HEIDENHAIN iTNC 530 Service Manual
Service Manual
iTNC 530
July 2010
1 How to Use this Service Manual........................................................................................ 11
1.1 Target Group.................................................................................................................. 11
1.2 About this Manual ......................................................................................................... 11
1.3 Other Service Manuals.................................................................................................. 12
1.4 Other Documentation.................................................................................................... 12
1.5 Support.......................................................................................................................... 12
1.6 Service Training ............................................................................................................. 12
1.7 Meaning of the Symbols Used in this Manual............................................................... 13
1.8 Safety ............................................................................................................................ 13
2 Safety Precautions............................................................................................................... 15
2.1 Overview ....................................................................................................................... 15
3 Code Numbers ..................................................................................................................... 17
3.1 Introduction ................................................................................................................... 17
3.2 Overview ....................................................................................................................... 17
3.3 Input of Code Numbers ................................................................................................ 18
4 Error Messages .................................................................................................................... 21
4.1 Introduction ................................................................................................................... 21
4.2 HELP Key....................................................................................................................... 25
4.3 ERR Key ........................................................................................................................ 26
4.4 CE Key .......................................................................................................................... 28
4.5 List of NC Error Messages ............................................................................................ 29
5 Errors Patterns ..................................................................................................................... 55
5.1 Introduction ................................................................................................................... 55
5.2 Overview of Possible Error Patterns ............................................................................. 55
6 Procedures and Tips for Error Diagnosis........................................................................... 59
6.1 Introduction ................................................................................................................... 59
6.2 Power Off and On ......................................................................................................... 59
6.3 Sequence for Finding Serious Electrical Errors.............................................................. 60
6.4 Sequence for Finding Errors in the Control Loop .......................................................... 62
6.5 Error Localization by Process of Interchange ................................................................ 65
6.6 Error Localization by Process of Exclusion .................................................................... 66
6.7 Finding Position Differences of Direct and Indirect Encoder......................................... 68
6.8 Error Localization by Switching from Direct to Indirect Position Measurement............ 70
6.9 Notes and Tips............................................................................................................... 72
7 Creating and Downloading of Service Files ...................................................................... 77
7.1 Introduction ................................................................................................................... 77
7.2 Automatic Generation of Service Files .......................................................................... 78
7.3 Automatic Generation of Service Files .......................................................................... 78
7.4 Downloading of Service Files ........................................................................................ 79
8 Log......................................................................................................................................... 81
8.1 Introduction ................................................................................................................... 81
8.2 Calling the Log............................................................................................................... 82
verview of Log En
8.3 O
8.4 Log Entries at Program Cancelation .............................................................................. 87
9 Integrated Diagnostic Functions and DriveDiag ............................................................... 89
9.1 Introduction ................................................................................................................... 89
9.2 Activation and Operation ............................................................................................... 90
9.3 For Error Diagnosis........................................................................................................ 98
10 Integrated Oscilloscope..................................................................................................... 99
10.1 Introduction ................................................................................................................. 99
10.2 Activation and Settings.............................................................................................. 100
10.3 Recording and Adjusting the Signals......................................................................... 105
10.4 Saving and Loading Recordings................................................................................. 110
tries................................................................................................ 83
July 2010 HEIDENHAIN Service Manual iTNC 530
10.5 For Error Diagnosis.................................................................................................... 111
10.5.1 Triggering on error marker ............................................................................... 111
10.5.2 Circular interpolation test ................................................................................. 113
10.5.3 Descriptions in this manual ............................................................................. 114
11 PLC Diagnosis................................................................................................................... 115
11.1 Introduction ............................................................................................................... 115
11.2 Possible Causes of Errors ......................................................................................... 118
11.3 Diagnosis Tools in the PLC Mode ............................................................................. 119
11.3.1 The TABLE function ......................................................................................... 119
11.3.2 The LOGIC diagram ......................................................................................... 125
11.3.3 The TRACE function ....................................................................................... 128
11.3.4 The WATCH LIST function .............................................................................. 129
11.3.5 The I / O - FORCE LIST .................................................................................... 131
11.3.6 PROFIBUS diagnosis ....................................................................................... 133
11.4 Non-Volatile PLC Markers and Words ....................................................................... 136
11.5 Overviews ................................................................................................................. 138
11.6 Specifications ............................................................................................................ 147
11.6.1 PLC inputs ....................................................................................................... 147
11.6.2 Analog inputs ................................................................................................... 148
11.6.3 Inputs for thermistors ...................................................................................... 148
11.6.4 PLC outputs ..................................................................................................... 149
12 Hard Disk and File Manager of the iTNC 530 ................................................................ 151
12.1 Introduction ............................................................................................................... 151
12.2 Structure of the Hard Disk......................................................................................... 152
12.3 Possible Causes of Error ........................................................................................... 152
12.4 Test of Hard Disk ..................................................................................................... 153
12.5 Setting the System Time........................................................................................... 159
12.6 Setting the Program Manager .................................................................................. 162
12.7 File Management of TNC Partition ........................................................................... 163
12.8 File Management of PLC Partition ............................................................................ 165
13 Data Backup ..................................................................................................................... 169
13.1 Introduction ............................................................................................................... 169
13.2 Connection Setup...................................................................................................... 172
13.2.1 Via Ethernet ..................................................................................................... 172
13.2.2 Via serial interface RS-232-C or RS-422 ........................................................... 182
13.2.3 Via USB ............................................................................................................ 185
13.3 Reading In and Out of Individual Files or Directories ................................................ 186
13.4 Backup on an External Data Medium........................................................................ 192
13.5 Extracting Files from the Backup File........................................................................ 196
13.6 Restoring Data........................................................................................................... 197
13.7 Cable Overview ......................................................................................................... 200
13.7.1 Ethernet interface RJ45 connection ................................................................ 200
13.7.2 RS-232-C (V.24) ............................................................................................... 201
13.7.3 RS-422 (V.11) .................................................................................................. 204
13.8 Operating Modes of the Data Interfaces................................................................... 205
13.8.1 Overview of operating modes ......................................................................... 205
13.8.2 Interface configuration and assignment of
13.9 Drive Symbols
14 Reloading the NC Software Used .................................................................................. 209
14.1 Introduction ............................................................................................................... 209
14.2 Preparations .............................................................................................................. 209
14.3 Proceeding up to NC Software 34049x-02 (Single-Processor Version) ..................... 210
14.4 Proceeding as of NC Software 34049x-02 (Single-Processor Version)...................... 212
14.5 Proceeding for the Dual-Processor Version............................................................... 215
........................................................................................................... 207
mode ............................................ 206
HEIDENHAIN Service Manual iTNC 530
15 Loading of Service Packs ................................................................................................ 219
15.1 Introduction ............................................................................................................... 219
15.2 Preparations............................................................................................................... 220
15.3 Execution up to NC Software 34049x-01 (Single and Dual Processor Version) ........ 221
15.4 Execution as of NC Software 34049x-02 (Single-Processor Version)........................ 223
15.5 Execution as of NC Software 34049x-02 (Dual-Processor Version) .......................... 226
16 Checking the Enables on the iTNC 530.......................................................................... 229
16.1 Introduction ............................................................................................................... 229
16.2 Examination............................................................................................................... 232
16.2.1 Checking the "Control is ready" output and input
(EMERGENCY STOP chain) ....................................................................................... 233
16.2.2 Checking the global drive enable I32, connector X42 / pin 33 ......................... 239
16.2.3 Checking the drive enabling for the axis groups via connector
X150 and X151 (if wired) ............................................................................................ 242
16.2.4 Checking the readiness of the inverter system ............................................... 243
16.2.5 Checking PLC modules, markers and words ................................................... 248
17 Power Supply ................................................................................................................... 251
17.1 Power Supply for the iTNC 530 ................................................................................. 251
17.1.1 Introduction ...................................................................................................... 251
17.1.2 UV 105, UV 105 B ............................................................................................ 256
17.1.3 UV 106, UV 106 B ............................................................................................ 260
17.2 Power Supply for "Control-Is-Ready Signal"............................................................... 262
17.3 Buffer Battery............................................................................................................ 264
17.4 Information Menu...................................................................................................... 267
17.5 Power Supply for PLC Outputs ................................................................................. 268
17.5.1 Introduction ...................................................................................................... 268
17.5.2 Supply voltage for PLC outputs on the MC ..................................................... 269
17.5.3 Supply voltage for PLC outputs on the PL 4xx B ............................................. 272
17.5.4 Supply voltage for PLC outputs on the PL 510 ................................................ 274
17.6 Power Supply for the Display Units........................................................................... 276
18 Encoder Interface ............................................................................................................. 277
18.1 Position Encoders...................................................................................................... 277
18.1.1 Introduction ...................................................................................................... 277
18.1.2 Possible causes of errors ................................................................................. 279
18.1.3 Troubleshooting ............................................................................................... 280
18.1.4 Possibilities with the integrated diagnosis or DriveDiag .................................. 282
18.1.5 Possibilities with the integrated oscilloscope .................................................. 283
18.1.6 Corrective action .............................................................................................. 286
18.1.7 Determining the field angle on linear motors, torque motors and
synchronous spindles ................................................................................................ 287
18.1.8 Resetting the machine datum ......................................................................... 288
18.1.9 Restoring the spindle orientation ..................................................................... 292
18.2 Speed Encoders ........................................................................................................ 293
18.2.1 Introduction ...
18.2.2 Possible causes of errors ................................................................................. 295
18.2.3 Trouble shooting on the CC 422 ...................................................................... 296
18.2.4 Trouble shooting on the CC 424 (B) ................................................................. 298
18.2.5 Possibilities with the integrated diagnosis or DriveDiag .................................. 300
18.2.6 Possibilities with the integrated oscilloscope .................................................. 301
18.2.7 Corrective action .............................................................................................. 304
18.2.8 Readjusting the trip dog for reference end position ........................................ 305
18.2.9 Resetting the machine datum ......................................................................... 306
18.2.10 Restoring the spindle orientation ................................................................... 306
18.3 Error Codes for Encoders with EnDat Interface ........................................................ 307
18.4 Further Examination of Position and Speed Encoders .............................................. 308
..............
.................................................................................... 293
July 2010 HEIDENHAIN Service Manual iTNC 530
18.5 Position Measurement via Motor Encoder (Indirect Position Measurement) ........... 311
18.6 Switching over the Position Display for Servicing ..................................................... 315
19 Reference Run .................................................................................................................. 317
19.1 Definition................................................................................................................... 317
19.2 Traversing the Reference Marks............................................................................... 318
19.3 Possible Causes of Errors ......................................................................................... 318
19.4 Troubleshooting......................................................................................................... 319
19.5 Corrective Action....................................................................................................... 320
19.6 Deselecting the Reference Run for Axes .................................................................. 320
19.7 Retraction after an Error with Control Reset ............................................................. 321
20 Interface to the Drives..................................................................................................... 323
20.1 Digital PWM Interface............................................................................................... 323
20.1.1 Introduction ..................................................................................................... 323
20.1.2 Tables for power supply modules, power stages and motors ........................ 326
20.1.3 Possible causes of error .................................................................................. 332
20.1.4 Sequence for finding errors in the control loop ............................................... 332
20.1.5 Troubleshooting: Interchanging PWM outputs on the CC 422 ........................ 333
20.1.6 Troubleshooting: Interchanging PWM outputs on the CC 424 (B) .................. 336
20.1.7 Troubleshooting: Interchanging power modules or output stages of
the same type ............................................................................................................. 339
20.1.8 Troubleshooting: Interchanging the HEIDENHAIN interface boards
for the SIMODRIVE 611 system ............................................................................... 342
20.1.9 Corrective action .............................................................................................. 343
20.2 Analog Speed Command Interface ........................................................................... 344
20.2.1 Introduction ..................................................................................................... 344
20.2.2 Possible causes of error .................................................................................. 344
20.2.3 Sequence for finding errors in the control loop ............................................... 345
20.2.4 Checking the analog speed command interface ............................................. 346
20.2.5 Adjusting the electrical offset (drift adjustment) ............................................. 349
20.2.6 Speed adjustment at the servo amplifier (tachometer adjustment) ................ 352
20.2.7 Corrective action .............................................................................................. 354
21 Visual Display Unit .......................................................................................................... 355
21.1 Introduction ............................................................................................................... 355
21.2 Possible Causes of Errors ......................................................................................... 355
21.3 Troubleshooting......................................................................................................... 356
21.4 Corrective Action....................................................................................................... 358
22 Keyboard Unit .................................................................................................................. 359
22.1 Introduction ............................................................................................................... 359
22.2 Front View of the Keyboard Units ............................................................................ 360
22.3 Possible Causes of Error ........................................................................................... 362
22.4 Checking the Keys..................................................................................................... 363
22.5 Checking the Potentiometers.................................................................................... 367
22.6 Checking the Touchpads ........................................................................................... 370
22.7 Corrective Action....................................................................................................... 371
22.8 Key Matrix of the Keyboard Units ............................................................................. 372
22.9 Key Matrix of the Keyboard Units ............................................................................. 388
23 Machine Operating Panel................................................................................................ 389
23.1 Introduction ............................................................................................................... 389
23.2 Possible Causes of Errors ......................................................................................... 390
23.3 Checking the Power Supply ...................................................................................... 391
23.4 Checking the Keys..................................................................................................... 392
23.5 Checking the Outputs ............................................................................................... 397
23.6 Corrective Action....................................................................................................... 398
HEIDENHAIN Service Manual iTNC 530
24 Handwheel........................................................................................................................ 399
24.1 Introduction ............................................................................................................... 399
24.2 Possible Causes of Errors.......................................................................................... 400
24.3 Error Location on Portable Handwheel with HR 420 Display .................................... 401
24.4 Error Diagnosis at HR 410 Portable Handwheel........................................................ 406
24.5 Deselecting and Disconnecting the Portable Handwheel ......................................... 409
24.6 Error Diagnosis at Panel-Mounted Handwheels........................................................ 410
24.7 Corrective Action....................................................................................................... 412
25 Touch Probe ..................................................................................................................... 413
25.1 Introduction ............................................................................................................... 413
25.2 Possible Causes of Errors.......................................................................................... 417
25.3 Error Diagnosis on TS Touch Probes......................................................................... 418
25.4 Error Diagnosis on TT Touch Probes ......................................................................... 422
25.5 Error Diagnosis on Laser Touch Probe...................................................................... 425
25.6 Deselecting and Disconnecting the Touch Probe...................................................... 426
25.7 Corrective Action....................................................................................................... 427
26 Important Features of HEIDENHAIN Components ....................................................... 429
26.1 HEIDENHAIN Components in a Machine Tool .......................................................... 429
26.2 Hardware Identification ............................................................................................. 430
26.3 Display of Important System Information.................................................................. 443
27 Connector Designation and Layout ............................................................................... 447
27.1 Important Note .......................................................................................................... 447
27.2 MC and CC ................................................................................................................ 447
27.2.1 Designation and position of connectors .......................................................... 447
27.2.2 Pin Layouts on the MC and CC ........................................................................457
27.3 Power Supply Units................................................................................................... 487
27.3.1 UV 105 power supply unit ............................................................................... 488
27.3.2 UV 105 B power supply unit ............................................................................ 490
27.3.3 UV 106 (B) power supply unit .......................................................................... 492
27.4 Monitors .................................................................................................................... 493
27.4.1 Designation and position of connectors ......................................................... 493
27.4.2 Pin layouts ...................................................................................................... 494
27.5 Keyboard Units .......................................................................................................... 495
27.5.1 Designation and position of connectors .......................................................... 495
27.5.2 Pin layouts ....................................................................................................... 497
27.6 BTS 1x0 Monitor/Keyboard Switch............................................................................ 498
27.7 Machine Operating Panel ....................................................................................... 499
27.7.1 Designation and position of connectors .......................................................... 499
27.7.2 Pin Layouts on MB 420 ................................................................................... 499
27.7.3 Pin layouts on MB 520 ..................................................................................... 500
27.8 Handwheels............................................................................................................... 503
27.8.1 HR 4xx portable handwheel ............................................................................. 503
27.8.2 HR 130 panel-mounted handwheel ................................................................. 504
27.8.3 HRA 110 handwheel adapter ........................................................................... 505
27.9 Touch Probes............................................................................................................. 507
27.10 PLC Input/Output Units........................................................................................ 507
27.10.1 Designation and position of connectors ........................................................ 507
27.10.2 PL 4xxB Pin Layouts ...................................................................................... 510
27.10.3 Pin layouts for PL 510 .................................................................................... 516
27.11 Encoders.................................................................................................................. 520
27.11.1 Position encoders .......................................................................................... 520
27.11.2 Speed encoders .............................................................................................
27.12 Inverters and Mo
27.13 Interface Boards for the SIMODRIVE System 611D............................................. 522
tors.............................................................................................. 522
522
July 2010 HEIDENHAIN Service Manual iTNC 530
28 Exchange of HEIDENHAIN Components........................................................................ 523
28.1 Important Information ............................................................................................... 523
28.2 Exchange of the MC 422........................................................................................... 531
28.3 Exchange of the Drive Assembly .............................................................................. 537
28.4 Exchange of the MC 422 B, MC 422 C, MC 420 ...................................................... 542
28.5 Exchange of the HDR................................................................................................ 544
28.6 Exchange of the CC................................................................................................... 551
28.7 Exchange of the Buffer Battery................................................................................. 552
28.8 Exchange of Other HEIDENHAIN Components ........................................................ 553
28.9 Exchange of HEIDENHAIN Components in the SIMODRIVE System ...................... 554
29 Measuring, Testing and Inspection Equipment............................................................ 561
29.1 Important Notes ........................................................................................................ 561
29.2 Test Adapter.............................................................................................................. 562
29.3 PWM 9 Encoder Diagnostic Set................................................................................ 566
29.4 PWT 10/17/18 Testing Unit ....................................................................................... 568
29.5 IK 215 Adjusting and Testing Package ...................................................................... 570
30 Machine Parameter ........................................................................................................ 571
30.1 Explanation................................................................................................................ 571
30.2 The Machine Parameter Editor.................................................................................. 572
30.3 Meaning of the Machine Parameters........................................................................ 579
30.4 List of Machine Parameters ...................................................................................... 580
30.4.1 Encoders and machines .................................................................................. 580
30.4.2 Positioning ....................................................................................................... 586
30.4.3 Operation with Velocity Feedforward Control ................................................. 592
30.4.4 Operation with following error (servo lag) ....................................................... 593
30.4.5 Integrated speed and current control .............................................................. 594
30.4.6 Spindle ............................................................................................................. 603
30.4.7 Integrated PLC ................................................................................................. 606
30.4.8 Configuration of the Data Interface ................................................................. 609
30.4.9 3-D touch probe ............................................................................................... 611
30.4.10 Tool Measurement with TT ........................................................................... 613
30.4.11 Tapping .......................................................................................................... 616
12 Display and operation ..
30.4.
30.4.13 Color .............................................................................................................. 624
30.4.14 Machining and Program Run ......................................................................... 627
30.4.15 Hardware ....................................................................................................... 634
30.4.16 Second spindle .............................................................................................. 643
.................................................................................. 617
1 Annex: Principle of Function of the iTNC 530 Control.................................................... 645
1.1 Introduction ................................................................................................................. 645
1.2 The Control Loop......................................................................................................... 645
1.3 PWM Signals............................................................................................................... 654
2 Annex: Principle of Function of the iTNC 530 Control.................................................... 657
3 Annex: Monitoring Functions........................................................................................... 661
3.1 Introduction ................................................................................................................. 661
3.2 During Start-Up............................................................................................................ 661
3.3 During Operation......................................................................................................... 663
3.3.1 Position or servo lag monitoring ........................................................................ 664
3.3.2 Nominal speed value monitoring ....................................................................... 666
3.3.3 Movement monitoring ....................................................................................... 667
3.3.4 Standstill monitoring .......................................................................................... 669
3.3.5 Positioning window ........................................................................................... 670
3.3.6 Monitoring of the power supply unit ................................................................. 672
3.3.7 Temperature monitoring .................................................................................... 674
3.3.8 Internal power supply and housing fan .............................................................. 675
HEIDENHAIN Service Manual iTNC 530
3.3.9 I2t monitoring ..................................................................................................... 676
3.3.10 Actual utilization of drive motors .....................................................................681
3.3.11 Status of HEIDENHAIN inverters ..................................................................... 682
3.3.12 Controlling the motor brakes ...........................................................................684
3.3.13 EMERGENCY STOP monitoring during operation ........................................... 687
July 2010 HEIDENHAIN Service Manual iTNC 530
HEIDENHAIN Service Manual iTNC 530
1 How to Use this Service Manual
Note
1.1 Target Group
This Service Manual has been written for specialist electricians for service, maintenance and
commissioning.
Specialists who perform work on the electrical system of a machine tool and its components
must have the required technical knowledge and competence!
1.2 About this Manual
This Service Manual assists service personnel in the field in diagnosing and
correcting errors on machine tools controlled by iTNC 530.
It includes:
Error messages and types of errors that indicate technical defects
Information on possible error causes
Descriptions of error diagnosis
Application descriptions of the diagnosis tools
Information on corrective action
Data backup instructions
Theoretical explanations of functions and their correlations
The ”List of NC Error Messages” on page 4 – 29 and the ”Overview of Possible Error Patterns”
on page 5 – 55 include many references to the descriptions for error diagnosis. You will find
these descriptions in the chapters of this Service Manual sorted by topics.
The Service Manual does not provide any commissioning support!
It comprises the service possibilities with the current hardware and software at the editing date
of this manual. The service possibilities of your devices may differ from those described here.
The descriptions also provide information on any peculiarities of the hardware or software.
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
For the instructions for the field service it is assumed that ...
the machine had been working perfectly before the error occurred!
only original parts are used!
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.
July 2010 1 – 11
Udpate service This Service Manual is updated at irregular intervals.
Note
Note
Caution
Note
You find the current printable version on our website -->
http://www.heidenhain.de/ ... /SHB iTNC 530
If you take part in a service training, you receive also a paper version of the Service Manual.
1.3 Other Service Manuals
Service Manual for Inverter Systems and Motors
1.4 Other Documentation
For more important information please refer to the following documentation:
Machine documentation by the manufacturer
(circuit diagrams, wiring diagrams, machine operating manual, etc.)
HEIDENHAIN User's Manual for iTNC 530
HEIDENHAIN TNCguide on DVD
Mounting instructions by HEIDENHAIN
Brochures of the respective HEIDENHAIN products
PWM 9 User's Manual
PWT Operating Instructions
IK 215 Operating Instructions
1.5 Support
However, support will also be provided by the Service Department of HEIDENHAIN Traunreut
or by the HEIDENHAIN agencies.
You will find telephone numbers as well as e-mail addresses on the back cover of this Service
Manual, or on the HEIDENHAIN website (www.heidenhain.de).
1.6 Service Training
HEIDENHAIN Traunreut offers service training courses in German language. We recommend
the HEIDENHAIN Service Training Seminars for iTNC 530 for the technician who works with this
Service Manual.
Please contact HEIDENHAIN Traunreut or visit our website (www.heidenhain.de).
You can find up-to-date issues of this and other HEIDENHAIN documents quickly on our
website --> www.heidenhain.de
HEIDENHAIN software tools (e.g. TNCremoNT) feature detailed on-line help.
The machine manufacturer must be contacted first for error diagnosis on your machine
tool!
If required, please inquire at the HEIDENHAIN subsidiary in your country whether Service
Training Seminars are offered in your language.
1 – 12 HEIDENHAIN Service Manual iTNC 530
1.7 Meaning of the Symbols Used in this Manual
DANGER
Caution
Note
DANGER
Failure to comply with this information could result in most serious or fatal injuries, and/or
in substantial material damage.
Failure to comply with this information could result in injuries and interruptions of operation,
including material damage.
These boxes contain important and useful information.
1.8 Safety
It is extremely important that you read the safety precautions in chapter 2 before you start
servicing!
See “Safety Precautions” on page 2 – 15.
July 2010 1 – 13
1 – 14 HEIDENHAIN Service Manual iTNC 530
2 Safety Precautions
DANGER
DANGER
DANGER
DANGER
DANGER
Caution
DANGER
2.1 Overview
Ground
Ensure that the equipment grounding conductor is continuous!
Interruptions in the equipment grounding conductor may cause damage to persons or
property.
Zero potential
Ensure that the main switch of the control is switched off and that connected devices are
not under power when you engage or disengage any connectors or terminals.
Take precautions against restart!
Use an appropriate voltage test unit to ensure that the unit is not under voltage!
Fundamental knowledge
In order to be able to judge the behavior of an NC controlled machine, service engineers
need to have fundamental knowledge of controls, encoders, drives, electronics and
mechanics.
Improper use can result in serious injury to persons and damage to equipment.
Know-how and competence
Suitable tools
Safety precautions of the machine manufacturer
Regulations for
power installations
and instructions for
safety and prevention of accidents
Technicians who work on the electrical system of the machine must have the required
know-how and competence!
Use suitable tools, e.g. insulated screwdrivers and pincers!
Note the safety precautions on the machine (e.g. labels, signs) and the safety precautions
in the documentation of the machine manufacturer (e.g., operating instructions).
Observe the national regulations for power installations and the general instructions for
safety and prevention of accidents!
July 2010 2 – 15
Basic insulation
DANGER
DANGER
DANGER
Caution
Vertical axes
Changes to entry values
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.
Always secure vertical axes to prevent them from falling down before you perform tests on
these axes!
Incorrect or non-optimized input values can lead to faulty machine performance and
therefore to serious injury to persons and damage to equipment.
Machine parameters may only be changed by the machine manufacturer or after consulting
the machine manufacturer!
Uncontrolled axis and spindle movements must be expected.
Settings that have an effect on the control's feedback loops may only be altered when the
EMERGENCY STOP button of the machine is pressed.
Liability
HEIDENHAIN does not accept any responsibility for indirect or direct damage caused to
persons or property through incorrect use or operation of the machine!
2 – 16 HEIDENHAIN Service Manual iTNC 530
3 Code Numbers
DANGER
Note
3.1 Introduction
With code numbers …
certain areas of the hard disk
certain file types
certain functions
... can be called.
Code numbers may only be passed on to and be used by trained service technicians.
Keep the code numbers confidential!
Inexpert handling may result in a loss of important data, in faulty machine performance and
thus lead to damage or injury to property or persons.
3.2 Overview
Code number Brief description Description in
this manual
0 Delete the code numbers entered so far --> Code-number
softkeys, such as MP EDIT or PLC EDIT are deleted.
123 Edit subset of machine parameters for the machine operator See page 30 - 571
75368 Offset adjustment for analog axes See page 20 – 349
79513 Info menu (U[BATT], U[ACCU], U[VCC], TEMP, T[CPU1]), See page 17 – 267
95148 Call the active machine parameter list See page 30 – 572
531210 Reset non-volatile PLC markers and PLC words in the RAM See page 11 – 133
688379 Integrated oscilloscope See page 10 – 99
807667 Call the PLC area See page 11 – 115
857282 Reset the operating times -
LOGBOOK Call and save the internal log of the TNC See page 8 – 81
NET123 Network settings for the single-processor control See page 13 – 172
SETUP Call for loading of service packs and NC software for the single-
processor control
SIK Display of the number of the system identification key and of the
enabled options
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.
In this chapter
See page 15 – 219
See page 28 – 525
-
The machine manufacturer can define own MP and PLC code numbers.
In this event the HEIDENHAIN code numbers do not function any longer, or only function to
a limited extent. --> Contact your machine manufacturer!
July 2010 3 – 17
3.3 Input of Code Numbers
Note
Note
Note
8 If open: Close the program management by pressing the END button.
Pressing the MOD key while the program manager is open calls the interface settings.
8 Select the Programming and Editing operating mode.
8 Call the code number window.
8 Enter the code number and press ENT to confirm.
When certain code numbers are entered, new soft keys are displayed, 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.
When you have finished your work, reset all previously entered code numbers:
8 Enter the code number 0 and press ENT to confirm.
8 Press END to exit the code-number page.
All key codes are reset when the control is restarted.
3 – 18 HEIDENHAIN Service Manual iTNC 530
Additional notes
As long as the machine parameter list is in the editor, no further code number can be
entered. First close the MP editor if you want to enter a new code number
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 extension .MP are displayed.
After entering the PLC code number all files in the PLC tree can be seen and loaded in the
editor.
However, to edit machine parameters, the soft key MP EDIT needs to be pressed first.
July 2010 3 – 19
3 – 20 HEIDENHAIN Service Manual iTNC 530
4Error Messages
Note
4.1 Introduction
iTNC features a comprehensive integral monitoring system for the prevention of input or
operation errors, as well as for identification and diagnosis of technical defects on the control
and the connected devices. 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 effect of the monitoring functions is described in the annex -- .> See “Annex: Monitoring
Functions” on page 3 – 661.
Moreover, the machine manufacturer can 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).
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 into error messages that result from operation, programming and machine
applications and those that indicate a technical defect (devices, electronic and mechanical
components, etc.)
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.
Is the displayed error message an NC or PLC error message?
Display PLC error message NC error message
ERR window in the column
"Group".
Call -->
See “ERR Key” on page 4 – 26.
Log
Call -->
See “Log” on page 8 – 81.
There are no error numbers assigned to NC error messages that begin with N-1.
Operating-system error messages
Often contain 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.
July 2010 4 – 21
PLC GENERAL
or
OPERATION
or
PROGRAMMING
P- (number and text of
error message)
N- (number and text of
error message)
Display of the error message
All error messages that can be acknowledged with the CE key are …
Displayed in the screen header (at the top of the screen) usually in red color.
As a plain-language message.
Figure: Error message in the header
The machine manufacturer can display additional information on PLC error messages in the
small PLC window (above the soft-key row).
Figure: Additional information in the small PLC window
Error messages that require a rebooting of the control ...
are displayed in a red or gray window (depending on the NC software version) in the center
of the screen.
are made known through a plain-language message.
Figure: Red error window
4 – 22 HEIDENHAIN Service Manual iTNC 530
Figure: Gray error window
July 2010 4 – 23
Reaction of control and machine
Display only
A message (info, warning, error) is only displayed.
The machine does not react. Programs are not stopped.
The error message can be acknowledged anytime.
Feed stop
The feed-rate enable is reset. The "F"symbol for the feed rate is highlighted.
The axes are braked at the nominal-value characteristic.
The contour of the workpiece is usually not damaged.
Once the error message is acknowledged, the machine continues to operate at the set feed
rate.
Program cancellation
The running NC progam is canceled.
The axes are braked at the nominal-value characteristic.
The contour of the workpiece is usually not damaged.
After the error message was acknowledged, the NC program needs to be restarted
(GOTO 0, NC-START).
NC stop
The running NC progam is stopped. The star "*" (STIB) flashes.
The axes are braked at the nominal-value characteristic.
The contour of the workpiece is usually not damaged.
After the error message was acknowledged, the NC program can be restarted at the position
where it was interrupted (NC-START key).
EMERGENCY STOP
Automatic generation of service files
An EMERGENCY STOP is triggered at the machine.
Axes and spindles decelerate at the current limit; the machine must be brought to a standstill
as quickly as possible.
The contour of the workpiece is not taken into account and may be damaged.
After the error message was acknowledged, the machine must be switched on completely.
Now, the PLC program can be restarted (GOTO 0, NC START).
RESET
An EMERGENCY STOP is triggered at the machine.
Axes and spindles decelerate at the current limit; the machine must be brought to a standstill
as quickly as possible.
The contour of the workpiece is not taken into account and may be damaged.
The error message cannot be acknowledged. The control must be shut down and restarted.
Now, the PLC program can be restarted (GOTO 0, NC START).
As of NC software version 340 49x-04:
In the event of serious NC software errors or PLC error messages especially defined for this
purpose service files are generated automatically.
See “Creating and Downloading of Service Files” on page 7 – 77.
4 – 24 HEIDENHAIN Service Manual iTNC 530
4.2 HELP Key
Note
8 Display help texts for error messages
(If you press this key again, the window will close.)
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!
Figure: HELP window
HELP texts cannot be displayed for error messages in red or gray windows. The control
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 4 – 29.
July 2010 4 – 25
4.3 ERR Key
Note
8 Display all pending error messages in a list
(If you press this key again, the window will close.)
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. When this key is pressed all
pending NC and PLC error messages of the control are displayed in an own window.
List of error messages
In the ERR window In the log
In order of priority In chronological order
Errors with a higher priority are at the top of
the list.
The log is written from top to bottom, i.e.,
older errors are at the top, younger errors at
the bottom.
In addition, the help window can be called with the HELP key.
If your machine still features an old keyboard without an ERR key over the HELP key, press
the respective "space key" over the HELP key. --> If the NC software of the iTNC 530
supports the function of the ERR key, it can also be used to call the ERR list!
4 – 26 HEIDENHAIN Service Manual iTNC 530
The columns in the ERR window have the following meanings:
Column Description
Number Error number (–1: no error number defined), issued by HEIDENHAIN or your
machine tool builder
Class Error class. Defines the reaction of the control:
ERROR
Program run is interrupted by the iTNC
FEED HOLD
The feed-rate release is canceled
PGM HOLD
The program run is interrupted (the control-in-operation symbol blinks)
PGM ABORT
The program run is interrupted (INTERNAL STOP)
EMERG. STOP
EMERGENCY STOP is set off
RESET
iTNC executes a system restart
WARNING
Warning message, program run resumes
INFO
Info message, program run resumes
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
message
Displayed error text
The individual error messages can be selected with the cursor; the open help window shows
the appertaining text.
July 2010 4 – 27
4.4 CE Key
Note
8 Clear error message (Clear Error)
Acknowledge error messages displayed by pressing the CE key.
If the error cause is still existing, the corresponding error message is displayed again. -->
Eliminate the error!
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 work --> Switch the power switch of the machine off and wait for several
seconds before you switch it on again.
4 – 28 HEIDENHAIN Service Manual iTNC 530
4.5 List of NC Error Messages
Complete list You can find the complete list of all NC error messages (including operator errors) on the
TNCguide DVD in several languages and sorted by error numbers.
This TNCguide information is also available on our website --> www.heidenhain.de/...
This is the official list of NC error messages which contains all possible errors of HEIDENHAIN
controls that operate with the HeROS operating system.
It consists primarily of error messages related to operation and handling as well as technical error
messages.
Filtered list The list below contains the most important error messages that indicate a technical defect
in numerical and subsequently in alphabetical order.
A reference is made, if there are additional descriptions in this Service Manual.
Error message Possible cause of error Measures for error diagnosis and/or
corrective action
8040 Heat-sink
temp. UV 1xx
8041 Excessive Iz
in UV 1xx
8043 No inverterready signal
8060 Leakage
current in UV 1xx
Additional information and descriptions in
the manual
Heat-sink temperature of UV 1xx power
supply unit is too high.
If the heat-sink temperature continues to
increase, the unit will be switched off.
See “Status of HEIDENHAIN inverters” on
page 3 – 682.
DC-link current of UV 1xx power supply unit
too high
See “Status of HEIDENHAIN inverters” on
page 3 – 682.
Readiness signal of the inverter (supply unit)
is inactive after the feedback control starts.
Master contactor has opened.
Error in PLC program
Inverter defective
See “Status of HEIDENHAIN inverters” on
page 3 – 682.
Insulation problem (e.g. defective motor). Check the motor.
Additional information and descriptions in
the manual
Stop the machine and let it cool down.
Continue working with lower power (reduce
the feed rate).
See Service Manual Inverter Systems and
Motors
Continue working with lower power (reduce
the feed rate).
See Service Manual Inverter Systems and
Motors
Try to restart.
Check the wiring (master contactor).
Check the PLC program.
Exchange the inverter (supply unit).
See “Checking the readiness of the inverter
system” on page 16 – 243.
See Service Manual Inverter Systems and
Motors.
Check the wiring.
See “Status of HEIDENHAIN inverters” on
page 3 – 682.
8061 No inverterready signal
July 2010 4 – 29
Readiness signal of the inverter (supply unit)
is inactive after the feedback control starts.
Master contactor has opened.
Error in PLC program
Inverter defective
See “Status of HEIDENHAIN inverters” on
page 3 – 682.
See Service Manual Inverter Systems and
Motors.
Try to restart.
Check the wiring (master contactor).
Check the PLC program.
Exchange the inverter (supply unit).
See “Checking the readiness of the inverter
system”
See Service Manual Invert
Motors.
on page 16 – 243.
er Systems and
Error message Possible cause of error Measures for error diagnosis and/or
corrective action
8080 Uz UV 1xx
too high
8092 Pos. contr.
cyc. time error
8130 Motor brake
defective <axis>
8140 Error <axis>
field orientation
Additional information and descriptions in
the manual
DC-link voltage of the power supply unit too
high.
See “Status of HEIDENHAIN inverters” on
page 3 – 682.
MC is outputting erroneous cycle time for
CC position controller.
Hardware error
Motor brake defective. Traverse the axis to a safe position before
Field orientation impossible for mechanical
reasons.
Incorrect relation between electrical field
and mechanical motor motion.
Incorrect motor encoder signal.
Incorrect motor connection.
Mechanical brakes not released.
Additional information and descriptions in
the manual
Check the configuration datum (braking of
the spindle).
Check the braking resistor.
Replace the power supply unit.
See Service Manual Inverter Systems and
Motors.
Check machine parameter 7600.x.
Exchange the drive control board.
power-off.
Check controls for motor brakes.
Exchange the motor.
See “Controlling the motor brakes” on page
3 – 684.
See Service Manual Inverter Systems and
Motors.
Check the machine parameters for number
of signal periods and distance for the
number of signal periods.
Check the machine parameter for the linear
distance of one motor revolution.
For linear motors: Check STR column of the
motor table.
Check the speed encoder connection.
Check the motor connection.
Release brakes during orientation.
8300 Motor brake
defective <axis>
831
0 No current in
brake test <axis>
See “Speed Encoders” on page 18 – 293. See “Sequence for Finding Errors in the
Control Loop” on page 6 – 62.
See “Speed Encoders” on page 18 – 293.
See Service Manual Inverter Systems and
Motors.
Motor brake defective. Traverse the axis to a safe position before
power-off.
Check controls for motor brakes.
Exchange the motor.
See “Controlling the motor brakes” on page
3 – 684.
Manual Inverter Systems and
Motor connected incorrectly
Inverter connected incorrectly
Inverter defective
Motor defective
See Service
Motors.
Check the wiring of motor and inverter.
Check the inverter.
Check the motor.
See “Controlling the motor brakes” on page
3 – 684.
See Service Manual Inverter Systems and
Motors.
4 – 30 HEIDENHAIN Service Manual iTNC 530
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