HEIDENHAIN iTNC 530 Service Manual
Service Manual
iTNC 530
May 2006
Contents
1 Safety Precautions................................................................................................................. 9
2 Using the Service Manual................................................................................................... 11
2.1 About this Manual ......................................................................................................... 11
2.2 Further Service Manuals................................................................................................ 11
2.3 Other Documentation:................................................................................................... 12
2.4 Support.......................................................................................................................... 12
2.5 Service Training Seminars............................................................................................. 12
2.6 Safety ............................................................................................................................ 12
3 Code Numbers ..................................................................................................................... 13
3.1 Introduction ................................................................................................................... 13
3.2 Overview ....................................................................................................................... 13
3.3 Notes on Entering the Code Numbers .......................................................................... 14
4 Error Messages .................................................................................................................... 17
4.1 Introduction ................................................................................................................... 17
4.2 HELP Key....................................................................................................................... 19
4.3 ERR Key ........................................................................................................................ 20
4.4 CE Key .......................................................................................................................... 21
4.5 List of NC Error Messages ............................................................................................ 22
5 Errors..................................................................................................................................... 23
5.1 Introduction ................................................................................................................... 23
5.2 Notes and Tips............................................................................................................... 23
5.3 Overview of Possible Errors.......................................................................................... 26
5.4 Important Notes on the
Use of HEIDENHAIN Interface Boards in SIMODRIVE System.................................... 29
6 Log......................................................................................................................................... 35
6.1 General .......................................................................................................................... 35
6.2 Calling the Log............................................................................................................... 36
6.3 Overview of Log Entries................................................................................................ 37
6.4 Example of a Log Entry ................................................................................................. 40
7 Integrated Diagnosis Functions.......................................................................................... 41
7.1 Introduction ................................................................................................................... 41
7.2 Meanings of the Signals under “DSP”.......................................................................... 43
7.3 Electronic ID Label......................................................................................................... 47
8 Integrated Oscilloscope.......................................................................................................49
8.1 General .......................................................................................................................... 49
8.2 Setup ............................................................................................................................. 50
8.3 Saving and Loading Recordings..................................................................................... 53
8.4 Circular Interpolation Test.............................................................................................. 54
9 Monitoring Functions..........................................................................................................55
9.1 Introduction ................................................................................................................... 55
9.2 During Booting............................................................................................................... 55
9.3 During Operation ........................................................................................................... 57
9.3.1 Position or Servo Lag Monitoring ........................................................................ 58
9.3.2 Nominal Speed Value ........................................................................................... 60
9.3.3 Movement Monitoring ......................................................................................... 61
9.3.4 Standstill Monitoring ............................................................................................ 62
9.3.5 Positioning Window ............................................................................................. 62
9.3.6 Monitoring of the Power Supply Unit .................................................................. 64
9.3.7 Temperature Monitoring ...................................................................................... 65
2
t Monitoring ....................................................................................................... 66
9.3.8 I
July 2002 HEIDENHAIN Service Manual iTNC 530
9.3.9 Current Utilization of the Drive Motors ................................................................ 67
9.3.10 Status of HEIDENHAIN Inverters ...................................................................... 68
9.3.11 Control of Motor Brakes .................................................................................... 70
9.3.12 EMERGENCY STOP Monitoring During Operation ............................................ 72
10 PLC Diagnosis..................................................................................................................... 73
10.1 General ........................................................................................................................ 73
10.2 Service Diagnosis in PLC Mode .................................................................................. 76
10.2.1 The TABLE Function .......................................................................................... 76
10.2.2 The LOGIC Diagram .......................................................................................... 82
10.2.3 The TRACE Function ......................................................................................... 84
10.2.4 The WATCH LIST Function ................................................................................ 85
10.2.5 The I/O-FORCE LIST .......................................................................................... 87
10.3 The COMPILE Function............................................................................................... 89
10.4 Calling the PLC Error Table for Diagnosis.................................................................... 91
10.5 Nonvolatile PLC Markers and Words .......................................................................... 93
10.6 Overviews ................................................................................................................... 95
10.7 Specifications ............................................................................................................ 106
10.7.1 PLC Inputs ....................................................................................................... 106
10.7.2 Analog Inputs ................................................................................................... 107
10.7.3 Inputs for Thermistors ..................................................................................... 107
10.7.4 PLC Outputs .................................................................................................... 108
11 Principle of Operation of the iTNC 530 Control ............................................................ 109
11.1 Introduction ............................................................................................................... 109
11.2 Block Diagrams with Short Explanations................................................................... 109
11.3 Basic Circuit Diagrams ........................................................................................... 116
11.4 Exchange Possibilities of the iTNC 530..................................................................... 118
12 Important Features of HEIDENHAIN Components ....................................................... 119
12.1 HEIDENHAIN Components in a Machine Tool.......................................................... 119
12.2 Hardware Identification ............................................................................................. 120
12.3 Display of System Information.................................................................................. 130
13 Connector Designation and Layout .............................................................................. 135
13.1 Important Note ......................................................................................................... 135
13.2 MC and CC................................................................................................................ 135
13.2.1 Designation and Position of Connectors ......................................................... 135
13.2.2 Pin Layouts on the MC and CC ....................................................................... 142
13.3 Power Supply Units................................................................................................... 173
13.3.1 UV 105 Power Supply Unit .............................................................................. 174
13.3.2 UV 105 B Power Supply Unit ........................................................................... 176
13.3.3 UV 106 (B) Power Supply Unit ......................................................................... 178
13.4 Inverters and Motors................................................................................................. 179
13.5 Interface boards for the SIMODRIVE system 611D.................................................. 179
13.6 Encoders ................................................................................................................... 180
13.6.1 Position encoders ............................................................................................ 180
13.6.2 Speed encoders ............................................................................................... 182
13.7 Touch Probe Systems ............................................................................................... 182
13.8 Handwheels .............................................................................................................. 183
13.8.1 HR 4xx Portable Handwheel ............................................................................ 183
13.8.2 HR 130 Panel-Mounted Handwheel ................................................................ 185
13.8.3 HRA 110 Handwheel Adapter ......................................................................... 185
13.9 PLC Input/Output Units ............................................................................................. 187
13.9.1 Designation and Position of Connectors ......................................................... 187
13.9.2 PL 4xxB Pin Layouts ........................................................................................ 190
13.9.3 Pin Layout PL 510 ............................................................................................ 195
13.10 Machine Operating Panel ...................................................................................... 199
HEIDENHAIN Service Manual iTNC 530
13.10.1 Designation and Position of Connectors on MB 420 ..................................... 199
13.10.2 Pin Layouts on MB 420 ................................................................................. 199
13.11 iTNC Keyboard......................................................................................................... 200
13.11.1 Designation and Position of Connectors ........................................................ 200
13.11.2 Pin layouts ..................................................................................................... 201
13.12 Visual Display Units ................................................................................................. 202
13.12.1 Designation and Position of Connectors ....................................................... 202
13.12.2 Pin layouts .................................................................................................... 203
13.13 BTS 1x0 Monitor/Keyboard Switch.......................................................................... 204
14 Power Supply................................................................................................................... 205
14.1 Power Supply for the iTNC 530................................................................................. 205
14.1.1 General ............................................................................................................ 205
14.1.2 UV 105, UV 105 B ............................................................................................ 210
14.1.3 UV 106, UV 106 B ............................................................................................ 214
14.2 Power Supply for Control-Is-Ready Signal................................................................. 216
14.3 Buffer Battery............................................................................................................ 217
14.4 Info menu .................................................................................................................. 220
14.5 Power Supply for the Display Units........................................................................... 221
14.6 Power Supply for PLC Outputs ................................................................................. 222
14.6.1 General ............................................................................................................ 222
14.6.2 Supply Voltage for PLC Outputs on the MC .................................................... 223
14.6.3 Supply Voltage for PLC Outputs on the PL 4xx B ............................................ 225
14.6.4 Supply Voltage for PLC Outputs on the PL 510 ............................................... 228
15 Hard Disk and File Manager of the iTNC 530................................................................. 231
15.1 Introduction ............................................................................................................... 231
15.2 Structure of the Hard Disk......................................................................................... 232
15.3 Hard Disk Test ......................................................................................................... 233
15.4 Setting the System Time........................................................................................... 237
15.5 File Management of TNC Partition (TNC:\) .............................................................. 239
15.6 File Management PLC Partition (PLC:\)..................................................................... 241
16 Data Backup ..................................................................................................................... 245
16.1 Introduction ............................................................................................................... 245
16.2 Connection Setup...................................................................................................... 247
16.2.1 Via Ethernet ..................................................................................................... 247
16.2.2 Via Serial Interface RS 232/V.24 or RS 422/V.11 ............................................. 256
16.3 Reading In and Out of Individual Files or Directories................................................. 258
16.4 Backup....................................................................................................................... 261
16.5 Extracting files from the backup file.......................................................................... 265
16.6 Restore...................................................................................................................... 266
16.7 Data Interface Operating Modes............................................................................... 269
16.7.1 Overview of operating modes ......................................................................... 269
16.7.2 Interface configuration and assignment of mode ............................................ 270
16.8 Drive Symbols ........................................................................................................... 271
16.9 Cable overview.......................................................................................................... 272
16.9.1 Ethernet Interface RJ45 Connection ............................................................... 272
16.9.2 RS-232-C/V.24 .................................................................................................. 273
16.9.3 RS-422/V.11 .................................................................................................... 278
17 Encoder Interface............................................................................................................. 279
17.1 Position encoders...................................................................................................... 279
17.1.1 Introduction ......................................................................................................279
17.1.2 Possible Causes of Error .................................................................................. 280
17.1.3 Service diagnosis ............................................................................................. 281
July 2002 HEIDENHAIN Service Manual iTNC 530
17.1.4 Additional Diagnosis Possibility on Encoders with EnDat Interface ................ 283
17.1.5 Corrective action .............................................................................................. 283
17.1.6 Re-Setting the Machine Datum ....................................................................... 284
17.2 Speed encoders ........................................................................................................ 286
17.2.1 Introduction .................................................................................................... 286
17.2.2 Possible Causes of Error ................................................................................. 287
17.2.3 Trouble Shooting on the CC 422 ..................................................................... 287
17.2.4 Trouble Shooting on CC the 422 ..................................................................... 289
17.2.5 Additional Diagnosis Possibility on Encoders with EnDat Interface ................ 292
17.2.6 Corrective action .............................................................................................. 292
17.2.7 Resetting the Spindle Orientation ................................................................... 293
17.3 Error Code for Encoders with EnDat Interface.......................................................... 294
17.4 Checking position and speed encoders..................................................................... 295
17.5 Position Measurement with the Motor Encoder ...................................................... 296
18 Referencing....................................................................................................................... 301
18.1 Definition................................................................................................................... 301
18.2 Traversing the Reference Marks............................................................................... 302
18.3 Deselect Referencing for Axes ................................................................................. 309
19 Checking the Enables on the iTNC................................................................................. 311
19.1 General ...................................................................................................................... 311
19.2 Examination............................................................................................................... 313
19.2.1 Examination of the output Control-is-ready (X41/pin34) and input Control-is-ready
signal acknowledgement I3 (X42/pin 4) .......................................................... 314
19.2.2 Checking the global drive enable I32, connector X42 / pin 33 ......................... 319
19.2.3 Checking the drive enabling for the axis groups via connector
X150 and X151 (if wired) ................................................................................ 321
19.2.4 Checking the readiness of the inverter system ............................................... 322
19.2.5 Überprüfung von PLC-Modulen, Merkern und WörternChecking PLC
modules, markers and words ......................................................................... 325
20 Interface to the Drives..................................................................................................... 327
20.1 Digital Drives ............................................................................................................. 327
20.1.1 Introduction ..................................................................................................... 327
20.1.2 Possible Causes of Errors ................................................................................ 328
20.1.3 Trouble Shooting: Exchanging PWM Outputs on the CC 422 ......................... 329
20.1.4 Trouble Shooting: Exchanging PWM Outputs on the CC 424 ......................... 333
20.1.5 Trouble Shooting: Exchanging Power Modules or Output Stages of the
Same Type ...................................................................................................... 337
20.1.6 Trouble Shooting: Exchanging the HEIDENHAIN Interface Boards for
the SIMODRIVE 611 System .......................................................................... 340
20.2 Analog Drives ............................................................................................................ 341
20.2.1 Introduction ..................................................................................................... 341
20.2.2 Possible Causes of Errors ................................................................................ 341
20.2.3 Testing the analog nominal speed value interface ......................................... 341
20.2.4 Adjusting the Electrical Offset (Drift Adjustment) ........................................... 346
20.2.5 Speed Adjustment at Servo Amplifier (Tachometer Adjustment) .................... 349
20.3 Switching the Position Display for Service Purposes................................................ 351
21 Visual Display Unit .......................................................................................................... 353
21.1 General ...................................................................................................................... 353
21.2 Possible Causes of Errors ......................................................................................... 353
21.3 Fault diagnosis........................................................................................................... 354
22 Keyboard Unit .................................................................................................................. 357
22.1 General ...................................................................................................................... 357
22.2 Front View of the Keyboard Units ............................................................................ 357
22.3 Possible Causes of Error ........................................................................................... 359
HEIDENHAIN Service Manual iTNC 530
22.4 Checking the Keys..................................................................................................... 360
22.5 Checking the Potentiometers.................................................................................... 364
22.6 Checking the Mouse Pad .......................................................................................... 366
22.7 Key Matrix of the Keyboard Units.............................................................................. 367
22.8 Key Matrix of the Keyboard Units.............................................................................. 382
23 Machine Operating Panel................................................................................................ 385
23.1 General ...................................................................................................................... 385
23.2 Checking the Power Supply ...................................................................................... 386
23.3 Checking the Keys..................................................................................................... 387
23.4 Checking the Outputs................................................................................................ 389
24 Handwheel........................................................................................................................ 391
24.1 General information................................................................................................... 391
24.2 HR 420 Portable Handwheel with Display................................................................. 393
24.2.1 Checking the Keys ........................................................................................... 393
24.2.2 Checking the Potentiometers .......................................................................... 393
24.3 HR 410 Portable Handwheel ..................................................................................... 396
24.3.1 Checking the Keys ........................................................................................... 396
24.4 HR 150 Panel-Mounted Handwheels with HRA 110 Handwheel Adapter ................ 398
24.4.1 Checking the Switch ........................................................................................ 398
25 Touch Probe ..................................................................................................................... 401
25.1 General information................................................................................................... 401
25.2 Touch Trigger Probe with Cable Connection for Workpiece Setup and
Measurement............................................................................................................. 403
25.3 Touch Trigger Probe with Infrared Transmission for Workpiece Setup
and Measuring........................................................................................................... 405
25.4 Triggering Touch Probe for Tool Measurement......................................................... 408
26 Exchange of HEIDENHAIN Components........................................................................ 411
26.1 Important Information................................................................................................ 411
26.2 Exchanging the MC 422 ............................................................................................ 418
26.3 Removing the Drive Assembly.................................................................................. 425
26.4 Exchanging the MC 422 B or the MC 420................................................................. 431
26.5 Exchanging the HDR ................................................................................................. 433
26.6 Exchanging the CC .................................................................................................... 441
26.7 Exchange of Further HEIDENHAIN Components...................................................... 442
27 Loading of Service Packs ................................................................................................ 443
27.1 Introduction ............................................................................................................... 443
27.2 Preparations and Execution up to NC Software 34049x-01
(Single and Dual-Processor Version)........................................................................... 444
27.3 Preparations and Execution as of NC Software 34049x-02
(Single-Processor Version).......................................................................................... 446
27.4 Preparations and Execution as of NC Software 34049x-02
(Dual-Processor Version) ............................................................................................ 449
27.5 Service Packs on the Control's Hard Disk ................................................................. 452
28 Activating the NC Software Used on the Machine....................................................... 453
28.1 Introduction ............................................................................................................... 453
28.2 Execution................................................................................................................... 453
29 Inspection, Measuring and Test Equipment.................................................................. 455
29.1 Important notes......................................................................................................... 455
29.2 Test Adapter, ID 375830-01 ...................................................................................... 456
29.3 Universal Measuring Adapter, ID 255480-01............................................................. 460
29.4 Encoder Diagnostic Set PWM 9, ID 512134-01 ....................................................... 461
29.5 Mounting Help PWT 10/17/18................................................................................... 463
29.6 IK 215 Adjustment and Testing Kit, ID 547858-01 ................................................... 464
July 2002 HEIDENHAIN Service Manual iTNC 530
30 Machine Parameters........................................................................................................ 465
30.1 What is a Machine Parameter? ................................................................................. 465
30.2 The Machine Parameter Editor.................................................................................. 465
30.3 Meaning of the Machine Parameters........................................................................ 473
30.4 List of Machine Parameters
(excerpt from the Technical Manual of iTNC 530 of November 2005) ....................... 474
30.4.1 Encoders and Machines .................................................................................. 474
30.4.2 Positioning ....................................................................................................... 480
30.4.3 Operation with velocity feedforward control ................................................... 484
30.4.4 Operation with following error (servo lag) ....................................................... 485
30.4.5 Integrated speed and current control .............................................................. 486
30.4.6 Spindle ............................................................................................................. 495
30.4.7 Integral PLC ..................................................................................................... 498
30.4.8 Configuration of the Data Interface ................................................................. 501
30.4.9 3-D touch probe ............................................................................................... 503
30.4.10 Tool Measurement with TT ........................................................................... 505
30.4.11 Tapping .......................................................................................................... 509
30.4.12 Display and Operation ................................................................................... 510
30.4.13 Color .............................................................................................................. 517
30.4.14 Machining and program run ........................................................................... 520
30.4.15 Hardware ....................................................................................................... 527
30.4.16 Second spindle .............................................................................................. 534
HEIDENHAIN Service Manual iTNC 530
1 Safety Precautions
DANGER
Ensure that the equipment grounding conductor is continuous!
Interruptions in the equipment grounding conductor may cause damage to persons or
property.
DANGER
Ensure that the main switch of the control and units are switched off when you engage or
disengage connecting elements or connection clamps.
Caution
In order to be able to judge the behavior of an NC controlled machine, you need to have
fundamental knowledge about controls, encoders, drives, electronics and mechanics.
Inappropriate use may cause considerable damage to persons or property.
DANGER
Incorrect or not optimized input values may lead to malfunction of the machine and may
thus cause damage to persons or property.
Machine parameters may only be changed by the machine manufacturer or after consulting
the machine manufacturer!
Caution
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 instruction).
Caution
HEIDENHAIN does not accept any responsibility for indirect or direct damage caused to
persons or property through incorrect use or operation of the machine!
DANGER
Technicians who work on the electricity of the machine must have the corresponding
technical knowledge and competence!
DANGER
Always secure vertical axes from falling down before you perform tests on these axes!
DANGER
The interfaces for the PLC inputs/outputs, machine operating panel and PL expansion cards
comply with the basic insulation in accordance with IEC 742 EN 50 178.
Only units that comply with the requirements of IEC 742 EN 50 178 for basic insulation may
be connected, otherwise damage to persons or property may be caused.
The maximum dc voltage mean value of the PLC inputs is 31 V.
May 2006 1 – 9
Meaning of the symbols used in this manual
DANGER
Failure to comply with this information could result in most serious up to fatal injuries or in
substantial material damage.
Caution
Failure to comply with this information could result in injuries and interruptions of operation
up to material damage.
Note
These boxes contain important and useful information for servicing.
1 – 10 HEIDENHAIN Service Manual iTNC 530
2 Using the Service Manual
2.1 About this Manual
This service manual will assist service personnel in the diagnosis and correction of errors on
TNC-controlled machine tools.
It includes:
Theoretical explanation of functions and their correlations
Details of possible error reasons
Descriptions of error diagnosis
Details of corrective action
The “Overview of Possible Errors” on page 26 often includes references to the descriptions of
error diagnosis. You will find these descriptions in the chapters of the Service Manual structured
according to topics.
The Service Manual does not provide commissioning support!
It comprises the service possibilities with the current hardware and software of the control at
the editing date of this manual. The service possibilities of your units may differ from the manual.
Hardware or software based differences in servicing are indicated in the corresponding
descriptions.
This manual is valid for:
iTNC 530 single-processor with NC software 340420 / 421
iTNC 530 single-processor with NC software 340422 / 423
iTNC 530 dual-processor with NC software 340480 / 481
iTNC 530 single-processor with NC software 340490 / 491
iTNC 530 dual-processor with NC software 340492 / 493
It must be provided that …
The machine had been working perfectly before the error ocurred.
Only genuine spare parts are used!
Note
Basic knowledge in Windows is required for some descriptions in this Service Manual
concerning the handling of the dual-processor control iTNC 530 and the use of a service
laptop or PC.
Udpate service This Service Manual is updated only at irregular intervals.
You find the current printable version on our website.
(http://www.heidenhain.de/Services/...)
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 telephoned request!
Loose-leaf binders or ring binders are only provided in connection with a service training course.
2.2 Further Service Manuals
Service Manual for Inverter Systems and Motors
May 2006 2 – 11
2.3 Other Documentation
In the following documents your find further important information:
Machine documentation of the machine manufacturer
(circuit diagrams, wiring diagrams, machine operation manual, etc.)
HEIDENHAIN User's Manual for iTNC 530
TNCguide (DVD)
Mounting instructions by HEIDENHAIN
Brochures of the corresponding HEIDENHAIN units
Note
Current HEIDENHAIN documentation can be obtained fast from our website.
--> www.heidenhain.de
2.4 Support
Caution
The machine manufacturer must be contacted for error diagnosis on your machine tool!
However, support will also be provided by the Service Department of HEIDENHAIN Traunreut
or by the nearest HEIDENHAIN agency.
You will find the necessary telephone and fax numbers, as well as relevant e-mail addresses, on
the back cover of the Service Manual, or on the HEIDENHAIN website at
http://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.
Note
If required, please inquire at the HEIDENHAIN subsidiary in your country whether Service
Training Seminars are offered in your language.
2.6 Safety
DANGER
It is extremely important to read also the general safety precautions in chapter 1!
See “Safety Precautions” on page 9.
2 – 12 HEIDENHAIN Service Manual iTNC 530
3 Code Numbers
3.1 Introduction
With code numbers …
Certain areas of the hard disk
Certain file types
Certain functions
... can be called.
DANGER
Code numbers may only be passed on and/or used by trained service technicians.
Inexpert handling may result in the loss of important data, in a faulty machine performance
and thus lead to damage or injury to property or persons.
3.2 Overview
Code number Brief Description
0 Delete the soft keys MP EDIT, PLC EDIT, OSCI, etc.
123 Edit subset of machine parameters for the machine operator
75368 Offset adjustment for analog axes, see page 1- 346
79513 Info menu (U[BATT], U[ACCU], U[VCC], TEMP, T[CPU1], see page 1- 220
95148 Call the active machine parameter list, see page 1- 468
531210 Reset non-volatile PLC markers and words in the RAM
688379 Integrated oscilloskop, see page 1- 49
807667 Call the PLC area, see page 1- 241
857282 Reset the operating times
LOGBOOK Call and save the internal log of the TNC, see page 1- 35
NET123 Network settings for the single-processor control, see page 1- 247
SIK Display of the number of the SIK system identification key and display of the
VERSION Create the file TNC:\Version.a
enabled options, see page 1- 414
System data is saved in this file for diagnostic purposes.
The file can be read out for diagnosis.
May 2006 3 – 13
3.3 Notes on Entering the Code Numbers
Keep the code numbers in confidence!
Code numbers can only be entered in the Programming and Editing mode.
The screen must be blank or the file editor is displayed.
The program manager must not be open (pressing the MOD key would activate the interface
settings screen).
Press MOD and enter the code number. Finish with ENTER.
Example of calling the active machine parameter list
Select the Programming and Editing operating mode.
Call window for code number
Enter and confirm code number
Note
The machine manufacturer can define own MP and PLC code numbers.
In this case the HEIDENHAIN code numbers do not function any longer.
--> Contact your machine manufacturer.
As long as the machine parameter list is in the editor no further code number can be entered.
I.e., first close the MP list when you want to enter a new code number
When certain code numbers are entered, new soft keys are displayed, e.g., MP EDIT, PLC
EDIT, OSCI.
With these soft keys you can also change to the corresponding areas without having to enter
the code number again.
After you have entered the code number for the machine parameters the PLC tree can be
seen in the program manager. Only files with the ending .MP are displayed.
3 – 14 HEIDENHAIN Service Manual iTNC 530
After you have entered the PLC code number, all files of the PLC tree can be seen and loaded
into the editor. However, to edit machine parameters, the soft key MP EDIT needs to be
pressed.
When you have finished your work do not forget to delete all code-number soft keys (MP
EDIT, PLC EDIT, OSCI, etc.) --> Enter code number 0, confirm with ENTER and exit the code-
number page with END or reboot the control.
May 2006 3 – 15
3 – 16 HEIDENHAIN Service Manual iTNC 530
4Error Messages
4.1 Introduction
iTNC 530 features a comprehensive integral monitoring system for the prevention of input or
operation errors, as well as for identification and diagnosis of technical errors on the control
and the connected units. The monitoring system is an integral component of the iTNC hardware
and software and is active as long as the control is switched on. The presence of a technical fault
or an operation error is made known through a plain-language message.
The machine manufacturer can also define specific PLC error messages.
Type of error message
PLC Error Messages
Machine-specific error messages
Are defined by the machine manufacturer (e.g., coolant pump defective, protective door open,
etc.)
The machine manufacturer defines how the control reacts to a PLC error message (NC stop,
EMERGENCY STOP, etc.).
The machine manufacturer defines whether the control can still be operated or has to be
rebooted after a PLC error message.
If you have any questions, please contact your machine manufacturer.
NC Error Messages
Are part of the HEIDENHAIN NC software
Can be subdivided in error messages that result from operation, programming and machine
applications and those that indicate a technical defect (units, electronical and mechanical
parts, etc.).
DSP error messages are special NC error messages. Such error messages are preceded by a
HEX code, e.g., "C300 track error". DSP errors may signalize defects in the CC 42x and/or connected units.
HEIDENHAIN defines how the control reacts to an NC error message (NC stop, EMERGENCY
STOP, etc.).
HEIDENHAIN defines whether the control can still be operated or has to be rebooted after an
NC error message.
If you have any questions, please contact your machine manufacturer and/or HEIDENHAIN.
Note
Is the displayed error message an NC or PLC error message?
If you cannot see this from the error text, press ERR --> See the Group column of the error
list in the newly displayed window. PLC errors are marked as such, NC errors are again
subdivided into subsections; See “ERR Key” on page 20.
A further possibility is to call the log. --> See “Log” on page 35. The NC error messages are
there distinguished by a N-, PLC error messages by a P-.
There are no error numbers assigned to NC error messages that begin with N-1 .
Operating System Error Messages
Often show the note CHILD PROCESS ERROR
The control cannot be operated any more and has to be rebooted.
If you have any questions, please contact your machine manufacturer and/or HEIDENHAIN.
May 2006 4 – 17
Display of error message
All error messages that can be acknowledged with the CE key are …
Displayed in the headline (upper edge of display; normally in red color).
Are made known through a plain-language message.
(before some error messages there is an additional HEX code. It is used for identification
purposes as so-called DSP error. These are errors in the control loop or errors that are
recognized by the control-loop software.)
The machine manufacturer can display additional information on PLC error messages in the
small PLC window (atop the soft-key row).
Error messages that require a rebooting of the control ...
Are displayed in a red window in the center of the screen.
Are made known through a plain-language message.
(before some error messages there is an additional HEX code. It is used for identification
purposes as so-called DSP error. These are errors in the control loop or errors that are
recognized by the control-loop software.)
Reaction of the control
4 – 18 HEIDENHAIN Service Manual iTNC 530
Display Only
The machine does not react. Programs are not stopped.
NC Stop
The axes decelerate at the nominal-value characteristics; normally the contour of the work-
piece is not damaged.
EMERGENCY STOP
Axes and spindle decelerate at the current limit; the machine should be stopped as fast as
possible. The contour of the workpiece is not regarded and may be damaged.
4.2 HELP Key
Display help texts for error messages
(if this key is pressed again, the window will be closed)
If the service technician presses the HELP key a window is shown that describes the cause
of error and possibilities of corrective action in addition to the displayed error message.
This support can also be realized for PLC error messages by the machine manufacturer!
Note
HELP texts cannot be displayed any more for error messages in red windows. The control
is not in operating condition any more. It must be rebooted.
Information on these errors can be found in the list of NC error messages;
See “List of NC Error Messages” on page 22.
May 2006 4 – 19
4.3 ERR Key
Display all pending error messages
(if this key is pressed again, the window will be closed)
If there is an AND symbol (little red roof) in the header in addition to the error message, there is
more than one pending error message.
The ERR key (ERROR) is located directly over the HELP key. If this key is pressed, an error list
appears. All pending NC and PLC error messages of the control are displayed in an own window.
In addition, the help window can be called with the HELP key.
Note
If there is no ERR key over the HELP key on your keyboard, press the corresponding space
bar over the HELP key. --> If the NC software of the iTNC 530 supports the function of the
ERR key, the ERR list can also be called!
4 – 20 HEIDENHAIN Service Manual iTNC 530
The ERR window is described below:
Column Description
Number Error number that was defined by HEIDENHAIN or the machine manufacturer
(-1: No error number defined)
Class Error class. Defines the reaction of the control:
ERROR
Program run is interrupted by the TNC (INTERNER STOP)
FEED HOLD
The feed rate enable is deleted
PGM HOLD
The program run is interrupted (control-in-operation symbol blinking)
PGM ABORT
The program run is aborted (INTERNER STOP)
EMERG. STOP
EMERGENCY STOP is generated
RESET
TNC executes a warm start
WARNING
Warning message, program run is continued
INFO
Info message, program run is continued
Group Error source.
GENERAL
General error
OPERATING
Error during machining and machine traverse
PROGRAMMING
Error during programming
PLC
PLC error message of the machine manufacturer
Error
Displayed error text
message
4.4 CE Key
The individual error messages can be selected with the cursor; the open help window shows
the appertaining text.
Delete the error message
Displayed error messages can be acknowledged with the CE key.
If the error cause is still existing, the corresponding error message is displayed again.
--> Eliminate the error!
Note
Messages regarding very fatal errors, cannot be confirmed with the CE key.
The control must be rebooted.--> Press the END key.
If this does not function ... --> Switch the power switch of the machine off and on again.
May 2006 4 – 21
4.5 List of NC Error Messages
You can find the complete list of NC error messages (incl. operation errors) on the DVD
TNCguide in several languages and sorted by error numbers. These TNCguide information
can also be found on our website http://www.heidenhain.de/Services/...
Note
Where 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.
Note:
In the next version of this Service Manual the list of NC error messages will be filtered for error
messages that indicate a technical defect.
Information and links to suitable routines for error diagnosis will be included!
4 – 22 HEIDENHAIN Service Manual iTNC 530
5Errors
5.1 Introduction
Not all error conditions on the control or machine can be shown by error messages on the
monitor.
Therefore, this chapter gives you an overview of errors with notes and tips how to proceed.
What is the cause of the error?
Static and nonstatic errors
Sporadic and nonsporadic errors
Ask the last operator or technician who has worked with or on the machine about the course
of events.
Have there been any particular incidences, such as …
Cleaning of the machine (humidity, etc.)
Thunderstorms
Modifications to the machine
NC software update
New machining program
Tool breakage
Collision
Power failure
Etc.
The error diagnosis will be easier for you by pointed questions and precise answers!
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, the error location of static errors is easier.
Check whether you can reproduce a certain error on the machine at any time (nonsporadic error).
This assists you in trouble shooting.
The integrated log or the PLC logic diagram are some possibilities to investigate sporadic errors.
5.2 Notes and Tips
Comparison with functioning machines
Connectors and females
If a dimensionally identical or similar machine is available, the functionality of this machine can
be compared with the defective machine.
This can be very helpful for trouble shooting!
Observe the following during connecting and disconnecting:
D-Sub Connectors or Females
Connect and disconnect straightly! Otherwise, the spring contact in the D-sub connectors
Ribbon Connectors or Females
Connect carefully and straightly with constant pressure to prevent a deflection of the males.
Signal Socket at the Motor
Slide the nib of the connector into the notch of the signal socket and screw the connector
could be widened. This may result in contact problems!
straightly. Do not use force! Otherwise the males could be bent or even pressed into the
socket.
May 2006 5 – 23
Low voltages All units connected to the control are also supplied by the control (encoders with long
cables are maybe provided with voltage amplifiers). It is thus possible that defective connected
units or also damaged cables have an influence on the low voltages in the control and generate
a variety of error messages.
Only the newer control hardware is equipped with the so-called polyfuses. These are electronic
fuses that separate defective peripheral units from the low voltages in the control in case of an
error. Polyfuses are equipped with a self-resetting function ("self-healing effect")
Always disconnect suspicious units from the control for error diagnosis!
If necessary, deactivate these units or the axis concerned in the machine parameter list.
Note
It is not sufficient to deactivate a suspicious axis with machine parameter MP10 (without
disconnecting suspicious units).
The corresponding units (e.g., position encoder for this axis) are not monitored any more but
are still supplied with power. The defective scale can thus influence the low voltages of the
control, for example!
Note
If you are not in a position/allowed to activate the axes with MP10, MP subfiles might be
active and/or this is not permitted by the PLC program. --> Ask the machine manufacturer!
Switch on the control and check whether errors still occur.
Shielding and grounding
Caution
For trouble shooting do not connect obviously defective controls (e.g., position encoder
with short circuit after entering of humidity) to other input connectors (z.B. X1-X6,
X35-X38) of the control.
Defective cables may result in interruptions but also in undefined conditions and direct
error messages. Therefore, especially check possible worn and squeezed positions of
the cables.
Also defective shieldings and groundings can result in undefined errors or in a malfunction
of the machine (e.g., vibration of axes, poor surface of the workpiece). The reason are
compensating currents that are caused by potential differences.
Therefore, check the terminals, shielded cables (the shielding braid must not contact the 0 V
conductor inside the cable), cover plates, grounding bars, contact plates, etc.
Caution
If HEIDENHAIN expansion boards for the SIMODRIVE system are used, please check the
mandatory grounding.
--> See “Important Notes on the Use of HEIDENHAIN Interface Boards in SIMODRIVE
System” on page 29.
5 – 24 HEIDENHAIN Service Manual iTNC 530
Sources of interference
Also observe likely sources of interference that may have a negative effect on the connected
units.
Noise is mainly produced by capacitive and inductive coupling from electrical conductors or from
device inputs/outputs, such as ...
Strong magnetic fields from transformers or electric motors
Relays, contactors and solenoid valves
High-frequency equipment, pulse equipment and stray magnetic fields from switch-mode
power supplies
Power lines and leads to the above equipment
Make sure that …
There is a minimum distance of 20 cm from the MC 42x(B), CC 42x and its leads to interfering
equipment.
There is a minimum distance of 10 cm from the MC 42x(B), CC 42x and its leads to cables that
carry interference signals. For cables in metallic ducting, adequate decoupling can be achieved
by using a grounded separation shield.
The cross section of potential compensating lines is min. 6 mm2.
Contact the machine manufacturer if these conditions are not fulfilled!
Caution
Only use original HEIDENHAIN cables, connectors and couplings as replacement!
Contamination Pay special attention to contaminated units (oil, grease, dust, etc.)!
What could be the reason for the contamination?
Some examples:
Machining of graphite
Coolant or coolant vapor
Defective filter system in the electrical cabinet (filter pads)
Oil or oil vapor
Oil in the compressed-air system
Humidity Check whether humidity has entered the units!
What could be the reason?
Some examples:
Defective climate control unit in the electrical cabinet
Coolant or coolant vapor
Condensation of boards due to differences in temperature
Defective tubes, sealings, etc.
Shipping brace of the hard disk
Check whether the shipping brace of the hard disk of the mounted control has
been removed.
May 2006 5 – 25
5.3 Overview of Possible Errors
This table shows an overview of specific errors on the machine or control, possible causes of
the errors as well as measures for correcting these errors.
The potential measures for correcting the errors are described in more detail in the
corresponding chapters.
Note
Where it is possible and makes sense, you may switch the control off and on again to
observe whether the error is generated again afterwards.
Error Possible Cause of Error Measures for Error Diagnosis and/
or Corrective action
The iTNC monitor remains dark after the
machine has been switched on.
The control does not boot completely (error
messages regarding the boot process are
sometimes displayed).
The message "RELAY EXTERNAL DC
VOLTAGE MISSING" does not disappear
although the key "Control voltage ON" is
pressed.
When the machine is switched on, the error
message "EMERGENCY STOP defective"
During switch-on or operation DSP errors
are generated. A mechanical reason or a
defective unit can be ruled out.
The "Power interrupted" message cannot
be confirmed or the login password cannot
be entered in a dual-processor control.
The machine cannot be referenced after
switch-on or the axes cannot be moved
during operation or the spindle cannot be
switched on during operation.
The machine is in the mode "Cross over
reference points" which is neither possible
with the NC-START key nor with the axis
direction keys.
During reference run, the machine moves
to the limit switch.
During reference run, the machine moves
to the mechanical stop (for machines
without limit stop).
An error message is sometimes displayed,
e.g. "8640 I2T value of motor is too high ..."
iTNC monitor defective
Power supply to monitor
defective
Power supply of the MC
defective
Defective unit connected to the
control (short circuit, etc.)
Hard disk defective Exchange MC or HDR or drive
EMERGENCY STOP chain
interrupted
24 V power supply (connector)
X34 missing
MC defective
Wiring defective, contactors
defective or too slow
MC defective
Data loss on the hard disk in the
range of the SYS partition.
The key gets caught See “Keyboard Unit” on page 357
Interruption between the
NC-stop key and control (the
NC-stop signal is lowactive)
Inverter system is not ready
for operation
The trip dogs for the reversal
of direction during reference run
are defective
The machine was switched off
at the wrong position
Check the visual display unit;
See “Visual Display Unit” on
page 353
Check power supply of the MC;
See “Power Supply” on page 205
Disconnect defective or suspicious
units or cables, See “Low voltages” on page 24
assembly; See “Exchange of
HEIDENHAIN Components” on
page 411
Check output "Control is ready" and
acknowledgement I3; See
“Checking the Enables on the
iTNC” on page 311
Check the related components;
See “Error message EMERGENCY
STOP DEFECTIVE” on page 317
Check the hard disk; See “Hard
Disk Test” on page 233
Activate the NC software again;
See “Activating the NC Software
Used on the Machine” on page 453
Eliminate the interruption, repair
the key, etc.
See “Machine Operating Panel” on
page 385
See “Checking the Readiness of
the Inverter System” on page 322
See “Referencing” on page 301
Referencing with axis-direction
keys (no automatic reference mark
traverse)!
5 – 26 HEIDENHAIN Service Manual iTNC 530
Error Possible Cause of Error Measures for Error Diagnosis and/
or Corrective action
iTNC monitor 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.
STIB ("Control-in-operation = "*" in status
display) remains in place even though
positioning appears to be completed.
The next NC block is not executed in the
automatic operating modes , the NC
program gets caught.
"Vibrating" axes, sometimes connected
with loud noises.
Servo lag is too high at standstill Electrical offset of analog axes Carry out offset adjustment;
Error messages regarding encoders or
other connected units are generated
although you find out that these do not
cause the errors!
Various error messages are generated but
are not substantiated.
NC functions do not function any more
(There might be an information by the
control that the corresponding files have
been deleted).
Bucking of the analog axis Carbon brushes for power
The axes cannot be traversed and the red
LEDs SH2 of all HEIDENHAIN drive
modules light up (or the red LEDs SH2 or
RESET of the HEIDENHAIN interface cards
for the SIMODRIVE system)
There are repeated hard disk errors Defects on the hard disk
Power failure
Failure of one or several phases
in the supply line
The power supply voltage has
fallen below the minimum value
Interruption in the electrical
cabinet
Inverter (power supply module)
defective
Short circuit of drives (drive
modules, motors)
Axis did not reach the posi-
tioning window
Excessive drift of analog axes
Approach behavior of axis not
optimized
Poor shielding or grounding
Connectors on grounding termi-
nal X131 of infeed/regenerative
module (Simodrive 611D) not
properly wired
Grounding terminal X131 of
power supply module
(Simodrive 611D) or grounding
connection damaged
Probe or handwheel that were
exposed to humidity (coolant,
etc.) or have been damaged.
--> Supply voltages (5 V, 12 V,
15 V) are impaired. A variety of
error messages are possible.
Connection (short circuit) of
shielding potential (chassis,
cable shielding) with 0 V voltage
potential of the NC power
supply
Data loss on the hard disk in the
range of the SYS partition
supply or tachometer measuring that have been abrided on
one side or used up
Drive release missing See “Checking the Enables on the
Defective unit connected to the
control (short circuit, etc.)
Check the primary supply (cables,
fuses, terminals);
See “Power Supply” on page 205
Check the wiring of the inverter
system, see circuit diagrams of the
machine manufacturer
Check the functioning of the
inverter system or the motor (see
Service Manual for Inverter
Systems and Motors)
Carry out drift adjustment;
See “Interface to the Drives” on
page 327
Re-optimization or new
optimization of the axis by the
machine manufacturer
Check the grounding of your
machine, refer to the machine
manufacturer
Ensure the grounding clamps are
secure
Check the shielding or the covers
See “Adjusting the Electrical Offset
(Drift Adjustment)” on page 346
Disconnect the probe and
handwheel including the cables.
Screw the dummy plug
(ID 271958-03) instead of the handwheel or bridge the handwheel in
the EMERGENCY STOP chain.
Deactivate the handwheel in
MP7640. Check whether the
error messages are still generated.
Check the cables for damage.
Check the machine for correct
shielding (ask the machine manufacturer).
Check the hard disk;
See “Hard Disk Test” on page 233
Activate the NC software again;
See “Activating the NC Software
Used on the Machine” on page 453
Exchange the carbon brushes
iTNC” on page 311
Check the hard disk; See “Hard
Disk Test” on page 233
Disconnect suspicious units;
See “Notes and Tips” on page 23
May 2006 5 – 27
Error Possible Cause of Error Measures for Error Diagnosis and/
or Corrective action
During processing the motors run (axes,
spindle) down out of loop.
An axis is to be traversed and an error
message is displayed, e.g. "8640 I2T value
of motor is too high ..."
(or a similar error message that indicates an
excessive load of the drive)
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)
Brake not released Check whether the brake is
Check the primary supply (cables,
fuses, terminals);
See “Power Supply” on page 205
Check the functioning of the
inverter system or the braking
resistor;
See Service Manual for Inverter
Systems and Motors
Check the wiring of the inverter
system, see circuit diagrams of the
machine manufacturer
released
Check the wiring of the motor
system;
See circuit diagrams of the
machine manufacturer
Some HEIDENHAIN inverters can
control the motor brakes;
See Service Manual for Inverter
Systems and Motors
5 – 28 HEIDENHAIN Service Manual iTNC 530
5.4 Important Notes on the Use of HEIDENHAIN Interface Boards in SIMODRIVE System
Version with D-Sub connector
HEIDENHAIN interface 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.
Interface 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.
Caution
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!
Note
The HEIDENHAIN interface boards of the first generation were built without metallic
insulation.
May 2006 5 – 29
Interface boards with metallic insulation are
distinguished 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 no transformer on the front panel.
These boards have the ID 324952-10 with index
A, 11, 12, ...
Transformer component on the board
Grounding screw on the front panel
5 – 30 HEIDENHAIN Service Manual iTNC 530
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