a PLC logic diagram or an integrated oscilloscope) can be used for the investigation of sporadic errors.
In case of errors that may lead to very high currents, e.g. ground fault or short circuit in the drive, do not switch on the machine again! First ensure that there are no defective units, cables, etc. Then eliminate all ground faults and short circuits in the machine!
June 2008 3 – 13

3.2 Overview of Possible Errors

The following table shows an overview of specific errors on the machine or control, possible causes of the errors as well as measures for finding these errors. The potential measures for finding and correcting the errors are described in more detail in the corresponding chapters.
Error Error causes Measures for error diagnosis and/or
corrective action
The machine, for example, has failed with a loud noise and cannot be switched on again.
When hooking up axes, an "overcurrent" error message is generated
The control generates error messages regarding the motor current (e.g., No motor current, Motor current too high)
Ground fault or short circuit on a
device, cable, etc.
Grave defect of the motors or in the
inverter system
Motor coil faultShort circuit in the motor cableShort circuit in the voltage protection
module
Short circuit in the power module or
in the end stage
Motor defectiveMotor cable defectiveInverter defectiveConductor bars for the dc-link not
tightened sufficiently
Check the fusesVisual inspection
(scorch marks, humidity, severe contamination, damages cable, etc.)
Is there a smell of burning?Measure ground faults and short
circuits, see respective descriptions in this manual
Replace inverters, motors, cables,
accessories that are obviously defective
Check the motor for an interturn
fault --> See “Inspection for Winding Short Circuit or Interruption” on page 6 – 50
Check the motor for a short circuit Check the voltage protection
module for a short circuit--> See “Inspection for Short Circuit” on page 8 – 155
Check power modules and end
stages for short circuits --> See respective descriptions in this manual
Replace inverters, motors, cables,
accessories that are obviously defective
Check the motor --> See
“Troubleshooting on Motors” on page 6 – 45
Check the motor for a short circuit Check power modules and end
stages --> See respective descriptions in this manual
Check the voltage protection
module for a short circuit--> See “Inspection for Short Circuit” on page 8 – 155
Tighten conductor bars with 3.5 NmReplace inverters, motors, cables,
accessories that are obviously defective
3 – 14 HEIDENHAIN Service Manual Inverter Systems and Motors
Error Error causes Measures for error diagnosis and/or
corrective action
The machine is switched on but the screen of the control remains dark.
Phase in the primary supply is
missing
Defective switch-mode power
supply in the power supply unit (UV, UVR) or compact inverter (UE, UR)
Defective power supply unit
UV 105 B
Ribbon cable X69 defectiveDefective 5V supply via terminal X74Defective unit that is connected to
the control impairs the low voltages
Check the phases in the primary
supply
Check the function of the supply unit
or the compact inverter
Check the function of the UV 105 BCheck the ribbon cable X69Check the 5V supply via terminal
X74
Disconnect suspicious units from
the control and deselect it in the machine parameters --> see service manual of the respective control
The dc-link voltage U
is not built up
z
(the screen of the control functions).
Phase in the primary supply is
missing
Interruption in the electrical cabinet,
safety relays are not released
Defective power supply unit (UV,
UVR) or compact inverter (UE, UR)
Defective capacitor moduleDc-link short circuit in the UM
Check the phases in the primary
supply
Check the releases for the safety
relays
Check the function of the supply unit
or the compact inverter
Replace the capacitor moduleMeasure short circuits, see
respective descriptions in this manual
The message RELAY EXTERNAL DC VOLTAGE MISSING does not disappear, although the key "Control voltage ON" is pressed.
Axes cannot be traversed. Drive release missing
EMERGENCY STOP chain
interrupted
24 Vdc power supply for outputs is
missing
Control defective
Inverter system is not ready for
operation
Check the EMERGENCY STOP
chain in the range of the inverter connectors X70, X71, X72
See service manual of the
respective HEIDENHAIN control
See service manual of the
respective HEIDENHAIN control
Check whether the inverter system
is ready
Axes that are enabled via an axis­release module, cannot be traversed.
Drive enable via axis group
connector X150, 151 on the CC is missing
Measure 24 V at X150, 151 Replace axis-release module
Axis-release module defective
The monitor of an iTNC 530 is frozen. The control has locked up. The main switch has to be switched off and on again. After reset of the control"Power fail Interrupt!" is entered in the log of new software versions.
Power failureFailure of one or several phases in
the supply line
The power supply voltage has fallen
below the minimum value
Interruption in the electrical cabinetDefective power supply unit (UV,
Check the primary voltageCheck the fusesCheck the wiring of the inverter
system --> See circuit diagrams of the machine manufacturer
Check the function of the supply unit
or the compact inverter
UVR) or compact inverter (UE, UR)
"Vibrating" axes, sometimes connected with loud noises. and/or Various error messages are generated which, however, are not substantive.
Poor shielding or groundingConnection (short circuit) of
shielding potential (chassis, cable shielding) with 0V voltage potential of the NC power supply
Connectors on grounding terminal
X131 of infeed/regenerative module (Simodrive 611D) not properly wired
Check the grounding of the machine
--> Consult the machine manufacturer!
Ensure that all grounding clamps are
secure
Check the cables for damage.Check the shieldings, covers, etc.Check the groundIng in connection
with the used HEIDENHAIN expansion boards, See “Error Diagnosis on the Inverter System” on page 7 – 67
June 2008 3 – 15
Error Error causes Measures for error diagnosis and/or
corrective action
When braking axes and spindles, the motors suddenly coast out of loop to a stop.
An axis is traversed and the error message I2T value of motor is too high ... is displayed (or a similar error message that indicates an excessive load of the drive). There is no mechanical damage!
SIMODRIVE system used with CC 422 The control can be switched on. During operation the power module always transmits the Ready signal. The signal reporting that the power module is no longer ready is not detected in some cases.
Defective braking resistor
(conversion of electrical energy to heat energy not possible)
Defective infeed/regenerative
feedback module (energy recovery not possible)
Interruption in the primary supply
(fuses, wires, etc.; energy recovery not possible)
Motor brake not released. Check whether the brake is released
"Old" HEIDENHAIN expansion board
in modified SIMODRIVE power module
Measure braking resistor, See
“Error Diagnosis on the PW Braking Resistor” on page 8 – 140
Check the fusesWiring interrupted
--> See circuit diagrams of the machine manufacturer
Check the function of the supply unit
or the compact inverter
Check the wiring of the motor
system --> See circuit diagrams of the machine manufacturer.
If the motor brake is connected to
the inverter module --> Check whether the brake output is supplied and triggered correctly.
Check the constellation
HEIDENHAIN expansion board and SIMODRIVE power module. See “Compatibility of HEIDENHAIN expansion boards to SIMODRIVE power modules” on page 3 – 22
SIMODRIVE system used with CC 424 (B): After power on, the power module transmits a "Ready" signal to the control although the power module is not ready yet. The control reports the error C510 Impermissible drive enable and cannot be put into operation.
SIMODRIVE system used with TNC 426 PB and TNC 430 PA: After the power module has been switched on, it constantly reports that it is ready, even if this is not the case. In certain situations the “Drives not ready” message can appear, even though it may no longer even be possible to switch the drives on.
"Old" HEIDENHAIN expansion board
in modified SIMODRIVE power module
"Old" HEIDENHAIN expansion board
in modified SIMODRIVE power module
Check the constellation
HEIDENHAIN expansion board and SIMODRIVE power module. See “Compatibility of HEIDENHAIN expansion boards to SIMODRIVE power modules” on page 3 – 22
Check the constellation
HEIDENHAIN expansion board and SIMODRIVE power module. See “Compatibility of HEIDENHAIN expansion boards to SIMODRIVE power modules” on page 3 – 22
3 – 16 HEIDENHAIN Service Manual Inverter Systems and Motors
3.3 Important Notes on the Use of HEIDENHAIN Expansion Boards in the
Caution
Note
SIMODRIVE System
Version with D-sub connector
HEIDENHAIN expansion boards for the SIMODRIVE system in the version with D-Sub connector are available with or without metallic insulation of HEIDENHAIN PWM signals to the Siemens interface.
Expansion boards without metallic insulation are recognized as follows:
On the front panel there are the LEDs NB (not ready) and
IF (pulse release).
There is no grounding screw on the front panel.
There is no transformer on the front panel.
These board have the Id.Nr. 291070-01, 324952-01, -02, -
03 and -10 without index A.
The terminal X131 of the Siemens E/R module of boards without metallic insulation may not be connected to the central signal ground of the machine!
The HEIDENHAIN expansion boards of the first generation were built without metallic insulation.
June 2008 3 – 17
Expansion boards with metallic insulation are recognized as follows:
On the front panel there are the LEDs RESET X1, READY
and RESET X2.
There is a grounding screw on the front panel.
There is a transformer on the front panel.
These boards have the Id.Nr. 324952-10 with index A, -11,
-12, ...
Transformer component on the board
Grounding screw on the front panel
3 – 18 HEIDENHAIN Service Manual Inverter Systems and Motors
Caution
The terminal X131 of the Siemens E/R module of boards with metallic insulation
Caution
must be connected to the central signal ground of the machine!
Expansion boards with and without metallic insulation may not be used together! Either all boards have a metallic insulation and X131 is wired or all boards do not have a metallic insulation and X131 is not wired!
Photo: Siemens E/R module with X131
June 2008 3 – 19
Photo: Siemens UEB module with X131
Caution
If a Siemens E/R module is used together with a so-called monitoring module (UEB module), the terminal X131 on this module has to be wired as on the E/R module!
3 – 20 HEIDENHAIN Service Manual Inverter Systems and Motors
Version with ribbon cable connector
HEIDENHAIN expansion boards for the SIMODRIVE system in the version with ribbon cable have a metallic insulation of the HEIDENHAIN PWM signals to the Siemens interface.
Thus X131 of the Siemens drive system must be wired!
Figure: Various HEIDENHAIN expansion boards with ribbon cable connectors
June 2008 3 – 21
Compatibility of
Caution
HEIDENHAIN expansion boards to SIMODRIVE power modules
SIEMENS has already improved the SIMODRIVE power modules. Among other things the interference suppression circuits have been supplemented. The HEIDENHAIN expansion boards suitable for the modified SIMODRIVE power modules have also been improved:
Modified SIMODRIVE power modules
At the end of the SIEMENS ordering designation of the improved power modules you find the code A2 or A3.
The HEIDENHAIN expansion boards listed in the above table, replace the previous variants. This means that they may also be inserted in "older" SIMODRIVE power modules.
"Older" HEIDENHAIN expansion boards may not be operated with modified SIMODRIVE power modules. Possible errors and error messages --> See “Overview of Possible Errors” on page 3 – 14
Suitable HEIDENHAIN expansion boards
324952-03, index A 2-axis version,
324952-12, index D 2-axis version,
324955-17 1-axis version,
359002-05 2-axis version,
515012-03 1-axis version,
Design
D-sub connector
D-sub connector
ribbon-cable connector
ribbon-cable connector
ribbon-cable connector
3 – 22 HEIDENHAIN Service Manual Inverter Systems and Motors

3.4 Error Messages on the Monitor of the Control

Note
HEIDENHAIN inverter systems and HEIDENHAIN motors are usually operated with HEIDENHAIN controls.
Errors on inverters and/or motor that occur when the machine is switched on or during operation are ideally shown as errors on the monitor. The operator or the service engineer obtains information on the possible causes of the error and on corrective action. In case of axis-specific errors, there is an axis symbol (e.g. X) in the error text!
Example of an NC error message on the monitor of an iTNC 530:
If it is possible and makes sense, you may switch the control off and on again to observe whether the error message is generated again afterwards.
List of NC error messages
PLC error messages In addition to the NC error messages defined by HEIDENHAIN, the machine manufacturer can
June 2008 3 – 23
HEIDENHAIN has defined NC error messages. You can find the complete list of all NC error messages for TNC controls on the TNCguide DVD in several languages and sorted by error numbers. You find this TNCguide information on our website www.heidenhain.de.
define PLC error messages.
The manufacturer can define the machine behavior in case of a PLC error (NC stop, EMERGENCY STOP, etc.). The machine can thus be protected additionally. The operator or the service engineer obtains machine-specific information on the possible causes of the error and on corrective action together with PLC error messages.
Example of an PLC error message on the monitor of an iTNC 530:
Log HEIDENHAIN controls feature a log. Information on key strokes, error messages etc. are
recorded in these logs.
You will find information in the respective service manuals of the controls (e.g. SHB iTNC 530)!
Example of NC error messages in the log of an iTNC 530:
3 – 24 HEIDENHAIN Service Manual Inverter Systems and Motors

4 Explanation of the LEDs

4.1 Compact Inverters

On the front of the compact inverters are several LEDs for functional control, with the following meaning:
UE 1xx
LED Meaning Signal direction Signal
U
DC LINK ON
SH1 (RED)
RDY (GREEN)
SH2 Safe stop 2; no drive enable from control
PWR RESET Reset signal from UE to LE, CC UE → LE, CC RES.PS
READY Inverter ready UE → LE, CC RDY
U
>> UZ too high (> approx. 850 V); power
DC LINK
PWR FAIL UZ too low, UZ < 410 V (e.g. failure of a
NC reset Reset signal from LE, CC to UE LE, CC → UE RES.LE
TEMP >> Temperature of heat sink too high (> 100 °C) UE → LE, CC ERR.TEMP
X 71 SP. Safety relay for spindle triggered – –
X 72 AXES Safety relay for axes triggered – –
Main contactor triggered – –
Safe stop 1; no enable from control (main contactor not active, DSP error, PLC error with EMERGENCY STOP, hardware or software error of LE, CC) Axis/spindle enabled
(e.g. by the PLC, active via external signal or SH1)
modules are switched off
phase under load, power < 290 V)
LE, CC → UE
UE → LE, CC
SH1B
RDY
LE, CC → UE SH2
UE → LE, CC ERR.UZ.GR
UE → LE, CC PF.PS
UE 2xx
LED Meaning Signal direction Signal
U
DC LINK ON
Main contactor triggered – –
+ 5 V + 5 V power supply available – –
U
>> UZ too high (> approx. 800 V); power
DC LINK
UE → LE, CC ERR.UZ.GR
modules are switched off
TEMP >> Temperature of heat sink too high (> 100 °C) UE → LE, CC ERR.TEMP
AXIS FAULT Short circuit between a phase of the motor
UE → LE, CC AXISFAULT
output and UZ (axes only)
POWER FAIL UZ too low, UZ < 410 V (e.g. failure of a
UE → LE, CC PF.PS
phase under load, power < 290 V)
POWER RESET Reset signal from UE to LE UE → LE, CC RES.PS
AXIS/SPINDLE
Axes/spindle disabled by LE LE, CC → UE SH2
RESET
AXIS/SPINDLE
Inverter ready UE → LE, CC RDY
READY
PULSE RELEASE
Safety relay for spindle triggered – –
SPINDLE
PULSE RELEASE
Safety relay for axes triggered – –
AXES
June 2008 4 – 25
UE 2xxB
LED Meaning Signal direction Signal
U
DC LINK ON
Main contactor triggered – –
X11x READY Inverter ready UE → LE, CC RDY
X11x SH1 DSP error, PLC error with emergency stop,
LE, CC → UE SH1B
LE hardware or software error
X11x SH2 No drive enable (e.g. by the PLC, active via
LE, CC → UE SH2
external signal or SH1)
READY Inverter ready UE → LE, CC RDY
POWER RESET Reset signal from UE to LE UE → LE, CC RES.PS
POWER FAIL UZ too low, UZ < 410 V (e.g. failure of a
UE → LE, CC PF.PS
phase under load, power < 290 V)
U
>> UZ too high (> approx. 800 V); power
DC LINK
UE → LE, CC ERR.UZ.GR
modules are switched off
TEMP >> (left)
TEMP >> (right)
Heat sink temperature too high for axis 4 and spindle (> 100 °C)
Heat sink temperature too high for axis 1 to axis 3 (> 100 °C)
UE → LE, CC ERR
UE → LE, CC ERR
NC reset Reset signal from the LE to the UE LE, CC → UE RES.LE
PULSE RELEASE
Safety relay for spindle triggered – –
SPINDLE
PULSE RELEASE
Safety relay for axes triggered – –
AXES
UR 2xx UR 2xx D
LED Meaning Signal direction Signal
U
DC LINK ON
Main contactor triggered – –
X11x READY Inverter ready UR → LE, CC RDY
X11x SH1 DSP error, PLC error with Emergency Stop,
LE, CC → UR SH1B
LE hardware or software error
X11x SH2 No drive enable (e.g. by the PLC, active via
LE, CC → UR SH2
external signal or SH1)
READY UV Inverter ready UR → LE, CC RDY
POWER RESET Reset signal from UR to LE UR → LE, CC RES.PS
POWER FAIL UZ too low, UZ < 410 V (because the main
UR → LE, CC PF.PS
contactor is off, for example)
U
>> UZ too high (> approx. 800 V); power
DC LINK
UR → LE, CC ERR.UZ.GR
modules are switched off
I
>> IZ > 52 A,
DC LINK
UR → LE, CC ERR.IZ.GR
warning signal to control at 58 A
I
>> Error current, e.g. through ground fault;
LEAK
UR → LE, CC ERR.ILEAK
warning signal to control
TEMP >> (left)
TEMP >> (right)
Heat sink temperature too high for axis 4 and spindle (> 100 °C)
Heat sink temperature too high for axis 1 to axis 3 (> 100 °C)
UR → LE, CC ERR
UR → LE, CC ERR
AC FAIL Phase missing UR → LE, CC PF.PS.AC
NC reset Reset signal from the LE to the UR 2xx LE, CC → UR RES.LE
AXES Safety relay for axes triggered – –
SPINDLE Safety relay for spindle triggered – –
4 – 26 HEIDENHAIN Service Manual Inverter Systems and Motors
Red LED SH1 The SH1 signal (safe stop 1, red LED at the inverter) is generated by the main computer (MC) of
the HEIDENHAIN control. The signal is low-active, i.e. line-break proof. If the main computer is not ready for operation or if an error is pending, SH1 is output. The red SH1 LED and the green READY LED at the inverter can never be lit at the same time. They are mutually locked.
Red LED SH2 The SH2 signal (safe stop 2, red LED at the inverter) is generated by the controller computer (CC)
of the HEIDENHAIN control. The signal is low-active, i.e. line-break proof. If an axis or spindle is not controlled, SH2 is pending and the red LED is on. This is for example the case with clamped axes or if a spindle is not controlled. SH2 and READY are on simultaneously.
June 2008 4 – 27

4.2 Power supply units

UV 120, UVR 120D, UVR 130D, UV 140, UVR 140D, UV 150, UVR 150, UVR 150D, UVR 160D, UVR 160DW
LED Meaning Signal direction Signal
READY End stage ready (only for service purposes) – –
RESET Reset for end stage (only for service
TEMP >> Temperature of heat sink too high (> 95 °C) UV → LE, CC ERR.TEMP
U
DC LINK ON
READY UV Power supply unit is ready UV → LE, CC RDY.PS
POWER RESET Reset signal from power supply unit to
POWER FAIL UZ too low, UZ < 410 V (e.g. line power < 290 V)UV → LE, CC PF.PS
––
purposes)
Main contactor triggered – –
UV → LE, CC RES.PS
control
U
>> UZ too high (> approx. 800 V); power
DC LINK
UV → LE, CC ERR.UZ.GR
modules are switched off
I
>> Warning signal to control at overcurrent.
DC LINK
UV 120: IZ > 52 A
a
UV → LE, CC ERR.IZ.GR
UVR 120D: IZ > 52.5 A UVR 130D: I
> 71 A
Z
UV 140: IZ > 103 A UVR 140D: IZ > 105 A UV 150: I
> 119.0 A
Z
UV 150: IZ > 103 A UVR 150D: IZ > 126 A UVR 160D: I
> 126 A
Z
UVR 160DW: IZ > 126 A
I
>> Error current, e.g. through ground fault;
LEAK
UV → LE, CC ERR.ILEAK
warning signal to control
AC FAIL Phase missing UV → LE, CC PF.PS.AC
NC reset Reset signal from control to power supply
LE, CC → UV RES.LE
unit
AXES Safety relay for axes triggered – –
SPINDLE Safety relay for spindle triggered – –
a. A further increase of around 10% results in the drives being switched off.
This also applies for the other stated dc-link currents of the power supply units.
4 – 28 HEIDENHAIN Service Manual Inverter Systems and Motors
UV 130
UV 130D
LED Meaning Signal direction Signal
U
DC LINK ON
Main contactor triggered – –
READY Power supply unit is ready UV → LE, CC RDY.PS
POWER RESET Reset signal from power supply unit to control UV → LE, CC RES.PS
POWER FAIL UZ too low, UZ < 410 V
UV → LE, CC PF.PS
(e.g. line power < 290 V)
U
>> UZ too high (> approx. 760 V); power modules
DC LINK
UV → LE, CC ERR.UZ.GR
are switched off
I
I
>> Warning signal to control at IZ > 75 A
DC LINK
>> Error current, e.g. through ground fault;
LEAK
a
UV → LE, CC ERR.IZ.GR
UV → LE, CC ERR.ILEAK
warning signal to control
TEMP >> Temperature of heat sink too high (> 95 °C) UV → LE, CC ERR.TEMP
NC reset Reset signal from control to power supply unit LE, CC → UV RES.LE
SPINDLE Safety relay for spindle triggered – –
AXES Safety relay for axes triggered – –
a. A further increase of around 10% results in the drives being switched off.
LED Meaning Signal direction Signal
U
DC LINK ON
Main contactor triggered – –
READY UV Power supply unit is ready UV → LE, CC RDY.PS
POWER RESET Reset signal from power supply unit to
UV → LE, CC RES.PS
control
POWER FAIL UZ too low, UZ < 410 V
UV → LE, CC PF.PS
(e.g. line power < 290 V)
U
>> UZ too high (> approx. 800 V); power
DC LINK
UV → LE, CC ERR.UZ.GR
modules are switched off
I
I
>> Warning signal to control at IZ > 85.2 A
DC LINK
>> Error current, e.g. through ground fault;
LEAK
a
UV → LE, CC ERR.IZ.GR
UV → LE, CC ERR.ILEAK
warning signal to control
AC FAIL Phase missing UV → LE, CC PF.PS.AC
NC reset Reset signal from control to power supply
LE, CC → UV RES.LE
unit
AXES Safety relay for axes triggered – –
SPINDLE Safety relay for spindle triggered – –
TEMP >> Temperature of heat sink too high (> 95 °C) UV → LE, CC ERR.TEMP
a. A further increase of around 10% results in the drives being switched off.
June 2008 4 – 29

4.3 Power Modules

UM 1xx
LED Meaning Signal direction Signal
READY Power module is ready UM → LE, CC RDY
SH 1 DSP error, PLC error with Emergency Stop, LE
hardware or software error
SH 2 No drive enable (e.g. by the PLC, active via
external signal or SH1)
TEMP >> Warning signal for IGBT temperature too high UM → LE, CC ERR
Red SH1 LED The SH1 signal (safe stop 1, red LED at the inverter) is generated by the main computer (MC) of
the HEIDENHAIN control. The signal is low-active, i.e. line-break proof. If the main computer is not ready for operation or if an error is pending, SH1 is output. The red SH1 LED and the green READY LED at the inverter can never be lit at the same time. They are mutually locked.
Red SH2 LED The SH2 signal (safe stop 2, red LED at the inverter) is generated by the controller computer (CC)
of the HEIDENHAIN control. The signal is low-active, i.e. line-break proof. If an axis or spindle is not controlled, SH2 is pending and the red LED is on. This is for example the case with clamped axes or if a spindle is not controlled. SH2 and READY are on simultaneously.
LE, CC → UM SH1
LE, CC → UM SH2
4 – 30 HEIDENHAIN Service Manual Inverter Systems and Motors
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