HEIDENHAIN Inverter Systems and Motors Service Manual

Service Manual

Inverter Systems

and Motors

Edition: Jan. /2001

HEIDENHAIN Service Manual for Inverter Systems and Motors

Changes / Enhancements

We are constantly advancing the technical development of our devices. For this reason, the information given in this manual may in some details differ from your specific device. Please request an updated Service Manual, as required.

Reproduction

Copying or reproducing the Service Manual, wholly or in part, is permitted only on our prior express approval.

Edition: Jan. /2001

HEIDENHAIN Service Manual for Inverter Systems and Motors

Table of Contents
1 The Service Manual for Inverter Systems and Motors ...........................................................................		................ 3
1.1	Introduction............................................................................................................................................................	3
1.2	Safety Precautions .................................................................................................................................................	4
1.3	Understanding Inverter Systems ...........................................................................................................................	5
1.4	Service Diagnosis ..................................................................................................................................................	7
	1.4.1 Checking the UM power modules or the power modules in the UE ...........................................................	8
2 UE 2xx Compact Inverter System ...........................................................................................................................		11
2.1	Hardware Components of the UE 2xx Compact Inverter System .......................................................................	11
2.2	UE 2xx Service Diagnosis ....................................................................................................................................	12
	2.2.1 The control cannot be switched on with the machine Start button ...........................................................	12
	2.2.2 Axis/spindle motor cannot be driven ..........................................................................................................	14
2.3	UE 2xx Compact Inverter.....................................................................................................................................	16
	2.3.1 Designation of the UE 2xx compact inverter..............................................................................................	16
	2.3.2 Overview of UE 2xx LEDs and connectors ................................................................................................	17
	2.3.3 Description of the UE 2xx LED display.......................................................................................................	17
	2.3.4 Connections on the UE 2xx compact inverters ..........................................................................................	19
2.4	Toroidal Cores......................................................................................................................................................	21
2.5	PW Braking Resistor ............................................................................................................................................	22
2.6	UV 102 Power Supply Unit ..................................................................................................................................	23
3 UE 2xxB Compact Inverter System.........................................................................................................................		25
3.1	Hardware Components of the UE 2xxB Compact Inverter System.....................................................................	25
3.2	UE 2xxB Service Diagnosis..................................................................................................................................	26
	3.2.1 The control cannot be switched on with the machine Start button ...........................................................	26
	3.2.2 Axis/spindle motor cannot be driven ..........................................................................................................	28
3.3	UE 2xxB Compact Inverter ..................................................................................................................................	31
	3.3.1 Designation of the UE 2xxB compact inverter ...........................................................................................	32
	3.3.2 Overview of UE 2xxB LEDs and connectors..............................................................................................	32
	3.3.3 Description of the UE 2xxB LED display ....................................................................................................	33
	3.3.4 Connections on the UE 2xxB compact inverters........................................................................................	34
3.4	PW Braking Resistor ............................................................................................................................................	39
4 Modular Inverter Systems .......................................................................................................................................		41
4.1	Hardware Components of Modular Inverter Systems .........................................................................................	41
4.2	Service Diagnosis for Modular Inverter Systems.................................................................................................	42
	4.2.1 The control cannot be switched on with the machine Start button ...........................................................	42
	4.2.2 Axis/spindle motor cannot be driven ..........................................................................................................	44
4.3	UM Power Modules ............................................................................................................................................	47
	4.3.1 Description of the power module functions...............................................................................................	47
	4.3.2 Specifications .............................................................................................................................................	47
	4.3.3 Designation of the UM ...............................................................................................................................	48
	4.3.4 UM 1x1 Power modules ............................................................................................................................	48
	4.3.5 Power modules UM 1x2, UM 111B, UM 121B..........................................................................................	49
	4.3.6 Power modules UM 113 and UM 114 .......................................................................................................	50
	4.3.7 Description of the UM LED display ............................................................................................................	51
4.4	Modular Inverter System – With Regenerative Power Supply ............................................................................	52
	4.4.1 UV 120/140 Power supply unit...................................................................................................................	52
	4.4.2 Overview of UV 120/140 LEDs and connectors.........................................................................................	53
	4.4.3 Description of the UV 120/140 LED display ...............................................................................................	54
	4.4.4 Connections on the UV 120/140 power supply units .................................................................................	55
	4.4.5 Line filter and KDR 120/140 commutating reactor .....................................................................................	57
	4.4.6 Option: UP 110 braking resistor module ....................................................................................................	57
4.5	Modular Inverter System – Without Regenerative Power Supply .......................................................................	58
	4.5.1 UV 130 Power supply unit..........................................................................................................................	58
	4.5.2 Overview of UV 130 LEDs and connectors................................................................................................	59
	4.5.3 Description of the UV 130 LED display ......................................................................................................	60
	4.5.4 Connections on the UV 130 power supply units ........................................................................................	61
	4.5.5 PW Braking resistor (pulse resistance module)..........................................................................................	63

Edition: Jan. /2001

HEIDENHAIN Service Manual for Inverter Systems and Motors

5 Non-HEIDENHAIN Inverter Systems.......................................................................................................................		65
5.1	Hardware Components........................................................................................................................................	65
5.2	Service Diagnosis for Non-HEIDENHAIN Inverter Systems ................................................................................	66
	5.2.1 Axis/spindle motor cannot be driven ..........................................................................................................	66
5.3	Interface Cards for SIMODRIVE 611D.................................................................................................................	69
	5.3.1 Designation of the interface cards .............................................................................................................	69
5.4	Interface Card for One Axis in Single-Row Configuration (Id.No. 324 955-xx).....................................................	70
	5.4.1 Overview of LEDs and connectors (interface card Id.No. 324 955-xx).......................................................	70
	5.4.2 Grounding (interface card Id.No. 324 955-xx)............................................................................................	70
	5.4.3 Description of the LEDs (interface card Id.No. 324 955-xx) ......................................................................	70
5.5	Interface Card for Two Axes in Single-Row Configuration (Id.No. 313 437-xx) ...................................................	71
	5.5.1 Overview of LEDs and connectors (interface card Id.No. 313 437-xx).......................................................	71
	5.5.2 Grounding (interface card Id.No. 313 437-xx)............................................................................................	71
	5.5.3 Description of the LEDs (interface card Id.No. 313 437-xx) ......................................................................	71
5.6	Interface Card with D-Sub Connections and Metallic Isolation (Id.No. 324 952-1x) ............................................	72
	5.6.1 Overview of LEDs and connectors (interface card Id.No. 324 952-1x) ......................................................	72
	5.6.2 Grounding (interface card Id.No. 324 952-1x)............................................................................................	72
	5.6.3 Description of the LEDs (interface card Id.No. 324 952-1x) ......................................................................	72
5.7	Interface Cards Id.No. 324 952-0x Without Metallic Isolation ............................................................................	73
	5.7.1 Overview of LEDs and connectors (interface card Id.No. 324 952-0x) ......................................................	73
	5.7.2 Grounding (interface card Id.No. 324 952-0x)............................................................................................	73
	5.7.3 Description of the LEDs (interface card Id.No. 324 952-0x) ......................................................................	74
5.8	Pin Layout for all Interface Cards .........................................................................................................................	75
	5.8.1 X1, X2 PWM connection to the UV 111x ...................................................................................................	75
	5.8.2 X111, X112 PWM connection to the LE.....................................................................................................	75
	5.8.3 X73 Enabling connector..............................................................................................................................	76
5.9	UV Power Supply Units .......................................................................................................................................	77
	5.9.1 UV 101B .....................................................................................................................................................	77
	5.9.2 UV 111........................................................................................................................................................	78

6 Motors .......................................................................................................................................................................		79
6.1	Description of the Motor Functions .....................................................................................................................	79
	6.1.1 Asynchronous motor ..................................................................................................................................	79
	6.1.2 Synchronous motor ....................................................................................................................................	79
6.2	Test Routines for Motors.....................................................................................................................................	80
	6.2.1 Checking the motor encoder......................................................................................................................	80
	6.2.2 Replacing the motor encoder of an asynchronous motor ..........................................................................	80
6.3	Axis Motor (QSY Synchronous Motor) ................................................................................................................	82
	6.3.1 Designation of the QSY synchronous motor..............................................................................................	82
	6.3.2 Cables and connectors ...............................................................................................................................	82
	6.3.3 Power connection for the HEIDENHAIN synchronous motors ..................................................................	83
6.4	Spindle Motor (QAN Asynchronous Motor) .........................................................................................................	85
	6.4.1 Designation of the QAN asynchronous motor ...........................................................................................	85
	6.4.2 Cables and connectors ...............................................................................................................................	85
	6.4.3 Power connection for the HEIDENHAIN asynchronous motors ................................................................	86

7 Testing Equipment ...................................................................................................................................................		87
7.1	Overview .............................................................................................................................................................	87
7.2	Drive Control Generator DCG (Id.No. 296 737-01)...............................................................................................	87
	7.2.1 Description of the controls and displays of the DCG .................................................................................	87
	7.2.2 DCG Accessories .......................................................................................................................................	89
7.3	PWM 8 Encoder Diagnostic Set (Id.No. 309 956-xx) ..........................................................................................	91

HEIDENHAIN Service Manual for Inverter Systems and Motors

1 The Service Manual for Inverter Systems and Motors

1.1Introduction

This Service Manual assists the service staff in troubleshooting and fault correction for HEIDENHAIN inverter systems, including motors that are driven with modular HEIDENHAIN controls (TNC 410 M, TNC 426 M, TNC 430 M and the lathe control MANUALplusM).

For the technical information on the controls, please refer to the Service Manuals for:

nTNC 410

nTNC 426 / TNC 430

nMANUALplusM

Note

To correctly judge problems in an NC-controlled machine tool, fundamental knowledge of drives, inverters, controls and encoders is necessary.

Incorrect behavior of the NC-controlled machine tool may result from improper use of the control, NC programming errors or incorrect or not properly optimized machine parameter values.

Caution

HEIDENHAIN accepts no liability for direct or indirect damage, or for property damage or bodily injury incurred due to non-compliance with the intended use or due to improper operation.

You will find important information in the following documents:

nMachine documentation of the machine tool builder

nUser's Manual (HEIDENHAIN)

nTechnical Manual (HEIDENHAIN)

nTNCguide CD-ROM (HEIDENHAIN)

The Technical Manual is not included with every inverter system or motor!

It is generally supplied only to the machine tool builder and is subject to a revision service performed by HEIDENHAIN-Traunreut.

Should you encounter errors concerning the machine parameters or control interface, it is essential that you consult your machine tool builder.

You will also receive support from the HEIDENHAIN-Traunreut service staff or HEIDENHAIN agencies.

The telephone and telefax numbers as well as e-mail addresses are given on the rear cover of the Service Manual or in the HEIDENHAIN homepage at http://www.heidenhain.de.

Note

Please read the information on the general safety precautions in the following section thoroughly from beginning to end, see page 1 - 4.

You will find basic information for a general understanding of the HEIDENHAIN inverter systems in section 1.3, see page 1 - 5.

Basic information on service diagnosis for HEIDENHAIN inverter systems is provided in section 1.4, see page 1 - 7. This section also deals with test routines which can be used for all inverter systems, see page 1 - 8.

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1.2Safety Precautions

Danger

Make sure that the main switches of the machine and encoder are switched off before you engage or disengage any connectors and terminals.

Danger

Ensure that there are no interruptions in the equipment grounding conductor. Interruptions of the equipment grounding conductor may cause property damage or bodily injury.

Danger

Incorrect or not properly optimized input values may lead to an incorrect behavior of the machine tool and thus cause property damage or bodily injury.

Machine parameters may be changed only by the machine tool builder or on consultation with the machine tool builder.

Caution

To correctly judge problems a TNC-controlled machine tool, fundamental knowledge of the machine and drives as well as their interaction with the encoders is necessary.

Non-compliance with the intended use may cause severe property damage or bodily injuries.

HEIDENHAIN accepts no liability for direct or indirect damage, or for property damage or bodily injury incurred due to non-compliance with the intended use or due to improper operation.

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HEIDENHAIN Service-Handbuch Umrichter-Systeme und Motoren

1.3Understanding Inverter Systems

An inverter generates a three-phase motor voltage of a variable frequency and voltage/current from a line voltage. With the help of an inverter, the speed of three-phase motors is controlled.

Block diagram

	The inverter is connected to the 400 V three-phase line power. The fuses are provided outside
	the inverter.
Load and	The line power is switched through two contactors. The load contactor charges the dc-link
main contactors	electrolytic capacitors via a dropping resistor.
	After charging, the time-delayed main contactor transfers the entire line power. The contactors
	are required by the German Employer's Liability Insurance Association. The proper state of the
	contactors is monitored by normally-closed contacts wired through to the outside.
Bridge	In inverters without regenerative power supply, the line voltage (ac voltage) is converted into a
rectifier	dc voltage (dc-link voltage Uz) through rectification. The rectifier is operated in the so-called B6
	bridge circuit. The resulting dc voltage is 565 Vdc at a line voltage of Ueff = 400 Vac.
Infeed/regenerative	In HEIDENHAIN regenerative inverters, the dc-link voltage Uz is controlled at 650 Vdc by an
feedback module	infeed/regenerative feedback module. For this purpose, regenerative inverters need to be
	connected to the line power via a so-called commutating reactor. This commutating reactor
	serves as an energy storage device for the infeed/regenerative feedback module. This is the only
	way the dc-link voltage can be stepped up to 650 Vdc. To ensure electromagnetic compatibility,
	a special line filter is additionally required.
Power supply unit	A power supply unit built into the inverter powers the inverter and the control. The power supply
	unit is supplied with the dc-link voltage and the line power.
	The dc-link voltage is buffered with electrolytic capacitors. Motors that are decelerated feed
	energy back into the dc-link as generators.
	In the event of a sudden power interruption, the dc-link voltage therefore still supplies enough
	energy for braking all axes and the spindle.
	The power supply unit is additionally supplied with the line power since no dc-link voltage exists
	yet during switch-on.

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Power modules	The dc-link voltage supplies all power modules. So-called intelligent IGBT modules have been
	used as the power modules. They contain a braking transistor in addition to the bridge
	transistors. They also include the transistor drivers as well as a short-cut monitor and an excess-
	temperature monitor.
Resistance module	When three-phase motors are braked, the kinetic energy is converted back into electric energy.
	This causes an increase in the dc-link voltage. To convert dangerous excess voltage into heat, a
	braking resistor is connected to the dc-link through an IGBT when a certain voltage has been
	reached. For this purpose, the dc-link voltage is measured with a voltage divider and an isolating
	amplifier.
Current	The currents of the motor phases U and V are measured with two current sensors and supplied
measurement	to the control as inverted signals. The third phase current can be calculated.
Supervisory circuit	A supervisory circuit monitors the dc-link voltage and switches off all inverter axes when a limit
	value is exceeded. This prevents further voltage increase. An excessive dc-link voltage may
	occur if a braking resistor is defective or the braking power is too high. In addition, the
	supervisory circuit monitors the heat sink temperature and reports excessive temperature to the
	control. It also includes a monitor which detects a short circuit of an individual IGBT and switches
	off the inverter.
Control circuit	The gate drivers are controlled and metallically isolated by optocouplers with a very high
	common mode rejection.
Safety relay	The supply voltage of the optocouplers is led over a safety relay to prevent the power switches
	from being activated inadvertently. The safety relay is controlled externally and its proper state
	is checked by a normally closed contact wired through to the outside.
EMC	The following measures have been taken to comply with the EMC regulations:
	n Capacitors from line input to housing
	n Capacitors between the individual line phases
	n Current-compensated toroidal core reactor in the dc-link line. This reactor has two windings
	which are wired in such a way that the go-and-return current compensates the magnetic field
	of the coil. This prevents a saturation of the coil. Current-compensated reactors are used for
	common mode rejection.
	n Two capacitors from dc-link to housing.
	n Toroidal cores in the motor lines. They suppress common mode interference, especially in the
	upper frequency range starting at approx. 1 MHz.

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HEIDENHAIN Service-Handbuch Umrichter-Systeme und Motoren

1.4Service Diagnosis

In modular inverter systems, service diagnosis is limited to analyzing which hardware component is defective. Defective hardware components are replaced and sent to HEIDENHAIN for repair.

Danger

Hardware components may be opened only by HEIDENHAIN service engineers.

HEIDENHAIN accepts no liability for direct or indirect damage, or for property damage or bodily injury incurred due to non-compliance with the intended use or due to improper operation.

Caution

To correctly judge problems in a TNC-controlled machine tool, fundamental knowledge of the machine, control and drives as well as their interaction with the encoders is necessary.

Non-compliance with the intended use may cause severe property damage or bodily injuries.

For service diagnosis, you can:

nMeasure the dc-link voltage, see page 2 - 19

nInterpret the LEDs

nInterpret the error messages from the control

The following faults indicate a defect in the inverter system. The test routines for finding the defective hardware component are described in the following sections for each inverter system:

Inverter system		Control cannot be	Axis/spindle motor
		switched on	cannot be driven
UE 2xx compact inverter		see page 2 - 12	see page 2 - 14
UE 2xxB compact inverter		see page 3 - 26	see page 3 - 28
Modular inverter system		see page 4 - 42	see page 4 - 44
Non-HEIDENHAIN inverter		see the technical manuals for	see page 5 - 66
system		the inverter system
	Note

For machines for which a downtime of a few days is not possible, spare hardware components for the inverter system as well as spare motors should be kept in reserve. This can be done either by the service engineer (machine tool builder) or by the company operating the machine.

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MP 10: MP 2101: MP 3411: MP 3412.0: MP 3415.0:

The following machine parameters need to be adjusted:

Switch on the control.

7

Connect the spindle motor and the PWM bus for the spindle instead.

7

Disconnect the motor and PWM bus of the axis to be checked.

7

1.4.1 Checking the UM power modules or the power modules in the UE

Without DCG If an axis does not move, you can check the power modules with the following test routine (independent of the inverter type) without using a measuring instrument:

Danger

Make sure that the main switch of the machine is switched off before you engage or disengage any connectors and terminals.

Disable the axis that is normally operated with the power module

Select the power module you want to check for the spindle

Reduce the value for M03 and M04 (flatter ramp gradient)

Reduce the multiplication factor for MP 3411 for M05

Increase the time (overshoot behavior of the spindle)

7 Leave the MP list.

In older software versions, the software reboots due to the change in MP 10.

7Switch on the machine control voltage.

7Enter the spindle speed (to take over the settings for MP 3411, MP 3412 and MP 3415).

7Enter an M function for the spindle, e.g. M03.

If the spindle cannot be driven, the UM power module or the power module in the UE is defective.

Note

This setup is intended only for checking the UM power modules and the power modules in the UE. It is not an official constellation. The spindle motor cannot destroy the power module since it limits the current.

With DCG	Before using the DCG, you should verify the following basic settings:
	Netz-Schalter	OFF
	Regler Ein	DOWN position (OFF)
	Err.1	UP position (active)
	Err.2	UP position (active)
	Drehmoment	Left stop (OFF)
	Drehzahl	Left stop (OFF)

If an axis does not move, you can check the power modules with the following test routine (independent of the inverter type):

Danger

Make sure that the main switch of the machine is switched off before you engage or disengage any connectors and terminals.

7Disconnect the motor and PWM bus of the axis to be checked.

7Connect the spindle motor and the switched-off DCG Drive Control Generator instead.

7Switch on the control.

The following machine parameters need to be adjusted:

MP 10: Disable the axis that is normally operated with the power module

MP 3010: Enter 0 (no spindle speed output)

7Switch on the DCG power switch.

7Switch on the controller by setting the Regler Ein toggle switch to the UP position. The DCG is now ready for operation.

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HEIDENHAIN Service-Handbuch Umrichter-Systeme und Motoren

7Turn up the two potentiometers Drehmoment (torque) and Drehzahl (speed) simultaneously until the axis moves continuously.

Caution

Turning only the Drehmoment potentiometer may destroy the motor.

If the spindle cannot be driven, the UM power module or the power module in the UE is defective.

Caution

If a non-HEIDENHAIN PLC program is used, you need to ensure that a vertical axis cannot drop when you run this test routine.

Note

You can use a regular three-phase asynchronous motor (as installed in a washing machine, for example) instead of the spindle motor.

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HEIDENHAIN Service-Handbuch Umrichter-Systeme und Motoren

2 UE 2xx Compact Inverter System

2.1Hardware Components of the UE 2xx Compact Inverter System

The UE 2xx compact inverter system consists of the following hardware components:

nUE 2xx compact inverter, see page 2 - 16

nToroidal cores, see page 2 - 21

nPW 210 (or PW 110, PW 120) braking resistor, see page 2 - 22

nUV 102 power supply unit (only LE 426 M), see page 2 - 23

With UE 2xx compact inverters, the power electronics for two to four axes and one spindle, as well as the power supply for the LE 410M logic unit are all contained in a single housing.

The PWM signals are transferred via internal ribbon cables.

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2.2UE 2xx Service Diagnosis

In inverter systems, service diagnosis is limited to analyzing which hardware component is defective. Defective hardware components are replaced and/or sent to HEIDENHAIN for repair.

Danger

Hardware components may be opened only by HEIDENHAIN service engineers.

HEIDENHAIN accepts no liability for direct or indirect damage, or for property damage or bodily injury incurred due to non-compliance with the intended use or due to improper operation.

The following faults indicate a defect in the inverter system.

nThe control cannot be switched on with the machine Start button, see page 2 - 12

nThe axis/spindle motor is at a standstill, see page 2 - 14

2.2.1The control cannot be switched on with the machine Start button

Enabling connector If you would like to perform the following test routine professionally, make one (better, three) enabling connector(s). A toggle switch bridges the contacts 1 and 2. Instead of the toggle switch, you can also use a jumper wire.

The enabling connector fits in the connectors X70, X71 and X72.

UE 2xx cannot be switched on

Caution

Please note that the UE 2xx and UE 2xxB compact inverters require different enabling connectors.

The UDC LINK ON LED is off. With the following test routine, you can check whether the fault lies in the UE 2xx.

Note

Make sure the 3-phase supply voltage is applied.

7Press EMERGENCY STOP.

7Switch on the main switch on the machine.

The following LEDs are on: +5V (green), POWER FAIL, SPINDLE RESET, AXIS 1/2/3/4 RESET

7 Do not acknowledge the power interruption message.

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HEIDENHAIN Service Manual for Inverter Systems and Motors

No drive enable by the UE 2xx

7To simulate enabling the load and main contactors, bridge the contacts 1 and 2 at the connector X70.

Note

Use an enabling connector for bridging, if possible. The contacts 1 and 2 at the connector X70 can also be bridged with a jumper wire.

The load and main contactors of the UE 2xx compact inverter are operating correctly if you observe the following:

nAre contactors switching audibly in the UV?

nIs the green UDC-LINK ON LED on?

nHas the red POWER FAIL LED gone out?

The following line chart shows you the sequence of operation when the UE 2xx compact inverter is working properly:

Power switch		on
Message "Power interrupted"				appears on the monitor -> do not confirm
X70, contact 2
Green LED "+5 V"			lit				off
Red LED "POWER FAIL"			lit
Red LED "SPINDLE RESET"			lit
Red LED "AXIS 1/2/3/4 RESET"			lit
Green LED "UDC-LINK ON"						lit
	The horizontal arrows
	represent time delay.

If the compact inverter is not working properly, replace it and send it to HEIDENHAIN for repair.

The previous test routine has not resulted in enabling the drives for the axes and spindle.

The following LEDs are on:

ngreen: UDC-LINK ON and +5V

nred: SPINDLE RESET, and AXIS 1/2/3/4 RESET

To simulate enabling the safety relay for the axes and spindle,

7 bridge the contacts 1 and 2 at X71/X72

Note

Use an enabling connector for bridging, if possible, see page 2 - 12.

The contacts 1 and 2 at the connector X71/72 can also be bridged with a jumper wire.

The safety relays of the UE 2xx compact inverter are operating properly if you observe the following:

nAre contactors switching audibly in the UE 2xx?

nIs the PULSE RELEASE AXES LED on?

nIs the PULSE RELEASE SPINDLE LED on?

nIs the AXIS 1/2/3/4 READY LED on?

nIs the SPINDLE READY LED on?

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The following line chart shows you the sequence of operation when the UE 2xx compact inverter is working properly.

Green LED "UDC-LINK ON"		lit
Green LED "-5 V"		lit
Red LED "SPINDLE RESET"		lit
Red LEDs "AXIS 1/2/3/4 RESET"		lit
X71, contact 2
X72, contact 2
Green LED "PULSE RELEASE SPINDLE"				lit
Green LED "PULSE RELEASE AXES"				lit
Green LED "SPINDLE READY"						lit
Green LEDs "AXIS 1/2/3/4 READY"						lit
		The horizontal arrows
		represent time delay.

If the compact inverter is not working properly, replace it and send it to HEIDENHAIN for repair.

2.2.2Axis/spindle motor cannot be driven

7 Inspect all cables for visible damage first.

Motor/spindle is at	With two successive test routines, you can determine whether the LE logic unit or the power
standstill	module in the UE or the motor is defective.
	Test routine	Modifications for test routine		Driving the motor Result
				not functioning		functioning
	LE	Exchange DCG		Run motor test		LE output
		or axis		routine		defective
	Motor	Spindle motor/service motor		Power module in		Motor defective
				UE defective
Example: X axis not	The test routines are illustrated in an example.
functioning	Assumed machine parameter settings
	X axis		MP 112.0=15		MP 120.0=51
	Y axis		MP 112.1=16		MP 120.0=52
Test routine	The drive control generator for one axis (DCG) serves to define PWM signals for HEIDENHAIN
LE with DCG	inverters. See ”Drive Control Generator DCG (Id.No. 296 737-01)” on page 87.
	Before using the DCG, you should verify the following basic settings:
	Netz-Schalter	OFF
	Regler Ein	DOWN position (OFF)
	Err.1	UP position (active)
	Err.2	UP position (active)
	Drehmoment	Left stop (OFF)
	Drehzahl	Left stop (OFF)

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HEIDENHAIN Service Manual for Inverter Systems and Motors

Connecting cable for acqusition

of encoder signals and temperature signals

Drive

PWM noml. value

Simulated by DCG

Danger

Power cable

Can be replaced by "service motor" or by spindle motor

Make sure that the main switches of the machine and encoder are switched off before you engage or disengage any connectors and terminals.

7Use a suitable adapter cable for connecting the switched-off DCG with the PWM input of the axis/spindle to be checked.

7Switch on the control.

7Deactivate the X axis in machine parameter MP 10.

7Switch on the DCG power switch.

7Switch on the controller by setting the Regler Ein toggle switch to the UP position.

The DCG is now ready for operation.

7Turn up the two potentiometers Drehmoment (torque) and Drehzahl (speed) simultaneously until the axis moves continuously.

Caution

Turning only the Drehmoment potentiometer may destroy the motor.

If the axis moves, the LE output of the X axis is defective.

7Use a free output on the LE. If the axis does not move

7run the test routine for the motor.

Motor test routine 7 Before running the motor test routine, you need to carry out the LE test routine: The DCG is connected.

The motor test routine is performed with a replacement motor (if possible, with a spindle motor). If the replacement motor can be driven, the original motor is defective.

If the replacement motor cannot be driven either, the power module in the UE is defective.

	Replacement motor		Modifications	Comment
	Spindle motor		Change motor connections	Keep the sequence of phases:
			MP 10 Disable X axis	U V W corresponds to 1 2 3
			MP 3010 = 0	Connect the equipment grounding
				conductor
	Service motor		Change motor connections
	(asynchronous motor)		MP 10 Disable X axis
		Note

Use the spindle motor, if possible.

If the spindle motor is to be checked, use a service motor.

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2.3UE 2xx Compact Inverter

With UE 2xx compact inverters, the power electronics for up to four axes and one spindle, as well as the power supply for the LE 410M logic unit are all contained in a single housing.

Specifications	UE 210	UE 212	UE 230	UE 240	UE 242
Power supply	400 Vac ±10 % 50 Hz to 60 Hz
Power consumption
Rated power	13 kW		20 kW
Peak power	18 kW		27.5 kW
Power loss	Approx.	Approx.	Approx.	Approx.	Approx.
	435 W	555 W	510 W	580 W	760 W
DC-link voltage	565 Vdc (at 400 V power supply)
Continuous load
3 axes	7.5 A	7.5 A	2 x 7.5 A	7.5 A	7.5 A
1 axis	–	14 A	–	–	23 A
spindle	19 A	19 A	31 A	31 A	31 A
Short-time loada
3 axes	15 A	15 A	2 x 15 A	15 A	15 A
1 axis	–	28.5 A	–	–	46 A
spindle	28.5 A	28.5 A	46 A	46 A	46 A
Continuous power of the	1 kW		No integral braking resistor
integral braking resistor
Peak power of the integral	23 kW		No integral braking resistor
braking resistorb
Degree of protection	IP 20
Weight	20 kg		23 kg
ID number	313 500-xx	313 501-xx	329 037-xx	313 502-xx	313 503-xx

a.Axes: 40% cyclic duration factor for duration of 5 s

Spindle: 40% cyclic duration factor for duration of 10 minutes (S6-40%)

b.0.4% cyclic duration factor for duration of 120 s

2.3.1Designation of the UE 2xx compact inverter

As of October 1999, the ID label is found on the bottom of the fixing plate of every HEIDENHAIN inverter. This makes it possible to read the ID label of an installed inverter.

On older inverters, the ID label is found on the side wall.

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HEIDENHAIN Service Manual for Inverter Systems and Motors

2.3.2Overview of UE 2xx LEDs and connectors

PE L1 L2 L3

U V W U V W

€

€€

Labels	Controls/displays
X31	Power supply for inverter,
	see page 2 - 19
X32	Output for power supply
	(L1, L2, +UZ, –UZ), see page 2 - 19
X33	Power supply for supply unit (L1, L2),
	see page 2 - 19
X70	Main contactor connector, see page 2 - 20
U DC-LINK ON	Main contactor activated
+5V	Internal supply voltage applied
UDC-LINK >>	DC-link voltage Uz > 760 V
TEMP.>>	Heat sink temperature > 100 °C
AXIS FAULT	Axis fault
POWER FAIL	DC-link voltage Uz < 410 V
POWER RESET	Supply voltage < 200 Vac and/or
	DC-link voltage < 200 Vdc
RESET	Axis/spindle disabled by LE
READY	Axis/spindle ready for operation
X71	Safety relay for spindle (pulse disable)
PULSE RELEASE
SPINDLE	Safety relay for spindle on
X72	Safety relay for axes, see page 2 - 20
PULSE RELEASE
AXES	Safety relay for axes on
X90	24 V output
X83	Motor connection for axis 3
X82	Motor connection for axis 2
X89	Braking resistor, see page 2 - 22
X81	Motor connection for axis 1
X80	Motor connection for spindle
X84	Motor connection for axis 4

Equipment ground

2.3.3Description of the UE 2xx LED display

LED	Status	Meanings/Possible error causes	Signal
U DC-LINK ON	LED on	Control voltage for main contactor applied	24 V at X70 contact 2
	(operational
	status)
+5 V	LED on	Supply voltage to logic modules from internal power
	(operational	supply unit applied
	status)
U DC-LINK >>	LED on (error)	DC-link voltage too high (Uz > 800 V).				zgr to LE
				U
		All power modules are switched off
TEMP>>	LED on (error)	Heat sink temperature too high (>100 °C)					to LE
				TEMP
AXIS FAULT	LED on (error)	Short circuit between a phase of the motor output and			stoer to LE
				A
		Uz (axes only) or power module(s) defective

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LED	Status	Meanings/Possible error causes		Signal
POWER	LED on (error)	Message from UE to LE if dc-link voltage < 410 V.					to LE
				PWF
FAIL		Message to PLC module 9167. With this module, power
		fail monitoring can be switched on and off.
		n Main contactor not on, e.g. EMERG. STOP?
		n Power phase failed during machining?
		n Supply voltage too low (e.g. 3 x 125V)?
POWER	LED on (error)	Reset signal from the UE to the LE if the supply voltage							to LE
					NRES
RESET		(< 200 Vac) and/or dc-link voltage (< 200 Vdc) is not
		sufficient.
		The error memory of the supply module is reset.
PULSE	LED on	Safety relay for spindle on		24 V at X71 contact 2
RELEASE	(operational
SPINDLE	status)
PULSE	LED on	Safety relay for axes on			24 V at X72 contact 2
RELEASE	(operational
AXES	status)
AXIS/	LED on	Axes/spindle have been disabled by the LE.				from LE
					RES
SPINDLE		The signal is transmitted by the control. This is indicated
RESET
		by the LED at the inverter.
AXIS/	LED on	Inverter is ready for operation						reset
					ERR1
SPINDLE	(operational
READY	status)
	LED off (error)	n Main contactor not on?
		n +5 V from power supply unit not applied?
		n Safety relay not on?
		n Uz too high?
		n POWER FAIL ?
		n POWER RESET ?
		n AXIS FAULT ?

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HEIDENHAIN Service Manual for Inverter Systems and Motors

2.3.4Connections on the UE 2xx compact inverters

Danger

Danger of electrical shock!

The compact inverters may be opened only by HEIDENHAIN service engineers.

Do not engage or disengage any terminals while they are under power.

X31 Supply voltage for Uz

With a power supply of 400 V, the inverter voltage Uz is 565 Vdc.

	Connections		UE 210, UE 212	UE 230, UE 240, UE 242
	L1		400 Vac ± 10 %	400 Vac ± 10 %
			50 Hz to 60 Hz	50 Hz to 60 Hz
	L2
	L3
	Cable		UE 210, UE 212	UE 230, UE 240, UE 242
	Wire cross section		6 mm2	10 mm2
	Line fuse		32 A	32 A
	Grounding terminal		≥ 10 mm2	≥ 10 mm2
		Note

If the power supply is other than 400 V, an autotransformer is required. It must comply at least with the connection specifications of the subsequent compact inverter.

Measuring the dc-	The dc-link voltage can be accessed at the conductor bars behind the protection cap marked with
link voltage	the warning symbol.
		Danger
		Caution! Danger! 650 V voltage
		Do not open the protection caps to measure the dc-link voltage.

7For measuring the dc-link voltage, use insulated test prods which are long and thin enough to reach the conductor bars with the protection cap closed.

	X33 Supply voltage
		Terminals	Assignment
	for the inverter
		1	Jumper to X32/pin 1 (with setup operation L1 from line power)
	supply unit
			290 Vac to 440 Vac, 50 Hz to 60 Hz
		2	Jumper to X32/pin 2 (with setup operation L2 from line power)

	X32 Output for
		Terminals	Assignment
	supply voltage of
		1	Jumper to X33/pin 1 (short-circuit protection with 4 A)
	power unit
		2	Jumper to X33/pin 2 (short-circuit protection with 4 A)
		3	+Uz (short-circuit protection with 4 A)
		4	–Uz (short-circuit protection with 4 A)

	X80	Spindle motor
			Terminals	Assignment
	X81	Axis motor 1
			U	Motor connection U
	X82	Axis motor 2
	X83	Axis motor 3	V	Motor connection V
	X84	Axis motor 4
			W	Motor connection W

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X70 Main contactor For information on the wiring and function, see the Basic Circuit Diagram for your control

	X71 Safety relay
		Terminals		Assignment
	spindle
		X70 to X72
	X72 Safety relay
		1		+24 V output (max. 250 mA)
	axes
		2		0 V
		3		Not assigned
		4		Normally closed contact 1
		5		Normally closed contact 2
	X89
		Terminal X89	Assignment		Internal braking			PW 210	PW 1x0
	Braking resistor
		UE 21x			resistor				terminal X1
		1	+UZ				Jumper	RB1	1
		2	Internal braking					Do not	Do not assign
			resistor					assign
		3	Switch against –UZ		Do not assign			RB2	2
		Terminal X89	Assignment		PW 210			PW 1x0
		UE 230/UE 24x						connecting terminal X1
		1	+UZ		RB1			1
		2	Switch against –UZ		RB2			2

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HEIDENHAIN Service Manual for Inverter Systems and Motors

2.4Toroidal Cores

To suppress occurrence of interference, toroidal cores must be mounted in the motor leads (X80 to X84), in the voltage supply lead (X31) and in the lead to the

braking resistor (only with UE 21x).

From line power

Wrap L1, L2, and L3 four times around the large toroidal core. Arrange the wires in parallel.

UE 2xx

UE 2xx B

-

UE 21x only:

Wrap the leads to the braking resistor three times around the small toroidal core. Arrange the wires in

Wrap W, V, U of the axes three times around the small toroidal core.

Wrap W, V, U of the spindle three times around the medium-sized toroidal core. Arrange the wires in parallel.

Intermediate terminal

for supply line to brake

To braking resistor

Connect the shield to the metal housing of the electrical

cabinet.

To the motor

Terminal on the compact inverter	Toroidal core
Power supply (X31)	87 mm (309 694-02)
Braking resistor (X89)a	42 mm (309 694-01)
Axis 1 to 3 (X81 to X83)	42 mm (309 694-01)
Axis 4 (X84)	59 mm (309 694-03)
Spindle (X80)	59 mm (309 694-03)

a. Only with UE 21x; not with UE 230, UE 24x, UE 2xxB

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2.5PW Braking Resistor

Cross section

The PW braking resistors convert the energy fed back into the dc-link during braking into heat.

The PW 110 and PW 120 have a cooling fan, the PW 210 cools only through heat radiation.

Danger

The surface of the braking resistor can attain temperatures of up to > 150 °C!

An external braking resistor must be connected to the UE 230 and UE 24x compact inverters, as these inverters are not equipped with internal braking resistor.

An external braking resistor can also be connected to the UE 210 and UE 212 compact inverters instead of the internal braking resistance. This is necessary if the internal braking resistor is no longer able to absorb all of the braking energy or if the braking resistor needs to be mounted outside the electrical cabinet.

Either one PW x10 or two PW 120 switched in series can be connected to all UE 2xx compact inverters.

The braking resistor is switched on when the inverter voltage UZ exceeds 700 V and is switched off again as soon as it falls below 670 V.

The following cross section is required for connecting the braking resistor:

Braking resistor	Cross section
1 x PW 210	1.5 mm2
1 x PW 110	1.5 mm2
2 x PW 120 in series	4.0 mm2

Temperature	The temperature switch is a normally closed contact and is set to protect the braking resistor
switch on the	from being damaged. It can have maximum load 250 V, 5 A. The switch can be connected to a
PW 210	PLC input on the LE and evaluated via the PLC.
	Connecting terminal on the PW 210	Assignment
	T1	1
	T2	2

X2 Fan for the external braking resistor PW 1x0

Connecting terminal X2	Assignment
+	+24 V (PLC)
–	0 V

See ”PW Braking resistor (pulse resistance module)” on page 63.

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HEIDENHAIN Service Manual for Inverter Systems and Motors

2.6UV 102 Power Supply Unit

The UV 102 has a 50-line ribbon cable for the power supply to the LE 426 M logic unit and five 20-line ribbon cables for the PWM signals of the axes and the spindle from the LE logic unit

	X31 Power supply
		Terminals				Assignment
						Equipment ground (YL/GY)
		U1				Phase 1 / 400 Vac ±10 % / 50 Hz to 60 Hz
		U2				Phase 2 / 400 Vac ±10 % / 50 Hz to 60 Hz
		–UZ				DC-link voltage –
		+UZ				DC-link voltage +
		Cable				1.5 mm2
		Wire cross section
		Line fuse				16 A (use smaller fuse with smaller wire cross section)
		Grounding terminal				≥ 10 mm2

Note

The voltage at the terminals U1 and U2 must be supplied via an isolating transformer (250 VA, basic insulation in accordance with EN 50178 or VDE 055).

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HEIDENHAIN Service Manual for Inverter Systems and Motors

3 UE 2xxB Compact Inverter System

3.1Hardware Components of the UE 2xxB Compact Inverter System

The UE 2xxB compact inverter system consists of the following hardware components:

nUE 2xxB compact inverter, see page 3 - 31

nToroidal cores, see page 2 - 21

nRibbon cables for PWM signals and supply voltage (and optional unit bus)

nCovers for the ribbon cables

nPW 210 (or PW 110, PW 120) braking resistor, see page 3 - 39

nOption: One UM 111 power module, see page 4 - 47

With UE 2xxB compact inverters, the power electronics for all of the axes and the spindle, as well as the power supply for the LE are all contained in a single unit. An additional UM 111 power module (an additional axis) can be connected via conductor bar.

The PWM signals are transferred via external 20-pin ribbon cables.

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3.2UE 2xxB Service Diagnosis

In inverter systems, service diagnosis is limited to analyzing which hardware component is defective. Defective hardware components are replaced and/or sent to HEIDENHAIN for repair.

Danger

Hardware components may be opened only by HEIDENHAIN service engineers.

HEIDENHAIN accepts no liability for direct or indirect damage, or for property damage or bodily injury incurred due to non-compliance with the intended use or due to improper operation.

The following faults are described in this chapter:

nThe control cannot be switched on with the machine Start button, see page 3 - 26

nThe axis/spindle motor cannot be driven, see page 3 - 33

3.2.1The control cannot be switched on with the machine Start button

Enabling connector If you would like to perform the following test routine professionally, make one (better, three) enabling connector(s). A toggle switch bridges the contacts 1 and 3. Instead of the toggle switch, you can also use a jumper wire.

The enabling connector fits in the connectors X70, X71 and X72.

Caution

Please note that the UE 2xx and UE 2xxB compact inverters require different enabling connectors.

UE 2xxB cannot be With the following test routine, you can check whether the fault lies in the UE 2xxB. switched on

Note

Make sure the 3-phase supply voltage is applied.

7Press EMERGENCY STOP.

7Switch on the main switch on the machine.

The following LEDs are on: X11x SH1(green), SH2 (green), POWER FAIL (red), NC RESET (red)

7 Do not acknowledge the power interruption message.

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HEIDENHAIN Service Manual for Inverter Systems and Motors

No drive enable by the UE 2xxB

7 To simulate enabling the load and main contactors, bridge the contacts 1 and 3 at X70.

Note

Use an enabling connector for bridging, if possible. The contacts 1 and 3 at the connector X70 can also be bridged with a jumper wire.

The load and main contactors of the UE 2xxB compact inverter are operating correctly if you observe the following:

nAre contactors switching audibly in the UE 2xxB?

nAre the green U DC-LINK ON and READY LEDs on?

nHave the red POWER FAIL and NC RESET LEDs gone out?

The following line chart shows you the sequence of operation when the UE 2xxB compact inverter is working properly:

Power switch	on
Message "Power interrupted"		appears on the monitor -> do not confirm
X70, contact 3
Red LED "POWER FAIL"	lit	off
Red LED "NC RESET"	lit	off
X11x: red LED "SH1"	lit
X11x: red LED "SH2"	lit
Green LED "UDC-LINK ON"		lit
Green LED "READY"		lit

If the compact inverter is not working properly, replace it and send it to HEIDENHAIN for repair.

The previous test routine has not resulted in enabling the drives for the axes and spindle. The following LEDs are on:

ngreen: U DC-LINK ON and READY

nred: X11x SH1, SH2

To simulate enabling the safety relay for the axes and spindle,

7 bridge the contacts 1 and 3 at X71

Note

Use an enabling connector for bridging, if possible, see page 3 - 26.

The contacts 1 and 3 at the connector X71 can also be bridged with a jumper wire.

The safety relays of the UE 2xxB compact inverter are operating properly if you observe the following:

nAre contactors switching audibly in the UE 2xxB compact inverter?

nIs the PULSE RELEASE AXES LED on?

nIs the PULSE RELEASE SPINDLE LED on?

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