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
8.3 ................................................................................................	Overview of Log Entries	83
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

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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 mode ............................................		206
13.9	Drive Symbols ...........................................................................................................	207
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

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 .....................................................................................................		293
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

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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 .............................................................................................				522
27.12		Inverters and Motors ..............................................................................................		522
27.13 Interface Boards for the SIMODRIVE System 611D .............................................				522

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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
30.4.12 Display and operation ....................................................................................		617
30.4.13 Color ..............................................................................................................		624
30.4.14 Machining and Program Run .........................................................................		627
30.4.15 Hardware .......................................................................................................		634
30.4.16 Second spindle ..............................................................................................		643
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

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HEIDENHAIN Service Manual iTNC 530

HEIDENHAIN Service Manual iTNC 530

1 How to Use this Service Manual

1.1Target 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!

1.2About 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!

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.

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Udpate service	This Service Manual is updated at irregular intervals.
	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.

1.3Other Service Manuals

Service Manual for Inverter Systems and Motors

1.4Other 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

Note

You can find up-to-date issues of this and other HEIDENHAIN documents quickly on our website --> www.heidenhain.de

Note

HEIDENHAIN software tools (e.g. TNCremoNT) feature detailed on-line help.

1.5Support

Caution

The machine manufacturer must be contacted first for error diagnosis on your machine tool!

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).

1.6Service 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).

Note

If required, please inquire at the HEIDENHAIN subsidiary in your country whether Service Training Seminars are offered in your language.

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HEIDENHAIN Service Manual iTNC 530

1.7Meaning of the Symbols Used in this Manual

DANGER

Failure to comply with this information could result in most serious or fatal injuries, and/or in substantial material damage.

Caution

Failure to comply with this information could result in injuries and interruptions of operation, including material damage.

Note

These boxes contain important and useful information.

1.8Safety

DANGER

It is extremely important that you read the safety precautions in chapter 2 before you start servicing!

See “Safety Precautions” on page 2 – 15.

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HEIDENHAIN Service Manual iTNC 530

2 Safety Precautions

2.1Overview

Ground

DANGER

Ensure that the equipment grounding conductor is continuous!

Interruptions in the equipment grounding conductor may cause damage to persons or property.

Zero potential

DANGER

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

DANGER

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

DANGER

Technicians who work on the electrical system of the machine must have the required know-how and competence!

Suitable

tools

DANGER

Use suitable tools, e.g. insulated screwdrivers and pincers!

Safety precautions of the machine

manufacturer

Caution

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).

Regulations for power installations and instructions for safety and prevention of accidents

DANGER

Observe the national regulations for power installations and the general instructions for safety and prevention of accidents!

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2 – 15

Basic insulation

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.

Vertical axes

DANGER

Always secure vertical axes to prevent them from falling down before you perform tests on these axes!

Changes to entry values

DANGER

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

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!

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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 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.

3.2Overview

Code number	Brief description	Description in
		this manual
0	Delete the code numbers entered so far --> Code-number	In this chapter
	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-	See page 15 – 219
	processor control
SIK	Display of the number of the system identification key and of the	See page 28 – 525
	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.
	Note

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!

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3.3Input of Code Numbers

8 Select the Programming and Editing operating mode.

8 If open: Close the program management by pressing the END button.

Note

Pressing the MOD key while the program manager is open calls the interface settings.

8 Call the code number window.

8 Enter the code number and press ENT to confirm.

Note

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:

8Enter the code number 0 and press ENT to confirm.

8Press END to exit the code-number page.

Note

All key codes are reset when the control is restarted.

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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.

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HEIDENHAIN Service Manual iTNC 530

4 Error Messages

4.1Introduction

Type of error message

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.

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	PLC	GENERAL
"Group".		or
Call -->		OPERATION
See “ERR Key” on page 4 – 26.		or
		PROGRAMMING
Log	P- (number and text of	N- (number and text of
Call -->	error message)	error message)
See “Log” on page 8 – 81.

Note

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.

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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

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Figure: Gray error window

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Reaction of control and machine

Automatic generation of service files

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

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.

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4.2HELP Key

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

Note

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.

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4.3ERR Key

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 log is written from top to bottom, i.e.,
the list.	older errors are at the top, younger errors at
	the bottom.

In addition, the help window can be called with the HELP key.

Note

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!

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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	Displayed error text
message

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

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4.4CE Key

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!

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 work --> Switch the power switch of the machine off and wait for several seconds before you switch it on again.

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4.5List 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
	Additional information and descriptions in	Additional information and descriptions in
	the manual	the manual
8040 Heat-sink	Heat-sink temperature of UV 1xx power	Stop the machine and let it cool down.
temp. UV 1xx	supply unit is too high.	Continue working with lower power (reduce
	If the heat-sink temperature continues to	the feed rate).
	increase, the unit will be switched off.
	See “Status of HEIDENHAIN inverters” on	See Service Manual Inverter Systems and
	page 3 – 682.	Motors
8041 Excessive Iz	DC-link current of UV 1xx power supply unit	Continue working with lower power (reduce
in UV 1xx	too high	the feed rate).
	See “Status of HEIDENHAIN inverters” on	See Service Manual Inverter Systems and
	page 3 – 682.	Motors
8043 No inverter-	Readiness signal of the inverter (supply unit)	Try to restart.
ready signal	is inactive after the feedback control starts.	Check the wiring (master contactor).
	Master contactor has opened.	Check the PLC program.
	Error in PLC program
		Exchange the inverter (supply unit).
	Inverter defective
	See “Status of HEIDENHAIN inverters” on	See “Checking the readiness of the inverter
	page 3 – 682.	system” on page 16 – 243.
		See Service Manual Inverter Systems and
		Motors.
8060 Leakage	Insulation problem (e.g. defective motor).	Check the motor.
current in UV 1xx		Check the wiring.
	See “Status of HEIDENHAIN inverters” on	See Service Manual Inverter Systems and
	page 3 – 682.	Motors.
8061 No inverter-	Readiness signal of the inverter (supply unit)	Try to restart.
ready signal	is inactive after the feedback control starts.	Check the wiring (master contactor).
	Master contactor has opened.	Check the PLC program.
	Error in PLC program
		Exchange the inverter (supply unit).
	Inverter defective
	See “Status of HEIDENHAIN inverters” on	See “Checking the readiness of the inverter
	page 3 – 682.	system” on page 16 – 243.
		See Service Manual Inverter Systems and
		Motors.

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Error message	Possible cause of error	Measures for error diagnosis and/or
		corrective action
	Additional information and descriptions in	Additional information and descriptions in
	the manual	the manual
8080 Uz UV 1xx	DC-link voltage of the power supply unit too	Check the configuration datum (braking of
too high	high.	the spindle).
		Check the braking resistor.
		Replace the power supply unit.
	See “Status of HEIDENHAIN inverters” on	See Service Manual Inverter Systems and
	page 3 – 682.	Motors.
8092 Pos. contr.	MC is outputting erroneous cycle time for	Check machine parameter 7600.x.
cyc. time error	CC position controller.	Exchange the drive control board.
	Hardware error
8130 Motor brake	Motor brake defective.	Traverse the axis to a safe position before
defective <axis>		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.
8140 Error <axis>	Field orientation impossible for mechanical	Check the machine parameters for number
field orientation	reasons.	of signal periods and distance for the
	Incorrect relation between electrical field	number of signal periods.
	and mechanical motor motion.	Check the machine parameter for the linear
	Incorrect motor encoder signal.	distance of one motor revolution.
		For linear motors: Check STR column of the
	Incorrect motor connection.
		motor table.
	Mechanical brakes not released.
		Check the speed encoder connection.
		Check the motor connection.
		Release brakes during orientation.
	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.
8300 Motor brake	Motor brake defective.	Traverse the axis to a safe position before
defective <axis>		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.
8310 No current in	Motor connected incorrectly	Check the wiring of motor and inverter.
brake test <axis>	Inverter connected incorrectly	Check the inverter.
	Inverter defective	Check the motor.
	Motor defective
		See “Controlling the motor brakes” on page
		3 – 684.
		See Service Manual Inverter Systems and
		Motors.

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