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
	9.3.8 I2t Monitoring .......................................................................................................	66

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

2.1About 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.

2.2Further Service Manuals

Service Manual for Inverter Systems and Motors

May 2006

2 – 11

2.3Other 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

2.4Support

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.

2.5Service 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.

2.6Safety

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

3.1Introduction

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.

3.2Overview

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
	enabled options, see page 1- 414
VERSION	Create the file TNC:\Version.a
	System data is saved in this file for diagnostic purposes.
	The file can be read out for diagnosis.

May 2006

3 – 13

3.3Notes 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	Select the Programming and Editing operating mode.
the active machine
parameter list	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 codenumber page with END or reboot the control.

May 2006

3 – 15

3 – 16

HEIDENHAIN Service Manual iTNC 530

4 Error Messages

4.1Introduction

Type of error message

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.

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

Reaction of the control

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.)

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 workpiece 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 – 18

HEIDENHAIN Service Manual iTNC 530

4.2HELP 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

4.3ERR 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

The individual error messages can be selected with the cursor; the open help window shows the appertaining text.

4.4CE Key

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

4.5List 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

5 Errors

5.1Introduction

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 Ask the last operator or technician who has worked with or on the machine about the course the error? 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!

Static and nonstatic	Errors can also be defined in the categories of static errors (e.g., interruption in the electrical
errors	cabinet, defective unit) and nonstatic errors (e.g., loose connection, shielding problems,
	interferences).
	Naturally, the error location of static errors is easier.
Sporadic and	Check whether you can reproduce a certain error on the machine at any time (nonsporadic error).
nonsporadic	This assists you in trouble shooting.
errors	The integrated log or the PLC logic diagram are some possibilities to investigate sporadic errors.

5.2Notes and Tips

Comparison with	If a dimensionally identical or similar machine is available, the functionality of this machine can
functioning	be compared with the defective machine.
machines	This can be very helpful for trouble shooting!

Connectors and Observe the following during connecting and disconnecting:

females

D-Sub Connectors or Females

Connect and disconnect straightly! Otherwise, the spring contact in the D-sub connectors could be widened. This may result in contact problems!

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 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.

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.

Shielding and	Also defective shieldings and groundings can result in undefined errors or in a malfunction
grounding	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	Also observe likely sources of interference that may have a negative effect on the connected
interference	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		Check whether the shipping brace of the hard disk of the mounted control has
the hard disk		been removed.

May 2006

5 – 25

5.3Overview 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	iTNC monitor defective	Check the visual display unit;
machine has been switched on.	Power supply to monitor	See “Visual Display Unit” on
	defective	page 353
		Check power supply of the MC;
	Power supply of the MC
		See “Power Supply” on page 205
	defective
		Disconnect defective or suspicious
	Defective unit connected to the
	control (short circuit, etc.)	units or cables, See “Low volta-
		ges” on page 24
The control does not boot completely (error	Hard disk defective	Exchange MC or HDR or drive
messages regarding the boot process are		assembly; See “Exchange of
sometimes displayed).		HEIDENHAIN Components” on
		page 411
The message "RELAY EXTERNAL DC	EMERGENCY STOP chain	Check output "Control is ready" and
VOLTAGE MISSING" does not disappear	interrupted	acknowledgement I3; See
although the key "Control voltage ON" is	24 V power supply (connector)	“Checking the Enables on the
pressed.	X34 missing	iTNC” on page 311
	MC defective
When the machine is switched on, the error	Wiring defective, contactors	Check the related components;
message "EMERGENCY STOP defective"	defective or too slow	See “Error message EMERGENCY
	MC defective	STOP DEFECTIVE” on page 317
During switch-on or operation DSP errors	Data loss on the hard disk in the	Check the hard disk; See “Hard
are generated. A mechanical reason or a	range of the SYS partition.	Disk Test” on page 233
defective unit can be ruled out.		Activate the NC software again;
		See “Activating the NC Software
		Used on the Machine” on page 453
The "Power interrupted" message cannot	The key gets caught	See “Keyboard Unit” on page 357
be confirmed or the login password cannot
be entered in a dual-processor control.
The machine cannot be referenced after	Interruption between the	Eliminate the interruption, repair
switch-on or the axes cannot be moved	NC-stop key and control (the	the key, etc.
during operation or the spindle cannot be	NC-stop signal is lowactive)	See “Machine Operating Panel” on
switched on during operation.		page 385
The machine is in the mode "Cross over	Inverter system is not ready	See “Checking the Readiness of
reference points" which is neither possible	for operation	the Inverter System” on page 322
with the NC-START key nor with the axis
direction keys.
During reference run, the machine moves	The trip dogs for the reversal	See “Referencing” on page 301
to the limit switch.	of direction during reference run
	are defective
During reference run, the machine moves	The machine was switched off	Referencing with axis-direction
to the mechanical stop (for machines	at the wrong position	keys (no automatic reference mark
without limit stop).		traverse)!
An error message is sometimes displayed,
e.g. "8640 I2T value of motor is too high ..."

5 – 26

HEIDENHAIN Service Manual iTNC 530

	Error	Possible Cause of Error	Measures for Error Diagnosis and/
			or Corrective action
	iTNC monitor is frozen.	Power failure	Check the primary supply (cables,
	The control has locked up.	Failure of one or several phases	fuses, terminals);
	The main switch has to be switched off and	in the supply line	See “Power Supply” on page 205
	on again.	The power supply voltage has	Check the wiring of the inverter
	After reset of the control"Power fail	fallen below the minimum value	system, see circuit diagrams of the
	Interrupt!" is entered in the log of new	Interruption in the electrical	machine manufacturer
	software versions.		Check the functioning of the
		cabinet
			inverter system or the motor (see
		Inverter (power supply module)
			Service Manual for Inverter
		defective
			Systems and Motors)
		Short circuit of drives (drive
		modules, motors)
	STIB ("Control-in-operation = "*" in status	Axis did not reach the posi-	Carry out drift adjustment;
	display) remains in place even though	tioning window	See “Interface to the Drives” on
	positioning appears to be completed.	Excessive drift of analog axes	page 327
	The next NC block is not executed in the	Approach behavior of axis not	Re-optimization or new
	automatic operating modes , the NC	optimized	optimization of the axis by the
	program gets caught.		machine manufacturer
	"Vibrating" axes, sometimes connected	Poor shielding or grounding	Check the grounding of your
	with loud noises.	Connectors on grounding termi-	machine, refer to the machine
		nal X131 of infeed/regenerative	manufacturer
		module (Simodrive 611D) not	Ensure the grounding clamps are
		properly wired	secure
		Grounding terminal X131 of	Check the shielding or the covers
		power supply module
		(Simodrive 611D) or grounding
		connection damaged
	Servo lag is too high at standstill	Electrical offset of analog axes	Carry out offset adjustment;
			See “Adjusting the Electrical Offset
			(Drift Adjustment)” on page 346
	Error messages regarding encoders or	Probe or handwheel that were	Disconnect the probe and
	other connected units are generated	exposed to humidity (coolant,	handwheel including the cables.
	although you find out that these do not	etc.) or have been damaged.	Screw the dummy plug
	cause the errors!	--> Supply voltages (5 V, 12 V,	(ID 271958-03) instead of the hand-
		15 V) are impaired. A variety of	wheel or bridge the handwheel in
		error messages are possible.	the EMERGENCY STOP chain.
			Deactivate the handwheel in
			MP7640. Check whether the
			error messages are still generated.
	Various error messages are generated but	Connection (short circuit) of	Check the cables for damage.
	are not substantiated.	shielding potential (chassis,	Check the machine for correct
		cable shielding) with 0 V voltage	shielding (ask the machine manu-
		potential of the NC power	facturer).
		supply
	NC functions do not function any more	Data loss on the hard disk in the	Check the hard disk;
	(There might be an information by the	range of the SYS partition	See “Hard Disk Test” on page 233
	control that the corresponding files have		Activate the NC software again;
	been deleted).		See “Activating the NC Software
			Used on the Machine” on page 453
	Bucking of the analog axis	Carbon brushes for power	Exchange the carbon brushes
		supply or tachometer measu-
		ring that have been abrided on
		one side or used up
	The axes cannot be traversed and the red	Drive release missing	See “Checking the Enables on the
	LEDs SH2 of all HEIDENHAIN drive		iTNC” on page 311
	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	Check the hard disk; See “Hard
		Defective unit connected to the	Disk Test” on page 233
		control (short circuit, etc.)	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,	Defective braking resistor	Check the primary supply (cables,
spindle) down out of loop.	(conversion of electrical energy	fuses, terminals);
	to heat energy not possible)	See “Power Supply” on page 205
	Defective infeed/regenerative	Check the functioning of the
	feedback module (energy	inverter system or the braking
	recovery not possible)	resistor;
	Interruption in the primary	See Service Manual for Inverter
		Systems and Motors
	supply (fuses, wires, etc.;
		Check the wiring of the inverter
	energy recovery not possible)
		system, see circuit diagrams of the
		machine manufacturer
An axis is to be traversed and an error	Brake not released	Check whether the brake is
message is displayed, e.g. "8640 I2T value		released
of motor is too high ..."		Check the wiring of the motor
(or a similar error message that indicates an		system;
excessive load of the drive)		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

5.4Important Notes on the Use of HEIDENHAIN Interface Boards in SIMODRIVE System

Version with	HEIDENHAIN interface boards for the SIMODRIVE system in the version with D-Sub connector
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