Professional Documents
Culture Documents
iTNC 530
May 2006
Contents
1 Safety Precautions ................................................................................................................. 9 2 Using the Service Manual ................................................................................................... 11 2.1 About this Manual ......................................................................................................... 11 2.2 Further Service Manuals................................................................................................ 11 2.3 Other Documentation:................................................................................................... 12 2.4 Support .......................................................................................................................... 12 2.5 Service Training Seminars ............................................................................................. 12 2.6 Safety ............................................................................................................................ 12 3 Code Numbers ..................................................................................................................... 13 3.1 Introduction ................................................................................................................... 13 3.2 Overview ....................................................................................................................... 13 3.3 Notes on Entering the Code Numbers .......................................................................... 14 4 Error Messages .................................................................................................................... 17 4.1 Introduction ................................................................................................................... 17 4.2 HELP Key....................................................................................................................... 19 4.3 ERR Key ........................................................................................................................ 20 4.4 CE Key .......................................................................................................................... 21 4.5 List of NC Error Messages ............................................................................................ 22 5 Errors..................................................................................................................................... 23 5.1 Introduction ................................................................................................................... 23 5.2 Notes and Tips............................................................................................................... 23 5.3 Overview of Possible Errors .......................................................................................... 26 5.4 Important Notes on the Use of HEIDENHAIN Interface Boards in SIMODRIVE System.................................... 29 6 Log......................................................................................................................................... 35 6.1 General .......................................................................................................................... 35 6.2 Calling the Log............................................................................................................... 36 6.3 Overview of Log Entries................................................................................................ 37 6.4 Example of a Log Entry ................................................................................................. 40 7 Integrated Diagnosis Functions.......................................................................................... 41 7.1 Introduction ................................................................................................................... 41 7.2 Meanings of the Signals under DSP.......................................................................... 43 7.3 Electronic ID Label......................................................................................................... 47 8 Integrated Oscilloscope....................................................................................................... 49 8.1 General .......................................................................................................................... 49 8.2 Setup ............................................................................................................................. 50 8.3 Saving and Loading Recordings..................................................................................... 53 8.4 Circular Interpolation Test.............................................................................................. 54 9 Monitoring Functions .......................................................................................................... 55 9.1 Introduction ................................................................................................................... 55 9.2 During Booting............................................................................................................... 55 9.3 During Operation ........................................................................................................... 57 9.3.1 Position or Servo Lag Monitoring ........................................................................ 58 9.3.2 Nominal Speed Value ........................................................................................... 60 9.3.3 Movement Monitoring ......................................................................................... 61 9.3.4 Standstill Monitoring ............................................................................................ 62 9.3.5 Positioning Window ............................................................................................. 62 9.3.6 Monitoring of the Power Supply Unit .................................................................. 64 9.3.7 Temperature Monitoring ...................................................................................... 65 9.3.8 I2t Monitoring ....................................................................................................... 66
July 2002
9.3.9 Current Utilization of the Drive Motors ................................................................ 67 9.3.10 Status of HEIDENHAIN Inverters ...................................................................... 68 9.3.11 Control of Motor Brakes .................................................................................... 70 9.3.12 EMERGENCY STOP Monitoring During Operation ............................................ 72 10 PLC Diagnosis..................................................................................................................... 73 10.1 General ........................................................................................................................ 73 10.2 Service Diagnosis in PLC Mode .................................................................................. 76 10.2.1 The TABLE Function .......................................................................................... 76 10.2.2 The LOGIC Diagram .......................................................................................... 82 10.2.3 The TRACE Function ......................................................................................... 84 10.2.4 The WATCH LIST Function ................................................................................ 85 10.2.5 The I/O-FORCE LIST .......................................................................................... 87 10.3 The COMPILE Function............................................................................................... 89 10.4 Calling the PLC Error Table for Diagnosis.................................................................... 91 10.5 Nonvolatile PLC Markers and Words .......................................................................... 93 10.6 Overviews ................................................................................................................... 95 10.7 Specifications ............................................................................................................ 106 10.7.1 PLC Inputs ....................................................................................................... 106 10.7.2 Analog Inputs ................................................................................................... 107 10.7.3 Inputs for Thermistors ..................................................................................... 107 10.7.4 PLC Outputs .................................................................................................... 108 11 Principle of Operation of the iTNC 530 Control ............................................................ 109 11.1 Introduction ............................................................................................................... 109 11.2 Block Diagrams with Short Explanations................................................................... 109 11.3 Basic Circuit Diagrams ........................................................................................... 116 11.4 Exchange Possibilities of the iTNC 530 ..................................................................... 118 12 Important Features of HEIDENHAIN Components ....................................................... 119 12.1 HEIDENHAIN Components in a Machine Tool .......................................................... 119 12.2 Hardware Identification ............................................................................................. 120 12.3 Display of System Information .................................................................................. 130 13 Connector Designation and Layout .............................................................................. 135 13.1 Important Note ......................................................................................................... 135 13.2 MC and CC ................................................................................................................ 135 13.2.1 Designation and Position of Connectors ......................................................... 135 13.2.2 Pin Layouts on the MC and CC ....................................................................... 142 13.3 Power Supply Units ................................................................................................... 173 13.3.1 UV 105 Power Supply Unit .............................................................................. 174 13.3.2 UV 105 B Power Supply Unit ........................................................................... 176 13.3.3 UV 106 (B) Power Supply Unit ......................................................................... 178 13.4 Inverters and Motors ................................................................................................. 179 13.5 Interface boards for the SIMODRIVE system 611D.................................................. 179 13.6 Encoders ................................................................................................................... 180 13.6.1 Position encoders ............................................................................................ 180 13.6.2 Speed encoders ............................................................................................... 182 13.7 Touch Probe Systems ............................................................................................... 182 13.8 Handwheels .............................................................................................................. 183 13.8.1 HR 4xx Portable Handwheel ............................................................................ 183 13.8.2 HR 130 Panel-Mounted Handwheel ................................................................ 185 13.8.3 HRA 110 Handwheel Adapter ......................................................................... 185 13.9 PLC Input/Output Units ............................................................................................. 187 13.9.1 Designation and Position of Connectors ......................................................... 187 13.9.2 PL 4xxB Pin Layouts ........................................................................................ 190 13.9.3 Pin Layout PL 510 ............................................................................................ 195 13.10 Machine Operating Panel ...................................................................................... 199
13.10.1 Designation and Position of Connectors on MB 420 ..................................... 199 13.10.2 Pin Layouts on MB 420 ................................................................................. 199 13.11 iTNC Keyboard......................................................................................................... 200 13.11.1 Designation and Position of Connectors ........................................................ 200 13.11.2 Pin layouts ..................................................................................................... 201 13.12 Visual Display Units ................................................................................................. 202 13.12.1 Designation and Position of Connectors ....................................................... 202 13.12.2 Pin layouts .................................................................................................... 203 13.13 BTS 1x0 Monitor/Keyboard Switch.......................................................................... 204 14 Power Supply ................................................................................................................... 205 14.1 Power Supply for the iTNC 530 ................................................................................. 205 14.1.1 General ............................................................................................................ 205 14.1.2 UV 105, UV 105 B ............................................................................................ 210 14.1.3 UV 106, UV 106 B ............................................................................................ 214 14.2 Power Supply for Control-Is-Ready Signal ................................................................. 216 14.3 Buffer Battery ............................................................................................................ 217 14.4 Info menu .................................................................................................................. 220 14.5 Power Supply for the Display Units........................................................................... 221 14.6 Power Supply for PLC Outputs ................................................................................. 222 14.6.1 General ............................................................................................................ 222 14.6.2 Supply Voltage for PLC Outputs on the MC .................................................... 223 14.6.3 Supply Voltage for PLC Outputs on the PL 4xx B ............................................ 225 14.6.4 Supply Voltage for PLC Outputs on the PL 510 ............................................... 228 15 Hard Disk and File Manager of the iTNC 530................................................................. 231 15.1 Introduction ............................................................................................................... 231 15.2 Structure of the Hard Disk......................................................................................... 232 15.3 Hard Disk Test ......................................................................................................... 233 15.4 Setting the System Time........................................................................................... 237 15.5 File Management of TNC Partition (TNC:\) .............................................................. 239 15.6 File Management PLC Partition (PLC:\) ..................................................................... 241 16 Data Backup ..................................................................................................................... 245 16.1 Introduction ............................................................................................................... 245 16.2 Connection Setup ...................................................................................................... 247 16.2.1 Via Ethernet ..................................................................................................... 247 16.2.2 Via Serial Interface RS 232/V.24 or RS 422/V.11 ............................................. 256 16.3 Reading In and Out of Individual Files or Directories................................................. 258 16.4 Backup....................................................................................................................... 261 16.5 Extracting files from the backup file .......................................................................... 265 16.6 Restore ...................................................................................................................... 266 16.7 Data Interface Operating Modes ............................................................................... 269 16.7.1 Overview of operating modes ......................................................................... 269 16.7.2 Interface configuration and assignment of mode ............................................ 270 16.8 Drive Symbols ........................................................................................................... 271 16.9 Cable overview .......................................................................................................... 272 16.9.1 Ethernet Interface RJ45 Connection ............................................................... 272 16.9.2 RS-232-C/V.24 .................................................................................................. 273 16.9.3 RS-422/V.11 .................................................................................................... 278 17 Encoder Interface ............................................................................................................. 279 17.1 Position encoders ...................................................................................................... 279 17.1.1 Introduction ...................................................................................................... 279 17.1.2 Possible Causes of Error .................................................................................. 280 17.1.3 Service diagnosis ............................................................................................. 281
July 2002
17.1.4 Additional Diagnosis Possibility on Encoders with EnDat Interface ................ 283 17.1.5 Corrective action .............................................................................................. 283 17.1.6 Re-Setting the Machine Datum ....................................................................... 284 17.2 Speed encoders ........................................................................................................ 286 17.2.1 Introduction .................................................................................................... 286 17.2.2 Possible Causes of Error ................................................................................. 287 17.2.3 Trouble Shooting on the CC 422 ..................................................................... 287 17.2.4 Trouble Shooting on CC the 422 ..................................................................... 289 17.2.5 Additional Diagnosis Possibility on Encoders with EnDat Interface ................ 292 17.2.6 Corrective action .............................................................................................. 292 17.2.7 Resetting the Spindle Orientation ................................................................... 293 17.3 Error Code for Encoders with EnDat Interface .......................................................... 294 17.4 Checking position and speed encoders..................................................................... 295 17.5 Position Measurement with the Motor Encoder ...................................................... 296 18 Referencing....................................................................................................................... 301 18.1 Definition ................................................................................................................... 301 18.2 Traversing the Reference Marks ............................................................................... 302 18.3 Deselect Referencing for Axes ................................................................................. 309 19 Checking the Enables on the iTNC................................................................................. 311 19.1 General ...................................................................................................................... 311 19.2 Examination ............................................................................................................... 313 19.2.1 Examination of the output Control-is-ready (X41/pin34) and input Control-is-ready signal acknowledgement I3 (X42/pin 4) .......................................................... 314 19.2.2 Checking the global drive enable I32, connector X42 / pin 33 ......................... 319 19.2.3 Checking the drive enabling for the axis groups via connector X150 and X151 (if wired) ................................................................................ 321 19.2.4 Checking the readiness of the inverter system ............................................... 322 19.2.5 berprfung von PLC-Modulen, Merkern und WrternChecking PLC modules, markers and words ......................................................................... 325 20 Interface to the Drives ..................................................................................................... 327 20.1 Digital Drives ............................................................................................................. 327 20.1.1 Introduction ..................................................................................................... 327 20.1.2 Possible Causes of Errors ................................................................................ 328 20.1.3 Trouble Shooting: Exchanging PWM Outputs on the CC 422 ......................... 329 20.1.4 Trouble Shooting: Exchanging PWM Outputs on the CC 424 ......................... 333 20.1.5 Trouble Shooting: Exchanging Power Modules or Output Stages of the Same Type ...................................................................................................... 337 20.1.6 Trouble Shooting: Exchanging the HEIDENHAIN Interface Boards for the SIMODRIVE 611 System .......................................................................... 340 20.2 Analog Drives ............................................................................................................ 341 20.2.1 Introduction ..................................................................................................... 341 20.2.2 Possible Causes of Errors ................................................................................ 341 20.2.3 Testing the analog nominal speed value interface ......................................... 341 20.2.4 Adjusting the Electrical Offset (Drift Adjustment) ........................................... 346 20.2.5 Speed Adjustment at Servo Amplifier (Tachometer Adjustment) .................... 349 20.3 Switching the Position Display for Service Purposes ................................................ 351 21 Visual Display Unit .......................................................................................................... 353 21.1 General ...................................................................................................................... 353 21.2 Possible Causes of Errors ......................................................................................... 353 21.3 Fault diagnosis........................................................................................................... 354 22 Keyboard Unit .................................................................................................................. 357 22.1 General ...................................................................................................................... 357 22.2 Front View of the Keyboard Units ............................................................................ 357 22.3 Possible Causes of Error ........................................................................................... 359
22.4 Checking the Keys..................................................................................................... 22.5 Checking the Potentiometers.................................................................................... 22.6 Checking the Mouse Pad .......................................................................................... 22.7 Key Matrix of the Keyboard Units.............................................................................. 22.8 Key Matrix of the Keyboard Units..............................................................................
23 Machine Operating Panel ................................................................................................ 385 23.1 General ...................................................................................................................... 385 23.2 Checking the Power Supply ...................................................................................... 386 23.3 Checking the Keys..................................................................................................... 387 23.4 Checking the Outputs................................................................................................ 389 24 Handwheel........................................................................................................................ 391 24.1 General information ................................................................................................... 391 24.2 HR 420 Portable Handwheel with Display................................................................. 393 24.2.1 Checking the Keys ........................................................................................... 393 24.2.2 Checking the Potentiometers .......................................................................... 393 24.3 HR 410 Portable Handwheel ..................................................................................... 396 24.3.1 Checking the Keys ........................................................................................... 396 24.4 HR 150 Panel-Mounted Handwheels with HRA 110 Handwheel Adapter ................ 398 24.4.1 Checking the Switch ........................................................................................ 398 25 Touch Probe ..................................................................................................................... 401 25.1 General information ................................................................................................... 401 25.2 Touch Trigger Probe with Cable Connection for Workpiece Setup and Measurement ............................................................................................................. 403 25.3 Touch Trigger Probe with Infrared Transmission for Workpiece Setup and Measuring ........................................................................................................... 405 25.4 Triggering Touch Probe for Tool Measurement......................................................... 408 26 Exchange of HEIDENHAIN Components........................................................................ 411 26.1 Important Information................................................................................................ 411 26.2 Exchanging the MC 422 ............................................................................................ 418 26.3 Removing the Drive Assembly .................................................................................. 425 26.4 Exchanging the MC 422 B or the MC 420................................................................. 431 26.5 Exchanging the HDR ................................................................................................. 433 26.6 Exchanging the CC .................................................................................................... 441 26.7 Exchange of Further HEIDENHAIN Components...................................................... 442 27 Loading of Service Packs ................................................................................................ 443 27.1 Introduction ............................................................................................................... 443 27.2 Preparations and Execution up to NC Software 34049x-01 (Single and Dual-Processor Version) ........................................................................... 444 27.3 Preparations and Execution as of NC Software 34049x-02 (Single-Processor Version) .......................................................................................... 446 27.4 Preparations and Execution as of NC Software 34049x-02 (Dual-Processor Version) ............................................................................................ 449 27.5 Service Packs on the Control's Hard Disk ................................................................. 452 28 Activating the NC Software Used on the Machine....................................................... 453 28.1 Introduction ............................................................................................................... 453 28.2 Execution................................................................................................................... 453 29 Inspection, Measuring and Test Equipment.................................................................. 455 29.1 Important notes ......................................................................................................... 455 29.2 Test Adapter, ID 375830-01 ...................................................................................... 456 29.3 Universal Measuring Adapter, ID 255480-01............................................................. 460 29.4 Encoder Diagnostic Set PWM 9, ID 512134-01 ....................................................... 461 29.5 Mounting Help PWT 10/17/18 ................................................................................... 463 29.6 IK 215 Adjustment and Testing Kit, ID 547858-01 ................................................... 464
July 2002
30 Machine Parameters........................................................................................................ 465 30.1 What is a Machine Parameter? ................................................................................. 465 30.2 The Machine Parameter Editor.................................................................................. 465 30.3 Meaning of the Machine Parameters ........................................................................ 473 30.4 List of Machine Parameters (excerpt from the Technical Manual of iTNC 530 of November 2005) ....................... 474 30.4.1 Encoders and Machines .................................................................................. 474 30.4.2 Positioning ....................................................................................................... 480 30.4.3 Operation with velocity feedforward control ................................................... 484 30.4.4 Operation with following error (servo lag) ....................................................... 485 30.4.5 Integrated speed and current control .............................................................. 486 30.4.6 Spindle ............................................................................................................. 495 30.4.7 Integral PLC ..................................................................................................... 498 30.4.8 Configuration of the Data Interface ................................................................. 501 30.4.9 3-D touch probe ............................................................................................... 503 30.4.10 Tool Measurement with TT ........................................................................... 505 30.4.11 Tapping .......................................................................................................... 509 30.4.12 Display and Operation ................................................................................... 510 30.4.13 Color .............................................................................................................. 517 30.4.14 Machining and program run ........................................................................... 520 30.4.15 Hardware ....................................................................................................... 527 30.4.16 Second spindle .............................................................................................. 534
Safety Precautions
DANGER Ensure that the equipment grounding conductor is continuous! Interruptions in the equipment grounding conductor may cause damage to persons or property. DANGER Ensure that the main switch of the control and units are switched off when you engage or disengage connecting elements or connection clamps. Caution In order to be able to judge the behavior of an NC controlled machine, you need to have fundamental knowledge about controls, encoders, drives, electronics and mechanics. Inappropriate use may cause considerable damage to persons or property. DANGER Incorrect or not optimized input values may lead to malfunction of the machine and may thus cause damage to persons or property. Machine parameters may only be changed by the machine manufacturer or after consulting the machine manufacturer! Caution Note the safety precautions on the machine (e.g., stickers, signs) and the safety precautions in the documentation of the machine manufacturer (e.g., operating instruction). Caution HEIDENHAIN does not accept any responsibility for indirect or direct damage caused to persons or property through incorrect use or operation of the machine! DANGER Technicians who work on the electricity of the machine must have the corresponding technical knowledge and competence! DANGER Always secure vertical axes from falling down before you perform tests on these axes! DANGER The interfaces for the PLC inputs/outputs, machine operating panel and PL expansion cards comply with the basic insulation in accordance with IEC 742 EN 50 178. Only units that comply with the requirements of IEC 742 EN 50 178 for basic insulation may be connected, otherwise damage to persons or property may be caused. The maximum dc voltage mean value of the PLC inputs is 31 V.
May 2006
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DANGER Failure to comply with this information could result in most serious up to fatal injuries or in substantial material damage.
Caution Failure to comply with this information could result in injuries and interruptions of operation up to material damage.
Note These boxes contain important and useful information for servicing.
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Udpate service
This Service Manual is updated only at irregular intervals. You find the current printable version on our website. (http://www.heidenhain.de/Services/...) A zip file can be downloaded. This zip file can be unzipped with a password. Your receive this password during a HEIDENHAIN service training course or upon telephoned request! Loose-leaf binders or ring binders are only provided in connection with a service training course.
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